Articles for use in non-flammable aerosol delivery systems

Abstract

An article for use in an aerosol providing system or as part of an aerosol providing system is disclosed. The article comprises an aerosol generating material (3) and a heat transfer material (40) for distributing heat from a first zone of the aerosol generating material to a second zone of the aerosol generating material. The heat transfer material (40) has a thermal conductivity of at least 220 W / mK. The heat transfer material (40) may comprise one or more individual parts of a material in contact with the first zone and the second zone, such as a rod, wire, fiber, thread, or rib. The heat transfer material may contain or include carbon.

Description

Technology Field

[0001] The present disclosure relates to an article for use in a non-flammable aerosol delivery system. Background Technology

[0002] Certain delivery systems generate aerosols that are inhaled by the user during use. For example, tobacco heating devices form aerosols by heating an aerosol-generating substrate, such as tobacco, without burning the substrate. Such delivery systems typically include a heating device having a heating element that heats the aerosol-generating substrate to release aerosols upon heating.

[0003] According to some embodiments, an article for use in an aerosol providing system or as part of an aerosol providing system is provided, the article comprises an aerosol generating material and a heat transfer material for distributing heat from a first zone of the aerosol generating material to a second zone of the aerosol generating material, and the heat transfer material has a thermal conductivity of at least 220 W / mK.

[0004] In some embodiments, the thermal conductivity of the heat transfer material is less than about 5000, 4000, 3000, 2000, or 1000 W / mK. In some embodiments, the thermal conductivity of the heat transfer material is greater than about 300, 400, or 500 W / mK. In some embodiments, the thermal conductivity of the heat transfer material is in the range of about 220 to 5000 W / mK, 220 to 4000 W / mK, 220 to 3000 W / mK, 220 to 2000 W / mK, 220 to 1000 W / mK, 220 to 500 W / mK, 300 to 5000 W / mK, 300 to 4000 W / mK, 300 to 3000 W / mK, 300 to 2000 W / mK, 300 to 1000 W / mK, 300 to 500 W / mK, or 220 to 470 W / mK.

[0005] In some embodiments, the weight of the heat transfer material present in the article is in the range of about 1 to 25 mg, 1 to 20 mg, 1 to 15 mg, 1 to 10, or 1 to 5 mg. In some embodiments, the ratio of the heat transfer material to the aerosol-generating material is in the range of about 1:10 to 1:100 by weight.

[0006] In some embodiments, the heat transfer material comprises at least one individual portion of the material in thermal contact with the first and second portions of the aerosol-generating material. The heat transfer material may comprise a single portion of the material. The heat transfer material may be in the form of a rod, wire, fiber, thread, or ribbon extending through at least a portion of the aerosol-generating material.

[0007] In some embodiments, the heat transfer material extends along the length of the aerosol generating material. If the aerosol generating material is generally cylindrical, the heat transfer material may extend along part or all of the length of the material. The heat transfer may be elongated and may extend parallel to or along the axis of the aerosol generating material. As mentioned below, the heat transfer material may be fed into or extruded into the aerosol generating material during the manufacture of the article.

[0008] In some embodiments, the heat transfer material extends along a length shorter than the length of the aerosol-generating material. The heat transfer material may extend along at least 10% of the length of the aerosol-generating material. The heat transfer material may extend along up to about 90% of the length of the aerosol-generating material. In some embodiments, the length of the heating element is in the range of 10 to 90%, 10 to 80%, 10 to 70%, 10 to 60%, or 10 to 50% of the length of the aerosol-generating material.

[0009] The heat transfer material may be separate and distinct from the aerosol generating material. The heat transfer material may comprise a single portion of the material, or may comprise multiple discrete portions of the material that are in thermal contact with individual first and second zones of the aerosol generating material. For example, the heat transfer material may be formed from three or more discrete portions of the material within the aerosol generating material, for example, 3 to 20, 3 to 10, or 3 to 5 discrete portions of the material.

[0010] In some embodiments, the heat transfer material may be formed from multiple parts of the material. In some embodiments, the heat transfer material may be more generally distributed through an aerosol-generating material, in contrast to being formed from one or more distinct parts of the material. In some embodiments, the heat transfer material may be considered to be mixed with the aerosol-generating material. In some embodiments, the heat transfer material is in the form of particles or powder.

[0011] In some embodiments, the heat transfer material is a nonmetal.

[0012] In some embodiments, the heat transfer material has or contains carbon. The heat transfer material may be formed from or contain one of graphene, diamond, graphite, pyrolytic graphite, carbon fiber, graphene fiber, or graphite fiber. The thermal conductivity values ​​for some of these materials are as follows: graphene 4000 W / mK; diamond 2200 W / mK; pyrolytic graphite 1700 W / mK. The heat transfer material may be provided with a backing material such as paper.

[0013] In some embodiments, the aerosol generating material comprises reconstituted tobacco. As mentioned above, a heat transfer material that may comprise carbon or graphite may be mixed with the reconstituted tobacco. The reconstituted tobacco typically comprises wood pulp, but the heat transfer material of the present disclosure may replace some or all of the wood pulp.

[0014] In some embodiments, the article is heated by an external heating element outside the aerosol-generating material. In other embodiments, the article is heated by an internal heating element inserted into the aerosol-generating material at use.

[0015] The heating element inserted into the aerosol-generating material may be an electric heating element or a susceptor heated by induction heating or magnetic hysteresis heating. The heating element may be part of the article. The heating element may be inserted into the article during manufacturing. Alternatively, the heating element may be part of the aerosol delivery device in which the article is used, and the insertion of the heating element into the aerosol-generating material occurs when the article is inserted into the aerosol delivery device.

[0016] Such heating elements can be formed of metal.

[0017] In some embodiments, the heat transfer material has apertures, pores, or cavities. The article may further comprise an amorphous solid, an active material, or a flavor. The amorphous solid, active material, or flavor may be located in one or more apertures, pores, or cavities of the heat transfer material.

[0018] According to some embodiments, an aerosol providing system comprising a non-flammable aerosol providing device, a heating element, and the aforementioned article is provided.

[0019] In some embodiments, the aerosol delivery device includes a power source for supplying power to a heating element, and the heating element heats the aerosol-generating material by electrical conduction. This type of heating element may be part of the aerosol delivery device.

[0020] In some embodiments, the aerosol delivery device includes a magnetic field generator, and the heating element is a susceptor that heats the aerosol-generating material by induction heating and / or magnetic hysteresis heating.

[0021] In some embodiments, the aerosol providing device includes an exothermic power source, and the heating element of the article is a second heat transfer material for transferring heat to an aerosol generating material.

[0022] The susceptor or the second heat transfer material may be part of the article or part of the aerosol delivery device.

[0023] According to some embodiments, a method for manufacturing an article for use in an aerosol providing system or as part of an aerosol providing system is provided, the article comprises an aerosol generating material, the method comprises the step of adding a heat transfer material for distributing heat from a first zone of the aerosol generating material to a second zone of the aerosol generating material, and the heat transfer material has a thermal conductivity of at least 220 W / mK.

[0024] The step of adding a heat transfer material may include the step of supplying or extruding the heat transfer material into the aerosol generating material. Alternatively, the step of adding a heat transfer material may include the step of mixing the heat transfer material with the aerosol generating material.

[0025] In some embodiments, a rod, wire, fiber, thread, or ribbon of the heat transfer material may be supplied into the aerosol generating material during manufacturing. When the aerosol generating material is formed from a plurality of cut tobacco strips, the heat transfer material may be supplied to the plurality of strips during the manufacturing of the article. As discussed above, the heat transfer material may contain carbon and may be graphite, such as graphite fiber. Brief explanation of the drawing

[0026] Now, embodiments will be described merely as examples with reference to the accompanying drawings: FIG. 1 is a side cross-sectional view of an article for use with a non-flammable aerosol providing device, wherein the article includes a mouthpiece. FIGS. 1a to 1d illustrate examples of aerosol-generating materials comprising a heat transfer material. FIG. 2a is a side cross-sectional view of an additional article for use with a non-flammable aerosol providing device, wherein the article includes a capsule-containing mouthpiece. FIG. 2b is a cross-sectional view of the capsule-holding mouthpiece shown in FIG. 2a. Figure 3 is a cross-sectional view of a non-flammable aerosol providing device. FIG. 4 is a simplified schematic diagram of the components within the housing of the aerosol delivery device shown in FIG. 3. FIG. 5 is a cross-sectional view of FIG. 3 of a non-flammable aerosol providing device with the article shown in FIG. 1 inserted into the device, and the article has an example of an aerosol generating material including a heat transfer material. Specific details for implementing the invention

[0027] As used herein, the term "delivery system" is intended to include systems for delivering at least one substance to a user, and includes the following:

[0028] Combustible aerosol delivery systems, for example, for cigarettes, cigarillos, cigars, and pipes, and for roll-your-own or make-your-own cigarettes (whether based on tobacco, tobacco derivatives, puffed tobacco, reconstituted tobacco, tobacco substitutes, or other smokeable materials);

[0029] Non-combustible aerosol provision systems that release compounds from an aerosol-generating material without burning the aerosol-generating material, such as hybrid systems that generate aerosols using a combination of electronic cigarettes, tobacco heating products, and aerosol-generating materials; and

[0030] Aerosol-free delivery systems that deliver at least one substance to a user orally, nasally, transdermally, or otherwise without forming an aerosol, comprising (but not limited to) (lozenges, gums, patches, and inhalable powders and oral tobacco such as snus or wet snuff) — at least one substance may or may not contain nicotine —.

[0031] According to the present disclosure, a "non-combustible" aerosol delivery system is a system that does not combust or burn the aerosol generating material of the aerosol delivery system (or its components) in order to facilitate the delivery of at least one material to a user.

[0032] In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as an electric non-combustible aerosol delivery system.

[0033] In some embodiments, the non-flammable aerosol delivery system may be 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 prerequisite.

[0034] In some embodiments, the non-combustible aerosol providing system is an aerosol-generating material heating system also known as a heat-not-burn system. An example of such a system is a cigarette heating system.

[0035] In some embodiments, the non-flammable aerosol delivery system is a hybrid system that generates an aerosol 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 comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or non-tobacco products.

[0036] Typically, a non-flammable aerosol delivery system may include a non-flammable aerosol delivery device and consumables for use with the non-flammable aerosol delivery device.

[0037] In some embodiments, the present disclosure relates to consumables comprising an aerosol-generating material and configured to be used with non-flammable aerosol-providing devices. These consumables are sometimes referred to as articles throughout the present disclosure.

[0038] The terms 'upstream' and 'downstream' as used herein are relative terms defined in relation to the direction of mainstream aerosol inhaled through an article or device during use.

[0039] In some embodiments, a non-flammable aerosol providing system, such as its non-flammable aerosol providing device, may include a power source and a controller. The power source may be, for example, an electric power source or a heating power source. In some embodiments, the heating power source comprises a carbon substrate capable of supplying energy to distribute power in the form of heat to an aerosol generating material or a heat transfer material adjacent to the heating power source.

[0040] In some embodiments, the non-flammable aerosol delivery system comprises an area for receiving consumables, an aerosol generator, an aerosol generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0041] In some embodiments, consumables for use with a non-flammable aerosol delivery device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material delivery component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0042] In some embodiments, the consumable comprises a material to be delivered. The material to be delivered may be an aerosol-generating material or a material not intended to be aerosolized. Where appropriate, the two materials may comprise one or more active components, one or more flavors, one or more aerosol-forming materials, and / or one or more other functional materials.

[0043] In some embodiments, the material to be delivered includes an active material.

[0044] The active substance used herein may be a physiologically active material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, nutraceuticals, nootropics, and psychoactives. The active substance may occur naturally or be obtained by synthesis. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or their constituents, derivatives, or combinations. The active substance may include one or more constituents, derivatives, or extracts of tobacco, cannabis, or other botanicals.

[0045] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin, or vitamin B12.

