JP7678129B2 - Components for articles for use in aerosol delivery systems - Patents.com - Google Patents

Description

The present disclosure relates to components for articles for use in or for use as non-combustion aerosol delivery systems, articles for use in or for use as non-combustion aerosol delivery systems, and methods for forming components for articles for use in or for use as non-combustion aerosol delivery systems.

(background)
Certain tobacco industry products, during use, produce an aerosol that is inhaled by the user. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, to form an aerosol by heating, but do not burn the aerosol-generating substrate. Such tobacco industry products generally include a mouthpiece through which the aerosol passes to the user's mouth.

(overview)
According to embodiments described herein, there is provided, according to a first aspect, a component for use in a non-combustion aerosol delivery system or for an article for use as a non-combustion aerosol delivery system, the component comprising a longitudinally extending body of material, the body of material comprising a corrugated sheet material formed to have a corrugated pattern comprising a series of substantially parallel ridges and grooves, the average spacing between adjacent ridges being greater than about 0.3 mm, and the average density of said body of material being between about 0.1 and about 0.25 mg/ ^mm3 .

According to embodiments described herein, there is provided, according to a second aspect, a component for use in a non-combustion aerosol delivery system or for an article for use as a non-combustion aerosol delivery system, the component comprising a longitudinally extending body of material, the body of material comprising a corrugated sheet material formed to have a corrugation pattern comprising a series of substantially parallel ridges and grooves, the corrugations having an amplitude of less than about 0.7 mm, and the body of material having an average density of about ^0.1 to about 0.25 mg/mm3.

According to embodiments described herein, there is provided an article for use in or as a non-combustion aerosol delivery system according to a third aspect, the article comprising an aerosol generating material and a downstream portion downstream of the aerosol generating material, the downstream portion comprising a component according to the first or second aspect above.

According to an embodiment described herein, in accordance with a fourth aspect, there is provided a non-combustible aerosol delivery system comprising an article according to the third aspect above.

According to embodiments described herein, there is provided, according to a fifth aspect, a method for forming a component for an article for use in a non-combustible aerosol delivery system, the method comprising the steps of: applying a corrugated pattern to a sheet material, the corrugated pattern comprising a series of substantially parallel ridges and grooves, with an average spacing between adjacent ridges being greater than about 0.3 mm; and forming the sheet material into a body of material, the body of material having an average density of about 0.1 to about 0.25 mg/ ^mm3 .

According to embodiments described herein, there is provided, according to a sixth aspect, a method for forming a component for an article for use in a non-combustible aerosol delivery system, the method comprising the steps of: applying a corrugated pattern to a sheet material, the corrugated pattern comprising a series of substantially parallel ridges and grooves, the corrugations having an amplitude of less than about 0.7 mm; and forming the sheet material into a body of material, the body of material having an average density of about 0.1 to about 0.25 mg/ ^mm3 .

Embodiments of the invention will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:
1 is a side cross-sectional view of an article for use with a non-combustible aerosol delivery device, the article including a body of material formed from a sheet material. 2 is a cross-sectional end view of the body of material of the article of FIG. 1 taken along line AA in FIG. 1; FIG. 2B is a side view of the sheet material forming the body of material of FIG. 2A. 1 is a cross-sectional side view of an article for use with a non-combustible aerosol delivery device. 1 is a cross-sectional side view of an article for use with a non-combustible aerosol delivery device. 1 is a cross-sectional side view of an article for use with a non-combustible aerosol delivery device. 6 is a side cross-sectional view of multiple lengths of rods for producing the body of material of the article of FIG. 5. FIG. FIG. 1 is a perspective view of a non-combustible aerosol delivery device. FIG. 8 is a view of the device of FIG. 7 with the outer cover removed and no article present. FIG. 9 is a side view, partially in cross section, of the device of FIG. 8. FIG. 9 is an exploded view of the device of FIG. 8 , omitting the outer cover. FIG. 9 is a cross-sectional view of a portion of the device of FIG. 8. FIG. 11B is an enlarged view of a region of the device of FIG.

Detailed Description
According to this disclosure, "aerosol delivery system" includes both combustible and non-combustible aerosol delivery systems.

In accordance with the present disclosure, a "combustible" aerosol delivery system is one in which an aerosol-generating component of the aerosol delivery system (or a component thereof) is combusted or burned during use to facilitate delivery of at least one substance to a user.

In some embodiments, the present disclosure relates to components for use in combustible aerosol delivery systems, such as filters, filter rods, filter segments, tobacco rods, spills, aerosol modifier-releasing components (such as capsules, threads, or beads), or papers (such as plug wrap, tipping paper, or cigarette paper).

In accordance with the present disclosure, a "non-combustible" aerosol delivery system is one in which the aerosol-generating components of the aerosol delivery system (or components thereof) are not combusted or burned to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as an energy-powered non-combustion aerosol delivery system.

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

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

In some embodiments, the non-combustion aerosol delivery system is a hybrid system for generating 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 solid, liquid, or gel form and may or may not include 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 a non-tobacco product.

Typically, a non-combustible aerosol delivery system may include a non-combustible aerosol delivery device and a consumable for use with the non-combustible aerosol delivery device.

In some embodiments, the present disclosure relates to consumables that include an aerosol generating material and are configured for use with a non-combustible aerosol delivery device. These consumables are sometimes referred to as articles throughout this disclosure.

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

In some embodiments, the non-combustible aerosol delivery system may include a consumable, an aerosol generator, an aerosol generation region, a housing, a mouthpiece, a filter, and/or a region for receiving an aerosol modifier.

In some embodiments, consumables for use with non-combustible aerosol delivery devices may include an aerosol generating material, an aerosol generating material storage region, an aerosol generating material transport component, an aerosol generator, an aerosol generating region, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol modifier.

In some embodiments, the substance to be delivered includes an active agent.

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

In some embodiments, the active agent includes nicotine. In some embodiments, the active agent includes caffeine, melatonin, or vitamin B12.

As described herein, the active agent may include or be derived from one or more botanical substances, or components, derivatives, or extracts thereof. As used herein, the term "botanical substances" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, petioles, roots, seeds, flowers, fruits, pollen, husks, skins, and the like. Alternatively, the material may include active compounds naturally occurring in the botanical substances or synthetically obtained. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cacao, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea (such as green tea or black tea), thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chive, calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mints include Mentha arventis, Grapefruit mint (Mentha c.v.), Egyptian mint (Mentha niliaca), Peppermint (Mentha piperita), Lime mint (Mentha piperita citrate c.v.), Chocolate mint (Mentha piperita c.v.), Curly mint (Mentha spicata crispa), Wild mint (Mentha cardifolia), Horse mint (Mentha longifolia), Pineapple mint (Mentha suaveolens variegata), Pennyroyal mint (Mentha The mint may be selected from the mint varieties Mentha pulegium, English spearmint (Mentha spicata c.v.), and apple mint (Mentha suaveolens).

In some embodiments, the active agent comprises or is derived from one or more botanical substances, or components, derivatives, or extracts thereof, and the botanical substance is tobacco.

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

In some embodiments, the active agent comprises or is derived from one or more botanical substances, or components, derivatives, or extracts thereof, and the botanical substances are selected from rooibos and fennel.

In some embodiments, the substance delivered includes a fragrance.

As used herein, the terms "flavoring agent" and "flavoring agent" refer to materials that can be used in products for adult consumers to create a desired taste, aroma, or other somatic sensation, where permitted by local regulations. They may be naturally occurring flavoring materials, botanical substances, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed, cinnamon, turmeric, Indian spice, Asian spice, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, etc.). citrus, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, ka Shea, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, star anise, cacao, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea (green or black), thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, turmeric, cilantro, myrtle, blackcurrant, balsamic vine, balsamic vine, balsamic vine, balsamic vine, balsamic vine Lien, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. They may be imitation, synthetic, or natural ingredients, or blends thereof. They may be in any suitable form, such as liquids (such as oils), solids (such as powders), or gases.

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

In some embodiments, the flavoring may include sensory agents intended to achieve somatic sensations that are typically chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves, and these may include agents that provide a heating effect, a cooling effect, a tingling effect, or a numbing effect. A suitable heating effect agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol, WS-3.

An aerosol-generating material is a material that can generate an aerosol when, for example, heated, irradiated, or in any other way energized. The aerosol-generating material may be, for example, in the form of a solid, liquid, or gel, which may or may not contain actives and/or flavorings. In some embodiments, the aerosol-generating material may comprise an "amorphous solid" (which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous)). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can hold some fluid therein, such as a liquid. In some embodiments, the aerosol-generating material may comprise, for example, about 50%, 60%, or 70% to about 90%, 95%, or 100% amorphous solid by weight.

The aerosol-generating materials may include one or more active substances and/or flavorings, one or more aerosol-forming materials, and, optionally, one or more other functional materials.

The aerosol-forming material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

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

The material may be on or in a support to form a substrate. The support may be or include, for example, paper, card, corrugated board, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

A consumable is an article that includes or consists of an aerosol-generating material, some or all of which is intended to be consumed by a user during use. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and/or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater that emits heat to cause the aerosol-generating material to generate an aerosol during use. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

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

An aerosol modifier is a substance configured to modify the generated aerosol, for example, by changing the taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided in an aerosol modifier emitting component operable to selectively emit the aerosol modifier.

The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, liquid, or gel. The aerosol modifier may be in the form of a powder, strings, or granules. The aerosol modifier may be free of a filtration material.

The 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 subject the aerosol-generating material to thermal energy, thereby releasing one or more volatile components 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 subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

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

The articles are also designated according to the circumference of the product: "regular" (about 23-25 mm), "wide" (more than 25 mm), "slim" (about 22-23 mm), "demi-slim" (about 19-22 mm), "super slim" (about 16-19 mm), and "micro-slim" (less than about 16 mm).

So, for example, a king size, super slim format item has a length of approximately 83mm and a circumference of approximately 17mm.

Each format may be made with a different length of tip. The tip length will be approximately 30mm to 50mm. The tipping paper connects the tip to the aerosol-generating material and is typically longer than the tip, for example 3-10mm longer, so that the tipping paper covers the tip and overlaps the aerosol-generating material, for example in the form of a rod of substrate material, connecting the tip to the rod.

The articles described herein, as well as their aerosol-generating materials and mouthpieces, can be made into any of the formats described above, including, but not limited to, the above.

As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction of mainstream aerosol being drawn through the article or device when used.

The filament tow materials described herein can include fiber tows of cellulose acetate. The filament tows can also be formed using other materials used to form fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. The filament tow may be plasticized with a suitable plasticizer for the tow, such as triacetin if the material is cellulose acetate tow, or the tow may be unplasticized. The tow may have any suitable specifications, such as fibers having a "Y" or other cross-section, such as an "X" shape, a single fineness value of 2.5 to 15 denier per filament, e.g., 8.0 to 11.0 denier per filament, and a total fineness value of 5,000 to 50,000 denier, e.g., 10,000 to 40,000 denier.

As used herein, the term "tobacco material" refers to any material that includes tobacco or its derivatives or substitutes. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco stems, reconstituted tobacco, and/or tobacco extract.

In the figures described herein, like reference numbers are used to indicate equivalent features, items, or components.

Figure 1 is a cross-sectional side view of an article 1 for use as part of a non-combustible aerosol delivery system.

The article 1 includes an aerosol-generating material 3, in this example a cylindrical rod of tobacco material, and a downstream portion, in this example referred to as tipping 2, connected to the aerosol-generating material 3 so as to be downstream of the aerosol-generating material 3. The aerosol-generating material 3 provides an aerosol when heated in a non-combustible aerosol delivery device (e.g., a non-combustible aerosol delivery device comprising a coil) as described herein, forming a system. In other embodiments, the article 1 can include its own heat source, forming an aerosol delivery system without the need for a separate aerosol delivery device.

The aerosol-generating material 3, also referred to herein as aerosol-generating substrate 3, comprises at least one aerosol-forming material. In this example, the aerosol-forming material is glycerol. In alternative examples, the aerosol-forming material can be another material or a combination thereof as described herein, for example, propylene glycol.

In this example, the mouthpiece includes a tubular portion 4a formed by a hollow tube, also referred to as a cooling element in this example. The mouthpiece 2 includes a component including a body of material 6 downstream of the tubular portion 4a in this example. In this example, the body of material 6 is adjacent to and in abutting relationship with the tubular portion 4a. The body of material 6 and the tubular portion 4a each define a substantially cylindrical overall outer shape and share a common longitudinal axis.

In this example, the body of material 6 of the component is formed from a corrugated sheet material. In this example, the body of material comprises a corrugated sheet material formed to have a corrugated pattern comprising a series of substantially parallel ridges and grooves, with an average spacing between adjacent ridges being greater than about 0.3 mm. Additionally, in this example, the amplitude of the corrugations is less than about 0.7 mm. In other examples, the sheet material can include either an average spacing between adjacent ridges greater than about 0.3 mm, or an amplitude of the corrugations less than about 0.7 mm. Alternatively, the amplitude of the corrugations can be between 0.7 mm and 1.2 mm. In any of these examples, the average density of the body of material can be between about 0.1 and about 0.25 mg/ ^mm3 .

