JP7702086B2 - Tobacco composition containing tobacco components and aerosol-forming material - Google Patents

Description

The present invention relates to a tobacco composition comprising an aerosol-forming material, a method for producing the tobacco composition, and an article for use in an aerosol-generating device, the article for use in an aerosol-generating device comprising the tobacco composition.

Many tobacco industry products include aerosol-generating articles, such as tobacco compositions. Articles such as cigarettes, cigars, etc., burn aerosolizable materials to produce tobacco smoke during use. Attempts have been made to provide alternatives to these types of articles that burn tobacco material by creating products that generate compounds without burning. Examples of such products are the so-called non-combustion heating products, known as tobacco heating products or tobacco heating devices, which heat aerosolizable materials without burning them to release compounds.

In some embodiments of the present invention, in a first aspect, a tobacco composition is provided that includes a tobacco component and an aerosol-forming material, the tobacco component including tobacco material in an amount of about 10% to about 90% by weight of the tobacco composition, and the nicotine content of the tobacco material is greater than 1.5% by weight of the tobacco material.

In some embodiments of the present invention, a tobacco composition is provided that includes a tobacco component and an aerosol-forming material, the tobacco component includes tobacco leaf material in an amount of about 10% to about 90% by weight of the tobacco composition, the tobacco leaf material includes said aerosol-forming material in an amount of about 10% or less by weight of the tobacco leaf material, and the tobacco composition includes said aerosol-forming material in an amount of about 10% to about 30% by weight of the tobacco composition.

In some embodiments of the present invention, a tobacco composition is provided in a third aspect, comprising a tobacco component and an aerosol forming material, the tobacco component comprising tobacco leaf material in an amount of about 10% to about 90% by weight of the tobacco composition, and the tobacco component comprising menthol in an amount of about 3 mg to about 16 mg.

In some embodiments of the present invention, a fourth aspect provides a method for producing the tobacco composition of the first and second aspects, the method comprising applying the aerosol-forming material to the tobacco leaf material.

In some embodiments of the present invention, a fifth aspect provides a tobacco composition produced using the method of the fourth aspect.

In some embodiments of the present invention, in a sixth aspect there is provided the use of a tobacco composition according to the first, second, third or fourth aspect in an article for use in an aerosol delivery device.

In some embodiments of the present invention, a seventh aspect provides an article for use in an aerosol delivery system comprising a tobacco composition as described in the first, second, third or fourth aspect above.

In some embodiments of the present invention, in an eighth aspect, a system is provided that includes a tobacco composition as described in the first, second, third or fourth aspect above, and a device arranged to heat the tobacco composition and generate an aerosol from the tobacco composition.

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

1 is a flow chart of the manufacturing process of reconstituted tobacco. 1 is a flow chart of a process for making extruded tobacco. 1 is a flow chart of a process for producing a tobacco composition. FIG. 1 is a side cross-sectional view of an article for use in a non-combustion based aerosol delivery device, the article including a mouthpiece. FIG. 2 is a side cross-sectional view of another article for use in a non-combustion based aerosol delivery device, the article including a capsule-containing mouthpiece. FIG. 5b is a cross-sectional view of the capsule-containing mouthpiece shown in FIG. 5a. FIG. 4b is a perspective view of a non-combustion based aerosol delivery device for generating aerosols from the aerosol-generating materials of the articles of FIGS. 7 shows the device of FIG. 6 with the outer cover removed and without an item. FIG. 7 is a side view showing a cross section of a portion of the device of FIG. 6. FIG. 7 is an exploded view of the device of FIG. 6 with the outer cover omitted. FIG. 7 is a cross-sectional view of a portion of the device of FIG. 6. FIG. 7 is an enlarged view of a region of the device of FIG. 6. FIG. 1 is a flow diagram of a method for manufacturing an article for use in a non-combustion based aerosol delivery device.

As used herein, the term "delivery system" is intended to encompass a system that delivers a substance to a user;
non-combustion aerosol delivery systems that release compounds from an aerosolizable material without burning the aerosolizable material, such as e-cigarettes, tobacco heating products, and hybrid systems that generate an aerosol using a combination of aerosolizable materials;
These include articles that contain an aerosolizable material and are configured to be used within one of these non-combustion based aerosol delivery systems, and aerosol-free delivery systems such as lozenges, gums, patches, articles that contain inhalable powders, and smokeless tobacco products such as snus and snuff that deliver material to the user without forming an aerosol.

For purposes of this disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosolizable materials of the aerosol delivery system (or its components) are not combusted or burned to facilitate delivery to a user.

In one embodiment, the delivery system is a non-combustion aerosol delivery system, such as an electrically powered non-combustion aerosol delivery system.

In one embodiment, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END).

In one embodiment, the non-combustion aerosol delivery system is a tobacco heating system, also known as a non-combustion heating system.

In one embodiment, the non-combustion aerosol delivery system is a hybrid system that uses a combination of aerosolizable materials and generates an aerosol by heating one or more of the materials. Each of the aerosolizable materials may be in the form of, for example, a solid, liquid, or gel. In one embodiment, the hybrid system includes 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, non-combustion aerosol delivery systems may include non-combustion aerosol delivery apparatus, also referred to herein as aerosol generating devices, and articles for use in non-combustion aerosol delivery systems. However, it is also contemplated that an article that itself includes a means for powering an aerosol generating member may itself form a non-combustion aerosol delivery system.

In one embodiment, the non-combustion aerosol delivery device may include a power source and a controller. The power source may be an electrical power source or a heat generating power source. In one embodiment, the heat generating power source includes a carbon substrate to which energy may be applied to distribute power in the form of heat to an aerosolizable material or heat transfer material adjacent thereto. In one embodiment, a power source, such as a heat generating power source, is provided to the article to form the non-combustion aerosol delivery.

In one embodiment, an article for use in a non-combustion based aerosol sharing device may include an aerosolizable material, an aerosol generating member, an aerosol generating region, and a mouthpiece and/or a region for receiving the aerosolizable material.

In one embodiment, the aerosol generating member is a heater that can interact with the aerosolizable material to release one or more volatile substances from the aerosolizable material to form an aerosol. In one embodiment, the aerosol can be generated from the aerosolizable material without applying heat thereto. For example, the aerosol generating member can generate the aerosol from the aerosolizable material without applying heat thereto, for example, by vibrational, mechanical, pressurized, or electrostatic means.

In one embodiment, the aerosolizable material may include an active material, an aerosol-forming material, and optionally one or more functional materials. The active materials may include nicotine (optionally contained in tobacco or a tobacco derivative) and one or more other odorless physiologically active materials. Odorless physiologically active materials are materials that are included in the aerosolizable material to achieve a physiological response other than the sense of smell.

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, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl base, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

The one or more functional ingredients may include one or more of a flavorant, a carrier, a pH regulator, a stabilizer, and/or an antioxidant.

In one embodiment, an article for use in a non-combustion based aerosol delivery device may include an aerosolizable material or an area for containing an aerosolizable material. In one embodiment, an article for use in a non-combustion based aerosol delivery device may include a mouthpiece. The area for containing an aerosolizable material may be a storage area for storing an aerosolizable material. In one embodiment, the area for containing an aerosolizable material may be separate from or combined with the aerosol generation area.

Aerosolizable materials, also referred to herein as aerosol-generating materials and aerosol-generating substrates, are materials that can generate an aerosol when activated, e.g., by heating, irradiation, or in some other way. Aerosolizable materials may be in the form of a solid, liquid, or gel, e.g., with or without nicotine and/or flavorants. In some embodiments, the aerosolizable material may comprise an "amorphous solid," alternatively 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 holds a fluid, such as a liquid, within it. In some embodiments, the aerosolizable material may comprise, e.g., about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

The aerosolizable material may be present on a substrate. The substrate may be or include, for example, paper, cardboard, paperboard, recycled aerosolizable material, plastic material, ceramic material, composite material, glass, metal or metal alloy.

An aerosol modifier is a substance that can modify an aerosol upon use. The modifier may thus modify the aerosol to produce a physiological or sensory effect on the human body. Examples of aerosol modifiers include flavorants and sensory agents. Sensory agents produce a sensory irritant sensation that is perceived through the senses, such as cold or sour.

The susceptor is a material that can be heated by the penetration of a fluctuating magnetic field, such as an alternating magnetic field. The heating material may be a conductive material, and the penetration of the fluctuating magnetic field may result in induction heating of the heating material. The heating material may be a conductive material, and the penetration of the fluctuating magnetic field may result in magnetic hysteresis heating of the heating material. The heating material may be both conductive and magnetic, such that the heating material can be heated by both heating mechanisms.

Induction heating is the process of heating an electrically conductive object by penetrating a changing magnetic field into the object. The process is explained 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 object to be heated and the electromagnet are placed in a suitable relative position such that the changing magnetic field generated 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 of heating an object made of a magnetic material by the penetration of the object into a changing 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 changing magnetic field such as an alternating magnetic field, e.g., one produced by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes in response to the applied changing 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 fluctuating magnetic field into the object can cause both Joule heating and magnetic hysteresis heating in the object. Furthermore, the use of magnetic materials can enhance the fluctuating magnetic field, thereby enhancing 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 a faster temperature rise and more uniform heat distribution within the object can be achieved. This can be achieved, among other things, by the appropriate choice of object material and geometry, and the 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, such as rod-shaped articles, are often named according to the length of the product: "standard" (usually 68-75mm, e.g. in the range of about 68mm to about 72mm), "short" or "mini" (68mm or less), "king size" (usually 75-91mm, e.g. in the range of about 79mm to about 88mm), "long" or "super king" (usually 91-105mm, e.g. in the range of about 94mm to about 101mm), and "extra long" (usually in the range of about 110mm to about 121mm).

They are also named according to the circumference of the cigarette: "standard" (approximately 23-25mm), "wide" (over 25mm), "slim" (approximately 22-23mm), "demi-slim" (approximately 19-22mm), "super slim" (approximately 16-19mm) and "micro-slim" (less than approximately 16mm).

So a king size extra thin cigarette, for example, is about 83mm in length and about 17mm in circumference.

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

The articles, aerosol generating materials and mouthpieces described herein can be made in any of the formats listed above, but are not limited to these.

As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction of mainstream smoke aerosol generating material being drawn through an article or device during use.

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

As used herein, the term "tobacco material" refers to any material containing tobacco or a derivative or substitute thereof. 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 tobacco powder, tobacco fiber, cut tobacco, extruded tobacco, leaf tobacco, tobacco stem, reconstituted tobacco, and/or tobacco extract. As used herein, "tobacco" refers to cut blade tobacco.

As used herein, the terms "flavoring" and "flavoring agent" refer to materials permitted by local regulations that may be used to impart a taste or odor to a product that is desired by an adult consumer.

As used herein, the terms "flavoring agent" and "flavoring agent" refer to materials permitted by local regulations that may be used to impart a taste or odor to a product desired by an adult consumer. Such materials include extracts (e.g., licorice, hydrangea, magnolia leaf, chamomile, fenugreek, clove, menthol, mint, aniseed, cinnamon, herbs, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, Scotch, whiskey, spearmint, peppermint, lavender, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey extract, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine, etc.) , ylang-ylang, sage, fennel, pimento, ginger, anise, coriander, coffee, peppermint oil from any species of the genus Mentha, etc.), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, mannitol, etc.), and other additives such as charcoal, chlorophyll, minerals, botanical breath fresheners, etc. These materials may be imitation, synthetic or natural ingredients, or may be blends thereof. These materials may be in any suitable form, for example, oils, liquids, powders, etc.

Preferably, the aerosol-generating material or substrate 3 is formed from a tobacco material as described herein that includes a tobacco component. The tobacco component includes leaf tobacco. In some embodiments, the tobacco component includes a tobacco material selected from the group consisting of extruded tobacco, band-cast tobacco, and mixtures thereof.

The tobacco that may be used in the tobacco compositions described herein may be any suitable tobacco, such as single grades or blends, shredded or whole leaf, including Virginia (flue-cured and/or air-cured) and/or Burley and/or Oriental. The tobacco compositions may also include mixtures of any of these tobacco materials.

The tobacco leaf is present in an amount of about 10% to about 90% by weight of the tobacco component. In some embodiments, the tobacco leaf may be present in an amount of about 11% to about 48%, about 12% to about 46%, about 13% to about 44%, about 14% to about 42%, about 15% to about 40%, about 16% to about 38%, about 17% to about 36%, about 18% to about 34%, or about 19% to about 32% by weight of the tobacco component. In preferred embodiments, the tobacco component comprises about 15% to about 25%, about 35% to about 45%, or about 55% to 65% of the tobacco leaf by weight of the tobacco component. In preferred embodiments, the tobacco component may comprise tobacco leaf in an amount of about 15%, about 16%, about 17%, about 18%, about 19%, about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29% or about 30% by weight of the tobacco component.

