JP7755665B2 - Components for use with non-combustible aerosol delivery devices - Google Patents

Description

The present invention relates to components for use with non-combustion aerosol delivery devices, articles for use with non-combustion aerosol delivery devices, and non-combustion aerosol delivery systems.

background

Some tobacco industry products, during use, generate 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 not burning the substrate. Such tobacco industry products typically include a mouthpiece through which the aerosol passes to reach the user's mouth.

overview

According to a first aspect of the present disclosure, there is provided an aerosol generating component for use with a non-combustible aerosol delivery device, the aerosol generating component including a heating material in thermal contact with an aerosol-generating material, the heating material including a plurality of elongated portions or elements extending through or around the aerosol-generating material in a first direction, the elongated portions or elements being substantially parallel.

According to a second aspect of the present disclosure, there is provided an aerosol-generating component for use with a non-combustible aerosol delivery device, the aerosol-generating component including a heating material in thermal contact with an aerosol-generating material, the heating material including a first elongated or flat portion extending around or through the aerosol-generating material in a first direction and at least one second elongated or flat portion extending around or through the aerosol-generating material in a second direction different from the first direction.

According to a third aspect of the present disclosure, there is provided an aerosol generating component for use with a non-combustible aerosol delivery device, the aerosol generating component including a heating material in thermal contact with an aerosol-generating material, the heating material extending generally longitudinally through the aerosol-generating material and having a length, a height, and a width, the width of the heating material being greater than the height of the heating material, and the height of a first portion of the heating material being at least 20% greater than the height of a second portion of the heating material.

According to a fourth aspect of the present disclosure, there is provided an article for use with a non-combustible aerosol delivery device comprising an aerosol generating component according to the first or second aspect.

According to a fifth aspect of the present disclosure, there is provided a non-combustible aerosol delivery system comprising a non-combustible aerosol delivery device and an aerosol generating component according to the first, second or third aspect, or an article according to the fourth aspect.

Embodiments of the present invention will now be described, by way of 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 mouthpiece. FIG. 2 is a cross-sectional side view of an aerosol-generation section including a susceptor element. FIG. 2b is a top cross-sectional view of the aerosol generation section of FIG. 2a. FIG. 10 is a cross-sectional side view of an aerosol-generation section including an alternative susceptor element. FIG. 3b is a top cross-sectional view of the aerosol generation section of FIG. 3a. FIG. 10 is a cross-sectional side view of an aerosol-generation section including an alternative susceptor element. FIG. 4b is a top cross-sectional view of the aerosol generation section of FIG. 4a. FIG. 10 is a cross-sectional side view of an aerosol-generation section including an alternative susceptor element. FIG. 10 is a cross-sectional side view of an aerosol-generation section including an alternative susceptor element. 6b is a further cross-sectional side view of the aerosol generation section of FIG. 6a. FIG. 10 is a cross-sectional side view of an aerosol-generation section including an alternative susceptor element. 7b is a further cross-sectional side view of the aerosol generation section of FIG. 7a. FIG. 7b is a top cross-sectional view of the aerosol generation section of FIG. 7a. FIG. 10 is a cross-sectional side view of an aerosol-generation section including an alternative susceptor element. 8b is a further cross-sectional side view of the aerosol generation section of FIG. 8a. FIG. 8b is a top cross-sectional view of the aerosol generation section of FIG. 8a. FIG. 10 is a side cross-sectional view of a further article for use with a non-combustible aerosol delivery device, in this example the article includes a capsule-containing mouthpiece. 9b is a cross-sectional view of the capsule-containing mouthpiece shown in FIG. 9a. FIG. 1 is a schematic diagram of a non-combustible aerosol delivery device. FIG. 1 is a schematic diagram of a non-combustible aerosol delivery device. FIG. 1 is a schematic diagram of a non-combustible aerosol delivery device. FIG. 1 is a schematic diagram of a non-combustible aerosol delivery device.

Detailed Description

As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user;
Combustion aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for hand-rolled or handmade cigarettes, whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials;
a non-combustion aerosol delivery system that releases compounds from an aerosol-forming material without burning the aerosol-forming material, such as an electronic cigarette, tobacco heating product, or mixing system for generating an aerosol using a combination of aerosol-forming materials;
an aerosol-free delivery system that delivers at least one substance, which may or may not contain nicotine, to a user orally, nasally, transdermally, or otherwise, without forming an aerosol, including, but not limited to, oral products such as lozenges, gums, patches, articles containing inhalable powders, and oral tobacco products, including snus and moist snuff;
Includes.

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-combustible aerosol delivery system, such as a powered non-combustible aerosol delivery system.

In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not 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 mixing system for generating an aerosol using a combination of aerosol-forming materials, and one or more of the aerosol-forming materials can be heated. Each of the aerosol-forming materials can be, for example, in solid, liquid, or gel form, and may or may not contain nicotine. In some embodiments, the mixing system includes a liquid or gel aerosol-forming material and a solid aerosol-forming material. The solid aerosol-forming material can 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 consumables for use with the non-combustible aerosol delivery system.

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

As used herein, the terms "upstream" and "downstream" are relative terms defined in relation to the direction in which mainstream aerosol is drawn through the article or device in use.

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

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

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

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

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

Aerosol modifiers are substances typically positioned downstream of the aerosol-generation area and configured to modify the generated aerosol, for example, by altering the flavor, fragrance, acidity, or other characteristics of the aerosol. The aerosol modifier may be provided within an aerosol modifier-releasing component operable to selectively release 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 coloring, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a string, or a granule. The aerosol modifier may not have a filter material.

An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy, liberating one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

The filament tow materials described herein can include cellulose acetate fiber tows. 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 tows can be plasticized with a suitable plasticizer for the tow, such as triacetin if the material is cellulose acetate tow, or the tows can be unplasticized. The tow can have any suitable specifications, such as other cross sections such as a "Y" or "X" shape, fibers having a single fineness value of 2.5 to 15, e.g., 8.0 to 11.0, and a total fineness value of 5,000 to 50,000, e.g., 10,000 to 40,000.

In the figures described herein, similar reference numerals are used to describe equivalent features, items or components.

Figure 1 is a cross-sectional side view of an article 1 for use in an aerosol delivery system.

Article 1 comprises a mouthpiece 2 and an aerosol-generating section 3 connected to mouthpiece 2. The aerosol-generating section may alternatively be referred to as an aerosol-generating component. In this example, aerosol-generating section 3 comprises a cylindrical rod of an aerosol-generating composition. The aerosol-generating composition comprises an aerosol-generating material 30 and a heating material disposed in thermal contact with the aerosol-generating material.

The aerosol-generating material 30 can include multiple strands or strips of aerosol-generating material. As described herein below, for example, the aerosol-generating material 30 can include multiple strands or strips of aerosolizable material and/or multiple strands or strips of an amorphous solid. In some embodiments, the aerosol-generating material 30 is comprised of multiple strands or strips of aerosolizable material. In this example, the aerosol-generating composition includes multiple strands and/or strips of aerosol-generating material 30 and is surrounded by a wrapper 10. In this example, the wrapper 10 is a moisture-impermeable wrapper.

In this example, the aerosol-generating composition includes a heating material in the form of a susceptor element 31. The susceptor element 31 includes a susceptor material that can be heated using induction heating. Induction heating is a process of heating a conductive object (such as a susceptor) by electromagnetic induction. The magnetic field generator can include an induction element, e.g., one or more inductor coils, and a device for passing a variable current, such as an alternating current, through the induction element. The varying current in the induction element generates a variable magnetic field. The variable magnetic field penetrates a susceptor appropriately positioned relative to the induction element and generates eddy currents within the susceptor. The susceptor has an electrical resistance to the eddy currents, and therefore, the flow of eddy currents against this resistance heats the susceptor by Joule heating. 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., by varying orientation of magnetic dipoles in the magnetic material as a result of alignment with the various magnetic fields. In induction heating, heat is generated within the susceptor, allowing for faster heating than, for example, conduction heating. Furthermore, there is no need for physical contact between the induction heater and the susceptor, allowing for greater flexibility in construction and application.

In this example, the susceptor element 31 is substantially centrally positioned within and extends through the rod of aerosol-generating composition. In other examples, the heating material may be positioned to extend around the aerosol-generating material, for example, as a wrap or as a pattern of susceptor material printed on a wrapping material. The inventors have advantageously found that providing an aerosol-generating material that includes a heating material (e.g., the heating material in the form of a susceptor element 31 that is positioned within or around the aerosol-generating material during manufacture of the article) can ensure proper placement of the heating material within or around the aerosol-generating material to improve thermal contact between the heating element and the aerosol-generating material, resulting in an improved article.

