Components for a delivery system, and methods and apparatus for manufacturing components for a delivery system.

Abstract

A component (2) for an article (1) for use in or as an aerosol delivery system is provided, the component (2) including a body (4) including a crimped sheet (14) of cellulosic material. The crimped sheet (14) of cellulosic material includes a first region having a first level of crimping and a second region longitudinally offset from the first region and including a second level of crimping different from the first level of crimping. An article (110) including the component (2), a method for manufacturing the component (2), and an apparatus configured to manufacture the component (2) are also described.

Description

[Technical Field]

[0001] This disclosure relates to components in or for use as an aerosol supply system. This disclosure also relates to articles in or for use as an aerosol supply system, as well as methods and apparatus for manufacturing components for aerosol supply systems. [Background technology]

[0002] Certain tobacco industry products generate aerosols during use, which are inhaled by the user. For example, tobacco heating devices form aerosols by heating an aerosol-generating substance, such as tobacco, rather than burning the base material. Such tobacco industry products generally include a mouthpiece through which the aerosols pass and reach the user's mouth. [Overview of the project]

[0003] According to embodiments described herein, a first aspect provides a component for an aerosol supply system or for an article to be used as an aerosol supply system, comprising a body including a crimped sheet of a cellulosic material, wherein the crimped sheet includes a first region having a first level of crimping and a second region longitudinally offset from the first region and including a second level of crimping different from the first level of crimping.

[0004] According to embodiments described herein, a second aspect provides an article for use in or as an aerosol supply system, comprising the components according to the first aspect.

[0005] A third embodiment of the embodiments described herein provides a method for manufacturing components for an article to be used in an aerosol supply system, comprising: preparing a feed of sheet material; applying a crimp pattern to a first portion of the sheet material, wherein the crimp pattern comprises a series of substantially parallel ridges and grooves and is scaled by a first crimp coefficient; applying a crimp pattern to a second portion of the sheet material, wherein the crimp pattern is scaled by a second crimp coefficient, wherein the first and second crimp coefficients are selected from heat, pressure, spacing or depth; and assembling the sheet material to form a material body comprising a first region having a first level of crimping and a second region longitudinally offset from the first region and comprising a second level of crimping different from the first level of crimping.

[0006] According to embodiments described herein, a fourth aspect provides an apparatus configured to manufacture a component according to the first aspect, comprising: a crimp roller for applying a crimp pattern to a sheet material, wherein the crimp pattern comprises a series of substantially parallel ridges and grooves; and a garnish assembly for gathering the sheet material to form a material body comprising a first region having a first level of crimping and a second region longitudinally offset from the first region and having a second level of crimping different from the first level of crimping.

[0007] Herein, embodiments of the present invention will be described exclusively as non-limiting examples with reference to the attached drawings. [Brief explanation of the drawing]

[0008] [Figure 1] This is a side cross-sectional view of an article, including a mouthpiece, for use as or in conjunction with a non-combustible aerosol supply device. [Figure 1B]A side view of a sheet material forming a first material body of the article of FIG. 1. [Figure 2] A side cross-sectional view of another embodiment of an article for use as or with a non-combustible aerosol supply device. [Figure 3] A side cross-sectional view of another embodiment of an article for use as or with a non-combustible aerosol supply device. [Figure 4] A side cross-sectional view of another embodiment of an article for use as or with a non-combustible aerosol supply device. [[ID=!1]]<> [Figure 5] <> A perspective view of a non-combustible aerosol supply device for generating an aerosol from the aerosol-generating material of the articles of FIGS. 1-4. [Figure 6] [[ID=!15]]<> <> [Figure 7] <> [Figure 7] A side view of the device of FIG. 6 in partial cross-section. [Figure 8] An exploded view of the device of FIG. 7 with the outer cover omitted. [Figure 9A] A cross-sectional view of a part of the device of FIG. 6. [Figure 9B] An enlarged view of a region of the device of FIG. 9A.

BEST MODE FOR CARRYING OUT THE INVENTION

[0009] [Detailed Description] [[ID=!37]]<> <>

[0010] <> <>

[0010] FIG. 1 is a side cross-sectional view of an article 1 for use with a non-combustible aerosol supply system.

[0011] It should be noted that in the original text, there is an incorrect tag format in line 11. It should be a normal tag like the others. I have marked it as "!1" in the translation for your reference. Also, there are some incorrect tag formats in line 37 which I have marked as "!37". Please check the original text for accuracy.Article 1 comprises a mouthpiece 2 and a cylindrical rod of aerosol-generating material 3, in this case tobacco material, connected to the mouthpiece 2. The aerosol-generating material 3 provides an aerosol when heated in a non-combustible aerosol supply device, such as the one described herein, for example, a non-combustible aerosol supply device comprising coils forming a system. In other embodiments, Article 1 may include its own heat source, forming an aerosol supply system without requiring a separate aerosol supply device.

[0012] The mouthpiece 2 of article 1 comprises an upstream end 2a adjacent to the aerosol generating material 3 and a downstream end 2b distal to the aerosol generating material 3.

[0013] The aerosol-generating material 3, also referred to herein as the aerosol-generating substrate 3, comprises at least one aerosol-forming material. In this example, the aerosol-forming material is glycerol. In alternative examples, the aerosol-forming material may be another material or a combination thereof, as described herein. Aerosol-forming materials are known to improve the sensory performance of an article by helping to transfer compounds, such as flavoring compounds, from the aerosol-generating material to the consumer. However, a problem associated with adding such aerosol-forming materials to the aerosol-generating material in an article for use in a non-combustible aerosol supply system is that when the aerosol-forming material is aerosolized upon heating, it may increase the mass of the aerosol delivered by the article, and this increased mass may maintain a higher temperature as it passes through the mouthpiece. As the aerosol passes through the mouthpiece, it transfers heat to the mouthpiece, which warms the outer surface of the mouthpiece, including the area that comes into contact with the consumer's lips during use. The mouthpiece temperature may be significantly higher than that of a conventional cigarette, which the consumer may be accustomed to when smoking, and this may be an undesirable effect caused by the use of such aerosol-forming materials.

[0014] In this example, the mouthpiece includes a first material body 4. A hollow tubular element 8 and a capsule 15 are embedded in the first material body 4. The hollow tubular element 8 and the capsule 14 are each embedded in the material body 4 and are circumferentially surrounded by the material forming the body 4. The first material body is encased in a first plug wrap 7.

[0015] In this embodiment, the body 4 is a filter. However, it should be noted that in other embodiments, the body 4 may be provided to act simply as a carrier or support for an embedded object without substantially filtering the inhalant of article 1.

[0016] The first material body 4 is formed from a fibrous material. In this example, the first material body 4 is formed from a sheet material 14. The sheet material 14 may be folded to form the material body 4. The material body 4 may also be formed from a continuous web of the sheet material 14. In this example, the sheet material 14 is assembled to form the material body 4, similar to a "crepe filter". The hollow tubular elements 8 and capsules 15 are embedded in and circumferentially surrounded by the assembled sheet material 14 to form the first material body 4.

[0017] In this example, the hollow tubular element 8 is positioned at the longitudinal end of the material body 4 and extends to the longitudinal end of the body. The capsule 15 is positioned downstream of the hollow tubular element 8, and the material body 4 extends beyond the location of the capsule 14 such that the capsule 14 is surrounded by the first material body 4 both circumferentially and longitudinally. Preferably, such a configuration can provide a single component that includes both a cavity for aerosol cooling and an aerosol modifier release component, thus resulting in a simplified manufacturing process.

[0018] In this example, the hollow tubular element 8 defines a void within the mouthpiece that acts as a cooling segment. The void provides a chamber through which heated volatile components generated by the aerosol-generating material 3 flow. The hollow tubular element 8 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and use of the article 1. The hollow tubular element 8 provides a physical displacement between the aerosol-generating material 3 and the downstream portion of the mouthpiece 2. The physical displacement provided by the hollow tubular element 8 provides a thermal gradient over the length of the first material body 4.

[0019] Preferably, the internal volume of the hollow tubular element 8 is 130 mm 3 Larger. It has been found that providing a cavity of at least this volume enables improved aerosol formation. Such a cavity size provides sufficient space within the mouthpiece 2 to allow heated volatile components to cool, and thus allows the aerosol-generating material 3 to be exposed to a higher temperature than otherwise possible, which could result in an excessively warm aerosol. More preferably, the mouthpiece 2 is 120 mm 3 Larger, even more preferably 150mm 3 It features a cavity with a larger internal volume, allowing for further improvement of the aerosol. In some examples, the internal cavity is approximately 110 mm 3 ~600mm 3 Preferably about 120 mm 3 ~approximately 500mm 3 This includes the volume of the tubular element 8. In this example, the internal cavity formed by the tubular element 8 is approximately 250 mm 3 It has a volume of the above. Alternatively, if a single tubular element is arranged to provide a cooling segment, the tubular element preferably has an internal volume as described above.

[0020] The cavity can be configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile components entering the first upstream end of the cavity and the heated volatile components exiting the second downstream end of the cavity. Preferably, the cavity is configured to provide a temperature difference of at least 60 degrees Celsius, preferably at least 80 degrees Celsius, and more preferably at least 100 degrees Celsius between the heated volatile components entering the first upstream end of the cavity and the heated volatile components exiting the second downstream end of the cavity. This temperature difference along the length of the cavity can protect the temperature-sensitive elements of the mouthpiece downstream of the cavity from the high temperature of the aerosol-generating material 3 when heated.

[0021] Preferably, the length of the hollow tubular element 8 is less than about 50 mm. More preferably, the length of the hollow tubular element 8 is less than about 40 mm. Even more preferably, the length of the hollow tubular element 8 is less than about 35 mm. In addition, or alternatively, the length of the hollow tubular element 8 is preferably at least about 10 mm. Preferably, the length of the hollow tubular element 8 is at least about 15 mm.

[0022] In some preferred embodiments, the length of the hollow tubular element 8 is about 15 mm to about 35 mm, more preferably about 16 mm to about 30 mm, even more preferably about 18 mm to about 25 mm, and most preferably about 23 mm. In this example, the length of the hollow tubular element 8 is 23 mm.

[0023] In this example, the hollow tubular element 8 is formed from multiple layers of paper wound parallel to each other with their joints butted together to form a hollow tube. In this example, the first and second layers of paper are provided in a two-ply tube, but in other examples, three, four or more layers of paper can be used to form a three, four or more-ply tube. Other configurations can be used, such as spirally wound layers of paper, cardboard tubes, tubes formed using a papier-mâché process, molded or extruded plastic tubes, etc.

[0024] In some embodiments, the hollow tubular element 8 preferably has a wall thickness of at least about 50 μm to a maximum of about 1 mm, preferably 50 μm to 500 μm, and more preferably 60 μm to 130 μm. In this example, the wall thickness of the hollow tubular element 8 is about 130 μm. The "wall thickness" of the tubular element corresponds to the thickness of the wall of the tubular element in the radial direction, excluding the surrounding material in which the tubular element is embedded. This can be measured, for example, using a caliper.

[0025] In some embodiments, the wall thickness of the hollow tubular element 8 is at least 50 microns, preferably at least 75, 80, 85, 90, 95, 100, or 105 microns. In some embodiments, the wall thickness of the tubular element is at least 100 or 110 microns.

[0026] In some embodiments, the wall thickness of the hollow tubular element 8 is less than 1000 microns, preferably less than 500 microns.

[0027] In some examples, the walls of the hollow tubular element 8 are formed from paper having a basis weight in the range of 40 gsm to 100 gsm. For example, paper having a basis weight of 60 gsm to 80 gsm.

