Consumables used in aerosol supply systems

Abstract

The present disclosure relates to a consumable (1) for use in an aerosol delivery system. The consumable (1) comprises one or more pouches containing first and second aerosol-generating materials (4, 5). The second aerosol-generating material (4, 5) has a higher density than the first aerosol-generating material (4). The present disclosure also relates to a method of manufacturing the consumable (1), a kit of parts comprising the consumable (1) and an aerosol delivery device, and packaging for the consumable (1).

Description

[Technical Field]

[0001] This disclosure relates to consumables used in aerosol supply systems. Furthermore, this disclosure relates to a method for manufacturing consumables, a component kit comprising consumables and an aerosol supply device, and packaging for consumables. Background

[0002] Aerosol supply systems generate inhalable aerosols or vapors by releasing compounds from aerosol-generating materials. These may be referred to as, for example, non-flammable smoking products, aerosol-generating assemblies, or aerosol supply devices. Overview

[0003] According to some embodiments described herein, there is a consumable used in an aerosol supply system, the consumable comprising one or more pouches containing a first aerosol generating material and a second aerosol generating material, wherein the second aerosol generating material has a higher density than the first aerosol generating material.

[0004] In some embodiments, the consumable comprises a first pouch containing a first aerosol-generating material and a second pouch containing a second aerosol-generating material.

[0005] In some embodiments, the consumable comprises a first pouch containing both a first aerosol-generating material and a second aerosol-generating material. The consumable may optionally comprise another pouch that may contain, for example, the first aerosol-generating material and / or the second aerosol-generating material.

[0006] Furthermore, the present disclosure provides a consumable used in an aerosol supply system, the consumable comprising a pouch, a first aerosol generating material and a second aerosol generating material contained in the pouch, wherein the second aerosol generating material has a higher density than the first aerosol generating material.

[0007] In some embodiments, the above or each pouch includes a sheet material.

[0008] In some embodiments, the sheet material constitutes the wall of the pouch.

[0009] In some embodiments, the sheet material includes paper.

[0010] In some embodiments, the sheet material has a thickness in the range of 20 to 100 microns, preferably in the range of 30 to 80 microns, 35 to 55 microns, or 40 to 50 microns.

[0011] In some embodiments, the sheet material is gas permeable.

[0012] In some embodiments, the sheet material has an air permeability in the range of 10 to 25,000 cholesta units, and optionally, an air permeability in the range of 25 to 100 cholesta units.

[0013] In some embodiments, the sheet material is folded and / or wound to form the above-mentioned or each pouch.

[0014] In some embodiments, the sheet material is porous. In some embodiments, the sheet material has one or more openings through which gas can flow.

[0015] In some embodiments, at least one edge of the sheet material is attached to another portion of the sheet material to hold a first aerosol-generating material and / or a second aerosol-generating material in the above or each pouch.

[0016] In some embodiments, the at least one edge of the sheet material is attached by adhesive, crimping, stapling, or sewing.

[0017] In some embodiments, the sheet material is a flexible material. In some embodiments, the first aerosol-forming material and the second aerosol-forming material are different materials and / or have one or more different properties.

[0018] In some embodiments, the pouch or each pouch is formed of a single sheet material.

[0019] In some embodiments, the pouch or each pouch is formed of two or more sheet materials joined together.

[0020] In some embodiments, the two or more sheet materials may be integrally adhered, stitched, and / or stapled.

[0021] In some embodiments, the sheet material of the pouch or each pouch completely encloses the aerosol-forming material contained in the pouch.

[0022] In some embodiments, the sheet material defines the entire boundary of the storage area containing the aerosol-forming material.

[0023] In some embodiments, no other components are required to hold the aerosol-forming material in the pouch or each pouch.

[0024] In some embodiments, the pouch or each pouch forms the outer surface of the consumable.

[0025] In some embodiments, the first aerosol-forming material and / or the second aerosol-forming material is a free-flowing material.

[0026] In some embodiments, the second aerosol-forming material includes an extruded and / or compressed aerosol-forming material.

[0027] In some embodiments, the second aerosol-forming material includes beads.

[0028] In some embodiments, the beads have a diameter in the range of 0.5 to 3 mm, preferably in the range of 1 to 2 mm.

[0029] In some embodiments, the first aerosol-generating material includes, consists of, or is essentially composed of a tobacco material.

[0030] In some embodiments, the tobacco material of the first aerosol-generating material is derived solely from tobacco laminae and not from other types of tobacco material.

[0031] In some embodiments, the first aerosol-generating material includes tobacco lamina and recycled tobacco.

[0032] In some embodiments, the second aerosol-generating material includes, consists of, or is essentially composed of a tobacco material.

[0033] In some embodiments, the first aerosol generating material and the second aerosol generating material integrally have an average nicotine level in the range of 0.5% to 2.5% by weight, preferably 1% to 2.1% by weight, of the first aerosol generating material and the second aerosol generating material.

[0034] In some embodiments, the tobacco material of the second aerosol-generating material is derived solely from tobacco laminae and not from any other type of tobacco material.

[0035] In some embodiments, the second aerosol-generating material includes laminated tobacco and / or recycled tobacco.

[0036] In some embodiments, the consumable includes a first aerosol-generating material in the range of about 20 to about 330 mg, preferably a first aerosol-generating material in the range of about 50 to about 300 mg or about 40 to about 125 mg.

[0037] In some embodiments, the consumable includes a second aerosol-generating material in the range of about 20 to about 330 mg, preferably a second aerosol-generating material in the range of about 50 to about 300 mg or about 40 to about 125 mg.

[0038] In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material is a solid material.

[0039] In some embodiments, this consumable does not contain plastic.

[0040] In some embodiments, the density of the second aerosol-generating material is at least 25% higher than the density of the first aerosol-generating material.

[0041] In some embodiments, the first aerosol-generating material is approximately 0.1 g / cm³ 3 ~Approx. 1g / cm 3 It has a density of .

[0042] In some embodiments, the second aerosol-generating material is approximately 0.4 g / cm³. 3 ~About 2g / cm 3 It has a density of .

[0043] In some embodiments, heating of the consumables results in a relatively constant release of volatile compounds into the aspirable medium.

[0044] In some embodiments, the second aerosol-generating material includes extruded tobacco.

[0045] In some embodiments, the second aerosol-generating material includes beads.

[0046] In some embodiments, the first aerosol-generating material comprises one or more tobacco materials selected from the group consisting of laminae and recycled tobacco materials.

[0047] In some embodiments, at least one of the first aerosol-generating material and / or the second aerosol-generating material comprises a combination of lamina and recycled tobacco material. In some embodiments, the lamina and recycled tobacco material are present in the aerosol-generating material in a weight ratio of 1:4 to 4:1.

[0048] In some embodiments, the first and second aerosol-generating materials have the same level of volatile compounds. In some embodiments, the volatile compound is nicotine.

[0049] In some embodiments, the release of volatile compounds from the first and second aerosol-generating materials is at the same rate once the material reaches a given temperature.

[0050] In some embodiments, the first and second aerosol-generating materials are present in the article in a weight ratio of 1:10 to 10:1.

[0051] In some embodiments, one pouch contains a first aerosol-generating material and a second aerosol-generating material.

[0052] In some embodiments, the first aerosol-generating material and the second aerosol-generating material are integrally mixed in the single pouch.

[0053] In some embodiments, the first aerosol-generating material and the second aerosol-generating material are provided in discrete regions within the single pouch.

[0054] In some embodiments, one pouch contains a first aerosol-generating material and a second aerosol-generating material, and the consumable comprises another pouch which may also contain the first aerosol-generating material and / or the second aerosol-generating material or another aerosol-generating material. In other embodiments, the one pouch containing the first aerosol-generating material and the second aerosol-generating material is the sole pouch of the consumable.

[0055] In some embodiments, the first and second regions are discrete regions.

[0056] In some embodiments, the first region is located on the first end side of the pouch, and the second region is located on the second end side of the pouch.

[0057] In some embodiments, one of the first or second region surrounds, or at least partially surrounds, the other of the first and second regions.

[0058] In some embodiments, the pouch includes a divider that separates a first region and a second region. The divider may be a dividing wall.

[0059] In some embodiments, the consumable comprises a first pouch containing a first aerosol-generating material and a second pouch containing a second aerosol-generating material.

[0060] In some embodiments, the first pouch and the second pouch are connected. For example, the first pouch and the second pouch may be directly connected, for example, by integral bonding, sewing, or stapling of the first pouch and the second pouch, or by forming at least a portion of the first pouch and the second pouch from the same sheet material. In other embodiments, the first pouch and the second pouch may be integrally joined by attaching the first pouch and the second pouch to the same substrate (e.g., a paper substrate).

[0061] In some embodiments, the first aerosol-generating material and the second aerosol-generating material are produced from the same aerosol-generating starting material that has been processed to have different forms.

[0062] In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material includes an aerosol-forming material.

[0063] In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material comprises about 10 to about 50% by weight of an aerosol-forming material, about 15 to about 60% by weight of a gelling agent, and optionally a filler, where the weight percentage values ​​are calculated on a dry weight basis.

[0064] In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material includes a flavoring agent.

[0065] Furthermore, the present disclosure provides a method for manufacturing consumables used in an aerosol supply system, comprising the step of forming one or more pouches containing a first aerosol generating material and a second aerosol generating material, wherein the second aerosol generating material has a higher density than the first aerosol generating material.

[0066] In some embodiments, one side of the pouch contains a first aerosol-generating material, and the other side of the pouch contains a second aerosol-generating material.

[0067] In some embodiments, the above or each pouch comprises a first aerosol-generating material and a second aerosol-generating material.

[0068] In some embodiments, the above or each pouch includes a sheet material.

[0069] In some embodiments, the method includes the step of forming the sheet material for the above or each pouch as a tube containing a first aerosol-generating material and / or a second aerosol-generating material.

[0070] In some embodiments, the method includes the step of forming a sheet material as a structure having one end closed and the other end open, wherein a first aerosol-generating material and / or a second aerosol-generating material are provided within the structure of the sheet material.

[0071] In some embodiments, the structure is a continuous tube of sheet material. The continuous tube is closed at one end. A first aerosol-generating material and / or a second aerosol-generating material may be inserted into the continuous tube through the open end of the continuous tube.

[0072] In some embodiments, the method includes the step of supplying a first aerosol-generating material and / or a second aerosol-generating material to a construct under gravity.

[0073] In some embodiments, the method includes the step of supplying a first aerosol-generating material and / or a second aerosol-generating material to the open end of the structure.

[0074] In some embodiments, the sheet material component is a continuous tube of sheet material.

[0075] In some embodiments, the method includes the step of supplying a continuous flow of a first aerosol-generating material and / or a second aerosol-generating material to a component.

[0076] In some embodiments, this method includes the step of sealing and cutting a sheet material component at a location away from the closed end of the component to form a pouch.

[0077] In some embodiments, the step of sealing the structure includes crushing the structure, preferably crushing the structure so that the opposing walls of the sheet material of the structure become one. The step of sealing the structure may optionally include crimping the sheet material of the structure.

[0078] In some embodiments, the step of sealing and cutting the sheet material construct forms a second closed end of the construct.

[0079] In some embodiments, the first aerosol-generating material and the second aerosol-generating material are contained in a pouch between the closed end and the portion of the sheet material that is subsequently sealed and cut.

[0080] In some embodiments, the sheet material components are repeatedly sealed and cut to form multiple pouches.

