JP7476313B2 - Articles for use in aerosol delivery systems - Google Patents

Description

The following relates to articles for use in non-combustion aerosol delivery systems, non-combustion aerosol delivery systems including the articles, and methods of making articles for use with non-combustion aerosol delivery devices.

Certain tobacco industry products generate an aerosol during use, which is inhaled by the user. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, to form an aerosol by heating the substrate without burning it. Such tobacco industry products typically include a mouthpiece through which the aerosol passes to the user's mouth.

In some embodiments described herein, in a first aspect, an article is provided for use with a non-combustion aerosol delivery device having a heater, the article comprising:
an aerosol-generating material comprising at least one aerosol-forming material;
a first tubular body disposed downstream of the aerosol-generating material, the first tubular body including a filament tow;
a mouth end section disposed downstream of the first tubular body;
The article is configured such that when the article is inserted into the non-combustible aerosol delivery device, the minimum distance between the heater and the first tubular body of the non-combustible aerosol delivery device is at least about 3 mm.

In some embodiments described herein, in a second aspect,
a non-combustible aerosol delivery device having a heater;
A system is provided comprising an article according to any one of claims 1 to 22.

In some embodiments described herein, in a third aspect, there is provided a method of making an article for use with a non-combustion aerosol delivery device having a heater, the method comprising:
Providing an aerosol-generating material comprising at least one aerosol-forming material;
positioning a tubular body downstream of the aerosol-generating material, the tubular body including a filament tow;
and positioning an oral end section downstream of the tubular body;
The article is configured such that when the article is inserted into the non-combustible aerosol delivery device, the minimum distance between the heater and the tubular body of the non-combustible aerosol delivery device is at least about 3 mm.

An embodiment will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 is a diagram of an article for use in a non-combustion aerosol delivery system, the article including a mouth end section having a first hollow tubular body, a second hollow tubular body, and a cylindrical body disposed between the first hollow tubular body and the second hollow tubular body. FIG. 2 is a diagram of an article for use in a non-combustion aerosol delivery system, the article including an aerosol generation section configured to extend a minimum distance away from a heater of the non-combustion aerosol delivery system. FIG. 1 is a diagram of an article for use in a non-combustion aerosol delivery system, the article including a cavity downstream of the aerosol-forming material formed by a wrapper. 1 is a diagram of an article for use in a non-combustible aerosol delivery system, the article including a first alternative mouth end section. FIG. 2 is a diagram of an article for use in a non-combustion aerosol delivery system, the article including a second alternative mouth end section. FIG. 2 is a diagram of an article for use in a non-combustion aerosol delivery system, the article including a third alternative mouth end section. FIG. 2 is a diagram of an article for use in a non-combustible aerosol delivery system, the article including a mouth end section with a body of material having a non-circular cross-section. 1 is a schematic diagram of steps in a method for manufacturing an article. FIG. 6 is a perspective view of a non-combustion aerosol delivery device for generating aerosols from the aerosol-forming materials of the articles of FIGS. 1, 2, 3, 4, 4a, 4b, and 5. FIG. 8 is a view of the device of FIG. 7 with the outer cover removed and no article present. FIG. 8 is a partial cross-sectional side view of the device of FIG. 7. FIG. 8 is an exploded view of the device of FIG. 7 with the outer cover omitted. 8 is a cross-sectional view of a portion of the device of FIG. 7. FIG. 11B is an enlarged view of a region of the device of FIG.

As used herein, the term "delivery system" is intended to include a system that delivers at least one substance to a user;
Combustible aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for rolling or hand-made cigarettes, whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials;
a non-combustion aerosol delivery system that releases a compound from an aerosol-generating material without combusting the aerosol-generating material, such as e-cigarettes, tobacco heating products, and hybrid systems that use a combination of aerosol-generating materials to generate an aerosol;
and aerosol-free delivery systems that deliver at least one substance, which may or may not contain nicotine, to a user orally, nasally, transdermally, or otherwise, without forming an aerosol, including, but not limited to, lozenges, gums, patches, articles containing inhalable powders, and oral products such as oral tobacco products (including snus and moist snuff).

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

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

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

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

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

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

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

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

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

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

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

In some embodiments, the substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolized. Optionally, either material may include one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and/or one or more other functional materials.

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

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

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

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

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

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

An aerosol modifier is a substance that is typically disposed downstream of the aerosol-generation region and configured to modify the generated aerosol, for example, by changing the taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided in an aerosol modifier-releasing component that is operable to selectively release the aerosol modifier.

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

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

Induction heating is a process in which a conductive object is heated by penetrating a changing magnetic field into the object. The process is described by Faraday's law of electromagnetic induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a changing electric current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are placed in a suitable relative position such that the changing magnetic field produced by the electromagnet penetrates the object, one or more eddy currents are generated in the object. The object has a resistance to the flow of electric current. Thus, when such eddy currents are generated in the object, they flow against the electrical resistance of the object, thereby heating the object. This process is called Joule heating, Ohmic heating, or resistive heating. Objects that can be inductively heated are known as susceptors.

In one embodiment, the susceptor is in the form of a closed circuit. It has been found that when the susceptor is in the form of a closed circuit, there is a stronger magnetic coupling between the susceptor and the electromagnet during use, which results in increased or improved Joule heating.