The amplitude of the corrugations (also known as the "crimp factor") refers to the depth of the grooves formed by the corrugation in the sheet material forming the body. That is, the corrugation of the sheet material results in a number of peaks and valleys in the sheet material when viewed from a first side of the sheet material, as shown in FIG. 2B. Here, the amplitude "A" of the corrugations is the depth of the valleys measured from the peaks. The corrugation may form a "zigzag" form or other shape. In some embodiments, the spacing between adjacent grooves in the corrugated sheet material is a distance in the range of 0.3 to 2 mm, preferably in the range of 0.4 to 1 mm, i.e., the pitch [P] is in these ranges. In some embodiments, the spacing between adjacent grooves in the corrugated sheet material is at least 0.4 mm, or at least 0.5, 0.6, 0.7, or 0.8 mm. In some embodiments, the spacing between adjacent grooves of the corrugated sheet material 10 is at most 1.5 mm, preferably at most 1.4, 1.3, 1.2, 1.1, or 1.0 mm. For example, the sheet material can have corrugations with a corrugation amplitude of less than 500 μm apart and a spacing between peaks (or valleys) of at least 300 μm, at least 400 μm, or at least 500 μm.

In some embodiments, the sheet material 10 is heated as it is corrugated. For example, the sheet material 10 may be passed between corrugating rollers, one or both of which are heated.

Advantageously, sheet materials, e.g., paper, having the above-described corrugation pitch and/or amplitude have been found to exhibit improved performance when used in components of an aerosol delivery system. In particular, these relatively small levels of corrugation pitch and amplitude surprisingly result in a lower pressure drop across the body of material compared to bodies formed from sheet materials with greater levels of corrugation.

In this example, the density of the body of material 6 is about 0.19 mg/mm ^3. In some embodiments, the density of the body 6 is at least 0.1 mg/mm ³ , 0.12 mg/mm ³ , or 0.15 mg/mm ³ . Alternatively or additionally, the density of the body of material 6 may be less than about 0.3 mg/mm ³ , less than 0.25 mg/mm ³ , or less than 0.22 mg/mm ³ . Advantageously, the density of the body of material 6 may be from about 0.15 mg/mm ³ to about 0.25 mg/mm ³ . These values include any additives contained within the body of material 6. Prior to being corrugated to form into a body of material, the density of the sheet material may be from about 0.2 to 0.5 mg/mm ³ , for example, about 0.25, 0.30, or 0.35 mg/mm ³ .

In some embodiments, the sheet material comprises fibers having a length in the range of 2 mm to 6 mm. Such fibers have the advantage of being a material that is less likely to absorb and retain aerosol formers (e.g., glycerol as in this example) and/or aerosol modifiers (e.g., menthol). Thus, a body of material comprising such fibers may allow a greater amount of aerosol formers and/or aerosol modifiers to pass through the body of material and reach the mouth of the user. In some embodiments, the body of material comprises fibers having a length in the range of 2 mm to 5 mm, 2 mm to 4 mm, or 2 mm to 3 mm.

The body of material may comprise fibers having a length of one or more of about 2 mm, about 2.5 mm, about 3 mm, about 3.5 mm, about 4 mm, about 4.5 mm, about 5 mm, about 5.5 mm, and about 6 mm.

The fiber length may be measured according to any suitable standard and the fiber length above may be a length-weighted average of the fiber lengths.

The body of material 6 may be formed from a continuous web of sheet material 6A. In this example, the sheet material 6A is pleated to form the body of material 6 in a manner similar to a "crepe filter." The sheet material 6A may be manufactured using a Decoufle™ CU-20 filter manufacturing machine. However, one skilled in the art will appreciate that other machines may be used to manufacture the body of material 6.

In this example, the sheet material 6A includes cellulose. In this example, the sheet material 6A is paper.

In some embodiments, the width of the continuous web of sheet material 6A is at least 60 mm, at least 70 mm, at least 80 mm, at least 90 mm, at least 100 mm, at least 110 mm, or at least 120 mm.

In some embodiments, the width of the continuous web of sheet material 6A is at most 240 mm, at most 230 mm, at most 220 mm, at most 210 mm, at most 200 mm, or at most 190 mm.

In some embodiments, the width of the sheet material is in the range of 120 mm to 200 mm, in the range of 150 mm to 190 mm, in the range of 160 mm to 190 mm, or in the range of 160 mm to 180 mm.

The thickness of the sheet material may be from about 50 to about 100 μm, or from about 60 to about 90 μm. In one example, the sheet material is paper having a thickness of 60 to 70 μm and a basis weight of 30 to 40 g/ ^m2 .

The sheet material 6A may additionally or alternatively comprise different materials. For example, in some embodiments, the sheet material 6A comprises reconstituted tobacco formed into the sheet material 6A arranged to form the body of material 6. The reconstituted tobacco comprises cellulose. In another embodiment (not shown), the reconstituted tobacco is manufactured into a uniform plug of material that forms the body 6. The reconstituted tobacco may optionally be paper reconstituted tobacco.

In some embodiments, the sheet material 6A comprises paper having a basis weight in the range of 15 gm to 80 gsm, or in the range of 20 gsm to 50 gsm.

In some embodiments, the basis weight of the sheet material 6A is at least 15 gsm, at least 20 gsm, at least 25 gsm, or at least 30 gsm.

In some embodiments, the basis weight of the sheet material is 100 gsm or less, 90 gsm or less, 80 gsm or less, or 70 gsm or less. Preferably, the basis weight of the sheet material is 60 gsm or less, 50 gsm or less, or 40 gsm or less.

In some embodiments, the basis weight of the sheet material is in the range of 20 gsm to 40 gsm, in the range of 24 gsm to 36 gsm, or in the range of 30 gsm to 40 gsm.

The body of material 6 is wrapped in a first plug wrap 7. In this example, the tubular section 4a and the body of material 6 are combined using a second plug wrap 9 wrapped around both sections. Tipping paper 5 is wrapped over the entire length of the tipping tip 2 and over a portion of the rod of aerosol-generating material 3 and has adhesive on its inner surface to connect the tipping tip 2 and the rod 3.

In this example, the tubular portion 4a is formed from multiple layers of paper that are rolled in parallel and abutted at seams to form a hollow tube. In this example, the first and second layers of paper are provided in a double tube, but in other examples, three, four, five or more layers of paper can be used to form triple, quadruple, or five or more tubes. Other constructions can be used, such as spirally rolled paper layers, cardboard tubes, tubes formed using a paper mache type process, molded or extruded plastic tubes, etc.

In some embodiments, the wall thickness of the tubular portion is at least about 150 μm up to about 2 mm, 200 μm to 1.5 mm, or 250 μm to 1 mm. In this example, the wall thickness of the tubular portion is about 300 μm. The "wall thickness" of the tubular portion corresponds to the radial wall thickness of the tubular portion. This can be measured, for example, using a vernier caliper.

The ventilation level of the article 1 is about 75% of the aerosol drawn through the article. In alternative embodiments, the ventilation level of the article can be 50% to 80%, for example 65% to 75%, of the aerosol drawn through the article. These levels of ventilation help to slow down the flow of aerosol drawn through the mouthpiece 2, so that the temperature of the aerosol can be sufficiently reduced before it reaches the downstream end 2b of the mouthpiece 2. The ventilation is provided directly into the mouthpiece 2 of the article 1. In this example, the ventilation is provided into the tubular portion 4a, which has been found to be particularly beneficial in aiding the aerosol generation process. The ventilation is provided through first and second parallel rows of ventilation holes 12, formed as laser drillings, located in this case 13.925 mm and 14.625 mm from the downstream mouth end 2b of the mouthpiece 2, respectively. These ventilation holes 12 pass through the tipping paper 5, the second plug wrap 9, and the tubular portion 4a. In alternative embodiments, ventilation may be provided in other locations within the mouthpiece. For example, ventilation may be provided within the body of material 6.

Alternatively, ventilation can be provided through a single row of ventilation holes, e.g., laser drilled, within the portion of the article in which the tubular body 4a is located. This has been found to improve aerosol formation, believed to be due to a more uniform airflow through these vents than multiple rows of ventilation holes for a given ventilation level.

In some examples, the aerosol-generating material 3 described herein may be a first aerosol-generating material and the tubular portion 4a may include a second aerosol-generating material. In one example, the wall 4b of the tubular portion 4a includes the second aerosol-generating material. For example, the second aerosol-generating material may be disposed on an inner surface of the wall 4b of the tubular portion 4a.

The second aerosol-generating material includes at least one aerosol-forming material and also includes at least one aerosol modifier or other sensory material. The aerosol-forming material and/or aerosol modifier can be any or a combination of aerosol-forming materials or aerosol modifiers as described herein.

When the aerosol generated from the aerosol-generating material 3, referred to herein as the first aerosol, is drawn through the tubular portion 4a of the mouthpiece, heat from the first aerosol can aerosolize the aerosol-forming material of the second aerosol-generating material to form a second aerosol. The second aerosol may include a flavoring, which may be any of the flavorings described herein, in addition to or to complement the flavor of the first aerosol.

By applying a second aerosol-generating material to the tubular body 4a, a second aerosol can be produced that enhances or complements the flavor or appearance of the first aerosol.

In this example, the circumference of the article 1 is about 21 mm (i.e., the article is in a demi-slim format). In some embodiments, the article 1 has a rod of aerosol-generating material with a circumference greater than 19 mm. This has been found to provide a sufficient circumference to generate improved and sustained aerosol over a typical aerosol generating session preferred by consumers. When the article is heated, heat is conducted through the rod of aerosol-generating material 3, volatilizing the rod's components, and circumferences greater than 19 mm have been found to be particularly effective in generating aerosol in this manner. Because the article is heated to release the aerosol, using an article with a circumference less than about 23 mm can improve heating efficiency. To achieve improved aerosol upon heating while maintaining a suitable product length, a rod circumference greater than 19 mm and less than 23 mm is preferred. In some examples, the rod circumference can be between 20 mm and 22 mm, which has been found to provide a good balance between providing effective aerosol delivery and allowing efficient heating.

The circumference of the tip 2 is substantially the same as the circumference of the rod of aerosol-generating material 3, resulting in a smooth transition between these components. In this example, the circumference of the tip 2 is approximately 20.8 mm.

In some examples, the tipping paper 5 includes a citrate salt, such as sodium citrate or potassium citrate. In such examples, the citrate content of the tipping paper 5 may be 2% by weight or less, or 1% by weight or less. It is believed that reducing the citrate content of the tipping paper 5 helps reduce charring that may occur during use.

In this example, the tipping paper 5 extends 5 mm over the rod of aerosol-generating material 3, but alternatively it may extend 3 mm to 10 mm, or 4 mm to 6 mm over the rod 3 to ensure adhesion between the tipping tip 2 and the rod 3. The basis weight of the tipping paper 5 may be greater than the basis weight of the plug wrap used in the article 1, for example 40 gsm to 80 gsm, or 50 gsm to 70 gsm, in this example 58 gsm. In these basis weight ranges, the tipping paper has been found to be flexible enough to be wrapped around the article 1 and adhered to itself along the longitudinal lap seam of the paper, whilst having acceptable tensile strength. The circumference of the tipping paper 5 when wrapped around the tipping tip 2 is approximately 21 mm.

In some embodiments, the basis weight of the first plug wrap 7 is less than 50 gsm, for example, between about 20 gsm and 40 gsm. However, it should be appreciated that the basis weight of the first plug wrap 7 may be greater to increase tip stiffness. For example, the basis weight of the first plug wrap 7 may be at least 50 gsm, at least 60 gsm, at least 70 gsm, at least 80 gsm, at least 90 gsm, or at least 100 gsm. In some embodiments, the basis weight of the first plug wrap 7 is in the range of 50 gsm to 110 gsm, or in the range of 60 gsm to 100 gsm.

In some embodiments, the basis weight of the first plug wrap 7 is at least 20 gsm, or at least 30 gsm. In some embodiments, the basis weight of the first plug wrap 7 is at most 120 gsm, 110 gsm, or 100 gsm. In some embodiments, the basis weight of the first plug wrap 7 is in the range of 20 gsm to 120 gsm, or in the range of 30 to 100 gsm.

In some embodiments, the thickness of the first plug wrap 7 is between 30 μm and 60 μm, or between 35 μm and 45 μm. However, it should be recognized that the thickness weight of the first plug wrap 7 may be greater to increase the stiffness of the mouthpiece. In some embodiments, for example, the thickness of the first plug wrap 7 may be at least 40 microns, 50 microns, 60 microns, 70 microns, 80 microns, 90 microns, or 100 microns. In some embodiments, the thickness of the first plug wrap 7 is in the range of 40 microns to 120 microns, or in the range of 50 to 100 microns.

In some embodiments, the first plug wrap 7 is a non-porous plug wrap having a permeability of, for example, less than 100 Coresta units, such as less than 50 Coresta units. However, in other embodiments, the first plug wrap 7 can be a porous plug wrap having a permeability of, for example, greater than 200 Coresta units.

In some embodiments, the length of the body of material 6 is less than about 20 mm. In this example, the length of the body of material 6 is about 12 mm.

In some embodiments, the axial length of the body of material 6 ranges from 10 mm to 20 mm.

In some embodiments, the aerosol-forming material is applied to the body of material 6. For example, the aerosol-forming material may be applied to the sheet of material 6A before the sheet of material 6A is folded to form the body of material 6. The aerosol-forming material may be sprayed onto the sheet of material 6A or may be applied by a brush or by dipping the sheet of material 6 into the aerosol-forming material.

In some embodiments, the aerosol forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. For example, the aerosol forming material may include triacetin and/or triethyl citrate.