[0081] In some embodiments, the components of the sheet material are sealed and cut simultaneously.

[0082] In some embodiments, the step of sealing the structure includes manipulating the structure such that the aerosol-generating material in the structure moves axially downstream and / or upstream of the portion of the structure to be sealed.

[0083] In some embodiments, the operation of the structure may include crushing the structure.

[0084] In some embodiments, the method includes the step of depositing a first aerosol-generating material and / or a second aerosol-generating material onto a sheet material, preferably the step of depositing a measured amount of the first aerosol-generating material and / or a second aerosol-generating material onto a sheet material.

[0085] In some embodiments, the method includes the step of wrapping a sheet material around a first aerosol-generating material and / or a second aerosol-generating material.

[0086] In some embodiments, the method includes the step of integrally mounting a first portion and a second portion of a sheet material such that a first aerosol-generating material and / or a second aerosol-generating material are held between the first portion and the second portion of the sheet material.

[0087] Furthermore, this disclosure provides consumables manufactured according to the methods disclosed herein.

[0088] Furthermore, this disclosure provides a package comprising several consumables disclosed herein. In some embodiments, this package is sealed.

[0089] Furthermore, this disclosure provides a component kit comprising consumables as disclosed herein and an aerosol supply device.

[0090] In some embodiments, the aerosol supply device includes a heating zone for receiving consumables and heating a first aerosol-generating material and a second aerosol-generating material.

[0091] The embodiments described below will be explained with reference to the attached drawings, but these are merely examples. [Brief explanation of the drawing]

[0092] [Figure 1] This is a top view of one embodiment of a consumable used with an aerosol supply system. [Figure 2] Figure 1 is a side cross-sectional view of the consumables. [Figure 3] This is a top view of the sheet material of the consumables shown in Figure 1, which is laid flat. [Figure 4] Figure 1 is a perspective view of the beads of the consumable aerosol generating material. [Figure 5] Figure 5A is a top view of the first step in a method for manufacturing consumables used with an aerosol supply system. Figure 5B is a top view of the second step in a method for manufacturing articles used with an aerosol supply system. Figure 5C is a top view of the third step in a method for manufacturing articles used with an aerosol supply system. [Figure 6] This is a schematic cross-sectional view of a continuous method for manufacturing articles used in conjunction with an aerosol supply system. [Figure 7] This is a schematic diagram of equipment for manufacturing articles used in conjunction with an aerosol supply system. [Figure 8]This is a side cross-sectional view of another embodiment of a consumable used with an aerosol supply system. [Figure 9] This is a side cross-sectional view of another embodiment of a consumable used with an aerosol supply system. [Figure 10] This is a side cross-sectional view of another embodiment of a consumable used with an aerosol supply system. [Figure 11] This is a cross-sectional view of one embodiment of a non-flammable aerosol supply device. [Figure 12] Figure 11 is a simplified schematic diagram of the components inside the housing of the aerosol supply device shown. [Figure 13] This is a cross-sectional view of the non-flammable aerosol supply device shown in Figure 11, into which the article shown in Figure 1 is inserted. Detailed explanation

[0093] In this specification, the term “delivery system” is intended to include a system for delivering at least one substance to a user. A combustible aerosol supply system for cigarettes, cigarillos, cigars, and pipe tobacco or homemade or home-rolled cigarette tobacco (whether based on tobacco, tobacco derivatives, extended tobacco, recycled tobacco, tobacco substitutes, or other smoking materials), A non-combustible aerosol supply system that releases compounds from aerosol-generating materials without combustion (such as a hybrid system that generates aerosols by combining e-cigarettes, tobacco heating products, and aerosol-generating materials), An aerosol-free delivery system that delivers at least one substance to a user orally, nasally, transdermally, or by other means without the formation of an aerosol (including, but not limited to, articles containing lozenges, gums, patches, inhalable powders, and oral products such as oral tobacco containing snus or moist snuff) (at least one substance may or may not contain nicotine), Includes.

[0094] According to this disclosure, a “non-flammable” aerosol supply system is one in which the aerosol-generating material (or its components) that make up the aerosol supply system is not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0095] In some embodiments, the delivery system is a non-flammable aerosol supply system, such as a powered non-flammable aerosol supply system.

[0096] In some embodiments, the non-flammable aerosol supply system is an e-cigarette, also known as a vaping device or electronic nicotine delivery system (END), but the presence of nicotine in the aerosol-generating material is not a requirement.

[0097] In some embodiments, the non-combustible aerosol supply system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a cigarette heating system.

[0098] In some embodiments, the non-flammable aerosol supply system is a hybrid system that generates an aerosol by a combination of aerosol-generating materials (one of which may be heated, or more of which may be heated). Each aerosol-generating material may be in the form of, for example, a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include a plant-based material (e.g., tobacco or non-tobacco product).

[0099] Typically, a non-flammable aerosol supply system may include a non-flammable aerosol supply device and consumables used in conjunction with the non-flammable aerosol supply device.

[0100] In some embodiments, the disclosure relates to consumables comprising aerosol-generating materials and configured for use with non-flammable aerosol supply devices. Throughout the disclosure, these consumables may be referred to as articles.

[0101] As used herein, the terms “upstream” and “downstream” are relative terms defined with respect to the direction of the mainstream aerosol drawn through the article or device during use. A “distal end” refers to the upstream end of a device, while a “proximal end” refers to the downstream end of a device.

[0102] In some embodiments, the non-flammable aerosol supply system (including the non-flammable aerosol supply device) may include a power source and a controller. The power source may be, for example, an electrical power source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate capable of supplying energy in the form of heat to an aerosol-generating material or heat-transferring material adjacent to the heat-generating power source.

[0103] In some embodiments, the non-flammable aerosol supply system comprises an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0104] In some embodiments, consumables used with a non-flammable aerosol supply device may include aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0105] The consumables include the delivered substance, which is an aerosol-generating material. This material may also optionally include one or more active components, one or more fragrances, one or more aerosol-forming materials, and / or one or more other functional materials.

[0106] In some embodiments, the delivered substance includes an active substance. The active substance used herein may be a physiologically active material (a material intended to realize or enhance a physiological reaction). The active substance may be selected from, for example, nutritional supplements, psychotropic drugs, and psychoactive agents. The active substance may be naturally occurring or obtained by synthesis. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or their components, derivatives, or combinations. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another plant. In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0107] As described herein, the active substance may include, or be derived from, one or more botanical substances or components, derivatives thereof, or extracts. In this specification, the term "botanical" may include, but is not limited to, any material derived from plants, such as extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, shells, pods, etc. Alternatively, the material may include active compounds that are naturally present in plants or obtained through synthesis. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, flakes, strips, sheets, etc. Examples of plants include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazelnut, hibiscus, laurel, licorice, matcha, mate, orange skin, papaya, rose, sage, tea (green or black), thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, Lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, peaflower, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, kalbi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.Mint varieties can be selected from the following: Mentha Arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0108] In some embodiments, the active substance comprises or is derived from one or more plant substances or components, derivatives thereof or extracts thereof, the plant being tobacco.

[0109] In some embodiments, the active substance comprises or is derived from one or more plant substances or components, derivatives thereof or extracts thereof, the plant being selected from eucalyptus, star anise, cocoa, and hemp.

[0110] In some embodiments, the active substance comprises or is derived from one or more plant substances or components, derivatives thereof or extracts thereof, the plant being selected from rooibos and fennel.

[0111] In some embodiments, the delivered substance includes a fragrance.

[0112] In this specification, the terms “flavor” and “flavorant” refer to materials that may be used to produce a desired flavor, aroma, or other sensation in products intended for adult consumers, where local regulations permit.These include naturally occurring flavorings, plant substances, extracts of plant substances, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaves, chamomile, fenugreek, clove, maple, matcha, menthol, mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes, tropical fruits). Roots, 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, chats, naswar, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-yi Orchid, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil of any species of the Mentha genus, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo leaf, hazelnut, hibiscus, laurel, mate, orange skin, rose, tea such as green or black tea, thyme, juniper, elderberry, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, peanut, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, dammi This product contains ingredients such as marjoram, olive, lemon balm, lemon basil, chives, kalbi, verbena, tarragon, limonene, thymol, and 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), as well as other additives such as charcoal, chlorophyll, minerals, plant-derived substances, or breath fresheners.These may be imitations, synthetic or natural ingredients, or mixtures thereof. They may also be in any preferred form, such as liquids like oil, solids like powders, or gels.

[0113] In some embodiments, the flavoring includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring includes cucumber, blueberry, citrus, and / or red berry flavorings. In some embodiments, the flavoring includes eugenol. In some embodiments, the flavoring includes flavorings extracted from tobacco. In some embodiments, the flavoring includes flavorings extracted from cannabis.

[0114] In some embodiments, the fragrance may contain sensory substances that are typically chemically induced and intended to produce a sensation perceived by stimulation of the fifth cranial nerve (trigeminal nerve), as an addition or replacement for olfactory or gustatory nerves, and these may include agents that produce heating, cooling, tingling, or numbing effects. A preferred thermal agent may be, but is not limited to, vanillyl ethyl ether. A preferred cooling agent may be, but is not limited to, eucalyptol or WS-3.

[0115] The aerosol-generating material may include an amorphous solid. In some embodiments, the aerosol-generating material includes an aerosol-generating film which is an amorphous solid. The amorphous solid may be a monolithic solid. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material capable of holding some fluid, such as a liquid, internally. In some embodiments, the amorphous solid may include, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% of amorphous solid. The aerosol-generating material may also be referred to as an aerosolizable material.

[0116] Aerosol-generating material is a material capable of generating an aerosol when energy is supplied, for example, by heating, irradiation, or any other method. The aerosol-generating material may be in the form of a solid, liquid, or gel, and may or may not contain active substances and / or flavorings. The aerosol-generating material is incorporated into articles used in an aerosol-generating system.

[0117] In this specification, the term "tobacco material" refers to any material including tobacco or its derivatives or substitutes. Tobacco material may be in any preferred form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, extended tobacco, re-tobacco, or tobacco substitutes. Tobacco material includes one or more of ground tobacco, tobacco fibers, loose tobacco, extruded tobacco, tobacco stems, tobacco laminas, re-tobacco, and / or tobacco extracts.

[0118] Consumables are articles containing aerosol-generating material or articles consisting of aerosol-generating material, which are intended to be consumed in whole or in part by the user during use. Consumables may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may also comprise an aerosol generator (in particular a heating element) that releases heat during use to generate an aerosol from the aerosol-generating material. The heater may comprise an electrically conductive material or a susceptor.

[0119] The aerosol-generating material may include one or more active substances and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0120] The aerosolizable material may be present on the substrate. The substrate may be, for example, paper, cardboard, thick paper, recycled aerosolizable material, plastic material, ceramic material, composite material, glass, metal, or alloy, or may contain these materials.

[0121] The aerosol-forming material may contain one or more constituent substances capable of forming an aerosol. In some embodiments, the aerosol-forming material may contain one or more of the following: glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl sulfate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0122] One or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0123] Consumables are articles containing aerosol-generating material or articles consisting of aerosol-generating material, which are intended to be consumed in whole or in part by the user during use. Consumables may also comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may also comprise an aerosol generator, such as a heater, which releases heat during use to generate an aerosol from the aerosol-generating material. The heater may include, for example, a flammable material, an electrically conductive material, or a susceptor.

