UA129250C2 - Component for use in an aerosol provision system - Google Patents

Abstract

A component for use in a non-combustion aerosol delivery system comprises an inner body (11) comprising a first material and an outer body (12) comprising a second material, the outer body surrounding the inner body. The resistance to gas flow through the length of the inner body is less than the resistance to gas flow through the length of the outer body. Also provided is an article of manufacture for use with a non-combustion aerosol delivery device, the article of manufacture comprising an aerosol generating material comprising at least one aerosol generating material. A method of manufacture is also described. WO 2021/123819 PCT/GB2020/053301

Description

Technology industry

The following relates to a component for use in a non-combustion aerosol delivery system, an article for use with a non-combustion aerosol delivery device, and a method of manufacturing a component for use in a non-combustion aerosol delivery system.

Background of the invention

Certain tobacco products, when used, produce an aerosol that is inhaled by the user. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, to produce an aerosol by heating rather than burning the substrate. Such tobacco products may include mouthpieces through which the aerosol passes to reach the user's mouth.

The essence of the invention

According to some embodiments described herein, in a first aspect, a component is provided for use in a non-combustion aerosol delivery system, the component comprising: an inner body comprising a first material, and an outer body comprising a second material, the outer body surrounding the inner body. The resistance to gas flow through the length of the inner body is less than the resistance to gas flow through the length of the outer body.

According to some embodiments described herein, in a second aspect, there is provided an article of manufacture for use with a device for providing an aerosol without combustion, the article of manufacture comprising: an aerosol-generating material comprising at least one aerosol-forming material; and a component according to the first aspect.

According to some embodiments described herein, in a third aspect, there is provided a method of manufacturing a component for use in a non-combustion aerosol delivery system, the method comprising: forming an inner body; and forming an outer body surrounding the inner body. The resistance to gas flow through the length of the inner body is less than the resistance to gas flow through the length of the outer body.

According to some embodiments described herein, a non-combustion aerosol delivery system is provided, comprising an article according to the second aspect and a device for providing a non-combustion aerosol.

Brief description of graphic materials

Embodiments of the present invention will be described below by way of example only with reference to the accompanying drawings, in which: Fig. 1a is a side sectional view of a component for use in a non-combustion aerosol delivery system; Fig. 15 is an end sectional view of the component shown in Fig. 1a; Fig. 2 is a side sectional view of an article for use with a non-combustion aerosol delivery device, the article comprising the component shown in Fig. 1a and Fig. 15; Fig. 3 is a perspective view of a non-combustion aerosol delivery device for generating an aerosol from the aerosol generating material of the article of Fig. 2; Fig. 4 illustrates the device of Fig. 3 with the outer casing removed and without the article; Fig. 5 is a side view of the device of Fig. 3 in partial section; Fig. 7B is an exploded view of the device of Fig. 5 without an outer casing; Fig. 7A is a cross-sectional view of a portion of the device of Fig. 3; Fig. 7B is an enlarged view of a portion of the device of Fig. 7A; and Fig. 8 is a flow chart showing a method of manufacturing a component for use in a non-combustion aerosol delivery system.

Detailed description

In the context of this document, the term "delivery system" is intended to encompass systems that deliver at least one substance to the user and includes: combustion aerosol delivery systems such as cigarettes, cigarillos, cigars and pipe tobacco, or roll-your-own tobacco, or home-made cigarettes (based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material);

non-combustion aerosol delivery systems that release compounds from an aerosol-generating material without combustion of the aerosol-generating material, such as electronic cigarettes, heated tobacco products, and hybrid aerosol-generating systems using a combination of aerosol-generating materials; and non-aerosol delivery systems that deliver at least one substance to a user orally, nasally, transdermally, or otherwise without generating an aerosol, including, but not limited to, lozenges, chewing gums, patches, inhalable powder products, and oral products such as oral tobacco, including chewing tobacco and snuff, wherein the at least one substance may or may not contain nicotine.

According to the present invention, a "combustion" aerosol delivery system is a system in which the aerosol-generating constituent material of the aerosol delivery system (or a component thereof) is combusted or burned during use to provide delivery of at least one substance to the user.

According to the present invention, a "non-combustion" aerosol delivery system is a system in which the aerosol-generating constituent material of the aerosol delivery system (or component thereof) is not combusted or burned to provide delivery of at least one substance to the user.

In embodiments described herein, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion 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 (EDS), although it is noted that the presence of nicotine in the aerosol-generating material is not a prerequisite.

In some embodiments, the non-combustion aerosol delivery system is a system for heating the aerosol-generating material, also known as a heat-but-not-combustion system. An example of such a system is a tobacco heating system.

In one embodiment, the non-combustion aerosol delivery system is a hybrid

An aerosol generating system using a combination of aerosolizable materials, one or a combination of which may be heated. Each of the aerosolizable materials may be, for example, in the form of a solid, liquid or gel, and may or may not contain nicotine. In one embodiment, the hybrid system comprises a liquid or gel aerosolizable material and a solid aerosolizable material. The solid aerosolizable material may comprise, for example, a tobacco or non-tobacco product.

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

In some embodiments, the present invention relates to consumable components that contain an aerosol-generating material and are adapted for use with non-combustion aerosol delivery devices. These consumable components are sometimes referred to as articles of manufacture in this specification.

A consumable component is an article of manufacture that consists of or contains an aerosol-generating material, some or all of which is intended to be consumed during use by a user. The consumable component 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-modifying agent. The consumable component may also include an aerosol generator, such as a heater that emits heat to cause the aerosol-generating material to generate an aerosol during use. The heater may, for example, include a combustible material, a material that is electrically conductive, or a current collector.

In some embodiments, a non-combustion aerosol delivery system, such as a non-combustion aerosol delivery device thereof, may include a power source and a controller.

The power source may, for example, be an electrical power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate to which energy can be supplied to distribute power in the form of heat across an aerosol generating material or a heat transfer material proximate to the exothermic power source.

In some embodiments, a non-combustion aerosol delivery system may include a consumable component receiving area, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and/or an aerosol modifier.

In some embodiments, a consumable component for use with a non-combustion aerosol delivery device may include an aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.

In some embodiments, the delivery agent may be an aerosol-generating material or a non-aerosolizable material. Each material may optionally contain one or more active ingredients, one or more flavoring agents, one or more aerosol-forming materials, and/or one or more other functional materials.

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, thereby releasing one or more volatiles 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.

An aerosol-generating material is a material that is capable of generating an aerosol, for example, when heated, irradiated, or energized in any other way.

The aerosol generating material may, for example, be in the form of a solid, liquid or gel, which may or may not contain an active ingredient and/or flavorings. In some embodiments, the aerosol generating material may comprise an "amorphous solid", which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dried gel.

An amorphous solid is a solid material that can contain some amount of a fluid, such as a liquid. In some embodiments, the aerosol-generating material may, for example, contain from about 50 wt. 95, 60 wt. 95, or 70 wt. 95 amorphous solid to about 90 wt. 95, 95 wt. 95, or 100 wt. 5 amorphous solid.

The aerosol-generating material may contain one or more active ingredients and/or flavoring agents, one or more aerosol-forming materials, and optionally one or more other functional materials.

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

One or more other functional materials may include one or more pH regulators, colorants, preservatives, binders, fillers, stabilizers, and/or antioxidants.

The material may be present on or in the support to form a substrate. The support may, for example, be or comprise paper, cardboard, paperboard, construction cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal or metal alloy. In some embodiments, the support comprises a current collector.

In some embodiments, the current collector is embedded in the material. In some alternative embodiments, the current collector is on one or both sides of the material.

An aerosol modifying agent is a substance, typically located downstream of the aerosol generation zone, that is configured to modify the generated aerosol, for example, by altering the taste, flavor, acidity, or other characteristic of the aerosol. The aerosol modifying agent may be provided in an aerosol modifying agent release component that is suitable for selectively releasing the aerosol modifying agent.

The aerosol modifying agent may, for example, be an additive or a sorbent. The aerosol modifying agent may, for example, comprise one or more of a flavoring agent, a colorant, water and a carbon adsorbent. The aerosol modifying agent may, for example, be a solid, a liquid or a gel. The aerosol modifying agent may be in the form of a powder, a thread or a granule. The aerosol modifying agent may not comprise a filtration material.

A current collector is a material made to be heated by the passage of a changing magnetic field, for example, an alternating magnetic field.

The current collector may be an electrically conductive material, such that the penetration of a changing magnetic field into it causes induction heating of the heating material.

The heating material may be a magnetic material, such that the passage of a changing magnetic field therethrough causes heating by means of the magnetic hysteresis of the heating material. The current collector may be either electrically conductive or magnetic, such that the current collector is configured to be heated by both heating mechanisms. A device configured to generate a changing magnetic field is referred to herein as a magnetic field generator.

Induction heating is a process in which an electrically conductive object is heated by passing a changing magnetic field through the object. This process is described by Faraday's law of induction and Ohm's law. An induction heater may include an electromagnet and a device for passing a changing electric current, such as alternating current, through the electromagnet. When the electromagnet and the object to be heated are properly positioned relative to each other so that the resulting changing magnetic field created by the electromagnet passes through the object, one or more eddy currents are generated within the object. The object has a resistance to the flow of electric currents. Therefore, when such eddy currents are generated in the object, their current, overcoming the electrical resistance of the object, causes the object to heat up. This process is called Joule, ohmic, or resistive heating.

An object that is capable of being inductively heated is known as a current collector.

In one embodiment, the current collector is in the form of a closed loop. It has been found that when the current collector is in the form of a closed loop, the magnetic coupling between the current collector and the electromagnet is improved during use, resulting in greater or improved Joule heating.

Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by the passage of a changing magnetic field through the object. A magnetic material can be considered to contain many atomic-level magnets or magnetic dipoles. When a magnetic field passes through such a material, the magnetic dipoles align with the magnetic field. Therefore, when a changing magnetic field, such as that produced by an electromagnet, passes through a magnetic material, the orientation of the magnetic dipoles changes along with the changing applied magnetic field. This reorientation of the magnetic dipoles causes heat to be generated in the magnetic material.

When an object has both conductive and magnetic properties, the passage of a changing magnetic field through the object can cause both Joule heating and heating by magnetic hysteresis in the object. In addition, the use of magnetic material can enhance the magnetic field, which can increase the intensity of Joule heating.

In each of the above processes, since the heat is generated within the object itself, rather than by an external heat source through thermal conduction, a rapid temperature rise in the object and a more uniform heat distribution can be achieved, especially by choosing the appropriate material and geometric shape of the object and the appropriate magnitude of the alternating magnetic field and its orientation relative to the object. In addition, since induction heating and heating by magnetic hysteresis do not require a physical connection between the alternating magnetic field source and the object, the design freedom and control of the heating profile can be greater and the costs can be lower.

Products, for example, those in the form of rods, are often referred to according to the length of the product: "regular" (typically in the range of 68-75 mm, e.g., from about 68 mm to about 72 mm), "short" or "mini" (68 mm or less), "large" (typically in the range of 75-91 mm, e.g., from about 79 mm to about 88 mm), "long" or "extra large" (typically in the range of 91-105 mm, e.g., from about 94 mm to about 101 mm), and "ultra long" (typically in the range of about 110 mm to about 121 mm).