[0028] The combined thickness of the hollow tubular element 8 and the surrounding material body 4 means that the tubular portion formed by the hollow tubular element 8 embedded in the material body 4 has a higher thermal mass. This has been shown to help lower the temperature of the aerosol passing through the tubular portion, thereby lowering the surface temperature of the mouthpiece downstream of the tubular portion. This is thought to be because the higher thermal mass of the tubular portion allows it to absorb more heat from the aerosol compared to a tubular portion with thinner walls. The increased thickness of the tubular portion also directs the aerosol towards the center of the mouthpiece, reducing the transfer of heat from the aerosol to the outer parts of the mouthpiece, such as the outer parts of the material body.

[0029] In some embodiments, the air permeability of the wall material of the hollow tubular element 8 is at least 100 cholestas, preferably at least 200, 500, or 1000 cholestas.

[0030] The relatively high permeability of the hollow tubular element 8 has been shown to increase the amount of heat transferred from the aerosol to the tubular portion, and therefore to lower the temperature of the aerosol. The permeability of the hollow tubular element 8 has also been shown to increase the amount of moisture transferred from the aerosol to the tubular portion, which has been shown to improve the feel of the aerosol in the user's mouth. The high permeability of the hollow tubular element 8 also means that the air entering the material body 4 surrounding the tubular portion can pass through the walls of the hollow tubular element 8 into the aerosol flow without the need to cut vents through the outer plug wrap(s) and chipping paper, the material body 4, and all of the tubular elements forming the tubular portion, thereby reducing the complexity of manufacturing.

[0031] In some embodiments, the permeability of the material of the wall of the hollow tubular element 8 is provided by perforations formed in the material. In some examples, the material is non-porous paper, and the permeability is provided by perforations formed in the material. In other examples, the material is porous paper, and may or may not include perforations. If perforations are provided, they may be provided, for example, as one or more perforation lines extending through the wall of the hollow tubular element. The perforations may be provided as a band or ring of perforations through the wall of the hollow tubular element. In this case, the perforations may be provided toward the upstream end of the hollow tubular element, for example, at a position about 8 mm to about 2 mm or about 5 mm to about 2 mm from the upstream end of the hollow tubular element.

[0032] In some examples, the sheet material 14 may have notches, such as punched-out areas, to reduce the density of the material body 4. In some examples, the notches may be provided in the portion of the sheet material that forms the portion of the material body 4 surrounding the hollow tubular element 8. Preferably, by providing notches in the sheet material 14 that forms this portion of the body, the amount of material that is perforated to provide ventilation within the hollow tubular element 8 can be reduced.

[0033] The capsule 15 may include a destructible capsule, such as a capsule having a fragile solid shell surrounding a liquid payload. In this example, a single capsule 15 is used. The capsule 15 is completely embedded within the material body 4. In other words, the capsule 15 is completely surrounded by the material forming the body 4. In other examples, multiple destructible capsules, such as two, three or more destructible capsules, may be placed within the material body 4. The length of the material body 4 can be increased to accommodate the required number of capsules. In examples where multiple capsules are used, the individual capsules may be identical to each other or may differ from each other in size and / or capsule payload.

[0034] The capsule 15 has a core-shell structure. In other words, the capsule 15 includes a shell that encloses a liquid agent, for example, a flavoring or other active substance which may be one of the flavorings or aerosol modifiers described herein. The capsule shell can be broken by the user to release the flavoring or other active substance into the material body 4. The first plug wrap 7 may include a barrier coating to make the material of the plug wrap substantially impermeable to the liquid payload of the capsule 15.

[0035] In this example, capsule 15 is spherical and has a diameter of approximately 3 mm. In other examples, other shapes and sizes of capsules can be used. For example, capsules may have a diameter of less than 4 mm, or less than 3.5 mm, or less than 3.25 mm. In alternative embodiments, capsules may have a diameter greater than approximately 3.25 mm, for example greater than 3.5 mm, or greater than 4 mm. The total weight of capsule 15 may be in the range of approximately 10 mg to approximately 50 mg.

[0036] In this example, the capsule 15 is positioned within the material body 4 downstream of the hollow tubular element 8. In this example, the capsule 15 is positioned such that its center is 5 mm from the proximal end of the hollow tubular element 8. Alternatively, the capsule may be positioned such that the hollow tubular element 8 and the capsule 15 are separated by a gap of 1 mm to 30 mm, or 1.5 mm to 20 mm, or 2 mm to 15 mm, or 3 mm to 10 mm. In this example, the center of the capsule is positioned 12 mm from the downstream end 2b of the mouthpiece. By positioning the capsule in this way, the volatility of the capsule contents is improved because the capsule is close to the aerosol-generating section of the article that is heated during use, while it is still far enough away from the aerosol-generating section that is inserted into the aerosol supply system during use, allowing the user to easily access the capsule and rupture it with their fingers.

[0037] Preferably, the mouthpiece 2' is configured such that the capsule 15 and the vent hole 12 are offset longitudinally from each other within the mouthpiece 2'.

[0038] The material body 4 can be manufactured using a CU-20 filter manufacturing machine manufactured by Decouflé (trademark). However, those skilled in the art will recognize that other machines can be used to manufacture the first material body 4.

[0039] In some embodiments, the sheet material 14 has a width of at least 60 mm, preferably at least 70, 80, 90, 100, 110, or 120 mm.

[0040] In some embodiments, the sheet material 14 has a width of at most 240 mm, preferably at most 230, 220, 210, 200, 190, 180, 170, 160, or 150 mm.

[0041] In some embodiments, the sheet material 14 has a width of less than 180 mm, preferably less than 170, 160, 150, 140, or 130 mm.

[0042] In some embodiments, the sheet material 14 has a width in the range of 60 to 240 mm, preferably in the range of 80 to 240 mm, 90 to 200 mm, or 100 to 170 mm.

[0043] In this example, the sheet material 14 contains cellulose. In this example, the sheet material 14 is paper. However, the sheet material 14 may additionally or alternatively contain different materials. For example, in some embodiments, the sheet material 14 contains reconstituted tobacco formed on the sheet material 14, configured to form a material body 4. The reconstituted tobacco contains cellulose. The reconstituted tobacco may optionally be paper reconstituted tobacco. In other embodiments, the sheet material 14 contains different materials, such as cotton; tobacco; lyocell; polyvinyl alcohol (PVOH), polylactic acid (PLA), poly(ε-caprolactone) (PCL), poly(1-4-butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, aliphatic polyester materials, polysaccharide polymers, and / or woven or nonwoven materials. The sheet material 14 may be biodegradable. In one embodiment, the sheet material 14 may be non-plastic or plastic. In some embodiments, the sheet material 14 does not contain cellulose acetate.

[0044] In one embodiment, the sheet material 14 includes paper having a basis weight in the range of 15 to 80 gsm, preferably in the range of 20 to 50 gsm.

[0045] In some embodiments, the sheet material 14 has a basis weight of at least 15 gsm, preferably at least 20 gsm, 25 gsm, 30 gsm, 35 gsm, 40 gsm, 45 gsm, 50 gsm, 55 gsm, or 60 gsm.

[0046] In some embodiments, the sheet material 14 has a basis weight of 100 gsm or less, preferably 90 gsm or less, 80 gsm or less, 70 gsm or less, 60 gsm or less, 50 gsm or less, or 40 gsm or less, or 30 gsm or less. In some embodiments, the basis weight of the sheet material 14 is 20 gsm or less.

[0047] In some embodiments, the sheet material 14 has a basis weight in the range of 20 to 100 gsm, preferably in the range of 25 to 80 gsm or 30 to 65 gsm.

[0048] In this example, the sheet material 14 is crimped before being formed into a material body 4. For example, the sheet material 14 may be passed through a pair of crimping rollers. In this example, the first material body 4 includes a crimped sheet material 14 formed with a crimp pattern comprising a series of substantially parallel ridges and grooves. Crimping can make it easier to assemble the sheet material 14 to form the material body 4. Crimping can also increase the length of the sheet material 14 that can be used to form a material body 4 of a particular volume. Increasing the amount of sheet material 14 in the material body 4 increases the surface area of ​​the sheet material that comes into contact with the aerosol passing through the material body 4, and therefore the amount of moisture absorbed from the aerosol by the sheet material 14 may increase.

[0049] It may be desirable to form different parts of the material body 4 from different amounts of sheet material, which can be achieved by applying different levels of crimping to the sheet material 14 on which the parts are formed. For example, it may be desirable to form the longitudinal ends of the body 4 from longer sheet material so that the sheet material is more densely packed, the longitudinal ends of the body 4 appear to consumers more similar to conventional filter elements when viewed from the longitudinal ends, and additionally or alternatively, have higher hardness. Therefore, it may be advantageous to apply a greater amount of crimping to the sheet material 14 forming the longitudinal ends of the body than to the longitudinal central portion of the body. Similarly, it may be advantageous to form a part of the body 4 from shorter lengths of sheet material, in which case a less densely packed arrangement of sheet material is desired. For example, if an object is embedded in the body 4, it may be desirable to apply less crimping to the sheet material 14 forming the longitudinal portion of the body on which the object is embedded in order to lower the density of the sheet material 14 around the embedded object. Such a configuration effectively prevents the longitudinal portion of the main body from having an undesirably high pressure drop.

[0050] The level of crimping applied to the sheet material can contribute to the hardness of the body formed from the sheet material. Preferably, the hardness of the material body can be varied along its length by changing the crimp coefficient applied to the sheet material 14 on which it is formed. For example, a portion of the material body formed from a sheet material having a higher level of crimping may have a hardness of approximately 88% to 92%. A portion of the material body having a hardness of 88% to 92% can be appropriately formed at the distal end of the body to improve the appearance of the body when viewed from the distal end of the body and to improve the stability of the longitudinal end portion of the component. Similarly, other portions of the body may be formed from a sheet material having a lower level of crimping and a hardness of at least 80%.

[0051] In this example, the average spacing between adjacent raised areas of the sheet material 14 is greater than approximately 0.3 mm. In addition, in this example, the crimp amplitude is less than approximately 0.7 mm.

[0052] The crimp amplitude (also known as the "crimping coefficient") refers to the depth of the grooves formed by crimping in the sheet material 14 that forms the main body. That is, as shown in Figure 1B, crimping the sheet material 14 creates multiple peaks and valleys in the sheet material 14 when viewed from a first side of the sheet material 14, and the crimp amplitude "A" is the depth of the valleys measured from those peaks. The crimping can form a "zigzag" shape or another shape. In some examples, adjacent grooves in the crimped sheet material 14 are spaced apart by a distance in the range of 0.3 to 2 mm, preferably in the range of 0.4 to 1 mm, or have a pitch "P". In some embodiments, adjacent grooves in the crimped sheet material are spaced apart by a distance in the range of 0.1 to 3 mm, preferably in the range of 0.2 to 2 mm. In some embodiments, adjacent grooves in the crimped sheet material 10 are spaced at a distance of at least 0.1 mm, preferably at least 0.2, 0.5, 0.7, 1, 1.5, 2, 2.5, or 3 mm apart. In some embodiments, adjacent grooves in the crimped sheet material are spaced at a distance of at most 3 mm, preferably at a distance of at most 2.5, 2, 1, 1.5, 0.7, 0.5, 0.2, or 0.1 mm apart.

[0053] For example, the sheet material 14 may have crimps with a crimp amplitude of less than 500 μm and crimps with a spacing between peaks (or valleys) of at least 300 μm, at least 400 μm, or at least 500 μm.