Magnetic hysteresis heating is the process by which an object made of a magnetic material is heated by the penetration of the object into a fluctuating magnetic field. A magnetic material can be thought of as containing many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipoles align themselves along the magnetic field. Thus, when a fluctuating magnetic field, such as an alternating magnetic field (e.g., produced by an electromagnet), penetrates a magnetic material, the orientation of the magnetic dipoles changes in response to the applied fluctuating magnetic field. This reorientation of the magnetic dipoles generates heat in the magnetic material.

When an object is both conductive and magnetic, the introduction of a varying magnetic field into the object can cause both Joule heating and magnetic hysteresis heating in the object. Furthermore, the use of magnetic materials can intensify the magnetic field, thereby intensifying Joule heating.

In each of the above processes, heat is generated within the object itself, rather than by conduction from an external heat source, so that rapid temperature rise and more uniform heat distribution within the object can be achieved, particularly by appropriate choice of object material and geometry, and appropriate choice of magnitude and orientation of the varying magnetic field relative to the object. Furthermore, induction heating and magnetic hysteresis heating do not require a physical connection between the source of the varying magnetic field and the object, allowing greater design freedom and control of the heating profile, as well as lower costs.

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

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

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

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

The articles and their aerosol-generating materials and mouthpieces described herein can be made in any of the formats described above, without limitation.

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

The filament tow or filter material described herein can include fiber tows of cellulose acetate. The filament tows can also be formed using other materials used to form fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. The filament tow may be plasticized with a suitable plasticizer for the tow, such as triacetin if the material is cellulose acetate tow, or the tow may be unplasticized. The tow may have any suitable specifications, such as fibers with a "Y", "X", or "O" shaped cross section. The fibers of the tow have a single fineness value of 2.5 to 15 denier per filament, e.g., 8.0 to 11.0 denier per filament, and a total fineness value of 5,000 to 50,000 denier, e.g., 10,000 to 40,000 denier. When viewed in cross section, the fibers may have an isoperimetric ratio ^L2 /A of 25 or less, preferably 20 or less, and more preferably 15 or less, where L is the perimeter of the cross section and A is the area of the cross section. The filter materials described herein also include cellulosic materials, such as paper. Such materials may have a relatively low density, such as from about 0.1 to about 0.45 grams per cubic centimeter, to allow air and/or aerosols to pass through the material. Although such materials are described as filter materials, the primary purpose may not be related to filtration per se, such as to increase the resistance to draw of a component.

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

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

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

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

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

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

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

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

In some embodiments, the substance delivered includes a fragrance.

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

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

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

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

FIGS. 1-5 show various articles 1a-1g for use as part of a non-combustion aerosol delivery system. The articles can be used, for example, with a non-combustion aerosol delivery device 100 (see FIGS. 7-11B) including a heater 101, according to some embodiments. In this example and other examples described herein, the articles can be tobacco heating product consumables.

With reference to FIG. 1, article 1a comprises a rod of aerosol-generating material 2 comprising at least one aerosol-forming material, a first tubular body 3 disposed downstream of the aerosol-generating material 2 and comprising a filament tow, and an oral end section 20 disposed downstream of the first tubular body 3. Article 1a is configured such that when article 1a is inserted into non-combustible aerosol delivery device 100, a minimum distance d between heater 101 of non-combustible aerosol delivery device 100 and first tubular body 3 is at least about 3 mm. In this example, the aerosol-generating material is tobacco material as described herein.

The minimum distance d between the heater 101 and the first tubular body of the non-combustible aerosol delivery device 100 prevents heat from the heater 101 from damaging the filament tow of the first tubular body 3. In particular, the filament tow may be cellulose acetate tow stiffened with a plasticizer, as known in the art. Heat from the heater 101 may cause the first tubular body 3 to shrink. This is avoided by providing a gap between the first tubular body 3 and the heater 101.

The minimum distance d may be 3 mm or more. The minimum distance d is preferably from about 3 mm to about 18 mm, more preferably from about 3 mm to about 12 mm, such as from about 3 mm to about 10 mm, and values therebetween. Exemplary minimum distances d include 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, and 10 mm.

The article 1a has a mouthpiece section 20 at the mouth end of the article 1a.

In each embodiment, the article further comprises a wrapper 6 at least partially surrounding the aerosol-generating material 2 and the first tubular body 3 and connecting the aerosol-generating material 2 to the first tubular body 3. The wrapper may extend along the entire length of the article 1a to also attach the mouth end section 20. Although the wrapper is shown extending along the entire length of the article 1a, the wrapper may instead extend partially along the length of the aerosol-generating material 2, for example extending 3 mm to 10 mm over the aerosol-generating material 2. The aerosol-generating material may be wrapped in a wrapper 10, also referred to as an additional wrapper 10.

The wrapper 6 may be a paper material that includes a citrate salt, such as sodium nitrate or potassium nitrate. In such examples, the wrapper 6 may have a citrate content of 2% by weight or less, or 1% by weight or less. This inhibits charring of the wrapper 6 when the article 1a is heated with the non-combustible aerosol delivery device 100.