[0046] As noted herein, the active substance may comprise or be derived from one or more plant medicinal substances or their constituents, derivatives, or extracts. As used herein, the term “plant medicinal substance” includes any material derived from plants, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, this material may comprise an active compound naturally present in the plant medicinal substance obtained by synthesis. This material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, etc. Examples of herbal medicines include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice, matcha, mate, orange peel, papaya, rose, sage, tea (e.g., green or black tea), thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, and nutmeg. Oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood,Cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint may be selected from the following mint varieties: Mentha Arvensis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0047] In some embodiments, the active substance comprises or is derived from one or more plant medicinal substances or their constituents, derivatives, or extracts, and the plant medicinal substance is tobacco.

[0048] In some embodiments, the active substance comprises or is derived from one or more herbal medicines or their constituents, derivatives, or extracts, and the herbal medicine is selected from eucalyptus, star anise, cocoa, and hemp.

[0049] In some embodiments, the active substance comprises or is derived from one or more herbal medicines or their constituents, derivatives, or extracts, and the herbal medicine is selected from rooibos and fennel.

[0050] In some embodiments, the substance to be delivered includes flavor.

[0051] As used herein, the terms “flavor” and “flavorant” refer to materials that, where permitted by local regulations, may be used to produce a desired taste, aroma, or other somatosensorial sensation in products for adult consumers. These are naturally produced flavoring ingredients, plants, plant extracts, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, Japanese white bark magnolia leaves, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise seeds, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruits, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, Scotch, whisky, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera vera), cardamom, celery, cascarilla, nutmeg, sandalwood oil, bergamot, geranium, khat, naswar, betel nut, hookah, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cinnamon tree, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass,Rooibos, flax, ginkgo, hazelnut, hibiscus, bay leaf, mate, orange skin, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, turmeric, coriander, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, They may include thymol, camphene), flavor enhancers, bitter taste receptor blockers, sensory receptor activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives, such as charcoal, chlorophyll, minerals, herbal medicines, or breath fresheners. These may be imitations, synthetic, or natural components or blends thereof. These may be in any suitable form, e.g., liquids such as oils, solids such as powders, or gases.

[0052] In some embodiments, the flavor comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavor comprises flavor components of cucumber, blueberry, citrus, and / or red berry. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.

[0053] In some embodiments, the flavor may comprise a sensation intended to achieve a somatosensory sensation that is generally chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the flavor or taste nerves, and may comprise agents that provide a fever, cold, tingling, or numbing effect. A suitable fever agent may be vanillyl ethyl ether, but is not limited thereto, and a suitable cold agent may be eucalyptol or WS-3, but is not limited thereto.

[0054] An aerosol generating material is a material capable of generating an aerosol when energized, irradiated, or heated in any other way, for example. The aerosol generating material may be in the form of a solid, liquid, or gel that may or may not contain active substances and / or flavoring agents. The aerosol generating material may be incorporated into an article for use in an aerosol generating system.

[0055] As used herein, the term “tobacco material” refers to any material comprising tobacco or its derivatives or substitutes. The tobacco material may be any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, puffed tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of crushed tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco, and / or tobacco extract.

[0056] A consumable is an article comprising or constituting an aerosol-generating material, in whole or in part intended to be consumed during use by a user. The consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. The consumable may also include an aerosol generator, such as a heater, which releases heat to cause the aerosol-generating material to generate an aerosol upon use. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0057] A susceptor is a material that can be heated by penetration of a changing magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material, and accordingly, its penetration by a changing magnetic field causes induction heating of the heating material. The heating material may be a magnetic material, and accordingly, its penetration by a changing magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may possess both electrical conductivity and magnetism, and accordingly, the susceptor may be heated by both heating mechanisms. A device configured to generate a changing magnetic field is referred to herein as a magnetic field generator.

[0058] An aerosol modifier is a substance typically located downstream of the aerosol generation region configured to modify the generated aerosol, for example, by altering the taste, flavor, acidity, or other properties of the aerosol. The aerosol modifier may be provided to an aerosol modifier release component operable to selectively release the aerosol modifier.

[0059] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of flavoring agents, coloring agents, 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 may not contain a filter material.

[0060] An aerosol generator is a device configured to generate an aerosol from an aerosol generating material. In some embodiments, the aerosol generator is a heater configured to apply thermal energy to the aerosol generating material 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 generate an aerosol from the aerosol generating material without heating. For example, the aerosol generator may be configured to apply one or more of vibration, increased pressure, or electrostatic energy to the aerosol generating material.

[0061] The filament tow materials described herein may include cellulose acetate fiber tow. Additionally, filament tow may 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. If the material is cellulose acetate tow, the filament tow may be plasticized with a plasticizer suitable for tow, such as triacetin, or the tow may not be plasticized. The tow may have any suitable specifications, such as fibers having different cross-sections like a 'Y' shape or an 'X' shape, filamentary denier values ​​of 2.5 to 15 denier per filament, for example 8.0 to 11.0 denier per filament, and total denier values ​​of 5,000 to 50,000, for example 10,000 to 40,000.

[0062] In the drawings described herein, the same reference numbers are used to illustrate equivalent features, articles, or components.

[0063] FIG. 1 is a side cross-sectional view of an article (1) for use in an aerosol delivery system.

[0064] The article (1) comprises a mouthpiece (2) and an aerosol generating section connected to the mouthpiece (2). In this example, the aerosol generating section comprises a source of aerosol generating material in the form of a cylindrical rod of aerosol generating material (3). In other examples, the aerosol generating section may comprise a cavity for receiving a source of aerosol generating material. The aerosol generating material may comprise a plurality of strands or strips of aerosol generating material. For example, the aerosol generating material may comprise a plurality of strands or strips of aerosol-capable material and / or a plurality of strands or strips of amorphous solid as described below. In some embodiments, the aerosol generating material is composed of a plurality of strands or strips of aerosol-capable material.

[0065] In this example, the cylindrical rod of the aerosol generating material (3) comprises a plurality of strands and / or strips of the aerosol generating material and is surrounded by a wrapper (10). In this example, the wrapper (10) is a moisture-impermeable wrapper.

[0066] Multiple strands or strips of aerosol-generating material may be aligned within an aerosol-generating section such that their longitudinal dimensions are aligned parallel to the longitudinal axis (X-X') of the article (1). Alternatively, the strands or strips may be arranged such that the generally aligned longitudinal dimensions run across the longitudinal axis of the article.

[0067] At least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 95% of the plurality of strands or strips may be arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. Most of the strands or strips may be arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. In some embodiments, about 95% to about 100% of the plurality of strands or strips are arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. In some embodiments, substantially all of the strands or strips are arranged in the aerosol generating section such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the aerosol generating section of the article.

[0068] When most strands or strips are arranged in an aerosol generating section such that their longitudinal axis is parallel to the longitudinal axis of the aerosol generating section of the article, the force required to insert an aerosol generator into the aerosol generating material may be relatively low. This may result in an article that is easier to use.

[0069] In this example, the rod of the aerosol generating material (3) has a circumference of about 22.7 mm. In alternative embodiments, the rod of the aerosol generating material (3) may have any suitable circumference, for example, from about 20 mm to about 26 mm.

[0070] Referring to FIGS. 1a through 1d, examples of an aerosol generating material (3) including a heat transfer material are illustrated. In FIGS. 1a through 1c, the aerosol generating material (3) is schematically illustrated as being formed of a plurality of strands (31) arranged to be generally parallel to the longitudinal axis of the article (1).

[0071] The embodiment of FIG. 1a has a single fiber (40) of a heat transfer material positioned centrally within an aerosol generating material (3) that generally follows the axis of the article (1). The heat transfer material is formed from graphite fibers supplied into the aerosol generating material (3) during manufacturing.

[0072] FIG. 1b illustrates an embodiment having fibers (40) of a plurality of heat transfer materials distributed within an aerosol generating material (3).

[0073] FIG. 1c illustrates an embodiment having fibers (40) of two heat transfer materials within an aerosol generating material (3), and the central region of the aerosol generating material (3) is in a state without heat transfer material.

[0074] FIG. 1d illustrates an embodiment having a plurality of distinct portions (41) of a heat transfer material distributed throughout the entire aerosol generating material (3).

[0075] Article (1) is configured for use in a non-combustible aerosol providing device comprising an aerosol generator for insertion into an aerosol generating section. In this example, the aerosol generator is a heater, and the article is configured to accommodate the aerosol generator in a rod of aerosol generating material.

[0076] The mouthpiece (2) includes a cooling section (8), also referred to as a cooling element, positioned immediately downstream of and adjacent to the source of the aerosol-generating material (3). In this example, the cooling section (8) is in contact with the source of the aerosol-generating material. The mouthpiece (2) also includes, in this example, a body (6) of the material downstream of the cooling section (8), and a hollow tubular element (4) downstream of the body (6) of the material at the mouth end of the article (1).

[0077] The tubular section (8) comprises a hollow channel having an inner diameter of about 1 mm to about 4 mm, for example, about 2 mm to about 4 mm. In this example, the hollow channel has an inner diameter of about 3 mm. The hollow channel extends along the entire length of the cooling section (8). In this example, the cooling section (8) comprises a single hollow channel. In alternative embodiments, the cooling section may comprise multiple channels, for example, two, three, or four channels. In this example, the single hollow channel is substantially cylindrical, but in alternative embodiments, other channel geometries / cross-sections may be used. The hollow channel may provide a space in which aerosols aspirated into the cooling section (8) can expand and cool. In all embodiments, the cooling section is configured to limit the cross-sectional area of ​​the hollow channel(s) to limit tobacco displacement into the cooling section when in use.

[0078] The impermeable wrapper (10) may have lower friction with respect to the aerosol generating material, which may result in the strands and / or strips of the aerosol generating material being more easily displaced longitudinally into the cooling section when the aerosol generator is inserted into the rod of the aerosol generating material. Providing a tubular section (8) containing an internal channel having a diameter in this range that is directly adjacent to the source of the aerosol generating material advantageously reduces the longitudinal displacement of the strands and / or strips of the aerosol generating material when the aerosol generator is inserted into the rod of the aerosol generating material. When used, reducing the displacement of the aerosol generating material can advantageously result in a more consistent packing density of the aerosol generating material along the length of the rod and / or within the cavity, which can result in more consistent and improved aerosol generation.

[0079] The cooling section (8) preferably has a radial wall thickness that can be measured, for example, using a caliper. The wall thickness of the cooling section (8) defines the inner diameter of the cavity enclosed by the walls of the cooling section (8) for a given outer diameter of the cooling section. The cooling section (8) may have a wall thickness of at least about 1.5 mm to a maximum of about 2 mm. In this example, the cooling section (8) has a wall thickness of about 2 mm. Providing a cooling section (8) having a wall thickness within this range improves the retention of the source of the aerosol generating material in the aerosol generating section during use by reducing the longitudinal displacement of strands and / or strips of the aerosol generating material when the aerosol generator is inserted into the article.

[0080] The cooling section (8) is formed from a filamentary tow. Other configurations may be used, such as multiple layers of paper wound parallel to butted seams to form the cooling section (8); or layers of paper wound spirally, cardboard tubes, tubes formed using a papier-mâché type process, molded or extruded plastic tubes, or similar materials. The cooling section (8) is manufactured to have sufficient rigidity to withstand axial compressive forces and bending moments that may occur during manufacturing and while the article (1) is in use.

[0081] The wall material of the cooling section (8) may be relatively non-porous, and accordingly, at least 90% of the aerosol generated by the aerosol generating material (3) passes longitudinally through one or more hollow channels rather than through the wall material of the tubular section (8). For example, at least 92% or at least 95% of the aerosol generated by the aerosol generating material (3) may pass longitudinally through one or more hollow channels.

[0082] The filament tow forming the cooling section (8) preferably has a total denier of less than 45,000, more preferably less than 42,000. This total denier has been found to allow for the formation of a cooling element (8) that is not too dense. Preferably, the total denier is at least 20,000, more preferably at least 25,000. In preferred embodiments, the filament tow forming the cooling section (8) has a total denier of 25,000 to 45,000, more preferably 35,000 to 45,000. Preferably, the cross-sectional shape of the filaments of the tow is a 'Y' shape, but in other embodiments, other shapes such as 'X' shaped filaments may be used.