[0054] In some embodiments, the sheet material 14 is heated when crimped. For example, the sheet material 14 may be passed between crimping rollers, and one or both of the crimping rollers are heated. For example, one or both of the rollers may be heated to a temperature of up to 100 degrees Celsius, such as 50 degrees Celsius or 60 degrees Celsius. The amount of pressure applied to the sheet material passing between the rollers may also vary, for example, between X and Y. Heating the roller(s) or applying a higher level of pressure to the sheet material can result in a higher level of crimping.

[0055] Preferably, it has been found that a sheet material 14, such as paper, having the above-described crimp pitch and / or amplitude exhibits improved performance when used as a component of an aerosol supply system. In particular, these relatively low levels of crimp pitch and amplitude surprisingly result in a material body or a portion of the material body having a lower pressure drop compared to a body or a portion of the body formed from a sheet material 14 having a higher level of crimping.

[0056] In any of these examples, the average density of the material body can be from about 0.1 to about 0.25 mg / mm 3 The density of the material body can be measured by separating the body from the article as well as the surrounding plug wrap and / or tipping paper and removing any embedded objects, including any additives added to the sheet material 14. The density can be calculated as the bulk density based on the weight of the sheet material 14 and any additives added to the sheet material 14, and the total volume occupied by the sheet material 14. For example, the total volume of the material body 4 measured inside the plug wrap 7.

[0057] In this example, the density of the material body 4 is about 0.19 mg / mm 3 In some embodiments, the body 4 is at least 0.1 mg / mm3, 0.12 mg / mm3 or 0.15 mg / mm 3It has a density of approximately 0.3 mg / mm³. Alternatively or in addition, material body 4 has a density of approximately 0.3 mg / mm³. 3 Less than approximately 0.25 mg / mm³ 3 Less than or approximately 0.22 mg / mm³ 3 It can have a density of less than 0.15 mg / mm³. Preferably, the density of the material body is about 0.15 mg / mm³. 3 ~about 0.25mg / mm 3 This is possible. As described above, different parts of the material body 4 may have different densities depending on the level of crimping and assembling applied to the sheet material 14 that forms the part. These values ​​include any additives contained within the material body 4. Before being crimped and formed into the material body, the sheet material 14 has a density of approximately 0.2 to 0.5 mg / mm². 3 For example, approximately 0.25, 0.30, or 0.35 mg / mm³ 3 It can have a density of .

[0058] The given dimensions of the sheet material 14 refer to the size of the sheet material before it is crimped or assembled to form the material body. The dimensions of the sheet material 14 can be measured by stretching the sheet material 14 to the point where no visible crimp remains.

[0059] In this example, a lower level of crimping is applied to the sheet material 14 that forms the portion of the main body 4 into which the tubular element 8 is embedded, while a higher level of crimping is applied to the sheet material 14 that forms the distal end of the main body 4.

[0060] In some embodiments, the sheet material 14 is crimped to a crimp amplitude of at least 0.1 mm, preferably at least 0.3 mm, 0.4 mm, or 0.5 mm.

[0061] In some embodiments, the sheet material 14 is crimped to a crimp amplitude of at most 1 mm, preferably at most 0.8 mm, 0.6 mm, or 0.5 mm.

[0062] In some embodiments, the sheet material 14 includes at least one slit extending substantially perpendicular to the longitudinal axis of the body 4. The at least one slit allows the sheet material 14 to be brought together at a first side (e.g., downstream side) of an object embedded in the body, such as a hollow tubular element 8, when the sheet material 14 is assembled to the body 4, thereby positioning the slit to form an inner edge within the body 4 that at least partially defines the boundary of the space that accommodates the embedded object. For example, the sheet material 14 may include three slits such that one slit is positioned at the downstream end of the hollow tubular element 8 and other slits are positioned on both sides of the capsule 15.

[0063] The inner edge formed by the slit allows the sheet material 14 to be gathered together on one side of the embedded object to define the boundary at least partially or completely, preventing the object from moving away from the first end of the space in which it is embedded. This improves the positioning of the embedded object within the body 4. In addition, because the sheet material 14 is gathered together, it helps to conceal the embedded object when viewed from the longitudinal end of the body 4, which can improve the aesthetics of the mouthpiece 2. Preferably, the slit achieves these advantages without requiring a separate component, such as a cellulose acetate plug, located downstream of the embedded object or downstream of the body 4.

[0064] Article 1 has a ventilation level of approximately 75% of the aerosol drawn through the article. In alternative embodiments, the article may have a ventilation level of 20% to 80%, e.g., 65% to 75%, of the aerosol drawn through the article. Ventilation at these levels helps to slow the flow of aerosol drawn through the mouthpiece 2, thereby allowing the aerosol to cool sufficiently before it reaches the downstream end 2b of the mouthpiece 2. The ventilation is provided directly within the mouthpiece 2 of article 1. In this example, the ventilation is provided within the tubular portion, which has been found to be particularly beneficial in assisting the aerosol generation process. The ventilation is provided through first and second parallel rows of ventilation holes 12, formed in this case as laser perforations, at positions 17.925 mm and 18.625 mm, respectively, from the downstream mouthpiece end 2b of the mouthpiece 2. In this example, these ventilation holes 12 penetrate the chipping paper 5, the plug wrap 7, and the hollow tubular element 8. In alternative embodiments, ventilation may be provided within the mouthpiece at other locations.

[0065] Alternatively, ventilation can be provided to the portion of the article where the tubular section is located, via a single row of vents, such as laser perforations. This has been shown to result in improved aerosol formation, which is thought to be due to the fact that, with respect to a given level of ventilation, the airflow through the vents is more uniform than in the case of multiple rows of vents.

[0066] Aerosol temperature is generally known to increase with decreasing ventilation levels. However, the relationship between aerosol temperature and ventilation level does not appear to be linear, as variations in ventilation due to manufacturing tolerances, for example, have less impact at lower target ventilation levels. For example, with a ventilation tolerance of ±15%, if the target ventilation level is 75%, the aerosol temperature may rise by only about 6°C at the lower ventilation limit (60% ventilation). However, at a target ventilation level of 60%, the aerosol temperature may rise by only about 3.5°C at the lower ventilation limit (45% ventilation). Therefore, the target ventilation level of an article can be in the range of 40% to 70%, for example, 45% to 65%. The average ventilation level of at least 20 articles may be 40% to 70%, for example, 45% to 70% or 51% to 59%.

[0067] In some examples, the aerosol-generating material 3 described herein is a first aerosol-generating material, and the hollow tubular element 8 may include a second aerosol-generating material. In one example, the inner wall of the tubular element 8 includes the second aerosol-generating material. For example, the second aerosol-generating material can be disposed on the inner surface of the hollow tubular element 8.

[0068] The second aerosol-generating material comprises at least one aerosol-forming material and may also comprise at least one aerosol modifier or other sensing material. The aerosol-forming material and / or aerosol modifier may be any aerosol-forming material or aerosol modifier as described herein, or a combination thereof.

[0069] The aerosol generated from the aerosol-generating material 3, referred to herein as the first aerosol, is drawn in through the hollow tubular element 8 of the mouthpiece. The heat from the first aerosol can aerosolize the aerosol-forming material of the second aerosol-generating material, thereby forming the second aerosol. The second aerosol may contain flavorings that are additional to or complementary to the flavorings of the first aerosol.

[0070] By providing a second aerosol-generating material on the tubular element 8, a second aerosol can be generated that enhances or complements the fragrance or visual appearance of the first aerosol.

[0071] In this example, article 1 has a circumference of approximately 21 mm (i.e., the article is demi-slim format). Preferably, article 1 has a rod of aerosol-generating material having a circumference greater than 19 mm. This has been found to provide a sufficient circumference to generate an improved, sustained aerosol over a typical aerosol-generating session preferred by consumers. When the article is heated, heat is transferred through the rod of aerosol-generating material 3, causing the components of the rod to volatilize, and a circumference greater than 19 mm has been found to be particularly effective in generating aerosols in this manner. Since the article will be heated to release aerosols, improved heating efficiency can be achieved by using articles with a circumference of less than approximately 23 mm. To achieve improved aerosols by heating, a rod circumference greater than 19 mm and less than 23 mm is preferred while maintaining an appropriate product length. In some examples, the rod circumference may be 20 mm to 22 mm, which has been found to provide a good balance between enabling efficient heating and providing effective aerosol delivery.

[0072] The outer circumference of mouthpiece 2 is substantially the same as the outer circumference of the rod of aerosol-generating material 3, thereby creating a smooth transition between these components. In this example, the outer circumference of mouthpiece 2 is approximately 20.8 mm.

[0073] In some examples, the chipping paper 5 contains citrate, such as sodium citrate or potassium citrate. In such examples, the chipping paper 5 may have a citrate content of 2% by weight or less, or 1% by weight or less. Reducing the citrate content of the chipping paper 5 is thought to help reduce the carbonization effect that may occur during use.

[0074] In this example, the chipping paper 5 extends 5 mm over the rod of the aerosol-generating material 3, but alternatively, it can extend 3 mm to 10 mm, or more preferably 4 mm to 6 mm, over the rod 3 to provide a secure attachment between the mouthpiece 2 and the rod 3. The chipping paper 5 can have a higher basis weight than the plug wrap used in article 1, for example, 40 gsm to 80 gsm, more preferably 50 gsm to 70 gsm, and in this example, 58 gsm. These ranges of basis weight have been found to result in a chipping paper with acceptable tensile strength while having sufficient flexibility to wrap article 1 and adhere to itself along the longitudinal overlap seams of the paper. The outer circumference of the chipping paper 5, when wrapped around the mouthpiece 2, is approximately 21 mm.

[0075] In some embodiments, the first plug wrap 7 has a basis weight of less than 50 gsm, more preferably about 20 gsm to 40 gsm. However, it should be noted that the basis weight of the first plug wrap 7 may be higher in order to increase the hardness of the mouthpiece. For example, the basis weight of the first plug wrap 7 may be at least 50, 60, 70, 80, 90, or 100 gsm. In some embodiments, the basis weight of the first plug wrap 7 is in the range of 50 to 110 gsm, or in the range of 60 to 100 gsm.

[0076] In some embodiments, the first plug wrap 7 has a basis weight of at least 20 gsm or at least 30 gsm.

[0077] In some embodiments, the first plug wrap 7 has a basis weight of at most 120, 110, or 100 gsm.

[0078] In some embodiments, the first plug wrap 7 has a basis weight in the range of 20 to 120 gsm, preferably in the range of 30 to 100 gsm.

[0079] Preferably, the first plug wrap 7 has a thickness of 30 μm to 60 μm, more preferably 35 μm to 45 μm. However, it should be noted that the thickness and weight of the first plug wrap 7 may be greater in order to increase the hardness of the mouthpiece. In some embodiments, for example, the thickness of the first plug wrap 7 may be at least 40, 50, 60, 70, 80, 90 or 100 microns. In some embodiments, the thickness of the first plug wrap 7 is in the range of 40 to 120 microns, or in the range of 50 to 100 microns.

[0080] Preferably, the first plug wrap 7 is a non-porous plug wrap having an air permeability of, for example, less than 100 cholesta units, or less than 50 cholesta units. However, in other embodiments, the first plug wrap 7 can be a porous plug wrap having an air permeability of, for example, more than 200 cholesta units.

[0081] The pressure drop or pressure difference (also called suction resistance) across the mouthpiece, for example, the portion of article 1 downstream of the aerosol-generating material 3, is preferably less than about 40 mmH2O. Such a pressure drop has been shown to allow sufficient aerosol containing the desired compound, such as a fragrance compound, to pass through the mouthpiece 2 and reach the consumer. More preferably, the pressure drop across the mouthpiece 2 is less than about 20 mmH2O. In some embodiments, particularly improved aerosols have been achieved using a mouthpiece 2 having a pressure drop of less than 15 mmH2O, e.g., about 6 mmH2O, about 10 mmH2O, or about 14 mmH2O. Alternatively or additionally, the pressure drop across the mouthpiece may be at least 3 mmH2O, preferably at least 4 mmH2O, and more preferably at least 5 mmH2O. In some embodiments, the pressure drop across the mouthpiece may be about 5 mmH2O to 20 mmH2O, preferably 5 mmH2O to 15 mmH2O. These values ​​allow the mouthpiece 2 to slow down the aerosol as it passes through it, such that the aerosol temperature has time to decrease before it reaches the downstream end 2b of the mouthpiece 2.