In FIG. 1, susceptor element 31 is shown schematically. FIGS. 2-8 show aerosol-generation sections 300, 301, 302, 303, 305, 306, each including a rod of aerosol-generating composition, including exemplary susceptor elements 31a, 31b, 31c, 31d, 31e, 31f, and 31g (described in more detail below). Each of the exemplary susceptor elements 31a-31g shown in FIGS. 2-8 is suitable for use as susceptor element 31 in the aerosol-generation section 3 shown in FIGS. 1, 9a, and 9b. The exemplary susceptor elements 31a-31g are not flat. The inventors have advantageously determined that providing a heating material with a non-flat structure can result in improved aerosol generation due to increased thermal contact between the heating material and the aerosol-generating material 30, compared to a heating material with a flat structure. Providing a non-planar susceptor element 31 can advantageously provide an increased surface area compared to a susceptor element having a flat structure, which can result in increased thermal contact between the susceptor element 31 and the aerosol-forming material 30. Additionally, the inventors have determined that a heating material having a non-planar structure can provide improved support and structure for the aerosol-forming material 30 around the heating material. Advantageously, a non-planar heating material provided in a rod of aerosol-forming composition can help reduce any loss of aerosol-forming material 30 from the end of the rod.

In some examples, the heating material can be printed on the wrapper 10 in a pattern, for example, a two-dimensional projection of any of the susceptor elements 31a-31g. In such examples, the wrapper 10 includes the heating material. Any of the aerosol-generation sections 300, 301, 302, 303, 305, 306 of Figures 2-8 may be provided in place of the aerosol-generation section 3 of the embodiments of Figures 1 and 9a.

Figures 2-4 show an exemplary non-planar susceptor element that includes multiple elongated portions extending through the aerosol-generation section.

Figure 2a is a side cross-sectional view of an aerosol-generating section 300 including a rod of aerosol-generating composition, including aerosol-generating material 30 and susceptor element 31a. Figure 2b is a top cross-sectional view of the aerosol-generating section 300 along line X-X'. The susceptor element 31a is formed from a susceptor material, for example, a conductive wire, that can be wound or bent into the shape shown. The nonlinear shape of the susceptor element 31a advantageously increases the contact area between the aerosol-generating material 30 and the susceptor element 31a.

The susceptor element 31a includes multiple elongated portions 311a, 311b, and 311c that extend through the aerosol-forming composition along the x-x' axis. The elongated portions 311a, 311b, and 311c are substantially parallel. In this example, the elongated portions 311a, 311b, and 311c are joined together by connecting portions 312a and 312b, which extend between the elongated portions 311a and 311c, and between the elongated portions 311a and 311b, respectively. The connecting portions 311a and 311b provide structure to the susceptor element 31a in the cross-sectional direction and can reduce movement of the aerosol-forming material in the longitudinal direction. The connecting portions 312a and 312b also hold the elongated portions 311a, 311b, and 311c in a spaced-apart configuration. Providing a susceptor element that includes spaced apart elongated portions 311a, 311b, and 311c improves thermal contact between the susceptor element and the aerosol-forming material 30 across the length and width of the rod of aerosol-forming composition. Connecting portions 312a and 312b between the elongated elements allow the entire susceptor element to be disposed as a single component. Elongated portions 311a, 311b, and 311c improve contact between the susceptor element 31a and the aerosol-forming material 30 along the length of the susceptor element.

A junction portion 313 extends from the first end of the susceptor element 31a. In this example, the junction portion 313 extends from the central elongated portion 311b to the distal end 300a of the aerosol-generation section 300. In other examples, the susceptor element 31a can be configured differently, and the junction portion 313 can extend from another of the elongated portions.

The susceptor elements 31a may suitably be formed from a single continuous piece of susceptor material. Multiple susceptor elements 31a may be formed together or consecutively on the single continuous piece of susceptor material to provide a supply of susceptor elements 31a. Each of the multiple susceptor elements 31a may be separated along the length of the susceptor material, the joint 313. The supply of susceptor elements 31a may be provided along with a source of aerosol-forming material such that a rod of aerosol-forming composition including the susceptor elements 31a is formed by forming a rod of aerosol-forming composition around the susceptor elements 31a and then cutting the rod where it overlaps the joint 313 to separate each of the susceptor elements 31a. The susceptor elements 31 are suitably included in the rod of aerosol-forming composition during the rod-forming step.

Figure 3 is a side cross-sectional view of an aerosol-generation section 301 including an aerosol-generating material 30 and a susceptor element 31b. Figure 3b is a top cross-sectional view of the aerosol-generation section 301 along line x-x'. The susceptor element 31b includes multiple elongated portions 311a', 311b', and 311c'. As described with respect to Figure 2a, the multiple elongated portions are substantially parallel. The elongated portions 311a', 311b', and 311c' are spaced apart and extend through the rod of aerosol-generating composition substantially parallel to the longitudinal axis. In this example, the elongated portions 311a', 311b', and 311c' are not connected. In this example, the susceptor element 31b includes three elongated portions. In other examples, the susceptor element can include a different number of elongated portions, for example, 2, 4, 5, or 6 elongated portions. The inventors have advantageously found that providing susceptor element 31b with spaced apart elongated portions can improve thermal contact between susceptor element 31b and aerosol-forming material 30 across both the length and cross-section of the rod of aerosol-forming composition. Each of elongated portions 311a', 311b', 311c' of susceptor element 31b can be formed from a single, continuous piece of susceptor material, such as conductive wire. In the example of FIG. 3, each of elongated portions 311a', 311b', 311c' can be formed from a different material, or from the same material (e.g., susceptor material) but with different physical properties, such as wire gauge.

Figure 4a is a side cross-sectional view of the aerosol-generation section 302 including the aerosol-generating material 30 and the susceptor element 31c. Figure 4b is a top cross-sectional view of the aerosol-generation section 302 along line x-x'. The susceptor element 31c includes two elongated portions 311a" and 311b" connected at their ends by connecting portions 312a' and 312b'. In this example, connecting portions 312a' and 312b' form curved sections at both ends of the susceptor element 31c. In other embodiments, connecting portions 312a' and 312b' extend straight between elongated portions 311a" and 311b" to form a substantially rectangular configuration with elongated portions 311a" and 311b", or can be configured to form any other suitable shape. In this example, junction portion 313' extends from the center of connecting portion 312a'. In this example, the junction portion 313' extends to the end of the rod of aerosol-forming composition; however, in other examples, the junction portion 313' may extend from the susceptor element 31c but not to the end of the rod of aerosol-forming composition.

As described with respect to FIG. 2a, multiple susceptor elements 31c can be formed from a single continuous piece of susceptor material to form a supply of susceptor elements 31c. Each of the susceptor elements 31c can be joined to an adjacent susceptor element by a joint 313'. During manufacture, the supply of susceptor elements can be combined with a source of aerosol-forming material 30 in a rod-forming step to form a rod of aerosol-forming composition that includes the supply of susceptor elements. The susceptor element containing the rod of aerosol-forming composition can be cut where it overlaps the joint 313' to form a rod of aerosol-forming composition that includes a single susceptor element 31c. The waisted profile of the susceptor element 31c at the joint 313' reduces the cutting force required during manufacture.

As described with respect to FIG. 2, the spaced apart elongated portions 311a", 311b", 311c" can improve thermal contact between the susceptor element 31c and the aerosol-generating material 30 across the length and width of the rod of aerosol-generating composition. The connecting portions 312a', 312b' between the elongated elements allow the entire susceptor element 31c to be disposed as a single component while still providing the benefits of a susceptor element extending through different portions of the rod of aerosol-generating composition.

Figures 5-8 show additional exemplary non-planar susceptor elements, each of which includes at least one portion extending in a different direction along the length of the susceptor element. Each of the exemplary non-planar susceptor elements shown in Figures 5-8 is positioned within a rod of aerosol-generating composition such that at least one portion of the susceptor element extends in a direction different from the direction of the longitudinal axis x-x'.

FIG. 5 is a cross-sectional side view of aerosol-generating section 303, including aerosol-generating material 30 and susceptor element 31d. Susceptor element 31d includes elongated portion 311a''' and intersection portion 314. Intersection portion 314 extends substantially perpendicular to elongated portion 311a''' to form an L-shaped susceptor element. Intersection portion 314 can provide additional support to aerosol-generating material 30 around intersection portion 314, which in this case is located at the distal end of the rod of aerosol-generating composition. Intersection portion 314 extends in a direction different from the direction in which elongated portion 311a''' extends. Providing a portion that extends in a direction different from the direction in which the first portion extends can provide improved structural support to the rod of aerosol-generating composition by forming a structural portion that can reduce movement of aerosol-generating material 30 and improve the structural stability of the rod. Providing susceptor element 31d with an L-shaped configuration reduces the problem of aerosol-generating material displacement from the end of the rod of aerosol-generating composition 303 due to intersection portion 314 providing a retention structure at the distal end of the rod. The inventors have determined that reducing the displacement of aerosol-generating material 30 during use advantageously results in a more consistent packing density of aerosol-generating material 30 along the length of the rod, which in turn results in more consistent and improved aerosol generation.

Figure 6a is a cross-sectional side view of the aerosol-generating section 304, including the aerosol-generating material 30 and the susceptor element 31e. The susceptor element 31e includes a repeating pattern of diagonally extending portions 315a, 315b. In this embodiment, the diagonally extending portions 315a, 315b extend at an angle relative to the longitudinal axis x-x'. Similar to the effects described with respect to the intersection portion 314 in Figure 5 and the connecting portions 312a, 312b, 312a', 312b' in Figures 2 and 4, the diagonally extending portions 315a, 315b improve thermal contact between the susceptor element 31e and the aerosol-generating material 30 across the width of the susceptor element 31e, provide additional support for the aerosol-generating material 30 around the diagonally extending portions, and help reduce displacement of the aerosol-generating material 30.