[0124] A susceptor is a material that can be heated by the intrusion of a fluctuating magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material so that induction heating of the heating material occurs upon intrusion of the fluctuating magnetic field. The heating material may be a magnetic material so that magnetic hysteresis heating of the heating material occurs upon intrusion of the fluctuating magnetic field. The susceptor may have both conductive and magnetic properties so that it can be heated by both heating mechanisms. In this specification, a device configured to generate a fluctuating magnetic field is referred to as a magnetic field generator.

[0125] Aerosol modifiers are typically located downstream of the aerosol generation area and are configured to modify the generated aerosol by altering, for example, the flavor, taste, acidity, or other properties of the aerosol. The aerosol modifier may be provided in an aerosol modifier release component that is operable to selectively release the aerosol modifier.

[0126] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may contain, for example, one or more of the following: flavorings, colorings, water, and carbon adsorbents. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in powder, thread, or granular form. The aerosol modifier may not have a filter material.

[0127] 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 form an aerosol by applying thermal energy to the aerosol-generating material, thereby causing one or more volatile substances to be released from the aerosol-generating material. In some embodiments, the aerosol generator is configured to generate an aerosol from an aerosol-generating material without heating. For example, the aerosol generator may be configured to apply one or more of the following to the aerosol-generating material: vibration, high pressure, or electrostatic energy.

[0128] The filamentous tow materials described herein may include cellulose acetate fiber tow. Furthermore, filamentous tow can be formed using other materials used for fiber formation, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4-butanediol succinate) (PBS), poly(butylene adipate coterephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. The filamentous tow may be plasticized with a tow-suitable plasticizer (triacetin in the case of cellulose acetate tow) or left unplasticized. The tow may have any suitable specifications, such as the fibers having a cross-section that is "Y"-shaped or "X"-shaped, the filament fineness value per filament being 2.5 to 15 denier (e.g., 8.0 to 11.0 denier), and the total fineness value being 5,000 to 50,000 (e.g., 10,000 to 40,000).

[0129] In the drawings described herein, the same reference numerals are used to indicate equivalent features, articles, or components.

[0130] Figure 1 is a top view of consumable 1 used in an aerosol delivery system equipped with an aerosol delivery device 200 (see Figures 11 to 13). Figure 2 is a side cross-sectional view of consumable 1 in Figure 1.

[0131] Consumable 1 has an upstream or distal end "D" and a downstream or proximal end "P". In some embodiments, the proximal end P is positioned relatively closer to the mouthpiece 207 of the aerosol delivery device 200 than the distal end D when in use. In another embodiment (not shown), the proximal end P of consumable 1 comprises a mouthpiece. In some embodiments (not shown), the proximal end P of consumable 1 constitutes a mouthpiece.

[0132] In some embodiments, it is recognized that the consumable 1 can be used with the aerosol delivery device 200 in any orientation, regardless of whether either end of the consumable 1 is upstream or downstream.

[0133] Consumable 1 comprises a pouch 2 containing a space 3 that encloses the first and second aerosol-generating materials 4 and 5. As will be explained in more detail below, the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4.

[0134] The first and second aerosol-generating materials 4 and 5 are configured to be heated in space 3 to generate aerosols. Space 3 may be filled with the first and second aerosol-generating materials 4 and 5, or at least partially filled with them. Space 3 may constitute a storage area 3 for the first and second aerosol-generating materials 4 and 5.

[0135] In alternative embodiments (not shown), the consumable comprises a first pouch containing a first aerosol-generating material and a second pouch containing a second aerosol-generating material. In some embodiments, the first and second pouches are connected. For example, the first and second pouches may be directly connected, for example, by integral bonding, sewing, or stapling of the first and second pouches, or by forming at least a portion of the first and second pouches from the same sheet material. In other embodiments, the first and second pouches may be integrally joined by attaching the first and second pouches to the same substrate (e.g., a paper substrate).

[0136] In this example, pouch 2 includes sheet material 6. In this example, sheet material 6 includes paper. Optionally, sheet material 6 may consist of paper or be essentially composed of paper. In other embodiments, it is recognized that sheet material 6 may include, as an addition or alternative, another material (e.g., metal foil, woven material (e.g., cotton), or laminate material (e.g., paper and metal foil laminate)). In some embodiments, sheet material 6 does not contain plastic.

[0137] In some embodiments, the sheet material 6 is gas permeable. This allows gas to enter the pouch 2 through the permeable sheet material 6, interact with the first and second aerosol-generating materials 4 and 5, and then exit the pouch 2, where it can be inhaled by the user. In some embodiments, the sheet material 6 has a permeability in the range of 10 to 25,000 centa units. In some embodiments, the sheet material 6 has a permeability of at least 10 centa units, preferably at least 100, 200, 500, 1000, 2000, 5000, 10000, 15000, 20000, or 25000 centa units. In some embodiments, the sheet material 6 has a permeability of up to 25,000 centa units, preferably up to 20000, 15000, 10000, 5000, 2000, 1000, 500, 200, 100, 75, or 50 centa units. In some embodiments, the sheet material 6 has an air permeability in the range of 25 to 100 cholesta units.

[0138] In some embodiments, the sheet material 6 is porous to promote breathability of the sheet material 6. As an alternative or addition, in some embodiments, the sheet material 6 has one or more openings (not shown) through which gas can pass.

[0139] In some embodiments, the sheet material 6 has a thickness in the range of 20 to 100 microns, optionally in the range of 30 to 80 microns, 35 to 55 microns, or 40 to 50 microns (therefore, the pouch wall has this thickness). In some embodiments, the thickness of the sheet material 6 (i.e., the thickness of the pouch wall) is at least 20 microns, preferably at least 30, 40, or 50 microns. In some embodiments, the thickness of the sheet material 6 (i.e., the thickness of the pouch wall) is up to 100 microns, preferably up to 90, 80, 70, 60, or 50 microns.

[0140] It has been found that increasing the air permeability of the sheet material 6 promotes heat transfer to the aerosol-generating materials 4 and 5 through the sheet material 6. It has also been found that reducing the thickness of the sheet material 6 promotes heat transfer to the aerosol-generating materials 4 and 5 through the sheet material 6. Promoting heat transfer through the sheet material 6 is advantageous because it improves the heating efficiency of the first and second aerosol-generating materials 4 and 5.

[0141] The sheet material 6 is configured to form the pouch 2, for example, by folding and / or winding.

[0142] In some embodiments, at least one edge 6A, 6B, 6C, 6D of the sheet material 6 is attached to another portion of the sheet material 6 to hold the first and second aerosol-generating materials 4, 5 in the space 3 of the pouch 2. In some embodiments, the at least one edge 6A, 6B, 6C, 6D of the sheet material 6 is attached by adhesive, crimping, stapling, or sewing.

[0143] In this example, the sheet material 6 is a flexible material. In this example, the wall of pouch 2 is flexible.

[0144] In some embodiments, the pouch 2 constitutes the outer surface of the consumable 1. In this example, the first surface of the sheet material 6 faces inward and constitutes the boundary of the space 3, and the second surface of the sheet material 6 faces outward and constitutes the outer surface 1A of the consumable 1.

[0145] In some embodiments, the first and / or second aerosol-generating materials 4, 5 are free materials. The first and / or second aerosol-generating materials 4, 5 may be in the form of discrete particles.

[0146] In this example, the second aerosol-generating material 5 includes an extruded and / or compressed aerosol-generating material, as will be described in more detail below. However, it should be recognized that in other embodiments, the second aerosol-generating material 5 may take a different form.

[0147] In some embodiments, the first and / or second aerosol-generating materials 4, 5 include beads. The beads may be cylindrical or of another shape (e.g., spherical, pyramidal, or cuboidal).

[0148] In this example, the second aerosol-generating material 5 includes beads 5 (as shown in Figure 3).

[0149] In some embodiments, the bead 5 has a diameter in the range of 0.5 to 3 mm, preferably in the range of about 1 to 2 mm (indicated by arrow "D" in Figure 4).

[0150] In some embodiments, the bead 5 has an axial length (indicated by the arrow "L" in Figure 4) in the range of 0.5 to 3 mm, preferably in the range of about 1 to 2 mm.

[0151] In some embodiments, the beads 5 have a particle size (measurable by sieving) in the range of 0.5 to 3 mm, preferably in the range of about 1 to 2 mm.

[0152] In some embodiments, the first and / or second aerosol-generating materials 4, 5 include, consist of, or essentially consist of tobacco material.

[0153] In some embodiments, the tobacco material of the first and / or second aerosol-generating materials 4 and 5 is derived solely from tobacco laminae and not from any other type of tobacco material.

[0154] In some embodiments, the first and / or second aerosol-generating materials 4, 5 include tobacco lamina and recycled tobacco.

[0155] In some embodiments, the first and second aerosol-generating materials 4 and 5 integrally have an average nicotine level in the range of 0.5% to 2.5% by volume, preferably 1% to 2.1% by volume.

[0156] In some embodiments, the first aerosol-generating material 4 has a nicotine level in the range of 0.5% to 2.5% by volume, preferably in the range of 1% to 2.1% by volume.

[0157] In some embodiments, the second aerosol-generating material 5 has a nicotine level in the range of 0.5% to 2.5% by volume, preferably in the range of 1% to 2.1% by volume.

[0158] In some embodiments, the article comprises about 20 to about 330 mg of a first aerosol-generating material 4, preferably about 50 to about 300 mg, about 100 to about 200 mg, or about 40 to about 125 mg of the first aerosol-generating material 4.

[0159] In some embodiments, the article comprises about 20 to about 330 mg of a second aerosol-generating material 5, preferably about 50 to about 300 mg, about 100 to about 200 mg, or about 40 to about 125 mg of the second aerosol-generating material 5.

[0160] In some embodiments, the total mass of the aerosol-generating materials 4 and 5 in space 3 is in the range of 80 to 300 mg. In some embodiments, the total mass of the tobacco material in space 3 is in the range of 80 to 300 mg or 150 to 270 mg.

[0161] In some embodiments, the first and / or second aerosol-generating materials 4, 5 are solid materials.

[0162] In some embodiments, the first and second aerosol-generating materials 4 and 5 are different materials and / or have one or more different properties.

[0163] Consumable 1 may have an axial length of at least 10 mm, preferably at least 12, 14, 16, 18, 20, 22, or 23 mm (indicated by the arrow "X" in Figure 1).

[0164] Consumable 1 may have an axial length of up to 36 mm, preferably up to 34, 32, 30, 28, 26, 24, or 23 mm.

[0165] Consumable 1 may have an axial length in the range of 10 to 36 mm, preferably in the range of 14 to 32 mm, 20 to 26 mm, or 22 to 24 mm.

[0166] In some embodiments, the sheet material 6 does not contain plastic. This makes the consumable 1 more environmentally friendly and is also convenient in embodiments where the entire consumable 1 is heated by the aerosol delivery device 200 (as described later).

[0167] In some embodiments, the sheet material 6 does not contain cellulose acetate.

[0168] In some embodiments, the entire consumable 1 does not contain plastic. In some embodiments, neither the sheet material 6 nor the entire consumable 1 contains cellulose acetate.

[0169] In some embodiments, the first and / or second aerosol-generating materials 4, 5 may contain tobacco material, consist of tobacco material, or essentially consist of tobacco material. The term "tobacco material" refers to any material including tobacco or its derivatives or substitutes. The tobacco material may be in any preferred form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, extended tobacco, re-tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fibers, loose tobacco, extruded tobacco, tobacco stems, tobacco laminas, re-tobacco, and / or tobacco extracts.