In some embodiments, at least 0.02 mg of aerosol-forming material is applied to the body of material per mm of axial length of the body of material. In some embodiments, at least 0.03 mg, at least 0.04 mg, or at least 0.05 mg of aerosol-forming material is applied to the body of material per mm of axial length of the body of material.

In some embodiments, 0.5 mg or less of aerosol-forming material is applied to the body of material per mm of axial length of the body of material. In some embodiments, 0.4 mg or less or 0.3 mg or less of aerosol-forming material is applied to the body of material per mm of axial length of the body of material.

At least some of the aerosol-forming material mixes with the aerosol as it passes through the body of material 6, helping the aerosol feel less dry in the user's mouth.

In some embodiments, the outer volume of the body of material 6 is at least 115 ^mm3 . In this example, the body of material 6 is generally cylindrical and therefore has a generally cylindrical outer volume. It should be appreciated that in other embodiments, the outer volume of the body of material 6 may be less than 115 ^mm3 .

In this example, the width W1 of the body of material 6 (which in this example corresponds to the diameter of the body of material 6) is about 6.36 mm, and the axial length L1 of the body of material 6 is 12 mm. The outer volume of the body of material 6 is therefore about 381 ^mm3 .

It has been found that the body of material 6A comprising cellulose and having a volume of at least 115 ^mm3 serves to remove moisture from the aerosol generated by the aerosol-generating material 3 as the aerosol passes through the body of material 6A of the mouthpiece 2. That is, the cellulose comprising sheet material 6A absorbs water from the aerosol. By removing moisture from the aerosol, the aerosol feels cooler in the user's mouth.

In some embodiments, the volume of the body of material 6 is at least ¹⁹ mm3 per mm of axial length of the body of material, at least 25 mm3 per ^mm of axial length, or at least 30 ^mm3 per mm of axial length. For example, if the volume of the body of material 6 is 19 mm3 per ^mm of axial length and the length L1 is 10 mm, then the volume of the body of material will be 190 ^mm3 .

The larger the volume of the body of material 6A, the more effective it will generally be at removing moisture from the aerosol. In some examples, the outer volume of the body of material 6A is at least 200 ^mm3 , at least 300 ^mm3 , at least 400 ^mm3 , at least 500 ^mm3 , at least 600 ^mm3 , at least 700 ^mm3 , at least 800 ^mm3 , at least 900 ^mm3 , or at least 1000 ^mm3 .

In some embodiments, the axial length L1 of the body of material 6 is at least 4 mm, at least 5 mm, at least 6 mm, at least 7 mm, at least 8 mm, at least 9 mm, or at least 10 mm.

In some embodiments, the axial length L1 of the body of material 6 ranges from 5 mm to 20 mm, 6 mm to 15 mm, or 8 mm to 14 mm.

In some embodiments, the width W1 of the body of material 6 is at least 4 mm, at least 5 mm, at least 6 mm, at least 7 mm, at least 8 mm, or at least 9 mm.

In some embodiments, the circumference of the body of material 6 is at least 16 mm, at least 18 mm, at least 20 mm, at least 22 mm, at least 25 mm, or at least 26 mm.

In some embodiments, the pressure drop across the body of material 6 is at least 2 mm water column, at least 3 mm water column, or at least 4 mm water column. The pressure drop across the body of material may be at least 5 mm water column, at least 6 mm water column, at least 7 mm water column, at least 8 mm water column, at least 9 mm water column, at least 10 mm water column, or at least 11 mm water column.

In some embodiments, the pressure drop across the body of material 6 is less than 30 mm of water, less than 28 mm of water, or less than 25 mm of water.

In some embodiments, the pressure drop across the body of material 6 is about 20 mm water column, 23 mm water column, or 28 mm water column.

In some embodiments, the pressure drop across the body of material 6 is in the range of 10 mm water column to 30 mm water column, or in the range of 15 mm water column to 25 mm water column.

In some embodiments, the pressure drop across the body of material 6 is at least 1.0 mm of water per mm of axial length of the body of material 6. In some embodiments, the pressure drop across the body of material 6 is at least 1.2 mm of water, 1.5 mm of water, or 1.8 mm of water per mm of axial length of the body of material 6.

In some embodiments, the pressure drop across the body of material 6 is less than 3.0 mm, 2.8 mm, or 2.6 mm of water per mm of axial length of the body of material 6. In some embodiments, the pressure drop across the body of material 6 is less than 2.5 mm, 2.4 mm, or 2.3 mm of water per mm of axial length of the body of material 6.

In some embodiments, the pressure drop across the body of material 6 is in the range of 1.5 mm water column to 2.5 mm water column per mm axial length of the body of material 6, or in the range of 1.6 to 2.4 mm WG per mm axial length of the body of material 6.

In some embodiments, the mass of the body of material 6 is at least 50 mg, at least 60 mg, or at least 70 mg. It has been advantageously found that providing a body of material 6 with a larger mass results in a greater amount of moisture being absorbed from the aerosol. In this example, the mass of the body of material is about 75 mg.

In some embodiments, the mass of the body of material 6 is less than 150 mg, less than 100 mg, less than 85 mg, or less than 80 mg.

In some embodiments, the weight of the body of material 6 is at least 2 mg per mm of axial length of the body of material. In some embodiments, the weight of the body of material 6 is at least 3 mg per mm of axial length, or at least 4 mg per mm of axial length.

In this example, the weight of the material body 6 is approximately 6 mg per mm. That is, in this example, when the axial length L1 of the material body 6 is 12 mm, the total mass of the material body 6 is approximately 74 mg.

In some embodiments, the body of material 6 is a solid, cylindrical body of material.

In some embodiments, the hardness of the tip 2 is in the range of about 80% to 95%, or in the range of about 85% to 90%. The hardness of the tip 2 may be at least 80%, at least 81%, at least 82%, at least 83%, at least 84%, at least 85%, at least 86%, at least 87%, at least 88%, at least 89%, at least 90%, at least 91%, or at least 92%.

The hardness of the mouthpiece 2 can be measured according to the following protocol. When the hardness of a section is referred to herein, the hardness is as determined by the following measurement process. Measurements may be made using any suitable device, such as a Borgwaldt Hardness Tester H10.

Hardness is defined as the ratio of the body height h0 to the body height h1 under a given load and is stated as a percentage of h0. Hardness can be expressed as:
Hardness = (h1/h0) x 100
For individual bodies, or bodies contained in a multi-section rod, the hardness measurement is taken at the longitudinal center of the body.

A load bar is used to apply a predetermined load to the body. The length of the load bar should be significantly longer than the specimen being measured. The body being measured is conditioned in accordance with ISO 3402 for a minimum of 48 hours prior to hardness measurement and is maintained at the environmental conditions according to ISO 3402 during the measurement.

To perform the hardness measurement, the body is placed in a Hardness Tester H10, a preload of 2 g is applied to the body, and after 1 second, the initial height of the body under the 2 g preload, h0, is recorded. The preload is then removed, a load bar carrying a load of 150 g is lowered onto the sample at a rate of 0.6 mm/s, and after 5 seconds, the height of the body under the 150 g load, h1, is measured.

Tip hardness is determined as the average hardness of at least 20 tips measured according to this protocol.

The hardness of the body of material 6 surrounded by the first plug wrap 7 (hereinafter collectively referred to as the "component" for purposes of determining hardness) may also be determined using the above protocol by carefully cutting the article to remove the body of material 6 surrounded by the first plug wrap 7. The hardness of the component may be at least 80%, at least 81%, at least 82%, at least 83%, at least 84%, at least 85%, at least 86%, at least 87%, at least 88%, at least 89%, at least 90%, at least 91%, or at least 92%.

The term "circularity" refers to the proportion of the cross-sectional shape of an article/component that conforms to a perfect circle. Circularity is calculated according to Equation 1 below.

To determine the circularity of the article 1, the maximum outer diameter "X" of the component is measured using a vernier caliper, and the minimum outer diameter "Y" of the article is measured using a vernier caliper (these diameters are perpendicular to the central axis of the article 1). The smaller the deviation between the maximum outer diameter X and the minimum outer diameter Y of the article 1, the higher the circularity, which indicates that the cross-sectional shape of the article 1 is closer to a perfect circle.

In some embodiments, the circularity of article 1 is at least 90%, at least 91%, at least 92%, at least 93%, at least 94%, or at least 95%.

The hardness of the body of material 6 surrounded by the first plug wrap 7 (hereinafter collectively referred to as the "component" for purposes of determining circularity) may also be determined using the above protocol by carefully cutting the article to remove the body of material 6 surrounded by the first plug wrap 7.

To determine the circularity of the body of material 6 surrounded by the first plug wrap 7 (hereinafter collectively referred to as the "component" for purposes of determining circularity), the maximum outer diameter "X" of the component is measured using a vernier caliper, and the minimum outer diameter "Y" of the component is measured using a vernier caliper (these diameters are perpendicular to the central axis of the component). The smaller the deviation between the maximum outer diameter X and the minimum outer diameter Y of the component, the higher the circularity, which indicates that the cross-sectional shape of the component is closer to being perfectly circular.

In some embodiments, the circularity of the component (i.e., the circularity of the body of material 6 surrounded by the first plug wrap 7) is at least 90%, at least 91%, at least 92%, at least 93%, at least 94%, or at least 95%.

This high circularity helps ensure that downstream parts can be processed reliably, as if the article/component was not highly circular, the downstream parts would become too oval and jam or become misaligned in the manufacturing machinery.

The first plug wrap 7 and/or the second plug wrap 9 can be glued around the component(s) of the article by adhesive applied to a wrap seam extending longitudinally along the first plug wrap and/or the second plug wrap. The first plug wrap 7 and/or the second plug wrap 9 can alternatively or additionally be glued directly to the underlying component(s) using adhesive. In both cases, the adhesive can be selected to be a water-soluble adhesive to aid in the decomposition of the component(s). Additionally or alternatively, the first plug wrap 7 and/or the second plug wrap 9 can be formed from paper or other materials with improved degradability, e.g., improved dispersibility when exposed to water.

Biodegradability can be measured according to the procedures set forth in ISO 14855. Components as described herein can achieve greater than 50% biodegradation in 30 days when exposed to either fresh water or salt water.

In some embodiments, the length of tubular portion 4a is less than about 50 mm. In some embodiments, the length of tubular portion 4a is less than about 40 mm. In some embodiments, the length of tubular portion 4a is less than about 35 mm. Additionally or alternatively, the length of tubular portion 4a is at least about 10 mm. In some embodiments, the length of tubular portion 4a is at least about 15 mm.

In some embodiments, the length of the tubular portion 4a is about 15 mm to about 35 mm, about 20 mm to about 30 mm, about 23 mm to about 29 mm, or about 25 mm or about 29 mm. In this example, the length of the tubular portion 4a is 25 mm.

In some embodiments, the basis weight of the second plug wrap 9 is less than 50 gsm. In some embodiments, the basis weight of the second plug wrap 9 is between about 20 gsm and 45 gsm. However, it should be appreciated that the basis weight of the second plug wrap 9 may be greater to increase tip hardness. For example, the basis weight of the second plug wrap 9 may be at least 50 gsm, at least 60 gsm, at least 70 gsm, at least 80 gsm, at least 90 gsm, or at least 100 gsm. In some embodiments, the basis weight of the second plug wrap 9 is in the range of 50 gsm to 110 gsm, or in the range of 60 gsm to 100 gsm.

In some embodiments, the basis weight of the second plug wrap 9 is at least 10 gsm, at least 15 gsm, at least 20 gsm, or at least 25 gsm.

In some embodiments, the basis weight of the second plug wrap 9 is less than 40 gsm, less than 35 gsm, or less than 30 gsm.

In some embodiments, the basis weight of the second plug wrap 9 is in the range of 10-40 gsm, in the range of 15-35 gsm, in the range of 20-30 gsm, or in the range of 25-30 gsm. In some embodiments, the basis weight of the second plug wrap 9 is about 27 gsm.

In some embodiments, the thickness of the second plug wrap 9 is between 30 μm and 60 μm, or between 35 μm and 45 μm. However, it should be appreciated that the thickness of the second plug wrap 9 may be greater to increase tip hardness. In some embodiments, for example, the thickness of the second plug wrap 9 may be at least 40 microns, at least 50 microns, at least 60 microns, at least 70 microns, at least 80 microns, at least 90 microns, or at least 100 microns. In some embodiments, the thickness of the second plug wrap 9 is in the range of 40 microns to 120 microns, or in the range of 50 microns to 100 microns.

In some embodiments, the second plug wrap 9 is a non-porous plug wrap having a permeability of less than 100 Coresta units, for example less than 50 Coresta units. However, in alternative embodiments, the second plug wrap 9 may be a porous plug wrap having a permeability of, for example, greater than 200 Coresta units.

The tubular portion 4a is disposed around and defines a cavity that functions as a cooling segment within the mouthpiece 2. The cavity provides a chamber through which the heated volatile components generated by the aerosol-generating material 3 flow. The tubular portion 4a is hollow to provide a chamber for storing the aerosol, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and when the article 1 is in use. The tubular portion 4a provides physical spacing between the aerosol-generating material 3 and the body of material 6. This physical spacing provided by the tubular portion 4a creates a thermal gradient across the length of the tubular portion 4a.