[0083] The filament tow forming the cooling section (8) preferably has a denier per filament greater than 3. This denier per filament has been found to allow for the formation of tubular elements (4) that are not too dense. Preferably, the denier per filament is at least 4, more preferably at least 5. In a preferred embodiment, the filament tow forming the hollow tubular elements (4) has a denier per filament of 4 to 10, more preferably 4 to 9. In one example, the filament tow forming the cooling section (8) has an 8Y40,000 tow formed of cellulose acetate and containing 18% plasticizer, e.g., triacetin.

[0084] Preferably, the density of the material forming the cooling section (8) is at least about 0.20 grams / cubic centimeter (g / cc), more preferably at least about 0.25 g / cc. Preferably, the density of the material forming the cooling section (8) is less than about 0.80 grams / cubic centimeter (g / cc), more preferably less than 0.6 g / cc. In some embodiments, the density of the material forming the cooling section (8) is 0.20 to 0.8 g / cc, more preferably 0.3 to 0.6 g / cc, or 0.4 g / cc to 0.6 g / cc or about 0.5 g / cc. These densities have been found to provide a good balance between the improved rigidity provided by denser materials and the reduction of the overall weight of the article. For the purposes of this disclosure, the “density” of the material forming the cooling section (8) refers to the density of any filament tow forming the element into which any plasticizer is incorporated. The density can be determined by dividing the total weight of the material forming the cooling section (8) by the total volume of the material forming the cooling body (8), and the total volume can be calculated using appropriate measurements of the material forming the cooling section (8) taken, for example, using calipers. If necessary, appropriate dimensions can be measured using a microscope.

[0085] Preferably, the length of the cooling section (8) is less than about 30 mm. More preferably, the length of the cooling section (8) is less than about 25 mm. Even more preferably, the length of the cooling section (8) is less than about 20 mm. Additionally, or alternatively, the length of the cooling section (8) is preferably at least about 10 mm. Preferably, the length of the cooling section (8) is at least about 15 mm. In some preferred embodiments, the length of the cooling section (8) is about 15 mm to about 20 mm, more preferably about 16 mm to about 19 mm. In this example, the length of the cooling section (8) is 19 mm.

[0086] The cooling section (8) is positioned around the air gap within the mouthpiece (2) that acts as a cooling segment and defines it. The air gap provides a chamber through which heated volatile components generated by the load of the aerosol-generating material (3) flow. The cooling section (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 while the article (1) is used. The cooling section (8) provides a physical displacement between the aerosol-generating material (3) and the material body (6). The physical displacement provided by the cooling section (8) will provide a thermal gradient along the length of the cooling section (8).

[0087] Preferably, the mouthpiece (2) comprises a cavity having an internal volume greater than 110 mm³. It has been found that providing a cavity of at least this volume enables the formation of an improved aerosol. More preferably, the mouthpiece (2) comprises a cavity formed, for example, within a cooling section (8), and the cavity has an internal volume greater than 110 mm³, more preferably greater than 130 mm³, allowing for further improvement of the aerosol. In some examples, the internal cavity comprises a volume of about 130 mm³ to about 230 mm³, for example, about 134 mm³ or 227 mm³.

[0088] The cooling section (8) may be configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile component entering the first upstream end of the cooling section (8) and the heated volatile component exiting the second downstream end of the cooling section (8). The cooling section (8) is preferably configured to provide a temperature difference of at least 60 degrees Celsius, preferably at least 80 degrees Celsius, more preferably at least 100 degrees Celsius between the heated volatile component entering the first upstream end of the cooling section (8) and the heated volatile component exiting the second downstream end of the cooling section (8). This temperature difference over the length of the cooling section (8) protects the temperature-sensitive material body (6) from the high temperatures of the aerosol-generating material (3) when heated.

[0089] When in use, the aerosol generating section may exhibit a pressure drop of about 15 to about 40 mm H2O. In some embodiments, the aerosol generating section exhibits a pressure drop of about 15 to about 30 mm H2O across the aerosol generating section.

[0090] The aerosol generating material may have a packing density of about 400 mg / cm³ to about 900 mg / cm³ within the aerosol generating section. A packing density higher than this may increase pressure drop by making it difficult to insert the aerosol generator of the aerosol providing device into the aerosol generating material. A packing density of less than 400 mg / cm³ may reduce the rigidity of the article. Furthermore, if the packing density is too low, the aerosol generating material may not be able to effectively grip the aerosol generator of the aerosol providing device.

[0091] At least about 70% of the volume of the aerosol generating section is filled with an aerosol generating material. In some embodiments, about 75% to about 85% of the volume of the cavity is filled with an aerosol generating material.

[0092] In this embodiment, the impermeable wrapper (10) surrounding the load of the aerosol-generating material comprises aluminum foil. In other embodiments, the wrapper (10) comprises a paper wrapper optionally comprising a barrier coating to make the material of the wrapper substantially impermeable. Aluminum foil has been found to be particularly effective in enhancing the formation of aerosols within the aerosol-generating material (3). In this example, the aluminum foil has a metal layer having a thickness of about 6 μm. In this example, the aluminum foil has a paper backing. However, in alternative arrangements, the aluminum foil may have other thicknesses, e.g., a thickness of 4 μm to 16 μm. The aluminum foil also does not need to have a paper backing, but may have a backing formed of other materials to help provide adequate tensile strength to the foil, for example, or it may not have a backing material. Other metal layers or foils other than aluminum may also be used. The total thickness of the wrapper is preferably 20 µm to 60 µm, more preferably 30 µm to 50 µm, which can provide a wrapper having appropriate structural integrity and heat transfer characteristics. The tensile force that can be applied to the wrapper before it breaks may exceed 3,000 gram-force, for example, 3,000 to 10,000 gram-force or 3,000 to 4,500 gram-force. If the wrapper comprises paper or a paper backing, i.e., a cellulose-based material, the wrapper may have a basis weight greater than about 30 gsm. For example, the wrapper may have a basis weight in the range of about 40 gsm to about 70 gsm. These basis weights provide improved stiffness to the load of the aerosol-generating material.The improved stiffness provided by wrappers having this range of basis weights can make the aerosol generating material rod (3) more resistant to creasing or other deformation under the forces the article receives during use, for example, when a device and / or heat generator is inserted into the article. Providing an aerosol generating material rod with increased stiffness may be advantageous if multiple strands or strips of the aerosol generating material are aligned within the aerosol generating section so that their longitudinal dimensions are aligned parallel to the longitudinal axis, because the longitudinally aligned strands or strips of the aerosol generating material can provide less stiffness to the aerosol generating material rod than if the strands or strips are not aligned. The improved stiffness of the aerosol generating material rod enables the article to withstand the increased forces it receives during use.

[0093] In this example, the impermeable wrapper (10) is also substantially impermeable to air. In alternative embodiments, the wrapper (10) preferably has a permeability of less than 100 Cholesta units, more preferably less than 60 Cholesta units. For example, low-permeability wrappers having a permeability of less than 100 Cholesta units, more preferably less than 60 Cholesta units, have been found to result in improved aerosol formation in the aerosol-generating material (3). Without being bound by theory, this is assumed to be due to reduced loss of aerosol compounds through the wrapper (10). The permeability of the wrapper (10) can be measured according to ISO 2965:2009 regarding the determination of air permeability for materials used as cigarette papers, filter plug wraps, and filter binding papers.

[0094] The material body (6) and the hollow tubular element (4) each define an overall external shape that is substantially cylindrical and share a common longitudinal axis. The material body (6) is wrapped in a first plug wrap (7). Preferably, the first plug wrap (7) has a basis weight of less than 50 gsm, more preferably about 20 gsm to 40 gsm. Preferably, the first plug wrap (7) has a thickness of 30 µm to 60 µm, more preferably 35 µm to 45 µm. Preferably, the first plug wrap (7) is a non-porous plug wrap having a permeability of, for example, less than 100 coresta units, for example, less than 50 coresta units. However, in other embodiments, the first plug wrap (7) may be a porous plug wrap having a permeability of, for example, more than 200 coresta units.

[0095] Preferably, the length of the material body (6) is less than about 15 mm. More preferably, the length of the material body (6) is less than about 12 mm. Additionally, or alternatively, the length of the material body (6) is at least about 5 mm. Preferably, the length of the material body (6) is at least about 8 mm. In some preferred embodiments, the length of the material body (6) is about 5 mm to about 15 mm, more preferably about 6 mm to about 12 mm, much more preferably about 6 mm to about 12 mm, most preferably about 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In this example, the length of the material body (6) is 10 mm.

[0096] In the present example, the material body (6) is formed from filament tow. In the present example, the tow used for the material body (6) has a denier (dpf) per filament of 5 and a total denier of 25,000. In the present example, the tow comprises plasticized cellulose acetate tow. The plasticizer used in the tow comprises about 9 weight percent of the tow. In the present example, the plasticizer is triacetin. In other examples, other materials may be used to form the material body (6). For example, instead of tow, the body (6) may be formed from paper in a manner similar to paper filters known to be used in cigarettes, for example. For example, paper or other cellulose-based materials may be provided as one or more portions of a sheet material that is folded and / or crimped to form the body (6). The sheet material may have a basis weight of 15 gsm to 60 gsm, for example, 20 to 50 gsm. The sheet material may have a basis weight in any range of, for example, 15 to 25 gsm, 25 to 30 gsm, 30 to 40 gsm, 40 to 45 gsm, and 45 to 50 gsm. Additionally or alternatively, the sheet material may have a width of 50 mm to 200 mm, for example, 60 mm to 150 mm, or 80 mm to 150 mm. For example, the sheet material may have a basis weight of 20 to 50 gsm and a width of 80 mm to 150 mm. This may, for example, allow the cellulose-based bodies to have an appropriate pressure drop for articles having dimensions as described herein.

[0097] Alternatively, the body (6) may be formed from tows other than cellulose acetate, e.g., polylactic acid (PLA), other materials described herein for filament tow, or similar materials. The tow is preferably formed from cellulose acetate. Whether formed from cellulose acetate or other materials, the tow preferably has at least 5 dpf. Preferably, to achieve a sufficiently uniform material body (6), the tow has a denier per filament of 12 dpf or less, preferably 11 dpf or less, more preferably 10 dpf or less.

[0098] The total denier of the tow forming the material body (6) is preferably up to 30,000, more preferably up to 28,000, and even more preferably up to 25,000. These total denier values ​​provide a tow that occupies a reduced proportion of the cross-sectional area of ​​the mouthpiece (2), which results in a lower pressure drop across the mouthpiece (2) than tows having higher total denier values. For proper rigidity of the material body (6), the tow preferably has a total denier of at least 8,000, and more preferably at least 10,000. Preferably, the denier per filament is 5 to 12, and the total denier is 10,000 to 25,000. Preferably, the cross-sectional shape of the tow filament is 'Y'-shaped, although other shapes such as 'X'-shaped filaments may be used in other embodiments, and has the same dpf and total denier values ​​as provided herein.

[0099] Regardless of the material used to form the body (6), the pressure drop across the body (6) may be, for example, 0.3 to 5 mmWG per mm of length of the body (6), or, for example, 0.5 mmWG to 2 mmWG per mm of length of the body (6). The pressure drop may be, for example, 0.5 to 1 mmW g / mm, 1 to 1.5 mmW g / mm, or 1.5 to 2 mmW g / mm. The total pressure drop across the body (6) may be, for example, 3 mmWG to 8 mmWG, or 4 mmWG to 7 mmWG. The total pressure drop across the body (6) may be about 5, 6, or 7 mmWG.

[0100] As illustrated in FIG. 1, the mouthpiece (2) of the article (1) comprises an upstream end (2a) adjacent to the rod of the aerosol generating material (3) and a downstream end (2b) distal from the rod of the aerosol generating material (3). At the downstream end (2b), the mouthpiece (2) has a hollow tubular element (4) formed of a filament tow. This has been found to advantageously significantly reduce the temperature of the outer surface of the mouthpiece (2) at the downstream end (2b) of the mouthpiece, which comes into contact with the consumer's mouth when the article (1) is in use. Additionally, the use of the tubular element (4) has also been found to significantly reduce the temperature of the outer surface of the mouthpiece (2) upstream of the tubular element (4). It is not desired to be bound by theory, and it is assumed that this is because the tubular element (4) channeles the aerosol closer to the center of the mouthpiece (2), and thus reduces the transfer of heat from the aerosol to the outer surface of the mouthpiece (2).