They are also called according to the circumference of the product: "regular" (approximately 23-25 mm), "wide" (greater than 25 mm), "thin" (approximately 22-23 mm), "semi-thin" (approximately 19-22 mm), 60 "ultra-thin" (approximately 16-19 mm) and "micro-thin" (less than approximately 16 mm).

Accordingly, a product whose format is defined as "large" and "ultra-thin" will have, for example, a length of approximately 83 mm and a circumference of approximately 17

MM.

Each format can be made with mouthpieces of varying lengths. The mouthpiece length will be from approximately 30 mm to 50 mm. The liner paper connects the mouthpiece to the aerosol generating material and will typically be longer than the mouthpiece, e.g. 3-10 mm longer, so that the liner paper covers the mouthpiece and overlaps the aerosol generating material, e.g. in the form of a core of substrate material, to connect the mouthpiece to the core.

The aerosol generating devices and their materials, as well as the mouthpieces described in this document, may be made in any of the above formats, but without limitation.

The terms "upstream" and "downstream" in the context of this document are relative terms defined with respect to the direction of the main flow of aerosol drawn through the product or device during use.

The fibrous tow material described herein may comprise a cellulose acetate fiber tow. The fibrous tow may also be formed using other materials used to form fibers, such as polyvinyl alcohol (PVA), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4-butanediol succinate) (PB5), butylene adipate terephthalate copolymer (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or a combination thereof. The fibrous tow may be plasticized using a suitable tow plasticizer, such as triacetin, wherein the material is a cellulose acetate tow, or the tow may be unplasticized. The tow may have any suitable characteristic, for example, fibers with a cross-section that is U-shaped, X-shaped, or O-shaped. The fibers of the tow may have a denier value of from 2.5 to 15 denier per thread, for example, from 8.0 to 11.0 denier per thread, and an overall denier value of from 5,000 to 50,000, for example, from 10,000 to 40,000. The cross-section of the fibers may have an isoperimetric ratio 12/A of 25 or less, preferably 20 or less, and more preferably, or 15 or less, where Η is the perimeter length of the cross-section and A is the cross-sectional area. Such fibers have a relatively small surface area for a given denier value per thread, which improves aerosol delivery to the consumer. The filter material described herein also includes cellulose-based materials such as paper.

Such materials may have a relatively low density, for example, from about 0.1 to about 0.45 grams per cubic centimeter, to allow air and/or aerosol to pass through the material. Although described as filter materials, such materials may have a primary purpose, for example, to increase resistance to entrainment of a component, that is not related to filtration per se.

In the context of this document, the term "tobacco material" refers to any material containing tobacco or its derivatives or substitutes. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may include one or more of shredded tobacco, tobacco fiber, cut tobacco, compressed tobacco, tobacco stem, tobacco flakes, reconstituted tobacco and/or tobacco extract.

In some embodiments, the delivery agent comprises an active agent.

An active substance in the context of this document may be a physiologically active material, which is a material intended to achieve or enhance a physiological response.

The active substance may, for example, be selected from nutraceuticals, nootropics, psychoactive substances. The active substance may be of natural origin or may be obtained synthetically. The active substance may comprise, for example, nicotine, caffeine, taurine, theine,

BO vitamins such as B6 or B12 or C, melatonin, cannabinoid or their components, derivatives, or combinations thereof. The active ingredient may comprise one or more components, derivatives or extracts of tobacco or other plant matter.

In some embodiments, the active ingredient comprises nicotine. In some embodiments, the active ingredient comprises caffeine, melatonin, or vitamin B12.

As used herein, an active ingredient may comprise or be derived from one or more plant substances or their constituents, derivatives or extracts. As used herein, the term "plant substance" includes any material derived from plants, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, the material may comprise an active compound that naturally occurs in the plant substance or be obtained synthetically.

The material can be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shavings, strips, sheets, etc. Examples of herbal raw materials are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice, matcha, mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, anise seeds (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, burdock, turmeric, curcuma longa, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassia, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, onion, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. Mint can be chosen from the following mint varieties:

Mepipa Aguepiiz, Mepipa s.m., Mepia piiasa, Mepipa rirepia, Mepina rirepa siigaia cm., Mepina riregpya s.m, Mepipa zrisaia sira, Mepia sagayoiia, Metiya Iopditoiia, Mepina 5ytsameoiepv5 mapedaya, Mepina riediit, Mepina 5risaya cm. and Mepina zchtsameoiepv.

In some embodiments, the active ingredient is derived from or contains one or more botanicals or their constituents, derivatives, or extracts, and the botanical is tobacco.

In some embodiments, the active ingredient is derived from or contains one or more botanicals or their constituents, derivatives or extracts, and the botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active ingredient is derived from or comprises one or more botanicals or their constituents, derivatives or extracts, and the botanical is selected from rooibos and fennel.

In some embodiments, the delivery agent comprises a flavoring agent.

In the context of this document, the terms "flavor" and "flavoring agent" refer to materials that, where permitted by local regulations, may be used to create a desired taste, aroma or other somatosensory sensation in a product for adult consumers. They may include naturally occurring flavors, botanicals, botanical extracts, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, Japanese white magnolia leaf, chamomile, gunbut, clove, maple, matcha, menthol, Japanese mint, anise seed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, coffee berry, lingonberry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus, Drambuie liqueur, bourbon, Scotch whisky, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, hookah, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, cumin, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, allspice, ginger, coriander, coffee, hemp, mint oil of any species of the genus Mepiipa, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, bay leaf, mate, orange peel, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, perilla, turmeric, coriander, myrtle, blackcurrant, valerian, pimento, mace, damien, marjoram, olive, lemon balm, basil, onion, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, blockers of bitterness receptor sites, activators or stimulants of sensitive receptor sites, sugars and/or sugar substitutes (e.g. sucralose, acesulfame potassium, aspartame, saccharin, cyclamates, lactose, sucrose, glucose, fructose, sorbitol or mannitol) and other additives such as charcoal, chlorophyll, minerals, botanicals or mouth fresheners. They may be artificial, synthetic or natural ingredients or mixtures thereof. They 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 agent comprises menthol, spearmint and/or peppermint. In some embodiments, the flavoring agent comprises cucumber, blueberry, citrus and/or cranberry flavorings. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring agent comprises tobacco-extracted flavorings. In some embodiments, the flavoring agent comprises cannabis-extracted flavorings.

In some embodiments, the flavoring agent may comprise a sensory agent intended to achieve a somatosensory sensation, typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of the nerves responsible for the perception of aroma or taste, and may include agents that provide a warming effect, a cooling effect, a tingling effect, a numbing effect. A suitable warming agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol, MU5-3.

In the figures described in this document, like reference numerals are used to depict equivalent features, articles, or components.

Fig. 156 is a cross-sectional side view of a component for use in a non-combustion aerosol delivery system. In the example shown and other examples described herein, the component is a component of a non-combustion aerosol delivery system, for example, a component of a tobacco heating product. Fig. 156 is a cross-sectional end view of the component shown in Fig. 156, taken along the line

"A-A".

The component 10 includes an inner main portion 11 and an outer main portion 12 surrounding the inner main portion. The inner main portion 11 includes a first material and the outer main portion 12 includes a second material. The resistance to gaseous flow through the length of the inner main portion 11 is less than the resistance to gaseous flow through the length of the outer main portion 12. This arrangement allows for increased gaseous flow through the inner main portion 11 compared to the outer main portion 12. The aerosol generated by the non-combustion aerosol delivery system is thus directed away from the user's lips during use.

In some examples, component 10 may be a mouthpiece for a product that is intended for use with a non-combustion aerosol delivery device. This is explained in more detail below with respect to Fig. 2.

In some examples, the resistance to gaseous flow (or pressure drop) across the length of the inner main portion 11 is less than about 30 mm Hg. It has been found that such pressure drop values ensure that a sufficient amount of aerosol containing desired compounds, such as flavor compounds, can pass through the inner main portion 11 to the user. In some examples, the resistance to gaseous flow across the length of the inner main portion 11 is less than about 25 mm Hg.

Alternatively or additionally, the resistance to gaseous flow through the length of the inner main portion 11 may be at least 10 mm Hg, in some examples at least 15 mm Hg, and in some examples at least 20 mm Hg. In some examples, the resistance to gaseous flow through the length of the inner main portion 11 may be from about 5 mm Hg to 30 mm Hg.

The resistance to gaseous flow through the length of the outer main body 12 may be at least 50 mm Hg, in some examples at least 55 mm Hg, and in some examples at least 60 mm Hg. In some examples, the resistance to gaseous flow through the length of the inner main body 11 may be from 40 mm Hg to 60 mm Hg.

In the example shown, the inner main part 11 is cylindrical and the outer main part 12 is tubular. The tubular outer main part 12 includes a hollow cavity that extends through the outer main part 12. The inner main part 11 is located inside the cavity of the outer main part 12, such that the outer main part 12 surrounds the inner main part 11. In the example shown, the inner main part 11 and the outer main part 12 have essentially the same length, and are arranged such that the longitudinal end surfaces of the inner main part 11 and the outer main part 12 are at the same level. The inner main part 11 and the outer main part 12 have a common longitudinal axis.

In the example shown, the inner main part 11 and the outer main part 12 are formed as one unit as a single main part of material. In some examples, the inner main part and the outer main part are formed as separate main parts of material that are bonded together, for example using an adhesive.

In some embodiments, the inner core 11 and/or the outer core 12 may be formed from a fibrous tow, such as a cellulose acetate tow. The density of the fibrous tow forming the inner core 11 is lower than the density of the fibrous tow forming the outer core 12. This results in a resistance to gas flow through the length of the inner core 11 that is lower than the resistance to gas flow through the length of the outer core 12. The density of the fibrous tow can be controlled by selecting the overall denier of the fibrous tow for a given cross-sectional area. This will be explained in more detail below.

In the example shown, both the inner core 11 and the outer core 12 are formed from a plasticized cellulose acetate tow. In other examples, the inner core 11 and/or the outer core 12 may be formed from non-cellulose acetate tows, such as polylactic acid (PLA), other materials described herein for fibrous tow, filter material, or the like.

In some examples, the density of the material forming the inner core 11 is at least about 0.1 grams per cubic centimeter (g/cm3), in some examples at least about 0.15 g/cm3. In some examples, the density of the material forming the inner core 11 is less than about 0.2 grams per cubic centimeter (g/cm3), in some examples less than 0.25 g/cm3. In some examples, the density of the material forming the inner core 11 is from 0.1 to 0.25 g/cm3, in some examples from 0.1 to 0.15 g/cm3 or from 0.15 to 0.2 g/cm3. These density values have been found to provide a good balance between the improved strength provided by the higher density material and the lower heat transfer capability of the lower density material. In the examples where the inner core is formed from a fibrous tow, the "density" of the inner core 11 is understood to mean the density of the fibrous tow forming the core with any incorporated plasticizer.