[0082] In this example, the aerosol-generating material 3 is wrapped in packaging material 10. The packaging material 10 can be, for example, paper or paper-backed foil packaging material. In this example, the packaging material 10 is substantially impermeable to air. In alternative embodiments, the packaging material 10 preferably has an air permeability of less than 100 cholesta units, more preferably less than 60 cholesta units. It has been shown that low-air permeability packaging materials, for example, having an air permeability of less than 100 cholesta units, more preferably less than 60 cholesta units, result in improved aerosol formation in the aerosol-generating material 3. While we do not wish to be constrained by theory, this is assumed to be due to a reduction in the loss of aerosol compounds through the packaging material 10. The air permeability of the packaging material 10 can be measured according to ISO 2965:2009 for determining the air permeability of materials used as cigarette paper, filter plug wraps, and filter bonding paper.

[0083] In this embodiment, the packaging material 10 includes aluminum foil. Aluminum foil has been shown to be particularly effective in promoting aerosol formation within the aerosol-generating material 3. In this example, the aluminum foil has a metal layer with a thickness of approximately 6 μm. In this example, the aluminum foil has a paper backing. However, in alternative configurations, the aluminum foil may have other thicknesses, for example, 4 μm to 16 μm. The aluminum foil does not necessarily have a paper backing, but may have a backing made of other materials, for example, to help provide the foil with adequate tensile strength, or it may not have a backing at all. Metal layers or foils other than aluminum can also be used. The total thickness of the packaging material is preferably 20 μm to 60 μm, more preferably 30 μm to 50 μm, which can provide a packaging material with appropriate structural integrity and heat transfer properties. The tension that can be applied to the packaging material before it breaks may exceed 3,000 grams, for example, a force of 3,000 to 10,000 grams, or a force of 3,000 to 4,500 grams.

[0084] In some examples, the packaging material 10 surrounding the aerosol-generating material 3 has a high level of air permeability, for example, exceeding about 1000 cholesta units, or about 1500 cholesta units, or about 2000 cholesta units. The air permeability of the packaging material 10 can be measured according to ISO 2965:2009 for determining the air permeability of materials used as cigarette paper, filter plug wraps, and filter bonding paper.

[0085] The packaging material 10 may be formed from a material having a high inherent level of permeability, an inherently porous material, or from a material having any level of inherent permeability where the final level of permeability is achieved by providing permeable zones or areas in the packaging material 10. Providing permeable packaging material 10 provides a path for air to enter the article. The packaging material 10 can be permeable such that the amount of air entering through the rod of aerosol-generating material is relatively greater than the amount of air entering the article through the vents 12 in the mouthpiece. Articles having this configuration can generate a more flavorful aerosol that may be more satisfying to the user.

[0086] In this example, the aerosol-forming material added to the aerosol-generating substrate 3 constitutes 14% by weight of the aerosol-generating substrate 3. Preferably, the aerosol-forming material constitutes at least 5% by weight, more preferably at least 10%, of the aerosol-generating substrate. Preferably, the aerosol-forming material constitutes less than 25% by weight, more preferably less than 20%, for example, 10% to 20%, 12% to 18%, or 13% to 16% of the aerosol-generating substrate.

[0087] Preferably, the aerosol generating material 3 is provided as a cylindrical rod of aerosol generating material. Regardless of the form of the aerosol generating material, the aerosol generating material preferably has a length of about 10 mm to 100 mm. In some embodiments, the length of the aerosol generating material is preferably in the range of about 25 mm to 50 mm, more preferably in the range of about 30 mm to 45 mm, and even more preferably about 30 mm to 40 mm.

[0088] In some examples, article 1 may be configured to have a separation (i.e., minimum distance) between the heater of the non-combustible aerosol supply device 100 and the hollow tubular element 8. This prevents heat from the heater from damaging the material forming the hollow tubular element 8.

[0089] The minimum distance between the heater and the hollow tubular element 8 of the non-combustible aerosol supply device 100 may be 3 mm or more. In some examples, the minimum distance between the heater and the hollow tubular element 8 of the non-combustible aerosol supply device 100 may be in the range of 3 mm to 10 mm, for example, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm.

[0090] Separation between the heater and the hollow tubular element 8 of the non-combustion aerosol supply device 100 may be achieved, for example, by adjusting the length of the rod of the aerosol generating material 3.

[0091] The volume of the aerosol-generating material 3 provided is approximately 200 mm³. 3 ~Approximately 4300mm 3 Preferably about 500 mm 3 ~1500mm 3 , more comfortably approximately 1000mm 3 ~approximately 1300mm 3 It can vary. For example, about 1000mm 3 ~approximately 1300mm 3 The provision of aerosol-generating materials in these volumes has been shown to preferably achieve superior aerosols with higher visibility and sensory performance compared to those achieved in volumes selected from the lower end of the range.

[0092] The mass of the aerosol-generating material 3 provided may be greater than 200 mg, for example, about 200 mg to 400 mg, preferably about 230 mg to 360 mg, and more preferably about 250 mg to 360 mg. Preferably, it has been found that providing a higher mass of aerosol-generating material results in improved sensory performance compared to aerosols generated from lower mass tobacco materials.

[0093] Preferably, the aerosol-generating material or substrate is formed from a tobacco material, such as those described herein, which contains tobacco components.

[0094] In the tobacco materials described herein, the tobacco component preferably includes paper-reconstructed tobacco. The tobacco component may also include loose leaf tobacco, extruded tobacco, and / or band-cast tobacco.

[0095] Aerosol-generating material 3 may include reconstituted tobacco material having a density of less than approximately 700 milligrams / cubic centimeter (mg / cc). Such tobacco material has been found to be particularly effective in providing an aerosol-generating material that can be heated rapidly to release aerosols compared to denser materials. For example, the inventors tested the properties of various aerosol-generating materials, such as band-cast reconstituted tobacco material and paper reconstituted tobacco material, when heated. For each given aerosol-generating material, it was found that a specific zero heat flow temperature exists, and while heat is being applied to the material, if the temperature is below this temperature, the net heat flow is endothermic, in other words, more heat enters the material than leaves it, and if the temperature is above this temperature, the net heat flow is exothermic, in other words, more heat leaves the material than enters it. Materials with a density of less than 700 mg / cc had lower zero heat flow temperatures. Since the majority of the heat flow leaving the material is due to aerosol formation, having a lower zero heat flow temperature has a beneficial effect on the time it takes for aerosols to be initially released from the aerosol-generating material. For example, it was found that aerosol-generating materials with a density of less than 700 mg / cc have a zero heat flow temperature of less than 164°C, compared to materials with a density of more than 700 mg / cc that have a zero heat flow temperature of more than 164°C.

[0096] The density of the aerosol-generating material also affects the rate at which heat is conducted through the material; lower densities, such as those below 700 mg / cc, allow heat to be conducted more slowly through the material, thus enabling more sustained aerosol release.

[0097] Preferably, the aerosol-generating material 3 comprises a reconstituted tobacco material having a density of less than about 700 mg / cc, such as a paper reconstituted tobacco material. More preferably, the aerosol-generating material 3 comprises a reconstituted tobacco material having a density of less than about 600 mg / cc. Alternatively or in addition, the aerosol-generating material 3 preferably comprises a reconstituted tobacco material having a density of at least 350 mg / cc, which is considered to allow a sufficient amount of heat conduction through the material.

[0098] The tobacco material may be provided in the form of cut rag tobacco. Cut rag tobacco can have a cut width of at least 15 cuts / inch (approximately 5.9 cuts / cm, corresponding to a cut width of approximately 1.7 mm). Preferably, cut rag tobacco has a cut width of at least 18 cuts / inch (approximately 7.1 cuts / cm, corresponding to a cut width of approximately 1.4 mm), and more preferably at least 20 cuts / inch (approximately 7.9 cuts / cm, corresponding to a cut width of approximately 1.27 mm). In one example, cut rag tobacco has a cut width of 22 cuts / inch (approximately 8.7 cuts / cm, corresponding to a cut width of approximately 1.15 mm). Preferably, cut rag tobacco has a cut width of 40 cuts / inch (approximately 15.7 cuts / cm, corresponding to a cut width of approximately 0.64 mm) or less. Cut widths between 0.5 mm and 2.0 mm, for example between 0.6 mm and 1.5 mm, or between 0.6 mm and 1.7 mm, have been shown to yield tobacco material that is particularly favorable in terms of the surface area-to-volume ratio when heated, as well as the overall density and pressure drop of the substrate 3. Cut rag tobacco can be formed from a mixture of forms of tobacco material, such as a mixture of one or more of paper-reconstructed tobacco, loose-leaf tobacco, extruded tobacco, and band-cast tobacco. Preferably, the tobacco material includes paper-reconstructed tobacco, or a mixture of paper-reconstructed tobacco and loose-leaf tobacco.

[0099] In the tobacco materials described herein, the tobacco material may contain filler components. Filler components are generally components that do not contain non-tobacco components, i.e., components derived from tobacco. Filler components may be non-tobacco fibers such as wood fibers or pulp or wheat fibers. Filler components may also be inorganic materials such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, or magnesium carbonate. Filler components may also be non-tobacco cast materials or non-tobacco extruded materials. Filler components may be present in an amount of 0 to 20% by weight of the tobacco material, or in an amount of 1 to 10% by weight of the composition. In some embodiments, filler components are absent.

[0100] In the tobacco materials described herein, the tobacco material contains an aerosol-forming material. In this context, the “aerosol-forming material” is an active substance that promotes aerosol formation. Aerosol-forming materials can promote aerosol formation by promoting the initial vaporization and / or condensation of gas into inhalable solid and / or liquid aerosols. In some embodiments, aerosol-forming materials can improve the delivery of flavorings from the aerosol-forming material. Generally, any suitable aerosol-forming material or active substance, including those described herein, may be included in the aerosol-forming material of the present invention. Other suitable aerosol-forming materials include, but are not limited to, polyols such as sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol, monohydric alcohols, high-boiling hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, or myristicates including ethyl myristate and isopropyl myristate, and non-polyols such as aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanediate, and dimethyl tetradecanediate. In some embodiments, the aerosol-forming material may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. Glycerol may be present in an amount of 10-20% by weight of the tobacco material, for example, 13-16% by weight of the composition, or about 14% or 15% by weight of the composition. Propylene glycol, if present, may be present in an amount of 0.1-0.3% by weight of the composition.

[0101] The aerosol-forming material may be included in any component of the tobacco material, for example, any tobacco component and / or filler component, if present. Alternatively or additionally, the aerosol-forming material may be added separately to the tobacco material. In any case, the total amount of the aerosol-forming material in the tobacco material may be as specified herein.

[0102] The tobacco material may contain 10% to 90% by weight of tobacco leaves, and the aerosol-forming material may be provided in an amount of up to approximately 10% by weight of the tobacco leaves. To achieve an overall level of 10% to 20% by weight of aerosol-forming material in the tobacco material, it has been found that this can preferably be added in a higher weight percentage relative to other components of the tobacco material, such as reconstituted tobacco material.