[0101] The "wall thickness" of the hollow tubular element (4) corresponds to the thickness of the wall of the tube (4) in the radial direction. This can be measured, for example, using a caliper. The wall thickness is advantageously greater than 0.9 mm and more preferably greater than 1.0 mm. Preferably, the wall thickness is substantially constant around the entire wall of the hollow tubular element (4). However, if the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9 mm at any point around the hollow tubular element (4) and more preferably greater than 1.0 mm. In this example, the wall thickness of the hollow tubular element (4) is about 1.3 mm.

[0102] Preferably, the length of the hollow tubular element (4) is less than about 20 mm. More preferably, the length of the hollow tubular element (4) is less than about 15 mm. Even more preferably, the length of the hollow tubular element (4) is less than about 10 mm. Additionally, or alternatively, the length of the hollow tubular element (4) is at least about 5 mm. Preferably, the length of the hollow tubular element (4) is at least about 6 mm. In some preferred embodiments, the length of the hollow tubular element (4) is about 5 mm to about 20 mm, more preferably about 6 mm to about 10 mm, much 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 hollow tubular element (4) is 7 mm.

[0103] Preferably, the density of the hollow tubular element (4) is at least about 0.25 grams / cubic centimeter (g / cc), more preferably at least about 0.3 g / cc. Preferably, the density of the hollow tubular element (4) is less than about 0.75 grams / cubic centimeter (g / cc), more preferably less than 0.6 g / cc. In some embodiments, the density of the hollow tubular element (4) is 0.25 to 0.75 g / cc, more preferably 0.3 to 0.6 g / cc, more preferably 0.4 g / cc to 0.6 g / cc or about 0.5 g / cc. These densities have been found to provide a good balance between the improved rigidity provided by denser materials and the lower heat transfer characteristics of low-density materials. For the purposes of this disclosure, the “density” of the hollow tubular element (4) refers to the density of the filament tow forming the element into which any plasticizer is incorporated. Density can be determined by dividing the total weight of the hollow tubular element (4) by the total volume of the hollow tubular element (4), where the total volume can be calculated using appropriate measurements of the hollow tubular element (4) taken, for example, using calipers. If necessary, appropriate dimensions can be measured using a microscope.

[0104] The filament tow forming the hollow tubular element (4) preferably has a total denier of less than 45,000, more preferably less than 42,000. This total denier has been found to allow for the formation of a tubular element (4) that is not too dense. Preferably, the total denier is at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filament tow forming the hollow tubular element (4) has a total denier of 25,000 to 45,000, more preferably 35,000 to 45,000. Preferably, the cross-sectional shape of the filaments of the tow is a 'Y' shape, but in other embodiments, other shapes such as 'X' shaped filaments may be used.

[0105] The filament tow forming the hollow tubular element (4) preferably has a denier per filament greater than 3. It has been found that such a denier per filament allows for the formation of a tubular element (4) that is not too dense. Preferably, the denier per filament is at least 4, more preferably at least 5. In a preferred embodiment, the filament tow forming the hollow tubular element (4) has a denier per filament of 4 to 10, more preferably 4 to 9. In one example, the filament tow forming the hollow tubular element (4) has a 7.3Y36,000 tow formed of cellulose acetate and containing 18% plasticizer, e.g., triacetin.

[0106] The hollow tubular element (4) preferably has an inner diameter greater than 3.0 mm. Smaller diameters than this can increase the speed of the aerosol passing through the mouthpiece (2) into the consumer's mouth more than desired, so the aerosol becomes too warm, for example, reaching a temperature greater than 40°C or greater than 45°C. More preferably, the hollow tubular element (4) has an inner diameter greater than 3.1 mm, and even more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the inner diameter of the hollow tubular element (4) is about 4.7 mm.

[0107] The hollow tubular element (4) preferably contains 15% to 22% by weight of a plasticizer. In the case of cellulose acetate tow, the plasticizer is preferably triacetin, but other plasticizers such as polyethylene glycol (PEG) may be used. More preferably, the hollow tubular element (4) contains 16% to 20% by weight of a plasticizer, for example, about 17% by weight, about 18% by weight, or about 19% by weight of a plasticizer.

[0108] In the present example, the first hollow tubular element (4), the material body (6), and the cooling section (8) are combined using a second plug wrap (9) that wraps around all three sections. Preferably, the second plug wrap (9) has a basis weight of less than 50 gsm, more preferably about 20 gsm to 45 gsm. Preferably, the second plug wrap (9) has a thickness of 30 µm to 60 µm, more preferably 35 µm to 45 µm. The second plug wrap (9) is preferably a non-porous plug wrap having a permeability of less than 100 Cholesta units, for example, less than 50 Cholesta units. However, in alternative embodiments, the second plug wrap (9) may be a porous plug wrap having a permeability of, for example, more than 200 Cholesta units.

[0109] In the present example, the article (1) has an outer circumference of about 23 mm. In other examples, the article may be provided in any of the forms described herein having an outer circumference of, for example, 20 mm to 26 mm. Since the article must be heated to release an aerosol, improved heating efficiency can be achieved by using articles with lower outer circumferences within this range, for example, circumferences of less than 23 mm. Article circumferences greater than 19 mm have also been found to be particularly effective for achieving improved aerosol through heating while maintaining an appropriate product length. Articles having circumferences of 20 mm to 24 mm, more preferably 20 mm to 23 mm, have been found to provide a good balance between allowing efficient heating and providing effective aerosol delivery.

[0110] A tipping paper (5) is wrapped around the entire length of the mouthpiece (2) and over a portion of the rod of the aerosol generating material (3), and has adhesive on its inner surface to connect the mouthpiece (2) and the rod (3). In this example, the rod of the aerosol generating material (3) is wrapped with a wrapper (10) forming a first wrapping material, and the tipping paper (5) forms an outer wrapping material that extends at least partially over the rod of the aerosol generating material (3) to connect the mouthpiece (2) and the rod of the aerosol generating material (3). In some examples, the tipping paper may extend only partially along the rod of the aerosol generating material.

[0111] In this example, the tipping paper (5) extends 5 mm over the rod (3) of the aerosol generating material, but alternatively, it may extend 3 mm to 10 mm, or more preferably 4 mm to 6 mm, over the rod (3) to provide a secure adhesion between the mouthpiece (2) and the rod (3). The tipping paper may have a basis weight greater than 20 gsm, e.g., greater than 25 gsm, or preferably greater than 30 gsm, e.g., greater than 37 gsm. These ranges of basis weights have been found to provide the tipping papers with sufficient flexibility to wrap around the article (1) and adhere to themselves along the longitudinal lap seam on the paper, while also having acceptable tensile strength. Once wrapped around the mouthpiece (2), the outer circumference of the tipping paper (5) is about 23 mm.

[0112] The article has a ventilation level of about 10% of the aerosol inhaled through the article. In alternative embodiments, the article may have a ventilation level of 1% to 20%, e.g., 1% to 12% of the aerosol inhaled through the article. This level of ventilation helps to increase the consistency of the aerosol inhaled by the user at the mouse end (2b) while assisting the aerosol cooling process. Ventilation is provided directly to the mouthpiece (2) of the article (1). In this example, ventilation is provided to the cooling section (8), which has been found to be particularly beneficial in assisting the aerosol generation process. Ventilation is provided through perforations (12), which are formed in this case as a single row of laser perforations, located 13 mm from the mouse end (2b) downstream of the mouthpiece (2). In alternative embodiments, two or more rows of ventilation perforations may be provided. These perforations pass through the tipping paper (5), the second plug wrap (9), and the cooling section (8). In alternative embodiments, air may be provided into the mouthpiece at other locations, for example, into the material body (6) or the first tubular element (4). Preferably, the article is configured so that perforations are provided about 28 mm or less from the upstream end of the article (1), preferably between 20 mm and 28 mm from the upstream end of the article (1). In this example, apertures are provided about 25 mm from the upstream end of the article.

[0113] FIG. 2a is a side cross-sectional view of an additional article (1') including a capsule-holding mouthpiece (2'). FIG. 2b is a cross-sectional view along line (A-A') of the capsule-holding mouthpiece shown in FIG. 2a. The article (1') and the capsule-holding mouthpiece (2') are identical to the article (1) and mouthpiece (2) shown in FIG. 1, except that the aerosol modifier is provided within the material body (6) in the form of a capsule (11) in this example, and an oil-resistant first plug wrap (7') surrounds the material body (6). In other examples, the aerosol modifier may be provided in other forms, such as when the material is injected into the material body (6), or on a thread carrying a flavoring agent or other aerosol modifier that may also be placed within the material body (6).

[0114] The capsule (11) may comprise a capsule that can be destroyed, for example, a capsule having a hard and brittle shell that encloses a liquid payload. In this example, a single capsule (11) is used. The capsule (11) is completely embedded within the body (6) of the material. In other words, the capsule (11) is completely surrounded by the material forming the body (6). In other examples, a plurality of capsules that can be destroyed may be placed within the body (6) of the material, for example, two, three, or more capsules that can be destroyed may be placed. The length of the body (6) of the material may be increased to accommodate the required number of capsules. In examples where a plurality of capsules are used, the individual capsules may be identical to one another, or may differ from one another in terms of size and / or capsule payload. In other examples, multiple bodies (6) of the material may be provided, each body holding one or more capsules.

[0115] The capsule (11) has a core-shell structure. In other words, the capsule (11) comprises a shell that encapsulates a flavoring agent or other agent, which may be a liquid formulation, for example, any one of the flavoring agents or aerosol modifiers described herein. The shell of the capsule can be ruptured by a user to release the flavoring agent or other agent into the body (6) of the material. The first plug wrap (7') may comprise a barrier coating that makes the material of the plug wrap substantially impermeable to the liquid payload of the capsule (11). Alternatively or additionally, the second plug wrap (9) and / or tipping paper (5) may comprise a barrier coating that makes the material of the plug wrap and / or tipping paper substantially impermeable to the liquid payload of the capsule (11).

[0116] In this example, the capsule (11) is spherical and has a diameter of about 3 mm. In other examples, other shapes and sizes of the capsule may be used. For example, the capsule may have a diameter of less than 4 mm, or less than 3.5 mm, or less than 3.25 mm. In alternative embodiments, the capsule may have a diameter greater than about 3.25 mm, for example, greater than 3.5 mm, or greater than 4 mm. The total weight of the capsule (11) may be in the range of about 10 mg to about 50 mg.

[0117] In this example, the capsule (11) is positioned at a longitudinal center position within the body (6) of the material. That is, the capsule (11) is positioned such that its center is 5 mm from each end of the body (6) of the material. In this example, the center of the capsule is positioned at 36 mm from the upstream end of the article (1). Preferably, the capsule is positioned at 28 mm to 38 mm from the upstream end of the article (1), more preferably at 34 mm to 38 mm from the upstream end of the article (1). In this example, the center of the capsule is positioned at 12 mm from the downstream end of the mouthpiece (2b). Providing the capsule in this position improves the volatilization of the capsule contents due to the proximity of the capsule to the aerosol generating section of the article heated during use, while being sufficiently far from the aerosol generating section so that it can be inserted into the aerosol supply system during use, allowing the user to easily access the capsule and pop it with their finger.

[0118] In other examples, the capsule (11) may be positioned at a position other than the longitudinal center position in the body (6) of the material, namely, closer to the downstream end of the body (6) of the material than to the upstream end, or closer to the upstream end of the body (6) of the material than to the downstream end. Preferably, the mouthpiece (2') is configured such that the capsule (11) and the ventilation holes (12) are offset from each other in the longitudinal direction in the mouthpiece (2'). For example, the ventilation holes (12) may be provided immediately upstream of the capsule position, i.e., about 1 mm to about 10 mm upstream of the capsule position.