[0170] In some embodiments, the first and / or second aerosol-generating materials 4, 5 or another material (not shown) in the space 6 may contain one or more aerosol-forming materials. For example, the first and / or second aerosol-generating materials 4, 5 or the other material may contain one or more components capable of forming aerosols. The aerosol-forming materials include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl sulfate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. Glycerol or propylene glycol are possible aerosol-forming materials.

[0171] The first and / or second aerosol-generating materials 4, 5 may be provided in the space 3 as free material held in the space 3 by the sheet material 6 that constitutes the wall of the pouch 2. The first and / or second aerosol-generating materials 4, 5 may be, for example, discrete strands or particles of aerosol-generating material. Another example of free aerosol-generating material is beads / pellets of aerosol-generating material, which include aerosol-generating material that has been cut into beads / pellets after being extruded. Yet another example of aerosol-generating material is a sheet of aerosol-generating material that has been cut into individual pieces (e.g., individual strips) of aerosol-generating material. The sheet of aerosol-generating material may be a sheet of recycled tobacco.

[0172] In this example, the first aerosol-generating material 4 includes shredded tobacco material (e.g., shredded lamina and / or shredded recycled tobacco).

[0173] In this example, the second aerosol-generating material 5 includes extruded and / or compressed tobacco. In such embodiments, the second aerosol-generating material 5 may include a single body of aerosol-generating material or may include multiple bodies of aerosol-generating material.

[0174] In this example, the second aerosol-generating material 5 includes beads / pellets / granules of the aerosol-generating material (hereinafter referred to as "beads" of the aerosol-generating material).

[0175] The second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4. This means that when the heater of the device 200 operates to heat the consumable 1, the second aerosol-generating material 5 heats up more slowly than the first aerosol-generating material 4. This means that, when the first aerosol-generating material 4 and the second aerosol-generating material 5 receive the same heating power, the first aerosol-generating material 4 initially releases one or more volatile compounds (e.g., nicotine) faster than the second aerosol-generating material 5. It also means that the first aerosol-generating material 4 relatively consumes the (one or more) volatile compounds more rapidly than the second aerosol-generating material 5. However, by the time the first aerosol-generating material 4 begins to relatively consume the (one or more) volatile compounds, the second aerosol-generating material 5 will begin to reach a temperature at which it begins to rapidly release the (one or more) volatile compounds. As a result of this, the release of (one or more) volatile compounds over the consumption period of consumable 1 becomes more consistent, with the first aerosol-generating material 4 releasing a larger proportion of (one or more) volatile compounds towards the start of consumption of consumable 1, and the second aerosol-generating material 5 releasing a larger proportion of (one or more) volatile compounds towards the end of consumption of consumable 1. This is particularly advantageous because it allows for a relatively smaller pouch 1 while still achieving a relatively consistent and / or sufficient release of (one or more) volatile compounds over the consumption period.

[0176] In some embodiments, the density of the second aerosol-generating material 5 is at least 25% higher than the density of the first aerosol-generating material 4.

[0177] In some embodiments, the first aerosol-generating material 4 is approximately 0.1 g / cm³ 3 ~Approx. 1g / cm 3 It has a density of .

[0178] In some embodiments, the second aerosol-generating material 5 is approximately 0.4 g / cm³. 3 ~About 2g / cm3 It has a density of .

[0179] In some embodiments, the one or more volatile compounds released by the first aerosol-generating material 4 are the same as the (one or more) volatile compounds released by the second aerosol-generating material 5.

[0180] In some embodiments, the first aerosol-generating material 4 is heated (for example, by a first heater) during the first period of a consumption session, and the second aerosol-generating material 5 is heated (for example, by a second heater) during the second period. For example, in some embodiments, the first and second aerosol-generating materials 4 and 5 are located in separate areas that are heated separately. In other embodiments, the first and second aerosol-generating materials 4 and 5 are heated simultaneously, but may, for example, be mixed together.

[0181] In some embodiments, the second aerosol-generating material 5 includes an aerosol-generating material that has been compressed or extruded to have a higher density than the first aerosol-generating material 4 (with no subsequent expansion, or relatively small / minimal expansion).

[0182] In some embodiments, the first aerosol-generating material 4 comprises one or more of tobacco laminae, tobacco stems, or recycled tobacco. In one such embodiment, the first aerosol-generating material 4 comprises a mixture of tobacco laminae and recycled tobacco. The first aerosol-generating material 4 may also comprise shredded or cut material. However, in other embodiments, it is recognized that the first aerosol-generating material 4 comprises compressed or extruded aerosol-generating material with a lower density than the second aerosol-generating material 5 (e.g., less compressible than the second aerosol-generating material 5, which may be optionally extruded or compressed).

[0183] In some embodiments, the first and second aerosol-generating materials 4 and 5 may contain the same material (e.g., tobacco) but are processed to have different densities. In one such embodiment, the first and second aerosol-generating materials 4 and 5 may be in different forms. For example, the first aerosol-generating material 4 may be shredded free material (e.g., shredded laminated tobacco and / or shredded recycled tobacco), while the second aerosol-generating material 5 may be compressed or extruded to be denser than the first aerosol-generating material 4 (with or without minimal expansion).

[0184] For example, the second aerosol-generating material 5 may be in the form of extruded / compressed beads of the aerosol-generating material (e.g., tobacco or another material), and the first aerosol-generating material 4 may be in the form of strands or strips of the aerosol-generating material (e.g., tobacco or another material), sheets of aerosol-generating material collected as plugs or cut into strips, free material (e.g., shredded tobacco), high-density ends of rods of the aerosol-generating material (e.g., tobacco), or tobacco laminae and / or stem material formed as plugs. However, it should be recognized that the first, second, and / or third aerosol-generating materials 4, 5 may, as an alternative, have the same form (e.g., both shredded tobacco) but still have different densities.

[0185] In some embodiments, the first aerosol-generating material 4 has at least one different property from the second aerosol-generating material 5. The different property may be one or more of the shape, size, water content, quantity (weight), one or more materials, or the ratio of materials that constitute the first and second aerosol-generating materials 4 and 5 (including the method of manufacturing the aerosol-generating materials 4 and 5 if each is manufactured from two or more materials). In one preferred embodiment, the first and second aerosol-generating materials 4 and 5 have no different properties other than density and are identical in that respect.

[0186] The first and / or second aerosol-generating materials 4 and 5 may include a plurality of strands or strips of the aerosol-generating material. For example, the first and / or second aerosol-generating materials 4 and 5 may include a plurality of strands or strips of the aerosolizable material and / or a plurality of strands or strips of the amorphous solid.

[0187] The first and / or second aerosol-generating materials 4 and 5 may contain plant-based materials such as tobacco material. The first and / or second aerosol-generating materials 4 and 5 may be sheets or shredded sheets of aerosolizable material containing plant-based materials such as tobacco material. The sheet material may be processed such that the second aerosol-generating material 5 is denser than the first aerosol-generating material 4.

[0188] The plant-based material may be particulate or granular. In some embodiments, the plant-based material is a powder. As an alternative or addition, the plant-based material may include tobacco strips, strands, or fibers. For example, if a tobacco material is provided, this tobacco material may include tobacco particles, granules, fibers, strips, and / or strands. In some embodiments, the tobacco material consists of tobacco particles or granules.

[0189] The tobacco material of the first and / or second aerosol-generating materials 4, 5 may include tobacco obtained from any part of the tobacco plant. In some embodiments, the tobacco material includes tobacco leaves.

[0190] The sheets or shredded sheets may contain 5% to approximately 90% by weight of tobacco leaves.

[0191] In some embodiments, the first and / or second aerosol-generating materials 4 and 5 each contain, consist of, or essentially consist of tobacco material.

[0192] In some embodiments, the first and / or second aerosol-generating materials 4, 5 comprise a sheet or shredded sheet of an aerosolizable material containing the aerosol-forming material. Optionally, the aerosol-forming material is provided in an amount of up to about 50% by weight of the sheet or shredded sheet 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 sheet on a dry weight basis, about 10% to about 30% by weight of the sheet or shredded sheet on a dry weight basis, or about 10% to about 20% by weight of the sheet or shredded sheet on a dry weight basis.

[0193] The first and / or second aerosol-generating materials 4, 5 may contain a filler. The filler is generally a non-tobacco component, i.e., a component that does not contain tobacco-derived inclusions. The filler may contain one or more inorganic fillers, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may also be a non-tobacco fiber, such as wood fiber, i.e., pulp or wheat fiber. The filler may also contain cellulose or a derivative of cellulose. Furthermore, the filler component may be a non-tobacco cast material or a non-tobacco extruded material. In some embodiments, the first and / or second aerosol-generating materials 4, 5 are in the form of a sheet or shredded sheet containing the filler.

[0194] The first and / or second aerosol-generating materials 4 and 5 may include an aerosol modifier, such as any of the fragrances described herein. In one embodiment, the first and / or second aerosol-generating materials 4 and 5 include menthol. When the first and / or second aerosol-generating materials 4 and 5 are incorporated into a consumable 1 used in an aerosol supply system, this article may be referred to as a menthol consumable or article 1. The first and / or second aerosol-generating materials 4 and 5 may 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.

[0195] In some embodiments, article 1 comprises an aerosol-generating composition comprising an aerosol-generating material. The aerosol-generating material may include first and / or second aerosol-generating materials 4, 5.

[0196] Aerosol-generating material is a material capable of generating an aerosol when energy is supplied, for example, by heating, irradiation, or any other method. The aerosol-generating material (e.g., the first and / or second aerosol-generating materials 4, 5) may be in the form of, for example, a solid, a liquid, or a semi-solid (such as a gel), and may or may not contain active substances and / or flavorings.

[0197] The aerosol-generating material (e.g., the first and / or second aerosol-generating material 4, 5) may contain a binder and an aerosol-forming agent. Optionally, an active material and / or a filler may also be present. Optionally, a solvent such as water may be present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material (e.g., the first and / or second aerosol-generating material 4, 5) is substantially free of plant-derived materials. In particular, in some embodiments, the aerosol-generating material (e.g., the first and / or second aerosol-generating material 4, 5) is substantially free of tobacco.

[0198] The aerosol-generating material (e.g., the first and / or second aerosol-generating materials 4, 5) may contain an "amorphous solid," or it may be an "amorphous solid." The amorphous solid may be a "monolithic solid." In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material capable of holding some fluid, such as a liquid, internally. In some embodiments, the aerosol-generating material may contain, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% of an amorphous solid. The amorphous solid may be substantially non-fibrous.

[0199] The aerosol-generating material (e.g., the first and / or second aerosol-generating materials 4, 5) may include an aerosol-generating film or may be an aerosol-generating film itself. The aerosol-generating film may be formed by combining a binder such as a gelling agent with a solvent such as water, an aerosol-forming agent, and one or more other components (e.g., an active substance) to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent. The slurry may be such that at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent is removed by heating. The aerosol-generating film may be a continuous film or a discontinuous film (e.g., a discrete film component on a support). The aerosol-generating film may not substantially contain tobacco.

[0200] The aerosol-generating film may contain a sheet, or may be a sheet in itself, and optionally, it may be formed into shredded sheets by shredding.

[0201] The aerosol-generating material (for example, the first and / or second aerosol-generating materials 4, 5) may include one or more active substances and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0202] In each embodiment of Article 1 described herein, the Article may contain the first and / or second aerosol-generating materials 4, 5 as described above, and may also contain the aerosol-generating composition as described above.