In some embodiments, the tipping tip 2 comprises a cavity having an internal volume greater than 450 mm ^3. It has been found that by providing a cavity of at least this volume, the formation of the aerosol can be improved. Such a cavity size provides sufficient space within the tipping tip 2 to allow the heated volatile components to cool, and thus allow the aerosol-generating material 3 to be exposed to a higher temperature than would otherwise be possible (which would otherwise result in an aerosol that is too hot). In this example, the cavity is formed by the tubular portion 4a, but in alternative configurations it can be formed within a different portion of the tipping tip 2. In some embodiments, the tipping tip 2 comprises a cavity formed, for example, within the tubular portion 4a, having an internal volume greater than 500 mm ³ , for example greater than 550 mm ³ , which can further improve the aerosol. In some embodiments, the internal cavity comprises a volume of about 550 mm ³ to about 850 mm ³ , or about 600 mm ³ to about 800 mm ^3. In this example, the volume of the internal cavity of the tubular portion 4a is about 762 mm ³ .

The tubular portion 4a can be configured to provide a temperature difference of at least 40° C. between the heated volatile component entering the first upstream end of the tubular portion 4a and the heated volatile component exiting the second downstream end of the tubular portion 4a. In some embodiments, the tubular portion 4a is configured to provide a temperature difference of at least 60° C., at least 80° C., or at least 100° C. between the heated volatile component entering the first upstream end of the tubular portion 4a and the heated volatile component exiting the second downstream end of the tubular portion 4a. This temperature difference over the length of the tubular portion 4a protects the temperature-sensitive body of material 6 from the high temperatures of the aerosol-generating material 3 when heated.

In an alternative article, the tubular portion 4a may be replaced by an alternative cooling element, for example an element formed from a body of material through which the aerosol can pass longitudinally and which also functions to cool the aerosol.

The mouthpiece 2 of the article 1 has an upstream end 3a adjacent to the aerosol-generating substrate 3 and a downstream end 2b distal to the aerosol-generating substrate 3.

The pressure drop or pressure difference (also referred to as resistance to draw) at the tip, e.g., at a portion of the article 1 downstream of the aerosol-generating material 3, is less than about 40 mm of water column. It has been found that such a pressure drop allows sufficient aerosol, including desirable compounds, such as flavor compounds, to pass through the tip 2 and reach the consumer. In some embodiments, the pressure drop at the tip 2 is less than about 20 mm of water column. In some embodiments, particularly improved aerosols have been achieved using a tip 2 having a pressure drop of less than 15 mm of water column, e.g., about 6 mm of water column, about 10 mm of water column, or about 14 mm of water column. Alternatively or additionally, the pressure drop at the tip can be at least 3 mm of water column, at least 4 mm of water column, or at least 5 mm of water column. In some embodiments, the pressure drop at the tip can be between about 5 mm of water column and 20 mm of water column, or between 5 mm of water column and 15 mm of water column. These values allow the aerosol to be decelerated at the mouthpiece 2 as it passes through it, so that the temperature of the aerosol has time to drop before it reaches the downstream end 2b of the mouthpiece 2.

In this example, the aerosol-generating material 3 is wrapped in a wrapper 10. The wrapper 10 may be, for example, a paper or paper-backed foil wrapper. In this example, the wrapper 10 is substantially air-impermeable. In alternative embodiments, the wrapper 10 has a permeability of less than 100 Coresta units or less than 60 Coresta units. It has been found that using a less permeable wrapper, for example a wrapper with a permeability of less than 100 Coresta units or less than 60 Coresta units, improves the formation of an aerosol with the aerosol-generating material 3. Without wishing to be bound by theory, it is hypothesized that this is due to reduced loss of aerosol compound through the wrapper 10. The permeability of the wrapper 10 may be measured in accordance with ISO 2965:2009 for measurement of air permeability of materials used as cigarette paper, filter plug wrap, and filter bonding paper.

In this embodiment, the wrapper 10 comprises aluminum foil. Aluminum foil has been found to be particularly effective in enhancing the formation of aerosol within the aerosol-generating material 3. In this example, the aluminum foil has a metal layer about 6 μm thick. In this example, the aluminum foil has a paper backing. However, in alternative configurations, the aluminum foil can be of other thicknesses, for example, between 4 μm and 16 μm thick. The aluminum foil also need not have a paper backing, but could have a backing formed from another material, for example, that helps to give the foil adequate tensile strength, or no backing material. Metal layers or foils other than aluminum can also be used. The total thickness of the wrapper is between 20 μm and 60 μm, or between 30 μm and 50 μm, which allows the wrapper to have adequate structural integrity and heat transfer properties. The tensile force that can be applied to the wrapper before it breaks can be greater than 3,000 grams, for example, between 3,000 and 10,000 grams, or between 3,000 and 4,500 grams.

In some examples, the wrapper 10 surrounding the aerosol-generating material 3 has a high level of permeability, for example, greater than about 1000 Coresta units, or greater than about 1500 Coresta units, or greater than about 2000 Coresta units. The permeability of the wrapper 10 can be measured in accordance with ISO 2965:2009 for measurement of air permeability of materials used as cigarette papers, filter plug wraps, and filter bonding papers.

The wrapper 10 may be formed from a material that has a high level of inherent permeability, an inherently porous material, or may be formed from a material that has any level of inherent permeability, where the final level of permeability is achieved by providing the wrapper 10 with permeable areas or regions. By providing a permeable wrapper 10, a path for air to enter the article is provided. The wrapper 10 may be permeable such that the amount of air entering through the rod of aerosol-generating material is relatively greater than the amount of air entering the article through the mouthpiece vent 12. Articles having this configuration may produce a better tasting aerosol, which may be more satisfying to the user.

In this example, the aerosol-forming material added to the aerosol-generating substrate 3 constitutes 14% by weight of the aerosol-generating substrate 3. In some embodiments, the aerosol-forming material constitutes at least 5% by weight of the aerosol-generating substrate, or at least 10% by weight of the aerosol-generating substrate. In some embodiments, the aerosol-forming material constitutes less than 25% by weight of the aerosol-generating substrate, or less than 20%, for example, between 10% and 20%, between 12% and 18%, or between 13% and 16%.

In some embodiments, the aerosol-generating material 3 is provided as a cylindrical rod of aerosol-generating material. Regardless of the form of the aerosol-generating material, the length can be between about 10 mm and 100 mm. In some embodiments, the length of the aerosol-generating material is in the range of about 25 mm and 50 mm, in the range of about 30 mm and 45 mm, or in the range of about 30 mm and 40 mm.

In some examples, the article 1 may be configured such that there is a spacing (i.e., a minimum distance) between the heater of the non-combustible aerosol delivery device 100 and the tubular body 4a. This prevents the heat of the heater from damaging the material forming the tubular body 4a.

The minimum distance between the heater and the tubular body 4a of the non-combustible aerosol delivery device 100 may be about 3 mm or more. In some examples, the minimum distance between the heater and the tubular body 4a of the non-combustible aerosol delivery device 100 may be in the range of 3 mm to 10 mm, e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm.

The spacing between the heater of the non-combustible aerosol delivery device 100 and the tubular body 4a may be achieved, for example, by adjusting the length of the rod of aerosol-generating material 3.

The volume of aerosol-generating material 3 provided can vary from about 200 ^mm to about 4300 ^mm , from about 500 ^mm to 1500 ^mm , or from about 1000 ^mm to about 1300 ^mm . Providing aerosol-generating material in ^these volumes, for example from about 1000 ^mm to about 1300 mm, has been advantageously shown to achieve superior aerosols with better visibility and sensory performance when compared to those achieved with volumes selected from the lower end of this range.

The mass of aerosol-generating material 3 provided may be greater than 200 mg, for example between about 200 mg and 400 mg, between about 230 mg and 360 mg, or between about 250 mg and 360 mg. Providing a greater mass of aerosol-generating material has been found to advantageously improve sensory performance when compared to aerosols generated from a smaller mass of tobacco material.

In some embodiments, the aerosol-generating material or substrate is formed from a tobacco material, as described herein, that includes a tobacco component.

In the tobacco materials described herein, the tobacco components may include reconstituted tobacco. The tobacco components may also include leaf tobacco, extruded tobacco, and/or band-cast tobacco.

The aerosol-generating material 3 may include a regenerated tobacco material having a density of less than about 700 milligrams per cubic centimeter (700 mg/cc). Such tobacco materials have been found to be particularly effective in providing an aerosol-generating material that can be heated quickly to release an aerosol, as compared to denser materials. For example, the inventors have tested the properties of various aerosol-generating materials, such as band-cast regenerated tobacco materials and paper regenerated tobacco materials, upon heating. It has been found that for each given aerosol-generating material, during the application of heat to the material, there is a particular temperature below which the net heat flow is endothermic, i.e., more heat enters the material than leaves it, and above which the net heat flow is exothermic, i.e., more heat leaves the material than enters it. The zero heat flow temperature for materials with a density less than 700 mg/cc was low. Since a significant portion of the heat flow leaving the material is due to the formation of the aerosol, a lower temperature at which the heat flow reaches zero has a beneficial effect on the time it takes to initially release the aerosol from the aerosol-generating material. For example, aerosol-generating materials with densities below 700 mg/cc have been found to have a lower temperature at which the heat flow reaches zero than 164° C. compared to materials with densities above 700 mg/cc (which have a higher temperature at which the heat flow reaches zero than 164° C.).

The density of the aerosol-generating material also affects the rate at which heat is transferred through the material; lower densities, e.g., below 700 mg/cc, will slow the rate at which heat transfers through the material, and therefore the aerosol emission can be sustained for longer.

The aerosol-forming material 3 may comprise a reconstituted tobacco material, such as a paper reconstituted tobacco material, having a density of less than about 700 mg/cc. In some embodiments, the aerosol-forming material 3 comprises a reconstituted tobacco material having a density of less than about 600 mg/cc. Alternatively or additionally, the aerosol-forming material 3 may comprise a reconstituted tobacco material having a density of at least 350 mg/cc that is believed to be capable of transmitting a sufficient amount of heat through the material.

The tobacco material may be provided in the form of cut rag tobacco. The cut rag tobacco may have a cut width of at least 15 cuts per inch (about 5.9 cuts per cm, equivalent to a cut width of about 1.7 mm). In some embodiments, the cut rag tobacco has a cut width of at least 18 cuts per inch (about 7.1 cuts per cm, equivalent to a cut width of about 1.4 mm), or at least 20 cuts per inch (about 7.9 cuts per cm, equivalent to a cut width of about 1.27 mm). In one example, the cut rag tobacco has a cut width of 22 cuts per inch (about 8.7 cuts per cm, equivalent to a cut width of about 1.15 mm). The cut rag tobacco may have a cut width of no more than 40 cuts per inch (about 15.7 cuts per cm, equivalent to a cut width of about 0.64 mm). It has been found that a cut width of 0.5 mm to 2.0 mm, for example 0.6 mm to 1.5 mm, or 0.6 mm to 1.7 mm, provides a suitable tobacco material in terms of surface area to volume ratio of the substrate 3, as well as overall density and pressure drop, especially when heated. The cut rag tobacco can be formed from a mixture of tobacco material forms, such as one or more of reconstituted tobacco, leaf tobacco, extruded tobacco, and band cast tobacco. In some embodiments, the tobacco material comprises reconstituted tobacco or a mixture of reconstituted tobacco and leaf tobacco.

In the tobacco materials described herein, the tobacco material may include a filler component. The filler component is generally a non-tobacco component, i.e., a component that does not include tobacco-derived components. The filler component may be a non-tobacco fiber, such as wood fiber or pulp or wheat fiber. The filler component may also be an inorganic material, such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, etc. The filler component may also be a non-tobacco cast material or a non-tobacco extrusion material. The filler component may be present in an amount of 0-20% by weight of the tobacco material, or 1-10% by weight of the composition. In some embodiments, no filler component is present.

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

The aerosol-forming material may be included in any component of the tobacco material, for example any tobacco component and/or filler component (if any). Alternatively or additionally, the aerosol-forming material may be added separately to the tobacco material. In either case, the total amount of aerosol-forming material in the tobacco material may be as defined herein.

The tobacco material may comprise 10% to 90% by weight of tobacco leaf, with the aerosol-forming material being provided in an amount of up to about 10% by weight of the tobacco leaf. It has been found advantageously that it can be added to another component of the tobacco material, such as reconstituted tobacco material, in a greater weight percentage, so that the overall level of aerosol-forming material is 10% to 20% by weight of the tobacco material.

The tobacco material described herein includes nicotine. The nicotine content may be 0.5-1.75% by weight of the tobacco material, for example 0.8-1.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material includes 10%-90% by weight of tobacco leaf having a nicotine content of greater than 1.5% by weight of the tobacco leaf. It has been advantageously found that the use of tobacco leaf having a nicotine content of greater than 1.5% in combination with a lower nicotine base material, such as reconstituted tobacco, results in a tobacco material having an adequate nicotine level, but with better sensory performance than reconstituted tobacco alone. Tobacco leaf, for example cut rag tobacco, may have a nicotine content of, for example, 1.5%-5% by weight of the tobacco leaf.