[0119] The aerosol-generating material comprises a sheet or crushed sheet of aerosol-capable material. The aerosol-capable material is arranged to generate an aerosol when heated.

[0120] The sheet or shredded sheet comprises a first surface and a second surface facing the first surface. The dimensions of the first surface and the second surface are congruent. The first and second surfaces of the sheet or shredded sheet may have any shape. For example, the first and second surfaces may be square, rectangular, oblong, or circular. Irregular shapes are also expected.

[0121] The first and / or second surfaces of the sheet or shredded sheet may be relatively uniform (e.g., relatively smooth) or uneven or irregular. For example, the first and / or second surfaces of the sheet may be textured or patterned to define a relatively coarse surface. In some embodiments, the first and / or second surfaces are relatively rough.

[0122] The smoothness of the first surface and the second surface may be influenced by a number of factors, such as the area density of the sheet or crushed sheet, the properties of the components constituting the aerosolizable material, or whether the surfaces of the material have been embossed, scored, or otherwise manipulated to impart a pattern or texture.

[0123] Areas of the first surface and the second surface are defined by a first dimension (e.g., width) and a second dimension (e.g., length), respectively. The measurements of the first and second dimensions may have a ratio of 1:1 or greater than 1:1, and accordingly, the sheet or shredded sheet may have an "aspect ratio" of 1:1 or greater than 1:1. As used herein, the term "aspect ratio" is the ratio of the measurement of the first dimension of the first surface or the second surface to the measurement of the second dimension of the first surface or the second surface. An "aspect ratio of 1:1" means that the measurement of the first dimension (e.g., width) and the measurement of the second dimension (e.g., length) are the same. An "aspect ratio greater than 1:1" means that the measurement of the first dimension (e.g., width) and the measurement of the second dimension (e.g., length) are different. In some embodiments, the first and second surfaces of the sheet or shredded sheet have an aspect ratio greater than 1:1, such as 1:2, 1:3, 1:4, 1:5, 1:6, 1:7 or greater.

[0124] The shredded sheet may comprise one or more strands or strips of an aerosolizable material. In some embodiments, the shredded sheet comprises a plurality (e.g., two or more) strands or strips of an aerosolizable material. The strands or strips of the aerosolizable material may have an aspect ratio of 1:1. In one embodiment, the strands or strips of the aerosolizable material have an aspect ratio greater than 1:1. In some embodiments, the strands or strips of the aerosolizable material have an aspect ratio of about 1:5 to about 1:16, or about 1:5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:11, or 1:12. If the aspect ratio of the strands or strips is greater than 1:1, the strands or strips include a longitudinal dimension or length extending between the first end of the strand or strip and the second end of the strand or strip.

[0125] When a shredded sheet comprises multiple strands or strips of material, the dimensions of each strand or strip may vary between different strands or strips. For example, the shredded sheet may comprise a first group of strands or strips and a second group of strands or strips, wherein the dimensions of the strands or strips of the first group differ from the dimensions of the strands or strips of the second group. In other words, the multiple strands or strips may comprise a first group of strands or strips having a first aspect ratio and a second group of strands or strips having a second aspect ratio different from the first aspect ratio.

[0126] The first dimension or cut width of the strands or strips of the aerosolizable material is 0.9 mm to 1.5 mm. If strands or strips of the aerosolizable material with a cut width of less than 0.9 mm are incorporated into an article for use in a non-combustible aerosol delivery system, the pressure drop across the article may increase to a level that renders the article unsuitable for use in a non-combustible aerosol delivery device. However, if the cut width of the strands or strips is greater than 2 mm (e.g., greater than 2 mm), it may be difficult to insert the strands or strips of the aerosolizable material into the article during manufacturing. In a preferred embodiment, the cut width of the strands or strips of the aerosolizable material is about 1 mm to 1.5 mm.

[0127] Strands or strips of material are formed by crushing a sheet of aerosolizable material. The sheet of aerosolizable material may be cut in the width direction, for example in a cross-cut type crushing process, to define the cutting length for the strands or strips of aerosolizable material in addition to the cutting width. The cutting length of the crushed aerosolizable material is preferably at least 5 mm, for example, at least 10 mm, or at least 20 mm. The cutting length of the crushed aerosolizable material may be less than 60 mm, less than 50 mm, or less than 40 mm.

[0128] In some embodiments, a plurality of strands or strips of an aerosolizable material are provided, and at least one of the plurality of strands or strips of the aerosolizable material has a length greater than about 10 mm. Alternatively or additionally, at least one of the plurality of strands or strips of the aerosolizable material may have a length of about 10 mm to about 60 mm, or about 20 mm to about 50 mm. Each of the plurality of strands or strips of the aerosolizable material may have a length of about 10 mm to about 60 mm, or about 20 mm to about 50 mm.

[0129] A sheet or shredded sheet of aerosol-capable material has a thickness of at least about 100 µm. The sheet or shredded sheet may have a thickness of at least about 120 µm, 140 µm, 160 µm, 180 µm, or 200 µm. In some embodiments, the sheet or crushed sheet has a thickness of about 150 µm to about 300 µm, about 151 µm to about 299 µm, about 152 µm to about 298 µm, about 153 µm to about 297 µm, about 154 µm to about 296 µm, about 155 µm to about 295 µm, about 156 µm to about 294 µm, about 157 µm to about 293 µm, about 158 ​​µm to about 292 µm, about 159 µm to about 291 µm, or about 160 µm to about 290 µm. In some embodiments, the sheet or crushed sheet has a thickness of about 170 µm to about 280 µm, about 180 to about 270 µm, about 190 to about 260 µm, about 200 µm to about 250 µm, or about 210 µm to about 240 µm.

[0130] The thickness of the sheet or shredded sheet may vary between the first surface and the second surface. In some embodiments, an individual strip or piece of the aerosolizable material has a minimum thickness over an area of ​​about 100 µm. In some cases, an individual strip or piece of the aerosolizable material has a minimum thickness over an area of ​​about 0.05 mm or about 0.1 mm. In some cases, an individual strip, strand, or piece of the aerosolizable material has a maximum thickness over an area of ​​about 1.0 mm. In some cases, an individual strip or piece of the aerosolizable material has a maximum thickness over an area of ​​about 0.5 mm or about 0.3 mm.

[0131] The thickness of the sheet can be determined using ISO 534: 2011 "Paper and board - Determination of thickness".

[0132] If the sheets or crushed sheets of aerosolizable material are too thick, heating efficiency may be compromised. This can have a negative impact on power consumption during use, such as the power consumption required to release flavor from the aerosolizable material. Conversely, if the aerosolizable material is too thin, it may be difficult to manufacture and handle; very thin materials are harder to cast and are fragile, which impairs aerosol formation during use.

[0133] It is assumed that if a sheet or shredded sheet of aerosolizable material is too thin (e.g., less than 100 μm), it may not have sufficient strength to be pulled in the machine direction without breaking.

[0134] It is assumed that a sheet or shredded sheet having a thickness of at least about 100 μm and an area density of about 100 g / m² to about 250 g / m² undergoes less tearing, splitting, or other deformations during its manufacture. A thickness of at least about 100 μm can have a positive effect on the overall structural integrity and strength of the sheet or shredded sheet. For example, it has good tensile strength and can therefore be relatively easy to process.

[0135] It is thought that the thickness of the sheet or shredded sheet also affects its area density. That is, increasing the thickness of the sheet or shredded sheet can increase the area density of the sheet or shredded sheet.

[0136] Conversely, reducing the thickness of a sheet or shredded sheet can reduce the area density of the sheet or shredded sheet. To avoid any doubt, when area density is referred to herein, it refers to the average area density calculated for a given strip, strand, piece, or sheet of aerosolizable material, and the area density is calculated by measuring the surface area and weight of a given strip, strand, piece, or sheet of aerosolizable material.

[0137] The sheet or shredded sheet of the aerosol-generating material has an area density of about 100 g / m² to about 250 g / m². The sheet or shredded sheet may have an area density of about 110 g / m² to about 240 g / m², about 120 g / m² to about 230 g / m², about 130 g / m² to about 220 g / m², or about 140 g / m² to about 210 g / m². In some embodiments, the sheet or shredded sheet has an area density of about 130 g / m² to about 190 g / m², about 140 g / m² to about 180 g / m², or about 150 g / m² to about 170 g / m². In a preferred embodiment, the sheet or shredded sheet has an area density of about 160 g / m².

[0138] An area density of about 100 g / m² to about 250 g / m² is thought to contribute to the strength and flexibility of the sheet or shredded sheet. Furthermore, a rod comprising a shredded sheet of aerosolizable material having an area density of about 180 gsm² and a minimum thickness of 220 to 230 μm can be packaged such that the aerosolizable material is kept in place within the rod while maintaining the weight of the desired tobacco material (e.g., about 300 mg) within the rod and delivering acceptable sensory characteristics (e.g., taste and smell) when heated in a non-combustible aerosol delivery device.

[0139] The flexibility of a sheet or shredded sheet is considered to depend, at least in part, on the thickness and area density of the sheet or shredded sheet. Thicker sheets or shredded sheets may be less flexible than thinner sheets or shredded sheets. Additionally, the greater the area density of the sheet, the lower the flexibility of the sheet or shredded sheet. The combined thickness and area density of the aerosol-capable material described herein are considered to provide a sheet or shredded sheet that is relatively flexible. When the aerosol-capable material is incorporated into an article for use in a non-flammable aerosol-providing device, this flexibility can provide various advantages. For example, strands or strips can be easily deformed and bent when an aerosol generator is inserted into the aerosol-capable material, thus facilitating the insertion of the aerosol generator (e.g., a heater) into the material and also improving the retention of the aerosol generator by the aerosol-capable material.

[0140] The area density of the sheet or crushed sheet of the aerosol-generating material may affect the roughness of the first surface and the second surface of the sheet or crushed sheet. By changing the area density, the roughness of the first and / or second surfaces may be customized.

[0141] The average bulk density of a sheet or crushed sheet of aerosol-generating material can be calculated from the thickness of the sheet and the area density of the sheet. The average bulk density may be greater than about 0.2 g / cm³, about 0.3 g / cm³, or about 0.4 g / cm³. In some embodiments, the average bulk density is about 0.2 g / cm³ to about 1 g / cm³, about 0.3 g / cm³ to about 0.9 g / cm³, about 0.4 g / cm³ to about 0.9 g / cm³, about 0.5 g / cm³ to about 0.9 g / cm³, or about 0.6 g / cm³ to about 0.9 g / cm³.

[0142] According to an aspect of the present disclosure, an aerosol-generating material is provided comprising a sheet or a crushed sheet of an aerosol-capable material comprising a tobacco material, an aerosol-forming material and a binder, wherein the sheet or the crushed sheet has a density greater than about 0.4 g / cm³. In some embodiments, the density is about 0.4 g / cm³ to about 2.9 g / cm³, about 0.4 g / cm³ to about 1 g / cm³, about 0.6 g / cm³ to about 1.6 g / cm³, or about 1.6 g / cm³ to about 2.9 g / cm³.

[0143] The sheet or crushed sheet may have a tensile strength of at least 4 N / 15 mm.

[0144] If the sheet or shredded sheet has a tensile strength of less than 4 N / 15 mm, there is a possibility that the sheet or shredded sheet will tear, break, or otherwise deform during manufacturing and / or subsequent incorporation into an article for use in a non-flammable aerosol delivery system. Tensile strength may be measured using ISO 1924:2008.

[0145] Aerosol-generating materials may include tobacco materials. Sheets or shredded sheets of aerosol-capable materials may include tobacco materials.

[0146] The tobacco material may be a particulate or granular material. In some embodiments, the tobacco material is a powder. Alternatively or additionally, the tobacco material may comprise strips, strands, or fibers of tobacco. For example, the tobacco material may comprise particles, granules, fibers, strips, and / or strands of tobacco. In some embodiments, the tobacco material consists of particles or granules of tobacco material.