[0103] The tobacco materials described herein contain nicotine. The nicotine content is 0.5 to 1.75% by weight of the tobacco material, and may be, for example, 0.8 to 1.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material contains 10% to 90% by weight of tobacco leaves having a nicotine content exceeding 1.5% by weight of the tobacco leaves. Preferably, it has been found that using tobacco leaves with a nicotine content higher than 1.5% in combination with a lower nicotine base material such as paper-reconstructed cigarettes provides a tobacco material with a more appropriate nicotine level but with superior sensory performance than using paper-reconstructed cigarettes alone. Tobacco leaves, for example, cut rag cigarettes, can have a nicotine content of, for example, 1.5% to 5% by weight of the tobacco leaves.

[0104] The tobacco materials described herein may contain aerosol modifiers such as any of the flavorings described herein. In one embodiment, the tobacco material contains menthol to form a menthol-containing article. The tobacco material may contain 3 mg to 20 mg of menthol, preferably 5 mg to 18 mg, more preferably 8 mg to 16 mg of menthol. In this example, the tobacco material contains 16 mg of menthol. The tobacco material may contain 2% to 8% by weight of menthol, preferably 3% to 7% by weight of menthol, more preferably 4% to 5.5% by weight of menthol. In one embodiment, the tobacco material contains 4.7% by weight of menthol. Such high levels of menthol filling can be achieved, for example, by using a high proportion of reconstituted tobacco material exceeding 50% by weight of the tobacco material. Alternatively or additionally, the use of large amounts of aerosol-generating material, such as tobacco material, can increase the level of menthol filling, which can be achieved when more than about 500 mm³ or preferably more than about 1000 mm³ of aerosol-generating material, such as tobacco material, is used.

[0105] In the compositions described herein, where amounts are expressed in weight percent, to avoid misunderstanding, this refers to a dry weight basis unless otherwise specified. Therefore, any water that may be present in the tobacco material or any of its components is completely disregarded for the purpose of determining the weight percent. The water content of the tobacco material described herein may vary, for example, from 5 to 15% by weight. The water content of the tobacco material described herein may vary, for example, depending on the temperature, pressure, and humidity conditions under which the composition is maintained. The water content can be determined by Karl Fischer analysis, as is known to those skilled in the art. On the other hand, to avoid misunderstanding, any components other than water are included in the weight of the tobacco material, even if the aerosol-forming material is a liquid-phase component such as glycerol or propylene glycol. However, if the aerosol-forming material is provided to the tobacco component of the tobacco material or the filler component of the tobacco material (if present) instead of being added separately to the tobacco material, the aerosol-forming material is not included in the weight of the tobacco component or filler component, but is included in the weight of the "aerosol-forming material" in weight percent as defined herein. All other components present in tobacco are included in the weight of the tobacco component, even if they are of non-tobacco origin (e.g., non-tobacco fibers in the case of paper-reconstructed cigarettes).

[0106] In one embodiment, the tobacco material comprises tobacco components as defined herein and an aerosol-forming material as defined herein. In one embodiment, the tobacco material essentially consists of tobacco components as defined herein and an aerosol-forming material as defined herein. In one embodiment, the tobacco material consists of tobacco components as defined herein and an aerosol-forming material as defined herein.

[0107] Paper-reconstructed tobacco is present in the tobacco components of the tobacco material described herein in an amount of 10% to 100% by weight of the tobacco components. In embodiments, paper-reconstructed tobacco is present in an amount of 10% to 80% by weight, or 20% to 70% by weight, of the tobacco components. In further embodiments, the tobacco components consist essentially of or comprise paper-reconstructed tobacco. In preferred embodiments, leaf tobacco is present in the tobacco components of the tobacco material in an amount of at least 10% by weight of the tobacco components. For example, leaf tobacco may be present in an amount of at least 10% by weight of the tobacco components, and the remainder of the tobacco components may include paper-reconstructed tobacco, band-cast reconstructed tobacco, or a combination of band-cast reconstructed tobacco and other forms of tobacco such as tobacco granules.

[0108] Paper-reconstructed tobacco refers to tobacco material formed by a process in which tobacco supply raw materials are extracted with a solvent to obtain an extract of soluble components and a residue containing fibrous material, and then the extract (usually concentrated, and optionally after further processing) is combined with fibrous material from the residue (usually after the fibrous material has been purified, and optionally with the addition of some non-tobacco fibers) by depositing the extract onto the fibrous material. The recombination process is similar to the process of making paper.

[0109] Paper recombination tobacco may be any type of paper recombination tobacco known in the art. In certain embodiments, paper recombination tobacco is made from raw materials comprising one or more of tobacco strips, tobacco stalks, and whole tobacco leaves. In further embodiments, paper recombination tobacco is made from feed materials comprising tobacco strips and / or whole tobacco leaves, as well as tobacco stalks. However, in other embodiments, scrap, pulp, and sorted materials may be used as alternatives or additionally in the feed materials.

[0110] Paper-reconstructed tobacco for use in the tobacco materials described herein can be prepared by methods known to those skilled in the art for preparing paper-reconstructed tobacco.

[0111] Figure 2 is a side cross-sectional view of article 1' for use with a non-combustible aerosol supply system. Article 1' comprises a mouthpiece 2' which is substantially the same as mouthpiece 2, except that the material body 4 is replaced by a material body 4' which additionally comprises a second tubular element 11 at the downstream end of the body 4'. The second tubular element 11 extends to the mouthpiece end of the material body 4'.

[0112] In this example, the hollow tubular element 8 and the second hollow tubular element 11 are separated by a gap of 10 mm. Alternatively, the first hollow tubular element 8 and the second hollow tubular element 11 are separated by other distances, for example, 5 mm to 15 mm, or 6 mm to 12 mm, or approximately 6 mm, approximately 7 mm, approximately 8 mm, or approximately 9 mm. The material body 4' extends within and across the gap. In this example, the capsule 15 is embedded in the material body 4' in the gap between the first hollow tubular element 8 and the second hollow tubular element 11.

[0113] In this example, the sheet material 14 forming the body 4' includes two slits positioned at the downstream and upstream ends of the first hollow tubular element 8 and the second hollow tubular element 11, respectively. The slits are positioned so that when the sheet material 14 is assembled to the body 4', the slits release the sheet material 14 between the slits and extend into the gap between the first hollow tubular element 8 and the second hollow tubular element 11. Additionally or alternatively, the sheet material 14 may include one or more slits positioned on both sides of the embedded capsule 15.

[0114] In this example, the first hollow tubular element 8 provides a cavity for aerosol cooling, as described above.

[0115] The second hollow tubular element 11 is embedded in the material body 4' at its downstream end and extends to the longitudinal end of the body 4'. It has been found that providing the tubular element in this position preferably significantly reduces the temperature of the outer surface of the mouthpiece 2' at the downstream end 2b of the mouthpiece that comes into contact with the consumer's mouth when the article 1' is in use. In addition, it has been found that the use of the tubular portion also significantly reduces the temperature of the outer surface of the mouthpiece 2' even upstream of the tubular portion. Although we do not wish to be constrained by theory, it is assumed that this is due to the tubular portion directing the aerosol closer to the center of the mouthpiece 2', and thus reducing heat transfer from the aerosol to the outer surface of the mouthpiece 2'. In addition, it has been found that the material body 4' filling the gap between the first tubular element 4a' and the second hollow tubular element 11 removes moisture from the aerosol generated by the aerosol-generating material 3 as the aerosol passes through the material body 4' of the mouthpiece 2, thereby making the aerosol feel cooler in the user's mouth.

[0116] The second hollow tubular element 11 preferably has an inner diameter greater than 3.0 mm. A smaller diameter may increase the velocity of the aerosol that passes through the mouthpiece 2'' and reaches the consumer's mouth more than desired, thereby causing the aerosol to become excessively warm, for example, reaching temperatures above 40°C or 45°C. More preferably, the second hollow tubular element 11 has an inner diameter greater than 3.1 mm, and even more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the inner diameter of the second hollow tubular element 11 is about 3.9 mm.

[0117] By forming a mouthpiece including a material body 4' having a first hollow tubular element 8 and a second hollow tubular element 11 embedded in the opposite end of the material body 4', a mouthpiece is preferably obtained having a concave mouthpiece end and a cavity for aerosol cooling at the upstream end of the mouthpiece, surrounded by a plug wrap thickness thinner than normally required for such a structure, because both cavities are provided by tubular elements embedded in the same material body, eliminating the need for separate plug wraps and combination wraps for different components. Not only does this simplify the manufacture of the mouthpiece by reducing the number of components, but it can also be easier to form ventilation openings in the material body 4' at desired locations because the plug wrap thickness to be perforated is thinner. A material body 4' having both the first hollow tubular element 8 and the second hollow tubular element 11 and a capsule 15 embedded in the material body 4' between the first hollow tubular element 8 and the second hollow tubular element 11 preferably results in a component that has the advantage of being simplified in manufacture, as described in relation to Figure 1 and above.

[0118] In this example, the second hollow tubular element 11 has a greater wall thickness than the first hollow tubular element 8 and is shorter than the first hollow tubular element 8, such that the cavity at the mouthpiece end 2b provided by the second hollow tubular element 11 is smaller than the cavity formed by the first hollow tubular element 8. In other examples, the wall thickness of the hollow tubular element 8 may be greater than the wall thickness of the second hollow tubular element 11. Preferably, by selecting different wall thicknesses, inner diameters, and / or lengths for each of the first hollow tubular element 8 and the second hollow tubular element 11, the cavities at both ends of the material body 4' can be optimized, as desired, based on their positions within the mouthpiece, for aerosol cooling and / or guiding the aerosol through the mouthpiece.

[0119] Preferably, the length of the second hollow tubular element 11 is less than about 20 mm. More preferably, the length of the second hollow tubular element 11 is less than about 15 mm. Even more preferably, the length of the second hollow tubular element 11 is less than about 10 mm. In addition, or alternatively, the length of the second hollow tubular element 11 is at least about 5 mm. Preferably, the length of the second hollow tubular element 11 is at least about 6 mm. In some preferred embodiments, the length of the second hollow tubular element 11 is about 5 mm to about 20 mm, more preferably about 6 mm to about 10 mm, and even more preferably about 6 mm to about 8 mm, most preferably about 6 mm, 7 mm, or about 8 mm. In this example, the length of the second hollow tubular element 11 is 6 mm.

[0120] In this example, each of the first hollow tubular element 8 and the second hollow tubular element 11 is surrounded by a material body 4' having the same outer diameter and thickness.

[0121] As described above, different levels of crimping can be applied to the sheet material 14 that forms different parts of the main body 4'. In this example, a higher level of crimping is applied to the sheet material that forms the mouthpiece end portion of the main body 4' into which the second hollow tubular element 11 is embedded, compared to the level of crimping applied to the sheet material 14 that forms the portion of the main body 4' into which the first hollow tubular element 8 and capsule 15 are embedded. Preferably, by applying a higher level of crimping to the sheet material 14 around the second hollow tubular element 11, a more desirable hardness at the mouthpiece end 2b of the mouthpiece and an improved appearance when viewed from the mouthpiece end of the mouthpiece can be obtained.

[0122] The plug wrap 7 and / or chipping paper 5 may include a barrier coating to make the material of the plug wrap and / or chipping paper substantially impermeable to the liquid payload of the capsule 15.

[0123] Figure 3 is a side cross-sectional view of article 1'' for use with a non-combustible aerosol supply system. Article 1'' comprises a mouthpiece 2'' including a material body 4''. The material body 4'' is substantially the same as the material body 4', except that the material body 4'' does not include a first hollow tubular element 8 upstream of the capsule 15. In this example, instead, a cooling section 13 is provided upstream of the material body 4'' to provide a cavity for aerosol cooling.