In some embodiments, the tobacco component comprises tobacco leaf in an amount of about 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, or 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, or 70%.

For the avoidance of doubt, when amounts are given in weight percent in the compositions described herein, this means on a dry weight basis unless otherwise specified. Thus, any water present in the tobacco composition or any component thereof is completely disregarded for purposes of measuring weight percent. The moisture content of the tobacco compositions described herein may vary, for example, from 5 to 15 weight percent. The moisture content of the tobacco compositions described herein may vary depending, for example, on the temperature, pressure and humidity conditions under which the composition is maintained. The moisture content may be measured by Karl-Fisher analysis as described herein.

However, for the avoidance of doubt, all components other than water are included in the weight of the tobacco composition, even if the aerosol-forming material is a component in the liquid phase, such as glycerin or propylene glycol. However, if the aerosol-forming material is provided in the tobacco component of the tobacco composition or in the filler member (if any) of the tobacco composition instead of or in addition to being added separately to the tobacco composition, the aerosol-forming material is not included in the weight of the tobacco composition or filler member, but is included in the weight of the "aerosol-forming material" in the weight percentages specified herein. All other components present in the tobacco composition are included in the weight of the tobacco component, even if they are non-tobacco-derived (e.g., non-tobacco fiber in the case of reconstituted tobacco).

The tobacco components described herein include nicotine. The nicotine content is 0.5-2% by weight of the tobacco component, and may be, for example, 0.5-1.75% by weight of the tobacco component, 0.8-1.2% by weight of the tobacco component, or about 0.8 to about 1.75% by weight of the tobacco component. In some embodiments, the nicotine content may be 0.8-1.0% by weight of the tobacco component.

In one aspect of the present disclosure, a tobacco composition is provided that includes a tobacco component and an aerosol forming material, the tobacco component including tobacco leaf in an amount of about 10% to about 90% by weight of the tobacco component, the tobacco leaf having a nicotine content of greater than 1.5% by weight of the tobacco leaf.

Adjusting the nicotine content of a composition can be important. In conventional tobacco heating products, the tobacco composition includes reconstituted tobacco material. The nicotine content of the reconstituted tobacco material is generally relatively low. For example, reconstituted tobacco material contains less than about 1.5% nicotine by weight of the reconstituted tobacco material. Increasing the nicotine content of such compositions is a challenge.

The inventors have discovered that the nicotine content of a tobacco composition may be carefully adjusted by incorporating tobacco leaf into the composition in addition to reconstituted tobacco material. In particular, they have discovered that incorporating tobacco leaf having a nicotine content of greater than 1.5% (by weight of the composition) into the composition is particularly advantageous. It has been found that incorporating tobacco leaf having a nicotine content of greater than about 1.5% by weight enhances the organoleptic properties (e.g., taste) of the tobacco composition when heated.

Without wishing to be bound by any theory, it is believed that incorporating tobacco material having a nicotine content of greater than 1.5% by weight of the tobacco material into the composition facilitates the release of components from the tobacco composition that beneficially affect the sensory properties of the tobacco composition when heated by an aerosol generating device. The amount of nicotine delivered to a user from a tobacco composition including tobacco material having a nicotine content of greater than 1.5% by weight of the tobacco material when heated by an aerosol generating device is similar to the amount of nicotine delivered to a user of a conventional combustion-based smoking article.

In some embodiments, the tobacco material consists essentially of a tobacco component as defined herein and an aerosol-forming material as defined herein. In some embodiments, the tobacco material consists essentially of a tobacco component as defined herein and an aerosol-forming material as defined herein.

The tobacco composition includes a tobacco component and an aerosol-forming material. The tobacco component may include tobacco material in an amount of about 10% to about 90% by weight of the tobacco component, and the tobacco material may include said aerosol-forming material in an amount of about 10% or less by weight of the tobacco material. The tobacco composition may include said aerosol-forming material in an amount of about 10% to about 30% by weight of the tobacco composition. Preferably, the tobacco composition includes aerosol-forming material in an amount of about 10% to about 20% by weight of the tobacco composition.

Incorporating an aerosol-forming material in an amount of about 10% to about 30% by weight of the tobacco composition has been found to further enhance the sensory properties of the tobacco composition when heated in an aerosol generating device. Loading an aerosol-generating material in an amount of about 10% to about 30% by weight of the tobacco composition is advantageous because it approximates the sensory properties of the composition to those of a conventional combustion-based smoking article.

The tobacco composition may include a tobacco component and an aerosol-forming material, the tobacco component including tobacco leaf material in an amount of about 10% to about 90% by weight of the tobacco component, and the tobacco component including menthol in an amount of about 3 mg to about 16 mg by weight of the tobacco component. Loading with menthol in an amount of about 3 mg to about 16 mg by weight of the tobacco component is advantageous because it improves the sensory characteristics of the tobacco composition when heated by an aerosol generating device.

The tobacco has a nicotine content of greater than 1.5% by weight of the tobacco. In some embodiments, the tobacco has a nicotine content of from 1.5% to about 5%, preferably from about 1.5% to about 4%, by weight of the tobacco. The tobacco may have a nicotine content of 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3%, 3.1%, 3.2%, 3.3%, 3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9%, 4%, 4.1%, 4.2%, 4.3%, 4.4%, 4.5%, 4.6%, 4.7%, 4.8%, 4.9%, or 5% by weight of the tobacco. In some embodiments, the tobacco has a nicotine content of greater than about 1.5% and less than or equal to about 4% by weight of the tobacco material.

The remainder of the tobacco component may include paper reconstituted tobacco, extruded tobacco, band-cast reconstituted tobacco, or a combination of band-cast reconstituted tobacco and another form of tobacco such as tobacco particles. Preferably, the tobacco component includes paper reconstituted tobacco material.

Reconstituted tobacco refers to tobacco material formed by a process in which raw tobacco material is extracted with a solvent to produce a residue containing soluble extract and fibrous material, and then the extract (usually after concentration, and optionally further processing) is recombined with the fibrous material from the residue (usually after removing impurities from the fibrous material, and optionally with the addition of small amounts of non-tobacco fiber) by depositing the extract onto the fibrous material. The recombination process is similar to the papermaking process.

The reconstituted tobacco may be any type of reconstituted tobacco known in the art. In certain embodiments, the reconstituted tobacco is produced from a raw material comprising one or more of tobacco strips, tobacco stems, and whole tobacco leaves. In other embodiments, the reconstituted tobacco is produced from a raw material consisting of tobacco strips and/or whole tobacco leaves and tobacco stems. However, in other embodiments, waste, fines, and rice husk may be employed in the raw material alternatively or in addition thereto.

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

Referring to FIG. 1, tobacco raw materials such as leaves, strips, stems, ash, fines, and/or rice husk (in some embodiments, leaves, strips, and stems) are first mixed with an aqueous solvent (e.g., water and a water-miscible solvent such as ethanol). Distilled water, deionized water, or tap water may be employed. The suspension of tobacco in the solvent is agitated, for example, by stirring or shaking to increase the rate of extraction of the soluble portion from the fibrous portion of the tobacco. Agitation is typically performed for 30 minutes to 6 hours or less. Agitation is performed in an agitator that includes a container and a blade that provides agitation. The amount of solvent in the suspension may vary over a wide range, from about 75% to 99% by weight of the suspension, depending on the tobacco raw materials, the type of solvent, and the agitation device (particularly the type of blade), and the temperature of the suspension. A typical temperature range for the suspension is from about 10° C. to about 100° C.

The soluble portion of the tobacco raw material is separated from the insoluble fibrous portion of the tobacco, for example by air pressure, hydraulic pressure, or mechanical pressing or filtration. After separation, the fibrous portion of the tobacco is typically subjected to mechanical refining to produce a fibrous pulp. Suitable refiners are typically disc or conical refiners. The fibrous pulp is formed on a Fourdrinier type papermaking machine into a base web containing the tobacco fibrous pulp. The base web is laid on a flat wire belt from which excess water is removed by gravity drainage or suction drainage. Non-tobacco fibers such as cellulose, wheat fiber, or wood fiber may be included in the tobacco-derived fibrous portion at this stage. The soluble portion of the tobacco raw material is concentrated using a conventional type of concentrator, such as a film evaporator or vacuum evaporator. After concentration, ingredients such as aerosol-forming materials (as defined herein), casings, acids such as cocoa, licorice, and malic acid, or flavorants (as defined herein) are added to mix with the concentrated tobacco solubles. The concentrated tobacco solubles, potentially including aerosol forming materials and/or casings and/or flavorants, are then combined with the dried tobacco fiber sheet to form reconstituted tobacco. The concentrated solubles can be added back to the fiber web in a variety of ways, such as spraying, coating, saturating, sizing, etc.

Finally, the reconstituted tobacco is dried. Optionally, the reconstituted tobacco may be cut into strips, wound into rolls, slit into bobbins, or shredded into shredded crumb. As used herein, the terms "flavor" and "flavoring" refer to ingredients permitted by local regulations that may be used to impart a taste or aroma desired by adult consumers to the product. Such ingredients include extracts (e.g., licorice, hydrangea, magnolia leaf, chamomile, fenugreek, clove, menthol, mint, aniseed, cinnamon, herbs, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, Scotch, whiskey, spearmint, peppermint, lavender, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey extract, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine, and the like). , ylang-ylang, sage, fennel, pimento, ginger, anise, coriander, coffee, peppermint oil from any species of the genus Mentha, etc.), 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, mannitol, etc.), and other additives such as charcoal, chlorophyll, minerals, botanicals, breath fresheners, etc. These materials may be imitation, synthetic or natural ingredients, or blends thereof. These materials may be in any suitable form, for example, as oils, liquids, powders, etc. Examples of reconstituted tobacco that can be used in the present invention are provided in the Examples.

The tobacco component may include a mixture of leaf tobacco and reconstituted tobacco paper. The reconstituted tobacco paper may have a nicotine content that is less than the nicotine content of an equivalent weight of leaf tobacco. For example, the reconstituted tobacco paper may have a nicotine content of less than 1.5% by weight of the reconstituted tobacco paper.

It has been found that the use of tobacco leaves with a nicotine content of greater than 1.5% in combination with a low-nicotine base material such as reconstituted tobacco advantageously results in a tobacco material that contains an appropriate amount of nicotine but has better sensory performance than reconstituted tobacco used alone.

The tobacco component may include reconstituted tobacco in an amount of about 10% to about 90% by weight of the tobacco component. In some embodiments, the reconstituted tobacco is present in an amount of 10% to 80% or 20% to 70% by weight of the tobacco component. In some embodiments, the tobacco component includes reconstituted tobacco material in an amount of about 50% to about 90% of the tobacco component.

In some embodiments, the reconstituted tobacco may be present in an amount of about 10% to about 89%, about 20% to about 88%, about 30% to about 87%, about 40% to about 86%, about 50% to about 85%, about 60% to about 84%, about 70% to about 83% by weight of the tobacco component. In some embodiments, the tobacco component may include reconstituted tobacco in an amount of about 75% to about 85% by weight of the tobacco component.

In preferred embodiments, the tobacco component may comprise reconstituted tobacco in an amount of about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84% or about 85% by weight of the tobacco component.

In one embodiment, leaf tobacco may be present in an amount of at least 10% by weight of the tobacco component, with the remainder of the tobacco component comprising paper reconstituted tobacco, band-cast reconstituted tobacco, or a combination of band-cast reconstituted tobacco and tobacco in another form, such as tobacco particles.

The reconstituted tobacco material may have a density of about 700 milligrams per cubic centimeter (mg/cc).

Such tobacco materials have been found to be particularly useful in providing an aerosol-generating material that can be heated quickly to release an aerosol compared to denser materials. For example, the inventors have tested the properties of various aerosol-generating materials, such as band-cast regenerated tobacco materials and paper regenerated tobacco materials, upon heating. For each given aerosol-generating material, during the application of heat to the material, there exists a particular zero heat flow temperature below which the net heat flow becomes endothermic, i.e., more heat enters the material than leaves it, and above which the net heat flow becomes exothermic, i.e., more heat leaves the material than enters it. Materials with densities less than 700 mg/cc have low zero heat flow temperatures. Since a significant portion of the heat flow leaving the material is through the formation of the aerosol, having a low zero heat flow temperature has a beneficial effect on the time it takes to initially release the aerosol from the aerosol-generating material. For example, they found that aerosol-generating materials with densities less than 700 mg/cc had zero heat flow temperatures less than 164°C compared to materials with densities greater than 700 mg/cc that had zero heat flow temperatures greater than 164°C.

The density of the aerosol-generating material also affects the rate at which heat travels through the material; lower densities, e.g., less than 700 mg/cc, will slow the rate at which heat travels through the material, thus allowing for more sustained aerosol release.

The weight ratio of leaf tobacco to reconstituted tobacco paper is 10:90, 11:89, 12:88, 13:87, 14:86, 15:85, 16:84, 17:83, 18:82, 19:81, 20:80, 21:79, 22:78, 23:77, 24:76, 25:75, 26:74, 27:73, 28:7 2, 29:71, 30:70, 31:69, 32:68, 33:67, 34:66, 35:65, 36:64, 37:63, 38:62, 39:61, 40:60, 41:59, 42:58, 43:57, 44:56, 45:55, 46:54, 47:53, 48:52, 49:51, 50:50, 51:49, 52:48, 53:47, 54:46, 55:45, 56:44, 57:43, 58:42, 59:41, 60:40, 61:39, 62:38, 63:37, 64:36, 65:35, 66:34, 67:33, 68:32, 69:31, 70:30, 71:29, 72:28, 73 :27, 74:26, 75:25, 76:24, 77:23, 78:22, 79:21, 80:20, 81:19, 82:18, 83:17, 84:16, 85:15, 86:14, 87:13, 88:12, 89:11 or 90:10 (weight of leaf tobacco:weight of reconstituted tobacco).

Preferably, the aerosol-generating material 3 comprises a reconstituted tobacco material, such as a paper reconstituted tobacco material, having a density of less than about 700 mg/cc. More preferably, the aerosol-generating material 3 comprises a reconstituted tobacco material having a density of less than about 600 mg/cc. Alternatively or additionally, the aerosol-generating material 3 preferably comprises a reconstituted tobacco material having a density of at least 350 mg/cc, which is believed to allow for a sufficient amount of heat transfer through the material.

The tobacco composition includes an aerosol-forming material. In this context, an "aerosol-forming material" is a chemical that enhances the generation of an aerosol. The aerosol-forming material may enhance the generation of an aerosol by enhancing the initial evaporation of a gas and/or condensation into an inhalable solid and/or liquid aerosol. In some embodiments, the aerosol-forming material may enhance the delivery of flavor from the aerosol-generating material.

Generally, any suitable aerosol former or forming agent may be included in the aerosol generating material of the present invention. Suitable aerosol formers include, but are not limited to, polyols such as sorbitol, glycerin, and glycols such as propylene glycol or triethylene glycol, non-polyols such as monohydric alcohols, high boiling point hydrocarbons, acids such as lactic acid, glycerin derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, myristate esters including triethyl citrate or ethyl myristate and isopropyl myristate, and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate. In a preferred embodiment, the aerosol former is selected from the group consisting of glycerin, sorbitol, propylene glycol, triethylene glycol, lactic acid, diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, ethyl myristate, isopropyl myristate, methyl stearate, dimethyl dodecanedioate, dimethyl tetradecanedioate, and mixtures thereof.

Aerosol-forming materials have been found to enhance the sensory performance of articles for use in aerosol generating devices containing tobacco compositions by assisting in the transfer of compounds, such as flavor compounds, from the tobacco material to the consumer.

The aerosol-forming materials may be included in any component of the tobacco composition. Alternatively or additionally, the aerosol-forming materials may be added separately to the tobacco composition. In any case, the total amount of aerosol-forming materials in the tobacco material must be as specified herein.

The tobacco material may include an aerosol-forming material in an amount of about 10% or less by weight of the tobacco material. In other embodiments, the tobacco may include an aerosol-forming material in an amount of about 20% or less or about 15% to about 20% by weight of the tobacco. The tobacco may include an aerosol-forming material in an amount of about 5%, about 10% or about 15% by weight of the tobacco.

It has been found to be advantageous to add this in high weight percentages to another component of the tobacco material, such as reconstituted tobacco material, to achieve a total amount of aerosol-forming material of 10% to 20% by weight of the tobacco material.

In one aspect of the present disclosure, a tobacco composition is provided that includes a tobacco component and an aerosol-forming material, the tobacco component includes a tobacco leaf material in an amount of about 10% to about 90% by weight of the tobacco component, the tobacco leaf material includes said aerosol-forming material in an amount of about 10% or less by weight of the tobacco leaf material, and the tobacco composition includes said aerosol-forming material in an amount of about 10% to about 30% by weight of the tobacco composition. Preferably, the tobacco composition includes the aerosol-forming material in an amount of about 10% to about 20% by weight of the tobacco composition.

In some embodiments, the aerosol forming material may be glycerin, propylene glycol, or a mixture of glycerin and propylene glycol. Preferably, the aerosol forming material comprises glycerin. Glycerin 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, if included, may be present in an amount of 0.1-0.3% by weight of the composition.

The aerosol-forming material may be contained in a component of the tobacco composition. For example, the aerosol-forming material may be contained in the reconstituted tobacco and/or filler component, if any.

Alternatively or additionally, the aerosol-forming materials may be added separately to the tobacco material. In either case, the total amount of aerosol-forming materials in the tobacco material must be as specified herein.

The reconstituted tobacco paper may include an aerosol-forming material. The reconstituted tobacco paper may include an aerosol-forming material in an amount of about 10% to about 20% by weight of the reconstituted tobacco material. In some embodiments, the reconstituted tobacco paper may include an aerosol-forming material in an amount of about 10%, about 11%, about 12%, about 13%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19%, or about 20% by weight of the reconstituted tobacco material.

The tobacco material described herein may include an aerosol modifying agent such as any of the flavourants as described herein. In one embodiment, the tobacco material includes menthol to form a mentholated article. The tobacco material may include 3 mg to 20 mg of menthol, preferably 5 mg to 18 mg, and more preferably 8 mg to 16 mg of menthol. In this example, the tobacco material includes 16 mg of menthol. The tobacco material may include 2% to 8% by weight of menthol, preferably 3% to 7% by weight of menthol, and more preferably 4% to 5.5% by weight of menthol. In one embodiment, the tobacco material includes 4.7% by weight of menthol. Such high loadings of menthol are achieved by using a high percentage of reconstituted tobacco material, for example greater than 50% by weight of tobacco material. Alternatively or additionally, the use of a high volume aerosol-generating material, for example tobacco material, can increase the menthol loading achieved when an aerosol-generating material, for example tobacco material, of greater than about 500 ^mm3 , or preferably greater than 1000 ^mm3 , is used.

The tobacco material may be provided in the form of shredded tobacco. The shredded tobacco has a cut width of at least 15 pieces per inch (5.9 pieces per centimeter, equivalent to a cut width of about 1.7 mm). Preferably, the shredded tobacco has a cut width of at least 18 pieces per inch (about 7.1 pieces per centimeter, equivalent to a cut width of about 1.4 mm), more preferably at least 20 pieces per inch (7.9 pieces per centimeter, equivalent to a cut width of about 1.27 mm). In one example, the shredded tobacco has a cut width of 22 pieces per inch (8.7 pieces per centimeter, equivalent to a cut width of about 1.15 mm). Preferably, the shredded tobacco has a cut width of at least 40 pieces per inch (about 15.7 pieces per centimeter, equivalent to a cut width of about 0.64 mm). A cut width of 0.5 mm to 2.0 mm, for example 0.6 mm to 1.5 mm or 0.6 mm to 1.7 mm, has been found to result in a tobacco material that is favorable in terms of surface area to volume ratio and overall density and pressure drop of the substrate 3, particularly when heated. Shredded tobacco can be formed from a mixture of tobacco material forms, for example a mixture of leaf tobacco and one or more of reconstituted tobacco, extruded tobacco and band-cast tobacco. Preferably the tobacco material comprises reconstituted tobacco.

The leaf tobacco and/or reconstituted tobacco paper material has a width of about 0.5 mm to about 2 mm, about 0.6 mm to about 1.75 mm, about 0.6 mm to about 1.7 mm, or about 0.7 to about 1.5 mm.

In the tobacco compositions described herein, the tobacco composition may include a filler component. The filler component is generally a non-tobacco component, i.e., a component that does not contain tobacco-derived components. The filler component may be a non-tobacco fiber, such as wood fiber or pulp or wheat fiber. The filler component may be an inorganic material, such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, etc. The filler component may be a non-tobacco cast material or a non-tobacco extruded material.

The filler component may be present in an amount of 0-20% by weight of the tobacco material or 1-10% by weight of the composition. In preferred embodiments, the tobacco composition comprises about 5% to about 10% of a filler component by weight of the tobacco composition. In some embodiments, no filler component is included.

Extruded tobacco may optionally be included in the tobacco compositions described herein. When extruded tobacco is included, it may be present, for example, in an amount of 10-30% or 10-20% by weight of the tobacco component. Extruded tobacco that may be used in the tobacco compositions described herein may be prepared by methods known to those skilled in the art for the preparation of extruded tobacco. In some embodiments, the extruded tobacco may be prepared as follows: The tobacco composition may include Virginia (flue-cured) tobacco, Burley tobacco, and/or Oriental tobacco. The tobacco composition may be stem, waste, strips, fines, or rice husk. Additional ingredients include non-tobacco fibers such as straw fiber or wheat fiber, binders, e.g., cellulose or modified celluloses such as hydroxypropyl cellulose and carboxymethyl cellulose, and casings, acids such as malic acid.

As shown in Figure 2, the tobacco composition and any additional ingredients are mixed in a mixing silo and conveyed by a metering screw and a conveying screw to the extruder where they are mixed with water, and aerosol forming materials are also added at this stage. After extrusion, the extruded tobacco is cooled on a cooling belt.

Materials similar to those described in the above sections but made using only non-tobacco fibers, such as wheat fiber or wood fiber, may also be used as a filler component in tobacco compositions.

Some embodiments of one aspect of the present disclosure provide a method for producing a tobacco composition as described herein, the method comprising adding an aerosol-forming material as described herein to a tobacco material.

The method of the present invention involves combining leaf tobacco material with a reconstituted tobacco paper that contains an aerosol-forming material in an amount of 10% to 20% by weight of the reconstituted tobacco paper.

As shown in FIG. 3, the tobacco composition is produced by a process that includes adding an aerosol-forming material to tobacco leaf and then combining the tobacco leaf containing the aerosol-forming material with reconstituted tobacco material.

For example, the aerosol-forming material may be added to the tobacco by spraying it onto the tobacco or by dipping the tobacco into the aerosol-forming material. Alternatively or additionally, a tobacco composition may be produced by adding an aerosol-forming material to reconstituted tobacco material.

Embodiments according to aspects of the present disclosure provide tobacco compositions produced by the methods described herein.

In embodiments according to aspects of the present disclosure, the tobacco compositions described herein are used in articles for use in aerosol generating devices. The tobacco compositions may be used in the manufacturing process of articles for use in aerosol generating devices.

In an embodiment according to an aspect of the present disclosure, an article for use in an aerosol generating device is provided that includes a tobacco composition as described herein. The article for use in an aerosol generating device includes a rod of the tobacco composition. The rod may have a total weight of about 250 mg to about 350 mg.

In some embodiments, the tobacco composition may be enclosed in a wrapper having a breathability of less than 100 Coresta units.

An article for use in an aerosol generating device may include reconstituted tobacco material having a density of less than about 700 milligrams per cubic centimeter.

The article for use in an aerosol generating device may have a circumference of at least 19 mm, preferably from about 19 mm to about 23 mm or about 21 mm. This makes it easier to insert the article for use in an aerosol generating device into the aerosol generating device.

In an embodiment according to an aspect of the present disclosure, a system is provided that includes a tobacco composition as described herein and a device arranged to heat the tobacco composition and generate an aerosol from the tobacco composition.

In some embodiments, the system includes an article for use in an aerosol generating device described herein, the aerosol generating device containing at least a portion of the article for use in an aerosol generating device comprising a tobacco composition, and is arranged to heat the portion of the article for use in an aerosol generating device comprising a tobacco composition and generate an aerosol from the tobacco composition.

Figure 4 is a cross-sectional side view of article 1 for use in a non-combustion based aerosol delivery device.

The article 1 includes a mouthpiece 2 and a cylindrical rod 3 of aerosol-generating material, in this example tobacco material, connected to the mouthpiece 2. The aerosol-generating material 3, also referred to herein as aerosol-generating substrate 3, includes at least one aerosol-forming material. In this example, the aerosol-forming material is glycerin. In alternative examples, the aerosol-forming material may be another material or combination of materials described herein. The aerosol-forming material has been found to improve the sensory performance of the article by aiding in the transfer of compounds, such as flavor compounds, from the aerosol-generating material to the consumer. However, adding such an aerosol-forming material to the aerosol-generating material in an article for use in a non-combustion aerosol delivery system has the problem that as the aerosol-forming material is aerosolized upon heating, it increases the mass of the aerosol delivered by the article, and this increased mass is maintained at a higher temperature as it passes through the mouthpiece. As the aerosol passes through the mouthpiece, the aerosol transfers heat into the mouthpiece, which warms the exterior surface of the mouthpiece, including the area that contacts the consumer's lips in use. The temperature of the mouthpiece can be significantly higher than a consumer is accustomed to when smoking, for example, a cigarette, which can be an undesirable effect of using such aerosol-forming materials.

The part of the mouthpiece that contacts the consumer's lips usually has a paper tube surrounding a hollow or cylindrical body made of filter material.

As shown in FIG. 4, the mouthpiece 2 of the article 1 includes an upstream end 2a adjacent the aerosol-generating substrate 3 and a downstream end 2b distal from the aerosol-generating substrate 3. At the downstream end 2b, the mouthpiece 2 has a hollow tubular member 4 formed from filamentary tow. This has been advantageously discovered to significantly reduce the temperature of the exterior surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece which contacts the consumer's lips during use of the article 1. In addition, it has been found that the use of the tubular member 4 significantly reduces the temperature of the exterior surface of the mouthpiece 2, even upstream of the tubular member 4. Without wishing to be bound by any theory, it is hypothesized that this is due to the tubular member 4 directing the aerosol closer to the center of the mouthpiece 2, thus reducing the transfer of heat from the aerosol to the exterior surface of the mouthpiece 2.

In this example, article 1 has a circumference of about 21 mm (i.e., the article is in a demi-slim format). In other examples, the article can be provided in any of the formats described herein, for example having a circumference between 15 mm and 25 mm. Because the article is heated to release an aerosol, improved heating efficiency can be achieved by using an article having a smaller circumference within this range, for example a circumference less than 23 mm. Article circumferences greater than 19 mm have been found to be particularly effective for achieving improved aerosol upon heating while maintaining a suitable product length. Articles having circumferences between 19 mm and 23 mm, more preferably between 20 mm and 22 mm, have been found to provide a good balance between efficient heating while effectively delivering an aerosol.

The circumference of the mouthpiece 2 is substantially the same as the circumference of the rod 3 of aerosol-generating material, which allows a smooth connection between these components. In this example, the circumference of the mouthpiece 2 is approximately 20.8 mm. A tipping paper 5 is wrapped around the entire length of the mouthpiece 2 and over part of the rod 3 of aerosol-generating material, has an adhesive on its inner surface, and connects the mouthpiece 2 to the rod 3. In this example, the tipping paper 5 extends 5 mm over the rod of aerosol-generating material, but may alternatively extend 3 mm to 10 mm, more preferably 4 mm to 6 mm, over the rod to ensure a secure attachment of the mouthpiece 2 to the rod 3. The tipping paper 5 may have a basis weight greater than that of the plug wrapper used for the article 1, for example a basis weight of 40 gsm to 80 gsm, more preferably 50 gsm to 70 gsm, in this example 58 gsm. Basis weights in these ranges have been found to result in a tipping paper that is flexible enough to wrap the article 1 while having acceptable tensile strength and that adheres to itself along the longitudinal hold-down seam of the paper. The circumference of the tipping paper 5 when wrapped around the mouthpiece 2 is approximately 21 mm.

The "wall thickness" of the hollow tubular member 4 corresponds to the thickness of the wall of the tube 4 in the radial direction. This is measured, for example, using a vernier caliper. Advantageously, the wall thickness is greater than 0.9 mm, more preferably greater than or equal to 1.0 mm. Preferably, the wall thickness is substantially constant around the entire wall of the hollow tubular member 4. However, if the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9 mm, more preferably greater than or equal to 1.0 mm, at any point around the circumference of the hollow tubular member 4.

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

Preferably, the density of the hollow tubular member 4 is at least about 0.25 grams per cubic centimeter (g/cc), more preferably at least about 0.3 g/cc. Preferably, the density of the hollow tubular member 4 is at least about 0.75 grams per cubic centimeter (g/cc), more preferably less than 0.6 g/cc. In some embodiments, the density of the hollow tubular member 4 is 0.25 to 0.75 g/cc, more preferably 0.3 to 0.6 g/cc, more preferably 0.4 g/cc to 0.6 g/cc or about 0.5 g/cc. These densities have been found to provide a good combination of good stiffness provided by high density materials and low thermal conductivity of low density materials. For purposes of the present invention, the "density" of the hollow tubular member 4 refers to the density of the filamentary tows forming the member, including any incorporated plasticizers. The density is determined by dividing the total weight of the hollow tubular member 4 by the total volume of the hollow tubular member 4, which can be calculated using suitable measurements of the hollow tubular member 4, for example using a caliper. If necessary, suitable dimensions can be measured using a microscope.

The filamentary tows forming the hollow tubular member 4 preferably have a total denier of less than 45,000, more preferably less than 42,000. It has been found that this total denier allows for the formation of a tubular member 4 that is not too dense. Preferably, the total denier is at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filamentary tows forming the hollow tubular member 4 have a total denier of 25,000 to 45,000, more preferably 35,000 to 45,000. Preferably, the cross-sectional shape of the filamentary tows is "Y" shaped, although other shapes such as "X" shaped filaments can be used in other embodiments.

The filamentary tows forming the hollow tubular member 4 preferably have a denier per filament greater than 3. It has been found that this denier per filament allows for the formation of a tubular member 4 that is not too dense. Preferably, the denier per filament is at least 4, more preferably at least 5. In a preferred embodiment, the filamentary tows forming the hollow tubular member 4 have a denier per filament between 4 and 10, more preferably between 4 and 9. In one example, the filamentary tows forming the hollow tubular member 4 are formed from cellulose acetate, e.g., 8Y40,000 tows with 18% plasticizer, such as triacetin.

The hollow tubular member 4 preferably has an inner diameter greater than 3.0 mm. A smaller inner diameter would result in aerosol traveling through the mouthpiece 2 to the consumer's mouth at a faster than desired rate, causing the aerosol to become too warm, for example reaching a temperature of greater than 40° C. or 45° C. More preferably, the hollow tubular member 4 has an inner diameter greater than 3.1 mm, and even more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the hollow tubular member 4 has an inner diameter of about 3.9 mm.

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

The pressure drop or pressure differential (also referred to as resistance to drawing) across the mouthpiece, e.g., the portion of the article 1 downstream of the aerosol-generating material 3, is preferably less than about 40 _mmH20 . Such a pressure drop has been found to allow sufficient aerosol, including flavor compounds and the like, to be transferred through the mouthpiece 2 to the consumer. More preferably, the pressure drop across the mouthpiece 2 is less than about _{32 mmH20} . In some embodiments, aerosol has been particularly improved using a mouthpiece 2 having a pressure drop of less than 31 mmH20, e.g., about 29 _mmH20 , about 28 _mmH20 or about 27.5 _mmH20 . Alternatively or additionally, the mouthpiece pressure drop is at least ₁₀ mmH20, preferably at least 15 _mmH20 and more preferably at least ₂₀ mmH20. In some embodiments, the mouthpiece pressure drop may be between about 15 mmH20 and 40 _mmH20 . These values allow the mouthpiece 2 to decelerate the aerosol as it passes through the mouthpiece 2 so that the temperature of the aerosol has time to drop before it reaches the downstream end 2 b of the mouthpiece 2 .

The mouthpiece 2 in this example includes a body of material 6 adjacent, in this example abutting and upstream of the hollow tubular member 4. The body of material 6 and the hollow tubular member 4 each define a substantially generally cylindrical outer shape and share a common longitudinal axis. The body of material 6 is wrapped in a first plug wrapper 7. Preferably the first plug wrapper 7 has a basis weight of 50 gsm, more preferably about 20 gsm to 40 gsm. Preferably the first plug wrapper 7 has a thickness of 30 μm to 60 μm, more preferably 35 μm to 45 μm. Preferably the first plug wrapper 7 is a non-porous plug wrapper having an air permeability of, for example, less than 100 Coresta units, for example less than 50 Coresta units. However, in other embodiments the first plug wrapper 7 may be a porous plug wrapper having an air permeability of, for example, more than 200 Coresta units.

Preferably, the length of the body of material 6 is less than about 15 mm. More preferably, the length of the body of material 6 is less than about 10 mm. Additionally or alternatively, the length of the body of material 6 is at least about 5 mm.

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

In this example, the body 6 is formed from filamentary tow. In this example, the tow used in the body 6 has a denier per filament (d.p.f.) of 8.4 and a total denier of 21,000. Alternatively, the tow may have a denier per filament (d.p.f.) of 9.5 and a total denier of 12,000, for example. In this example, the tow comprises plasticized cellulose acetate tow. The plasticizer used in the tow comprises 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 6. For example, rather than tow, the body 6 can be formed from paper, similar to conventional paper filters for use in, for example, cigarettes.

Alternatively, the body 6 can be formed from a tow other than cellulose acetate, such as polylactic acid (PLA), other materials described herein for filamentary tow, or similar materials. The tow is preferably formed from cellulose acetate. Whether formed from cellulose acetate or another material, the tow preferably has a d.p.f. of at least 5, more preferably at least 6, and even more preferably at least 7. These values of denier per filament provide a tow that is relatively coarse, thick, and has a narrow surface area that reduces mouthpiece pressure drop than tows having smaller d.p.f. values. Preferably, to obtain a sufficiently uniform body 6, the tow has a denier per filament of 12 d.p.f. or less, preferably 11 d.p.f. or less, and even more preferably 10 d.p.f. or less.

The total denier of the tow forming the body 6 is preferably at most 30,000, more preferably at most 28,000 and even more preferably at most 25,000. These values of total denier provide the tow with a smaller percentage of the cross-sectional area of the mouthpiece 2, resulting in a lower pressure drop through the mouthpiece 2 than tows having higher total denier values. For adequate hardness of the body 6, the tow preferably has a total denier of at least 8,000, more preferably at least 10,000. Preferably, the denier per filament is 5-12 and the total denier is 10,000-25,000. More preferably, the denier per filament is 6-10 and the total fineness is 11,000-22,000. Preferably, the cross-sectional shape of the filaments of the tow is "Y" shaped, although in other embodiments the d.p.f.f. as provided herein may be used. Other shapes such as "X" shaped filaments of the same total denier are also possible.

In this example, the hollow tubular member 4 is a first hollow tubular member 4, and the mouthpiece includes a second hollow tubular member 8, also referred to as a cooling member, upstream of the first hollow tubular member 4. In this example, the second hollow tubular member 8 is upstream of, adjacent to, and abutting the body of material 6. The body of material 6 and the second hollow tubular member 8 each define a substantially generally cylindrical outer shape and share a common longitudinal axis. The second hollow tubular member 8 is formed from a plurality of paper layers wound in parallel to form the tubular member 8 with a joined seam. In this example, the first and second paper layers are provided in a double tube, but in other examples three, four or more layers may be used to form a triple, quadruple or more stacked tube. Other constructions, such as spirally wound paper layers, cardboard tubes, tubes formed using a composite paper mold process, molded or extruded plastic tubes, or the like, may also be used. The second hollow tubular member 8 may be formed using a stiff plug wrapper and/or tipping paper as the second plug wrapper 9 and/or tipping paper 5 described herein, meaning that a separate tubular member is not required. The stiff plug wrapper and/or tipping paper is manufactured to have a stiffness sufficient to withstand axial compressive forces and bending movements that may occur during manufacture and while the article 1 is in use. For example, the stiff plug wrapper and/or tipping paper may have a basis weight of 70 gsm to 120 gsm, more preferably 80 gsm to 110 gsm. Additionally or alternatively, the stiff plug wrapper and/or tipping paper may have a thickness of 80 μm to 200 μm, more preferably 100 μm to 160 μm or 120 μm to 150 μm. It is desirable for the second plug wrapper 9 and tipping paper 5 to have values in these ranges to obtain an acceptable level of stiffness for the second hollow tubular member 8.

The second hollow tubular member 8 has a wall thickness, measured in the same manner as the first hollow tubular member 4, of at least about 100 μm and no more than about 1.5 mm, preferably between 100 μm and 1 mm, more preferably between 150 μm and 500 μm or about 300 μm. In this example, the second hollow tubular member 8 has a wall thickness of about 290 μm.

Preferably, the length of the second hollow tubular member 8 is less than about 50 mm. More preferably, the length of the second hollow tubular member 8 is less than about 40 mm. Even more preferably, the length of the second hollow tubular member 8 is less than about 30 mm. Additionally or alternatively, the length of the second hollow tubular member 8 is preferably at least about 10 mm. Preferably, the length of the second hollow tubular member 8 is at least about 15 mm. In some preferred embodiments, the length of the second hollow tubular member 8 is between about 20 mm and about 30 mm, more preferably between about 22 mm and about 28 mm, even more preferably between about 24 mm and about 26 mm, and most preferably about 25 mm. In this example, the length of the second hollow tubular member 8 is 25 mm.

The second hollow tubular member 8 is positioned around the mouthpiece 2 and defines a cavity within the mouthpiece, which acts as a cooling segment. The cavity provides a chamber through which the heated volatile components generated by the aerosol-generating material 3 flow. The second hollow tubular member 8 is hollow to provide a chamber for the deposition of the aerosol, yet is rigid enough to withstand axial compressive forces and bending movements that may occur during manufacture and while the article 1 is in use. The second hollow tubular member 8 provides a physical transition between the aerosol-generating material 3 and the body of material 6. The physical transition by the second hollow tubular member 8 provides a temperature gradient over the length of the second hollow tubular member 8.

Preferably, the mouthpiece 2 includes a cavity having an internal volume of greater than 450 mm3. It has been found that a cavity of at least this volume provides good aerosol formation. Such a cavity size allows sufficient space within the mouthpiece 2 to cool the heated volatile components, which would otherwise result in an aerosol that is too warm, and thus subject the aerosol-generating material 3 to higher temperatures. In this example, the cavity is formed by the second hollow tubular member 8, but in alternative configurations it may be formed within a different portion of the mouthpiece 2. More preferably, the mouthpiece 2 includes a cavity, for example formed within the second hollow tubular member 8, having an internal volume of greater than 500 mm3, even more preferably greater than 550 mm3, further enhancing the aerosol. In some examples, the internal cavity includes a volume of about 550 mm3 to about 750 mm3, for example about 600 mm3 or 700 mm3.

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

In another article, the second hollow tubular member 8 may be replaced by another cooling member, for example a member formed from a body of material through which the aerosol passes longitudinally and which also performs the function of cooling the aerosol.

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

In this example, the aerosol-generating material 3 is wrapped in a wrapper 10. The wrapper 10 may be, for example, a paper or paper-supported foil wrapper. In this example, the wrapper 10 is substantially air-tight. In another embodiment, the wrapper 10 has an air permeability of preferably less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that wrappers with low air permeability, for example less than 100 Coresta units, more preferably less than 60 Coresta units, result in improved formation of aerosols at the aerosol-generating material 3. Without wishing to be bound by any theory, it is assumed that this is due to less loss of aerosol compounds through the wrapper 10. The air permeability of the wrapper 10 may be measured in accordance with ISO 2965:2009 for measurement of air permeability of materials used as cigarette papers, filter plug wrappers and filter bonding papers.

In this embodiment, the wrapper 10 comprises aluminum foil. Aluminum foil has been found to be particularly effective in enhancing the formation of aerosol within the aerosol-generating material 3. In this example, the aluminum foil has a metal layer having a thickness of about 6 μm. In this example, the aluminum foil has a backing. However, in alternative configurations, the aluminum foil may be of other thicknesses, for example, between 4 μm and 16 μm. The aluminum foil may also have no backing, for example formed from another material that helps provide the foil with adequate tensile strength. Metal layers or foils other than aluminum may also be used. The total thickness of the wrapper is preferably between 20 μm and 60 μm, more preferably between 30 μm and 50 μm, to provide the wrapper with suitable structural integrity and heat transfer properties. The tension that can be applied to the wrapper before it breaks is greater than 3,000 gram force, for example between 3,000 and 10,000 gram force or between 3,000 and 4,500 gram force.

The article has a ventilation level of about 75% of the aerosol drawn through the article. In another embodiment, the article may have a ventilation level of 50% to 80%, for example 65% to 75%, of the aerosol drawn through the article. These levels of ventilation assist in slowing down the flow of aerosol drawn through the mouthpiece 2, allowing the aerosol to cool before it reaches the downstream end 2b of the mouthpiece 2. The ventilation is provided directly within the mouthpiece 2 of the article 1. In this example, the ventilation is provided within the second hollow tubular member 8, which has been found to be particularly beneficial in assisting the aerosol generation process. The ventilation is provided via first and second parallel rows of perforations 12, in this case formed as laser drillings, at positions 17.925 mm and 18.625 mm, respectively, from the downstream mouth end 2b of the mouthpiece 2. These perforations pass through the tipping paper 5, the second plug wrapper 9 and the second hollow tubular member 8. In alternative embodiments, ventilation may be provided elsewhere in the mouthpiece, such as in the body of material 6 or the first tubular member 4.

In this example, the aerosol-forming material added to the aerosol-generating substrate 3 comprises 14% by weight of the aerosol-generating substrate 3. Preferably, the aerosol-forming material comprises at least 5% by weight of the aerosol-generating substrate, more preferably at least 10%. Preferably, the aerosol-forming material comprises less than 25% by weight of the aerosol-generating substrate, more preferably less than 20%, for example 10%-20%, 12%-18% or 13%-16%.

Preferably, the aerosol-generating material 3 is provided as a cylindrical rod of aerosol-generating material. Regardless of the shape of the aerosol-generating material, the aerosol-generating material has a length of about 10 mm to 100 mm. In some embodiments, the length of the aerosol-generating material is preferably in the range of about 25 mm to 50 mm, more preferably in the range of about 30 mm to 45 mm, and even more preferably about 30 mm to 40 mm.

The volume of the aerosol-generating material 3 provided may vary from about 200 mm3 to about 4300 mm3, preferably from about 500 mm3 to 1500 mm3, and more preferably from about 1000 mm3 to about 1300 mm3. Providing these volumes of aerosol-generating material, for example from about 1000 mm3 to about 1300 mm3, has been shown to be advantageous in achieving superior aerosols with better visibility and perception performance than those achieved with volumes selected from the lower end of that range.

The mass of the aerosol-generating material 3 provided may be greater than 200 mg, for example between about 200 mg and 400 mg, preferably between about 230 mg and 360 mg, more preferably between about 250 mg and 360 mg. Providing a larger mass of aerosol-generating material has been found to be advantageous in that it results in better sensory performance compared to aerosols generated from tobacco material with a smaller mass.

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

5a is a side cross-sectional view of another article 1' including a capsule-containing mouthpiece 2'. FIG. 5b is a cross-sectional view of the capsule-containing mouthpiece shown in FIG. 5a taken along line A-A' in FIG. 5a. The article 1' and capsule-containing mouthpiece 2' are the same as the article 1 and mouthpiece 2 illustrated in FIG. 4, except that the aerosol modifier is provided within the body of material 6, in this example in the form of a capsule 11, and a first oil-resistant plug wrapper 7' surrounds the body of material 6. In other examples, the aerosol modifier may be provided in other forms, such as a material injected within the body of material 6, or may be provided on a strand, such as a strand carrying a flavorant or other aerosol modifier, which may also be disposed within the body of material 6.

The capsule 11 may comprise a frangible capsule, for example a capsule having a solid frangible shell surrounding a liquid payload. In this example, one capsule 11 is used. The capsule 11 is fully embedded within the body of material. In other words, the capsule 11 is fully surrounded by the body of material 6. In other examples, multiple frangible capsules may be disposed within the body of material, for example two, three or more frangible capsules. The length of the body of material 6 may be increased to accommodate as many capsules as required. In examples where multiple capsules are used, the individual capsules may be identical to one another or may differ in size and/or capsule payload. In other examples, multiple bodies of material 6 may be provided, each containing one or more capsules.

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

In this example, capsule 11 is spherical and has a diameter of about 3 mm. In other examples, other shapes and sizes may be used. The total weight of capsule 11 may be in the range of about 10 mg to about 50 mg.

In this example, the capsule 11 is located in the longitudinal center of the material 6. That is, the capsule 11 is positioned so that its center is 4 mm away from both ends of the material 6. In other examples, the capsule 11 may be located in a position other than the longitudinal center of the material 6, i.e. closer to the downstream end of the material 6 than the upstream end, or closer to the upstream end of the material 6 than the downstream end. Preferably, the mouthpiece 2' is configured such that the capsule 11 and the ventilation hole 12 are longitudinally offset from each other within the mouthpiece 2'.

A cross section of the mouthpiece 2' is shown in Figure 5b, taken along line A-A' in Figure 5a. Figure 5b shows the capsule 11, the body of material 6, the first and second plug wrappers 7', 9 and the tipping paper 5. In this example, the capsule 11 is centred on the longitudinal axis (not shown) of the mouthpiece 2'. The first and second plug wrappers 7', 9 and the tipping paper 5 are arranged concentrically around the body of material 6.

The frangible capsule 11 has a core-shell structure, i.e., the encapsulating or barrier material forms a shell around a core containing the aerosol modifier. The shell structure prevents migration of the aerosol modifier during storage of the article 1', but allows for controlled release of the aerosol modifier, also referred to as aerosol modifier, during use.

In some cases, the barrier material (also referred to as the encapsulant) is frangible. The capsule is crushed or otherwise broken or destroyed by the user to release the encapsulated aerosol modifier. Typically, the capsule is broken just before heating is initiated, but the user can choose when to release the aerosol modifier. The term "frangible capsule" refers to a capsule whose shell can be broken by pressure to release the core, and more specifically, the shell can be ruptured by pressure applied by the user's finger when the user wishes to release the capsule's core.

In some cases, the barrier material is heat resistant, i.e., in some cases, the barrier does not rupture but melts or fails at temperatures reached by the capsule during operation of the aerosol delivery device. Specifically, the capsule located within the mouthpiece may be exposed to temperatures in the range of, for example, 30°C to 100°C, and the barrier material may continue to retain the liquid core up to at least about 50°C to 120°C.

In other cases, the capsule releases the core composition upon heating, for example by swelling of the capsule melting or rupturing the barrier material.

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

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

A capsule according to the present invention comprises a core and a shell as described above. The capsule may exhibit a crush strength of about 4.5N to about 40N, more preferably about 5N to about 30N or about 28N (e.g., about 9.8N to about 24.5N). Capsule crush strength can be measured using a gauge that removes the capsule from the body of material 6 and measures the force at which the capsule bursts when pressed between two flat metal plates. A suitable measuring device is a Sauter FK 50 fall gauge with a flat-headed attachment that can be used to crush the capsule against a flat, hard surface with a surface similar to that of the attachment.

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

The cross-sectional area of the capsule 11 at its largest cross-sectional area is in some embodiments less than 28%, more preferably less than 27%, even more preferably less than 25% of the cross-sectional area of the portion of the mouthpiece 2' in which the capsule 11 is provided. For example, for a spherical capsule with a diameter of 3.0 mm, the maximum cross-sectional area of the capsule is 7.07 mm2. For the mouthpiece 2' described here with a circumference of 21 mm, the material body 6 has an outer circumference of 20.8 mm, which gives a radius of this member of 3.31 mm, corresponding to a cross-sectional area of 34.43 mm2. The cross-sectional area of the capsule is 20.5% of the cross-sectional area of the mouthpiece 2' in this example. As another example, if the capsule has a diameter of 3.2 mm, its maximum cross-sectional area is 8.04 ^mm2 . In this case, the cross-sectional area of the capsule is 23.4% of the cross-sectional area of the material body 6. A capsule having a maximum cross-sectional area of less than 28% of the cross-sectional area of the portion of the mouthpiece 2' in which the capsule 11 is provided has the advantage that the pressure drop across the mouthpiece 2' is reduced compared to a capsule having a larger cross-sectional area, and adequate space for the aerosol remains around the capsule to allow the aerosol to pass without the body of material 6 removing significant amounts of bulk aerosol as it passes through the mouthpiece 2'.

Preferably, the pressure drop or pressure differential (also referred to as resistance to draw), measured as the opening pressure drop (i.e. ventilation openings open), decreases by less than 8 mm _H2O when the capsule is broken. More preferably, the opening pressure drop decreases by less than 6 mm, more preferably less than 5 mm. These values are measured as averages obtained with at least 80 articles made with the same design. Such small pressure drop changes mean that other aspects of the product design, such as setting the correct ventilation level for a given product pressure drop, can be achieved regardless of whether the consumer chooses to break the capsule or not.

The barrier material may include one or more of a gelling agent, a bulking agent, a buffer, a colorant, and a plasticizer.

Suitably, the gelling agent may be, for example, a polysaccharide or cellulosic gelling agent, gelatin, gum, gel, wax or mixtures thereof. Suitable polysaccharides include alginates, dextrans, maltodextrins, cyclodextrins and pectins. Suitable alginates include, for example, salts of alginic acid, esterified alginates or glyceryl alginate. Salts of alginic acid include ammonium alginate, triethanolamine alginate and alginates of group I or II metal ions such as sodium alginate, potassium alginate, calcium alginate and magnesium alginate. Esterified alginates include polypropylene glycol alginate and glyceryl alginate. In one embodiment, the barrier material is sodium alginate and/or calcium alginate. Suitable cellulosic materials include methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, cellulose acetate and cellulose ethers. The gelling agent may include one or more modified starches. The gelling agent may include carrageenan. Suitable gums include agar, gellan gum, gum arabic, pullulan gum, mannan gum, ghatti gum, tragacanth gum, karaya gum, carob, acacia gum, guar, quince seed gum and xanthan gum. Suitable gels include agar, agarose, carrageenan, fleudan and fructoseleran. Suitable waxes include carnauba wax. In some cases, the gelling agent may include carrageenan and/or gellan gum, which are particularly suitable for inclusion as gelling agents when the pressure required to break the resulting capsule is particularly suitable.

The barrier material may include one or more bulking agents such as starch, modified starch (such as oxidized starch) and sugar alcohols such as maltitol.

The barrier material may contain a colorant to facilitate placement of the capsule in the aerosol generating device during the manufacturing process of the aerosol generating device. The colorant is preferably selected from dyes and pigments.

The barrier material may further include at least one buffer, such as a citrate compound or a phosphate compound.

The barrier material may further comprise at least one plasticizer, such as glycerin, sorbitol, maltitol, triacetin, polyethylene glycol, propylene glycol or another polyhydric alcohol having plasticizing properties and in particular any acid of the mono-, di- or tri-acid type, such as citric acid, fumaric acid, malic acid, etc. The amount of plasticizer ranges from 1 to 30% by weight, preferably 2 to 15% by weight, even more preferably 3 to 10% by weight of the total dry weight of the shell.

The barrier material also comprises one or more filler materials. Suitable filler materials are starch derivatives such as dextrin, maltodextrin, cyclodextrin (alpha, beta or gamma) or cellulose derivatives such as hydroxypropylmethylcellulose (HPMC), hydroxypropylcellulose (HPC), methylcellulose (MC), carboxy-methylcellulose (CMC), polyvinyl alcohol, polyols or mixtures thereof. Dextrin is a preferred filler material. The amount of filler in the shell is up to 98.5% by weight, preferably 25-95% by weight, more preferably 40-80% by weight, even more preferably 50-60% by weight of the total dry weight of the shell.

The capsule shell may additionally comprise a hydrophobic outer layer to prevent the capsule from disintegrating due to moisture. The hydrophobic outer layer is preferably selected from the group comprising waxes, in particular carnauba wax, candelilla wax or beeswax, carbowax, shellac (in alcoholic or aqueous solution), ethyl cellulose, hydroxypropyl methylcellulose, hydroxypropyl cellulose, latex compositions, polyvinyl alcohol, or combinations thereof. More preferably, the at least one moisture barrier agent is ethyl cellulose or a mixture of ethyl cellulose and shellac.

The capsule core includes an aerosol modifier. The aerosol modifier may be any volatile material that alters at least one property of the aerosol. For example, the aerosol material may alter the pH, sensory properties, moisture content, delivery properties, or flavor. In some cases, the aerosol modifier may be selected from an acid, a base, water, or a flavoring agent. In some embodiments, the aerosol modifier includes one or more flavoring agents.

The flavouring may suitably be liquorice, rose oil, vanilla, lemon oil, orange oil, a mint flavouring, suitably menthol and/or peppermint oil and/or spearmint oil, or a mint oil from any species of the Mentha genus, or lavender, fennel or anise.

In some cases, flavorings include menthol.

In some cases, the capsule may contain at least about 25% w/w flavorant (based on the total weight of the capsule), preferably at least about 30% w/w flavorant, 35% w/w flavorant, 40% w/w flavorant, 45% w/w flavorant or 50% w/w flavorant.

In some cases, the core may comprise at least about 25% w/w flavorant (based on the total weight of the core), preferably at least about 30% w/w flavorant, 35% w/w flavorant, 40% w/w flavorant, 45% w/w flavorant or 50% w/w flavorant. In some cases, the core may comprise up to about 75% w/w flavorant (based on the total weight of the core), preferably up to about 65% w/w flavorant, 55% w/w flavorant or 50% w/w flavorant. In particular, the capsule may comprise flavorant in an amount ranging from 25-75% w/w (based on the total weight of the core), about 35-60% w/w or about 40-55% w/w.

The capsule may contain at least about 2 mg, 3 mg or 4 mg of aerosol modifier, preferably at least about 4.5 mg of aerosol modifier, 5 mg of aerosol modifier, 5.5 mg of aerosol modifier or 6 mg of aerosol modifier.

In some cases, the consumable contains at least about 7 mg of aerosol modifier, preferably at least about 8 mg of aerosol modifier, 10 mg of aerosol modifier, 12 mg of aerosol modifier or 15 mg of aerosol modifier.

Any suitable solvent may be used.

When the aerosol modifier comprises a flavouring agent, the solvent may suitably comprise a short or medium chain fat. For example, the solvent may comprise triesters of glycerin such as C2-C12 triglycerides, suitably C6-C10 triglycerides or Cs-C12 triglycerides. For example, the solvent may comprise medium chain triglycerides (MCT-C8-C12), which may be derived from palm oil and/or coconut oil.

The esters may be formed with caprylic acid and/or capric acid. For example, the solvent may include medium chain triglycerides that are caprylic triglyceride and/or capric triglyceride. For example, the solvent may include compounds identified in the CAS Registry by Nos. 73398-61-5, 65381-09-1, 85409-09-2. Such medium chain triglycerides are odorless and tasteless.

The hydrophilic lipophilic balance (HLB) of the solvent may be in the range of 9 to 13, preferably 1 to 12. The method of manufacture of the capsules may include extrusion, optionally followed by centrifugation and hardening and/or drying. The contents of WO 2007/010407 A2 are incorporated by reference in their entirety.

In the above examples, the mouthpieces 2, 2' each include a single body of material 6. In other examples, either the mouthpiece of FIG. 4 or of FIGS. 2a and 2b may include multiple bodies of material. The mouthpieces 2, 2' may include cavities between the bodies of material.

In some examples, the mouthpiece 2, 2' downstream of the aerosol-generating material 3 may include a wrapper, such as the first or second plug wrapper 7, 9, or tipping paper 5, which may include an aerosol modifier as described herein. The aerosol modifier may be disposed on an inwardly or outwardly facing surface of the mouthpiece wrapper. For example, the aerosol modifier may be provided in an area of the wrapper, such as the outwardly facing surface of the tipping paper 5, which contacts the consumer's lips during use. By disposing the aerosol modifier on the outwardly facing surface of the mouthpiece wrapper, the aerosol modifier may be transferred to the consumer's lips during use. Transfer of the aerosol modifier to the consumer's lips during use of the article alters the organoleptic properties (e.g., taste) of the aerosol generated by the aerosol-generating substrate 3 or otherwise provides the consumer with a different sensory experience. For example, the aerosol modifier may impart flavor to the aerosol emitted by the aerosol-generating substrate 3. The aerosol modifier may be at least partially soluble in water such that it is transferred to the user via the consumer's saliva. The aerosol modifier may be one that volatilizes due to heat generated by the aerosol supply system. This makes it easier for the aerosol modifier to transfer to the aerosol generated by the aerosol-generating substrate 3.

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

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

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

The device of the present invention may include one or more heating elements, e.g. one or more electrically conductive heating elements, which may be suitably positioned or positionable relative to the coil to allow heating of the one or more heating elements. The one or more heating elements may be fixed relative to the coil. Alternatively, at least one heating element, e.g. at least one electrically conductive heating element, may be included in an article 1, 1' for insertion into a heating area of the device, the article 1, 1' including an aerosol generating material 3, and removed from the heating area after use. Alternatively, the device and such article 1, 1' may include at least one respective heating element, e.g. at least one electrically conductive heating element, and the coil causes heating of the one or more heating elements of the device and article, respectively, when the article is in the heating area.

In some examples, the coil is helical. In some examples, the coil surrounds at least a portion of a heating region of a device configured to contain the aerosol generating material. In some examples, the coil is a helical coil that surrounds at least a portion of a heating region.

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

In some examples, the use of a coil allows a non-combustion aerosol delivery device to reach an operating temperature more quickly than a non-coil aerosol delivery device. For example, a non-combustion aerosol delivery device including a coil as described above can reach an operating temperature such that a first puff can be provided in less than 30 seconds, and preferably less than 25 seconds, from initiation of the device heating program. In some examples, the device can reach an operating temperature in about 20 seconds from initiation of the device heating program.

The use of coils as described herein in devices to induce heating of the aerosol-generating material has been found to enhance the aerosol produced. For example, consumers have reported that aerosols produced by devices including coils such as those described herein feel closer to factory made cigarettes (FMC) than aerosols produced by other non-combustion based aerosol delivery systems. Without wishing to be bound by any theory, it is hypothesized that this is due to the reduced time to reach the required heating temperature when using coils, the higher heating temperatures achieved when using coils, and/or the coils allowing such systems to simultaneously heat a relatively large amount of aerosol-generating material, resulting in an aerosol with a temperature similar to that of FMC. In FMC products, a burning ember generates a hot aerosol that heats the tobacco in the tobacco rod behind the ember as the aerosol is drawn through the rod. It is understood that this hot aerosol releases flavor compounds from the tobacco in the rod behind the burning ember. It is believed that devices including coils as described herein can also heat aerosol-generating materials, such as tobacco materials as described herein, to release flavor compounds, resulting in aerosols that have been reported to be more similar to FMC aerosols.

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

Optionally, at least 10 μg of nicotine, preferably at least 30 μg or 40 μg of nicotine, is aerosolized from the aerosol-generating material under an airflow of at least 1.50 L/m during that 2 second period. Optionally, less than about 200 μg of nicotine, preferably less than about 150 μg or less than about 125 μg of nicotine, is aerosolized from the aerosol-generating material under an airflow of at least 1.50 L/m during that 2 second period.

Optionally, at least 100 μg of the aerosol forming material, preferably at least 200 μg, 500 μg or 1 mg of the aerosol forming material is aerosolized from the aerosol generating material under an air flow of at least 1.50 L/m during the 2 second period. Preferably, the aerosol forming material may comprise or consist of glycerin.

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

In some cases, the average particle size or droplet size of 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 size 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 the period may be at least 0.1 μg/cc. In some cases, the aerosol density is at least 0.2 μg/cc, 0.3 μg/cc, or 0.4 μg/cc. In some cases, the aerosol density is less than about 2.5 μg/cc, 2.0 μg/cc, 1.5 μg/cc, or 1.0 μg/cc.

The non-combustion aerosol delivery device is configured to heat the aerosol-generating material 3 of the article 1, 1' to a maximum temperature of preferably at least 160°C. Preferably, the non-combustion aerosol delivery device is configured to heat the aerosol-forming material 3 of the article 1, 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 step with the non-combustion aerosol delivery device.

The use of an aerosol delivery system including a coil as described herein, e.g., an induction coil that heats at least a portion of the aerosol-generating material to at least 200°C, more preferably at least 220°C, allows for a higher temperature aerosol to be generated from the aerosol-generating material of the article 1, 1' described herein than previous devices that contribute to the generation of aerosols that are believed to be closer to FMC products as the aerosol exits the mouth end of the mouthpiece 2, 2'. For example, the maximum aerosol temperature measured at the mouth end of the article 1, 1' is preferably greater than 50°C, more preferably greater than 55°C, even more preferably greater than 56°C or 57°C. Additionally or alternatively, the maximum aerosol temperature measured at the mouth end of the article 1, 1' is less than 62°C, more preferably less than 60°C, more preferably less than 59°C. In some embodiments, the maximum aerosol temperature measured at the mouth end of the article 1, 1' is preferably between 50°C and 62°C, more preferably between 56°C and 60°C.

Figure 6 shows an example of a non-combustion based aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium/material, such as the aerosol-generating material 3 of the articles 1, 1' described herein. In general terms, the device 100 may be used to heat a replaceable article 110, such as the articles 1, 1' described herein, that contains an aerosol-generating medium 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 includes a housing 102 (in the form of an outer cover) that encloses and contains the various components of the device 100. The device 100 has an opening 104 at one end through which an item 110 is inserted for heating by the heating assembly. In use, the item 110 is fully or partially inserted into the heating assembly where it is heated by one or more components of the heating assembly.

The device 100 in this example includes a first end member 106, which includes a lid 108 that is movable relative to the first end member 106 to close the opening 104 when the item 110 is not in place. Although the lid 108 is shown in an open configuration in FIG. 6, the lid 108 may be moved to a closed configuration. For example, a user slides the lid 108 in the direction of arrow "B."

The device 100 may include a user-operable adjustment member 112, such as a button or switch that, when pressed, activates the device 100. For example, a user may operate the switch 112 to turn on the device 100.

The device 100 also includes electrical components such as a socket/port 114, which may accommodate a cable for charging a battery in the device 100. The socket 114 may be a charging port, such as a USB charging port.

Figure 7 illustrates the device 100 of Figure 6 with the outer cover 102 removed and without the item 110 present. The device 100 defines a longitudinal axis 134.

7, a first end member 106 is disposed at one end of the device, 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 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 also defines 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 closer to the opening 104 is also known as the proximal end (or mouth end) of the device 100 because it is closer to the user's mouth during use. In use, a user inserts an item 110 into the opening 104, operates a user control to initiate heating of the aerosol-generating material, and inhales the aerosol generated by the device, thereby causing the aerosol to flow through the device 100 along a flow path toward the proximal end of the device 100.

The other end of the apparatus away from the opening 104 is also known as the distal end of the device 100, as this is the end that is away from the user's mouth during use. When a user inhales the aerosol generated by the device, the aerosol flows away from the distal end of the device 100.

The device 100 further includes a power source 118. The power source 118 may be a battery, for example a rechargeable or non-rechargeable battery. Examples of suitable batteries include lithium batteries (such as lithium ion batteries), nickel batteries (such as nickel-cadmium batteries), and alkaline batteries. The battery is electrically connected to the heating assembly and provides power as needed and 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 electronic module. The electronic module 122 may include, for example, a printed circuit board (PCB). The PCB 122 may support a controller, such as at least one processor and memory. The PCB 122 may also include one or more electrical tracks that electrically connect 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 a battery via the electrical tracks.

In the example of device 100, the heating assembly is an induction heating assembly, which includes various components for heating the aerosol-generating material of article 110 via an induction heating process. Induction heating is a process of heating an electrically conductive object (such as a susceptor) by electromagnetic induction. The induction heating assembly may include an induction member, for example one or more inductor coils, and a device for passing a fluctuating current, such as an alternating current, through the induction member. The fluctuating current in the induction member generates a fluctuating magnetic field. The fluctuating magnetic field penetrates a susceptor, which is preferably positioned relative to the induction member, and generates eddy currents inside the susceptor. The susceptor has an electrical resistance to the eddy currents, and thus the flow of eddy currents against this resistance causes the susceptor to heat by Joule heating. If the susceptor includes a ferromagnetic material, such as iron, nickel, or cobalt, heat may be generated by magnetic hysteresis losses in the susceptor, i.e., by a change in the orientation of the magnetic dipoles of the magnetic material as a result of matching the fluctuating magnetic field. In induction heating, heat is generated inside the susceptor, which allows for quicker heating than heating by conduction, for example. Furthermore, there is no need for any physical contact between the dielectric heater and the susceptor, allowing for greater flexibility in structure and application.

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

The first inductor coil 124 is configured to generate a first fluctuating magnetic field for heating a first section of the susceptor 132, and the second inductor coil 126 is configured to generate a second fluctuating 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 and second inductor coils 124, 126 do not overlap). The susceptor structure 132 may include a single susceptor or two or more susceptors. Ends 130 of the first and second inductor coils 124, 126 are connected to the PCB 122.

Of course, in some examples, the first and second inductor coils 124, 126 may have at least one different characteristic. For example, the first inductor coil 124 may have at least one different characteristic 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. 7, the first and second inductor coils 124, 126 are different in length 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 and second inductor coils 124, 126 may be substantially the same.

In this example, the first and second inductor coils 124, 126 are shown wound in opposite directions. This is useful when the inductor coils are active at different times. For example, the first inductor coil 124 may be activated first to heat a first section/portion of the article 110, and then the second inductor coil 126 may be activated to heat a second section/portion of the article 110. Winding the coils in different directions helps reduce the current induced in the inductor coils when used with certain types of control circuits. In the device 100 of FIG. 7, 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 coils 124, 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 receiving portion within which the aerosol-generating material is received. For example, the article 110 is inserted into the susceptor 132. In this example, the susceptor 120 is tubular and has a circular cross-section.

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

In some examples, the susceptor 132 may include at least two materials that can be heated at two different frequencies for selective aerosolization of the 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 separately 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 separately based on the operation of the second inductor coil 126. The third and fourth materials 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 these materials may be different. The susceptor may include, for example, carbon steel or aluminum.

7 further includes an insulating member 128 that is generally tubular and at least partially surrounds the susceptor 132. The insulating member 128 may be constructed from any insulating material, such as, for example, plastic. In this particular example, the insulating member is constructed from polyetheretherketone (PEEK). The insulating member 128 serves to insulate various components of the device 100 from heat generated within the susceptor 132.

The insulating member 128 may also fully or partially support the first and second inductor coils 124, 126. For example, as shown in FIG. 7, the first and second inductor coils 124, 126 are positioned around the insulating member 128 and contact the radially outer surface of the insulating member 128. In some examples, the insulating member 128 does not abut the first and second inductor coils 124, 126. For example, a small gap may exist between the outer surface of the insulating member 128 and the inner surfaces of the first and second inductor coils 124, 126.

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

Figure 8 is a side view of the device 100 in partial cross section. The outer cover 102 is shown in this example. The rectangular cross-sectional shape of the first and second inductor coils 124, 126 can be more clearly seen.

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 also includes a second printed circuit board 138 associated with the adjustment member 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 opens the second lid 140 to allow access to the susceptor 132. A user may open the second lid 140 to clean the susceptor 132 and/or the support 136.

The device 100 further includes an expansion chamber 144 that extends away from the proximal end of the susceptor 132 toward the opening 104 of the device. Disposed at least partially within the expansion chamber 144 is a retention clip 146 that abuts and retains the article 110 when contained within the device 100. The expansion chamber 144 is connected to the end member 106.

Figure 9 is an exploded view of the device 100 of Figure 8 with the outer cover 102 omitted.

10A is a cross-sectional view of a portion of the device 100 of FIG. 8. FIG. 10B is an enlarged view of an area of FIG. 10A. FIGS. 10A and 10B show an article 110 contained within a susceptor 132, with the article 110 sized such that its outer surface abuts the inner surface of the susceptor 132, thereby providing the most efficient heating. The article 110 in this example includes an aerosol-generating material 110a. The aerosol-generating material 110a is positioned within the susceptor 132. The article 110 may also include other components, such as a filter wrapper and/or a cooling structure.

FIG. 10B shows that the outer surface of the susceptor 132 is spaced from the inner surface of the inductor coils 124, 126 by a distance 150 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.

10B 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 abut and touch the insulating member 128.

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

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

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

In use, an article 1, 1' described herein is inserted into a non-combustion aerosol delivery device, such as device 100 described with reference to Figures 6-10. At least a portion of the mouthpiece 2, 2' of the article 1, 1' protrudes from the non-combustion aerosol delivery device 100 and is placed into the mouth of a user. An aerosol is generated by heating an aerosol-generating material 3 using the device 100. The aerosol generated by the aerosol-generating material 3 travels through the mouthpiece 2 to the mouth of the user.

The articles 1, 1' described herein are particularly advantageous when used in a non-combustion based aerosol delivery device, such as the device 100 described with reference to Figures 6-10. It has been found, particularly surprisingly, that the first tubular member 4 formed from filamentary tow has a particularly significant effect on the temperature of the outer surface of the mouthpiece 2, 2' of the article 1, 1'. For example, it has been found that when the hollow tubular member 4 formed from filamentary tow is wrapped in an outer wrapper, such as tipping paper 5, the outer surface of the outer wrapper reaches a maximum temperature of less than 42°C, preferably less than 40°C, and more preferably less than 38°C or less than 36°C, during use.

The various embodiments described herein are provided merely to aid in the understanding and teaching of the claimed features. These embodiments are merely representative examples and are not intended to be comprehensive or exclusive. It is to be understood that the advantages, embodiments, examples, features, features, structures, and/or other aspects of the present disclosure should not be construed as limiting the present disclosure to the claims as set forth herein or to the equivalents of the claims, but that other embodiments may be utilized or modified without departing from the scope and/or spirit of the present disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of the disclosed components, ingredients, features, parts, steps, means, or other combinations. The present disclosure also includes other inventions not currently claimed but which may be claimed in the future.

Working Example
experiment

Measurement of Nicotine and Aerosol-Generating Material Content The amount of nicotine and aerosol-forming material may be measured using the following method.

Prepare the extract as follows: Weigh 2.5 ± 0.01 g of n-heptadecane into a weighing vessel and add to a 5 L volumetric flask containing 400-500 mL of methanol, and mix the contents of the flask thoroughly to dissolve the n-heptadecane. Once dissolved, add methanol to correct for the correct volume of the volumetric flask to form the extract solution.

Place the aerosol-generating material (5-10 mm wide pieces) in a sealed plastic bag or airtight container prior to analysis. Mix the sample in the bag to ensure homogeneity before use.

Weigh 1.0 g (± 0.01 g) of sample into a 150 mL Erlenmeyer flask. Add 1.00 mL of deionized water via graduated pipette and allow the mixture to stand for 5 minutes. Add 50 mL of extraction solution (see above) via graduated dispenser. Stopper the flask and then shake on an Orbital/horizontal shaker at 150 rpm for 3 hours.

Using a 5 mL plastic syringe, filter a portion of the extract through a 0.45 μm PVDF filter into a 2 mL GC vial.

The extract in the GC vial is then analyzed against previously prepared working calibration solutions using GC (see table below for parameters).

The sample is injected into an injection port connected to an analytical column. A capillary GC column (phenomenex ZB-WAXplus (30 m x 0.53 mm id x 1.00 μm)) and a flame ionization detector (FID) may be used for analysis.

The final results for nicotine and aerosol formers [CNH(%)(dwb)] are expressed as percent of the dry sample corrected for moisture using the following formula. Moisture may be measured by the Karl-Fisher method:

ＮＨ：ニコチンおよび／または湿潤剤（プロピレングリコールおよびグリセリン）検体
ＣＮＨ（ｍｇ／ｇ）：ｍｇ／ｇで表される検体の濃度
ＣＮＨ（％）（ｄｗｂ）：乾燥サンプルの％で表される検体の濃度
Ｄｗｂ：乾式重量基準
ＣＷａｔｅｒ （％）：％で表される水の濃度
ＡＮＨ：検体（ニコチン、グリコールおよびグリセリン）の領域
ＡＩＳＴＤ：内部標準の領域
ＩＮＴ：線形回帰のｙ軸切片
ＣＩＳＴＤ：抽出溶液中の内部標準の濃度（ｍｇ／ｍＬ）
Ｖ：抽出溶液（ｍＬ）＋１．００ｍＬの脱イオン水の容量
Ｄ：線形回帰の傾き
ｍ：抽出に使用された全ＴＨＰ再生タバコの質量

NH: Nicotine and/or humectants (propylene glycol and glycerin) samples
CNH (mg/g): concentration of the analyte expressed in mg/g
CNH(%)(dwb): concentration of the analyte expressed as a % of the dry sample
Dwb: Dry weight standard
CWater (%): Water concentration expressed as a percentage
ANH: Analyte (nicotine, glycol and glycerin) area
AISTD: Area of Internal Standards
INT: y-axis intercept of linear regression
CISTD: concentration of internal standard in extraction solution (mg/mL)
V: volume of extraction solution (mL) + 1.00 mL of deionized water
D: Linear regression slope
m: total mass of THP reconstituted tobacco used for extraction

The nicotine target % herein may be determined by analyzing a series of samples (e.g., 20-40 samples) for nicotine content and then taking the average.

Determining Moisture Content In the compositions described herein, weight percent refers to a dry weight basis unless otherwise specified. Thus, any water present in the tobacco composition or any of its components is completely ignored for purposes of determining weight percent. Thus, any water present in the tobacco composition or any of its components is completely ignored for purposes of determining weight percent. However, other liquid ingredients, such as aerosol forming materials, are included in the weight percent. The moisture content of the tobacco compositions described herein may vary, for example, from 5 to 15 weight percent. The moisture content may be determined by Karl-Fisher analysis.

Moisture content by Karl-Fisher analysis
Karl-Fisher water analysis may be performed with a Mettler Toledo Karl Fisher V30 Volumetric Titrator. Prior to sample testing, the background water content of the extraction solution (methanol) is measured and the value is recorded in the method.

Approximately 0.5 g of the material to be analyzed is accurately weighed (to 4 decimal places) into a 100 mL Erlenmeyer flask and the weight is recorded. 50 mL of dry methanol is dispensed into the Erlenmeyer flask, which is then sealed and shaken (155 rpm) on a flat-bed shaker for 30 minutes. Approximately 2 mL of sample extract is taken up in a syringe and injected into the titrator (weight measured by back-weighing the syringe). Results are reported as % moisture of the sample by weight. Samples are measured in triplicate and the average is reported with the standard deviation.

Leaf Material Nine blends of leaf materials were prepared. The amount of nicotine in each blend by weight of the blend was measured. The results are shown in Tables 5 and 5a.

Comparative Examples Six reconstituted tobacco materials (Reconstituted Tobacco 1-6), including low nicotine reconstituted tobacco (LNRT) and/or medium nicotine reconstituted tobacco (MNRT) and/or high nicotine reconstituted tobacco (HNRT), were prepared and then analyzed to confirm their nicotine content. The results are shown in Table 6 and Table 6a.

Notably, the nicotine content of the reconstituted tobacco material was less than 1.5% by weight.

Notably, the nicotine content of the reconstituted tobacco material was less than 1.5% by weight.

Examples 1 to 3
Three blends containing leaf tobacco, low nicotine reconstituted tobacco (LNRT) and/or medium nicotine reconstituted tobacco (MNRT) and/or high nicotine reconstituted tobacco (HNRT) were prepared and then analyzed to ascertain their nicotine content. The results are shown in Table 7.

Example 4-21
Eighteen additional blends containing leaf tobacco and reconstituted tobacco materials were prepared and analyzed for nicotine content, and the results are shown in Tables 8, 9, 9a, 9b, and 9c.

The results show that the nicotine content of the tobacco composition can be adjusted by combining reconstituted tobacco material with tobacco having a nicotine content greater than about 1.5% by weight of the tobacco. Thus, a variety of tobacco compositions having a wide range of nicotine concentrations can be produced.

Table 10 shows the temperature of the outer surface of the article 1 described herein with reference to FIG. 4 when heated using the device 100 described herein with reference to FIGS. 6-10B. First, second and third temperature measurement probes were used at corresponding first, second and third positions along the mouthpiece 2 of the article 1. The first position (numbered as position 1 in Table 10) was 4 mm from the downstream end 2b of the mouthpiece 2, the second position (numbered as position 2 in Table 10) was 8 mm from the downstream end 2b of the mouthpiece 2, and the third position (numbered as position 3 in Table 10) was 12 mm from the downstream end 2b of the mouthpiece 2.

The first location was therefore the outer surface of the portion of the mouthpiece 2 in which the first tubular member 4 was located, and the second and third locations were the outer surfaces of the portion of the mouthpiece 2 in which the material body 6 was located.

A control article was tested as a comparison to the filamentary tow tubular member 4 described herein, in which the filamentary tow tubular member 4 was replaced with a conventional spirally paper-wrapped tube having the same structure as the second hollow tubular member 8 described herein, but measuring 6 mm in length rather than 25 mm in length.

Testing was performed on the first five puffs of the article, as by the fifth puff the temperature gradually reaches a maximum and then begins to decline until the maximum temperature is observed. Each sample was tested five times and the resulting temperature is the average of these five tests. The known Health Canada Intense puffing regime (55ml puff volume applied for 2 seconds every 30 seconds) was applied using standard testing equipment.

As shown in the table below, it was surprisingly found that the use of the tubular member 4 formed from filamentary tow reduced the outer surface temperature of the mouthpiece 2 with each puff and at all test locations on the mouthpiece 2 compared to the control article. The tubular member 4 formed from filamentary tow was particularly effective in reducing the temperature at the first probe location where the consumer's lips are located when using the article 1. In particular, the outer surface temperature of the mouthpiece 2 at the first probe location was reduced by more than 7°C after the first three puffs and by more than 5°C after the fourth and fifth puffs.

11 illustrates a method of manufacturing an article for use in a non-combustion based aerosol delivery system. In step S101, first and second portions of aerosol generating material, each including an aerosol forming material, are positioned adjacent first and second longitudinal ends, respectively, of a mouthpiece rod, the mouthpiece rod including a hollow tubular member rod formed from filamentary tow disposed between the first and second ends. In this example, the hollow tubular member includes two lengths of tubular member 4 disposed between first and second bodies of material 6. A corresponding second tubular member 8 is positioned at the outer end of each body of material 6 adjacent the outer ends of those tubular members 8 where the first and second portions of aerosol generating material are positioned. The mouthpiece rod is wrapped in a second plug wrapper as described herein.

In step S102, the first and second portions of aerosol-generating material are connected to the mouthpiece rod. In this example, this is done by wrapping tipping paper 5 as described herein around the mouthpiece rod and at least a portion of each portion of aerosol-generating material 3. In this example, the tipping paper 5 extends longitudinally for about 5 mm over the outer surface of each of the portions of aerosol-generating material 3.

In step S103, the hollow tubular member is cut to form first and second articles, each of which includes a mouthpiece that includes a portion of the hollow tubular member at the downstream end of the mouthpiece. In this example, the first hollow tubular member 4, which is the length of two mouthpiece rods, is cut approximately halfway along its length to form substantially identical first and second articles.

The various embodiments described herein are provided merely to aid in the understanding and teaching of the claimed features. These embodiments are merely representative examples and are not intended to be comprehensive or exclusive. It is to be understood that the advantages, embodiments, examples, features, features, structures, and/or other aspects of the present disclosure should not be construed as limiting the present disclosure to the claims as set forth herein or to the equivalents of the claims, but that other embodiments may be utilized or modified without departing from the scope and/or spirit of the present disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of the disclosed components, ingredients, features, parts, steps, means, or other combinations. The present disclosure also includes other inventions not currently claimed but which may be claimed in the future.

Claims (28)

A tobacco composition comprising a tobacco component and an aerosol-forming material for use in an article for use in a non-combustion based aerosol delivery system, the composition comprising the aerosol-forming material in an amount of 10% to 30% by weight of the tobacco composition, the tobacco component comprising leaf tobacco material in an amount of 10% to 90% by weight of the tobacco component, and reconstituted tobacco having a density of less than 700 mg/cc and a nicotine content of less than 1.5% by weight of the reconstituted tobacco, the nicotine content of the leaf tobacco material being greater than 1.5% by weight of the leaf tobacco material, and the leaf tobacco being cut blade tobacco . 1. A tobacco composition comprising a tobacco component for use in an article for use in a non-combustion based aerosol delivery system, wherein the tobacco component comprises a leaf tobacco material in an amount of 10% to 90% by weight of the tobacco component , and reconstituted tobacco having a density of less than 700 mg/cc, the reconstituted tobacco having a nicotine content of less than 1.5% by weight of the reconstituted tobacco, the leaf tobacco material having a nicotine content of greater than 1.5% by weight of the leaf tobacco material, the leaf tobacco material comprising an aerosol-forming material in an amount of 10% or less by weight of the leaf tobacco material, the tobacco composition comprising said aerosol-forming material in an amount of 10% to 30% by weight of the tobacco composition , and the leaf tobacco being cut blade tobacco . A tobacco composition comprising a tobacco component and an aerosol-forming material for use in an article for use in a non-combustion based aerosol delivery system, the composition comprising the aerosol-forming material in an amount of 10% to 30% by weight of the tobacco composition, the tobacco component comprising leaf tobacco material in an amount of 10% to 90% by weight of the tobacco component, and reconstituted tobacco having a density of less than 700 mg/cc, the reconstituted tobacco having a nicotine content of less than 1.5% by weight of the reconstituted tobacco, the leaf tobacco material having a nicotine content of greater than 1.5% by weight of the leaf tobacco material, the tobacco composition comprising menthol in an amount of 3 mg to 16 mg, and the leaf tobacco being cut blade tobacco. The tobacco composition according to any one of claims 1 to 3, characterized in that the total amount of the aerosol-forming material is 10% to 20% by weight of the tobacco composition. The tobacco composition according to any one of claims 1 to 4, characterized in that the tobacco component contains tobacco leaf material in an amount of 11% to 48%, 12% to 46%, 13% to 44%, 14% to 42%, 15% to 40%, 16% to 38%, 17% to 36%, 18% to 34%, or 19% to 32% by weight of the tobacco component. The tobacco composition according to any one of claims 1 to 5, characterized in that the tobacco component contains tobacco leaf material in an amount of 15% to 25% by weight of the tobacco component. The tobacco composition according to any one of claims 1 to 5, characterized in that the tobacco component contains tobacco leaf material in an amount of 35% to 45% by weight of the tobacco component. The tobacco composition according to any one of claims 1 to 5, characterized in that the tobacco component contains tobacco leaf material in an amount of 55% to 65% by weight of the tobacco component. A tobacco composition according to any one of claims 1 to 8, characterized in that the tobacco component has a nicotine content of 0.8% to 1.75% by weight of the tobacco component. The tobacco composition according to any one of claims 1 to 9, characterized in that the leaf tobacco material has a nicotine content of more than 1.5% and not more than 4% by weight of the leaf tobacco material. The tobacco composition according to any one of claims 1 to 10, characterized in that the aerosol forming material is selected from the group consisting of glycerol, sorbitol, propylene glycol, triethylene glycol, lactic acid, diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, ethyl myristate, isopropyl myristate, methyl stearate, dimethyl dodecanedioate, dimethyl tetradecanedioate, and mixtures thereof. The tobacco composition according to claim 11, characterized in that the aerosol-forming material includes glycerol. The tobacco composition according to any one of claims 1 to 12, characterized in that the reconstituted tobacco comprises paper reconstituted tobacco material. The tobacco composition according to claim 13, characterized in that the tobacco component contains recycled tobacco material in an amount of 50% to 90% by weight of the tobacco component. The tobacco composition according to any one of claims 1 to 14, characterized in that the tobacco component comprises a tobacco material selected from the group consisting of extruded tobacco, band-cast tobacco and mixtures thereof. The tobacco composition according to any one of claims 1 to 15, characterized in that the tobacco composition contains a filler material. The tobacco composition according to claim 16, characterized in that the tobacco composition contains 5% to 10% filler. 18. The tobacco composition according to any one of claims 1 to 17, wherein the leaf tobacco material and the reconstituted paper tobacco material have a width of 0.5 mm to 2 mm, or 0.6 mm to 1.75 mm, or 0.7 mm to 1.5 mm. Use of a tobacco composition according to any one of claims 1 to 18 in an article for use in a non-combustion based aerosol delivery system. An article for use in an aerosol delivery system comprising the tobacco composition of any one of claims 1 to 18. The article of claim 20, wherein the article for use in an aerosol delivery system comprises a rod of the tobacco composition. The article of claim 21, characterized in that the rod of tobacco composition has a length of 10 mm to 100 mm. The article according to claim 21 or 22, characterized in that the rod has a total weight of 250 mg to 350 mg. The article of any one of claims 20 to 23, characterized in that the tobacco composition is wrapped in a wrapper having a breathability of less than 100 Coresta units. The article for use in an aerosol delivery system has a circumference of at least 19 mm.
25. An article according to any one of claims 20 to 24. An article according to any one of claims 20 to 25, characterized in that the article for use in an aerosol delivery system has a circumference of between 19 mm and 23 mm. A system comprising a tobacco composition according to any one of claims 1 to 18 and a device arranged to heat the tobacco composition and generate an aerosol from the tobacco composition. 27. The system of claim 26, comprising an article for use with the aerosol delivery system of any one of claims 20 to 26 , wherein the device is configured to accommodate at least a portion of an article for use with an aerosol delivery system that contains a tobacco composition, to heat the portion of the article for use with an aerosol delivery system that contains a tobacco composition, and to generate an aerosol from the tobacco composition.

Images