[0147] The density of tobacco materials affects the rate at which heat is conducted through the material, and lower densities, for example, less than 900 mg / cc, conduct heat more slowly through the material, thus enabling a more sustained release of aerosol.

[0148] The tobacco material may include a reconstituted tobacco material having a density of less than about 900 mg / cc, for example, a paper reconstituted tobacco material. For example, the aerosol generating material includes a reconstituted tobacco material having a density of less than about 800 mg / cc. Alternatively or additionally, the aerosol generating material may include a reconstituted tobacco material having a density of at least about 350 mg / cc.

[0149] The tobacco material may be provided in the form of shredded sheets. The sheets of the reconstituted tobacco material may have any suitable thickness. The reconstituted tobacco material may have a thickness of at least about 0.145 mm, for example, at least about 0.15 mm, or at least about 0.16 mm. The reconstituted tobacco material may have a maximum thickness of about 0.30 mm or 0.25 mm, for example, the thickness of the reconstituted tobacco material may be less than about 0.22 mm, or less than about 0.2 mm. In some embodiments, the reconstituted tobacco material may have an average thickness in the range of 0.175 mm to 0.195 mm.

[0150] In some embodiments, the tobacco is a particulate tobacco material. Each particle of the particulate tobacco material may have a maximum dimension. As used herein, the term “maximum dimension” means the longest straight-line distance from any point on the surface of a particle of tobacco or on any other surface point on the same tobacco particle or on the particle surface. The maximum dimension of a particle of the particulate tobacco material may be measured using a scanning electron microscope (SEM).

[0151] The maximum size of each particle of the tobacco material can be up to about 200 µm. In some embodiments, the maximum size of each particle of the tobacco material is up to about 150 µm.

[0152] A group of particles of the tobacco material may have a particle size distribution (D90) of at least about 100 μm. In some embodiments, the group of particles of the tobacco material has a particle size distribution (D90) of about 110 μm, at least about 120 μm, at least about 130 μm, at least about 140 μm, or at least about μm. In one embodiment, the group of particles of the tobacco material has a particle size distribution (D90) of about 150 μm. Additionally, sieve analysis may be used to determine the particle size distribution of the particles of the tobacco material.

[0153] A particle size distribution of at least about 100 μm (D90) is thought to contribute to the tensile strength of sheets or crushed sheets of aerosolizable materials.

[0154] A sheet or shredded sheet of an aerosol-capable material having excellent tensile strength is provided with a particle size distribution (D90) of less than 100 µm. However, including fine particles of this tobacco material in the sheet or shredded sheet can increase its density. When the sheet or shredded sheet is included in an article for use in a non-combustible aerosol delivery system, this higher density can reduce the fill-value of the tobacco material. Advantageously, a balance between satisfactory tensile strength and appropriate density (and thus fill-value) can be achieved when the particle size distribution (D90) is at least about 100 µm.

[0155] In addition, the particle size of the fine particulate tobacco material can affect the roughness of the sheets or crushed sheets of the aerosol-generating material. It is assumed that forming sheets or crushed sheets of the aerosol-generating material by incorporating relatively large particles of the tobacco material reduces the density of the sheets or crushed sheets of the aerosol-generating material.

[0156] The tobacco material may include tobacco obtained from any part of a tobacco plant. In some embodiments, the tobacco material includes tobacco leaves. The sheet or shredded sheet may contain 5% by weight to about 90% by weight of tobacco leaves.

[0157] The tobacco material may comprise a laminated tobacco and / or a tobacco stem, such as a midrib stem. The laminated tobacco may be provided in an amount of 0% to about 100% by weight, about 20% to about 100% by weight, about 40% to about 100% by weight, about 40% to about 95% by weight, about 45% to about 90% by weight, about 50% to about 85% by weight, or about 55% to about 80% by weight of the sheet or shredded sheet and / or tobacco material. In some embodiments, the tobacco material consists of the laminated tobacco material or is composed essentially of it.

[0158] The tobacco material may include tobacco stems in an amount of 0% to about 100% by weight, about 0% to about 50% by weight, about 0% to about 25% by weight, about 0% to about 20% by weight, or about 5% to about 15% by weight of the sheet or crushed sheet.

[0159] In some embodiments, the tobacco material comprises a combination of a laminar and a tobacco stem. In some embodiments, the tobacco material may comprise an amount of laminar from about 40% to about 95% by weight and a amount of stem from about 5% to about 60% by weight of a sheet or shredded sheet of aerosolizable material, or an amount of laminar from about 60% to about 95% by weight and a amount of stem from about 5% to about 40% by weight, or an amount of laminar from about 80% to about 95% by weight and a amount of stem from about 5% to about 20% by weight.

[0160] The incorporation of stems can reduce the tackiness of aerosolizable materials. Incorporating tobacco materials containing stem tobacco into aerosolizable materials can increase their burst strength.

[0161] Sheets or shredded sheets of aerosol-capable material may have a burst strength of at least about 75g, at least about 100g, or at least about 200g.

[0162] If the burst strength is too low, the sheet or shredded sheet may be relatively brittle. Consequently, breakage of the sheet or shredded sheet may occur during the process of manufacturing aerosolizable materials. For example, when a sheet is shredded by a cutting process to form a shredded sheet, the sheet may shatter, break into pieces, or become fragments when cut.

[0163] The tobacco material described herein may contain nicotine. The nicotine content may be 0.1% to 3% by weight of the tobacco material, for example, 0.5% to 2.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material contains 10% to 90% by weight of tobacco leaves having a nicotine content of more than about 1% by weight or about 1.5% by weight of the tobacco leaves. For example, tobacco leaves such as cut rag tobacco may have a nicotine content of, for example, 1% to 5% by weight of the tobacco leaves.

[0164] A sheet or shredded sheet of aerosol-capable material may contain nicotine in an amount of about 0.1% to about 3% by weight of the sheet or shredded sheet.

[0165] Reconstituted paper tobacco may also be provided in the aerosol-generating materials described herein. Reconstituted paper tobacco refers to tobacco material formed by a process in which a tobacco feedstock is extracted with a solvent to provide a residue comprising extracts of solubles and fibrous material, the extracts (typically after concentration and optionally after further processing) are then recombined with the fibrous material from the residue by depositing the extracts onto the fibrous material (typically after purification of the fibrous material and optionally adding a portion of non-tobacco fibers). The recombination process is similar to a papermaking process.

[0166] The paper-reconstituted cigarette may be any type of paper-reconstituted cigarette known in the art. In certain embodiments, the paper-reconstituted cigarette is prepared from a feedstock comprising one or more of tobacco strips, tobacco stems, and whole leaf tobacco. In further embodiments, the paper-reconstituted cigarette is prepared from a feedstock consisting of tobacco strips and / or whole leaf tobacco, and tobacco stems. However, in other embodiments, scraps, fines, and winnowings may be used alternatively or additionally in the feedstock.

[0167] Paper-reconstructed cigarettes for use in the tobacco materials described herein can be manufactured by methods known to those skilled in the art for manufacturing paper-reconstructed cigarettes.

[0168] In the examples, the paper-reconstituted cigarette is provided in an amount of 5% to 90% by weight, 10% to 80% by weight, or 20% to 70% by weight of the aerosol-generating material.

[0169] The aerosol generating material includes an aerosol forming agent material. The aerosol forming agent material includes one or more components capable of forming an aerosol. The aerosol-forming agent materials are glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, and myristic acid. It includes one or more of acid), and propylene carbonate. Preferably, the aerosol-forming agent material is glycerol or propylene glycol.

[0170] A sheet or shredded sheet of an aerosol-capable material comprises an aerosol-forming agent material. The aerosol-forming agent material is provided in an amount of up to about 50% based on the dry weight of the sheet or shredded sheet. In some embodiments, the aerosol-forming agent material is provided in an amount of about 5% to about 40% by weight based on the dry weight of the sheet or shredded sheet, about 10% to about 30% by weight based on the dry weight of the sheet or shredded sheet, or about 10% to about 20% by weight based on the dry weight of the sheet or shredded sheet.

[0171] The sheet or shredded sheet may also contain water. The sheet or shredded sheet of the aerosolizable material may contain water in an amount of less than about 15 weight percent, less than about 10 weight percent, or less than about 5 weight percent of the aerosolizable material. In some embodiments, the aerosolizable material contains water in an amount of about 0 weight percent to about 15 weight percent or about 5 weight percent to about 15 weight percent of the aerosolizable material.

[0172] A sheet or shredded sheet of aerosolizable material may contain water and aerosol-forming agent materials in an amount of less than about 30% by weight of the sheet or shredded sheet of aerosolizable material, or less than about 25% by weight of the sheet or shredded sheet of aerosolizable material, in total amount. It is believed that incorporating water and aerosol-forming agent materials into a sheet or shredded sheet of aerosolizable material in an amount of less than about 30% by weight can advantageously reduce the tackiness of the sheet. This can improve the ease with which the aerosolizable material can be handled during processing. For example, it may be easier to roll a sheet of aerosolizable material to form a bobbin of material and then unroll the bobbin so that the layers of the sheet do not stick together. Additionally, reducing tackiness can further improve processing efficiency and the quality of the final product by reducing the tendency of strands or strips of shredded material to clump together or stick.

[0173] The sheet or shredded sheet may include a binder. The binder is arranged to bind the components of the aerosol-generating material to form the sheet or shredded sheet. The binder may at least partially coat the surface of the tobacco material. If the tobacco material is in the form of fine particles, the binder may at least partially coat the surface of the tobacco particles and bind them together.

[0174] The binder may be selected from one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), cellulose (and derivatives), gums, silica or silicon compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the binder comprises alginate and / or pectin or carrageenan. In a preferred embodiment, the binder comprises guar gum.

[0175] The binder may be provided in an amount of about 1 to about 20 weight percent of the sheet or shredded sheet of the aerosolizable material, or in an amount of 1 to about 10 weight percent of the sheet or shredded sheet of the aerosolizable material. For example, the binder may be provided in an amount of about 1 weight percent, 2 weight percent, 3 weight percent, 4 weight percent, 5 weight percent, 6 weight percent, 7 weight percent, 8 weight percent, 9 weight percent, or 10 weight percent of the sheet or shredded sheet of the aerosolizable material.

[0176] The aerosol-generating material may include a filler. In some embodiments, the sheet or shredded sheet includes a filler. The filler is generally a non-tobacco component, that is, a component that does not include components derived from tobacco. The filler may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may be a non-tobacco fiber, such as wood fiber or pulp or wheat fiber. The filler may be a material containing cellulose, or the material may contain a derivative of cellulose. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material.

[0177] In certain embodiments containing a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood, wood pulp, hemp fiber, cellulose, or cellulose derivatives. Although not bound by theory, it is believed that the inclusion of a fibrous filler can increase the tensile strength of the material.

[0178] Additionally, fillers can contribute to the texture of sheets or shredded sheets of aerosolizable material. For example, fibrous fillers, such as wood or wood pulp, can provide sheets or shredded sheets of aerosolizable material having relatively rough first and second surfaces. Conversely, non-fibrous particulate fillers, such as powdered chalk, can provide sheets or shredded sheets of aerosolizable material having relatively smooth first and second surfaces. In some embodiments, the aerosolizable material comprises a combination of different filler materials.

[0179] The filler component may be provided in an amount of 0 to 20 weight percent of the sheet or shredded sheet, or in an amount of 1 to 10 weight percent of the sheet or shredded sheet. In some embodiments, the filler component is not present.

[0180] Fillers can help improve the general structural properties of aerosolizable materials, such as their tensile strength and burst strength.