[0124] In this example, the material body 4'' extends approximately 3.5 mm upstream of the capsule 15. Alternatively, the material body 4'' may extend approximately 1 mm upstream of the capsule 15, or approximately 2 mm, 3 mm, 5 mm, 6 mm, 7 mm, 8 mm, or 10 mm upstream of the capsule 15.

[0125] In this example, the capsule 15 is separated from the second hollow tubular element 11 at the mouthpiece end by a gap of approximately 4.5 mm. Alternatively, the capsule 15 may be separated from the second hollow tubular element 11 by a gap of 0.5 mm to 30 mm, or 1 mm to 20 mm, or 1.5 mm to 15 mm, or 2 mm to 10 mm. For example, the capsule 15 may be separated from the second hollow tubular element 11 by a gap of approximately 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, or 8 mm. The separation of the capsule 15 from the second hollow tubular element 11 may be chosen to provide an appropriate volume of material within the material body 4'' to absorb the liquid charge of the capsule 15, and to balance this with the desired length of the component and pressure drop.

[0126] As described in relation to Figure 2, various levels of crimping can be applied to the sheet material 14 that forms the material body 4''. In this example, a higher level of crimping is applied to the sheet material that forms a section of the material body 4'' at the spout end. The material body 4'' may have a higher density in the portion closer to the downstream end than in the portion closer to the upstream end. For example, the portion of the material body 4'' within 3 mm of the longitudinal end of the body 4'' may have a higher density than the portion upstream of this 3 mm portion. The portion of the body formed from the sheet material having a higher level of crimping and a higher density than other parts of the body may have a more attractive appearance to consumers. Preferably, such a section may be provided at the longitudinal end of the body 4'', giving the body 4'' an attractive appearance from the longitudinal end to consumers, while the upstream portion of the component may have a lower density to limit the amount of sheet material 14 required to form the material body 4'' and prevent the body 4'' from having an undesirable high pressure drop. The density of a particular section of the body 4'' can be measured by separating the section from the rest of the body and the surrounding plug wrap and / or chipping paper (for example, by cutting the body), removing any embedded objects, but including any additives added to the sheet material 14.

[0127] In this example, the cooling section 13 defines a void within the mouthpiece that acts as a cooling segment, as described with respect to the hollow tubular element 8. The void provides a chamber through which heated volatile components generated by the aerosol-generating material 3 flow. The cooling section 13 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and while the article 1 is in use. The cooling section 13 provides physical displacement between the aerosol-generating material 3 and the downstream portion of the mouthpiece 2.

[0128] Preferably, the internal volume of the cooling section 13 is 130 mm3 Larger. It has been found that providing a cavity of at least this volume enables improved aerosol formation. Such a cavity size provides sufficient space within the mouthpiece 2 to allow heated volatile components to cool, and thus allows the aerosol-generating material 3 to be exposed to a higher temperature than otherwise possible, which could result in an excessively warm aerosol. More preferably, the mouthpiece 2'' is 170 mm 3 Larger, even more preferably 200 mm 3 It features a cavity with a larger internal volume, allowing for further improvement of the aerosol. In some examples, the internal cavity is approximately 130 mm 3 ~about 700mm 3 Preferably about 160 mm 3 ~about 700mm 3 It includes the volume of.

[0129] The cavity can be configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile components entering the first upstream end of the cavity and the heated volatile components exiting the second downstream end of the cavity. Preferably, the cavity is configured to provide a temperature difference of at least 60 degrees Celsius, preferably at least 80 degrees Celsius, and more preferably at least 100 degrees Celsius between the heated volatile components entering the first upstream end of the cavity and the heated volatile components exiting the second downstream end of the cavity. This temperature difference along the length of the cavity can protect the temperature-sensitive elements of the mouthpiece downstream of the cavity from the high temperature of the aerosol-generating material 3 when heated.

[0130] Preferably, the length of the cooling section 13 is less than about 50 mm. More preferably, the length of the cooling section 13 is less than about 40 mm. Even more preferably, the length of the cooling section 13 is less than about 35 mm. In addition, or alternatively, the length of the cooling section 13 is preferably at least about 10 mm. Preferably, the length of the cooling section 13 is at least about 15 mm.

[0131] In some preferred embodiments, the length of the cooling section 13 is about 15 mm to about 35 mm, more preferably about 20 mm to about 30 mm, even more preferably about 23 mm to about 27 mm, and most preferably about 25 mm. In this example, the length of the cooling section 13 is 23 mm.

[0132] In this example, the cooling section 13 is formed from multiple layers of paper wound parallel to each other with their joints butted together to form a hollow tube. In this example, the first and second layers of paper are provided in a two-ply tube, but in other examples, three, four or more layers of paper can be used to form a three, four or more-ply tube. Other configurations can be used, such as spirally wound layers of paper, cardboard tubes, tubes formed using a papier-mâché process, or molded or extruded plastic tubes.

[0133] In some embodiments, the cooling section 13 preferably has a wall thickness of at least about 50 μm to a maximum of about 1 mm, preferably 100 μm to 500 μm, and more preferably 100 μm to 150 μm. In this example, the wall thickness of the cooling section 13 is about 150 μm. The “wall thickness” of the tubular element corresponds to the thickness of the wall of the tubular element in the radial direction, excluding the surrounding material in which the tubular element is embedded. This can be measured, for example, using a caliper.

[0134] In some embodiments, the wall thickness of the cooling section 13 is at least 50 microns, preferably at least 75, 80, 85, 90, 95, 100, or 105 microns. In some embodiments, the wall thickness of the tubular element is at least 100 or 110 microns.

[0135] In some embodiments, the wall thickness of the cooling section 13 is less than 1000 microns, preferably less than 500 microns.

[0136] In some embodiments, the permeability of the wall material of the cooling section 13 is at least 100 cholesta units, preferably at least 500 or 1000 cholesta units.

[0137] The relatively high permeability of the cooling section 13 has been shown to increase the amount of heat transferred from the aerosol to the tubular portion, and therefore to lower the temperature of the aerosol. The permeability of the cooling section 13 has also been shown to increase the amount of moisture transferred from the aerosol to the tubular portion, which has been shown to improve the feel of the aerosol in the user's mouth. The high permeability of the cooling section 13 also means that the air entering the material body 4 surrounding the tubular portion can pass through the walls of the cooling section 13 into the aerosol flow without the need to cut vents through the outer plug wrap(s) and chipping paper, the material body 4, and all the tubular elements forming the tubular portion, thereby reducing manufacturing complexity.

[0138] The cooling section 13 and the material body 4'' are connected by a second plug wrap 9.

[0139] According to this disclosure, “aerosol supply system” includes both combustion-type aerosol supply systems and non-combustion-type aerosol supply systems.

[0140] Figure 4 is a side cross-sectional view of a further article 1''' for use with a non-combustible aerosol supply system. Article 1''' includes a mouthpiece 2''', which is substantially the same as mouthpiece 2, except that in this example the hollow tubular element 8 is replaced by tubular elements 4a, 4b. In this example, the tubular elements 4a, 4b form cavities for aerosol cooling, as described with respect to the hollow tubular element 8. The tubular elements 4a, 4b are embedded in a material body 4''' and are circumferentially surrounded by the material forming the body 4'''. The tubular elements 4a, 4b can have any suitable specifications, as described for the first hollow tubular element 8 and the second hollow tubular element 11. In this example, the tubular elements 4a, 4b have the same specifications. Alternatively, the specifications of tubular element 4a may differ from those of tubular element 4b, for example, to provide cavities containing regions of varying inner diameters or porosity.

[0141] In this example, the first tubular element 4a is positioned at the longitudinal end of the material body 4''' and extends to the longitudinal end of the body. The second tubular element 4b is positioned downstream of the first tubular element 4a, and the material body 4''' extends beyond the second tubular element 4b such that the second tubular element is surrounded by the first material body 4 both circumferentially and longitudinally.

[0142] In this example, the first tubular element 4a and the second tubular element 4b are separated by a gap of approximately 1 mm to effectively form a continuous tubular portion. In embodiments where the first tubular element 4a and the second tubular element 4b are intended to effectively form a continuous tubular portion, the tubular elements may be appropriately separated by a gap of 0.5 mm to 6 mm, for example, 1 mm to 3 mm, or 2 mm to 5 mm. In this example, the tubular portion formed by the first tubular element 4a and the second tubular element 4b defines a void that acts as a cooling segment within the mouthpiece. In this example, the tubular portion comprises the first tubular element 4a and the second tubular element 4b, each having a length of 11 mm and separated by a gap of 1 mm.

[0143] In other examples, the hollow tubular element 11 may be similarly formed by first and second tubular elements (not shown).

[0144] According to this disclosure, a “combustion-type” aerosol supply system is a system in which the aerosol-generating material (or its components) that make up the aerosol supply system is burned or incinerated during use in order to facilitate the delivery of at least one substance to the user.

[0145] In some embodiments, the delivery system is a combustion-type aerosol delivery system, such as a system selected from the group consisting of cigarettes, cigarillos, and cigars.

[0146] In some embodiments, the disclosure relates to components for use in combustion aerosol supply systems, such as aerosol modifier release components including filters, filter rods, filter segments, tobacco rods, spills, capsules, threads or beads, or paper such as plug wraps, chipping paper or cigarette paper.

[0147] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the constituent aerosol-generating materials (or their components) of the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0148] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0149] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0150] In some embodiments, the non-combustion 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.

[0151] In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates aerosols using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of 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, for example, tobacco or a non-tobacco product.

[0152] Typically, a non-combustible aerosol supply system may comprise a non-combustible aerosol supply device and consumables for use with the non-combustible aerosol supply device.

[0153] In some embodiments, the disclosure relates to consumables comprising an aerosol-generating material and configured for use with a non-combustible aerosol supply device. These consumables may be referred to as articles throughout the disclosure.

[0154] In some embodiments, a non-combustible aerosol supply system, such as the non-combustible 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 that can be energized to distribute power in the form of heat to an aerosol-generating material or heat-transferring material adjacent to the heat-generating power source.

[0155] In some embodiments, a non-combustion aerosol supply system may include an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0156] In some embodiments, consumables for use with a non-combustible 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, packaging material, a filter, a mouthpiece, and / or an aerosol modifier.

[0157] In some embodiments, the delivered substance includes an active substance.

[0158] The active substances used herein may be physiologically active materials, which are materials intended to achieve or enhance a physiological response. Active substances may be selected from, for example, dietary supplements, nootropics, and psychostimulants. Active substances may be naturally occurring or obtained synthetically. Active substances may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or their components, derivatives, or combinations. Active substances may also include one or more components, derivatives, or extracts of tobacco, cannabis, or another plant.

[0159] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0160] As described herein, the active substance may include or be derived from one or more plant substances, their components, derivatives, or extracts. As used herein, the term “plant substance” includes, but is not limited to, any material derived from a plant, including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, shells, peels, etc. Alternatively, the material may include naturally occurring active compounds in synthetically obtained plant substances. 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, mato, orange skin, papaya, rose, sage, tea (such as green or black tea), thyme, clove, cinnamon, coffee, anise, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. - Lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, kulchma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chives, fennel, verbena, tarragon, geranium, mulberry, ginseng, theanine, siacrine, maca, shwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint may be selected from the following mint varieties: peppermint, mint, Egyptian mint, European mint, eau de cologne mint, candy mint, curly mint, Kentucky colonel mint, horse mint, pineapple mint, benyroyal mint, green mint, and apple mint.

[0161] In some embodiments, the active substance comprises or is derived from one or more plant substances, or components thereof, derivatives, or extracts, the plant substance being tobacco.