The tobacco material described herein may include an aerosol modifier, such as any of the flavourings described herein. In one embodiment, the tobacco material includes menthol to form a mentholated article. The tobacco material may include 3 mg to 20 mg menthol, 5 mg to 18 mg, or 8 mg to 16 mg menthol. In this example, the tobacco material includes 16 mg menthol. The tobacco material may include 2% to 8% menthol, 3% to 7% menthol, or 4% to 5.5% menthol by weight. In one embodiment, the tobacco material includes 4.7% menthol by weight. Such high levels of menthol may be achieved by using a high proportion of reconstituted tobacco material, for example greater than 50% by weight of the tobacco material. Alternatively or additionally, high levels of menthol may be achieved by using a large amount of aerosol-forming material, e.g. tobacco material, e.g. in this case greater than about 500 ^mm3 , or preferably greater than about 1000 ^mm3 of aerosol-forming material, such as tobacco material, is used.

In the compositions described herein, when amounts are given in weight percent, this refers to dry weight, unless specifically indicated otherwise, for the avoidance of doubt. Any water that may be present in the tobacco material or any component is therefore completely ignored for the purposes of determining the weight percent. The moisture content of the tobacco materials described herein may vary, and may be, for example, 5-15% by weight. The moisture content of the tobacco materials described herein may vary, for example, according to the temperature, pressure, and humidity conditions in which the compositions are kept. The moisture content may be determined by Karl Fischer analysis, as known to those skilled in the art. On the other hand, for the avoidance of doubt, any component other than water is included in the weight of the tobacco material, even when the aerosol-forming material is a component that is in a liquid phase, such as glycerol or propylene glycol. However, when an aerosol-forming material is provided within the tobacco component of the tobacco material or within a filler component (if present) of the tobacco material instead of or in addition to being added separately to the tobacco material, the aerosol-forming material is not included in the weight of the tobacco component or filler component, but is included in the weight of the "aerosol-forming material" in the weight percents 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 reconstituted tobacco).

In one embodiment, the tobacco material comprises a tobacco component as defined herein and an aerosol-forming material as defined herein. In one embodiment, the tobacco material consists essentially of a tobacco component as defined herein and an aerosol-forming material as defined herein. In one embodiment, the tobacco material consists essentially of a tobacco component as defined herein and an aerosol-forming material as defined herein.

The paper reconstituted tobacco is present in the tobacco component of the tobacco material described herein in an amount of 10% to 100% by weight of the tobacco component. In some embodiments, the paper reconstituted tobacco is present in an amount of 10% to 80% by weight, or 20% to 70% by weight of the tobacco component. In further embodiments, the tobacco component consists essentially of paper reconstituted tobacco, or consists of paper reconstituted tobacco. In some embodiments, leaf tobacco is present in the tobacco component of the tobacco material in an amount of at least 10% by weight of the tobacco component. For example, leaf tobacco can be present in an amount of at least 10% by weight of the tobacco component, while the remainder of the tobacco component includes paper reconstituted tobacco, band cast reconstituted tobacco, or a combination of band cast reconstituted tobacco and another form of tobacco, such as tobacco granules.

Reconstituted tobacco paper refers to tobacco material formed by a process in which tobacco raw materials are extracted with a solvent to a residue containing soluble extract and fibrous material, and then the extract (usually after concentration, and optionally after further processing) is recombined with fibrous material from the residue (usually after purification of the fibrous material, and optionally with the addition of a portion of non-tobacco fiber) by depositing the extract onto the fibrous material. This recombination process is similar to the papermaking process.

The reconstituted tobacco paper may be any type of reconstituted tobacco paper known in the art. In certain embodiments, the reconstituted tobacco paper is made from raw materials including one or more of tobacco strips, tobacco stems, and whole tobacco leaves. In further embodiments, the reconstituted tobacco paper is made from raw materials consisting of tobacco strips and/or whole tobacco leaves, and tobacco stems. However, in other embodiments, raw materials may alternatively or additionally include shreds, fines, and husks.

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

In some embodiments, it is particularly advantageous to use a hollow tubular element 8 that is longer than about 10 mm, for example, from about 10 mm to about 30 mm, or from about 12 mm to about 25 mm in length. It has been found that the consumer's lips may in some cases extend up to about 12 mm from the mouth end of the article 1 when inhaling aerosol through the article 1, and therefore a length of the hollow tubular element 8 of at least 10 mm or at least 12 mm means that most of the consumer's lips will surround this element 8.

Figure 3 is a side cross-sectional view of a further article 1' including a tip 2' including a hollow tubular element 8. The tip 2' is substantially the same as the tip 2 described above in connection with Figure 1, except that at the downstream end 2b, the tip 2' includes a hollow tubular element 8 formed from a filament tow. In this example, the tubular portion 4a, the body of material 6, and the hollow tubular element 8 are joined together using a second plug wrap 9 wrapped around all three sections.

The body of material 6 of the article 1' of Figure 3 is similar to the body of material 6 described above in relation to Figures 1 and 2. As before, the body of material 6 is manufactured from a sheet material that includes cellulose, for example the sheet material may be paper. The sheet material is pleated to form the body of material 6.

In this example, the axial length L1 of the body of material 6 is about 10 mm. However, one of ordinary skill in the art will recognize that the axial length L1 of the body of material 6 may vary. In some embodiments, the length L1 of the body of material 6 is less than about 20 mm, or less than 15 mm. In some embodiments, the length L1 of the body of material 6 is less than about 10 mm. Additionally or alternatively, the length L1 of the body of material 6 may be at least about 5 mm. In some embodiments, the length L1 of the body of material 6 is at least about 6 mm. In some embodiments, the length L1 of the body of material 6 is between about 5 mm and about 15 mm, between about 6 mm and about 12 mm. In some embodiments, the length L1 of the body of material is 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm.

The part of the mouthpiece that contacts the consumer's lips is usually a paper tube, which is hollow or surrounds a cylindrical body of filter material. The provision of the hollow tubular element 8 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 that contacts the consumer's mouth when the article 1' is in use. In addition, the use of the tubular portion 4a has also been found to significantly reduce the temperature of the outer surface of the mouthpiece 2', even upstream of the tubular portion 4a. Without wishing to be bound by theory, it is hypothesized that this is due to the tubular portion 4a directing the aerosol closer to the center of the mouthpiece 2', thus reducing the transfer of heat from the aerosol to the outer surface of the mouthpiece 2'. In addition, it has been found that the material body 6 removes moisture from the aerosol generated by the aerosol-generating material 3 as the aerosol passes through the material body 6A of the mouthpiece 2, which makes the aerosol feel cooler in the user's mouth.

In this example, the hollow tubular element 8 is formed from a filament tow. In alternative embodiments, the hollow tubular element may be formed using any of the structures as described herein for the tubular portion 4a.

The "wall thickness" of the hollow tubular element 8 corresponds to the radial wall thickness of the tube 8. This can be measured in the same way as the wall thickness of a tubular portion. The wall thickness is advantageously greater than 0.9 mm, and may be 1.0 mm or greater. In some embodiments, the wall thickness is substantially constant throughout the wall of the hollow tubular element 8. However, if the wall thickness is not substantially constant, the wall thickness may be greater than 0.9 mm, for example 1.0 mm or greater, at any point around the hollow tubular element 8.

The length of the hollow tubular element 8 is less than about 20 mm. In some embodiments, the length of the hollow tubular element 8 is less than about 15 mm. In some embodiments, the length of the hollow tubular element 8 is less than about 10 mm. Additionally or alternatively, the length of the hollow tubular element 8 may be at least about 5 mm. In some embodiments, the length of the hollow tubular element 8 is at least about 6 mm. In some embodiments, the length of the hollow tubular element 8 is between about 5 mm and about 20 mm, between about 6 mm and about 10 mm, or between about 6 mm and about 8 mm. In some embodiments, the length of the hollow tubular element 8 is 6 mm, 7 mm, or 8 mm. In this example, the length of the hollow tubular element 8 is 6 mm.

The density of the hollow tubular element 8 is at least about 0.25 grams per cubic centimeter (0.25 g/cc), such as at least about 0.3 g/cc. In some embodiments, the density of the hollow tubular element 8 is less than about 0.75 grams per cubic centimeter (0.75 g/cc), such as less than 0.6 g/cc. In some embodiments, the density of the hollow tubular element 8 is between 0.25 g/cc and 0.75 g/cc, between 0.3 g/cc and 0.6 g/cc, or between 0.4 g/cc and 0.6 g/cc. In some embodiments, the density of the hollow tubular element 8 is about 0.5 g/cc. These densities have been found to provide a good balance between the improved stiffness provided by the denser material and the lower heat transfer characteristics of the less dense material. For purposes of the present invention, the "density" of the hollow tubular element 8 refers to the density of the filament tow forming the element with any plasticizer incorporated therein. The density can be determined by dividing the total weight of the hollow tubular element 8 by the total volume of the hollow tubular element 8, and the total volume can be calculated using appropriate measurements of the hollow tubular element 8 taken, for example, with a vernier caliper. If necessary, appropriate dimensions may be measured using a microscope.

The total fineness of the filament tows forming the hollow tubular element 8 may be less than 45,000 denier, for example less than 42,000 denier. It has been found that this total fineness allows for the formation of a hollow tubular element 8 that is not too dense. In some embodiments, the total fineness is at least 20,000 denier, for example at least 25,000 denier. In some embodiments, the total fineness of the filament tows forming the hollow tubular element 8 is between 25,000 and 45,000 denier, for example between 35,000 and 45,000 denier. In some embodiments, the cross-sectional shape of the filaments of the tow is "Y" shaped, although in other embodiments, other cross-sectional shapes of filaments such as "X" shaped can be used.

The filament tow forming the hollow tubular element 8 may be thicker than 3 denier per filament. It has been found that this fineness per filament allows for the formation of a hollow tubular element 8 that is not too dense. In some embodiments, the fineness per filament is at least 4 denier, such as at least 5 denier. In some embodiments, the filament tow forming the hollow tubular element 8 is 4 to 10 denier per filament, such as 4 to 9 denier. In one example, the filament tow forming the hollow tubular element 8 is formed from cellulose acetate and has an 8Y40,000 tow with 18% plasticizer, such as triacetin.

The inner diameter of the hollow tubular element 8 may be greater than 3.0 mm. A smaller diameter may increase the velocity of the aerosol passing through the mouthpiece 2' to the consumer's mouth above the desired velocity, which may result in the aerosol becoming too warm, for example reaching a temperature of greater than 40°C or even greater than 45°C. In some embodiments, the inner diameter of the hollow tubular element 8 is greater than 3.1 mm, for example greater than 3.5 mm or 3.6 mm. In one embodiment, the inner diameter of the hollow tubular element 8 is about 3.9 mm.

In some embodiments, the hollow tubular element 8 includes 15% to 22% by weight of plasticizer. For cellulose acetate tow, the plasticizer may be triacetin, although other plasticizers such as polyethylene glycol (PEG) can be used. In some embodiments, the hollow tubular element 8 includes 16% to 20% by weight of plasticizer, for example, about 17%, about 18%, or about 19% plasticizer.

In this example, tubular portion 4a is the first hollow tubular element and hollow tubular element 8 is the second hollow tubular element.

In this example, the ventilation is provided within the tubular portion 4a, as described in connection with FIG. 1. In alternative embodiments, the ventilation can be provided elsewhere in the mouthpiece, for example within the body of material 6 or within the hollow tubular element 8.

In the above example, the mouthpieces 2, 2' each comprise a single body of material 6. In other examples, the mouthpieces 2, 2' may comprise multiple bodies of material. The mouthpieces 2, 2' may comprise cavities between the bodies of material.

In some examples, the tipping tip 2, 2' downstream of the aerosol-generating material 3 can include a wrapper, such as the first plug wrap 7 or the second plug wrap 9, or the tipping paper 5, that includes an aerosol modifier or other sensory material as described herein. The aerosol modifier may be disposed on an inwardly or outwardly facing surface of the tipping tip wrapper. For example, the aerosol modifier or other sensory material may be provided in an area of the wrapper that contacts the consumer's lips during use, such as the outwardly facing surface of the tipping paper 5. By disposing the aerosol modifier or other sensory material on the outwardly facing surface of the tipping tip wrapper, the aerosol modifier or other sensory material may be delivered to the consumer's lips during use. Delivering the aerosol modifier or other sensory material to the consumer's lips during use of the article can change the organoleptic properties (e.g., taste) of the aerosol generated by the aerosol-generating substrate 3 or can otherwise provide the consumer with an alternative sensory experience. For example, the aerosol modifier or other sensory material may provide a flavor to the aerosol generated by the aerosol-generating substrate 3. The aerosol modifier or other sensory material may be at least partially water-soluble so as to be transferred to the user by the consumer's saliva. The aerosol modifier or other sensory material may be volatilized by the heat generated by the aerosol delivery system, which may facilitate transfer of the aerosol modifier to the aerosol generated by the aerosol-generating substrate 3. Suitable sensory materials may be flavors, sucralose, or cooling agents such as menthol, as described herein.

In some embodiments (not shown), the mouthpiece 2, 2' may comprise an aerosol modifier emitting component operable to emit the aerosol modifier. In some embodiments, the aerosol modifier emitting component may be operable to selectively emit the aerosol modifier. As discussed above, the body of material 6 may comprise fibers having a length in the range of 2 mm to 6 mm, which results in the body of material 6 being less likely to absorb a particular aerosol modifier as it is emitted from the aerosol modifier emitting component.

The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, liquid, or gel. The aerosol modifier may be in the form of a powder, strings, or granules. The aerosol modifier may be free of a filtration material.

The aerosol modifier-releasing component may be, for example, a capsule, a thread, or a bead. In some embodiments, multiple aerosol modifier-releasing components are provided and may include multiple charcoal particles loaded with the aerosol modifier.