The density can be determined by dividing the total weight of the inner core 11 by the total volume of the inner core 11.

In the example given, the webbing used in the inner main body 11 has a denier per thread (d.p.) value of 8.4 and a total denier value of 7,500.

The plasticizer used in the tow is present in an amount of about 7.95 by weight of the tow. In the example provided, the plasticizer is triacetin. In some examples, the tow formed from cellulose acetate or other materials has an a.r.i. of at least 5, in some examples at least 6, and in some examples at least 7. These denier values per thread provide a tow that has relatively coarse, thick fibers with a lower surface area, resulting in a lower pressure drop across the inner body 11 compared to tows having lower a.r.i. values. To achieve a sufficiently uniform body 11 material, the tow has a denier value per thread that does not exceed 12 a.r.i., in some examples not greater than 11 a.r.i., and in some examples not greater than 10 a.r.i.

In some examples, the total denier of the tow forming the inner main body 11 is no more than 11,000, in some examples no more than 10,000, and in some examples no more than 9,000. These total denier values provide a tow that occupies a smaller fraction of the cross-sectional area of the main body 11, resulting in a smaller pressure drop across the inner main body 11 compared to tows having higher total denier values. For proper strength of the inner core 11, the tow has an overall denier of at least 3000, and in some examples at least 4000. In some examples, the denier per yarn is from 5 to 12, with an overall denier of from 3000 to 9000. In some examples, the denier per yarn is from 1 to 10, with an overall denier of from 4000 to 8000. In some examples, the cross-sectional shape of the yarns of the tow is U-shaped, although in other examples, other shapes such as X-shaped or O-shaped yarns with the same a.r.i. and overall denier values as set forth herein may be used. The tow may include yarns with a cross-sectional isometric ratio of 25 or less, 20 or less, or 15 or less.

In some examples, the inner body 11 may comprise a capsule disposed within the main body of material. The capsule may comprise a frangible capsule, e.g., a capsule having a hard, brittle shell surrounding a liquid content. In some examples, a single capsule is used. The capsule is completely recessed within the main body of material. In other words, the capsule is completely surrounded by the material forming the main body. In other examples, a plurality of frangible capsules may be disposed within the main body of material, e.g., 2, 3, or more frangible capsules. The length of the main body of material may be increased to accommodate the required number of capsules. In examples where multiple capsules are used, the individual capsules may be the same as each other, or may differ from each other in size and/or capsule content. In other examples, multiple main bodies of material may be provided, each main body containing one or more capsules.

In some embodiments, the main body of the material comprises a first and a second capsule. In some embodiments, the first capsule is located in a first portion of the main body of the material, and the second capsule is located in a second portion of the main body of the material downstream of the first portion. In other embodiments, the article comprises two main bodies of the material, with the first and second capsules located in the first and second main bodies, respectively.

The first capsule is heated to a first temperature during use, and the second capsule is heated to a second temperature during use, wherein the second temperature is at least 4 degrees Celsius lower than the first temperature. Preferably, the second temperature is at least 5, 6, 7, 8, 9 or 10 degrees Celsius lower than the first temperature.

In some embodiments, the second capsule is located at least 7 mm from the first capsule, measured as the distance between the centers of the first and second capsules. Preferably, the second capsule is located at least 8, 9, or 10 mm from the first capsule. Increasing the distance between the first and second capsules increases the temperature difference between the first and second temperatures.

The first capsule contains an aerosol modifying agent. The second capsule contains an aerosol modifying agent, which may be the same as or different from the aerosol modifying agent of the first capsule. In some embodiments, a user may selectively break the first and second capsules by applying an external force to the capsules to release the aerosol modifying agent from each capsule.

The aerosol modifying agent of the second capsule is heated to a lower temperature than the aerosol modifying agent of the first capsule due to the difference between the first and second temperatures. The aerosol modifying agents of the first and second capsules can be selected based on this temperature difference. For example, the first capsule can contain a first aerosol modifying agent that has a lower vapor pressure than the second aerosol modifying agent of the second capsule. If both capsules are heated to the same temperature, the higher vapor pressure of the aerosol modifying agent of the second capsule will mean that a greater amount of the second aerosol modifying agent will be vaporized relative to the aerosol modifying agent of the first capsule. However, since the second capsule is heated to a lower temperature, this effect is less pronounced, such that a more uniform amount of the aerosol modifying agents of the first and second capsules will be vaporized after the first and second capsules are broken, respectively.

In some embodiments, the first and second capsules have the same aerosol modifying profiles, meaning that both capsules contain the same type of aerosol modifying agent and in the same amount, such that if both capsules are heated to the same temperature and rupture, both capsules will result in the same aerosol modification.

However, since the first capsule is heated to a higher temperature than the second capsule, more of the aerosol modifying agent of the first capsule will, for example, be evaporated compared to the modifying agent of the second capsule and thus cause a more pronounced aerosol modification than the second capsule.

Therefore, even though both capsules are identical, which may make the aerosol modifying component lighter and/or less expensive to manufacture, the user may decide to destroy the first capsule to cause a more pronounced aerosol modification, or the second capsule to cause a less pronounced aerosol modification, or both capsules to cause the greatest aerosol modification.

In some embodiments, both the first and second capsules contain first and second aerosol modifying agents. The first aerosol modifying agent has a lower vapor pressure than the second aerosol modifying agent. Thus, when the second capsule is broken, a greater proportion of the second aerosol modifying agent will be vaporized relative to the first aerosol modifying agent compared to when the hotter first capsule is broken during use of the aerosol generating system. Thus, the same capsule can be used to generate different aerosol modifications based on the position of the capsule in the first or second portion of the aerosol modifying component.

One or more capsules may comprise a "core-shell" structure. In other words, the capsules comprise a shell encapsulating a liquid agent, such as a flavoring agent or other agent, which may be any of the flavoring agents or aerosol modifiers described herein. The shell may be broken by a user to release the flavoring agent or other agent into the main body of the material. The first phycell 16 may comprise a barrier coating to render the phycell material substantially impermeable to the liquid contents of the capsule. Alternatively or in addition, the second phycell 17 and/or the liner 18 may comprise a barrier coating to render the phycell material and/or the liner substantially impermeable to the liquid contents of the capsule.

In some examples, one or more capsules are spherical and have a diameter of about 3.5 mm. In other examples, other capsule shapes and sizes may be used, such as capsules having a diameter of 2.5 mm, 3 mm, 4 mm, or 4.5 mm. The total weight of one or more capsules may range from about 10 mg to about 50 mg.

It is known to generate a bundle capability curve for given bundle specifications (e.g., 8.4x21000) that represents the pressure drop across the length of the rod formed by the bundle for each of a range of bundle weights. Parameters such as the rod length and circumference, the wrap thickness, and the level of plasticizer in the bundle are specified and combined with the bundle specifications to generate a bundle capability curve that provides an indication of the pressure drop that will be provided by different bundle weights between the minimum and maximum weights that can be achieved using standard filter rod forming equipment. Such bundle capability curves can be calculated, for example, using software available from bundle suppliers. It has been found to be particularly advantageous to use an inner core 11 comprising a fibrous tow having a weight per mm of length of the inner core 11 that is from about 10.95 to about 30.95 of the range between the minimum and maximum values of the tow weight capability curve generated for the fibrous tow. This can provide an acceptable balance between providing sufficient tow weight to avoid compression after formation of the inner core 11, providing an acceptable pressure drop, and facilitating capsule placement within the tow, for capsules of the sizes described herein.

In some examples, the density of the material forming the hollow tubular outer body 12 is at least about 0.25 grams per cubic centimeter (g/cm3), in some examples at least about 0.3 g/cm3. In some examples, the density of the hollow tubular outer body 12 is less than about 0.75 grams per cubic centimeter (g/cm3), in some examples less than 0.6 g/cm3. In some examples, the density of the hollow tubular outer body 12 is from 0.25 to 0.75 g/cm3, in some examples from 0.3 to 0.6 g/cm3, and in some examples from 0.4 g/cm3 to 0.6 g/cm3, or about 0.5 g/cm3. cm. It has been found that these density values provide a good balance between the improved strength provided by the higher density material and the lower heat transfer capability of the lower density material. In the examples where the outer core is formed from a fibrous tow, the "density" of the hollow tubular outer core 12 is understood to mean the density of the fibrous tow forming the core with any plasticizer incorporated. The density can be determined by dividing the total mass of the hollow tubular outer core 12 by the total volume of the hollow tubular outer core 12, the total volume being calculated using appropriate measurements of the hollow tubular outer core 12, taken, for example, with a caliper. If necessary, the appropriate dimensions can be measured using a microscope.

In some examples, the fibrous tow forming the hollow tubular outer body 12 has an overall denier of less than 45,000, in some examples less than 42,000. This overall denier has been found to provide the ability to form the tubular outer body 12 without having an excessively high density. In some examples, the overall denier is at least 20,000, in some examples at least 25,000. In some examples, the fibrous tow forming the hollow tubular outer body 12 has an overall denier of from 25,000 to 45,000, in some examples from 35,000 to 45,000. In some examples, the cross-sectional shape of the tow yarns is

U-shaped, although in other examples other shapes may be used, such as X-shaped or

O-shaped filaments. The bundle may contain filaments with a cross-sectional isometric ratio of 25 or less, 20 or less, or 15 or less.

In some examples, the fibrous tow forming the outer main body 12 has a denier per thread of greater than 3. This denier per thread has been found to provide an outer main body 12 that is not excessively dense. In some examples, the denier per thread is at least 4, in some examples, at least 5. In some examples, the fibrous tow forming the outer main body 12 has a denier per thread of from 4 to 10, in some examples, from 4 to 9. In one example, the fibrous tow forming the outer main body 12 has a denier per thread of from 4 to 10, in some examples, from 4 to 9.

840000, which is formed from cellulose acetate and contains 18 95 of a plasticizer, for example, triacetin.

In some examples, the hollow tubular body 12 contains from 15% to 22% by weight of plasticizer. For cellulose acetate tow, the plasticizer is preferably triacetin, although other plasticizers such as polyethylene glycol (PEG) may be used.

In some examples, the outer body 12 contains from 1695 to 2095 by weight of plasticizer, for example about 1795, about 18595 or about 1995 plasticizer.

In some embodiments, the inner body 11 and/or the outer body 12 may be formed of paper, for example, similar to paper filters intended for use in cigarettes. In such embodiments, the density of the paper forming the inner body is lower than the density of the paper forming the outer body, to achieve a resistance to gas flow through the length of the inner body that is less than the resistance to gas flow through the length of the outer body.

In some examples, the length of the inner main portion 11 is less than about 15 mm. In some examples, the length of the inner main portion 11 is less than about 12 mm. Additionally or alternatively, the length of the inner main portion 11 is at least about 5 mm. In some examples, the length of the inner main portion 11 is at least about 6 mm. In some examples, the length of the inner main portion 12 is from about 5 mm to about 20 mm, in some examples from about 6 mm to about 10 mm, in some examples from about 6 mm to about 8 mm, in some examples about 6 mm, 7 mm, or about 8 mm.