The first tubular body 3 is configured to act as a heat sink to reduce the phenomenon of "hot puffs". A "hot puff" is defined as an aerosol delivered to a user at an uncomfortably high temperature. A hot puff can be exacerbated when a user draws the aerosol through the heated article 1a at a high rate, thereby reducing the time for the heat of the aerosol to dissipate. When inserted into the non-combustible aerosol delivery device 100, the first tubular body 3 positions the mouth end section away from the heater 101 to provide space for heat to dissipate before the aerosol reaches the mouth end section 20. It will further be appreciated that as the aerosol is drawn through the first tubular body 3, heat is conducted away from the aerosol to the first tubular body 3. In this manner, the first tubular body 3 acts as a heat sink.

The wall thickness of the first tubular body 3 is preferably at least about 325 μm to about 2 mm, preferably 500 μm to 1.5 mm, and more preferably 750 μm to 1 mm. In this example, the first tubular body 3 has a wall thickness of about 1 mm. In alternative examples, the wall thickness can be about 0.5 mm to about 3 mm, for example, about 1 mm to about 2.5 mm or about 2 mm. The "wall thickness" of the first tubular body 3 corresponds to the radial wall thickness of the first tubular body 3. This can be measured, for example, using a vernier caliper. In some examples, if the wall thickness is not uniform, the wall thickness refers to the minimum wall thickness of the tubular body 3.

In some embodiments, the wall thickness of the first tubular body 3 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 first tubular body 3 is at least 1250 microns or 1500 microns.

In some embodiments, the wall thickness of the first tubular body 3 is less than 2000 microns, preferably less than 1500 microns.

It has been found that the thicker wall thickness of the first tubular body 3 means a larger thermal mass, which helps to lower the temperature of the aerosol passing through the first tubular body 3 and to lower the surface temperature of the mouth end section 20 downstream of the first tubular body 3. This is believed to be because the larger thermal mass of the first tubular body 3 allows the first tubular body 3 to absorb more heat from the aerosol compared to a first tubular body 3 with a thinner wall thickness. Also, the thicker thickness of the first tubular body 3 forces the aerosol to flow toward the center of the mouth end section 20, resulting in less heat from the aerosol being transferred to the outer portion of the mouth end section 20.

In some embodiments, the permeability of the wall material of the first tubular body 3 is at least 100 Coresta units, preferably at least 500 or 1000 Coresta units.

It has been found that the relatively high permeability of the first tubular body 3 increases the amount of heat transferred from the aerosol to the first tubular body 3, and therefore reduces the temperature of the aerosol. The permeability of the first tubular body 3 has also been found to increase the amount of moisture transferred from the aerosol to the first tubular body 3, which has been found to improve the feel of the aerosol in the user's mouth. The high permeability of the first tubular body 3 also makes it easier to use a laser to drill vents in the first tubular body 3, which means that a lower power laser can be used.

The first tubular body 3 may comprise a filament tow comprising filaments having a cross-section with an isoperimeter ratio ^L2 /A of 25 or less, 20 or less, or 15 or less, where L is the perimeter of the cross-section and A is the area of the cross-section. In other words, the filaments may have a substantially "O" shaped cross-section, or a cross-section as close as possible to that. For a given monofilament, filaments having a substantially "O" shaped cross-section have a smaller surface area than other cross-sectional shapes, such as "Y" or "X" shaped filaments. Thus, the delivery of the aerosol to the user is improved.

It will be appreciated that the aerosol drawn through the first tubular body 3 passes partially through the filaments of the first tubular body 3 itself as well as through the central cavity 3a of the first tubular body 3. By providing filaments having a substantially "O" shaped cross section, a greater proportion of the aerosol passes through the filaments of the first tubular body 3 itself, further increasing heat transfer to the first tubular body 3.

In some embodiments, the aerosol-generating material 2 described herein may be a first aerosol-generating material 2, and the first tubular body 3 may comprise a second aerosol-generating material. For example, the second aerosol-generating material may be disposed on an inner surface of the first tubular body 3.

The second aerosol-generating material includes at least one aerosol-forming material and may also include at least one aerosol modifier or other sensate material. The aerosol-forming material and/or aerosol modifier may be any aerosol-forming material or aerosol modifier described herein, or a combination thereof.

In use, the aerosol generated from the first aerosol-generating material 2 is drawn through the first tubular body 3 so that heat from the first aerosol can aerosolize the aerosol-forming material of the second aerosol-generating material to form a second aerosol. The second aerosol may include a flavoring that is in addition to or complementary to the flavoring of the first aerosol.

Providing a second aerosol-generating material in the first tubular body 3 can produce a second aerosol that enhances or complements the flavor or appearance of the first aerosol.

The article 1a may further comprise at least one ventilation area 12 arranged to allow external air to flow into the article. In the illustrated embodiment, the ventilation area 12 comprises a row of ventilation openings or perforations cut into the wrapper 6 and any other wrappers at the location of the ventilation area 12. The ventilation openings may extend in a row around the circumference of the article 1a. The ventilation area 12 may comprise two or more rows of ventilation openings. By providing the ventilation area 12, ambient air may be drawn into the article during use to further cool the aerosol.

In the illustrated embodiment, at least one ventilation area 12 is positioned to supply outside air to the cavity 3a of the first tubular body 3. To accomplish this, one or more rows of ventilation openings extend around the article to cover the first tubular body 3.