As previously described, the non-planar structure of the susceptor element 31e provided by the diagonally extending portions 315a, 315b provides an increased surface area compared to a planar susceptor element of the same length, thereby resulting in improved thermal contact between the susceptor element and the aerosol-generating material 30. In this example, the diagonally extending portion 315a extends in a first direction, and the diagonally extending portion 315b extends in a second direction different from the first direction. The angle formed between adjacent diagonally extending portions 315a, 315b may be from about 90° to about 170°, e.g., about 95°, about 100°, or about 110°. The susceptor element 31e may suitably comprise a corrugated wire or a pleated sheet of heating material. The susceptor element 31e may be formed from wire having any suitable gauge or from a sheet of heating material having any suitable width. Figure 6b is a further cross-sectional side view of the aerosol-generation section 304 of Figure 6a taken along line y-y'. In the view of Figure 6b, the white areas represent the alternating ridges and valleys between the diagonally extending portions 315a, 315b.

Each of the exemplary non-planar susceptor elements 31a-31e described above may be suitably formed from wire or sheet material configured to have a non-planar structure. The wire or sheet material may be bent or shaped to provide the non-planar structure, or the wire or sheet material may have elements that form the non-planar structure embossed or deposited on its surface.

7a is a cross-sectional side view of the aerosol-generation section 305 including a susceptor element 31f. The susceptor element 31f includes an elongated portion 311a'''' having protrusions 316 disposed thereon. As described in connection with FIG. 2, the elongated portion 311a'''' is substantially parallel to the longitudinal axis x-x'. The protrusions 316 extend outward at positions along the elongated portion 311a'''', i.e., at an angle relative to the longitudinal axis. The structure of the protrusions 316 disposed on the elongated portion 311a'''' effectively forms peaks and valleys, with the protrusions 316 forming peaks and valleys between adjacent protrusions. This peak and valley structure advantageously grips the aerosol-generating material, resulting in improved structural integrity of the rod of aerosol-generating material.

The protrusions 316 are preferably formed by compressing a flat sheet of susceptor material to form thicker and thinner regions, respectively. The thicker regions form the protrusions 316 on the elongated elements. The susceptor elements 31f are preferably molded or embossed to form the elongated portions 311a'''' and the protrusions 316 from a single piece of material. Alternatively, the protrusions 316 may be formed as deposits on the surface of the wire or sheet material forming the elongated portions 311a'''''', or the protrusions 316 may be formed separately and glued or otherwise attached or secured to the elongated portions 311a''''. The protrusions 316 provide additional surface area along the length of the elongated portions 311a'''', which can improve thermal contact between the susceptor elements 31f and the aerosol-forming material. The protrusions 316 can also reduce displacement of the aerosol-forming material by providing additional structure to the rods of aerosol-forming composition. The protrusions 316 are shown in FIG. 7 as having substantially square edges. In other examples, the protrusions 316 may have a wavy profile along the elongated portion 311a'''', depending on the type of embossing design or other manufacturing method used.

The protrusions 316 may be positioned diametrically opposite or longitudinally offset from another protrusion 316 on the opposite surface of the elongate element 311a''''.

Figure 7b is a further cross-sectional side view of the aerosol generation section 305 of Figure 7a taken along line y-y'.

Figure 7c is a top cross-sectional view of the aerosol generation section 305 of Figure 7a.

Figure 8a is a cross-sectional side view of the aerosol-generation section 306 including a susceptor element 31g. The susceptor element 31g includes an elongated portion 311a'''''' extending along the length of the susceptor element 31g. The lateral portions 316 extend outwardly from the elongated portion 311a'''''' and in the same plane as the elongated portion 311a''''''. Figure 8b is a further cross-sectional side view of the aerosol-generation section 306 of Figure 8a taken along line y-y'. First alternating tabs 317 extend in a first direction away from the elongated portion, where the first direction is not in the same plane as the lateral portions 316. In this example, the first direction is substantially perpendicular to the direction in which the lateral portions 316 extend. The second alternating tabs 318 extend in a second direction away from the elongated portion, which again is different from the first direction and different from the plane in which the lateral portion 316 is located. In this example, the second direction is also substantially perpendicular to the direction in which the lateral portion 316 extends. The arrangement of the first and second alternating tabs 317, 318, the lateral portion 316, and the elongated portion 311a''''' can be more easily visualized in Figure 8c, which is a top cross-sectional view of the aerosol-generation section of Figure 8a.

An exemplary method of forming the susceptor element 31g is described below. The first and second alternating tabs 317, 318 can be formed by making cuts in the sides of the sheet of susceptor material to form separate tabs on either side of the elongated portion 311a''''''. The first separate tab may be bent or shaped in a first direction to form the first alternating tab 317. The separate tab immediately adjacent to the first alternating tab 317 is not bent to form a side portion 316. The next separate tab along the opposite edge of the side portion 316, immediately adjacent to this edge, may be bent or shaped in the first direction to form another first alternating tab 317. This process may be repeated or performed simultaneously to form a configuration of alternating side portions 316 and first alternating tabs 317 on one side of the sheet of susceptor material. Similarly, cuts may be made on opposite sides of the sheet of susceptor material to form alternating side portions 316 and second alternating tabs 318, which may be bent or formed in a second direction, e.g., opposite the first direction, as shown in Figures 8a, 8b, and 8b.

Each of the exemplary susceptor elements 31a-31g may be configured to extend through the entire length of the rod of aerosol-forming composition or partially through the rod of aerosol-forming composition. For example, the susceptor element may extend through 100% of the length of the rod of aerosol-forming composition, or through about 90%, about 80%, or about 70% of the length of the rod of aerosol-forming composition.

Multiple strands or strips of aerosol-generating material 30 can be aligned within the aerosol-generating section so that their longitudinal dimensions are aligned parallel to the longitudinal axis X-X' of the article 1. Alternatively, the strands or strips can be generally arranged so that their aligned longitudinal dimensions are transverse to the longitudinal axis of the article.

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

The aerosol-forming composition includes an aerosol-forming material 30. The aerosol-forming material 30 may include a binder and an aerosol-forming agent.

An aerosol-forming material is a material capable of generating an aerosol when activated, for example, by heating, irradiation, or any other method. The aerosol-forming material 30 can be in the form of a solid, liquid, or semi-solid, such as a gel, and may or may not contain active substances and/or flavorings.

The aerosol-generating composition includes at least one aerosol-generating material 30. The aerosol-generating material 30 may include multiple aerosol-generating materials. The multiple aerosol-generating materials may be the same or different. For example, the aerosol-generating composition may include a first aerosol-generating material and a second aerosol-generating material. Additional (e.g., third, fourth, fifth, or more) aerosol-generating materials may also be included in the composition.

At least one of the aerosol-generating materials is an aerosol-generating material that includes a binder (which may be a gelling agent) and an aerosol-forming agent. Optionally, an active substance and/or a filler may also be present. Optionally, a solvent, such as water, is also present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent.

In some embodiments, the binder includes or is a gelling agent. The binder can include one or more compounds selected from the group including alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder includes one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the binder includes a hydrocolloid. In some cases, the binder includes alginate and/or pectin and may be combined with a hardening agent (calcium source), etc., during formation of the aerosol-forming material. In some cases, the aerosol-forming material may include calcium-crosslinked alginate and/or calcium-crosslinked pectin.

The binder may include one or more compounds selected from cellulosic binders, non-cellulosic binders, guar gum, acacia gum, and mixtures thereof.

In some embodiments, the cellulosic binder is selected from the group consisting of hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

In some embodiments, the binder includes (or is) one or more of hydroxyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia gum.

In some embodiments, the binder comprises one or more non-cellulosic binders (or is one or more non-cellulosic gelling agents), including, but not limited to, agar, xanthan gum, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginic acid, and combinations thereof. In preferred embodiments, the non-cellulose-based binder is alginic acid or agar.

In some examples, the binder contains alginate in an amount of about 5-40 wt %, or 15-40 wt %, of the aerosol-forming material. That is, the aerosol-forming material contains alginate in an amount of about 5-40 wt %, or 15-40 wt %, of the aerosol-forming material by dry weight. In some examples, the aerosol-forming material contains alginate in an amount of about 20-40 wt %, or about 15-35 wt %, of the aerosol-forming material.

In some examples, the binder contains pectin in an amount of about 3-15 wt % of the aerosol-forming material. That is, the aerosol-forming material contains pectin in an amount of about 3-15 wt % of the aerosol-forming material, based on the dry weight of the aerosol-forming material. In some examples, the aerosol-forming material contains pectin in an amount of about 5-10 wt % of the aerosol-forming material.