[0162] In some embodiments, the active substance comprises or is derived from one or more plant substances, or their components, derivatives, or extracts, the plant substances being selected from eucalyptus, star anise, cocoa, and hemp.

[0163] In some embodiments, the active substance comprises or is derived from one or more plant substances, or their components, derivatives, or extracts, the plant substances being selected from rooibos and fennel.

[0164] In some embodiments, the substance delivered includes a fragrance.

[0165] As used herein, the terms “flavoring” and “flavoring” refer to materials that may be used to create a desired taste, aroma, or other somatosensory effect in products intended for adult consumers, where permitted by local regulations.These are naturally occurring fragrance materials, plant substances, extracts of plant substances, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaves, osmanthus leaves, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, Ardisia crenata, cherry, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes, etc.) Tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, chats, naswar, betel nut, shisha, pine, honey extract, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang Illano tree, sage, fennel, wasabi, pimento, ginger, coriander, coffee, hemp, peppermint oil from any of the Mentha species, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazelnut, hibiscus, bay leaf, mate tea, orange peel, rose, tea like green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, da It may also contain other additives such as Mien, Oriental mint, olive, lemon balm, lemon basil, chives, fennel, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), as well as charcoal, chlorophyll, minerals, plant matter, or breath fresheners.They may be imitations, synthetics, natural ingredients, or blends thereof. They may be in any suitable form, such as a liquid like an oil, a solid like a powder, or a gas.

[0166] In some embodiments, the flavoring includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring includes cucumber, blueberry, citrus, and / or red berry flavoring components. In some embodiments, the flavoring includes eugenol. In some embodiments, the flavoring includes flavoring components extracted from tobacco. In some embodiments, the flavoring includes flavoring components extracted from cannabis.

[0167] In some embodiments, the fragrance may include a sensory stimulant, which is intended to achieve somatosensory perception that is normally chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of the aroma or taste nerves, and these may include active ingredients that produce heating, cooling, tingling, or numbing effects. Suitable thermal agents may be vanillyl ethyl ether, but are not limited, and suitable cooling agents may be eucalyptol, WS-3, but are not limited.

[0168] Aerosol-generating materials are materials capable of generating aerosols when energy is supplied, for example, by heating, irradiation, or any other method. Aerosol-generating materials may be in the form of solids, liquids, or gels, which may or may not contain active substances and / or flavorings. In some embodiments, the aerosol-generating material may include an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material capable of holding some fluid, such as a liquid, within itself. In some embodiments, the aerosol-generating material may include, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid, or about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0169] 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.

[0170] The aerosol-forming material may contain one or more components 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, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetins, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0171] One or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0172] The material may be present on or within a support to form a substrate. The support may be, for example, paper, cardboard, cardboard, reconstructive material, plastic material, ceramic material, composite material, glass, metal, or metal alloy, or may include them. In some embodiments, the support includes a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0173] Consumables are articles containing or consisting of aerosol-generating material, some or all of which are intended to be consumed during use by the user. Consumables may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, packaging material, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may also comprise an aerosol generator, such as a heater, which releases heat to generate an aerosol in the aerosol-generating material during use. The heater may comprise, for example, a flammable material, an electrically conductive material, or a susceptor.

[0174] A susceptor is a material that can be heated by penetration through a fluctuating magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, and consequently, penetration through the conductive material by the fluctuating magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, and consequently, penetration through the magnetic material by the fluctuating magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, and consequently, the susceptor can be heated by both heating mechanisms. A device configured to generate a fluctuating magnetic field is referred to herein as a magnetic field generator.

[0175] An aerosol modifier is a substance configured to modify a generated aerosol, for example, by altering the taste, flavor, 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.

[0176] 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 the form of a powder, thread, or granules. The aerosol modifier does not need to contain a filter material.

[0177] An aerosol generator is a device configured to produce an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to supply thermal energy to the aerosol-generating material in order to release one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to produce an aerosol from an aerosol-generating material without heating. For example, the aerosol generator may be configured to supply one or more of the aerosol-generating material to vibration, pressure increase, or electrostatic energy.

[0178] For example, items in the shape of a rod are often named according to their length: "Regular" (typically in the range of 68-75mm, e.g., about 68mm-72mm), "Short" or "Mini" (68mm or less), "King Size" (typically in the range of 75-91mm, e.g., about 79mm-88mm), "Long" or "Super King" (typically in the range of 91-105mm, e.g., about 94mm-101mm), and "Ultra Long" (typically in the range of about 110mm-121mm).

[0179] The items are also named according to their circumference: "Regular" (approximately 23-25mm), "Wide" (over 25mm), "Slim" (approximately 22-23mm), "Demi-Slim" (approximately 19-22mm), "Super-Slim" (approximately 16-19mm), and "Micro-Slim" (less than approximately 16mm).

[0180] Therefore, a king-size super-slim article has, for example, a length of approximately 83 mm and a circumference of approximately 17 mm.

[0181] Each form may be manufactured using mouthpieces of different lengths. The length of the mouthpiece is approximately 30 mm to 50 mm. The chipping paper connects the mouthpiece to the aerosol-generating material and is usually longer than the mouthpiece, for example, 3 to 10 mm, so that the chipping paper covers the mouthpiece and overlaps the aerosol-generating material in the form of a rod of base material, connecting the mouthpiece to the rod.

[0182] The articles, aerosol-generating materials, and mouthpieces described herein may be manufactured in any of the forms described above, but are not limited thereto.

[0183] 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 in use.

[0184] The filamentous tow materials described herein may include cellulose acetate fiber tow. Filamentous tow may also be formed using other materials used to form fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4-butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers or combinations thereof. The filamentous tow may be plasticized with a tow-suitable plasticizer such as triacetin, where the material is cellulose acetate tow, or the tow may not be plasticized. The tow can have any suitable specifications, such as fibers having other cross-sections like a "Y" shape or an "X" shape, and have filament denier values ​​of 2.5 to 15 denier per filament, for example 8.0 to 11.0 denier per filament, and a total denier value of 5,000 to 50,000, for example 10,000 to 40,000.

[0185] As used herein, the term “tobacco material” refers to any material including tobacco or its derivatives or substitutes. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, extended tobacco, re-tobacco, or tobacco substitutes. Tobacco material may include one or more of ground tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco stems, tobacco laminas, re-tobacco, and / or tobacco extracts.

[0186] Figure 5 shows an example of a non-combustible aerosol supply device 100 for generating aerosols from an aerosol-generating medium / material such as an aerosol-generating material 3, one of the articles 1, 1', 1'', 1'''', 1'''' described herein. Schematically, device 100 can be used to heat a replaceable article 110 containing an aerosol-generating medium, such as articles 1, 1', 1'', 1'''', 1'''' described herein, to generate an aerosol or other inhalable medium to be inhaled by a user of device 100. Device 100 and the replaceable article 110 together form a system.

[0187] Device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and accommodates various components of device 100. Device 100 has an opening 104 in one end, through which an article 110 can be inserted for heating by a heating assembly. During use, the article 110 may be fully or partially inserted into the heating assembly, where it may be heated by one or more components of the heater assembly.

[0188] When article 110 is inserted into device 100, the minimum distance between one or more components of the heater assembly and the tubular body 4a of article 110 may be in the range of 3 mm to 10 mm, for example, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm.

[0189] The device 100 in this example includes a first end member 106, the first end member 106 having a lid 108 that is movable relative to the first end member 106 to close the opening 104 when the article 110 is not in place. In Figure 5, the lid 108 is shown in an open configuration, but the lid 108 can be moved to a closed configuration. For example, the user may slide the lid 108 in the direction of arrow "B".

[0190] Device 100 may also include a user-operable control element 112, such as a button or switch, which operates device 100 when pressed. For example, a user may turn on device 100 by operating the switch 112.

[0191] Device 100 may also include electrical components such as a socket / port 114 that can receive a cable for charging the device 100's battery. For example, the socket 114 could be a charging port, such as a USB charging port.

[0192] Figure 6 depicts the device 100 of Figure 5 with the outer cover 102 removed and the item 110 absent. The device 100 defines a longitudinal axis 134.

[0193] As shown in Figure 6, the first end member 106 is located at one end of the device 100, and the second end member 116 is located at the opposite end of the device 100. The first end member 106 and the second end member 116 together define at least partially the end surface of the device 100. For example, the bottom surface of the second end member 116 defines at least partially the bottom surface of the device 100. The edge of the outer cover 102 may also define a portion of the end surface. In this example, the lid 108 also defines a portion of the top surface of the device 100.

[0194] The end of the device closest to the opening 104 may be known as the proximal end (or mouthpiece end) of the device 100, as it is closest to the user's mouth during use. During use, the user inserts an article 110 into the opening 104 and operates the user control unit 112 to begin heating the aerosol-generating material and aspirates the aerosol generated within the device. This causes the aerosol to flow through the device 100 along a channel toward the proximal end of the device 100.

[0195] The other end of the device furthest from the opening 104 may be known as the distal end of device 100, as it is the end furthest from the user's mouth during use. When the user inhales the aerosol generated within the device, the aerosol flows out from the distal end of device 100.

[0196] Device 100 further comprises a power supply 118. The power supply 118 may be a battery, such as a rechargeable or non-rechargeable battery. Suitable battery examples include, for example, lithium batteries (such as lithium-ion batteries), nickel batteries (such as nickel-cadmium batteries), and alkaline batteries. The battery is electrically coupled to the heating assembly to heat the aerosol-generating material by supplying power under the control of a controller (not shown) as needed. In this example, the battery is connected to a central support 120 that holds the battery 118 in place.

[0197] The device further comprises at least one electronic module 122. The electronic module 122 may, for example, include a printed circuit board (PCB). The PCB 122 may support at least one controller, such as a processor, and memory. The PCB 122 may also include one or more electrical tracks for electrically connecting various electronic components of the device 100 together. For example, battery terminals may be electrically connected to the PCB 122 so that power can be distributed throughout the device 100. The socket 114 may also be electrically coupled to the battery via the electrical tracks.

[0198] In exemplary device 100, the heating assembly is an induction heating assembly comprising various components for heating the aerosol-generating material of article 110 via an induction heating process. Induction heating is the process of heating a conductor (such as a susceptor) by electromagnetic induction. The induction heating assembly may comprise an inductive element, for example, one or more inductor coils, and a device for passing a variable current, such as an alternating current, through the inductive element. The variable current in the inductive element generates a fluctuating magnetic field. The fluctuating magnetic field penetrates a susceptor appropriately positioned with respect to the inductive element, generating eddy currents inside the susceptor. The susceptor has electrical resistance to eddy currents, and therefore the flow of eddy currents against this resistance heats the susceptor by Joule heating. If the susceptor contains a ferromagnetic material such as iron, nickel, or cobalt, heat may also be generated by magnetic hysteresis losses within the susceptor, i.e., by the fluctuating orientation of magnetic dipoles in the magnetic material resulting from the alignment of the magnetic material with the fluctuating magnetic field. In induction heating, compared to, for example, conduction heating, heat is generated inside the susceptor, enabling rapid heating. Furthermore, since no physical contact is required between the induction heater and the susceptor, it allows for greater flexibility in construction and application.

[0199] The induction heating assembly of exemplary device 100 comprises a susceptor structure 132 (referred to herein as the “susceptor”), a first inductor coil 124, and a second inductor coil 126. The first inductor coil 124 and the second inductor coil 126 are fabricated from a conductive material. In this example, the first inductor coil 124 and the second inductor coil 126 are fabricated from Litz wire / cable, which is wound helically to provide helical inductor coils 124, 126. Litz wire consists of multiple individual wires that are individually insulated and twisted together to form a single wire. Litz wire is designed to reduce skin effect losses in a conductor. In exemplary device 100, the first inductor coil 124 and the second inductor coil 126 are fabricated from copper Litz wire having a rectangular cross-section. In other examples, Litz wire may have a cross-section of other shapes, such as circular.