In one example, the vent region 12 includes first and second parallel rows of laser drilled holes located 17.925 mm and 18.625 mm from the mouth end, respectively. The drilled holes pass through the wrapper 6 and any other wrappers disposed about the first tubular body, and into the first tubular body 3. In alternative embodiments, the venting can be provided at other locations.

Alternatively, ventilation can be achieved through a single row of perforations, e.g. laser perforations, in the portion of the article 1a in which the first tubular body 3 is located. This has been found to improve aerosol formation, believed to be due to the fact that for a given ventilation level, the airflow through the perforations is more uniform than through multiple rows of perforations.

It will be appreciated that the exact location of the at least one vent region 12 is not critical. In another embodiment, the at least one vent region 12 is positioned to supply outside air to the aerosol-generating material 2. To accomplish this, one or more rows of vent openings extend around the periphery of the article to cover the rod of aerosol-generating material 2.

The level of ventilation provided by the at least one ventilation region 12 is within the range of 40% to 70% of the amount of aerosol generated by the aerosol-generating material 2 passing through the article 1a when the article 1a is heated by the non-combustible aerosol delivery device 100.

It has been found that the temperature of the aerosol generally increases with decreasing ventilation level. However, the relationship between the temperature of the aerosol and the ventilation level does not appear to be linear, e.g., variations in ventilation due to manufacturing tolerances have less impact at lower target ventilation levels. For example, with a ventilation tolerance of ±15%, for a target ventilation level of 75%, the aerosol temperature may increase by about 6°C at the lower limit of ventilation (60% ventilation). However, at a target ventilation level of 60%, the aerosol temperature may increase by only about 3.5°C at the lower limit of ventilation (45% ventilation). Thus, the target ventilation level of the article may be in the range of 40% to 70%, e.g., 45% to 65%. The average ventilation level of at least 20 articles may be 40% to 70%, e.g., 45% to 70%, or 51% to 59%.

In some embodiments, the additional wrapper 10 at least partially surrounds the aerosol-generating material 2 between the aerosol-generating material 2 and the wrapper 6. In particular, during manufacture of the article, the aerosol-generating material is first wrapped by the additional wrapper 10 and then assembled with other components of the article 1a by the wrapper 6.

In some embodiments, the additional wrapper 10 surrounding the aerosol-generating material has a high level of permeability, for example, greater than about 1000 Coresta units, or greater than about 1500 Coresta units, or greater than about 2000 Coresta units. The permeability of the additional wrapper 10 can be measured according to ISO 2965:2009 for determination of air permeability of materials used as cigarette paper, filter plug wrap, and filter bonding paper.

The additional wrapper 10 may be formed from a material with an inherently high level of permeability, an inherently porous material, or may be formed from a material with any inherent level of permeability, where the final level of permeability is achieved by providing the additional wrapper 10 with permeable areas or regions. Providing a permeable additional wrapper 10 provides a path for air to enter the smoking article. The additional wrapper 10 may have a permeability such that the amount of air entering through the rod of aerosol-generating material 2 is relatively greater than the amount of air entering the article 1a through the mouthpiece ventilation area 12. An article 1a having this configuration may produce a better tasting aerosol, which may be more satisfying to the user.

In the embodiment shown in FIG. 1, the article 1a further comprises a second tubular body 5 disposed between the aerosol-generating material 2 and the first tubular body 3. The length of the second tubular body 5 is such that it extends at least a minimum distance d away from the heater 101 of the non-combustible aerosol delivery device 100 to provide the necessary separation between the first tubular body 3 and the heater.

The second tubular body 5 defines a cavity 5a between the aerosol-generating material 2 and the first tubular body 3, and the length of the cavity 5a is such that when the article is inserted into the non-combustible aerosol delivery device 100, it extends away from the heater 101 of the non-combustible aerosol delivery device 100 by at least about 3 mm.

The second tubular body 5 is formed from paper. In particular, the second tubular body 5 comprises a paper tube 5 underlying a wrapper 6. The paper tube provides additional rigidity to the article 1a around the cavity 5a.

The second tubular body 5 preferably has a wall thickness of at least 200 microns, at least 300 microns, and/or a permeability of at least 100 Coresta units. By configuring the second tubular body 5 to have a permeability of at least 100 Coresta units, the second tubular body 5 can absorb moisture from the aerosol generated by the aerosol-generating material 2 when the article 1a is heated by the non-combustible aerosol delivery device 100. Furthermore, papers with a permeability greater than 100 Coresta units are generally lighter and easier to work with during manufacturing.

In the embodiment illustrated by FIG. 2, the length of the rod of aerosol-generating material 2 is such that when the article 1b is inserted into the non-combustible aerosol-delivery device 100, it extends a minimum distance d away from the heater 101 of the non-combustible aerosol-delivery device 100. Thus, the rod of aerosol-generating material 2 provides the necessary spacing between the first tubular body 3 and the heater without the need to space the first tubular body 3 from the rod of aerosol-generating material.

In the embodiment illustrated by FIG. 3, the first tubular body is spaced from the aerosol-generating material 2 such that a minimum distance d between the heater 101 of the non-combustible aerosol-delivery device 100 and the first tubular body 3 is maintained when the article 1c is inserted into the non-combustible aerosol-delivery device 100. The space between the aerosol-generating material 2 and the first tubular body 3 defines a cavity 6a.