In some examples, the length of the hollow tubular outer main portion 12 is less than about 15 mm. In some examples, the length of the hollow tubular outer main portion 12 is less than about 12 mm. Additionally or alternatively, the length of the hollow tubular outer main portion 12 is at least about 5 mm. In some examples, the length of the hollow tubular outer main portion 12 is at least about 6 mm. In some examples, the length of the hollow tubular outer main portion 12 is from about 5 mm to about 20 mm, in some examples from about 6 mm to about 10 mm, in some examples from about 6 mm to about 8 mm, in some examples about 6 mm, 7 mm, or about 8 mm.

In some examples, the length of the inner main part is the same as the length of the outer main part. In the example shown, both the inner main part and the outer main part have a length of 10 mm.

In the example shown, the tubular outer body 12 has an outer circumference of approximately 21 mm, which is equal to an outer diameter of approximately 6.7 mm. In some examples, the hollow tubular outer body 12 has an inner diameter of greater than 3.0 mm. Diameters smaller than this may cause the aerosol to travel through the component 10 to the user's mouth at a rate greater than desirable, such that the aerosol becomes too warm, for example, reaching temperatures greater than 40°C or greater than 45°C. In some examples, the hollow tubular outer body 12 has an inner diameter of greater than 3.1 mm, and in some examples greater than 3.5 mm or 3. mm. In the example shown, the inner diameter of the hollow tubular outer body 12 is approximately 3.9 mm. The "wall thickness" of the hollow tubular outer body 12 corresponds to the thickness of the wall of the outer body 12 in the radial direction. It can be measured, for example, using a caliper. The wall thickness is preferably greater than 0.9 mm and in some examples is 1.0 mm or more. In some examples, the wall thickness is substantially constant around the entire wall of the hollow tubular outer body 12.

However, in examples where the wall thickness is not substantially constant, the wall thickness is greater than 0.9 mm at any point around the hollow tubular outer body portion 12, in some examples 1.0 mm or more.

In the example shown, the component 10 further comprises a hollow tubular member 14. The tubular member 14 comprises a hollow cavity 14a extending through the hollow tubular member 14.

Each of the outer main body 12 and the hollow tubular member 14 forms a substantially cylindrical overall external shape and has a common longitudinal axis. In the example shown, the hollow tubular member 14 is positioned adjacent to and adjacent to the outer main body 12. In some examples, the hollow tubular member 14 may be positioned adjacent to and adjacent to both the inner main body 11 and the outer main body 12.

In the example shown, the tubular member 14 is positioned so as to be downstream of the inner main body 11 and the outer main body 12 when the component 10 is integrated into an article to be used with a device for providing an aerosol without combustion. The tubular member 14 thus forms the mouth end of the component 10. Alternatively or additionally, the tubular member may be positioned so as to be upstream of the inner main body and the outer main body when the component 10 is integrated into an article to be used with a device for providing an aerosol without combustion.

The tubular member 14 may be substantially the same as the hollow tubular outer body 12, and may have any of the dimensions mentioned above with respect to the hollow tubular outer body 12.

In the example shown, the tubular member 14 is 6 mm long. In some examples, it may be particularly advantageous to use a hollow tubular member 14 with a length greater than about 10 mm, for example, from about 10 mm to about 30 mm, or from about 12 mm to about 25 mm. It has been found that the lips of the consumer are likely to extend in some cases up to about 12 mm from the mouth end of the article 1 when drawing the aerosol through the article 1, and therefore having a hollow tubular member 14 that is at least 10 mm long or at least 12 mm long means that a majority of the consumer's lips surround the member 14.

In the example shown, component 10 includes phycell 18 wrapped around outer body 12 and tubular body 14. In some examples, phycell 18 has a basis weight of less than 50 g/m2, in some examples from about 20 g/m2 to 40 g/m2. In some examples, phycell 18 has a thickness of from 30 μm to 60 μm, in some examples from 35 μm to 45 μm. In some examples, phycell 18 is a non-porous phycell having a permeability of, for example, less than 100 Sogevsia units, for example, less than 50 Sogevsia units. However, in other examples, phycell 18 may be a porous phycell having a permeability of, for example, greater than 200 Sogevsia units.

In some examples, component 10 includes an additional phycell (not shown) wrapped around inner body 11. In some examples, the additional phycell has a basis weight of less than 50 g/m2, in some examples from about 20 g/m2 to 40 g/m2. In some examples, the additional phycell has a thickness of from 30 μm to 60 μm, in some examples from 35 μm to 45 μm.

In some examples, the additional phycell is a non-porous phycell having a permeability of, for example, less than 100 Sogevia units, for example, less than 50 Sogevia units. However, in other examples, the additional phycell may be a porous phycell, for example, having a permeability of greater than 200 Sogevia units.

Fig. 2 shows a side cross-sectional view of an article for use with a device for providing an aerosol without combustion. In the example shown, article 1 includes component 10 shown in Fig. 1 and Fig. 165. Component 10 functions as a mouthpiece of article 1 and forms the mouth end of article 1.

The article 1 comprises a cylindrical rod of aerosol-generating material 21, in this case tobacco material; a hollow tubular member 23 located downstream of the aerosol-generating material 21; and a mouthpiece 10 located downstream of the tubular member 23. The mouthpiece 10, comprising an inner body 11 and an outer body 12, provides better insulation between the aerosol and the user's lips than a standard cellulose acetate rod, without increasing the overall length of the article 1.

In the example given, the aerosol-generating material 21 is wrapped in a wrapper 22.

The wrapper 22 may, for example, be a wrapper made of paper or foil on a paper base.

The wrapper 22 may have a high level of permeability, in some examples greater than about 1000 Sogezia units, in some examples greater than about 1500 units

Sogevia, in some examples more than about 2000 Sogevia units. The wrapper 22 may have a maximum permeability of less than about 20,000 Sogevia units, in some examples less than about 15,000 Sogevia units, in some examples less than about 5,000 Sogevia units. The permeability of the wrapper 22 may be measured according to

IBO 2965:2009, which regulates the determination of air permeability of materials used as types of cigarette paper, filter phytella and filter connecting paper.

The wrapper 22 may be formed from a material with a high natural permeability level, such as a naturally porous material, or may be formed from a material with any level of natural permeability, where the ultimate level of permeability is achieved by providing the wrapper 22 with a permeable zone or area. When the wrapper 22 is provided with a permeable zone, the permeable zone may be a discrete area or the permeable zone may extend substantially throughout the wrapper 22. For example, the wrapper 22 may be provided with discrete bands of ventilation perforations or the wrapper may be provided with ventilation perforations that extend substantially throughout and substantially around the entire wrapper 22.

The wrapper 22 may be provided with ventilation perforations in any configuration to achieve the ultimate permeability level. The percentage of the wrapper surface area having the permeability level described herein may be greater than 50%, greater than 75%, greater than 90%, or 100% by weight.

In the example shown, ventilation is provided directly in the tubular element 23 via a ventilation zone 24. In the example shown, the ventilation zone 24 comprises first and second parallel rows of perforations, in this case created as laser perforations, at positions 17,925 mm and 18,625 mm respectively from the downstream end of the mouthpiece 10. These perforations extend through the rim paper 28 and the hollow tubular element 23. Alternatively, ventilation may be provided by a single row of perforations, e.g. laser perforations, in the tubular element.

This has been found to result in improved aerosol formation, which is believed to be the result of a more uniform air flow through the perforations than in the case of multiple rows of perforations, for a given level of ventilation.

In use, when a user inhales air through the product 1, air enters the product 1 through perforations 24. The ventilation zone 24 provides the product with a ventilation level that is less than 50% of the air drawn through the product. In some examples, the product may have a ventilation level of 50% to 80% of the aerosol drawn through the product, such as 45% to 65%. Ventilation at these levels helps slow the flow of aerosol drawn through the product 1 and, as a result, allows the aerosol to cool sufficiently before it reaches the downstream end of the product 1.

It was found that aerosol temperature generally increases with decreasing ventilation level. However, the relationship between aerosol temperature and ventilation level does not appear to be linear, with variations in ventilation, for example due to manufacturing tolerances, having less of an impact at low ventilation target levels. For example, with a ventilation tolerance of 15595 for a ventilation target level of 75595, the aerosol temperature may increase by approximately 6°C at the low ventilation limit (60 95 ventilation). However, with a ventilation target level of 60 96, the aerosol temperature may only increase by approximately 3.592°C at the low ventilation limit (45 95 ventilation). Therefore, the target ventilation level of the product may be in the range of 40 95 to 70 95, for example, from 45 95 to 65 95. The average ventilation level of at least 20 products may be from 40 95 to 70 95, for example, from 45 95 to 70 95 or from 51 95 to 59 95.

Providing a permeable wrapper 22 provides a path for air to enter the product 1. In some cases, the wrapper 22 may be made permeable such that the amount of air entering the product through the core of aerosol-generating material is relatively greater than the amount of air entering the product through the vent area 24 in the tubular member 23. A product having such a configuration may produce a larger amount of a fragrance aerosol, which may be more palatable to the user.

The article 1 comprises a cavity having an internal volume of greater than 450 mm3. It has been found that providing a cavity of at least such a volume enables the formation of an improved aerosol. This size of the cavity provides sufficient space within the article 1 to allow the heated vaporized components to cool, thereby allowing the aerosol generating material 21 to be exposed to higher temperatures than would otherwise be possible, as this would result in excessive heating of the aerosol.

In the example shown, the cavity is a cavity 23a formed within the hollow tubular member 23, but in alternative arrangements the cavity may be formed within another part of the article 1. In some examples, the article 1 includes a cavity, e.g., a cavity 23a formed within the hollow tubular member 23, which has an internal volume of greater than 500 mm, and in some examples greater than 550 mm3, which allows for further improvement of the aerosol. In some examples, the internal cavity has a volume of from about 550 mm3 to about 750 mm3, e.g., about 600 mm? or 700 mm3.

In the example shown, the hollow tubular member 23 is located immediately upstream of and adjacent to the inner main portion 11 and the outer main portion 12. Each of the hollow tubular member 23, the outer main portion 12 and the tubular main portion 14 forms a substantially cylindrical overall external shape and has a common longitudinal axis.

In the example shown, the hollow tubular member 23 is formed from multiple layers of paper that are wound in parallel, butt-seamed, to form the tubular member 23. In the example shown, the first and second paper layers are provided in a two-layer tube, although in other examples, 3, 4, or more paper layers may be used to form tubes of 3, 4, or more layers. Other constructions may be used, such as spirally wound layers of paper, cardboard tubes, tubes formed using the papier-mâché technique, molded or extruded plastic tubes, or the like.

The hollow tubular member 23 may also be formed using a rigid ficella and/or liner paper, such as ficella 18 and/or liner paper 28, which means that a separate tubular member is not required. The rigid ficella and/or liner paper are made to have sufficient rigidity to resist axial compressive forces and bending moments that may occur during manufacture and use of the article 1. For example, the rigid ficella and/or liner paper may have a basis weight of from 70 g/m2 to 120 g/m2, in some examples from 80 g/m2 to 110 g/m2.