[0203] The first and / or second aerosol-generating materials 4, 5 may include recycled tobacco material. The composition may, as an alternative or addition, include any of the forms of tobacco described herein. The first and / or second aerosol-generating materials 4, 5 may include a sheet or shredded sheet containing tobacco material comprising 10% to 90% by weight of tobacco leaves, wherein the aerosol-generating material is provided in an amount up to about 20% by weight of the sheet or shredded sheet, and the remaining portion of the tobacco material contains recycled tobacco.

[0204] If the first and / or second aerosol-generating materials 4, 5 include an amorphous solid material, this amorphous solid material may be a dry gel containing menthol.

[0205] In some embodiments, the first and / or second aerosol-generating materials 4, 5 include extruded aerosol-generating materials that are cut into pellet beads.

[0206] Referring now to Figures 5A to 5C, these figures illustrate a method for manufacturing consumables 1 for the aerosol supply device 200.

[0207] In the first step, a sheet material 6 is prepared and placed flat or in a U-shape. In the second step, the first and second aerosol-generating materials 4 and 5 are deposited onto the sheet material 6 (as shown in Figure 5A). In some embodiments, predetermined amounts or quantities of the first and second aerosol-generating materials 4 and 5 are each deposited onto the sheet material 6 using a weighing drum, which may include, for example, pneumatic or pocket wheel weighing.

[0208] The first and second aerosol-generating materials 4 and 5 may be pre-mixed prior to deposition onto the sheet material 6. Alternatively, the first and second aerosol-generating materials 4 and 5 may be integrally mixed during or after deposition onto the sheet material 6. In some embodiments, the first and second aerosol-generating materials 4 and 5 may be mixed during storage, transport, and / or use of the consumable 1. In yet another embodiment, the first and second aerosol-generating materials 4 and 5 may be provided in separate regions 4A and 5A to constitute any of the consumables 1 shown in Figures 8 to 10, for example.

[0209] In the third step, the sheet material 6 is wrapped around the first and second aerosol-generating materials 4 and 5 to form a roughly tubular structure with open ends (as shown in Figure 5B). In this example, the first edge 6A of the sheet material 6 is positioned to overlap the opposite second edge 6B to form a tube, but the sheet material 6 is then held in place, for example, by applying adhesive to the sheet material 6 in the region of one or both of the first and second edges 6A and 6B, or by stapling, welding, or sewing the sheet material 6 in the region of the first and second edges 6A and 6B.

[0210] In the fourth step, the open end of the tube is sealed to form a pouch 2 containing the first and second aerosol-generating materials 4 and 5. In this example, the third edge 6C of the sheet material 6 is folded over and held in place, for example by adhesive, sewing or stapling of the sheet material 6. Similarly, the opposite fourth edge 6D of the sheet material 6 is also folded over and held in place, for example by adhesive, sewing or stapling of the sheet material 6. However, in alternative embodiments, it is recognized that one or both of the open ends are not folded over, and instead, the third and fourth edges 6C and 6D of the sheet material 6 are sealed (for example by adhesive, welding, sewing or stapling of the sheet material 6) without first folding them over.

[0211] Referring here to Figures 6 and 7, these figures illustrate another method for manufacturing consumables 1 for the aerosol supply device 200 and an apparatus 300 for carrying out this method.

[0212] A continuous web W of sheet material is supplied from a reel R of sheet material 6. The web W is supplied along a transport path (indicated by the arrow "P" in Figures 6 and 7). For example, the web W may be transported along the transport path P by one or more rollers 301, 302.

[0213] In the first step S1, the web W is formed as a component of the sheet material 6, which in this example is a continuous tube T of the sheet material 6. For example, the web W may be supplied through a molding device 303 (e.g., a cone, garnish, or tongue that molds the initially flat web W into a tube T). The molding device 303 may have a conical or O-shaped cross-section that molds the web W into a tube T.

[0214] The molding device 303 may be configured to apply an adhesive to the web W to hold the web W in the shape of a tube. Alternatively or additionally, the adhesive may be pre-applied to the web W and activated after or during the formation of a portion of the web W as a tube T to hold the web W in the shape of a tube. In some embodiments, the adhesive is applied to the tube T downstream of the molding device 303, for example, by a separate adhesive dispenser (not shown).

[0215] In the second step S2, the first and second aerosol-generating materials 4 and 5 are supplied to the tube T. In this example, the first and second aerosol-generating materials 4 and 5 are supplied to the tube T from above so that they fall due to the effect of gravity and are delivered to the lower region of the tube T. However, it is recognized that in other embodiments, the first and second aerosol-generating materials 4 and 5 may be supplied by, for example, pneumatic pressure as an addition or alternative.

[0216] In this example, the first and / or second aerosol-generating materials 4 and 5 are supplied to tube T as a continuous flow of the first and / or second aerosol-generating materials 4 and 5.

[0217] In this example, the first and second aerosol-generating materials 4 and 5 are supplied to the tube T through the molding device 303. For example, the first and second aerosol-generating materials 4 and 5 may be supplied through a conical member that forms the web W into the tube T.

[0218] The first and second aerosol-generating materials 4 and 5 are placed inside a tube T, and at least a portion of the tube T is configured to be transported continuously together with the first and second aerosol-generating materials 4 and 5 located inside it.

[0219] In this example, the first aerosol-generating material 4 is supplied to tube T by the first supply device 304, and the second aerosol-generating material 4 is supplied to tube T by the second supply device 305. However, in other embodiments, it is recognized that the first and second aerosol-generating materials 4 and 5 may be pre-mixed and then supplied integrally to tube T via a single supply device (not shown).

[0220] The above-mentioned or each of the supply devices 304, 305 may be configured to transfer the aerosol-generating material 4, 5 by gravity supply and / or alternative or additional means (e.g., pneumatics). The above-mentioned or each of the supply devices 304, 305 may be configured to supply a continuous flow of the aerosol-generating material, or to provide metered aerosol-generating material (e.g., using a metering wheel).

[0221] In the third step S3, the portion of tube T containing the first and second aerosol-generating materials 4 and 5 passes through the sealing device 306. The sealing device 306 is configured to crush the tube T so that the first and second aerosol-generating materials 4 and 5 contained within are pushed axially upstream and downstream of the sealing device 306 (i.e., upstream and downstream in the direction of the transport path P), causing the walls of tube T to seal themselves. For example, tube T can be sealed by crimping its ends.

[0222] In this example, tube T is sealed along the dashed line "Z1-Z1" shown in Figure 6.

[0223] The sealing device 306 is configured to hold the end of the tube T in a sealed configuration. For example, the sealing device 306 may be configured to apply an adhesive (e.g., a suitable adhesive such as PVA), stitching, or stapling to the crimped / compressed portion of the tube T, or to weld the portion of the tube T. In some embodiments, the web W is pre-coated with adhesive. In one such embodiment, the sealing device 306 is configured to activate a hot-melt adhesive at the crimped / compressed portion of the tube T so that the adhesive holds the tube T in a sealed configuration.

[0224] In this example, the sealing device 306 includes a pair of sealing members 307 and 308 that reciprocate toward each other to intermittently compress and seal a portion of the tube T, and then move away from each other, allowing the portion of the tube T containing the aerosol-generating materials 4 and 5 to pass through without being compressed. In other embodiments (not shown), the sealing members are mounted on a rotating wheel, and a plurality of consecutive pairs of sealing members are intermittently aligned to compress and seal a portion of the tube T.

[0225] In this example, each sealing member 307, 308 includes wedge-shaped members 307A, 308A. Due to the shape of each wedge-shaped member 307A, 308A, the first and second aerosol-generating materials 4, 5 contained in the tube T are pushed axially upstream and downstream (i.e., upstream and downstream in the direction of the transport path P) of the wedge-shaped members 307A, 308A of the sealing device.

[0226] In the fourth step S4, the sealed portion of the tube T passes through a cutting device 309 that cuts the tube T at the sealed portion to form individual consumables 1 (for example, the tube T may be cut along the dashed line "Z2-Z2" shown in Figure 6).

[0227] In this example, the cutting device 309 comprises a pair of cutting rollers 310, 311, each having cutting blades 310A, 311A ​​that intermittently meet to cut the tube T at its sealed end. However, it is recognized that in alternative embodiments (not shown), the cutting device 309 may have a different configuration (for example, comprising one or more reciprocating cutting knives or one or more lasers that intermittently cut the tube T).

[0228] In an alternative embodiment, it is recognized that a single device performs the functions of both the sealing device 306 and the cutting device 309 described above. For example, in one alternative embodiment, the cutting device 309 is omitted, and instead, wedge-shaped members 307A and 308A each have sharp cutting edges that cut the tube T upon joining.

[0229] In the consumables shown in Figures 1 and 2, the first aerosol generating material and the second aerosol generating materials 4 and 5 are integrally mixed in the space 3 of the pouch 2. In other embodiments, one of the first and second aerosol generating materials 4 and 5 may be scattered in part or in whole of the other.

[0230] Referring now to Figure 8, this figure shows an alternative embodiment of consumable 1. Consumable 1 has similar features to consumable 1 described above with respect to Figures 1 and 2, and the same reference numerals are used for similar features. The difference is that the first and second aerosol-generating materials 4 and 5 are not mixed integrally, but rather the first aerosol-generating material 4 is provided in the first region 4A and the second aerosol-generating material 5 is provided in the second region 5A. The first and second regions 4A and 5A may be discrete, and may be separated from each other as an option. In this example, the first and second regions 4A and 5A are in contact with each other, rather than being separated.

[0231] The first region 4A is provided on the first end side of the consumable 1, and the second region 5A is provided on the second end side of the consumable 1. For example, the first region 4A may be provided on one side of the proximal end P and distal end D of the consumable 1, and the second region 5A may be provided on the other side of the proximal end P and distal end D of the consumable 1.

[0232] Referring now to Figure 9, this figure shows another embodiment of consumable 1. Consumable 1 has similar features to consumable 1 described above with respect to Figure 8, and the same reference numerals are used for similar features. In this case as well, the first and second aerosol-generating materials 4 and 5 are provided in the first and second regions 4A and 5A, respectively. The difference is that instead of the first region 4A being located on the first end side of consumable 1 and the second region 5A being located on the second side of consumable 1, both regions 4A and 5A extend between the first and second ends of consumable 1. In some embodiments, the first and second regions 4A and 5A are located on either side of the central axis of consumable 1.

[0233] Referring now to Figure 10, this figure shows another embodiment of consumable 1. Consumable 1 has similar features to consumable 1 described above with respect to Figure 8, and the same reference numerals are used for similar features. In this case as well, the first and second aerosol-generating materials 4 and 5 are provided in the first and second regions 4A and 5A, respectively. The difference is that a divider 7 is provided to facilitate the separation of the first and second aerosol-generating materials 4 and 5. The divider 7 may be gas permeable and may, for example, have a portion of mesh or sheet material (optionally, it may be porous and may have one or more openings to facilitate gas flow through consumable 1). Optionally, the divider 7 may be a sheet material integrally formed with the rest of the sheet material 6 of the pouch 2.