In some examples, the binder contains guar gum in an amount of about 3 to 40 wt % of the aerosol-forming material. That is, the aerosol-forming material contains guar gum in an amount of about 3 to 40 wt % based on the dry weight of the aerosol-forming material. In some examples, the aerosol-forming material contains guar gum in an amount of about 5 to 10 wt % of the aerosol-forming material. In some examples, the aerosol-forming material contains guar gum in an amount of about 15 to 40 wt %, or about 20 to 40 wt %, or about 15 to 35 wt % of the aerosol-forming material.

In examples, the alginic acid is present in an amount of at least about 50 wt% of the binder. In examples, the aerosol-forming material includes alginic acid and pectin, and the ratio of alginic acid to pectin is 1:1 to 10:1. The ratio of alginic acid to pectin is typically greater than 1:1, i.e., the alginic acid is present in an amount greater than the amount of pectin. In examples, the ratio of alginic acid to pectin is about 2:1 to 8:1, or about 3:1 to 6:1, or approximately 4:1.

The aerosol-forming material can be formed by forming a slurry and then drying the slurry to form a solid. The inclusion of a binder in the slurry results in the aerosol-forming material being formed from a dried gel. It has been found that the inclusion of a binder in the aerosol-forming material stabilizes flavor compounds, such as menthol, within the gel matrix, allowing for higher flavor loadings than non-gel compositions. The flavoring (e.g., menthol) is stable at high concentrations, and the product has a good shelf life.

In some embodiments, the binder comprises alginic acid, and the binder is present in the aerosol-forming material in an amount of 10-30 wt %, 20-35 wt %, or 25-30 wt % of the slurry/aerosol-forming material (calculated on a dry weight basis). In some embodiments, alginic acid is the only binder present in the aerosol-forming material. In other embodiments, the binder comprises alginic acid and at least one additional binder, such as pectin.

The aerosol-forming material includes an aerosol-forming agent. An "aerosol-forming agent" (also referred to herein as an aerosol-forming agent material) is an agent that facilitates the generation of an aerosol. The aerosol-forming agent can facilitate 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 agent can improve the delivery of flavorants from the aerosol-forming material. Generally, any suitable aerosol-forming agent material or agent can 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 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.

The aerosol-forming agent may be present in the aerosol-forming material in an amount up to about 80 wt% of the aerosol-forming material, such as from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10% to about 80 wt%, 75 wt%, 70 wt%, 65 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of the aerosol-forming material. In some embodiments, the aerosol-forming material includes the aerosol-forming agent in an amount of about 40-80 wt%, 40-75 wt%, 50-70 wt%, or 55-65 wt%.

In some embodiments, the aerosol-forming agent can be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. Glycerol can 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, when present, can be present in an amount of 0.1-0.3% by weight of the composition.

The aerosol former may act as a plasticizer. In some cases, the aerosol former material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol former material consists essentially of or consists of glycerol. It has been established that if the plasticizer content is too high, the aerosol-generating material can absorb water, resulting in a material that does not produce a suitable consumption experience during use. It has been established that if the plasticizer content is too low, the aerosol-generating material can become brittle and easily break. The plasticizer content specified herein provides flexibility to the aerosol-generating material, allowing the sheet to be wound onto a bobbin, which may be useful in the manufacture of consumable products or allow the sheet to be transported before shredding.

The aerosol-forming agent can enhance the mouthfeel, and generally the sensory characteristics, of the aerosol generated by the aerosol-forming material when heated and inhaled by a user, particularly when the aerosol-forming material contains a relatively large amount (e.g., >40 wt%) of the aerosol-forming agent. The ability of the aerosol-forming material to retain large amounts of the aerosol-forming agent can reduce the need to add other components of the aerosol-forming material, such as expanded plant matter material, along with large amounts of the aerosol-forming agent, thereby improving manufacturing efficiency.

The aerosol-forming material may include a filler. The filler is generally a non-tobacco component, i.e., a component that does not contain tobacco-derived materials. 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, or magnesium carbonate. 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 in an amount of 1-10% by weight of the composition. In some embodiments, no filler component is present.

In some cases, the aerosol-generating material comprises 5 to 50 wt%, 10 to 40 wt%, or 15 to 30 wt% of filler. In some such cases, the aerosol-generating material comprises at least 1 wt% of filler, e.g., at least 5 wt%, at least 10 wt%, at least 20 wt%, at least 30 wt%, at least 40 wt%, or at least 50 wt% of filler. In exemplary embodiments, the aerosol-generating material comprises 5 to 25 wt% of filler, including fibers. Preferably, the filler consists of fibers or is in the form of fibers.

In some embodiments, the aerosol-forming material contains less than 60 wt% filler, such as 1 wt% to 60 wt%, or 5 wt% to 50 wt%, or 5 wt% to 30 wt%, or 10 wt% to 20 wt%.

In other embodiments, the aerosol-forming material contains less than 20 wt%, preferably less than 10 wt%, or less than 5 wt%, of filler.

The filler may include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives (such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). Inorganic fillers, such as calcium carbonate or chalk, may also be used. In some embodiments, the aerosol-forming material does not include calcium carbonate, such as chalk.

Preferably, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or a cellulose derivative (e.g., methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). Without wishing to be bound by theory, it is believed that including a fibrous filler within the aerosol-generating material can increase the tensile strength of the material. Additionally, including a fibrous filler has been found to improve handling of the aerosol-generating material during manufacturing. In particular, the resulting aerosol-generating material has been found to be less "sticky" and, as a result, more easily shredded during manufacturing. Therefore, including a fibrous filler can increase manufacturing efficiency and reduce the likelihood of machine stoppages during shredding. Including a fibrous filler in the aerosol-generating material also means that the aerosol-generating material is less likely to clump together (e.g., clump) when shredded. When shredded aerosol-generating material is included in a consumable product, reducing clumping optimizes the distribution of the shredded aerosol-generating material within the consumable product. Therefore, having each consumable contain a similar amount of chopped aerosol-forming material likely improves the consistency of flavor loading within a batch of consumables and/or within a given consumable.

In some embodiments, the aerosol-generating material comprises the substance to be delivered. The substance to be delivered may include one or more active ingredients, one or more flavorings, one or more aerosol former materials, and/or one or more other functional materials.

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, a dietary supplement, a nootropic, or a psychoactive substance. The active substance may be naturally derived or synthetically derived. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives (including, but not limited to, the corresponding acidic forms of these materials, where appropriate), or combinations thereof. The active substance may also include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance.

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

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

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

As used herein, the term "tobacco material" refers to material derived from a plant of the Nicotiana species. The selection of the plant of the Nicotiana species is not limited, and the type or types of tobacco used may vary. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, leaf tobacco, tobacco stems, reconstituted tobacco, and/or tobacco extract. As used herein, "leaf tobacco" means cut laminar tobacco.

In some embodiments, the tobacco material is selected from flue-cured or Virginia, burley, sun-cured, Maryland, dark (fire-cured), dark (air-cured), light (air-cured), Indian (air-cured), Red Russian, and rustica tobaccos, and mixtures thereof, as well as various other rare or specialty tobaccos (green or cured). Tobacco materials produced through any other type of tobacco processing that can modify the tobacco taste, such as fermented tobacco or genetic modification or hybridization techniques, are also within the scope of this disclosure. For example, it is contemplated that tobacco plants may be genetically engineered or hybridized to increase or decrease the production of a component, property, or attribute.

In some embodiments, the tobacco material is sun-cured tobacco selected from Indian Kurnool and Oriental tobaccos, including Izmir, Basma, Samsun, Katerini, Prelip, Komotini, Xanthi, and Yambol tobaccos. In some embodiments, the tobacco material is dark (air-cured) tobacco selected from Passanda, Cubano, Jatin, and Beski tobaccos. In some embodiments, the tobacco material is light (air-cured) tobacco selected from North Wisconsin and Galpao tobaccos.

In some embodiments, the tobacco material is selected from Brazilian tobacco, including Matafina and Bahia tobacco. In some embodiments, the tobacco material is selected from Criollo, Pilotto Cubano, Olor, Green River, Isabela DAC, White Pata, Elulu, Jatim, Madura, Kasturi, Connecticut Seed, Broadleaf, Connecticut, Pennsylvania, Italian (air-cured), Paraguayan (air-cured), and Wansucker tobacco.

For the preparation of smokeable/electronic smoking or smokeless tobacco products, plants of the Nicotiana species may be subjected to a curing method. Certain types of tobacco may be subjected to other types of curing methods, such as flue-curing or sun-drying. Preferably, but not necessarily, the cured harvested tobacco is aged.

Tobacco can be harvested at different stages of growth, for example, when the plant reaches a level of maturity and the lower leaves can be harvested while the upper leaves are still growing.

In some embodiments, at least a portion of a plant of the Nicotiana species (e.g., at least a portion of the tobacco material) is used in an immature form. That is, in some embodiments, the plant or at least a portion of the plant is harvested before reaching a stage normally considered ripe or mature.

In some embodiments, at least a portion of a plant of the Nicotiana species (e.g., at least a portion of the tobacco material) is used in a mature form. That is, in some embodiments, the plant or at least a portion of the plant is harvested when the plant (or plant portion) has reached a point traditionally considered ripe, overripe, or mature, and harvesting can be done using tobacco harvesting techniques traditionally used by farmers. Both Oriental and Burley tobacco plants can be harvested. Additionally, Virginia tobacco leaves can be harvested or picked according to the position of their petioles.