Additionally or alternatively, the rigid phycel and/or liner paper may have a thickness of from 80 μm to 200 μm, in some examples from 100 μm to 160 μm or from 120 μm to 150 μm.

The tubular member 23 preferably has a wall thickness of at least about 325 μm and no more than about 2 mm, preferably from 500 μm to 1.5 mm and more preferably from 750 μm to 1 mm. In the example shown, the tubular member 23 has a wall thickness of about 1 mm. The "wall thickness" of the tubular member 23 corresponds to the thickness of the wall of the tubular member 23 in the radial direction. It can be measured, for example, using a caliper.

In some embodiments, the wall thickness of the tubular element is at least 325 microns and preferably at least 400, 500, 600, 700, 800, 900, or 1000 microns.

In some embodiments, the wall thickness of the tubular element is at least 1250 or 1500 microns.

In some embodiments, the wall thickness of the tubular element is less than 2000 microns and preferably less than 1500 microns.

The increased wall thickness of the tubular element means that it has a greater thermal mass, which has been found to help reduce the temperature of the aerosol passing through the tubular element and reduce the surface temperature of the product downstream of the tubular element. This is believed to be because the greater thermal mass of the tubular element allows the tubular element to absorb more heat from the aerosol compared to a tubular element with a thinner wall thickness. The increased thickness of the tubular element also directs the aerosol centrally within the product such that less heat from the aerosol is transferred to the outer parts of the product, such as the outer parts of the main body of the material.

In some embodiments, the permeability of the wall material of the tubular element is at least 100 Sogezia units and preferably at least 500 or 1000 units.

Sogevia.

It has been found that the relatively high permeability of the tubular element increases the amount of heat transferred to the tubular element from the aerosol, thereby reducing the temperature of the aerosol. It has also been found that the permeability of the tubular element increases the amount of moisture transferred from the aerosol to the tubular element, which has been found to improve the feel of the aerosol in the user's mouth. The high permeability of the tubular element also makes it easier to cut the vent holes with a laser, which means that lower laser power can be used.

In some examples, the length of the hollow tubular member 23 is less than about 50 mm. In some examples, the length of the hollow tubular member 23 is less than about 40 mm. In some examples, the length of the hollow tubular member 23 is less than about 30 mm. Additionally or alternatively, the length of the hollow tubular member 23 is at least about 10 mm. In some examples, the length of the hollow tubular member 23 is at least about 15 mm. In some examples, the length of the hollow tubular member 23 is from about 20 mm to about 30 mm, in some examples from about 22 mm to about 28 mm, in some examples from about 24 to about 26 mm. In the example shown, the length of the hollow tubular member 23 is 25 mm.

The hollow tubular member 23 forms an air gap within and around the product 1, which 60 functions as a cooling segment. The air gap provides a chamber through which heated vaporized components generated by the aerosol generating material 21 flow. The hollow tubular member 23 is hollow to provide a chamber for the aerosol to accumulate, but is sufficiently rigid to resist axial compressive forces and bending moments that may occur during manufacture and use of the product 1. The hollow tubular member 23 provides a physical displacement between the aerosol generating material 21 and the inner and outer main parts 11, 12. The physical displacement provided by the hollow tubular member 23 will provide a temperature gradient along the length of the hollow tubular member 23.

The hollow tubular element 23 may be configured to provide a temperature difference of at least 40 degrees Celsius between the heated vaporized component entering the first upstream end of the hollow tubular element 23 and the heated vaporized component exiting the second downstream end of the hollow tubular element 23. The hollow tubular element 23 is preferably configured to provide a temperature difference of at least 60, 80 or preferably 100 degrees Celsius between the heated vaporized component entering the first upstream end of the hollow tubular element 23 and the heated vaporized component exiting the second downstream end of the hollow tubular element 23. This temperature difference along the length of the hollow tubular element 23 protects the temperature-sensitive main parts 11, 12 of the material from high temperatures of the aerosol-generating material 21 when it is heated.

In some examples, the aerosol generating material described herein is a first aerosol generating material, and the hollow tubular member 23 may include a second aerosol generating material. The wall of the hollow tubular member 23 may include a second aerosol generating material. For example, the second aerosol generating material may be disposed on an inner surface of the wall of the hollow tubular member 23.

The second aerosol generating material comprises at least one aerosol forming material and may also comprise at least one aerosol modifying agent or other sensory material. The aerosol forming material and/or aerosol modifying agent may be any aerosol forming material or aerosol modifying agent as described herein, or a combination thereof.

As the aerosol generated from the aerosol generating material 21, which in this case is referred to as the first aerosol, is drawn through the hollow tubular member 23 of the mouthpiece 10, heat from the first aerosol can aerosolize the aerosol generating material of the second aerosol generating material to form a second aerosol.

The second aerosol may contain a flavoring agent, which may be additional or complementary to the flavoring agent of the first aerosol.

Providing a second aerosol-generating material on the hollow tubular member 23 may result in the generation of a second aerosol that enhances or complements the taste or appearance of the first aerosol.

In alternative embodiments, the hollow tubular member 23 may be replaced by an alternative cooling member, such as one formed from a bulk material that allows the aerosol to pass therethrough in a longitudinal direction and that also functions to cool the aerosol.

The aerosol-generating material 21, also referred to herein as the aerosol-generating substrate 21, comprises at least one aerosol-forming material. In the example provided, the aerosol-forming material is glycerol. In alternative examples, the aerosol-forming material may be another material as described herein, or a combination thereof. The aerosol-forming material has been found to improve the sensory characteristics of the product by helping to transfer compounds, such as flavor compounds, from the aerosol-generating material to the consumer. However, a problem with adding such aerosol-forming materials to the aerosol-generating material within an article intended for use in a non-combustion aerosol delivery system can be that when the aerosol-forming material is converted to an aerosol upon heating, it can increase the mass of aerosol delivered by the article, and this increased mass can maintain a higher temperature as it passes through the mouthpiece. As it passes through the mouthpiece, the aerosol transfers heat to the mouthpiece, and this heats the outer surface of the mouthpiece, including the area that contacts the consumer's lips during use. The temperature of the mouthpiece can be significantly higher than the 60°C temperature that consumers are accustomed to when smoking, for example, conventional cigarettes, and this can be an undesirable phenomenon caused by the use of such aerosol-forming materials.

In the example provided, product 1 has an outer circumference of approximately 21 mm (i.e., the product is of a semi-thin format). In other examples, the product may be provided in any of the formats described herein, for example, with an outer circumference of 15 mm to 25 mm. Since the product is to be heated with the release of an aerosol, improved heating efficiency may be achieved by using products having smaller outer circumferences within this range, for example, circumferences less than 23 mm.

It has also been found that, in order to provide improved aerosol delivery by heating while maintaining an acceptable product length, product circumferences greater than 19 mm are particularly effective. Products with circumferences of 19 mm to 23 mm, and more preferably 20 mm to 22 mm, have been found to provide a good balance between providing effective aerosol delivery and at the same time allowing for effective heating.

The liner paper 28 is wrapped around the outer body 12, the tubular body 14, the tubular member 23 and over at least a portion of the aerosol generating material core 21. The liner paper 28 includes an adhesive on its inner surface to bond the outer body 12, the tubular body 14, the tubular member 23 and the aerosol generating material core 21. In the example shown, the liner paper 28 extends 5 mm over the aerosol generating material core 21, but it may alternatively extend 3 mm-10 mm over the core 21, or in some examples 4 mm-6 mm, to provide a secure bond between the outer body 12, the tubular body 14, the tubular member 23 and the aerosol generating material core 21.

The wrapping paper 28, also referred to herein as the wrapper, may have a basis weight higher than the basis weight of the phycels used in the article 1, for example, a basis weight of from 40 g/m2 to 80 g/m2, in some cases from 50 g/m2 to 70 g/m2, and in the example given 58 g/m2. It has been found that these ranges of basis weight values result in varieties of wrapping paper having acceptable values of tensile strength, while being sufficiently flexible to wrap the article 1 and adhere to itself along the longitudinal seam with the overlap of the paper. The outer circumference of the wrapping paper 28 after wrapping around the aerosol generating material 20 is approximately 21 mm.

In some examples, the liner paper contains a citrate, such as sodium citrate and/or potassium citrate. In such examples, the liner paper may have a citrate content of 2.95 by weight or less, or 195 by weight or less. Reducing the citrate content in the wrapper may help reduce visible discoloration of the wrapper during use.

In the example provided, the aerosol-forming material added to the aerosol-generating substrate 21 comprises 1495 by weight of the aerosol-generating substrate 21. In some examples, the aerosol-forming material comprises at least 5 95 by weight of the aerosol-generating substrate, in some examples at least 10 95. In some examples, the aerosol-forming material comprises less than 25 95 by weight of the aerosol-generating substrate, in some examples less than 20 95, for example, from 10 95 to 20 95, from 12 95 to 18 95, or from 13 95 to 16 95.

In some examples, the article 1 may be configured such that there is a separation (i.e., a minimum distance) between the heater of the non-combustion aerosol delivery device 100 and the hollow tubular member 23. This prevents damage from the heat from the heater to the material forming the hollow tubular member.

The minimum distance between the heater of the non-combustion aerosol delivery device 100 and the hollow tubular member 23 may be 3 mm or more. In some examples, the minimum distance between the heater of the non-combustion aerosol delivery device 100 and the hollow tubular member 23 may be in the range of 3 mm to 10 mm, such as 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm.

The separation between the heating element of the device 100 for providing an aerosol without combustion and the hollow tubular element 23 can be achieved, for example, by adjusting the length of the aerosol generating material 21.

In some examples, the aerosol generating material 21 is provided in the form of a cylindrical rod of aerosol generating material. Regardless of the shape of the aerosol generating material, it preferably has a length of about 10 mm to 100 mm. In some examples, the length of the aerosol generating material is in the range of about 25 mm to 50 mm, in some examples in the range of about 30 mm to 45 mm, and in some examples from about 30 mm to 40 mm.

The volume of aerosol generating material 21 provided may vary from about 200 mm to about 4300 mm, preferably from about 500 mm to 1500 mm, more preferably from about 1000 mm to about 1300 mm. It has been shown that providing such volumes of aerosol generating material, for example from about 1000 mm to about 1300 mm, is advantageous for providing a higher quality aerosol with better visibility and sensory characteristics compared to volumes selected from the lower end of the range.

The mass of the aerosol generating material 21 provided may be greater than 200 mg, for example, from about 200 mg to 400 mg, preferably from about 230 mg to 360 mg, more preferably from about 250 mg to 360 mg. It has been found that providing a greater mass of aerosol generating material results in improved sensory characteristics compared to an aerosol generated from a tobacco material with a lower mass.

Preferably, the aerosol-generating material or substrate is formed from a tobacco material as described herein, containing a tobacco component.

In the tobacco material described herein, the tobacco component preferably comprises reconstituted tobacco in the form of paper. The tobacco component may also comprise leaf tobacco, extruded tobacco and/or tobacco cast in the form of tape.