In some embodiments, the aerosol modifier-releasing component includes a thread in which the additive is loaded. The thread may be made, for example, from cellulose acetate or cotton fibers.

In some embodiments, the aerosol modifier releasing component has an aerosol modifier in the range of 1 mg to 20 mg, for example, an aerosol modifier in the range of 2 mg to 15 mg.

An aerosol modifier-emitting component, e.g., a capsule, may be disposed within the body 6. The or each aerosol modifier-emitting component may be combined with the sheet material 6A, e.g., adhered to the sheet material 6A before the sheet material 6A is formed into the body 6.

In some embodiments, a non-combustible aerosol delivery system is provided that includes an aerosol modifier releasing component and a heater operable to heat the aerosol generating material 3, in use, such that the aerosol generating material 3 delivers an aerosol.

The aerosol modifier-emitting component may comprise a capsule. In some embodiments, the aerosol modifier-emitting component comprises a first capsule and a second capsule. The first capsule is disposed in a first portion of the aerosol modifier-emitting component and the second capsule is disposed in a second portion of the aerosol modifier-emitting component downstream of the first portion.

A first portion of the aerosol modifier-releasing component is heated to a first temperature during operation of the heater to generate an aerosol, and a second portion is heated to a second temperature during operation of the heater to generate an aerosol, the second temperature being at least 4° C. lower than the first temperature. In some embodiments, the second temperature is at least 5, 6, 7, 8, 9, or 10° C. lower than the first temperature.

The aerosol modifier-releasing component may constitute one or more components of the article 1. In some embodiments, the first capsule and the second capsule are disposed in a body of material 6. In one embodiment, the aerosol modifier-releasing component comprises two bodies of material (not shown), with the first capsule disposed in the first body of material and the second capsule disposed in the second body. In some embodiments, the aerosol modifier-releasing component alternatively or additionally comprises one or more tubular elements upstream and/or downstream of the one or more bodies of material. The aerosol generating component may comprise a mouthpiece 2, 2'.

In some embodiments, the second capsule is spaced from the first capsule by a distance of at least 7 mm (measured as the distance between the center of the first capsule and the center of the second capsule). In some embodiments, the second capsule is spaced from the first capsule by a distance of at least 8 mm, 9 mm, or 10 mm. It has been found that increasing the distance between the first and second capsules increases the difference between the first and second temperatures.

The first capsule contains an aerosol modifier. The second capsule contains an aerosol modifier that may be the same as or different from the aerosol modifier in the first capsule. In some embodiments, a user can selectively rupture the first capsule and the second capsule by applying an external force to the aerosol modifier releasing component to release the aerosol modifier from each capsule.

The aerosol modifier in the second capsule is heated to a lower temperature than the aerosol modifier in the first capsule due to the difference between the first temperature and the second temperature.

The aerosol modifiers in the first and second capsules can be selected based on this temperature difference. For example, the first capsule may contain a first aerosol modifier with a lower vapor pressure than the second aerosol modifier in the second capsule. If both capsules are heated to the same temperature, the higher vapor pressure of the aerosol modifier in the second capsule means that a greater amount of the second aerosol modifier will be volatilized than the aerosol modifier in the first capsule. However, because the second capsule is heated to a lower temperature, this effect is less pronounced and a more uniform amount of the aerosol modifier in the first capsule and the aerosol modifier in the second capsule are volatilized when the first and second capsules are broken, respectively.

In some embodiments, the first capsule and the second capsule have the same aerosol modification profile, meaning that both capsules contain the same amount of the same type of aerosol modifier, such that if both capsules are heated to the same temperature and broken, both capsules will cause the same modification of the aerosol. However, because the first capsule is heated to a higher temperature than the second capsule, for example, more of the aerosol modifier in the first capsule will be volatilized compared to the modifier in the second capsule, and therefore cause more pronounced modification of the aerosol than the second capsule. Thus, even though both capsules are the same (which may make the aerosol modifier releasing component easier and/or cheaper to manufacture), the user can decide whether to break the first capsule to cause more pronounced modification of the aerosol, break the second capsule to cause less pronounced modification of the aerosol, or break both capsules to cause maximum modification of the aerosol.

In some embodiments, both the first capsule and the second capsule contain a first aerosol modifier and a second aerosol modifier. The vapor pressure of the first aerosol modifier is lower than the vapor pressure of the second aerosol modifier. Thus, when using the system to generate an aerosol, a greater proportion of the second aerosol modifier is vaporized when the second capsule is broken compared to when the hotter first capsule is broken. Thus, the same capsule can be used to produce different modifications of the aerosol based on the location of the capsule in the first or second portion of the aerosol modifier-releasing component.

In some embodiments, the or each capsule comprises an outer shell and an inner core.

The shell of each capsule may be solid at room temperature. The shell may comprise, consist of, or consist essentially of alginate. However, it should be recognized that in alternative embodiments, the shell is formed from a different material. For example, the shell may alternatively comprise, consist of, or consist essentially of gelatin, carrageenan, or pectin. The shell may comprise, consist of, or consist essentially of one or more of alginate, gelatin, carrageenan, or pectin.

The shell of each additive capsule may be impermeable or substantially impermeable to the core aerosol modifier. Thus, the shell initially prevents the core modifier from escaping from the capsule. When a user wishes to modify the aerosol, the capsule shell is crushed so that the modifier is released.

In some embodiments (not shown), the (or each) capsule further comprises a carrier material. The carrier material may include, for example, gelatin.

In some embodiments, the diameter of the capsule (or each capsule) ranges from 1 mm to 5 mm, or from 2 mm to 4 mm. In some embodiments, the diameter of the capsule (or each capsule) is about 3 mm. The capsule (or each capsule) may be generally spherical. In other examples, capsules of other shapes and sizes may be used.

The total weight of each capsule may range from about 5 mg to about 50 mg, or from about 10 mg to about 30 mg. In some embodiments, each capsule weighs about 14 mg.

In some embodiments, one or more aerosol modifier-emitting components are contained within the body of material 6, and the body of material 6 is formed from a sheet material having a basis weight of less than 40 gsm, e.g., less than 35 or 30 gsm. This helps to reduce the density of the body of material 6 (which may otherwise become stiff) to offset the presence of the aerosol modifier-emitting components within the body 6.

In some embodiments, one or more aerosol modifier-emitting components are included within the body of material 6, which is formed from a sheet material having a width of less than 100 mm, e.g., less than 90 mm or 80 mm. This helps to reduce the density of the body of material 6 (which may otherwise become stiff) to offset the presence of the aerosol modifier-emitting components within the body 6.

In some embodiments, the capsule (or each capsule) is positioned centrally along the longitudinal axis of the mouthpiece 2.

As discussed above, the capsule (or each capsule) may have a core-shell structure; that is, the encapsulating or barrier material creates a shell around a core comprising the aerosol modifier. The shell structure prevents migration of the aerosol modifier during storage of the article, but allows for controlled release of the aerosol modifier, also referred to as aerosol modifier, during use.

In some cases, the barrier material (also referred to herein as the encapsulating material) is frangible. The capsule (or each capsule) is crushed or otherwise broken or destroyed by the user to release the encapsulated aerosol modifier. Typically, one or more of the capsules are broken just before heating is initiated, but the user can choose when to release the aerosol modifier in said capsule. The user can then choose to break the other capsule at a later time, for example after heating is initiated. The user can choose to break said other of the capsules once a portion of the aerosol has been released from the aerosol-generating material, so that the remaining aerosol-generating material is modified by the aerosol modifier in the other capsule. Alternatively, the user may choose to break multiple capsules simultaneously.

The term "breakable capsule" refers to a capsule whose shell can be broken by pressure to release the core, and more specifically, to a capsule whose shell can be burst by pressure applied by a user's finger when the user wishes to release the capsule's core.

In some cases, the barrier material is heat resistant; that is, in some cases, the barrier does not burst, melt, or otherwise fail at temperatures reached at the location of the capsule during operation of the aerosol delivery device. Illustratively, a capsule disposed at the mouthpiece may be exposed to temperatures ranging from, for example, 30° C. to 100° C., and the barrier material may continue to retain the liquid core up to at least about 50° C. to 120° C.

In other cases, the capsule (or each capsule) releases the core constituents upon heating, for example, by melting of the barrier material or by expansion of the capsule resulting in rupture of the barrier material.

The total weight of each capsule may range from about 1 mg to about 100 mg, from about 5 mg to about 60 mg, from about 8 mg to about 50 mg, from about 10 mg to about 20 mg, or from about 12 mg to about 18 mg.

The total weight of the core formulation may range from about 2 mg to about 90 mg, from about 3 mg to about 70 mg, from about 5 mg to about 25 mg, from about 8 mg to about 20 mg, or from about 10 mg to about 15 mg.

In some embodiments, the (or each) capsule comprises a core and shell as described above. Each capsule may exhibit a crush strength of about 4.5N to about 40N, about 5N to about 30N, or about 5N to about 28N (e.g., about 9.8N to about 24.5N). The capsule burst strength of each capsule can be measured by removing the capsule from the body of material 6 and using a force gauge to measure the force at which the capsule bursts when pressed between two flat metal plates. A suitable measuring device is a Sauter FK50 force gauge with a flat mounting head that can be used to crush the capsule against a flat hard surface with a similar surface to the mounting head.

The capsule (or each capsule) may be substantially spherical and may have a diameter of at least about 0.4 mm, 0.6 mm, 0.8 mm, 1.0 mm, 2.0 mm, 2.5 mm, 2.8 mm, or 3.0 mm. The capsule (or each capsule) may have a diameter of less than about 10.0 mm, 8.0 mm, 7.0 mm, 6.0 mm, 5.5 mm, 5.0 mm, 4.5 mm, 4.0 mm, 3.5 mm, or 3.2 mm. Illustratively, the capsule diameter may range from about 0.4 mm to about 10.0 mm, from about 0.8 mm to about 6.0 mm, from about 2.5 mm to about 5.5 mm, or from about 2.8 mm to about 3.2 mm. In some cases, the capsule (or each capsule) may have a diameter of about 3.0 mm. These sizes are particularly suitable for incorporating the capsules into the articles described herein.

The cross-sectional area of each capsule at its maximum cross-sectional area is in some embodiments less than 28%, such as less than 27% or less than 25% of the cross-sectional area of the portion of the tipping 2 in which the capsule is provided. For example, for a spherical capsule with a diameter of 3.0 mm, the maximum cross-sectional area of the capsule is 7.07 ^mm2 . For a tipping with a circumference of 21 mm as described herein, the circumference of the body of material 6 is 20.8 mm, giving this component a radius of 3.31 mm, which corresponds to a cross-sectional area of 34.43 ^mm2 . The cross-sectional area of the capsule is, in this example, 20.5% of the cross-sectional area of the tipping 2. As another example, if the capsule has a diameter of 3.2 mm, its maximum cross-sectional area is 8.04 ^mm2 . In this case, the cross-sectional area of the capsule is 23.4% of the cross-sectional area of the body of material 6. A capsule having a maximum cross-sectional area less than 28% of the cross-sectional area of the portion of the tip 2 in which the capsule is provided has the advantage over a capsule having a larger cross-sectional area that the pressure drop across the tip 2 is reduced and sufficient space is left around the capsule for the aerosol to pass through without the body of material 6 removing a significant amount of aerosol mass as the aerosol passes through the tip 2. In some embodiments, a first capsule and a second capsule are provided, which may be the same size or different sizes.

Figure 4 is a cross-sectional side view of a further article 1" including a tip 2". The tip 2" is substantially the same as the tip 2 described above in relation to Figures 1 and 2. The difference is that the material body 6 of the article 1" is located upstream of the tubular portion 4a.

In this example, the tubular portion 4a and the body of material 6 are joined using a second plug wrap 9 wrapped around both sections.

The body of material 6 of the article 1'' of FIG. 4 is similar to the body of material 6 described above in relation to FIGS. 1-3. As before, the body of material 6 is manufactured from a sheet material that includes cellulose, for example the sheet material may be paper. The sheet material is pleated to form the body of material 6.

The material body 6 is disposed at the upstream end 2a of the mouthpiece 2'. The material body 6 is adjacent to the aerosol-generating material 3.

The tubular portion 4a is disposed at the downstream end 2b of the mouthpiece 2'', thus forming a cavity at the downstream end 2b. The tubular portion 4a is disposed downstream of the body of material 6. In this example, the tubular portion 4a is immediately adjacent to the body of material 6.

The axial length L2 of the tubular portion 4a is at least 20 mm, for example at least 22 mm. In this example, the axial length L2 of the tubular portion 4a is about 25 mm.

It has been found that an axial length L2 of the tube of at least 20 mm significantly cools the aerosol as it passes through the tubular portion 4a. In addition, as previously mentioned, the cellulose comprising sheet material of the body of material 6 absorbs water from the aerosol. Removing moisture from the aerosol makes the aerosol feel cooler in the user's mouth.

In some embodiments, the tubular portion 4a includes one or more ventilation holes, which also contribute to cooling the aerosol.

In some embodiments, the tubular portion 4a is made from paper.

Figure 5 is a cross-sectional side view of a further article 1''' that includes a tip 2'''. The tip 2''' is substantially similar to the tip 2 described above in relation to Figures 1 and 2. The difference is that the tip 2''' further comprises a tubular element 20 disposed within the body of material 6.

In this example, the tubular portion 4a and the body of material 6 are joined using a second plug wrap 9 wrapped around both sections.