Nicotiana species may be selected for the content of various compounds present in the plants. For example, plants may be selected based on their production of relatively large amounts of one or more of the compounds desired to be isolated (i.e., volatile compounds of interest). In certain embodiments, Nicotiana species plants are specifically cultivated for their abundance of leaf surface compounds. Tobacco plants may be grown in greenhouses, growth chambers, or outdoor fields, or may be grown hydroponically.

Various parts or portions of the Nicotiana species plant may be utilized. In some embodiments, the whole plant or substantially the whole plant is harvested and used as is. As used herein, the term "substantially the whole plant" means that at least 90% of the plant is harvested, such as at least 95% of the plant, for example, at least 99% of the plant. Alternatively, in some embodiments, various parts or pieces of the plant are harvested or separated for further use after harvest. In some embodiments, the tobacco material is selected from the leaves, stems, petioles, and various combinations of these parts of the plant. Thus, the tobacco material of the present disclosure may include the whole Nicotiana species plant or any part of the plant.

The tobacco material may comprise or consist of reconstituted tobacco, tobacco lamina, paper reconstituted tobacco, extruded tobacco, band-cast reconstituted tobacco, band-cast reconstituted tobacco, or a combination of reconstituted tobacco and another form of tobacco, such as tobacco lamina or tobacco granules.

In some embodiments, the aerosol-forming material is substantially free of plant material. In particular, in some embodiments, the aerosol-forming material is substantially free of 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 substance 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 to be delivered includes a fragrance.

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

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

In some embodiments, the aerosol-forming material may contain up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% flavoring. In some cases, the aerosol-forming material may contain at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% flavoring (all calculated on a dry weight basis). For example, the aerosol-forming material may contain 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% flavoring. In exemplary embodiments, the aerosol-forming material contains 35-50 wt% flavoring. In some cases, the flavoring includes, consists essentially of, or consists of menthol.

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

The aerosol-forming composition may include an aerosol-forming material in the form of an "amorphous solid." The amorphous solid may be a "monolithic solid." In some embodiments, the aerosol-forming material may be a dry gel.

The aerosol-generating composition may include an aerosol-generating material in the form of an aerosol-generating film. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-forming agent, and one or more other ingredients, such as an active agent, to form a slurry, and then heating the slurry to volatilize at least some of the solvent and form the aerosol-generating film. The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent. The aerosol-generating film may be a continuous or discontinuous film, such as a construction of separate portions of film on a substrate. The aerosol-generating film may be substantially free of tobacco.

The aerosol-generating material may include or be a sheet, which may optionally be shredded to form shredded sheets. The sheet of aerosolizable material may be cut lengthwise and/or widthwise, e.g., in a cross-cut shredding process, to define a cut length of strands or strips of aerosolizable material in addition to a cut width.

The aerosol-generating composition can include any combination of the above aerosol-generating materials. For example, the aerosol-generating composition can include a mixture of aerosol-generating materials, at least one of which includes a binder and an aerosol-forming agent. In some embodiments, the aerosol-generating composition includes a (e.g., first) aerosol-generating material that includes a binder and an aerosol-forming agent, and a (e.g., second) different aerosol-generating material. For example, the second aerosol-generating material can be a plant material such as tobacco lamina.

In some embodiments, the aerosol-generating material is prepared by forming a slurry including components of the aerosol material or its precursor, forming a layer of the slurry, solidifying the slurry to form a gel, and drying to form the aerosol-generating material. Optionally, the step of solidifying the gel can include applying a solidifying agent to the slurry. In some embodiments, the solidifying agent is sprayed onto the slurry, such as on top of the slurry.

In some embodiments, the solidifying agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof. In some embodiments, the solidifying agent comprises or consists of calcium formate and/or calcium lactate. In particular embodiments, the solidifying agent comprises or consists of calcium formate. It has been determined that the use of calcium formate as the solidifying agent typically results in aerosol-generating materials having higher tensile strength and higher resistance to elongation.

The total amount of hardening agent, such as a calcium source, may be 0.5 to 5 wt % (calculated on a dry weight basis). Preferably, the total amount may be from about 1 wt %, 2.5 wt %, or 4 wt % to about 4.8 wt % or 4.5 wt %. It has been found that adding too little hardening agent can result in an aerosol-forming material that does not stabilize the components of the aerosol-forming material, causing these components to drop out of the aerosol-forming material. It has been found that adding too much solidifying agent can result in an aerosol-forming material that is very sticky and therefore difficult to handle.

When the aerosol-forming material does not contain tobacco, a larger amount of hardener may need to be applied. Thus, in some cases, the total amount of hardener may be 0.5 to 12 wt%, such as 5 to 10 wt%, calculated on a dry weight basis. Preferably, the total amount may be from about 5 wt%, 6 wt%, or 7 wt% to about 12 wt% or 10 wt%. In this case, the aerosol-forming material typically does not contain tobacco.

The process involves forming a layer of the slurry. This typically involves spraying, casting, or extruding the slurry. In an example, the slurry layer is formed by electrostatically spraying the slurry. In an example, the slurry layer is formed by casting the slurry.

In some instances, all steps of the process occur at least partially simultaneously (e.g., during electrostatic spraying). In some instances, steps of the process occur sequentially.

The aerosol-generating material may contain 1-60 wt% gelling agent, 0.1-70 wt% aerosol former material, 5-50% filler in the form of fibers, and 0.1-80 wt% flavoring and/or active substance.

The aerosol-generating material may comprise 10-40 wt% gelling agent, 10-70 wt% aerosol former material, 20-40 wt% filler, and optionally 10-50 wt% flavoring.

In an embodiment, the aerosol-forming material comprises alginate in an amount of 32.8 wt%, glycerol in an amount of 19.2 wt%, and menthol in an amount of 48 wt%.

In one embodiment, the aerosol-forming material comprises alginate in an amount of 26.2 wt%, glycerol in an amount of 15.4 wt%, menthol in an amount of 38.4 wt%, and fiber (derived from wood pulp) in an amount of 20 wt%.

In an embodiment, the aerosol-forming material comprises alginate in an amount of 32 wt%, pectin in an amount of 8 wt%, and glycerol in an amount of 60 wt%.

In an embodiment, the aerosol-forming material comprises alginate in an amount of 24 wt%, pectin in an amount of 6 wt%, cellulose fiber in an amount of 10 wt%, and glycerol in an amount of 60 wt%.

In an embodiment, the aerosol-forming material comprises carboxymethyl cellulose (CMC) in an amount of about 7 wt%, cellulose fibers (derived from wood pulp) in an amount of about 43 wt%, and glycerol in an amount of about 50 wt%.

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

The cooling section 8 includes a hollow channel having an inner diameter of about 1 mm to about 4 mm, for example, about 2 mm to about 4 mm. In this example, the hollow channel has an inner diameter of about 3 mm. The hollow channel extends along the entire length of the cooling section 8. In this example, the cooling section 8 includes a single hollow channel. In alternative embodiments, the cooling section may include multiple channels, for example, two, three, or four channels. In this example, the single hollow channel is substantially cylindrical, although other channel shapes/cross-sections may be used in alternative embodiments. The hollow channel may provide space in which aerosol drawn into the cooling section 8 can expand and cool. In all embodiments, the cooling section is configured to limit the cross-sectional area of the hollow channel and limit the displacement of tobacco into the cooling section during use.

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

The cooling section 8 is formed from filament tow. Multiple paper layers wound in parallel and butt-stitched to form the cooling section 8 may also be used, or other configurations may be used, such as spirally wound paper, cardboard tubes, tubes formed using a papier-mâché process, molded or extruded plastic tubes, or the like. The cooling section 8 is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacturing and use of the article 1.

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

The filament tows forming the cooling section 8 preferably have a total fineness of less than 45,000, more preferably less than 42,000. This total fineness has been found to enable the formation of a cooling section 8 that is not too dense. The total fineness is preferably at least 20,000, more preferably at least 25,000. In preferred embodiments, the filament tows forming the cooling section 8 have a total fineness of 25,000 to 45,000, more preferably 35,000 to 45,000. The cross-sectional shape of the filaments in the tow is preferably "Y" shaped, although other shapes, such as "X" shaped filaments, can be used in other embodiments.

The filament tow forming the cooling section 8 preferably has a monofilament fineness greater than 3. This monofilament fineness has been found to enable the formation of tubular elements 4 that are not too dense. The monofilament fineness is preferably at least 4, more preferably at least 5. In a preferred embodiment, the filament tow forming the hollow tubular elements 4 has a monofilament fineness of 4 to 10, more preferably 4 to 9. In one example, the filament tow forming the cooling section 8 has an 8Y40,000 tow formed from cellulose acetate and includes 18% plasticizer, such as triacetin.