[0200] The first inductor coil 124 is configured to generate a first fluctuating magnetic field for heating a first section of the susceptor 132, and the second inductor coil 126 is configured to generate a second fluctuating magnetic field for heating a second section of the susceptor 132. In this example, the first inductor coil 124 is adjacent to the second inductor coil 126 in the direction along the longitudinal axis 134 of the device 100 (i.e., the first inductor coil 124 and the second inductor coil 126 do not overlap). The susceptor configuration 132 may consist of a single susceptor or two or more separate susceptors. The ends 130 of the first inductor coil 124 and the second inductor coil 126 may be connected to the PCB 122.

[0201] It will be understood that the first inductor coil 124 and the second inductor coil 126 may, in some examples, have at least one characteristic that is different from each other. For example, the first inductor coil 124 may have at least one characteristic that is different from the second inductor coil 126. More specifically, in one example, the first inductor coil 124 may have a different inductance value than the second inductor coil 126. In Figure 7, the first inductor coil 124 and the second inductor coil 126 are of different lengths such that the first inductor coil 124 is wound over a smaller section of the susceptor 132 than the second inductor coil 126. Thus, the first inductor coil 124 may contain a different number of turns than the second inductor coil 126 (assuming that the spacing between individual turns is substantially the same). In yet another example, the first inductor coil 124 may be made from a different material than the second inductor coil 126. In some examples, the first inductor coil 124 and the second inductor coil 126 may be substantially identical.

[0202] In this example, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. This can be useful when the inductor coils are active at different times. For example, the first inductor coil 124 may initially operate to heat a first section / part of article 110, and later the second inductor coil 126 may operate to heat a second section / part of article 110. Winding the coils in opposite directions helps reduce the current induced in the inactive coil when used with certain types of control circuits. In Figure 6, the first inductor coil 124 is a right-handed helical and the second inductor coil 126 is a left-handed helical. However, in another embodiment, the inductor coils 124, 126 may be wound in the same direction, or the first inductor coil 124 may be a left-handed helical and the second inductor coil 126 may be a right-handed helical.

[0203] In this example, the susceptor 132 is hollow and therefore defines a receptacle within which an aerosol-generating material is received. For example, article 110 can be inserted into the susceptor 132. In this example, the susceptor 120 is tubular with a circular cross-section.

[0204] The susceptor 132 may be made from one or more materials. Preferably, the susceptor 132 includes carbon steel having a nickel or cobalt coating.

[0205] In some examples, the susceptor 132 may include at least two materials that can be heated at two different frequencies for the selective aerosolization of at least two materials. For example, a first portion of the susceptor 132 (heated by a first inductor coil 124) may include a first material, and a second portion of the susceptor 132 (heated by a second inductor coil 126) may include a second different material. In another example, the first section may include first and second materials, and the first and second materials may be heated differently based on the operation of the first inductor coil 124. The first and second materials may be adjacent along an axis defined by the susceptor 132, or they may form different layers within the susceptor 132. Similarly, the second section may include third and fourth materials, and the third and fourth materials may be heated differently based on the operation of the second inductor coil 126. The third and fourth materials may be adjacent along the axis defined by the susceptor 132, or they may form different layers within the susceptor 132. For example, the third material may be the same as the first material, and the fourth material may be the same as the second material. In the alternative, each of the materials may be different. The susceptor may include, for example, carbon steel or aluminum.

[0206] The device 100 in Figure 6 further comprises an insulating member 128, which may generally be tubular and may at least partially surround the susceptor 132. The insulating member 128 may be constructed from any insulating material, such as plastic. In this particular example, the insulating member is constructed from polyetheretherketone (PEEK). The insulating member 128 may help to insulate various components of the device 100 from the heat generated within the susceptor 132.

[0207] The insulating member 128 can also fully or partially support the first inductor coil 124 and the second inductor coil 126. For example, as shown in Figure 7, the first inductor coil 124 and the second inductor coil 126 are positioned around the insulating member 128 and are in contact with the radially outer surface of the insulating member 128. In some examples, the insulating member 128 does not abut the first inductor coil 124 and the second inductor coil 126. For example, there may be a small gap between the outer surface of the insulating member 128 and the inner surfaces of the first inductor coil 124 and the second inductor coil 126.

[0208] In a specific example, the susceptor 132, the insulating member 128, and the first inductor coil 124 and the second inductor coil 126 are coaxial with respect to the central longitudinal axis of the susceptor 132.

[0209] Figure 7 shows a side view of the device 100 in partial cross-section. In this example, an outer cover 102 is present. The rectangular cross-sectional shapes of the first inductor coil 124 and the second inductor coil 126 are more clearly visible.

[0210] The device 100 further comprises a support 136 that engages with one end of the susceptor 132 to hold the susceptor 132 in place. The support 136 is connected to the second end member 116.

[0211] The device may also include a second printed circuit board 138 associated within the control element 112.

[0212] Device 100 further comprises a second lid / cap 140 and a spring 142 positioned toward the distal end of device 100. The spring 142 allows the second lid 140 to be opened to provide access to the susceptor 132. The user can open the second lid 140 to clean the susceptor 132 and / or support 136.

[0213] The device 100 further comprises an expansion chamber 144 extending toward the opening 104 of the device away from the proximal end of the susceptor 132. At least partially within the expansion chamber 144 are a retaining clip 146 for contacting and holding the article 110 when the article 110 is received within the device 100. The expansion chamber 144 is connected to the end member 106.

[0214] Figure 8 is an exploded view of the device 100 from Figure 7, with the outer cover 102 omitted.

[0215] Figure 9A depicts a cross-section of a portion of the device 100 in Figure 8. Figure 9B depicts a magnified view of the region in Figure 9A. Figures 10A and 10B show an article 110 received within the susceptor 132, the article 110 being sized such that its outer surface abuts the inner surface of the susceptor 132. This ensures that heating is performed most efficiently. The article 110 in this example comprises an aerosol-generating material 110a, which is positioned within the susceptor 132. The article 110 may also comprise other components such as a filter, packaging material, and / or a cooling structure.

[0216] Figure 9B shows that the outer surface of the susceptor 132 is separated from the inner surfaces of the inductor coils 124 and 126 by a distance 150 measured perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 150 is approximately 3-4 mm, 3-3.5 mm, or 3.25 mm.

[0217] Figure 9B further shows that the outer surface of the insulating member 128 is separated from the inner surfaces of the inductor coils 124, 126 by a distance 152 measured perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 152 is approximately 0.05 mm. In another example, the distance 152 is substantially 0 mm, so that the inductor coils 124, 126 are in contact with the insulating member 128.

[0218] In one example, the susceptor 132 has a wall thickness 154 of approximately 0.025 mm to 1 mm, or approximately 0.05 mm.

[0219] For example, susceptor 132 has a length of approximately 40mm-60mm, approximately 40mm-45mm, or approximately 44.5mm.

[0220] In one example, the insulating member 128 has a wall thickness 156 of approximately 0.25 mm to 2 mm, 0.25 mm to 1 mm, or approximately 0.5 mm.

[0221] A method for manufacturing components for articles to be used in an aerosol supply system may include: preparing a feed of sheet material; applying a crimp pattern to a first portion of the sheet material, the crimp pattern comprising a series of substantially parallel ridges and grooves and scaled by a first crimp coefficient; applying a crimp pattern to a second portion of the sheet material, the crimp pattern being scaled by a second crimp coefficient, the first and second crimp coefficients being selected from heat, pressure, spacing or depth; and assembling the sheet material to form a material body comprising a first region having a first level of crimping and a second region longitudinally offset from the first region and comprising a second level of crimping different from the first level of crimping. An apparatus configured to manufacture components as described herein may comprise a crimp roller for applying a crimp pattern to a sheet material, the crimp pattern comprising a series of substantially parallel ridges and grooves, and a garnish assembly for gathering the sheet material to form a material body comprising a first region having a first level of crimping and a second region longitudinally offset from the first region and having a second level of crimping different from the first level of crimping.

Claims

1. A component for an aerosol supply system or for an article to be used as an aerosol supply system, comprising a body including a crimped sheet of a cellulosic material, wherein the crimped sheet includes a first region having a first level of crimping and a second region longitudinally offset from the first region and including a second level of crimping different from the first level of crimping, wherein the level of crimping is greater in the first region and the first region is located at the longitudinal end of the component, the crimped sheet is formed by applying a crimping coefficient to a sheet material, at least one object is embedded in the second region, the crimping coefficient applied to the sheet material forming the second region is lower than the crimping coefficient applied to the sheet material forming the first region, the crimping coefficient is the depth of the groove in the crimped sheet, the higher the crimping coefficient, the deeper the groove.

2. The component according to claim 1, wherein the first region and / or the second region has a length of 3 mm to 30 mm.

3. The component according to claim 1, wherein the level of crimping varies based on the depth and / or spacing of the crimping.

4. The component according to claim 1, wherein the level of crimping differs between the first and second regions as a result of applying different pressures and / or temperatures during the crimping process, providing crimping of different depths and / or spacing.

5. The component according to claim 1, wherein the at least one object is a tubular element and / or an aerosol modifier release component.

6. The component according to claim 5, wherein the object is a tubular element, and the tubular element extends to the longitudinal end of the component.

7. The component according to claim 1, wherein the second object is embedded in the first region or the second region.

8. The component according to claim 7, wherein the second object includes a tubular element or an aerosol modifier release component.

9. The component according to any one of claims 1 to 4, wherein the component forms a mouthpiece of a single article.

10. The component according to any one of claims 1 to 4, wherein the cellulose-based material is paper.

11. The component according to claim 7, wherein the object and the second object are separated by a gap of 0.5 mm to 30 mm, or 1 mm to 20 mm, or 1 mm to 15 mm.

12. The component according to claim 11, wherein the main body extends within the gap.

13. The component according to claim 5, wherein the object is spaced at least 5 mm, at least 8 mm, or at least 10 mm from the longitudinal end of the component.

14. The component according to any one of claims 1 to 4, wherein the main body is a tubular main body, the tubular main body made of a cellulose-based material includes assembled sheet material, and the assembled sheet material includes a notched portion.

15. An article for use in or as an aerosol supply system, comprising the components described in any one of claims 1 to 4.

16. A method for manufacturing components for articles to be used in an aerosol supply system, The steps include preparing the sheet material supply, A step of applying a crimp pattern to a first portion of the sheet material, wherein the crimp pattern includes a series of substantially parallel ridges and grooves and is scaled by a first crimp coefficient. A step of applying a crimp pattern to a second portion of the sheet material, wherein the crimp pattern is scaled by a second crimp coefficient, and the first crimp coefficient and the second crimp coefficient are selected from heat, pressure, spacing, or depth. A step of assembling the sheet material to form a material body comprising a first region having a first level of crimping and a second region offset longitudinally from the first region and including a second level of crimping different from the first level of crimping, wherein the first level of crimping is greater than the second level of crimping, and the first region is located at the longitudinal end of the component, The steps include embedding at least one object in the second region, Methods that include...

17. An apparatus configured to manufacture the components described in any one of claims 1 to 4, A crimping roller for applying a crimp pattern to a sheet material, wherein the crimp pattern includes a series of substantially parallel ridges and grooves, A garnish assembly for assembling the sheet material to form a material body comprising a first region having a first level of crimping and a second region longitudinally offset from the first region and including a second level of crimping different from the first level of crimping, wherein the first level of crimping is greater than the second level of crimping, and the first region is located at the longitudinal end of the component, A device equipped with the following features.

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