The body of material 6 of the article 1''' of FIG. 5 is similar to the body of material 6 described above in relation to FIGS. 1-3. As before, the body of material 6 is manufactured from a sheet material that includes cellulose, for example the sheet material may be paper. The sheet material is pleated to form the body of material 6.

The tubular element 20 may be, for example, a paper or plastic tube disposed within the body of material 6. The tubular element 20 forms a cavity 21 within the body of material 6. Optionally, the tubular element 20 is substantially radially centrally disposed within the body of material 6.

In this example, the cavity 21 extends to the downstream end 2b of the mouthpiece 2'''.

In this example, the axial length L1 of the body of material 6 is about 10 mm. However, one of ordinary skill in the art will recognize that the axial length L1 of the body of material 6 may vary. In some embodiments, the length L1 of the body of material 6 is less than about 15 mm. In some embodiments, the length L1 of the body of material 6 is less than about 10 mm. Additionally or alternatively, the length L1 of the body of material 6 may be at least about 5 mm. In some embodiments, the length L1 of the body of material 6 is at least about 6 mm. In some embodiments, the length L1 of the body of material 6 is between about 5 mm and about 15 mm, between about 6 mm and about 12 mm, or between about 6 mm and about 12 mm. In some embodiments, the length L1 of the body of material 6 is 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm.

In some embodiments, the axial length L3 of the tubular element 20 is at least 4 mm, for example about 5 mm.

The cavity 21 has been found to facilitate cooling of the aerosol. The portion 6b of the body of material 6 surrounding the tubular element 21 has been found to effectively insulate the user's lips from the heat of the aerosol. For example, in embodiments in which the body of material 6 is fabricated from a sheet material disposed within the body of material, it is believed that the multiple layers of the sheet material of the body of material 6 help insulate the user's lips from the heat of the aerosol. In some embodiments, there may optionally be gaps, e.g., voids, between the layers of the sheet material that contribute to the insulating effect.

The body of material 6 may also be more readily biodegradable than a structure in which a tubular portion of cellulose acetate is instead provided at the downstream end 2b of the mouthpiece.

The body of material 6 may be manufactured from multiple lengths of rod 22, in this example four lengths of rod, as shown in FIG. 6. The rod is cut at lines C-C to form individual bodies of material 6 each comprising a tubular element 20 with a corresponding cavity 21.

The non-combustible aerosol delivery device is used to heat the aerosol-generating material 3 of any of the articles 1, 1', 1'', 1''' described herein. The non-combustible aerosol delivery device may include a coil, which has been found to improve heat transfer to the article 1, 1', 1'', 1''' compared to other configurations.

In some examples, the coil is configured to, in use, cause heating of at least one conductive heating element such that thermal energy can be conducted from the at least one conductive heating element to the aerosol generating material, thereby causing heating of the aerosol generating material.

In some examples, the coil is configured to generate a varying magnetic field that, in use, penetrates at least one heating element, thereby causing inductive heating and/or magnetic hysteresis heating of the at least one heating element. In such an arrangement, the or each heating element may be referred to as a "susceptor" as defined herein. A coil configured to generate a varying magnetic field that, in use, penetrates at least one electrically conductive heating element, thereby causing inductive heating of the at least one electrically conductive heating element may be referred to as an "induction coil" or "inductor coil."

The device may include heating element(s), e.g. conductive heating element(s), which may be suitably positioned or positionable relative to the coil to allow such heating of the heating element(s). The heating element(s) may be in a fixed position relative to the coil. Alternatively, at least one heating element, e.g. at least one conductive heating element, may be included in an article 1, 1', 1'', 1''', for insertion into a heating section of the device, the article 1, 1', 1'', 1''', also comprising an aerosol-generating material 3 and removable from the heating section after use. Alternatively, both the device and such article 1, 1', 1'', 1''', may each comprise at least one heating element, e.g. at least one conductive heating element, and the coil may be such that it causes heating of the respective heating element(s) of the device and article when the article is in the heating section.

In some examples, the coil is helical. In some examples, the coil surrounds at least a portion of a heated section of a device configured to receive an aerosol generating material. In some examples, the coil is a helical coil that surrounds at least a portion of a heated section.

In some examples, the device includes a conductive heating element at least partially surrounding the heating section, and the coil is a helical coil surrounding at least a portion of the conductive heating element. In some examples, the conductive heating element is tubular. In some examples, the coil is an inductor coil.

In some examples, the use of a coil allows a non-combustible aerosol delivery device to reach an operating temperature more quickly than an aerosol delivery device without a coil. For example, a non-combustible aerosol delivery device including a coil as described above can reach an operating temperature such that a first puff can be provided in less than 30 seconds, and more preferably less than 25 seconds, from activation of the device heating program. In some examples, the device can reach an operating temperature in about 20 seconds from activation of the device heating program.

It has been found that the use of a coil as described herein in a device to cause heating of the aerosol-generating material enhances the aerosol generated. For example, consumers have reported that the aerosol generated by a device including a coil as described herein feels closer to factory made cigarette (FMC) products than aerosols produced by other non-combustible aerosol delivery systems. Without wishing to be bound by theory, it is hypothesized that this is a result of the time required to reach the required heating temperature being reduced when a coil is used, higher heating temperatures being achievable when a coil is used, and/or the coil allows such systems to simultaneously heat a relatively large amount of aerosol-generating material, resulting in aerosol temperatures similar to those of FMC. In FMC products, a burning ember generates a hot aerosol that heats the tobacco in the tobacco rod behind the ember as the aerosol is drawn through the rod. It is understood that this hot aerosol releases flavor compounds from the tobacco in the rod behind the burning ember. It is believed that coil-containing devices as described herein can also heat aerosol-forming materials, such as the tobacco materials described herein, to release flavor compounds, resulting in aerosols that are reported to be more similar to FMC aerosols. Particular improvements in aerosols can be achieved by using coil-containing devices to heat articles comprising rods of aerosol-forming material having a circumference greater than 19 mm, e.g., from about 19 mm to about 23 mm.

Using an aerosol delivery system including a coil as described herein, e.g., an induction coil that heats at least a portion of the aerosol-generating material to at least 200° C., more preferably at least 220° C., it is possible to generate an aerosol from the aerosol-generating material having certain characteristics that are believed to be more similar to the aerosols of FMC products. For example, when an aerosol-generating material containing nicotine is heated to at least 250° C. for 2 seconds under an air flow of at least 1.50 L/m using an induction heater, one or more of the following characteristics have been observed:
At least 10 μg of nicotine is aerosolized from the aerosol-generating material; The weight ratio of aerosol-forming material to nicotine in the generated aerosol is at least about 2.5:1, preferably at least 8.5:1; At least 100 μg of aerosol-forming material can be aerosolized from the aerosol-generating material; The average particle or droplet size of the generated aerosol is less than about 1000 nm; The density of the aerosol is at least 0.1 μg/cc. In some cases, at least 10 μg of nicotine, preferably at least 30 μg or 40 μg of nicotine, is aerosolized from the aerosol-generating material during the period under an airflow of at least 1.50 L/m. In some cases, less than about 200 μg of nicotine, preferably less than about 150 μg or less than about 125 μg of nicotine, is aerosolized from the aerosol-generating material during the period under an airflow of at least 1.50 L/m.

In some cases, the aerosol comprises at least 100 μg of aerosol-forming material, preferably at least 200 μg, 500 μg, or 1 mg of aerosol-forming material is aerosolized from the aerosol-generating material under an airflow of at least 1.50 L/m during the period. Preferably, the aerosol-forming material comprises or consists of glycerol.

As defined herein, the term "average particle or droplet size" refers to the average size of the solid or liquid components of the aerosol (i.e., the components suspended in the gas). When the aerosol includes suspended liquid droplets and suspended solid particles, the term refers to the average size of all components combined.

In some cases, the average particle or droplet size of the aerosol produced may be less than about 900 nm, less than 800 nm, less than 700 nm, less than 600 nm, less than 500 nm, less than 450 nm, or less than 400 nm. In some cases, the average particle or droplet size may be greater than about 25 nm, 50 nm, or 100 nm.

In some cases, the aerosol density generated during this period is at least 0.1 μg/cc. In some cases, the aerosol density is at least 0.2 μg/cc, 0.3 μg/cc, or 0.4 μg/cc. In some cases, the aerosol density is less than about 2.5 μg/cc, less than 2.0 μg/cc, less than 1.5 μg/cc, or less than 1.0 μg/cc.

The non-combustible aerosol delivery device may be configured to heat the aerosol-forming material 3 of the article 1, 1', 1'', 1''' to a maximum temperature of at least 160°C. In some embodiments, the non-combustible aerosol delivery device is configured to heat the aerosol-forming material 3 of the article 1, 1', 1'', 1''' to a maximum temperature of at least about 200°C, or at least about 220°C, at least about 240°C, or at least about 270°C at least once during the heating process following the non-combustible aerosol delivery device.

Using an aerosol delivery system including a coil as described herein, e.g., an induction coil, that heats at least a portion of the aerosol-generating material to at least 200°C or at least 220°C.

In some embodiments, the temperature of the aerosol leaving the mouth end of the mouthpiece 2, 2', 2'', 2''' is less than 50°C, for example less than 45°C.

7 shows an example of a non-combustion aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium/material, such as the aerosol-generating material 3 of any of the articles 1, 1', 1'', 1''' described herein. Generally, the device 100 can be used to heat a replaceable article 110 comprising an aerosol-generating material, such as any of the articles 1, 1', 1'', 1''' described herein, to generate an aerosol or other inhalable medium that is inhaled by a user of the device 100. The device 100 and the replaceable article 110 together form a system.

The device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and contains the various components of the device 100. The device 100 has an opening 104 at one end through which an item 110 can be inserted for heating by the heating assembly. In use, the item 110 can be fully or partially inserted into the heating assembly and heated by one or more components of the heater assembly.

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

The device 100 in this example includes a first end member 106 that includes a lid 108 that is movable relative to the first end member 106 to close the opening 104 when the article 110 is not in place. In FIG. 8, the lid 108 is shown in an open configuration, but the lid 108 can be moved to a closed configuration. For example, a user can slide the lid 108 in the direction of arrow "B."

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

The device 100 may also include an electrical component, such as a socket/port 114 that can accept a cable to charge a battery of the device 100. For example, the socket 114 may be a charging port, such as a USB charging port.

FIG. 8 shows the device 100 of FIG. 7 with the outer cover 102 removed and without the article 110 present. The device 100 defines a longitudinal axis 134.

As shown in FIG. 8, the first end member 106 is disposed at one end of the device 100 and the second end member 116 is disposed at an opposite end of the device 100. The first end member 106 and the second end member 116 together at least partially define an end surface of the device 100. For example, the bottom surface of the second end member 116 at least partially defines the bottom surface of the device 100. An edge of the outer cover 102 may also define a portion of the end surface. In this example, the lid 108 also defines a portion of the top surface of the device 100.

The end of the device closest to the opening 104 is sometimes known as the proximal end (or mouth end) of the device 100 because it is closest to the user's mouth during use. In use, a user inserts an article 110 into the opening 104 and operates a user control 112 to initiate heating of the aerosol-generating material and draw in the aerosol generated within the device. This causes the aerosol to flow along a flow path through the device 100 toward the proximal end of the device 100.

The other end of the device furthest from the opening 104 is sometimes known as the distal end of the device 100 because it is the end furthest from the user's mouth when in use. When a user draws in aerosol generated within the device, the aerosol flows away from the distal end of the device 100.

The device 100 further comprises a power source 118. The power source 118 may be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium ion batteries), nickel batteries (such as nickel cadmium batteries), and alkaline batteries. The battery is electrically coupled to the heating assembly to provide power to heat the aerosol generating material when needed under the control of a controller (not shown). In this example, the battery is connected to a central support 120 that holds the battery 118 in place.

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

In the exemplary device 100, the heating assembly is an induction heating assembly, which includes various components for heating the aerosol-generating material of the article 110 by an induction heating process. Induction heating is a process of heating an electrical conductor (such as a susceptor) by electromagnetic induction. The induction heating assembly can include an induction element, for example one or more inductor coils, and a device for passing a fluctuating current, such as an alternating current, through the induction element. The fluctuating current in the induction element produces a fluctuating magnetic field. The fluctuating magnetic field penetrates a susceptor, which is suitably positioned relative to the induction element, and generates eddy currents in the susceptor. The susceptor has an electrical resistance to the eddy currents, and thus the susceptor is heated by Joule heating due to the eddy currents flowing against this resistance. If the susceptor includes a ferromagnetic material, such as iron, nickel, or cobalt, heat can also be generated by magnetic hysteresis losses in the susceptor, i.e., the orientation of the magnetic dipoles in the magnetic material fluctuates as a result of aligning with the fluctuating magnetic field. In induction heating, heat is generated inside the susceptor, which allows for rapid heating, as compared to, for example, heating by conduction. Furthermore, no physical contact between the induction heater and the susceptor is required, which allows for greater flexibility in design and application.

The induction heating assembly of the exemplary device 100 includes a susceptor structure 132 (referred to herein as a "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first inductor coil 124 and the second inductor coil 126 are made from an electrically conductive material. In this example, the first inductor coil 124 and the second inductor coil 126 are made from a Litz wire/cable that is wound in a helical shape to provide the helical inductor coils 124, 126. The Litz wire includes multiple individual wires that are individually insulated and twisted together to form a single wire. The Litz wire is designed to reduce the skin effect losses of the conductor. In the exemplary device 100, the first inductor coil 124 and the second inductor coil 126 are made from copper Litz wire with a rectangular cross section. In other examples, the Litz wire can have other shaped cross sections, such as circular.