In the embodiment illustrated by Figures 1-3, the mouth end section 20 comprises a third tubular body 22. The third tubular body 22 defines the mouth end of the articles 1a-1c. The third tubular body 22 may comprise a tube of cellulose acetate stiffened with a plasticizer. The third tubular body 22 defines a cavity 22a in the mouth end section 20 that opens at the mouth end.

In some embodiments, it may be particularly advantageous to use a tubular body 22 having a length of more than about 10 mm, for example from about 10 mm to about 30 mm, or from about 12 to about 25 mm. It has been found that when drawing aerosol through the article 1, the consumer's lips may in some cases extend up to about 12 mm from the mouth end of the article 1, and therefore a tubular body 22 having a length of at least 10 mm, or at least 12 mm, means that most of the consumer's lips will surround this element 4.

The articles 1a-1c include a body of material 21. The body of material 21 is wrapped with additional packaging material, such as a first plug wrap 23. The first plug wrap 23 preferably has a basis weight of less than 50 gsm, more preferably has a basis weight of about 20 gsm to 40 gsm. The first plug wrap 23 preferably has a thickness of 30 μm to 60 μm, more preferably 35 μm to 45 μm. The first plug wrap 23 is preferably a non-porous plug wrap, for example having a permeability of less than 100 Coresta units, for example less than 50 Coresta units. However, in other embodiments, the first plug wrap 23 may be a porous plug wrap, for example having a permeability of more than 200 Coresta units.

The length of the body of material 21 is preferably less than about 15 mm. More preferably, the length of the body of material 21 is less than about 10 mm. Additionally or alternatively, the length of the body of material 21 is at least about 5 mm. Preferably, the length of the body of material 21 is at least about 6 mm. In some preferred embodiments, the length of the body of material 21 is from about 5 mm to about 15 mm, more preferably from about 6 mm to about 12 mm, even more preferably from about 8 mm to about 12 mm, and most preferably about 8 mm, 9 mm, or 10 mm. In this example, the length of the body of material 21 is 10 mm.

In this example, the body of material 21 is formed from filament tow. In this example, the tow used in the body of material 21 has a single fineness of 8.4 denier (d.p.f.: denier per filament) and a total fineness of 21,000 denier. Alternatively, the tow may have, for example, a single fineness of 9.5 denier (d.p.f.) and a total fineness of 12,000 denier. Alternatively, the tow may have, for example, a single fineness of 8 denier (d.p.f.) and a total fineness of 15,000 denier. In this example, the tow comprises plasticized cellulose acetate tow. The plasticizer used in the tow constitutes about 7% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, different materials can be used to form the body of material 21. For example, rather than tow, the body 21 of material can be formed from paper, for example in a manner similar to paper filters known for use in cigarettes. Alternatively, the body 21 can be formed from tow other than cellulose acetate, such as polylactic acid (PLA), other materials described herein for filament tow, or similar materials. The tow is preferably formed from cellulose acetate. Whether the tow is formed from cellulose acetate or other materials, it preferably has a d.p.f. of at least 5, more preferably at least 6, and even more preferably at least 7 d.p.f. These fineness values result in a tow with relatively coarse, thick fibers with a smaller surface area that results in a lower pressure drop across the body 21 of material than a tow with a smaller d.p.f. value. To achieve a sufficiently uniform body 21 of material, the fineness of the tow is preferably 12 d.p.f. or less, and more preferably 11 d.p.f. or less. Less than 10 d.p.f. is preferred, and less than 10 d.p.f. is even more preferred.

The total fineness of the tows forming the material body 21 is preferably at most 30,000 denier, more preferably at most 28,000 denier, and even more preferably at most 25,000 denier. Tows of these total fineness values occupy a small percentage of the cross-sectional area of the article 1, resulting in a lower pressure drop across the article 1 than tows having higher total fineness values. To provide the material body 21 with an appropriate hardness, the total fineness of the tows is preferably at least 8,000 denier, and more preferably at least 10,000 denier. A total fineness of 10,000 to 25,000 denier while the single fineness is preferably 5 to 12 denier. A total fineness of 11,000 to 22,000 denier while the single fineness is more preferably 6 to 10 denier. Although it is preferred that the cross-sectional shape of the filaments of the tow is "Y" shaped, in other embodiments, the same d.p.f.f. as provided herein may be used. Other shapes such as "X" or "O" shaped filaments can be used, having a total fineness value of 0.1 and 0.2. The tow may include filaments having a cross section with an isoperimeter ratio of 25 or less, preferably 20 or less, and more preferably 15 or less. In some examples, the body of material 21 may include an adsorbent material (e.g., charcoal) dispersed within the tow.

In some examples, the body of material 21 may comprise a capsule. The capsule may comprise a breakable capsule, e.g., a capsule having a solid, brittle shell surrounding a liquid payload. In some examples, a single capsule is used. The capsule is entirely embedded within the body of material 21. In other words, the capsule is completely surrounded by the material forming the body of material. In other examples, multiple breakable capsules, e.g., two, three, or more breakable capsules, may be disposed within the body of material 21. The length of the body of material 21 may be extended to accommodate the number of capsules required. In examples where multiple capsules are used, the individual capsules may be the same as one another or may differ from one another in terms of size and/or capsule payload. In other examples, multiple bodies of material may be provided, each body of material containing one or more capsules.