The density of the material forming the cooling section 8 is preferably at least about 0.20 grams per cubic centimeter (g/cc), more preferably at least about 0.25 g/cc. The density of the material forming the cooling section 8 is preferably less than about 0.80 grams per cubic centimeter (g/cc), more preferably less than about 0.6 g/cc. In some embodiments, the density of the material forming the cooling section 8 is 0.20 to 0.8 g/cc, more preferably 0.3 to 0.6 g/cc, or 0.4 g/cc to 0.6 g/cc, or about 0.5 g/cc. These densities have been found to provide a good balance between the improved stiffness afforded by a higher density material and minimizing the overall weight of the article. For purposes of this invention, the "density" of the material forming the cooling section 8 refers to the density of any filament tows forming the element into which any plasticizer is incorporated. Density can be determined by dividing the total weight of the material forming the cooling section 8 by the total volume of the material forming the cooling section 8, and the total volume can be calculated using appropriate measurements of the material forming the cooling section 8, for example, obtained using calipers. If necessary, appropriate dimensions can be measured using a microscope.

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

The cooling section 8 is disposed around and defines a cavity within the mouthpiece 2 that acts as the cooling section. The cavity provides a chamber through which heated volatile components generated by the rod of aerosol-generating material 3 flow. The cooling section 8 is hollow, providing an aerosol accumulation chamber that is sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacturing and use of the article 1. The cooling section 8 provides a physical displacement between the aerosol-generation section 3 and the body of material 6. The physical displacement provided by the cooling section 8 provides a thermal gradient across the length of the cooling section 8.

Preferably, the mouthpiece 2 includes a cavity having an internal volume greater than 110 mm ^3. It has been found that providing a cavity of at least this volume allows for improved aerosol formation. More preferably, the mouthpiece 2 includes a cavity (e.g., a cavity formed within the cooling section 8) having an internal volume greater than 110 mm ³ , and even more preferably greater than 130 mm ³ , thereby further improving the aerosol. In some examples, the internal cavity includes a volume of between about 130 mm ³ and about 230 mm ³ , for example, about 134 mm ³ or 227 mm ³ .

The cooling section 8 can be configured to provide a temperature difference of at least 40°C between the heated volatile components entering the first upstream end of the cooling section 8 and the heated volatile components exiting the second downstream end of the cooling section 8. The cooling section 8 is preferably configured to provide a temperature difference of at least 60°C, more preferably at least 80°C, and even more preferably at least 100°C between the heated volatile components entering the first upstream end of the cooling section 8 and the heated volatile components exiting the second downstream end of the cooling section 8. This temperature difference across the length of the cooling section 8 protects the temperature-sensitive body of material 6 from the high temperatures of the aerosol-generation section 3 when heated.

In use, the aerosol-generation section may exhibit a pressure drop of about 15 to about 40 mm H ₂ O. In some embodiments, the aerosol-generation section 3 exhibits a pressure drop across the aerosol-generation section of about 15 to about 30 mm H 2 O.

The aerosol-forming material 30 may have a packing density of about 400 mg/cm ³ to about 900 mg/cm ³ within the aerosol-generation section 3. Higher packing densities may increase the pressure drop.

At least about 45% of the volume of the aerosol-generating section 3 is filled with aerosol-generating material 30. In some embodiments, about 65% to about 85% of the volume of the cavity is filled with aerosol-generating material 30. The susceptor elements 31 can fill about 1% of the volume of the aerosol-generating section 3, or up to about 5% of the volume of the aerosol-generating section 3. Advantageously, the uneven susceptor elements 31 can provide a structure for providing gaps in the aerosol-generating material 30 to the rod of aerosol-generating composition while also gripping and rod-removing the aerosol-generating material 30, thereby reducing the amount of aerosol-generating material required. In some examples, the susceptor elements 31 and aerosol-generating material 30 can fill up to about 50% of the volume of the aerosol-generating section 3, or up to about 60% of the volume of the aerosol-generating section 3, or up to about 70% of the volume of the aerosol-generating section 3, or up to about 80% of the volume of the aerosol-generating section 3.

In this embodiment, the moisture-impermeable wrapper 10 surrounding the rod of aerosol-forming material comprises aluminum foil. In other embodiments, the wrapper 10 comprises a paper wrapper, optionally including a barrier coating that renders the wrapper material substantially moisture-impermeable. Aluminum foil has been found to be particularly effective in promoting aerosol formation within the aerosol-generation section 3. In this example, the aluminum foil has a metal layer having a thickness of approximately 6 μm. In this example, the aluminum foil has a paper backing. However, in alternative configurations, the aluminum foil can be of other thicknesses, for example, from 4 μm to 16 μm. The aluminum foil also need not have a paper backing and can have a backing formed from another material, for example, to help provide the foil with adequate tensile strength, or can have no backing material at all. Metal layers or foils other than aluminum can also be used. The total thickness of the wrapper is preferably 20 μm to 60 μm, more preferably 30 μm to 50 μm, which can provide a wrapper with adequate structural integrity and heat transfer properties. The pulling force that can be applied to the wrapper before it breaks can be greater than 3,000 grams of force, for example, 3,000 to 10,000 grams of force, or 3,000 to 4,500 grams of force. When the wrapper comprises paper or a paper backing, i.e., a cellulose-based material, the wrapper can have a basis weight greater than about 30 gsm. For example, the wrapper can have a basis weight in the range of about 40 gsm to about 70 gsm. Such a basis weight provides high stiffness to the rod of aerosol-forming composition. The high stiffness provided by a wrapper having a basis weight in this range can make the aerosol-generating section 3 more resistant to wrinkling or other deformation due to forces experienced by the article during use. Providing a rod of aerosol-generating composition with high stiffness can be advantageous when multiple strands or strips of aerosol-generating material are aligned within the aerosol-generating section with their longitudinal dimensions aligned parallel to the longitudinal axis. This is because the longitudinally aligned strands or strips of aerosol-forming material can impart less stiffness to the rod of aerosol-forming composition than when the strands or strips are not aligned. The increased stiffness of the rod of aerosol-forming composition allows the article to withstand the increased forces to which the article is subjected during use.

In this example, the moisture-impermeable wrapper 10 is also substantially impermeable to air. In an alternative embodiment, the wrapper 10 preferably has a permeability of less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that a low-permeability wrapper, for example, having a permeability of less than 100 Coresta units, more preferably less than 60 Coresta units, results in improved aerosol formation in the aerosol-generation section 3. Without wishing to be bound by theory, it is hypothesized that this is due to reduced loss of aerosol compound in the wrapper 10. The permeability of the wrapper 10 can be measured in accordance with ISO 2965:2009 for determination of the air permeability of materials used as cigarette paper, filter plug wrap, and filter bonding paper.

The body of material 6 and the hollow tubular element 4 each define a substantially cylindrical overall outer shape and share a common longitudinal axis. The body of material 6 is rolled up within a first plug wrap 7. The first plug wrap 7 preferably has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. The first plug wrap 7 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The first plug wrap 7 is preferably a non-porous plug wrap, e.g., having a permeability of less than 100 Coresta units, e.g., less than 50 Coresta units. However, in other embodiments, the first plug wrap 7 can be a porous plug wrap, e.g., having a permeability of greater than 200 Coresta units.

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

In this example, the body of material 6 is formed from filament tow. In this example, the tow used in the body of material 6 has a d.p.f. (d.p.f.) of 5 and a total d.p.f. of 25,000. In this example, the tow comprises plasticized cellulose acetate tow. The plasticizer used in the tow accounts for approximately 9% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, a different material can be used to form the body of material 6. For example, rather than tow, the body 6 can be formed from paper, for example, in a manner similar to paper filters known for use in cigarettes. For example, the paper or other cellulose-based material can be provided as one or more portions of a sheet material that is folded and/or corrugated to form the body 6. The sheet material can have a basis weight of 15 gsm to 60 gsm, for example, 20 to 50 gsm. The sheet material may have a basis weight ranging from, for example, 15 to 25 gsm, 25 to 30 gsm, 30 to 40 gsm, 40 to 45 gsm, and 45 to 50 gsm. Additionally or alternatively, the sheet material may have a width ranging from 50 mm to 200 mm, e.g., from 60 mm to 150 mm or from 80 mm to 150 mm. For example, the sheet material may have a basis weight of 20 to 50 gsm and a width of 80 mm to 150 mm. This may allow, for example, the cellulose-based body to have an appropriate pressure drop for an article having the dimensions described herein.

Alternatively, the body 6 can be formed from a tow other than cellulose acetate, such as polylactic acid (PLA), other materials described herein with respect to filament tow, or similar materials. The tow is preferably formed from cellulose acetate. Whether formed from cellulose acetate or another material, the tow preferably has a d.p.f. of at least 5. To achieve a sufficiently uniform body 6 of material, the tow preferably has a monofilament fineness of 12 d.p.f. or less, preferably 11 d.p.f. or less, and even more preferably 10 d.p.f. or less.