The aerosol generating material 21 may comprise a reconstituted tobacco material having a density of less than about 700 milligrams per cubic centimeter (mg/cm3). Such tobacco material has been found to be particularly effective in providing an aerosol generating material that can be heated rapidly to release an aerosol, compared to materials with higher densities. For example, the present inventors have tested the properties of various aerosol generating materials, such as reconstituted tobacco material cast in the form of a ribbon and reconstituted tobacco material in the form of a paper, when heated. It has been found that for any given aerosol-generating material, there is a specific zero heat flux temperature below which the net heat flux is endothermic, in other words, more heat enters the material than leaves the material, and above which the net heat flux is exothermic, in other words, more heat leaves the material than enters the material, while heat is being applied to the material. Materials having a density of less than 700 mg/cm3 have a lower zero heat flux temperature.

Since a significant portion of the heat flux outward from a material originates in aerosol formation, a lower zero heat flux temperature has a beneficial effect on the time required for the first release of aerosol from an aerosol-generating material. For example, aerosol-generating materials with densities less than 700 mg/cm3 have been found to have zero heat flux temperatures less than 164°C compared to materials with densities greater than 700 mg/cm3, for which zero heat flux temperatures exceed 164°C.

The density of the aerosol-generating material also affects the rate at which the material conducts heat, with lower densities, such as less than 700 mg/cm3, conducting heat through the material more slowly, resulting in a longer-lasting aerosol release.

Preferably, the aerosol generating material 21 comprises a reconstituted tobacco material having a density of less than about 700 mg/cubic cm, such as a reconstituted tobacco material in the form of paper. More preferably, the aerosol generating material 20 comprises a reconstituted tobacco material having a density of less than about 600 mg/cubic cm.

Alternatively or additionally, the aerosol generating material 21 preferably comprises a reconstituted tobacco material having a density of at least 350 mg/cc, selected to provide a sufficient amount of thermal conductivity through the material.

The tobacco material may be provided in the form of cut tobacco leaves. The cut tobacco leaves may have a cut width of at least 15 cuts per inch (about 5.9 cuts per cm, equivalent to a width between cuts of about 1.7 mm). Preferably, the cut tobacco leaves have a cut width of at least 18 cuts per inch (about 7.1 cuts per cm, equivalent to a width between cuts of about 1.4 mm), more preferably at least 20 cuts per inch (about 7.9 cuts per cm, equivalent to a width between cuts of about 1.27 mm). In one example, the cut tobacco leaves have a cut width of 22 cuts per inch (about 8.7 cuts per cm, equivalent to a width between cuts of about 1.15 mm).

Preferably, the cut tobacco leaf has a cut width of 40 cuts per inch or less (approximately 15.7 cuts per cm, equivalent to a width between cuts of approximately 0.64 mm). Cut widths of 0.5 mm to 2.0 mm, such as 0.6 mm to 1.5 mm or 0.6 mm to 1.7 mm, have been found to result in tobacco material that is advantageous in terms of surface area to volume ratio, particularly during heating, and overall density and pressure drop of the substrate 20. The cut tobacco leaf may be formed from a mixture of forms of tobacco material, such as a mixture of one or more of reconstituted tobacco in paper form, leaf tobacco, extruded tobacco, and cast tobacco in ribbon form. Preferably, the tobacco material comprises reconstituted tobacco in paper form or a mixture of reconstituted tobacco in paper form and leaf tobacco.

In the tobacco material described herein, the tobacco material may comprise a filler component. The filler component is generally a non-tobacco component, i.e. a component that does not contain ingredients derived from tobacco. The filler component may be a non-tobacco fiber, such as wood fiber or pulp, or wheat fiber. The filler component may also be an inorganic material, such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate. The filler component may also be a cast non-tobacco material or an extruded non-tobacco material. The filler component may be present in an amount of from 0 to 20% by weight of the tobacco material or in an amount of from 1 to 10% by weight of the composition. In some embodiments, the filler component is absent.

In the tobacco material described herein, the tobacco material comprises an aerosol-forming material. In the context of this document, an "aerosol-forming material" is a means that facilitates the generation of an aerosol. The aerosol-forming material can facilitate the generation of an aerosol by facilitating the initial evaporation and/or condensation of a gas to produce an inhalable aerosol of solid and/or liquid particles. In some embodiments, the aerosol-forming material can enhance the delivery of a flavorant from the aerosol-generating material. In general, any suitable aerosol-forming material or means can be included in the aerosol-generating material of the present invention, including those described herein. Other suitable aerosol-forming materials include, but are not limited to, the following: 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 myristates, including ethyl myristate and isopropyl myristate, and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate. In some embodiments, the aerosol-forming material may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. Glycerol may be present in an amount of from 10 to 20% by weight of the tobacco material, for example from 13 to 16% by weight of the composition or about 14% or 15% by weight of the composition. If propylene glycol is present, its amount may be 0.1-0.3% by weight of the composition.

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

The tobacco material may contain from 10% to 90% by weight of tobacco leaf, with the aerosol forming material being provided in an amount of up to about 10% by weight of tobacco leaf. It has been found that to achieve a total aerosol forming material level of from 10% to 20% by weight of tobacco material, it is advantageous to add it in higher weight percentages to another component of the tobacco material, such as reconstituted tobacco material.

The tobacco material described herein contains nicotine. The nicotine content is 0.5-1.75% by weight of the tobacco material and may be, for example, 0.8-1.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material contains from 10% to 90% by weight of tobacco leaf having a nicotine content greater than 1.5% by weight of the tobacco leaf. It has been found that the use of tobacco leaf having a nicotine content greater than 1.5% in combination with a base material having a lower nicotine content, such as reconstituted tobacco in paper form, provides a tobacco material with an acceptable level of nicotine but with better sensory characteristics than using reconstituted tobacco in paper form alone. The tobacco leaf, for example, cut tobacco leaf, may, for example, have a nicotine content of from 1.5% to 5% by weight of the tobacco leaf.

The tobacco material described herein may contain an aerosol modifier, such as any of the flavoring agents described herein. In one embodiment, the tobacco material contains menthol, forming a menthol-enriched product. The tobacco material may contain from 3 mg to 20 mg of menthol, preferably from 5 mg to 18 mg, and more preferably from 8 mg to 16 mg of menthol. In the example provided, the tobacco material contains 16 mg of menthol. The tobacco material may contain from 2.95 to 8.9% by weight of menthol, preferably from 3.95 to 7.95% by weight of menthol, and more preferably from 4.95 to 5.596% by weight of menthol. In one embodiment, the tobacco material contains 4.7% by weight of menthol. Such high levels of added menthol can be achieved by using a significant percentage of reconstituted tobacco material, for example, greater than 50% by weight of tobacco material. Alternatively or in addition, using a large volume of aerosol generating material, such as tobacco material, can increase the level of added menthol, which can be achieved, for example, by using more than about 500 mm3 or more than about 1000 mm3 of aerosol generating material, such as tobacco material.

In the compositions described herein, for the amounts given in 95% by weight, for the avoidance of doubt, this refers to the dry weight unless specifically stated otherwise. Thus, any water that may be present in the tobacco material or in any of its components is completely ignored for the purpose of determining 95% by weight. The water content of the tobacco material described herein may vary and may be, for example, 5-1595% by weight. The water content of the tobacco material described herein may vary according to, for example, the temperature, pressure and humidity conditions under which the compositions are stored. The water content may be determined by Karl analysis

Fischer, as known to those skilled in the art. On the other hand, for the avoidance of doubt, even if the aerosol-forming material is a liquid phase component, such as glycerol or propylene glycol, any component other than water is included in the weight of the tobacco material. However, if the aerosol-forming material is provided in the tobacco component of the tobacco material or in the filler component (if present) of the tobacco material, instead of or in addition to being added separately to the tobacco material, the aerosol-forming material is not included in the weight of the tobacco component or filler component, but is included in the weight of the "aerosol-forming material" in weight 956, as defined herein. All other ingredients present in the tobacco component are included in the weight of the tobacco component, even if they are of non-tobacco origin (e.g., non-tobacco fibers in the case of reconstituted tobacco in paper form).

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

The reconstituted tobacco in the form of paper is present in the tobacco component of the tobacco material described herein in an amount of from 1095 to 10095 by weight of the tobacco component. In embodiments, the reconstituted tobacco in the form of paper is present in an amount of from 10 95 to 80 95 by weight or from 20 95 to 70 95 by weight of the tobacco component. In another embodiment, the tobacco component consists of or consists essentially of reconstituted tobacco in the form of paper. In preferred embodiments, the leaf tobacco is present in the tobacco component of the tobacco material in an amount of at least 10 95 by weight of the tobacco component. For example, leaf tobacco may be present in an amount of at least 10% by weight of the tobacco component, while the remainder of the tobacco component comprises reconstituted tobacco in paper form, reconstituted tobacco cast in ribbon form, or a combination of reconstituted tobacco cast in ribbon form and another form of tobacco, such as tobacco granules.

Reconstituted tobacco paper is tobacco material formed by a process in which tobacco raw material is extracted with a solvent to obtain an extract of soluble components and a residue containing fibrous material, and then the extract (usually after concentration and optionally after further processing) is recombined with fibrous material from the residue (usually after purification of the fibrous material and optionally with the addition of a portion of non-tobacco fibers) by depositing the extract on the fibrous material. The recombination process resembles the process of making paper.

The reconstituted tobacco paper may be any type of reconstituted tobacco paper known in the art. In a specific embodiment, the reconstituted tobacco paper 60 is made from a feedstock that includes one or more of tobacco strips, tobacco stems, and whole-leaf tobacco. In another embodiment, the reconstituted tobacco paper is made from a feedstock that includes tobacco strips and/or whole-leaf tobacco and tobacco stems. However, in other embodiments, the feedstock may alternatively or additionally include trimmings, chips, and screenings.

Reconstituted tobacco in paper form for use in the tobacco material described herein can be made by methods known to those skilled in the art for making reconstituted tobacco in paper form.

The non-combustion aerosol delivery device is used to heat the aerosol generating material 21 of the article 1. The non-combustion aerosol delivery device preferably includes a coil as it has been found that this provides the possibility of improved heat transfer to the article 1 compared to other arrangements.

In some examples, the coil is configured to, during use, cause the at least one electrically conductive heating element to heat, such that thermal energy is capable of being conducted from the at least one electrically conductive heating element to the aerosol-generating material, thereby causing the aerosol-generating material to heat.

In some embodiments, the coil is adapted to generate, when used, a variable magnetic field to penetrate at least one heating element, thereby causing induction heating and/or heating by magnetic hysteresis of at least one heating element. In such an arrangement, the or each heating element may be referred to as a "current collector", as defined herein. A coil adapted to generate, when used, a variable magnetic field to penetrate at least one electrically conductive heating element, thereby causing induction heating of at least one electrically conductive heating element, may be referred to as an "inductance coil" or "induction coil".

The device may include a heating element(s), for example an electrically conductive heating element(s), and the heating element(s) may be suitably positioned or capable of being positioned relative to the coil in a manner that enables such heating of the heating element(s). The heating element(s) may be in a fixed position relative to the coil.