[0234] By placing the first and second aerosol-generating materials 4 and 5 in separate regions 4A and 5A (for example, as shown in Figures 8 to 10), the first and second aerosol-generating materials 4 and 5 can be heated separately at different times using, for example, first and second heaters. For example, by first heating the first region 4A containing the relatively low-density first aerosol-generating material 4 with the first heater, aerosols can be generated toward the start of the consumption session. Subsequently, by heating the second region 5A containing the relatively high-density second aerosol-generating material 5, or by starting and heating them simultaneously for a longer period, aerosols can be generated toward the end of the consumption session, thereby promoting more consistent aerosol generation over the duration of the consumption session. However, in other embodiments, the first and second aerosol-generating materials 4 and 5 are not located in separate regions, and it is recognized that the different densities of the first and second aerosol-generating materials 4 and 5 still promote more consistent aerosol generation over the duration of the consumption session.

[0235] It is recognized that the above method and apparatus can be modified so that the first aerosol-generating material 4 is contained in a first pouch and the second aerosol-generating material 5 is contained in a second pouch. The first and second pouches may be joined together, for example, by stapling, sewing, welding, and / or adhesive. In another embodiment, the first and second pouches may be formed from the same sheet material. For example, the method and apparatus of Figures 6 and 7 can be modified so that a certain amount of the first aerosol-generating material 4 is first supplied to a sheet material structure (e.g., a continuous tube), and then a first pouch containing the first aerosol-generating material 4 is formed by sealing a portion of the sheet material 6, and then a second pouch containing the second aerosol-generating material 5 is formed adjacent to the first pouch by sealing a portion of the sheet material 6, after which a certain amount of the second aerosol-generating material 5 is supplied to the sheet material structure (e.g., a continuous tube), and then a second pouch containing the second aerosol-generating material 5 is formed adjacent to the first pouch by sealing a portion of the sheet material 6. Subsequently, the sheet material may be cut to form a consumable having the first and second patches (for example, cut downstream of the first pouch and upstream of the second pouch). In other embodiments, the first and second pouches, each containing the first and second aerosol-generating materials 4 and 5 respectively, may be manufactured separately and then joined together to form a consumable.

[0236] Referring now to Figures 11 to 13, these figures illustrate one embodiment of the aerosol supply device 200.

[0237] Consumable 1 is configured for use in an aerosol supply device 200 (see Figure 11) which includes an aerosol generator in the form of a heating element 203 for heating consumable 1. In this example, the heating element 203 at least partially surrounds the heating area 202 (e.g., the heating chamber 202). The heating element 203 may be configured to be resistively and / or inductively heated.

[0238] In other embodiments (not shown), the heating element 203 may instead comprise a blade or pin inserted into the consumable 1, for example, the blade or pin may be inserted through the sheet material 10 (e.g., through the sheet material 10) and optionally also inserted through the first and / or second aerosol-generating materials 4, 5. In other embodiments (not shown), the consumable 1 may comprise a heating element that can be embedded in, for example, the first and / or second aerosol-generating materials 4, 5.

[0239] Figure 11 briefly illustrates the components of one embodiment of the aerosol supply device 200. In particular, the elements of the aerosol supply device 200 depicted in Figure 11 are not scaled to actual size. For the sake of simplification, elements not relevant to understanding this embodiment have been omitted.

[0240] In the example shown in Figure 11, the aerosol supply device 200 is a non-flammable aerosol supply device 200. The non-flammable aerosol supply device 200 comprises a housing 201 including an area 202 for receiving consumables 1.

[0241] When the consumable 1 is received in the heating area 202, at least a portion of the consumable 1 is thermally close to the heater 203. As a result, at least a portion of the aerosol-generating materials 4 and 5 is thermally close to the heater 203. In some embodiments, the heater 203 is spaced away from the consumable 1 (e.g., it defines the boundary of the consumable 1 but is spaced away due to its large diameter). In other embodiments, the heater 203 is in direct contact with the consumable 1 (e.g., it is in contact with the outer surface of the sheet material 6 of the consumable 1). In yet another embodiment, the heater 203 is equipped with blades or pins that are in contact with the inside of the consumable 1 (e.g., they are in contact with the aerosol-generating materials 4 and 5).

[0242] When consumable 1 is heated, the first and / or second aerosol-generating materials 4, 5 in the space 3 of pouch 2 release one or more volatile compounds, and may release various volatile compounds at different temperatures. By controlling the maximum operating temperature of the electrically heated aerosol-generating system 200, the release of certain volatile compounds may be prevented, thereby controlling the selective release of undesirable compounds.

[0243] As shown in Figure 12, an electrical energy source 204 (e.g., a rechargeable lithium-ion battery) is located inside the housing 201. A controller 205 is connected to the heater 203, the electrical energy source 204, and the user interface 206 (e.g., buttons or a display). The controller 205 controls the power supplied to the heater 203 to regulate its temperature. Typically, the aerosol-forming substrate is heated to a temperature of 250-450°C.

[0244] Figure 13 is a schematic cross-section of the non-flammable aerosol supply device 200 as shown in Figure 11, where the consumable 1 is received in the heating area 202 of the device 200 for heating by the heater 203. As shown in the figure, the non-flammable aerosol supply device 200 receives the aerosol generating consumable 1 for consumption by the user.

[0245] The housing 201 of the non-flammable aerosol supply device 200 defines an area 202 in the form of a cavity that is open at the proximal end (or mouth end) for receiving aerosol generating consumables 1 consumed by the user.

[0246] In this example, the aerosol supply device 200 includes a removable mouthpiece 207 from the rest of the device 200 to allow access to area 202 so that consumables 1 can be inserted into and removed from area 202. After consumables 1 have been supplied to area 202, the mouthpiece 207 can be reattached. In some embodiments, the mouthpiece 207 is removablely attached to the housing 201 of the device 200, for example, by a screw thread or bayonet connection.

[0247] When the user uses the mouthpiece 207, air is drawn into the consumable 1, and volatile substances condense to form an inhalable aerosol. This aerosol passes through the mouthpiece 207 of the device 200 and enters the user's mouth.

[0248] In other embodiments, it is recognized that the mouthpiece 207 of device 200 may be omitted. In some embodiments, the consumable 1 may constitute the mouthpiece and come into contact with the user's mouth.

[0249] In all of the above examples, the first and / or second aerosol-generating materials 4, 5 may include an extruded or compressed body of tobacco material, or consist of an extruded or compressed body of tobacco material, or essentially consist of an extruded or compressed body of tobacco material, preferably the extruded or compressed body of tobacco material contains beads of tobacco material.

[0250] In each of the above examples, the first and / or second aerosol generating materials 4 and 5 may comprise a body or rod of the aerosol generating material.

[0251] In each of the above examples, the first and / or second aerosol-generating materials 4 and 5 may contain recycled tobacco, consist of recycled tobacco, or essentially consist of recycled tobacco, and preferably contain shredded recycled tobacco sheets.

[0252] In all of the above examples, the first and / or second aerosol-generating materials 4, 5 may contain, consist of, or essentially consist of lamina tobacco.

[0253] In all of the above examples, the first and / or second aerosol-generating materials 4 and 5 may contain reclaimed tobacco and laminated tobacco, consist of reclaimed tobacco and laminated tobacco, or consist essentially of reclaimed tobacco and laminated tobacco, preferably being integrally mixed.

[0254] In all of the above examples, the first and / or second aerosol-generating materials 4, 5 may include, consist of, or essentially consist of sheets of aerosol-generating material collected to constitute the body of the material, preferably the sheet material is crimped. The sheet is preferably a sheet of recycled tobacco.

[0255] In all of the above examples, the first and / or second aerosol-generating materials 4, 5 may include, consist of, or essentially consist of sheets of aerosol-generating material cut into strips. The sheets are preferably sheets of recycled tobacco.

[0256] In all of the above examples, the first and / or second aerosol-generating materials 4 and 5 may contain tobacco material, which is manufactured solely from tobacco laminae and not from any other type of tobacco material.

[0257] In all of the above examples, the first and second aerosol-generating materials 4 and 5 are produced from the same aerosol-generating starting material that has been processed to have different forms.

[0258] In each of the above-mentioned examples of articles (including the articles shown in Figures 1 to 10 and Figure 13), the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4. Otherwise, the aerosol-generating materials of the articles may be the same or different.

[0259] It has been found that if the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4, when both materials are exposed to the same heating, the higher density material heats up more slowly, and therefore the higher density material releases volatile compounds (e.g., nicotine) at a lower rate than the lower density material. For this reason, the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4 so that when exposed to the same heating, the second aerosol-generating material 5 heats up more slowly than the first aerosol-generating material 4 and releases volatile compounds (e.g., nicotine) at a lower rate than the first aerosol-generating material 4. Thus, by combining aerosol-generating materials of different densities, the release of (one or more) volatile compounds is more consistent and sustained for a longer period. In some embodiments, the aerosol-generating materials of different densities can be optionally combined with separate heating of different times and / or temperatures to further control the release of (one or more) volatile compounds, for example, over the shelf life of the article. Alternatively, it may be desirable to enhance the initial effect on the user by releasing volatile substances more rapidly or in larger quantities towards the start of consumption of the item. The ability to control aerosol generation and the release of volatile compounds is particularly advantageous because it allows for a relatively small item while achieving a specific and desired release of (one or more) volatile compounds over the course of consumption.

[0260] In some embodiments, the second aerosol-forming material 5 has a density that is at least about 25% higher, optionally at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, or 75% higher, than the density of the first aerosol-forming material 4. The second aerosol-forming material 5 may have a density that is about 200% or less, optionally about 150%, 125%, 100%, or 75% or less, higher than the density of the first and second aerosol-forming materials 4. In some embodiments, the second aerosol-forming material 5 has a density that is about 25% to about 75% higher than the density of the first aerosol-forming material 4.

[0261] In some embodiments, the second aerosol-forming material 5 has a density of at least about 0.4 g / cm 3 , optionally at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2 g / cm 3 . The second aerosol-forming material 5 may have a density of about 2 g / cm 3 or less, optionally about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6, or 0.5 g / cm 3 or less. In some embodiments, the density of the second aerosol-forming material 5 is about 0.4 to 1.99 g / cm 3 .

[0262] In some embodiments, the first aerosol-forming material 4 has a density of at least about 0.1 g / cm 3 , optionally at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9 g / cm 3 . The first aerosol-forming material 4 may have a density of about 1 g / cm 3 or less, optionally about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, or 0.2 g / cm 3 or less. In some embodiments, the density of the first aerosol-forming material 4 is about 0.1 to 0.9 g / cm3 That is the case.

[0263] In some embodiments, the first and second aerosol-generating materials 4 and 5 contain the same components. Therefore, upon heating, they release very similar aerosols, and potentially, the content of active substances and / or fragrances is the same. Due to their different densities, aerosols may be generated from the two materials at different rates and / or times upon heating.

[0264] In other embodiments, the first and / or second aerosol-generating materials 4 and 5 contain different components (their densities may be the same or different). Therefore, when heated, they release different aerosols, potentially with different compositions of active substances and / or fragrances. Due to their different densities, different aerosols may be generated from the two materials at different rates and / or times when heated, which may cause the aerosols provided to change during use.