In some embodiments, a non-combustion aerosol delivery system is provided comprising an aerosol modifying component and a heater 101 operable to heat the aerosol generating material such that, in use, the aerosol generating material delivers an aerosol. The aerosol modifying component comprises a first and a second capsule. The first capsule is disposed in a first portion of the aerosol modifying component and the second capsule is disposed in a second portion of the aerosol modifying component downstream of the first portion.

A first portion of the aerosol modifying component is heated to a first temperature during operation of the heater 101 to generate an aerosol, and a second portion is heated to a second temperature during operation of the heater to generate an aerosol, the second temperature being at least 4 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.

The aerosol modifying component may comprise one or more components of the article. In some embodiments, the aerosol modifying component comprises a body of material 21, and the first and second capsules are disposed within the body of material 21. The body of material may comprise cellulose acetate or paper. In another embodiment, the aerosol modifying component comprises two bodies of material, and the first and second capsules are disposed within the first and second bodies of material, respectively. In some embodiments, the aerosol modifying component alternatively or additionally comprises one or more tubular elements upstream and/or downstream of the body(s) of material. The aerosol generating component may comprise a mouthpiece.

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

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

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

Based on this temperature difference, the aerosol modifier in the first capsule and the aerosol modifier in the second capsule can be selected. For example, the first capsule may comprise a first aerosol modifier that has a lower vapor pressure than the second aerosol modifier in the second capsule. If both capsules are heated to the same temperature, the higher vapor pressure of the aerosol modifier in the second capsule means that a greater amount of the second aerosol modifier will volatilize than the aerosol modifier in the first capsule. However, because the second capsule is heated to a lower temperature, this effect is less, so that upon disruption of the first and second capsules, a more equal amount of the aerosol modifier in the first capsule and the aerosol modifier in the second capsule will volatilize.

In some embodiments, the first and second capsules have the same aerosol modification profile, meaning that they contain the same amount of the same type of aerosol modifier, so that when both capsules are heated to the same temperature and broken, both capsules will cause the same modification of the aerosol. However, because the first capsule is heated to a higher temperature than the second capsule, a greater amount of the aerosol modifier in the first capsule will e.g. volatilize compared to the modifier in the second capsule, thus causing a more pronounced modification of the aerosol than the second capsule. Thus, even though both capsules are the same (which may make the aerosol modification components easier and/or cheaper to manufacture), the user can decide whether to break the first capsule to cause a more pronounced modification of the aerosol, break the second capsule to cause a less pronounced modification of the aerosol, or break both capsules to cause maximum modification of the aerosol.

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

The capsule has a core-shell structure. In other words, the capsule comprises a shell that encapsulates a liquid agent, such as a flavoring or other agent, which may be any one of the flavorings or aerosol modifiers described herein. The capsule shell can be burst by a user to release the flavoring or other agent into the body of material 21. The first plug wrap 23 may comprise a barrier coating to render the plug wrap material substantially impermeable to the liquid payload of the capsule. Alternatively or additionally, the second plug wrap 23 and/or the packaging material 6 may comprise a barrier coating to render the plug wrap material substantially impermeable to the liquid payload of the capsule.

In some examples, the capsule is spherical and has a diameter of about 3 mm. In other examples, capsules of other shapes and sizes can be used. The total weight of the capsule can be in the range of about 10 mg to about 50 mg.

For a given tow specification (e.g., 8.4Y21000), it is known to generate a tow performance curve that represents the pressure drop through the length of a rod formed using the tow for each of a range of tow weights. Parameters such as the length and circumference of the rod, wrapper thickness, and tow plasticizer level are specified and combined with the tow specification to generate a tow performance curve. The tow performance curve shows the pressure drop provided by different tow weights between a minimum and a maximum weight achievable using standard filter rod forming machines. Such tow performance curves can be calculated, for example, using software available from tow suppliers. It has been found to be particularly advantageous to use a material body 21 that includes a filament tow having a weight per mm of material body 21 length that is about 10% to about 30% of the range between the minimum and maximum weights of the tow performance curve generated for the filament tow. This can provide an acceptable balance between providing a tow weight sufficient to avoid shrinkage after the body 21 is formed, providing an acceptable pressure drop, while also aiding capsule placement within the tow for capsules of the size described herein.

The third tubular body 22 is separated from the first tubular body 3 by the body of material 21. The third tubular body 22 is attached to the body of material 21 by the plug wrap 23. In particular, during manufacture of the article, the third tubular body 22 is first attached to the body of material 21 by the plug wrap 23 and then assembled with other components of the article 1 by the wrapper 6.

It will be appreciated that the third tubular body 22 is not required and may be omitted. For example, in the article 1d shown in FIG. 4, the mouth end of the mouth end section 20' comprises a body of material 21 adjacent to the first tubular body 3.

In another embodiment shown by FIG. 4a, the mouth end section 20'' of the article 1e comprises a body of material 21 separated from the first tubular body 3 by a fourth tubular body 24.

In another embodiment shown by FIG. 4b, the mouth end section 20''' of the article 1f comprises a body of material 21 comprising an inner body 21a and an outer body 21b. The outer body 21b is a tube that surrounds the inner body 21a. The resistance to gas flow through the length of the inner body 21a is less than the resistance to gas flow through the length of the outer body 21b. This can be achieved by providing the outer body 21b with a higher fiber density than the inner body 21a.

In another embodiment, shown in cross-section by FIG. 5, the mouth end section 20'''' of the article 1g comprises a body of material 21 having a non-circular cross-section. In this embodiment, the sheet of additional wrapping material 23 extending between the body of material 21 and the wrapper 6 comprises a pattern of strength discontinuities. The strength discontinuities result in a non-uniform curvature of at least a portion of the additional wrapping material 23, giving the body of material 21 its non-circular cross-section. In the illustrated embodiment, the additional wrapping material 23, and the body of material 21 within the additional wrapping material 23, exhibit a star-shaped cross-section.

In the tobacco materials described herein, the tobacco material includes an aerosol-forming material. In this context, an "aerosol-forming material" is an agent that promotes the generation of an aerosol. The aerosol-forming material can promote the generation of an aerosol by promoting the initial vaporization and/or condensation of the gas into an inhalable solid and/or liquid aerosol. In some embodiments, the aerosol-forming material can improve the delivery of flavorants from the aerosol-forming material. Generally, any suitable aerosol-forming material or agent may be included within the aerosol-forming material of the present invention, including those described herein. Other suitable aerosol-forming materials include, but are not limited to, polyols such as sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol, non-polyols such as monohydric alcohols, high boiling point hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, or myristic acid, including ethyl myristate and isopropyl myristate, and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate. In some embodiments, the aerosol-forming material may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. The total amount of glycerol, propylene glycol, or a mixture of glycerol and propylene glycol used may range from 10% to 30%, such as 15% to 25%, of the tobacco material, measured on a dry weight basis. Glycerol may be present in an amount of 10-20% by weight of the tobacco material, such as 13-16% by weight of the composition, or about 14% or 15% by weight of the composition. Propylene glycol, when present, may be present in an amount of 0.1-0.3% by weight of the composition.

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

A method of manufacturing an article for use with non-combustion aerosol delivery device 100 with heater 101 will now be described with reference to Figure 6. The method comprises:
Step S1 of providing an aerosol-generating material 2 including at least one aerosol-forming material;
a step S2 of disposing a first tubular body 3 downstream of the aerosol-generating material, the tubular body 3 including a filament tow;
and positioning the oral end section 20 downstream of the tubular body S3. The article can be configured such that when the article is inserted into the non-combustible aerosol delivery device, a minimum distance between the heater of the non-combustible aerosol delivery device and the tubular body is at least about 3 mm.

7 shows an example of a non-combustion aerosol delivery device 100 with a heater 101 for generating an aerosol from an aerosol-generating medium/material, such as the aerosol-generating material 2 of the articles described herein. Generally, the device 100 can be used to heat a replaceable article 110 comprising an aerosol-generating medium, such as any of the articles described herein, to generate an aerosol or other inhalable medium that is inhaled by a user of the device 100. The device 100 and the replaceable article 110 together form a system.

The device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and contains the various components of the device 100. The device 100 has an opening 104 at one end through which an item 110 can be inserted for heating by a heater 101 (hereafter referred to as the heating assembly). In use, the item 110 can be fully or partially inserted into the heating assembly and heated by one or more components of the heater assembly.

The device 100 in this example includes a first end member 106 with a lid 108 movable relative to the first end member 106 to close the opening 104 when the article 110 is not in place. In FIG. 7, the lid 108 is shown in an open configuration, but the lid 108 can be moved to a closed configuration. For example, a user can slide the lid 108 in the direction of arrow "B."

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

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

8 illustrates the device 100 of FIG. 7 with the outer cover 102 removed and without the article 110 present. The device 100 defines a longitudinal axis 134. As shown in FIG. 8, the first end member 106 is disposed at one end of the device 100 and the second end member 116 is disposed at an opposite end of the device 100. The first end member 106 and the second end member 116 together at least partially define an end surface of the device 100. For example, the bottom surface of the second end member 116 at least partially defines the bottom surface of the device 100. An edge of the outer cover 102 may also define a portion of the end surface. In this example, the lid 108 also defines a portion of the top surface of the device 100.

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

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

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

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

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

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

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

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

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

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

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

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

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

The insulating member 128 may also fully or partially support the first inductor coil 124 and the second inductor coil 126. For example, as shown in FIG. 8, the first inductor coil 124 and the second inductor coil 126 are disposed around the insulating member 128 and are in contact with the radially outward surface of the insulating member 128. In some examples, the insulating member 128 does not abut the first inductor coil 124 and the second inductor coil 126. For example, there may be a slight gap between the outer surface of the insulating member 128 and the inner surfaces of the first inductor coil 124 and the second inductor coil 126.

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

Figure 9 is a partial cross-sectional side view of device 100, with outer cover 102 present in this example. The rectangular cross-sectional shapes of first inductor coil 124 and second inductor coil 126 can be seen more clearly.

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

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

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

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

Figure 10 is an exploded view of the device 100 of Figure 9, omitting the outer cover 102.

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

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

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

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

In one example, the susceptor 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, any of the articles described herein can be inserted into a non-combustible aerosol delivery device, such as device 100 described with reference to Figures 7-11. At least a portion of the mouthpiece 20, 20', 20'', 20''', 20'''' of the article protrudes from the non-combustible aerosol delivery device 100 and can be placed in the mouth of a user. An aerosol is generated by heating an aerosol-generating material 2 using device 100. The aerosol generated by the aerosol-generating material 2 passes through mouthpiece 20, 20', 20'', 20'''', 20'''' to the user's mouth.

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

Claims (27)

1. An article for use with a non-combustion aerosol delivery device having a heater, comprising:
an aerosol-generating material comprising at least one aerosol-forming material;
a first tubular body disposed downstream of the aerosol-generating material, the first tubular body including a filament tow;
a mouth end section disposed downstream of the first tubular body;
An article configured such that when the article is inserted into the non-combustible aerosol delivery device, a minimum distance between the heater and the first tubular body of the non-combustible aerosol delivery device is at least 3 mm. a second tubular body disposed between the aerosol-forming material and the first tubular body;
2. The article of claim 1, wherein the length of the second tubular body is such that it extends at least 3 mm away from the heater of the non-combustible aerosol delivery device when the article is inserted into the non-combustible aerosol delivery device. The article of claim 2, wherein the second tubular body is formed from paper. The article of claim 2 or 3, wherein the second tubular body has a wall thickness of at least 300 microns and/or a permeability of at least 100 Coresta units. 2. The article of claim 1, wherein the length of the aerosol-forming material is such that when the article is inserted into the non-combustible aerosol delivery device, the length extends at least 3 mm away from the heater of the non-combustible aerosol delivery device. The article of claim 1, further comprising a wrapper at least partially surrounding the aerosol-generating material and the first tubular body. 7. The article of claim 6, wherein the wrapper defines a cavity between the aerosol-forming material and the first tubular body, the length of the cavity being such that it extends at least 3 mm away from the heater of the non-combustible aerosol delivery device when the article is inserted into the non-combustible aerosol delivery device. The article of claim 6 or 7, wherein the wrapper has a citrate content of 1% by weight or less. The article according to any one of claims 1 to 8, wherein the first tubular body has a wall thickness of 0.5 mm to 2.5 mm. The article according to any one of claims 1 to 9, wherein the first tubular body has a length of at least 12 mm. The article according to any one of claims 1 to 10, wherein the filament tow of the first tubular body includes filaments having a cross section with an isoperimeter ratio of 25 or less. The article of any one of claims 1 to 11, further comprising at least one ventilation area arranged to allow outside air to flow into the article. The article of claim 12, wherein the at least one ventilation area is positioned to supply outside air to the aerosol-forming material. The article of claim 12 or 13, wherein the at least one ventilation area is arranged to supply outside air to the cavity of the first tubular body. The article of any one of claims 12 to 14, wherein the at least one ventilation area comprises a single row of ventilation openings. The article according to any one of claims 12 to 15, wherein the at least one ventilation area has two or more rows of ventilation openings. The article of any one of claims 12 to 16, wherein the level of ventilation provided by the at least one ventilation region is within the range of 45% to 65% of the amount of aerosol generated by the non-combustible aerosol delivery device passing through the article, or 40% to 60% of the amount of aerosol generated by the non-combustible aerosol delivery device passing through the article. The article of any one of claims 1 to 17, wherein the mouth end section comprises a third tubular body. The article of claim 18, wherein the third tubular body defines a mouth end of the article. 20. The article of claim 18 or 19, wherein the length of the third tubular body is greater than 10 mm, or greater than 12 mm. The article of any one of claims 1 to 20, wherein the mouth end section comprises an inner body and an outer body, and 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. Further comprising a sheet material;
The article of any one of the preceding claims, wherein the sheet material has a pattern of strength discontinuities resulting in a non-uniform curvature of at least a portion of the sheet material. The article of any one of claims 1 to 22, wherein the first tubular body comprises a second aerosol-generating material. 24. The article of any one of claims 1 to 23, wherein the aerosol-forming material is wrapped in a wrapper having a level of permeability greater than 2,000 Coresta units, and the article comprises a downstream portion downstream of the aerosol-forming material, the downstream portion comprising at least one vent region. 25. The article of any one of claims 1 to 24, wherein the mouth end section comprises a body of filament tow, the filament tows of the body of filament tow having a weight per mm of the body length that is 10% to 30 % of the range between a minimum weight and a maximum weight of a tow performance curve generated for the filament tow. a non-combustible aerosol delivery device having a heater;
A system comprising an article according to any one of claims 1 to 25. 1. A method of making an article for use with a heated non-combustion aerosol delivery device, comprising:
Providing an aerosol-generating material comprising at least one aerosol-forming material;
disposing a tubular body downstream of the aerosol-generating material, the tubular body including a filament tow;
and disposing an oral end section downstream of the tubular body;
The method, wherein the article is configured such that when the article is inserted into the non-combustible aerosol delivery device, the minimum distance between the heater and the tubular body of the non-combustible aerosol delivery device is at least 3 mm.

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