Alternatively, at least one heating element, e.g., at least one electrically conductive heating element, may be incorporated into the article 1 for insertion into the heating zone of the device, wherein the article 1 also includes an aerosol generating material 21 and is removable from the heating zone after use. Alternatively, both the device and such article 1 may include at least one corresponding heating element, e.g., at least one electrically conductive heating element, and the coil may be capable of causing the heating element(s) of each of the device and the article to heat when the article is in the heating zone.

In some examples, the coil is helical. In some examples, the coil surrounds at least a portion of the heating zone of the device adapted to accommodate the aerosol-generating material. In some examples, the coil is a helical coil that surrounds at least a portion of the heating zone.

In some examples, the device includes an electrically conductive heating element that at least partially surrounds the heating zone, and the coil is a helical coil that surrounds at least a portion of the electrically conductive heating element. In some examples, the electrically conductive heating element is tubular. In some examples, the coil is an induction coil.

In some embodiments, the use of a coil allows the non-combustion aerosol delivery device to reach operating temperature more quickly than an aerosol delivery device without a coil. For example, a non-combustion aerosol delivery device that includes a coil as described above can reach operating temperature such that the first puff can be taken in less than 30 seconds from the start of the device's heating program, more preferably in less than 25 seconds. In some embodiments, the device can reach operating temperature in about 20 seconds from the start of the device's heating program.

It has been found that the use of a coil as described herein in a device for causing heating of an aerosol-generating material improves the aerosol produced. For example, consumers have reported that the aerosol produced by a device incorporating a coil such as the coil described herein is sensory closer to the aerosol produced in manufactured cigarette (MOC) products than the aerosol produced by other non-combustion aerosol delivery systems. Without being limited by theory, it is believed that this is due to the reduced time to reach the desired heating temperature when using a coil, the higher heating temperatures that can be achieved when using a coil, and/or the fact that the coil allows such systems to simultaneously heat a relatively large volume of aerosol-generating material, resulting in aerosol temperatures similar to those of MOC aerosols. In EMC products, the burning coal generates a hot aerosol that heats the tobacco in the tobacco rod behind the coal as the aerosol is drawn through the rod. It is understood that this hot aerosol releases flavor compounds from the tobacco in the rod behind the burning coal. A device comprising a coil as described herein is also contemplated to be capable of heating an aerosol-generating material, such as the tobacco material described herein, to release flavor compounds, resulting in an aerosol that is reported to be quite similar to an EMO aerosol.

The use of an aerosol delivery system comprising a coil as described herein, e.g., an inductance coil that heats at least some portion of the aerosol generating material to at least 200°C, more preferably at least 220°C, can provide for the generation of an aerosol from the aerosol generating material with specific characteristics that are considered to be more similar to the characteristics of the product.

EMO. For example, when heating an aerosol-generating material containing nicotine using an induction heater heated to at least 250°C for a two-second period under an air flow of at least 1.50 L/min, one or more of the following characteristics are observed during this period: at least 10 μg of nicotine is aerosolized from the aerosol-generating material; the weight ratio of aerosol-generating material to nicotine in the generated aerosol is at least about 2.5:1, respectively at least 8.5:1; at least 100 μg of aerosol-generating material can be aerosolized from the aerosol-generating material; the average particle or droplet size in the generated aerosol is less than about 1000 nm; and the density of the aerosol is at least 0.1 μg/cc.

In some cases, at least 10 μg of nicotine, respectively at least 30 μg or 40 μg of nicotine is aerosolized from the aerosol generating material under the influence of an air flow of at least 1.50 L/min during a given period. In some cases, less than about 200 μg, respectively less than about 150 μg or less than about 125 μg of nicotine is aerosolized from the aerosol generating material under the influence of an air flow of at least 1.50 L/min during a given period.

In some cases, the aerosol contains at least 100 μg of aerosol-forming material, respectively at least 200 μg, 500 μg or 1 mg of aerosol-forming material, which is aerosolized from the aerosol-generating material by an air flow of at least 1.50 L/min during a given period. Accordingly, the aerosol-forming material may contain or consist of glycerol.

In the context of this document, the term "average particle or droplet size" means the average size of the solid or liquid components of the aerosol (i.e., components suspended in the gas).

If an aerosol contains suspended liquid droplets and suspended solid particles, the term refers to the average size of all components combined.

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

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

The non-combustion aerosol delivery device is preferably configured to heat the aerosol-generating material 21 of the product 1 to a maximum temperature of at least 160°C. Preferably, the non-combustion aerosol delivery device is configured to heat the aerosol-generating material 21 of the product 1 to a maximum temperature of at least about 200°C, or at least about 220°C, or at least about 240°C, more preferably at least about 270°C at least once during the heating process followed by the non-combustion aerosol delivery device.

The use of an aerosol delivery system comprising a coil as described herein, e.g., an induction coil that heats at least some portion of the aerosol generating material to at least 200°C, more preferably at least 220°C, can provide for the generation of an aerosol from the aerosol generating material in the article 1 as described herein, which has a higher temperature as the aerosol exits the mouth end of the mouthpiece 10, compared to prior art devices, facilitating the generation of an aerosol that is considered to be more similar to an EMO product. For example, the maximum aerosol temperature measured at the mouth end of the article 10 may preferably exceed 50°C, more preferably exceed 55°C, and even more preferably exceed 56°C or 57°C. Additionally or alternatively, the maximum aerosol temperature measured at the mouth end of the article 10 may be less than 62°C, more preferably less than 60°C, and more preferably less than 59°C. In some embodiments, the maximum aerosol temperature measured at the mouth end of the article 10 may preferably be from 50°C to 62°C, more preferably from 56°C to 60°C.

Fig. C shows an example of a non-combustion aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium/material, such as the aerosol-generating material 21 of the articles 1 described herein. In general, the device 100 can be used to heat a replaceable article 110 that contains an aerosol-generating medium, such as the articles 1 described herein, to generate an aerosol or other inhalable medium that is inhaled by a user of the device 100.

The device 100 and the replaceable article 110 together form a non-combustion aerosol delivery system.

The device 100 includes a housing 102 (in the form of an outer casing) that surrounds and houses the various components of the device 100. The device 100 has an opening 104 at one end through which an article 110 can be inserted for heating by a heating unit. In use, the article 110 can be fully or partially inserted into the heating unit, where it can be heated by one or more components of the heating unit. When the article 110 is inserted into the device 100, the minimum distance between the one or more components of the heater unit and the tubular element of the article 110 can be in the range of 3 mm to 10 mm, for example, 3 mm, 4 mm, 5 mm, 6

MM, 7mm, 8mm, 9mm or 10mm.

The device 100 of this example includes a first end member 106 that includes a cover 108 that is movable relative to the first end member 106 to close the opening 104 when the article 110 is not in place. In Fig. 3, the cover 108 is shown in an open configuration, however, the cover 108 can be moved to a closed configuration. For example, a user can slide the cover 108 in the direction of arrow "B".

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

Device 100 may also include an electrical component, such as a socket/port 114, that may accommodate a cable for charging the battery of device 100. For example, socket 114 may be a charging port, such as an O5B charging port.

Fig. 4 shows the device 100 of Fig. 3 with the outer casing 102 removed and without the article 110. The device 100 defines a longitudinal axis 134. As shown in Fig. 4, a first end member 106 is disposed at one end of the device 100, and a second end member 116 is disposed at the opposite end of the device 100. The first and second end members 106, 116 together at least partially define the end surfaces of the device 100. For example, the lower surface of the second end member 116 at least partially defines the lower surface of the device 100. The edges of the outer casing 102 may also define a portion of the end surfaces. In this example, the cover 108 also defines a portion of the upper surface of the device 100.

The end of the device closest to the opening 104 may be known as the proximal end (or mouth end) of the device 100 because it is closest to the user's mouth during use. During use, the user inserts the article 110 into the opening 104, interacts with the user control 112 to begin heating the aerosol-generating material, and draws the aerosol generated into the device. This causes the aerosol to flow through the device 100 along a flow path to the distal end of the device 100.

The other end of the device, farthest from the opening 104, may be known as the distal end of the device 100, since during use it is the end furthest from the user's mouth. As the user inhales the aerosol generated in the device, the aerosol flows outward from the device 100.

The device 100 further includes a power source 118. The power source 118 may be, for example, a battery, such as a rechargeable battery or a non-rechargeable battery.

Examples of suitable batteries include, for example, a lithium battery (such as a lithium-ion battery), a nickel battery (such as a nickel-cadmium battery), and an alkaline battery. The battery is electrically connected to the heating assembly to supply electrical energy when required, under the control of a controller (not shown) to heat the aerosol-generating material. In this example, the battery is connected to a central support 120 that holds the battery 118 in place.

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

In the exemplary device 100, the heating unit is an induction heating unit and includes various components for heating the aerosol-generating material of the product 110 using an induction heating method. Induction heating is the process of heating an electrically conductive object (such as a current collector) using electromagnetic induction. The induction heating unit may include an inductive element, such as one or more induction coils, and a device for passing an alternating electric current, such as an alternating electric current, through the inductive element.

A changing electric current in an inductive element creates a changing magnetic field.

The changing magnetic field penetrates a current collector, properly positioned relative to the inductive element, and generates eddy currents inside the current collector.

The current collector is characterized by an electrical resistance to eddy currents, and therefore the flow of eddy currents overcoming this resistance causes the current collector to heat up by Joule heating. In cases where the current collector contains a ferromagnetic material such as iron, nickel or cobalt, heat can also be generated by magnetic hysteresis losses in the current collector, i.e. by changing the orientation of magnetic dipoles in the magnetic material as a result of their alignment along the lines of a changing magnetic field.

Induction heating, compared to, for example, conduction heating, heat is generated inside the current collector, allowing for rapid heating. Furthermore, there is no need for any physical contact between the induction heater and the current collector, which provides greater freedom in design and application.

The induction heating assembly of the exemplary device 100 includes a current receiving arrangement 132 (referred to herein as a "current receiver"), a first induction coil 124, and a second induction coil 126. The first and second induction coils 124, 126 are made of an electrically conductive material. In this example, the first and second induction coils 124, 126 are made of a litzen wire/litzen wire cable wound in a spiral manner to provide the helical induction coils 124, 126. The litzen wire includes a set of individual wires that are individually insulated and twisted together to form a single wire. The litzen wire is designed to reduce skin-effect losses in the conductor. In the exemplary device 100, the first and second induction coils 124, 126 are made of copper litz wire having a rectangular cross-section. In other examples, the litz wire may have other cross-sections, such as circular.

The first induction coil 124 is configured to generate a first alternating magnetic field to heat the first current collector section 132, and the second induction coil 126 is configured to generate a second alternating magnetic field to heat the second current collector section 132. In this example, the first induction coil 124 is adjacent to the second induction coil 126 in a direction along the longitudinal axis 134 of the device 100 (i.e., the first and second induction coils 124, 126 do not overlap). The current collector arrangement 132 may include a single current collector or two or more separate current collectors. The ends 130 of the first and second induction coils 124, 126 may be connected to the PCB 122.