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

It will be appreciated that in some examples, the first inductor coil 124 and the second inductor coil 126 may have at least one characteristic that differs from one another. For example, the first inductor coil 124 may have at least one characteristic that differs from the second inductor coil 126. More specifically, in one example, the first inductor coil 124 may have a different inductance value than the second inductor coil 126. In FIG. 8, the first inductor coil 124 and the second inductor coil 126 are of different lengths, such that the first inductor coil 124 is wound on a smaller section of the susceptor 132 than the second inductor coil 126. Thus, the first inductor coil 124 may have a different number of turns than the second inductor coil 126 (assuming that the spacing between the individual turns is substantially the same). In yet another example, the first inductor coil 124 may be made of a different material than the second inductor coil 126. In some examples, the first inductor coil 124 and the second inductor coil 126 may be substantially identical.

In this example, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. This can be useful when the inductor coils are operating at different times. For example, the first inductor coil 124 may initially operate to heat a first section/portion of the article 110, and then the second inductor coil 126 may operate to heat a second section/portion of the article 110. Winding the coils in opposite directions helps reduce current induced in the inactive coil when used with certain types of control circuits. In FIG. 8, the first inductor coil 124 is a right-handed spiral and the second inductor coil 126 is a left-handed spiral. However, in other embodiments, the inductor coil 124 and the inductor coil 126 may be wound in the same direction, or the first inductor coil 124 may be a left-handed spiral and the second inductor coil 126 may be a right-handed spiral.

The susceptor 132 in this example is hollow and thus defines a receptacle for receiving the aerosol-generating material. For example, the article 110 can be inserted into the susceptor 132. In this example, the susceptor 120 is tubular with a circular cross-section.

The susceptor 132 may be made from one or more materials. Preferably, the susceptor 132 comprises carbon steel with a nickel or cobalt coating.

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

8 further includes an insulating member 128, which may be generally tubular and at least partially surround the susceptor 132. The insulating member 128 may be constructed from any insulating material, such as, for example, plastic. In this particular example, the insulating member is constructed from polyether ether ketone (PEEK). The insulating member 128 may help insulate various components of the device 100 from heat generated by the susceptor 132.

The insulating member 128 may also fully or partially support the first inductor coil 124 and the second inductor coil 126. For example, as shown in FIG. 9, the first inductor coil 124 and the second inductor coil 126 are disposed around the insulating member 128 and are in contact with the radially outward surface of the insulating member 128. In some examples, the insulating member 128 does not abut the first inductor coil 124 and the second inductor coil 126. For example, there may be a slight gap between the outer surface of the insulating member 128 and the inner surfaces of the first inductor coil 124 and the second inductor coil 126.

In a particular example, the susceptor 132, the insulating member 128, and the first and second inductor coils 124 and 126 are concentric about a central longitudinal axis of the susceptor 132.

Figure 10 is a partial cross-sectional side view of device 100. In this example, outer cover 102 is present. The rectangular cross-sectional shapes of first inductor coil 124 and second inductor coil 126 can be seen more clearly.

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

The device may also include an associated second printed circuit board 138 within the control element 112.

The device 100 further includes a second lid/cap 140 and a spring 142 disposed toward the distal end of the device 100. The spring 142 allows the second lid 140 to be opened to access the susceptor 132. A user can open the second lid 140 to clean the susceptor 132 and/or the support 136.

The device 100 further comprises an expansion chamber 144 extending away from the proximal end of the susceptor 132 toward the opening 104 of the device. A retaining clip 146 is at least partially disposed within the expansion chamber 144 for abutting and retaining the article 110 when the article 110 is received within the device 100. The expansion chamber 144 is connected to the end member 106.

Figure 10 is an exploded view of the device 100 of Figure 9 without the outer cover 102.

11A shows a cross-section of a portion of the device 100 of FIG. 9. FIG. 11B shows an enlarged view of an area of FIG. 11A. FIGS. 11A and 11B show the article 110 received within the susceptor 132, where the article 110 is dimensioned such that the outer surface of the article 110 abuts the inner surface of the susceptor 132. This ensures that heating is most efficient. The article 110 in this example comprises an aerosol-generating material 110a. The aerosol-generating material 110a is disposed within the susceptor 132. The article 110 may also comprise other components, such as a filter, packaging material, and/or cooling structures.

FIG. 11B shows that the outer surface of the susceptor 132 is spaced a distance 150 from the inner surfaces of the inductor coils 124, 126, measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 150 is about 3 mm to 4 mm, about 3 to 3.5 mm, or about 3.25 mm.

11B further illustrates that the outer surface of the insulating member 128 is spaced a distance 152 from the inner surfaces of the inductor coils 124, 126, measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 152 is about 0.05 mm. In another example, the distance 152 is substantially 0 mm, such that the inductor coils 124, 126 are in abutting contact with the insulating member 128.

In one example, the wall thickness 154 of the susceptor 132 is about 0.025 mm to 1 mm, or about 0.05 mm.

In one example, the length of the susceptor 132 is about 40 mm to 60 mm, about 40 mm to 45 mm, or about 44.5 mm.

In one example, the wall thickness 156 of the insulating member 128 is about 0.25 mm to 2 mm, 0.25 mm to 1 mm, or about 0.5 mm.

In use, the articles 1, 1', 1'', 1''' described herein can be inserted into a non-combustible aerosol delivery device, such as the device 100 described with reference to Figures 7-11B. At least a portion of the mouthpiece 2, 2', 2'', 2''' of the article 1, 1', 1'', 1''' protrudes from the non-combustible aerosol delivery device 100 and can be placed into the mouth of a user. An aerosol is generated by heating an aerosol-generating material 3 using the device 100. The aerosol generated by the aerosol-generating material 3 passes through the mouthpiece 2 to the mouth of the user.

The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided as merely representative examples of embodiments and are not exhaustive or exclusive of all embodiments. The advantages, embodiments, examples, features, structures, and/or other aspects described herein should not be considered as limiting the scope of the invention as defined by the claims or the equivalents of the claims, and it will be understood that other embodiments can be utilized and modifications can be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims (38)

A component for an article for use in, or as, a non-combustion aerosol delivery system, comprising:
a longitudinally extending body of material comprising a corrugated sheet material formed to have a corrugated pattern comprising a series of substantially parallel ridges and grooves, the average spacing between adjacent ridges being greater than about 0.3 mm, and the body of material having an average density of about 0.1 to about 0.25 mg/ ^mm3 ;
a tubular element disposed within the body of material, the tubular element comprising a cavity;
The tubular element comprises paper . The component of claim 1, wherein the amplitude of the waveform is less than about 0.7 mm, or is between about 0.7 mm and about 1.2 mm. A component for an article for use in, or as, a non-combustion aerosol delivery system, comprising:
a longitudinally extending body of material comprising a corrugated sheet material formed to have a corrugated pattern comprising a series of substantially parallel ridges and grooves, the corrugations having an amplitude of less than about 0.7 mm, the body of material having an average density of about 0.1 to about 0.25 mg/ ^mm3 ;
a tubular element disposed within the body of material, the tubular element comprising a cavity;
wherein the tubular element comprises paper . The component according to any one of claims 1 to 3, wherein the average spacing between adjacent ridges is greater than about 0.4 mm, greater than about 0.5 mm, or greater than about 0.6 mm. The component of any one of claims 1 to 4, wherein the body of material comprises corrugated fibers having a corrugation amplitude of less than about 600 μm, less than about 500 μm, or less than about 400 μm. The component of any one of claims 1 to 5, wherein the body of material has a density of about 0.15 mg/mm ³ to about 0.2 mg/mm ³ , or about 0.17 mg/mm ³ to about 0.2 mg/mm ³ . 7. A component ^according to any one of claims 1 to 6, wherein the volume of the body of material is at ^{least 100mm3} , at least ^115mm3 , at least ^150mm3 , at least ^200mm3 , at least ^300mm3 , at least ^400mm3 , at least ^500mm3 , at least ^{600mm3, at least 700mm3} , at least ^800mm3 , at least 900mm3, or at least ^1000mm3 . 8. The component of any one of claims 1 to ⁷ , wherein the volume of the body of material is at least 19 ^mm3 per mm of axial length of the body of material, at least 25 mm3 per mm of axial length of the body of material, or at least 30 mm3 per ^mm of axial length of the body of material. The component according to any one of claims 1 to 8, wherein the weight of the body of material is at least 4 mg per mm of axial length of the body of material, at least 5 mg per mm of axial length of the body of material, or at least 6 mg per mm of axial length of the body of material. The component according to any one of claims 1 to 9, wherein the body of material is substantially cylindrical. The component according to any one of claims 1 to 10, wherein the body of material is wrapped in a plug wrap having a wet tensile strength of less than 1 N per 15 mm of paper width. Component according to any one of the preceding claims, wherein the sheet material has a basis weight of at least 20 g/m ² , at least 22 g/m ² , or at least 24 g/m ² . 13. The component of claim 12, wherein the sheet material has a basis weight of less than 50 g/ ^m2 , less than 45 g/ ^m2 , or less than 40 g/ ^m2 . The component according to any one of claims 1 to 13, wherein the sheet material has a width when stretched of 120 mm to 200 mm, or 150 mm to 200 mm. The component of any one of claims 1 to 14, wherein the sheet material comprises paper. The component of any one of claims 1 to 14, wherein the sheet material comprises reconstituted tobacco. A component according to any one of claims 1 to 16, wherein the closing pressure drop across the body of material is at least 1.0 mm water column per mm of longitudinal length, or at least 1.2 mm water column per mm of longitudinal length, or at least 1.5 mm water column per mm of longitudinal length. A component according to any one of claims 1 to 17, wherein the closing pressure drop in the body of material is less than 3 mm of water column per mm of longitudinal length, or less than 2.8 mm of water column per mm of longitudinal length, or less than 2.5 mm of water column per mm of longitudinal length. The component of any one of claims 1 to 18, wherein the axial length of the body of material is at least 4 mm, at least 5 mm, at least 6 mm, at least 7 mm, at least 8 mm, at least 9 mm, at least 10 mm, or from about 6 mm to about 15 mm. The component of claim 19, wherein the axial length of the body of material is about 12 mm. The component according to any one of claims 1 to 20, wherein the circumference of the body of material is at least 16 mm, at least 18 mm, or at least 20 mm. The component of any one of claims 1 to 21, further comprising an aerosol modifier disposed within the body of material. The component of claim 22, further comprising an aerosol modifier releasing component comprising the aerosol modifier. The component of claim 23, wherein the aerosol modifier releasing component comprises a capsule. The component of claim 24, wherein the capsule comprises a solid shell and a liquid core, the liquid core comprising the aerosol modifier. The component of any one of claims 1 to 25, further comprising an aerosol-forming material applied to the body of material. The component of claim 26, wherein the aerosol forming material comprises one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The component of claim 27, wherein the aerosol-forming material comprises triethyl citrate or triacetin. The component of claim 27 or 28, wherein at least 0.02 mg, 0.03 mg, 0.04 mg, or 0.05 mg of aerosol-forming material is applied to the body of material per mm of axial length of the body of material. The component of any one of claims 27 to 29, wherein 0.5 mg or less, 0.45 mg or less, 0.4 mg or less, 0.35 mg or less, or 0.3 mg or less of aerosol-forming material is applied to the body of material per mm of axial length of the body of material. 31. The component of any one of claims 1 to 30 , wrapped in a wrapper having a basis weight greater than 40 grams per ^m2 and/or a thickness greater than 35 μm. 32. The component of any one of claims 1 to 31 , wherein the sheet material comprises fibres with an average length in the range of 2mm to 6mm, 2mm to 5mm, 2mm to 4mm, or 2mm to 3mm. 33. The component of any one of claims 1 to 32 , wherein the sheet material has a thickness of about 50 to about 100 μm, or about 60 to about 90 μm. An article for use in or for use as a non-combustion aerosol delivery system, the article comprising an aerosol-forming material and a downstream portion downstream of the aerosol-forming material, the downstream portion comprising a component according to any one of claims 1 to 33 . 35. A non-combustible aerosol delivery system comprising the article of claim 34 . 36. The non-combustion aerosol delivery system of claim 35 , which is an aerosol-generating material heating system, optionally a tobacco heating system. 1. A method for forming a component for an article for use in a non-combustible aerosol delivery system, comprising:
applying a corrugated pattern to the sheet material, said corrugated pattern comprising a series of substantially parallel ridges and grooves, with an average spacing between adjacent ridges being greater than about 0.3 mm;
forming the sheet material into a body of material, the body of material having an average density of about 0.1 to about 0.25 mg/ ^mm3 ;
the component having a tubular element disposed within the body of material and having a cavity;
the tubular element comprises paper;
method. 1. A method for forming a component for an article for use in a non-combustible aerosol delivery system, comprising:
applying a corrugated pattern to a sheet material, said corrugated pattern comprising a series of substantially parallel ridges and grooves, said corrugations having an amplitude of less than about 0.7 mm;
forming the sheet material into a body of material, the body of material having an average density of about 0.1 to about 0.25 mg/ ^mm3 ;
the component having a tubular element disposed within the body of material and having a cavity;
the tubular element comprises paper;
method.

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