The total fineness of the tow forming the body of material 6 is preferably at most 30,000, more preferably at most 28,000, and even more preferably at most 25,000. These total fineness values provide the tow with a smaller percentage of the cross-sectional area of the mouthpiece 2, resulting in a lower pressure drop across the mouthpiece 2 than tows with higher total fineness values. For a body of material 6 of appropriate stiffness, the tow preferably has a total fineness of at least 8,000, more preferably at least 10,000. The single fineness is preferably 5 to 12, and the total fineness is preferably 10,000 to 25,000. The cross-sectional shape of the filaments of the tow is preferably "Y" shaped, although other shapes, such as "X" shaped filaments, having the same d.p.f. and total fineness values provided herein may be used in other embodiments.

Regardless of the material used to form the body 6, the pressure drop across the body 6 can be, for example, 0.3 to 5 mmWG per mm of body 6 length, e.g., 0.5 to 2 mmWG per mm of body 6 length. The pressure drop can be, for example, 0.5 to 1 mmWG/mm of length, 1 to 1.5 mmWG/mm of length, or 1.5 to 2 mmWG/mm of length. The total pressure drop across the body 6 can be, for example, 3 to 8 mmWG, or 4 to 7 mmWG. The total pressure drop across the body 6 can be approximately 5, 6, or 7 mmWG.

As shown in FIG. 1 , the mouthpiece 2 of the article 1 has an upstream end 2a adjacent the aerosol-generation section 3 and a downstream end 2b remote from the aerosol-generation section 3. The mouthpiece 2 has a hollow tubular element 4 formed from filament tow at the downstream end 2b. Advantageously, this has been found to significantly reduce the temperature of the outer surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece, which contacts the consumer's mouth, when the article 1 is in use. In addition, the use of the tubular element 4 has also been found to significantly reduce the temperature of the outer surface of the mouthpiece 2 further upstream of the tubular element 4. While not wishing to be bound by theory, it is hypothesized that this is due to the tubular element 4 causing the aerosol to pass 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.

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

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

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

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

The filament tow forming the hollow tubular element 4 preferably has a monofilament fineness greater than 3. This monofilament fineness has been found to enable the formation of a tubular element 4 that is not too dense. Preferably, the monofilament fineness is at least 4, more preferably at least 5. In a preferred embodiment, the filament tow forming the hollow tubular element 4 has a monofilament fineness of 4 to 10, more preferably 4 to 9. In one example, the filament tow forming the hollow tubular element 4 has a 7.3Y36,000 tow formed from cellulose acetate and includes 18% plasticizer, such as triacetin.

Preferably, the hollow tubular element 4 has an inner diameter greater than 3.0 mm. A smaller diameter may undesirably increase the velocity of the aerosol passing through the mouthpiece 2 and into the consumer's mouth, resulting in the aerosol becoming too warm, for example reaching temperatures greater than 40°C or even greater than 45°C. More preferably, the hollow tubular element 4 has an inner diameter greater than 3.1 mm, and even more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the inner diameter of the hollow tubular element 4 is approximately 4.7 mm.

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

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

In this example, Article 1 has a circumference of approximately 23 mm. In other examples, the article may be provided in any of the formats described herein, for example, having a circumference of 20 mm to 26 mm. Because the article is heated to release the aerosol, improved heating efficiency can be achieved using an article having a smaller circumference within this range, for example, a circumference less than 23 mm. It has also been found that an article circumference greater than 19 mm is particularly effective for achieving improved aerosol upon heating while maintaining an adequate product length. Articles having a circumference of 20 mm to 24 mm, more preferably 20 mm to 23 mm, have been found to provide a good balance between effective aerosol delivery and allowing efficient heating.

Tipping paper 5 is wrapped around the entire length of mouthpiece 2 and a portion of aerosol-generating section 3, and has adhesive on its inner surface, connecting mouthpiece 2 and rod 3. In this example, the rod of aerosol-generating composition is wrapped in wrapper 10, which forms a first wrapping material, and tipping paper 5 forms an outer wrapping material that extends at least partially over the rod of aerosol-generating composition and connects mouthpiece 2 and aerosol-generating section 3. In some examples, the tipping paper can extend only partially over the aerosol-generating section.

In this example, the tipping paper 5 extends 5 mm over the aerosol-generation section 3, but may alternatively extend 3 mm to 10 mm, or more preferably 4 mm to 6 mm, over the rod 3 to securely attach the mouthpiece 2 to the rod 3. The tipping paper may have a basis weight of more than 20 gsm, for example more than 25 gsm, or preferably more than 30 gsm, for example 37 gsm. Basis weights in these ranges have been found to provide tipping paper with acceptable tensile strength yet sufficient flexibility to wrap around the article 1 and adhere to itself along the paper's longitudinal lap seam. After being wrapped around the mouthpiece 2, the tipping paper 5 has a circumference of approximately 23 mm.

The article has a ventilation level of approximately 10% of the aerosol drawn through the article. In an alternative embodiment, the article may have a ventilation level of 1% to 20%, for example 1% to 12%, of the aerosol drawn through the article. These levels of ventilation help to increase the concentration of aerosol inhaled by the user at the mouth end 2b and aid in the aerosol cooling process. The ventilation is provided directly in the mouthpiece 2 of the article 1. In this example, the ventilation is provided in the cooling section 8, which has been found to be particularly advantageous in aiding the aerosol generation process. The ventilation is provided by perforations 12, in this case formed as a single row of laser perforations located 13 mm from the mouth end 2b downstream of the mouthpiece 2. In an alternative embodiment, more than one row of ventilation perforations may be provided. These perforations pass through the tipping paper 5, the second plug wrap 9, and the cooling section 8. In alternative embodiments, the vent may be located elsewhere in the mouthpiece, such as in the body of material 6 or the first tubular element 4. The article is preferably configured so that the perforations are located no more than about 28 mm from the upstream end of the article 1, preferably between 20 mm and 28 mm from the upstream end of the article 1. In this example, the opening is located about 25 mm from the upstream end of the article.

Figure 2a is a side cross-sectional view of a further article 1' including a capsule-containing mouthpiece 2'. Figure 2b is a side cross-sectional view of the capsule-containing mouthpiece shown in Figure 2a, taken through line A-A' in Figure 2a. Article 1' and capsule-containing mouthpiece 2' are the same as article 1 and mouthpiece 2 shown in Figure 1, except that the aerosol modifier is provided within the body of material 6, in this example in the form of capsules 11, and an oil-resistant first plug wrap 7' surrounds the body of material 6. In other examples, the aerosol modifier can be provided in other forms, such as a material infused into the body of material 6, or on a thread, for example, a thread carrying a flavoring or other aerosol modifier, which can also be disposed within the body of material 6.

The capsule 11 may comprise a breakable capsule, e.g., a capsule having a solid, frangible shell surrounding a liquid payload. In this example, a single capsule 11 is used. The capsule 11 is embedded entirely within the body of material 6. In other words, the capsule 11 is completely surrounded by the material forming the body 6. In other examples, multiple breakable capsules, e.g., two or more breakable capsules, may be disposed within the body of material 6. The length of the body of material 6 may be increased to accommodate the required number of capsules. In examples where multiple capsules are used, the individual capsules may be identical to one another or may differ from one another in terms of size and/or capsule payload. In other examples, multiple bodies of material 6 may be provided, each containing one or more capsules.

The capsule 11 has a core-shell structure. In other words, the capsule 11 includes a shell that encapsulates a liquid agent, for example, a flavorant or other agent, which may be any of the flavorants or aerosol modifiers described herein. The capsule shell can be ruptured by a user to release the flavorant or other agent into the body of material 6. The first plug wrap 7' may include a barrier coating to render the plug wrap material substantially impermeable to the liquid payload of the capsule 11. Alternatively or additionally, the second plug wrap 9 and/or tipping paper 5 may include a barrier coating to render the plug wrap and/or tipping paper material substantially impermeable to the liquid payload of the capsule 11.

In this example, capsule 11 is spherical and has a diameter of approximately 3 mm. In other examples, other capsule shapes or sizes can be used. For example, the capsule can have a diameter of less than 4 mm, or less than 3.5 mm, or less than 3.25 mm. In alternative embodiments, the capsule can have a diameter of greater than approximately 3.25 mm, e.g., greater than 3.5 mm, or greater than 4 mm. The total weight of capsule 11 can be in the range of approximately 10 mg to approximately 50 mg.

In this example, the capsule 11 is positioned at a longitudinally central location within the body of material 6. That is, the capsule 11 is positioned so that its center is 5 mm from each end of the body of material 6. In this example, the center of the capsule is positioned 36 mm from the upstream end of the article 1. The capsule is preferably positioned so that its center is 28 mm to 38 mm from the upstream end of the article 1, more preferably 34 mm to 38 mm from the upstream end of the article 1. In this example, the center of the capsule is positioned 12 mm from the downstream end of the mouthpiece 2b. As a result of locating the capsule in this position, volatilization of the capsule contents is improved due to the capsule's proximity to the aerosol-generation section of the article, which is heated during use, while still being far enough away from the aerosol-generation section that is inserted into the aerosol delivery system during use to allow a user to easily access and rupture the capsule with their fingers.