[0181] In the compositions described herein where amounts are provided in weight percent, to avoid any doubt, this refers to a dry weight basis unless otherwise specifically indicated. Accordingly, any moisture that may be present in the aerosol-generating material or any of its components is completely ignored for the purpose of determining the weight percent. The moisture content of the aerosol-generating material described herein may vary and, for example, may be 5 to 15 weight percent. The moisture content of the aerosol-generating material described herein may vary, for example, depending on the temperature, pressure, and humidity conditions under which the compositions are maintained. The moisture content may be determined by Karl-Fisher analysis, as is known to those skilled in the art. Meanwhile, to avoid any doubt, any component other than water is included in the weight of the aerosol-generating material, even if the aerosol-forming material is a liquid component such as glycerol or propylene glycol. However, where an aerosol-forming material is provided to the tobacco component of the aerosol-forming material or the filler component of the aerosol-forming material (if present), instead of being added separately to the aerosol-forming material or in addition thereto, the aerosol-forming material is not included in the weight of the tobacco component or the filler component, but is included in the weight of the "aerosol-forming material" in the weight percent defined herein. All other components present in the tobacco component 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-reconstituted tobacco).

[0182] The aerosol generating material of the present invention may include an aerosol modifier such as any of the flavors described herein. In one embodiment, the aerosol generating material includes menthol. When the aerosol generating material is included in an article for use in an aerosol delivery system, the article may be referred to as a menthol-containing article. The aerosol generating material may include 0.5 mg to 20 mg of menthol, 0.7 mg to 20 mg of menthol, 1 mg to 18 mg, or 8 mg to 16 mg of menthol. In the present example, the aerosol generating material includes 16 mg of menthol. The aerosol generating material may include 1 wt% to 8 wt% of menthol, preferably 3 wt% to 7 wt% of menthol, and more preferably 4 wt% to 5.5 wt% of menthol. In one embodiment, the aerosol generating material includes 4.7 wt% of menthol. These high levels of menthol loading can be achieved by using a high percentage of reconstituted tobacco material, for example, more than 50 weight percent of tobacco material. Alternatively or additionally, the use of a high volume of, for example, tobacco material, can increase the menthol loading level that can be achieved when, for example, more than about 500 mm³ or suitably more than about 1000 mm³ of aerosol-generating material such as tobacco material is used.

[0183] In some embodiments, the composition comprises an aerosol-forming "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dried gel. An amorphous solid is a solid material capable of holding some fluid, such as a liquid, within it.

[0184] In some examples, amorphous solids,

[0185] - 1 to 60 weight% of gelling agent;

[0186] - 0.1 to 50 weight% of an aerosol-forming agent material; and

[0187] - Contains 0.1 to 80 weight% of flavor;

[0188] These weights are calculated based on dry weight.

[0189] In some additional embodiments, the amorphous solid is,

[0190] - 1 to 50 weight% of gelling agent;

[0191] - 0.1 to 50 weight% of an aerosol-forming agent material; and

[0192] - Contains 30 to 60 weight percent of flavor;

[0193] These weights are calculated based on dry weight.

[0194] Amorphous solid materials may be provided in the form of sheets or crushed sheets. Amorphous solid materials may take the same form as the sheets or crushed sheets of the previously described aerosolizable materials.

[0195] Suitably, the amorphous solid may comprise about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1 to 50 wt%, 5 to 45 wt%, 10 to 40 wt%, or 20 to 35 wt% of a gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), cellulose (and derivatives), gums, silica or silicon compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the gelling agent comprises alginate and / or pectin and may be combined with a setting agent (e.g., a calcium source) during the formation of the amorphous solid. In some cases, the amorphous solid may comprise calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0196] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid as an amount of 10 to 30 weight percent of the amorphous solid (calculated on a dry weight basis). In some embodiments, the alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one additional gelling agent, such as pectin.

[0197] In some embodiments, the amorphous solid may include a gelling agent comprising carrageenan.

[0198] Suitably, the amorphous solid may comprise about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10 wt% to about 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of an aerosol-forming agent material (all calculated on a dry weight basis). The aerosol-forming agent material may act as a plasticizer. For example, the amorphous solid may comprise 0.5 to 40 wt%, 3 to 35 wt%, or 10 to 25 wt% of an aerosol-forming agent material. In some cases, the aerosol-forming agent material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol-forming material contains glycerol, consists essentially of glycerol, or is composed of glycerol.

[0199] The amorphous solid contains flavor. Suitably, the amorphous solid may contain up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% of flavor.

[0200] In some cases, the amorphous solid may contain at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% (all calculated on a dry weight basis) of flavor.

[0201] For example, the amorphous solid may contain 1 to 80 weight%, 10 to 80 weight%, 20 to 70 weight%, 30 to 60 weight%, 35 to 55 weight%, or 30 to 45 weight% of flavor. In some cases, the flavor contains menthol, consists essentially of menthol as an essential element, or is composed of menthol.

[0202] In some cases, the amorphous solid may further contain an emulsifying agent that emulsifies the melted flavor during preparation. For example, the amorphous solid may contain about 5% by weight to about 15% by weight of an emulsifying agent (calculated on a dry weight basis), suitably about 10% by weight. The emulsifying agent may include acacia gum.

[0203] In some embodiments, the amorphous solid is a hydrogel and contains less than about 20 wt% of water calculated on a wet weight basis. In some cases, the hydrogel may contain about 15 wt%, 12 wt%, or less than 10 wt% of water calculated on a wet weight basis. In some cases, the hydrogel may contain at least about 1 wt%, 2 wt%, or at least about 5 wt% of water (WWB).

[0204] In some embodiments, the amorphous solid further comprises an active material. For example, in some cases, the amorphous solid further comprises tobacco material and / or nicotine. In some cases, the amorphous solid may comprise 5 to 60 weight% (calculated on a dry weight basis) of tobacco material and / or nicotine. In some cases, the amorphous solid may comprise about 1 weight%, 5 weight%, 10 weight%, 15 weight%, 20 weight%, or 25 weight% to about 70 weight%, 60 weight%, 50 weight%, 45 weight%, 40 weight%, 35 weight%, or 30 weight% (calculated on a dry weight basis) of an active material. In some cases, the amorphous solid may contain about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of tobacco material. For example, the amorphous solid may contain 10 to 50 wt%, 15 to 40 wt%, or 20 to 35 wt% of tobacco material. In some cases, the amorphous solid may contain about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may contain 1 to 20 weight%, 2 to 18 weight%, or 3 to 12 weight% of nicotine.

[0205] In some cases, the amorphous solid contains an active substance such as a tobacco extract. In some cases, the amorphous solid may contain 5 to 60 weight% (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid may contain about 5 weight%, 10 weight%, 15 weight%, 20 weight%, or 25 weight% to about 60 weight%, 50 weight%, 45 weight%, 40 weight%, 35 weight%, or 30 weight% (calculated on a dry weight basis) of tobacco extract. For example, the amorphous solid may contain 10 to 50 weight%, 15 to 40 weight%, or 20 to 35 weight% of tobacco extract. Tobacco extract may contain nicotine at a concentration in which the amorphous solid contains 1 wt%, 1.5 wt%, 2 wt% or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt% or 4 wt% (calculated on a dry weight basis).

[0206] In some cases, amorphous solids may not contain nicotine other than that resulting from tobacco extract.

[0207] In some embodiments, the amorphous solid does not contain tobacco material but contains nicotine. In some of these cases, the amorphous solid may contain about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may contain 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% of nicotine.

[0208] In some cases, the total content of the active substance and / or flavor may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of the active substance and / or flavor may be about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or less than 40 wt% (all calculated on a dry weight basis).

[0209] In some cases, the total content of tobacco material, nicotine, and flavor may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of active substance and / or flavor may be about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or less than 40 wt% (all calculated on a dry weight basis).

[0210] The amorphous solid can be prepared as a gel, and the gel may further contain a solvent included in an amount of 0.1 to 50 weight%. However, the inclusion of a solvent in which the flavor is soluble may reduce gel stability, and the flavor may crystallize from the gel. Therefore, in some cases, the gel does not contain a solvent in which the flavor is soluble.

[0211] In some embodiments, the amorphous solid comprises less than 60 weight%, e.g., 1 weight% to 60 weight%, or 5 weight% to 50 weight%, or 5 weight% to 30 weight%, or 10 weight% to 20 weight% of a filler.

[0212] In other embodiments, the amorphous solid comprises less than 20 weight%, suitably less than 10 weight% or less than 5 weight% of filler. In some cases, the amorphous solid comprises less than 1 weight% of filler, and in some cases, does not comprise filler.

[0213] The filler (if present) may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may comprise one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives. In special cases, the amorphous solid does not contain calcium carbonate, such as chalk.

[0214] In certain embodiments containing a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fiber, cellulose, or cellulose derivatives. Although not bound by theory, it is believed that including a fibrous filler in an amorphous solid can increase the tensile strength of the material.

[0215] In some embodiments, the amorphous solid does not contain tobacco fibers.

[0216] In some examples, the amorphous solid in sheet form may have a tensile strength of about 200 N / m to about 1500 N / m. In some examples, such as when the amorphous solid does not contain a filler, the amorphous solid may have a tensile strength of 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or about 250 N / m. These tensile strengths may be particularly suitable for embodiments in which the amorphous solid material is formed into a sheet and then crushed and incorporated into an aerosol-producing article.

[0217] In some examples, such as when the amorphous solid contains a filler, the amorphous solid may have a tensile strength of 600 N / m to 1500 N / m, or 700 N / m to 900 N / m, or about 800 N / m. These tensile strengths may be particularly suitable for embodiments in which the amorphous solid material is suitably included in an aerosol-generating article as a rolled sheet in the form of a tube.

[0218] In some cases, the amorphous solid may be composed essentially of or composed of a gelling agent, water, aerosol-forming material, flavor, and optionally an active substance.

[0219] In some cases, the amorphous solid may be composed essentially of or composed of a gelling agent, water, an aerosol-forming agent material, a flavoring agent, and optionally a tobacco material and / or nicotine source.

[0220] The amorphous solid may comprise one or more active substances and / or flavors, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0221] The aerosol-generating material may include a paper-reconstituted tobacco material. The composition may, alternatively or additionally, include any of the forms of tobacco described herein. The aerosol-generating material may include a sheet or shredded sheet comprising a tobacco material comprising 10% to 90% by weight of tobacco leaves, and the aerosol-forming material is provided in an amount of about 20% by weight or less of the sheet or shredded sheet, and the remainder of the tobacco material comprises paper-reconstituted tobacco.

[0222] If the aerosol generating material comprises an amorphous solid material, the amorphous solid material may be a dry gel containing menthol. In alternative embodiments, the amorphous solid may have any composition as described herein.

[0223] An improved article may be produced comprising an aerosol-generating material comprising a first component comprising a sheet or crushed sheet of an aerosol-capable material and a second component comprising an amorphous solid, wherein material properties (e.g., density) and specifications (e.g., thickness, length, and cross width) fall within the ranges set forth herein.

[0224] In some cases, the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may be in the range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm. A material having a thickness of about 0.09 mm may be used. The amorphous solid may comprise more than one layer, and the thickness described herein refers to the collective thickness of these layers.

[0225] The thickness of an amorphous solid material can be measured using calipers or a microscope such as a scanning electron microscope (SEM), or any other suitable technique known to those skilled in the art.

[0226] If the amorphous solid is too thick, heating efficiency may be compromised. This can have a negative impact on power consumption during use, such as the power consumption required to release flavor from the amorphous solid. Conversely, if the aerosol-forming amorphous solid is too thin, manufacturing and handling may be difficult; very thin materials are harder to cast and fragile, impairing aerosol formation during use. In some cases, individual strips or pieces of the amorphous solid have a minimum thickness over an area of ​​approximately 0.015 mm. In some cases, individual strips or pieces of the amorphous solid have a minimum thickness over an area of ​​approximately 0.05 mm or approximately 0.1 mm. In some cases, individual strips or pieces of the amorphous solid have a maximum thickness over an area of ​​approximately 1.0 mm. In some cases, individual strips or pieces of the amorphous solid have a maximum thickness over an area of ​​approximately 0.5 mm or approximately 0.3 mm.

[0227] In some cases, the thickness of the amorphous solid may vary by 25%, 20%, 15%, 10%, 5%, or less than 1% over the area.

[0228] Providing sheets or crushed sheets of amorphous solid materials and aerosolizable materials having different area density values ​​less than a given percentage results in less separation in a mixture of these materials. In some examples, the area density of the amorphous solid material may be 50% to 150% of the area density of the aerosolizable material. For example, the area density of the amorphous solid material may be 60% to 140% of the density of the aerosolizable material, or 70% to 110% of the area density of the aerosolizable material, or 80% to 120% of the area density of the aerosolizable material.