[0265] In some embodiments, the first aerosol-generating material 4 and the second aerosol-generating material 5 each contain tobacco. The tobacco contains volatile components including nicotine, aroma, and flavor. The tobacco may be any type of tobacco and any part of the tobacco plant, including tobacco leaves, laminas, stems, stalks, ribs, scraps, and shorts, or mixtures of two or more of these. Suitable tobacco materials include types such as Virginia or hot-air dried tobacco, Burley tobacco, Oriental tobacco, or blends of tobacco materials (including, optionally, those described herein). The tobacco may be expanded, such as Dry-Ice Expanded Tobacco (DIET), or processed by any other means. In some embodiments, the tobacco material may be recycled tobacco material. Tobacco may or may not be pre-treated, for example, solid stems (SS), shredded-dried stems (SDS), steam-treated stems (STS), or any combination thereof. Tobacco material may be fermented, hardened, unhardened, roasted, or pre-treated.

[0266] The first and second aerosol-generating materials 4 and 5 may contain different tobaccos. Alternatively, the tobaccos may be the same, but provided in different forms, thereby giving the second aerosol-generating material 5 a higher density than the first aerosol-generating material 4.

[0267] In some embodiments, the first aerosol-generating material 4 has at least one (different) property compared to the second aerosol-generating material 5. The different property may be one or more of the shapes, sizes, water content, quantity (weight), one or more materials, or ratios of materials that constitute the first and second aerosol-generating materials 4 and 5 (including the method of manufacturing the aerosol-generating materials if each is manufactured from two or more materials). In some embodiments, the first and second aerosol-generating materials 4 and 5 have no different properties other than their respective different densities.

[0268] In some embodiments, the first aerosol-generating material 4 comprises one or more tobacco pieces in the form of shredded rags. This tobacco material may be lamina or recycled tobacco material. In some embodiments, the first aerosol-generating material 4 is a blend containing both lamina and recycled tobacco. For example, the ratio of lamina to recycled tobacco may be about 1:4 to about 4:1.

[0269] The second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4. In some embodiments, this high-density second aerosol-generating material 5 may contain particles, be in the form of beads, or be in the form of one or more sheets. Each bead or sheet may be formed of clumps of small particles. In some embodiments, both the first and second aerosol-generating materials 4 and 5 may be in the form of beads, or be in the form of one or more sheets, and optionally, the second aerosol-generating material 5 may be treated to have a higher density than the first aerosol-generating material 4.

[0270] In this specification, the term “bead” includes beads, pellets, or other discrete small units formed, molded, compressed, or shaped into a desired form. Beads may have a smooth and regular shape (e.g., spherical, cylindrical, oval, etc.) and / or an irregular shape.

[0271] In some embodiments, the beads have a diameter of at least about 0.5 mm (by measurement, e.g., by sieving), and optionally at least about 1, 1.5, 2, 2.5, or 3 mm. The beads may have a diameter of about 5 mm or less (by measurement, e.g., by sieving), and optionally at least about 4.5, 4, 3.5, 3, 2.5, 2, or 1.5 mm. In some embodiments, the diameter of each bead may be in the range of about 0.5 mm to about 3 mm or about 1 mm to about 2 mm. The size of the beads may represent the average size of each bead, such as the average size of the number or volume.

[0272] In some embodiments, the desired density of the aerosol-generating materials 4, 5 is achieved or controlled by the method of forming the material and / or by the method (one or more) in which the material is processed. The density of the material tends to increase by processes involving aggregation, particularly aggregation with the application of some compressive force.

[0273] Therefore, in some embodiments, the first and / or second aerosol-generating materials 4, 5 include particles of the material in a clump.

[0274] In the case of sheet materials, the sheet may be formed of particles of the material that, by bonding and optionally compression, form a sheet having desired dimensions and density.

[0275] In some embodiments, the beads or pellets may be formed by using a so-called marmarising process.

[0276] In some embodiments, agglomeration is achieved by pelletization. Pelletization is an agglomeration process that converts fine particles of material into free-flowing units called pellets, optionally with excipients. Depending on the selected equipment and type of process, pellet formation and growth can occur in many ways. These pellets may be formed by agitation, or by the rotation and rolling of particles in the presence of a suitable amount of liquid, resulting in the formation of clumps. Ballization may involve the use of equipment such as pans, discs, drums, or mixers that produce pellets. Compression pelletization is a form of pressure agglomeration in which particles are integrated by mechanical force, optionally with the use of a forming aid. The compressive force means that the density of the formed pellets is higher than that of the starting material.

[0277] In some embodiments, aggregation is achieved by extrusion. In some embodiments, a higher-density molded product may be formed by extruding pellets formed by pelletization.

[0278] The extruded particles may have a size selected to produce a denser aerosol-generating material (e.g., a denser second aerosol-generating material 5), which will affect heat transfer and the release of volatile components within the material.

[0279] In extrusion, an extruded product is produced by supplying a composition (also called a precursor composition) through a mold. In this process, pressure is applied to the composition in combination with shear force.

[0280] Extrusion may be carried out using one of the main classifications of extruders, such as screw, sieve and basket, roll, ram, and pin barrel extruders. Single-screw or twin-screw extruders may be used. Forming tobacco beads by extrusion has the advantage that this process combines compression, mixing, adjustment, homogenization, and molding of the composition.

[0281] In some embodiments, during extrusion, a free - flowing composition containing particles such as tobacco particles is exposed to high pressure and high temperature and passed through an orifice such as a shaping nozzle or a mold, thereby forming a shaped article. In some embodiments, the shaped article is in a rod - like form and may be cut into segments of a desired length.

[0282] In some embodiments, the composition is exposed to a temperature of about 40°C to about 150°C, about 80°C to about 130°C, or about 60°C to about 95°C in an extruder. In some embodiments (including embodiments using double extrusion), the precursor composition is exposed to a temperature of about 70°C to about 95°C in an extruder. In some embodiments (including embodiments using single extrusion), the precursor composition is exposed to a temperature of about 60°C to about 80°C in an extruder.

[0283] The composition may be exposed to a pressure in the range of about 2 bar to about 100 bar or about 5 bar to about 60 bar (just before the mold or nozzle) depending on the design of the mold or nozzle used. The higher the pressure, the higher the density of the shaped article is likely to be. For this reason, the extrusion process may be adjusted to provide an extruded aerosol - generating material having a desired density.

[0284] In some embodiments where tobacco particles are extruded, the density of the shaped article is relatively high and the surface of the tobacco particles is relatively open, so the tobacco beads formed from the shaped article exhibit good heat transfer and mass transfer, which has a favorable effect on the release of tobacco constituent substances such as flavors and nicotine.

[0285] In some embodiments, the extrusion may be a substantially dry process, and the composition containing aerosol - generating particles is dry or substantially dry. The composition may optionally contain other particulate substances such as, for example, a base, a diluent, a solid aerosol - forming agent, a solid flavor modifier, etc.

[0286] In some embodiments, a liquid may be added to the composition before or during the extrusion process. For example, water may be added as a processing aid to assist in the dissolution or solubilization of the components of the composition, or to assist in their binding or aggregation. Alternatively or in addition, a wetting agent may be added to the composition.

[0287] In some embodiments, the liquid may be an aerosol-forming material such as glycerol, as discussed herein. When the liquid is added to the composition in this way, the liquid is not only applied to the surface, but the molded article is impregnated with the liquid as a result of strong mixing due to large shear forces and the pressure of the extruder. If the liquid is an aerosol-forming material, this results in a higher likelihood of aerosol formation in the resulting beads and promotes the evaporation of volatile components.

[0288] In some embodiments, the amount of aerosol-forming material incorporated into the extruded beads may be up to about 30% by weight, or even up to about 40% by weight. Generally, such a large amount of aerosol-forming material makes the composition difficult to handle. However, this is not a significant problem if the particles are impregnated with the aerosol-forming material as a result of extrusion. If the beads generate aerosols in addition to releasing volatile components, it is desirable to include an amount of aerosol-forming material such as at least about 10% by weight or at least about 20% by weight. If the main function of the beads is to release volatile components supported on them into existing aerosols or airflow, a small amount of aerosol-forming material, such as up to about 5% by weight, may be sufficient.

[0289] In some embodiments, the aggregate does not contain a binder or binding additives. For example, extruded beads may not require a binder to maintain their structural integrity. In other embodiments, the aggregate contains a binder or binding additives. Binding additives may be selected to help form aggregated structures by assisting the adhesion of particles to each other and to other components in the composition. Suitable binding additives include thermoreversible gelling agents such as gelatin, starch, polysaccharides, pectin, alginates, wood pulp, cellulose, and cellulose derivatives such as carboxymethylcellulose.

[0290] In some embodiments, the extrusion process is sufficient to increase the density of the second aerosol-generating material 5, if desired. However, in other embodiments, the density of the second aerosol-generating material 5 may be further increased by a separate process of the molded article.

[0291] For example, in some embodiments, the extruded aerosol-generating material is spheroidized. In spheroidization, the extruded cylindrical particles are crushed to a uniform length and then gradually deformed into a spherical shape by plastic deformation. If the molded product is initially crushed to a uniform length, the spheroidization step generates spheres of uniform diameter.

[0292] A sample of the second aerosol-generating material 5 was prepared according to one specific example of the embodiments discussed herein (however, in some embodiments, the sample may be prepared according to the following and used as an alternative to the first aerosol-generating material).

[0293] Table 1 shows three sample formulations for each case, with and without a binder, and their quantities are shown as wet weight ratios (WWB).

[0294] [Table 1] The tobacco was ground into a fine powder, taking care not to overheat it. The ground tobacco particles were sieved to select the desired size, for example, a particle size of less than 250 μm, less than 100 μm, or less than 60 μm.

[0295] Next, all the dry (non-liquid) components of the formulation were combined and mixed or blended in a mixer. In this particular case, the mixture was mixed at a speed of 75 RPM for 1 minute. This was to ensure that the dry components were uniformly dispersed in the mixture.

[0296] Next, half of the glycerol and half of the water were added to the dry mixture and mixed. Specifically, the mixture was mixed for another minute at 75 RPM. Then, the remaining glycerol and water were added and mixed again for another minute at 75 RPM. Mixing was then continued until the mixture was brittle enough to be squeezed together to obtain a homogeneous mixture. In this specific example, mixing was continued for an additional 3 minutes.

[0297] The mixture was then extruded using a Caleva Multilab. This extruder was operated at approximately 1500 rpm to produce molded parts of spaghetti-like length.

[0298] The molded product emerged from the extruder broken into small pieces of varying lengths. These pieces were then spheroidized. Spheroidization was carried out until spherical beads were formed. In this case, the molded product was first spheroidized for 1 minute in a Caleva Multilab operating at 2,500 RPM, and then checked for defects in the beads. Spheroidization was then continued for another 1-2 minutes. This spheroidization step broke the extruded tobacco into individual pieces, forming high-density spherical beads.

[0299] In the final step, the spherical beads were dried in a 65°C oven for 30 minutes. After each drying period, the beads were weighed, and drying was stopped when the desired reduction in moisture weight was achieved. Generally, this type of drying takes about one hour.

[0300] In some embodiments, the other of the first and / or second aerosol-generating materials 4 and 5 is in the form of discrete particles or particle aggregates. These particles may share various properties such as particle size with the (higher density) second aerosol-generating material 5, but will have a lower density. As described above, there are various methods for adjusting the density of the aerosol-generating materials 4 and 5, such as forming and / or processing the material as particles, beads, or pellets.

[0301] In some embodiments, the first aerosol-generating material 4 comprises a combination of 60% recycled tobacco and 40% laminated tobacco, and the density of this material is approximately 0.1 to approximately 0.9 g / cm³. 3 The second aerosol-generating material 5 contains approximately 30-90% tobacco and has a density of approximately 0.4-1.99 g / cm³. 3 The amount of aerosol-forming material contained in one of the first and / or second aerosol-forming materials 4, 5 may be about 8 to about 15%. The second aerosol-forming material 5 may contain large spherical beads with a particle size of about 0.5 to about 3 mm. In some embodiments, the aerosol-forming material in the article comprises about 50% by weight of the first aerosol-forming material 4 and about 50% by weight of the second aerosol-forming material 5. For example, an article containing 260 mg of aerosol-forming material may contain 130 mg of the first aerosol-forming material 4 and 130 mg of the second aerosol-forming material 5.

[0302] In some embodiments, the aerosol-generating material includes tobacco, and the tobacco is present in an amount of about 10% to about 90% by weight of the aerosol-generating material.

[0303] In some embodiments, tobacco may be present in an amount of at least about 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, or lastly about 35% based on the weight of the aerosol-generating material.

[0304] In some embodiments, the tobacco may be present in an amount of about 90%, 89%, 88%, 87%, 86%, 85%, 84%, 83%, 82%, 81%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45% or less, or may be present in an amount of about 40% or less based on the weight of the aerosol - generating material.

[0305] The tobacco described herein may contain nicotine. In some embodiments, the nicotine content is 0.5 - 2% by volume of the tobacco, for example, 0.5 - 1.75% by volume of the tobacco, 0.8 - 1.2% by volume of the tobacco, or about 0.8 - about 1.75% by volume of the tobacco. In some embodiments, the nicotine content may be 0.8 - 1% by volume of the tobacco.

[0306] In some embodiments, the first and second aerosol - generating materials 4, 5 have the same nicotine content.

[0307] In some embodiments, the first and second aerosol - generating materials 4, 5 contain one or more volatile components. In some embodiments, the first and second aerosol - generating materials 4, 5 have the same content of volatile components.

[0308] In some embodiments, the first and / or second aerosol - generating materials 4, 5 contain tobacco. For example, the first and / or second aerosol - generating materials 4, 5 may contain about 80 - about 350 mg of tobacco. In some specific embodiments, the aerosol - generating material in the article or consumable has a weight of 260 mg and includes a combination of 130 mg of the first aerosol - generating material 4 (including, for example, a blend of lamina and reconstituted tobacco) and 130 mg of the second aerosol - generating material 5 (including, for example, higher - density tobacco beads).

[0309] In some embodiments, the article may include areas of aerosol-generating material, each area containing an equal amount of aerosol-generating material containing tobacco. In alternative embodiments, these areas may contain different amounts of tobacco. If the total amount of tobacco is about 80 to about 350 mg, one area of ​​the aerosol-generating material may contain about 20 to about 330 mg, about 50 to about 300 mg, or about 40 to about 125 mg of tobacco, and the other area of ​​the aerosol-generating material may contain about 20 to about 330 mg, about 30 to about 300 mg, or about 40 to about 125 mg of tobacco.

[0310] Furthermore, this disclosure provides a parts kit comprising a consumable 1 relating to any of the examples described herein and an aerosol supply device 200.

[0311] Furthermore, this disclosure provides a package comprising a plurality of consumables relating to any of the examples described herein. In some embodiments, the package is sealed and airtight. The package may comprise a container including a body and a lid, the body of which is provided with space for receiving the plurality of consumables. The lid may be, for example, a hinged lid, a snap-fit ​​lid, or a screw-type lid.

[0312] The various embodiments described herein are presented solely to aid in understanding and teaching the features of the claims. These embodiments are provided as representative examples of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations to the scope of the invention as defined by the claims, nor to equivalents of the claims, and it should be understood that other embodiments can be used and improved upon without departing from the scope of the invention as defined by the claims. Various embodiments of the invention may suitably include, consist of, or essentially consist of suitable combinations of elements, components, features, parts, steps, means, etc. of the disclosure other than those specifically described herein. Furthermore, this disclosure may include other inventions that are not claimed at present but may be claimed in the future.

Claims

1. A consumable used in an aerosol supply system, wherein the consumable comprises one or more pouches containing a first aerosol generating material and a second aerosol generating material, and the second aerosol generating material has a higher density than the first aerosol generating material. Each of the one or more pouches comprises a gas-permeable sheet material, A consumable item in which the first aerosol generating material and / or the second aerosol generating material is a free material.

2. The consumable product according to claim 1, wherein the sheet material includes paper.

3. The consumable product according to claim 1, wherein the sheet material has a thickness in the range of 20 to 100 microns.

4. The consumable product according to claim 1, wherein the sheet material has a thickness in the range of 30 to 80 microns, 35 to 55 microns, or 40 to 50 microns.

5. The consumable product according to claim 1, wherein the sheet material has an air permeability in the range of 10 to 25,000 cholesta units, and optionally has an air permeability in the range of 25 to 100 cholesta units.

6. The consumable according to claim 1, wherein the sheet material is folded and / or wound so as to constitute each of the one or more pouches.

7. The consumable according to claim 1, wherein at least one edge of the sheet material is attached to another portion of the sheet material so as to hold the first aerosol generating material and / or the second aerosol generating material in each of the one or more pouches.

8. The consumable product according to claim 1, wherein each of the one or more pouches is formed from a single sheet material.

9. The consumable product according to claim 1, wherein each of the one or more pouches is formed from two or more sheet materials that are integrally joined together.

10. The consumable product according to claim 1, wherein each of the sheet materials of the one or more pouches completely encloses the aerosol-generating material contained in the pouch.

11. The consumable product according to any one of claims 1 to 10, wherein each of the one or more pouches constitutes the outer surface of the consumable product.

12. The consumable according to any one of claims 1 to 10, wherein the second aerosol generating material includes an extruded and / or compressed aerosol generating material.

13. The consumable product according to any one of claims 1 to 10, wherein the second aerosol generating material includes beads.

14. The consumable product according to claim 13, wherein the beads have a diameter in the range of 0.5 to 3 mm.

15. The consumable product according to claim 13, wherein the beads have a diameter in the range of 1 to 2 mm.

16. The consumable according to claim 1, wherein the first aerosol generating material contains, consists of, or is essentially made of tobacco material.

17. The consumable product according to claim 16, wherein the tobacco material of the first aerosol generating material is derived solely from tobacco laminae and not from any other type of tobacco material.

18. The consumable product according to claim 16, wherein the first aerosol generating material includes tobacco lamina and recycled tobacco.

19. The consumable according to any one of claims 16 to 18, wherein the second aerosol generating material contains, consists of, or is essentially made of tobacco material.

20. The consumable product according to claim 19, wherein the first aerosol generating material and the second aerosol generating material integrally have an average nicotine level in the range of 0.5% by weight to 2.5% by weight of the first aerosol generating material and the second aerosol generating material.

21. The consumable product according to claim 19, wherein the first aerosol generating material and the second aerosol generating material integrally have an average nicotine level in the range of 1% to 2.1% by weight of the first aerosol generating material and the second aerosol generating material.

22. The consumable product according to claim 19, wherein the tobacco material of the second aerosol generating material is derived solely from tobacco laminae and not from any other type of tobacco material.

23. The consumable according to claim 19, wherein the second aerosol generating material includes laminated tobacco and / or recycled tobacco.

24. The consumable according to claim 1, wherein the consumable comprises the first aerosol-generating material in an amount ranging from about 20 to about 330 mg.

25. The consumable according to claim 1, wherein the consumable comprises the first aerosol-generating material in an amount in the range of approximately 50 to approximately 300 mg or approximately 40 to approximately 125 mg.

26. The consumable according to claim 1, wherein the consumable comprises the second aerosol-generating material in an amount ranging from approximately 20 to approximately 330 mg.

27. The consumable according to claim 1, wherein the consumable comprises the second aerosol-generating material in an amount in the range of approximately 50 to approximately 300 mg or approximately 40 to approximately 125 mg.

28. The consumable item according to claim 1, wherein the consumable item does not contain plastic.

29. The consumable according to claim 1, wherein the density of the second aerosol-generating material is at least 25% higher than the density of the first aerosol-generating material.

30. The first aerosol generating material is present in a concentration of approximately 0.1 g / cm³. ３ ~Approx. 1g / cm ３ A consumable product according to claim 1, having the density of [a certain value].

31. The second aerosol generating material is approximately 0.4 g / cm³ ３ ~Approx. 2g / cm ３ A consumable product according to claim 1, having the density of [a certain value].

32. The consumable according to claim 1, wherein one pouch contains the first aerosol generating material and the second aerosol generating material.

33. The consumable product according to claim 32, wherein the first aerosol generating material and the second aerosol generating material are integrally mixed in one pouch.

34. The consumable product according to claim 32, wherein the first aerosol generating material and the second aerosol generating material are provided in a discrete region within the single pouch.

35. The consumable according to claim 1, wherein the consumable comprises a first pouch containing the first aerosol generating material and a second pouch containing the second aerosol generating material.

36. The consumable product according to claim 1, wherein the first aerosol generating material and / or the second aerosol generating material includes an aerosol forming material.

37. The consumable according to claim 1, wherein the first aerosol generating material and / or the second aerosol generating material comprises about 10 to about 50% by weight of an aerosol forming material, about 15 to about 60% by weight of a gelling agent, and optionally a filler, wherein the weight percentage values ​​are calculated on a dry weight basis.

38. The consumable product according to claim 37, wherein the first aerosol generating material and / or the second aerosol generating material contains a flavoring agent.

39. A method for manufacturing consumables used in an aerosol supply system, The step of forming one or more pouches containing a first aerosol generating material and a second aerosol generating material, wherein the second aerosol generating material has a higher density than the first aerosol generating material. Each of the one or more pouches comprises a gas-permeable sheet material, A method wherein the first aerosol-generating material and / or the second aerosol-generating material is a free material.

40. The method according to claim 39, comprising the step of forming the sheet material of each of the one or more pouches as a tube containing the first aerosol generating material and / or the second aerosol generating material.

41. The method according to claim 39, comprising the step of forming the sheet material as a structure having one end closed and the other end open, wherein the first aerosol generating material and / or the second aerosol generating material are provided within the structure of the sheet material.

42. The method according to claim 41, comprising the step of supplying the first aerosol generating material and / or the second aerosol generating material to the structure under gravity.

43. The method according to claim 42, comprising the step of supplying a continuous flow of the first aerosol generating material and / or the second aerosol generating material to the structure.

44. The method according to any one of claims 41 to 43, comprising the step of sealing and cutting the sheet material component at a location spaced apart from the closed end of the component to form a pouch.

45. The method according to claim 44, wherein the components of the sheet material are repeatedly sealed and cut to form a plurality of pouches.

46. The method according to claim 44, wherein the components of the sheet material are simultaneously sealed and cut.

47. The method according to claim 44, wherein the step of sealing the structure includes manipulating the structure such that the aerosol-generating material in the structure moves axially downstream and / or upstream of the portion of the structure to be sealed.

48. The method according to claim 39 or 40, comprising the step of depositing a first aerosol generating material and / or a second aerosol generating material onto the sheet material.

49. The method according to claim 39 or 40, comprising the step of depositing a measured first aerosol-generating material and / or a second aerosol-generating material onto the sheet material.

50. The method according to claim 39, comprising the step of winding the sheet material around the first aerosol generating material and / or the second aerosol generating material.

51. The method according to claim 39, comprising the step of integrally attaching the first portion and the second portion of a sheet material such that the first aerosol generating material and / or the second aerosol generating material are held between the first portion and the second portion of the sheet material.

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