It should be understood that the first and second inductors 124, 126 may, in some embodiments, have at least one characteristic that distinguishes them from one another. For example, the first inductor 124 may have at least one characteristic that distinguishes it from the second inductor 126. More specifically, in one embodiment, the first inductor 124 may have a different inductance value than the second inductor 126. In FIG. 8, the first and second inductors 124, 126 have different length values such that the first inductor 124 is wound over a smaller cross-section of the current collector 132 compared to the second inductor 126. Thus, the first inductor 124 may contain a different number of turns compared to the second inductor 126 (assuming that the distance between the individual turns is substantially the same). In another example, the first induction coil 124 may be made of a different material than the second induction coil 126. In some examples, the first and second induction coils 124, 126 may be substantially the same.

In this example, the first induction coil 124 and the second induction coil 126 are wound in opposite directions. This may be useful when the induction coils are active at different times. For example, the first induction coil 124 may initially heat a first section/portion of the product 110 during operation, and the second induction coil 126 may later heat a second section/portion of the product 110 during operation. Winding the coils in opposite directions helps to reduce the current induced in the inactive coil when used in conjunction with a particular type of control circuit. In Fig. 4, the first induction coil 124 is a right-handed coil and the second induction coil 126 is a left-handed coil. However, in another embodiment, the induction coils 124, 126 may be wound in the same direction, or the first induction coil 124 may be a left-handed coil and the second induction coil 126 may be a right-handed coil.

The current collector 132 in this example is hollow and, as a result, forms a container within which the aerosol-generating material is contained. For example, the article 110 may be inserted into the current collector 132. In this example, the current collector 120 is tubular with a circular cross-section.

The current collector 132 may be made of one or more materials. Preferably, the current collector 132 comprises carbon steel coated with nickel or cobalt.

In some examples, the current collector 132 may include at least two materials that are capable of being heated at two different frequencies to selectively aerosolize at least two materials. For example, a first section of the current collector 132 (which is heated by the first induction coil 124) may include a first material, and a second section of the current collector 132, which is heated by the second induction coil 126, may include a second, different material. In another example, the first section may include a first and a second material, with the first and second materials being heated differently depending on the operation of the first induction coil 124. The first and second materials may be adjacent along an axis defined by the current collector 132, or may form different layers within the current collector 132.

Similarly, the second section may include third and fourth materials, wherein the third and fourth materials may be heated differently depending on the operation of the second induction coil 126. The third and fourth materials may be adjacent along an axis defined by the current collector 132, or may form different layers within the current collector 132. For example, the third material may be the same as the first material, and the fourth material may be the same as the second material. Alternatively, each of the materials may be different. The current collector may, for example, comprise carbon steel or aluminum.

The device 100 of FIG. 4 further includes an insulating member 128, which may be generally tubular and at least partially surround the current collector 132. For example, the insulating member 128 may be made of any insulating material, such as a plastic. In this particular example, the insulating member is made of polyetheretherketone (PEEK).

The insulating member 128 may help to insulate various components of the device 100 from heat generated by the current collector 132.

The insulating member 128 may also be a support for the first and second induction coils 124, 126 in whole or in part. For example, as shown in Fig. 4, the first and second induction coils 124, 126 are disposed around the insulating member 128 and are in contact with a radially outwardly facing surface of the insulating member 128. In some examples, the insulating member 128 is not adjacent to the first and second induction coils 124, 126. For example, there may be a small gap between the outer surface of the insulating member 128 and the inner surface of the first and second induction coils 124, 126.

In a specific example, the current collector 132, the insulating member 128, and the first and second induction coils 124, 126 are arranged coaxially about the central longitudinal axis of the current collector 132.

Fig. 5 shows a side view of the device 100 in partial section. The outer casing 102 is present in this example. The rectangular cross-sectional shape of the first and second induction coils 124, 126 is more clearly visible.

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

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

The device 100 further includes a second cover/cap 140 and a spring 142 disposed near the distal end of the device 100. The spring 142 provides the ability to open the second cover 140 to provide access to the current collector 132. The user may open the second cover 140 to clean the current collector 132 and/or the support 136.

The device 100 further includes an expansion chamber 144 extending from the distal end of the current collector 132 to the opening 104 of the device. A retaining clip 146 is disposed at least partially within the expansion chamber 144 for engaging and retaining the article 110 during insertion into the device 100. The expansion chamber 144 is connected to the end piece 106.

Fig. 6 shows an exploded view of the device 100 of Fig. 5 without the outer casing 102.

Fig. 7A is a cross-sectional view of a portion of the device 100 of Fig. 5. Fig. 7B is a magnified view of the portion of Fig. 7A. Figs. 7A and 7B show an article 110 disposed within a current collector 132, with the article 110 sized such that the outer surface of the article 110 is adjacent to the inner surface of the current collector 132. This provides the greatest heating efficiency. The article 110 in this example includes an aerosol-generating material 110a. The aerosol-generating material 110a is disposed within the current collector 132.

The product 110 may also include other components, such as a filter, wrapping materials, and/or a cooling structure.

Fig. 7B shows that the outer surface of the current collector 132 is located at a distance 150 from the inner surface of the induction coils 124, 126, measured in a direction perpendicular to the longitudinal axis 158 of the current collector 132. In one particular example, the distance 150 is from about 3 mm to 4 mm, about 3-3.5 mm, or about 3.25

MM.

Fig. 7B further shows that the outer surface of the insulating member 128 is located at a distance 152 from the inner surface of the induction coils 124, 126, measured in a direction perpendicular to the longitudinal axis 158 of the current collector 132. In one particular example, the distance 152 is approximately 0.05 mm. In another example, the distance 152 is substantially 0 mm, such that the induction coils 124, 126 are adjacent to and in contact with the insulating member 128.

In one example, the current collector 132 has a wall thickness 154 of about 0.025 mm to 1 mm or about 0.05 mm.

In one example, the current collector 132 has a length of about 40 mm to 60 mm, about 40 mm to 45 mm, or about 44.5 mm.

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

In use, the article 1 described herein may be inserted into a non-combustion aerosol delivery device, such as the device 100 described with reference to FIGS. 3-7. At least a portion of the mouthpiece 10 of the article 1 extends from the non-combustion aerosol delivery device 100 and may be placed in the mouth of a user. The aerosol is generated by heating an aerosol-generating material 21 by the device 100. The aerosol generated from the aerosol-generating material 21 passes through the mouthpiece 10 into the mouth of the user.

Figure 8 is a flow chart showing a method of manufacturing a component for use in a non-combustion aerosol delivery system.

The method includes the following steps: forming an inner body comprising a first material (5101); and forming an outer body surrounding the inner body, wherein the resistance to gaseous flow through the length of the inner body is less than the resistance to gaseous flow through the length of the outer body (5102).

In some examples, forming the outer main part includes forming the outer main part as a single unit with the inner main part.

In some examples, forming the outer main portion includes forming the outer main portion separately from the inner main portion and arranging the inner main portion and the outer main portion such that the outer main portion surrounds the inner main portion.

The various embodiments described herein are presented solely to aid in understanding and comprehending the claimed features. These embodiments are provided only as representative examples of embodiments and are not intended to be exhaustive and/or exclusive.

It is to be understood that the advantages, embodiments, examples, functions, features, structures and/or other aspects described herein are not to be construed as limitations on the scope of the invention as defined by the claims or as limitations on the equivalents of the claims, and that other embodiments may be employed and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may accordingly include, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, the invention may include other inventions not presently claimed but which may be claimed in the future.

Claims (26)

FORMULA OF THE INVENTION 1. A component for use in a non-combustion aerosol delivery system, the component comprising: an inner body comprising a first material; and an outer body comprising a second material, the outer body surrounding the inner body, wherein the resistance to gaseous flow through the length of the inner body is less than the resistance to gaseous flow through the length of the outer body, and wherein the first material and the second material comprise paper. 2. The component of claim 1, wherein the density of the first material is lower than the density of the second material. 3. A component according to one of claims 1 or 2, characterized in that the inner main part is essentially cylindrical and/or the outer main part is tubular. 4. The component according to any one of claims 1-3, characterized in that the inner main part and/or the outer main part has a length in the range from 5 to 15 mm. 5. The component according to any one of claims 1-4, characterized in that the length of the inner main part is essentially the same as the length of the outer main part. 6. The component according to any one of claims 1-5, characterized in that it further comprises an adhesive that bonds the inner main part and the outer main part to each other. 7. The component according to any one of claims 1-6, characterized in that it further comprises a tubular main part. 8. The component of claim 7, wherein the tubular body forms the mouth end of the component. 9. The component according to one of claims 7 or 8, characterized in that the tubular main part has a length of at least about 10 mm or at least about 12 mm. 10. The component according to any one of claims 1-9, further comprising a wrapper surrounding the outer main portion. 11. The component of claim 10, wherein the wrapper has a citrate content of 2.95 by weight or less or 1.95 by weight or less. 12. An article of manufacture for use with a device for providing an aerosol without combustion, comprising: an aerosol-generating material comprising at least one aerosol-forming material; and a component according to any one of claims 1-11. 13. The product of claim 12, further comprising a tubular section located downstream of the aerosol generating material. 14. The product of claim 13, characterized in that the tubular section has a wall thickness of from 0.5 to 2.5 mm. 15. The product according to one of claims 13 or 14, characterized in that the tubular section has a length of at least 10 mm. 16. The product of any one of claims 13-15, wherein the tubular section comprises a wall containing an aerosol-generating material. 17. The product of any one of claims 13-16, wherein the tubular section comprises paper having a thickness of greater than 325 microns and/or a wall having a permeability of at least 100 Sogezia units. 18. The product according to any one of claims 12-17, further comprising at least one ventilation zone positioned to allow outside air to flow into the product. 19. The product of claim 18, wherein said at least one ventilation zone comprises one row of ventilation holes. 20. The product of claim 18, wherein said at least one ventilation zone comprises two or more rows of ventilation holes. 21. The article of any one of claims 18-20, wherein the aerosol generating material is wrapped in a wrapper having a permeability level greater than about 1000 or 2000 Sogevia units. 22. The product of any one of claims 18-21, wherein the at least one ventilation zone provides a ventilation level in the range of 45 to 65% of the volume of aerosol generated by said non-combustion aerosol delivery device passing through the product, or in the range of 40 to 60% of the volume of aerosol generated by said non-combustion aerosol delivery device passing through the product. 23. The article of any one of claims 13-17, characterized in that it is made in such a way that when the article is inserted into the device for providing an aerosol without combustion, the minimum distance between the heater of the device for providing an aerosol without combustion and the tubular section of the article is at least about 3 mm. 24. A method of making a component for use in a non-combustion aerosol delivery system, the method comprising: forming an inner body from a first material; and forming an outer body surrounding the inner body, the outer body being formed from a second material, wherein the resistance to gaseous flow through the length of the inner body is less than the resistance to gaseous flow through the length of the outer body, and wherein the first material and the second material comprise paper. 25. The method of claim 24, wherein forming the outer main portion includes forming the outer main portion integrally with the inner main portion. 26. 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