[0229] In the embodiments described herein, the amorphous solid material may be incorporated into the article in the form of a sheet. The amorphous solid material in the form of a sheet may be crushed and then incorporated into the article and appropriately mixed with an aerosolizable material, such as a sheet of the aerosolizable material or a crushed sheet described herein.

[0230] In additional embodiments, the amorphous solid sheet may be additionally included as a flat sheet, a gathered or bundled sheet, a crimped sheet, or a rolled sheet (i.e., in the form of a tube). In some of these cases, the amorphous solid of these embodiments may be included in the aerosol-generating article as a sheet, such as a sheet surrounding a rod containing an aerosol-capable material. For example, the amorphous solid sheet may be formed on wrapping paper surrounding an aerosol-capable material, such as tobacco.

[0231] Amorphous solids in sheet form may have any suitable areal density, such as about 30 g / m² to about 150 g / m². In some cases, the sheet may have a mass per unit area of ​​about 55 g / m² to about 135 g / m², or about 80 to about 120 g / m², or about 70 to about 110 g / m², or particularly about 90 to about 110 g / m², or suitably about 100 g / m². These ranges may provide densities similar to the density of cut lag tobacco, and consequently provide a mixture of these materials that will not be easily separated. These areal densities may be particularly suitable when the amorphous solid material is included in an aerosol-generating article as a crushed sheet (described further below). In some cases, the sheet may have a mass per unit area of ​​about 30 to 70 g / m², 40 to 60 g / m², or 25 to 60 g / m² and may be used to wrap aerosolizable materials, for example, the aerosolizable materials described herein.

[0232] The aerosol generating material may comprise a blend of an aerosol-capable material and an amorphous solid material as described herein. Such an aerosol generating material can provide an aerosol having a desirable flavor profile upon use because additional flavors can be introduced into the aerosol generating material by incorporating them into the amorphous solid material component. The flavors provided to the amorphous solid material can be retained more stably within the amorphous solid material compared to flavors directly added to the tobacco material, and as a result, a more consistent flavor profile is produced among the articles produced according to the present disclosure.

[0233] As previously mentioned, tobacco materials having a density of at least 350 mg / cc and less than about 900 mg / cc, preferably about 600 mg / cc to about 900 mg / cc, have been found to advantageously result in a more sustained release of aerosols. To provide an aerosol with a consistent flavor profile, the amorphous solid material component of the aerosol-generating material must be evenly distributed throughout the load. This can be achieved by casting the amorphous solid material to have a thickness as described herein to provide an amorphous solid material having an area density similar to that of the tobacco material, and by processing the amorphous solid material as described below to ensure even distribution throughout the aerosol-generating material.

[0234] As mentioned above, optionally, the aerosol generating material comprises a plurality of strips of amorphous solid material. When the aerosol generating section comprises a plurality of strands and / or strips of sheets of aerosol-capable material and a plurality of strips of amorphous solid material, the material properties and / or dimensions of at least two components may be suitably selected in other ways to enable a relatively uniform mixing of the components and reduce separation or unmixing of the components during or after the manufacture of the aerosol generating material load.

[0235] The longitudinal dimension of the plurality of strands or strips may be substantially the same as the length of the aerosol-generating section. The plurality of strands and / or strips may have a length of at least about 5 mm.

[0236] In FIG. 3, the components of an embodiment of a non-flammable aerosol providing device (100) are illustrated in a simplified manner. In particular, the elements of the non-flammable aerosol providing device (100) are not illustrated in actual scale in FIG. 3. To simplify FIG. 3, elements that are not relevant to understanding the embodiment have been omitted.

[0237] As illustrated in FIG. 3, the non-flammable aerosol providing device (100) includes a non-flammable aerosol providing device having a housing (101) that includes an area (102) for receiving an article (1).

[0238] Area (102) is arranged to accommodate an article (1). When the article (1) is accommodated within the area (102), at least a portion of the aerosol-generating material comes into thermal proximity with the heater (103). When the article (1) is fully accommodated within the area (102), at least a portion of the aerosol-generating material may come into direct contact with the heater (103). The aerosol-generating material will release various volatile compounds at different temperatures. By controlling the maximum operating temperature of the electric heating aerosol-generating system (100), the selective release of undesirable compounds can be controlled by preventing the release of selected volatile compounds.

[0239] As illustrated in FIG. 4, within the housing (101), there is an electric energy supply unit (104), for example, a rechargeable lithium-ion battery. A controller (105) is connected to a heater (103), an electric energy supply unit (104), and a user interface (106), for example, a button or display. The controller (105) controls the power supplied to the heater (103) to control the temperature of the heater (103). Typically, the aerosol-forming substrate is heated to a temperature of 250 to 450 degrees Celsius.

[0240] FIG. 5 is a schematic cross-sectional view of a non-combustible aerosol providing device of the type shown in FIG. 3, in which a heater (103) is inserted into the aerosol generating material (3) of the article (1). The non-combustible aerosol providing device is exemplified as engaging with the aerosol generating article (1) for consumption of the aerosol generating article (1) by a user.

[0241] The housing (101) of the non-flammable aerosol providing device defines a cavity-shaped region (102) that is open at the proximal end (or mouse end) to accommodate an aerosol-generating article (1) for consumption. The distal end of the cavity is extended by a heating assembly comprising a heater (103). The heater (103) is held by a heater mount (not shown) such that the active heating area of ​​the heater is located within the cavity. The active heating area of ​​the heater (103) is located within the aerosol-generating section of the aerosol-generating article (1) when the aerosol-generating article (1) is fully accommodated within the cavity.

[0242] The heater (103) is configured for insertion into the aerosol generating material (3). The heater (103) is shaped like a blade ending at one point. That is, the heater has a length dimension greater than its width dimension, which is greater than its thickness dimension. The first and second sides of the heater are defined by the width and length of the heater.

[0243] As the article (1) is pushed into the cavity, the tapered point of the heater engages with the aerosol generating material (3). The blade is shaped to allow easy insertion and removal into and out of the aerosol generating material (3). By applying force to the article (1), the heater penetrates into the aerosol generating material (3). When the article (1) is properly engaged with the non-flammable aerosol providing device, the heater (103) is inserted into the aerosol generating material (3). When the heater is driven, the aerosol generating material (3) is heated and volatile substances are generated or released. As the user inhales through the mouthpiece (2), air is drawn into the article (1) and the volatile substances condense to form an inhalable aerosol. This aerosol passes through the mouthpiece (2) of the article (1) and enters the user's mouth.

[0244] The aerosol generating material (3) illustrated in FIG. 5 has two fibers (40) made of a heat transfer material in the aerosol generating material (3). These fibers transfer heat received from the heater (103) to other areas of the aerosol generating material (3) to achieve a more uniform heat distribution.

[0245] Generally, the heat transfer material of the present disclosure facilitates the distribution of heat through an aerosol-generating material. This enables more uniform heat distribution and allows for the avoidance of localized hot spots.

[0246] In some embodiments, the heat transfer material is nonmetallic. These materials may have the advantage of having a relatively light weight and low thermal mass. Therefore, they are more efficient at transferring heat from one zone to another without significantly increasing the weight of the article. A combination of a metal heating element and a nonmetallic heat transfer material, such as graphite, is considered to be an advantageous combination for achieving heat distribution through aerosol-generating materials.

[0247] The various embodiments described herein are presented merely to aid understanding and to teach the claimed features. These embodiments are provided only as representative samples of the embodiments and are not comprehensive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not to be considered as limitations on the scope of the invention as defined by the claims or limitations on equivalents thereof, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably include, be composed of, or constitute essentially of other disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions that are not currently claimed but will be claimed in the future.

Claims

Claim 1 An article for use in an aerosol providing system or as part of an aerosol providing system, wherein the article comprises an aerosol generating material and a heat transfer material for distributing heat from a first zone of the aerosol generating material to a second zone of the aerosol generating material, wherein the heat transfer material has a thermal conductivity of at least 220 W / mK and the heat transfer material is in the form of a single graphite fiber located centrally within the aerosol generating material. Claim 2 Article for use in an aerosol supply system or as part of an aerosol supply system, wherein the thermal conductivity of the heat transfer material is less than 5000, 4000, 3000, 2000, or 1000 W / mK. Claim 3 An article for use in an aerosol supply system or as part of an aerosol supply system, wherein, in claim 1 or 2, the thermal conductivity of the heat transfer material is greater than 300, 400, or 500 W / mK. Claim 4 An article for use in an aerosol supply system or as part of an aerosol supply system, wherein, in claim 1 or 2, the thermal conductivity of the heat transfer material is in the range of 220 to 5000 W / mK, 220 to 4000 W / mK, 220 to 3000 W / mK, 220 to 2000 W / mK, 220 to 1000 W / mK, 220 to 500 W / mK, 300 to 5000 W / mK, 300 to 4000 W / mK, 300 to 3000 W / mK, 300 to 2000 W / mK, 300 to 1000 W / mK, 300 to 500 W / mK, or 220 to 470 W / mK. Claim 5 An article for use in an aerosol delivery system or as part of an aerosol delivery system, wherein, in claim 1 or 2, the weight of the heat transfer material present in the article is in the range of 1 to 25 mg, 1 to 20 mg, 1 to 15 mg, 1 to 10 mg, or 1 to 5 mg. Claim 6 An article for use in an aerosol providing system or as part of an aerosol providing system, wherein, in claim 1 or 2, the ratio of the heat transfer material to the aerosol generating material is in the range of 1:10 to 1:100 by weight. Claim 7 Article 1 or 2, wherein the heat transfer material extends parallel to the axis of the article, an article for use in an aerosol delivery system or as part of an aerosol delivery system. Claim 8 Article for use in an aerosol providing system or as part of an aerosol providing system, wherein the heat transfer material extends along the length of the aerosol generating material. Claim 9 Article for use in an aerosol delivery system or as part of an aerosol delivery system, further comprising a heating element in accordance with claim 1 or 2. Claim 10 Article for use in an aerosol delivery system or as part of an aerosol delivery system, wherein the heating element is a susceptor. Claim 11 An aerosol providing system comprising a non-flammable aerosol providing device, a heating element, and an article of claim 1 or 2. Claim 12 In claim 11, the aerosol providing device comprises an electrical power source for supplying power to the heating element, and the heating element heats the aerosol generating material by electrical conduction, an aerosol providing system. Claim 13 In claim 11, the aerosol providing device comprises a magnetic field generator, and the heating element is a susceptor that heats the aerosol generating material by induction heating and / or magnetic hysteresis heating, an aerosol providing system. Claim 14 In claim 11, the aerosol providing device comprises an exothermic power source, and the heating element of the article is a second heat transfer material for transferring heat to the aerosol generating material, an aerosol providing system. Claim 15 In claim 13, the article is an aerosol providing system comprising the heating element. Claim 16 In claim 12, the aerosol providing device comprises the heating element, an aerosol providing system. Claim 17 A method for manufacturing an article to be used in an aerosol providing system or as part of an aerosol providing system, wherein the article comprises an aerosol generating material, and the method comprises the step of adding a heat transfer material for distributing heat from a first zone of the aerosol generating material to a second zone of the aerosol generating material, wherein the heat transfer material has a thermal conductivity of at least 220 W / mK, and the heat transfer material is in the form of a single graphite fiber located centrally within the aerosol generating material. Claim 18 A method for manufacturing an article to be used in an aerosol providing system or as part of an aerosol providing system, wherein the step of adding the heat transfer material comprises the step of supplying the heat transfer material into the aerosol generating material. Claim 19 delete Claim 20 delete Claim 21 delete Claim 22 delete Claim 23 delete Claim 24 delete Claim 25 delete Claim 26 delete Claim 27 delete Claim 28 delete Claim 29 delete Claim 30 delete Claim 31 delete Claim 32 delete Claim 33 delete Claim 34 delete Claim 35 delete Claim 36 delete Claim 37 delete

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