In other examples, the capsule 11 may be positioned at a position other than the longitudinal center of the body of material 6, i.e., closer to the downstream end of the body of material 6 than the upstream end, or closer to the upstream end of the body of material 6 than the downstream end. The mouthpiece 2' is preferably configured so that the capsule 11 and ventilation holes 12 are longitudinally offset from each other in the mouthpiece 2'. For example, the ventilation holes 12 may be provided immediately upstream of the capsule position, i.e., approximately 1 mm to approximately 10 mm upstream of the capsule position.

Item 1 is suitable for use with a non-combustible aerosol delivery device.

Figure 10 shows an example of a non-combustible aerosol delivery device 16 having a proximal end 16a and a distal end 16b.

In general, device 16 can be used to cause article 1, including a susceptor and an aerosol-generating material, such as article 1 described herein, to generate an aerosol that is inhaled by a user of device 16. Together, device 16 and article 1 form a system.

Device 16 comprises a magnetic field generator including a coil 17 configured to generate a varying magnetic field. The varying magnetic field generates heat in a susceptor within article 1, which in turn heats the resulting aerosol to form an aerosol.

Device 16 includes a housing 18 that encloses and contains the various components of device 16. Device 16 has an opening 19 at one end through which item 1 can be inserted. In use, item 1 can be fully or partially inserted into the heating assembly.

Device 16 may also include a user-actuable control element 20, such as a button or switch, that, when pressed, operates device 16. For example, a user may turn device 16 on by operating switch 20.

Device 16 may also include an electrical component such as a socket/port 21 capable of receiving a cable for charging device 100's power source 22. For example, socket 21 may be a charging port, such as a USB charging port.

In use, a user inserts the item 1 into the opening 19 and operates the user control 20 to initiate heating of the aerosol-generating material, utilizing the aerosol generated within the device. This causes the aerosol to flow through the device 16 along the flow path toward the proximal end 16a of the device 16.

The other end of the device furthest from the opening 19 may be known as the distal end 16b of the device 16, as it is the end furthest from the user's mouth during use. When a user utilizes the aerosol generated within the device, the aerosol flows away from the distal end of the device 100.

The power source 22 may be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (e.g., lithium-ion batteries), nickel batteries (e.g., nickel-cadmium batteries), and alkaline batteries. The battery is electrically coupled to the magnetic field generator to provide power under the control of a controller (not shown) when the aerosol-generating material needs to be heated.

The device further includes at least one electronics module 23. The electronics module 23 may include, for example, a printed circuit board (PCB). The PCB 23 may support at least one controller, such as a processor and memory. The PCB 23 may also include one or more electrical tracks for electrically connecting the various electronic components of the device 16 together. For example, battery terminals (not shown) may be electrically connected to the PCB 23 so that power can be distributed throughout the device 16. The socket 21 may also be electrically coupled to a battery via electrical tracks.

Device 16 includes a magnetic field generator including a coil 17 configured to inductively heat a susceptor within article 1.

Coil 17 is an inductor coil. Inductor coils are made from a conductive material. In this example, the inductor coil is made from litz wire/cable that is spirally wound to form a helical inductor coil. Litz wire includes multiple individual wires that are individually insulated and twisted together to form a single wire. Litz wire is designed to reduce skin effect losses in the conductor. In exemplary device 16, the inductor coil is made from copper, and the litz wire has a rectangular cross-section. In other examples, the litz wire may have other cross-section shapes, such as circular.

The inductor coil 17 is configured to generate a first varying magnetic field for heating the susceptor of the article. The inductor coil 17 can be connected to the PCB 23.

The device includes an inductor coil support tube 24. The coil support tube 24 is defined by an outer surface and an inner surface. The outer surface of the coil support tube supports the inductor coil of the magnetic field generator 17. The inner surface defines a cavity into which the item 1 can be inserted. The tube 24 is preferably made from a material that is not heatable by penetration by a fluctuating magnetic field. This prevents the inductor from heating the tube during use and also reduces power consumption.

Referring to FIG. 10, device 16' includes two magnetic field generators, including first inductor coil 17a and second inductor coil 17b. First inductor coil 17a is configured to generate a first varying magnetic field for heating a susceptor in article 1, and second inductor coil 17b is configured to generate a second varying magnetic field for heating a second susceptor. In this example, first inductor coil 17a is adjacent to second inductor coil 17b in a direction along the longitudinal axis of device 16 (i.e., first inductor coil 17a and second inductor coil 17b do not overlap). First inductor coil 17a and second inductor coil 17b can be connected to PCB 23. The first and second coils are supported by coil support tube 24'.

It will be appreciated that in some examples, the first inductor coil 17a and the second inductor coil 17b can have at least one characteristic that differs from one another. For example, the first inductor coil 17a can have at least one characteristic that differs from the second inductor coil 17b. More specifically, in one example, the first inductor coil 17a can have a different inductance value than the second inductor coil 17b. The first inductor coil 17a and the second inductor coil 17b can be different lengths. Thus, the first inductor coil 17a can include a different number of turns than the second inductor coil 17b (assuming the spacing between individual turns is substantially the same). In yet another example, the first inductor coil 17a can be made of a different material than the second inductor coil 17b. In some examples, the first inductor coil 17a and the second inductor coil 17b can be substantially identical.

In this example, the first inductor coil 17a and the second inductor coil 17b are wound in opposite directions. This can be useful when the inductor coils are active at different times. For example, initially, the first inductor coil 17a may be operating to heat a first section/portion of the item 110, and at a later time, the second inductor coil 17b may be operating to heat a second section/portion of the item 110. Winding the coils in opposite directions can help reduce current buildup in inactive coils when used in conjunction with certain types of control circuitry. In FIG. 10, the first inductor coil 17a is a right-handed spiral and the second inductor coil 17b is a left-handed spiral. However, in other embodiments, the inductor coils 17a and 17b can be wound in the same direction, or the first inductor coil 17a can be a left-handed spiral and the second inductor coil 17b can be a right-handed spiral.

In use, the article 1 described herein can be inserted into a non-combustible aerosol delivery device, such as the devices 16 and 16' described with reference to Figures 10 and 11. At least a portion of the mouthpiece 2 of the article 1 protrudes from the non-combustible aerosol delivery device 16, 16' and can be placed in the mouth of a user. An aerosol is generated by using the device 16, 16' to heat the aerosol-generating section 3 containing the aerosol-generating material and a susceptor at least partially embedded in the aerosol-generating material. The aerosol generated by the aerosol-generating material passes through the mouthpiece 2 and into the user's mouth.

Referring to FIG. 12, the magnetic field generator includes a single coil 17. The magnetic field generator is configured to inductively heat a susceptor within the aerosol-forming composition 3 by generating a varying magnetic field.

The outer surface of the article 1 can be dimensioned so that the outer surface of the article 1 abuts the inner surface of the coil support tube 24'. This ensures that the aerosol generation section is closer to the coil 17 and therefore heating is most efficient.

Figure 13 shows an article 1 described herein received within a coil support tube 24' of a device 16'. The magnetic field generator includes two coils 17a and 17b, which allows different portions of the aerosol-generation section 3 to be heated at different times and/or to different temperatures.

The various embodiments described herein are presented solely as an aid in understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not intended to be exhaustive and/or exclusive. It is understood that the advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein should not be construed as limitations on the scope of the invention as defined by the claims or equivalents thereof, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. The various embodiments of the present invention may suitably include, 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. Additionally, the present disclosure may include other inventions not claimed herein but which may be claimed in the future.

Claims (13)

1. An aerosol-generating component for use with a non-combustion aerosol-delivery device, the aerosol-generating component including a heating material in thermal contact with an aerosol-forming material, the heating material including a plurality of elongated portions extending in a first direction through or around the aerosol-forming material, the elongated portions being substantially parallel;
An aerosol generating component , wherein the heating material includes elongated portions connected at ends by connecting portions, the connecting portions forming curved sections at both ends of the heating material . The aerosol-generating component of claim 1 , wherein the aerosol-generating material comprises a plurality of strands of aerosol-generating material. The aerosol-generating component of claim 1 , wherein the heating material is uneven. The aerosol-generating component of any one of claims 1 to 3, wherein the heating material is in the form of a susceptor. An aerosol-generating component according to any one of claims 1 to 3, wherein the multiple elongated portions together form a single continuous piece of heating material. The aerosol-generating component of any one of claims 1 to 3, wherein the multiple elongated portions are arranged in a spaced-apart configuration. 4. The aerosol-generating component of claim 1, wherein the heating material comprises 2 to 6 of the elongated portions. The aerosol-generating component of any one of claims 1 to 3, wherein each of the multiple elongated portions is formed from a different material. The aerosol-generating component of any one of claims 1 to 3, wherein each of the multiple elongated portions is formed from the same material. 4. An aerosol-generating component according to any one of claims 1 to 3, wherein the aerosol-generating component comprises a junction portion extending from a central location of the connecting portion to each elongated end of the component . An article for use with a non-combustible aerosol delivery device, comprising the aerosol generating component of claim 1. The article of claim 11 , further comprising a mouthpiece disposed downstream of the aerosol-generating component. a non-combustible aerosol delivery device;
an aerosol-generating component according to any one of claims 1 to 3 or an article according to claim 11 or 12 ;
A non-flammable aerosol delivery system comprising: