JP7735342B2 - Articles for use in aerosol delivery systems - Google Patents

Description

The present invention relates to a system including an article for use in a non-combustion aerosol delivery system, a method for manufacturing the article, and a device for heating the aerosol-generating material of the article.

Certain tobacco industry products generate aerosols that are inhaled by a user during use. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, to form an aerosol by heating the substrate without burning it. Such tobacco industry products commonly include a mouthpiece through which the aerosol passes to reach the user's mouth, and a wrapper (also known as tipping paper) that extends around the mouthpiece and around at least a portion of the aerosol-generating substrate.

In a first aspect, according to some embodiments of the present invention, an article for use in a non-combustion aerosol delivery system is provided, comprising an aerosol-generating material, a mouthpiece downstream of the aerosol-generating material, and a wrapper, the wrapper containing a sensate.

In a second aspect, some embodiments of the present invention provide a method for producing an article according to the first aspect, comprising coating at least a portion of the wrapper with a sensate.

In a third aspect, according to some embodiments of the present invention, there is provided an article made according to the second aspect for use in a non-combustion aerosol delivery system.

In a fourth aspect, according to some embodiments of the present invention, a system is provided comprising an article according to the first or third aspect and a device for heating an aerosol-generating material.

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

1 is a cross-sectional side view of an article for use in a non-combustion based aerosol delivery device including a mouthpiece. FIG. 1 is a side view of a mouthpiece including a wrapper and a sensate. FIG. 1b is a top view of a flat sheet of the wrapper of FIG. 1a. FIG. 1 is a cross-sectional side view of an article for use in a non-combustion based aerosol delivery device, in this example the article includes a capsule-containing mouthpiece. 2b is a cross-sectional view of the capsule-containing mouthpiece shown in FIG. 2a. FIG. 2 is a perspective view of a non-combustion aerosol delivery device for generating aerosol from the aerosol-generating material of the article of FIGS. 1, 2a, and 2b. 4 shows the device of FIG. 3 with the outer cover removed and without any articles. FIG. 4 is a side view, partially in cross section, of the device of FIG. 3; FIG. 4 is an exploded view of the device of FIG. 3 with the outer cover omitted. FIG. 4 is a cross-sectional view of a portion of the device of FIG. 3. FIG. 7B is an enlarged view of a region of the device of FIG. 7A. FIG. 1 is a flow diagram illustrating a method of 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;
Combustible aerosol delivery systems, such as cigarettes, cigarillos, cigars and pipes or tobacco for roll-your-own or homemade cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smoking materials);
non-combustion aerosol delivery systems that release compounds from aerosolizable materials without burning the aerosolizable material, such as e-cigarettes, tobacco heating products, and hybrid systems that generate aerosols using a combination of aerosolizable materials;
Articles that include an aerosolizable material and are configured for use in one of these non-combustible aerosol delivery systems, as well as aerosol-free delivery systems such as lozenges, gums, patches, articles that include patch-inhalable powders, and smokeless tobacco products such as snus and snuff that deliver nicotine-containing or non-nicotine containing materials to the user without forming an aerosol.

A "combustible" aerosol delivery system according to the present disclosure is one in which the constituent aerosolizable materials of the aerosol delivery system (or components thereof) are combusted or burned to facilitate delivery to a user.

A "non-combustible" aerosol delivery system according to the present disclosure is one that does not burn or require combustion to facilitate delivery of the constituent aerosolizable materials of the aerosol delivery system (or components thereof) to a user.

In the embodiments described herein, 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), although it should be noted that the presence or absence of nicotine in the aerosol-generating material is not a requirement.

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, for example, in solid, liquid, or gel form, and may or may not contain nicotine. 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, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and an article for use in a non-combustion aerosol delivery system. However, it is also contemplated that an article that itself includes a means for powering an aerosol-generating element 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 source or a heat-generating power source. In one embodiment, the heat-generating power source comprises a carbon substrate to which energy may be applied to deliver power in the form of heat to an adjacent aerosolizable material or heat transfer material. In one embodiment, a power source, such as a heat-generating power source, is provided to an 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 element 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 element 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 material may include nicotine (optionally contained in tobacco or a tobacco derivative) and one or more other odorless physiologically active materials. An odorless physiologically active material is a material 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 with a non-combustion aerosol delivery device may include an aerosolizable material or an area for containing an aerosolizable material. In one embodiment, an article for use with a non-combustion aerosol delivery device may include a mouthpiece. The area for containing an aerosolizable material may be a storage area for storing the aerosolizable material. In one embodiment, the area for containing the aerosolizable material may be separate from or combined with the aerosol-generation area.

An aerosolizable material, also referred to herein as an aerosol-generating material, is a material that can generate an aerosol when activated, for example, by heating, irradiation, or some other method. The aerosolizable material may be in the form of a solid, liquid, or gel, with or without nicotine and/or flavorings, for example. 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 its interior. In some embodiments, the aerosolizable material may comprise, for example, from 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, cardboard, recycled aerosolizable material, plastic material, ceramic material, composite material, glass, metal, or metal alloy.

Aerosol modifiers are substances that can modify an aerosol during use. They may do so to modify the aerosol and produce a physiological or sensory effect in the human body. Aerosol modifiers include flavors and sensates. Sensates produce an organoleptic sensation that is perceived through the sensation of coolness or sourness.

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, allowing the heating material to be heated by both heating mechanisms.

Induction heating is the process of heating a conductive object by penetrating a changing magnetic field into the object. This process is explained by Faraday's law of electromagnetic induction and Ohm's law. An induction heater can include an electromagnet and a device for passing a changing current, such as an alternating current, through the electromagnet. When the object to be heated and the electromagnet are positioned relative to each other so that the changing magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are generated in the object. The object therefore has a resistance to the flow of current. When such eddy currents are generated in the object, they flow against the object's electrical resistance, thereby heating the object. This process is called Joule heating, Ohmic heating, or resistive heating. An object that can be inductively heated is known as a susceptor.

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, resulting in increased or improved Joule heating.

Magnetic hysteresis heating is the process of heating an object made of a magnetic material by penetrating it with a fluctuating magnetic field. Magnetic materials can be thought of as containing a large number of atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipoles align with the field. Thus, when a fluctuating magnetic field, such as that produced by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes in response to the applied fluctuating field. This reorientation of the magnetic dipoles generates heat within the magnetic material. When an object is both conductive and magnetic, penetrating a fluctuating magnetic field can produce 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, which allows for rapid temperature rise and more uniform heat distribution within the object. This can be achieved, among other things, by appropriately selecting the object's material and geometry, and the 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, thereby increasing design freedom and control over the heating profile, while reducing costs.

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

Each format may be provided with a mouthpiece of a different length. The mouthpiece length will be approximately 30mm to 50mm. The tipping paper connects the mouthpiece to the aerosol-generating material and is typically longer than the mouthpiece, for example by 3-10mm, so that the tipping paper covers the mouthpiece and overlaps the aerosol-generating material, which may be 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 relative 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 its derivatives or substitutes. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Tobacco material may include one or more of powdered tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco, and/or tobacco extract.

As used herein, the terms "flavorant" and "flavoring agent" refer to materials that are permitted by local regulations and that can be used to impart a taste or aroma desired by an adult consumer to a product. In some embodiments, a sensate may include or consist of a flavoring agent. One or more flavoring agents can be used as aerosol modifiers as described herein.

Such ingredients include extracts (e.g., licorice, hydrangea, magnolia leaf, chamomile, fenugreek, clove, menthol, Japanese peppermint, 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) , ylang-ylang, sage, fennel, pimento, ginger, anise, coriander, coffee, peppermint oil from any species of the genus Mentha, etc.), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, 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 blends thereof. These materials may be in any suitable form, such as oils, liquids, or powders.

The same reference numbers are used throughout this specification and drawings to indicate equivalent features, items, or components.

Figure 1 is a cross-sectional side view of an article for use in an aerosol generating device 1, or, as used herein, an article for use in a non-combustion-based aerosol delivery system.

The article 1 includes a mouthpiece 2 and a cylindrical rod 3 made of an aerosol-generating material, in this example tobacco, connected to the mouthpiece 2.

A mouthpiece wrapper 5, also referred to as tipping paper 5, is wrapped around the entire length of the mouthpiece 2 and a portion of the rod 3 of aerosol-generating material, has 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 aerosol-generating material rod 3, but may alternatively extend 3 mm to 10 mm, more preferably 4 mm to 6 mm, over the rod to ensure secure attachment of the mouthpiece 2 to the rod 3. The basis weight of the tipping paper 5 is greater than the basis weight of plug wrappers used for articles intended for use in the aerosol-generating device 1, for example, 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 tipping paper that is flexible enough to wrap the article 1 while having acceptable tensile strength, and that adheres to itself along the paper's longitudinal hold-down seam. The circumference of the tipping paper 5 when wrapped around the mouthpiece 2 is approximately 21 mm.

In some embodiments of one aspect of the present disclosure, an article is provided for use in an aerosol delivery system, comprising an aerosol-generating material or substrate, a mouthpiece downstream of the aerosol-generating material, and a wrapper, the wrapper comprising a sensate.

The portion of the mouthpiece wrapper 5 near the downstream end of the mouthpiece 2 comes into contact with the consumer's lips during use.

Referring to FIG. 1a, the mouthpiece wrapper 5 includes a first end 5c that terminates at the downstream end 2b of the mouthpiece 2 and a second end opposite the first end 5c.

The wrapper 5 is arranged to extend around at least a portion of the aerosol-generating material 3 and at least a portion of the mouthpiece 2 of the article for use in the aerosol-generating device 1.

The mouthpiece wrapper 5 is thus positioned to wrap around and surround the mouthpiece 2 in the region between the upstream end 2a and downstream end 2B of the mouthpiece 2. The second end 5d extends beyond the upstream end 2a (not shown) of the mouthpiece 2 and across the portion of the aerosol-generating material 3 surrounded by the aerosol-generating material wrapper 10 (not shown), terminating midway along the length of the aerosol-generating material wrapper 10. The mouthpiece wrapper 5 may be positioned such that when the article 1 is inserted into a heating device, a portion of the mouthpiece wrapper 5 is heated to the same or similar temperature as the aerosol-generating material. In some embodiments, the first end 5c of the mouthpiece wrapper 5 defines a portion of the mouthpiece wrapper proximate the downstream end 2b of the mouthpiece, and the second end 5d of the mouthpiece wrapper 5 defines a portion of the mouthpiece wrapper proximate the aerosol-generating material 3.

The mouthpiece wrapper 5 includes a sensate 5a (shaded area). The sensate may include a flavoring agent as described herein. In some embodiments, the flavoring agent may be licorice, rose oil, vanilla, lemon oil, orange oil, mint flavoring, preferably menthol and/or peppermint oil and/or spearmint oil from any species of Mentha, or lavender, fennel, or anise. In preferred embodiments, the sensate includes sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol). Additionally or alternatively, the sensate may include a material that delivers a cooling, hot, or sour sensation to the consumer during use of the article.

In some embodiments, the sensory material may include one or more of a pH regulator, a stabilizer, and/or an antioxidant. These materials may help to extend the shelf life of the mouthpiece wrapper 5 and, therefore, the article 1.

The sensate can be encapsulated in an encapsulating material. For example, the sensate can be provided in the form of microcapsules that are applied to the wrapper 5. Encapsulating the sensate can provide various benefits. For example, as described below, the sensate can include or consist of a flavorant having a desired taste or aroma. Encapsulation can extend the longevity of the taste and/or aroma.

In particular, the encapsulation of the sensory material may enhance the longevity of the sensory material's scent by enhancing the flavor detected by the user. Thus, the scent continues to be detected by the user even after the flavor has diminished (e.g., when the flavor is no longer detectable by the user or has become less detectable to the consumer), enhancing the user experience.

The encapsulated sensate also helps mask other scents emitted by components of the article for use in a non-combustion aerosol delivery system before or during use.

The encapsulated sensate may emit a scent indicative of the flavor of the sensate. For example, the scent may alert the user to the flavor of the sensate, thereby making it easier for the user to quickly identify the flavor of the sensate.

The mouthpiece wrapper 5 includes an inwardly facing surface and an outwardly facing surface, and the sensate may be present on at least a portion of the inwardly facing surface and/or the outwardly facing surface of the wrapper. As shown in FIG. 1a, the sensate 5a may be disposed on the outwardly facing surface of the mouthpiece wrapper 5 in the area that will contact the consumer's lips during use. By disposing the sensate 5a on the outwardly facing surface of the mouthpiece wrapper 5, the sensate may be transferred to the consumer's lips during use. Transferring the sensate to the consumer's lips during use of the article may modify the organoleptic properties (e.g., taste) of the aerosol generated by the aerosol-generating substrate 3. For example, the sensate 5a may impart a flavor to the aerosol generated by the aerosol-generating substrate. The sensate 5a may be at least partially soluble in water so that it is transferred to the user via the consumer's saliva.

In some embodiments, the sensory material 5a may include an aerosol modifier, such as a sensory material that is volatilized by heat generated by the article 1, thereby promoting transfer of the sensory material 5a into the aerosol generated by the aerosol-generating substrate 3.

Additionally or alternatively, sensate 5a may be disposed on the inwardly facing surface of mouthpiece wrapper 5. In such an embodiment, sensate 5a may modify the aerosol emitted by aerosol-generating substrate 3 as it travels from the aerosol-generating substrate to the downstream end of mouthpiece 2.

The temperature of the mouthpiece 2 can be significantly higher than the temperature to which a consumer is accustomed when smoking, for example, a conventional cigarette. Because the mouthpiece wrapper 5 is positioned to wrap around at least a portion of the aerosol-generating substrate 3 (which heats up during use of the article 1), the mouthpiece wrapper 5 heats up during use of the article 1. In some embodiments, the temperature of the portion of the mouthpiece wrapper 5 closest to the aerosol-generating substrate 3 reaches about 300°C or less, about 350°C or less, or about 400°C or less or more during use. The temperature of the mouthpiece wrapper 5 decreases between the end of the mouthpiece wrapper 5 closest to the aerosol-generating substrate 3 and the end of the mouthpiece wrapper 5 closest to the mouthpiece 2 of the article. The higher temperature achieved by the mouthpiece 2 (and therefore the mouthpiece wrapper 5), relative to, for example, a conventional cigarette 1, aids in the transfer of the sensory material 5a to the consumer.

In some embodiments, the article 1 is configured so that when the aerosol-generating substrate 3 is heated to above about 200°C, the temperature of the portion of the mouthpiece wrapper 5 closest to the aerosol-generating substrate 3 is at least about 60%, at least about 70%, at least about 80%, or at least about 90% higher than the temperature of the portion of the mouthpiece wrapper 5 closest to the downstream end of the mouthpiece.

In some embodiments, the temperature of the portion of the mouthpiece wrapper 5 near the downstream end of the mouthpiece 2 is between about 30°C and about 45°C. In a preferred embodiment, the temperature of the portion of the mouthpiece wrapper 5 near the downstream end of the mouthpiece 2 is between about 36°C and 43°C.

The sensate 5a may be located in a portion of the mouthpiece wrapper 5 that reaches relatively high temperatures (e.g., a portion of the mouthpiece wrapper 5 that is close to the aerosol-generating substrate). The sensate 5a may volatilize at these high temperatures during use of the article 1 and may modify the aerosol emitted by the aerosol-generating substrate 3 (e.g., by being entrained in the aerosol-generating substrate). This may change (e.g., enhance) the organoleptic properties of the aerosol.

Alternatively or additionally, the sensate 5a may be located in a portion of the mouthpiece wrapper 5 that is closer to the mouthpiece 2 of the article 1. This portion of the mouthpiece wrapper 5 is cooler than the portion of the mouthpiece wrapper 5 that is closer to the aerosol-generating substrate 3. This provides a more suitable location on the mouthpiece wrapper 5 for certain sensates, such as sensates that cannot withstand high temperatures and/or sensates intended to be transferred directly to the consumer's lips from the outward-facing surface of the mouthpiece wrapper 5. The mouthpiece wrapper 5 may be impregnated with the sensate 5a such that the sensate 5a is present on the outward-facing surface of the mouthpiece wrapper 5, the inward-facing surface of the mouthpiece wrapper 5, or the entire mouthpiece wrapper 5.

Advantageously, a relatively small amount of sensate 5a is required to modify the sensory properties delivered to the consumer during use of article 1, although this will depend to some extent on the nature of sensate 5a, as the minimum amount required to alter the sensory properties will vary for different sensates. This is advantageous because adding a sensate to mouthpiece wrapper 5 does not result in a significant increase in the final weight of article 1.

The mouthpiece wrapper 5 comprises sensate 5a in an amount of about 0.3 g/ ^m2 by weight of the mouthpiece wrapper 5 or less, about 0.2 g/ ^m2 by weight of the mouthpiece wrapper 5 or less, or about 0.1 g/ ^m2 by weight of the mouthpiece wrapper 5 or less. The mouthpiece wrapper 5 may comprise sensate 5a in an amount of about 0.01 g/ ^m2 to about 0.3 g/ ^m2 . In a preferred embodiment, the mouthpiece wrapper 5 comprises sensate in an amount of about 0.02 g/ ^m2 to about 0.2 g/ ^m2 .

It is desirable for approximately 100% of the surface area of the inwardly facing and/or outwardly facing surfaces to comprise the sensory material 5a. In other words, approximately 100% of the inwardly facing and/or outwardly facing surfaces may be coated with the sensory material 5a.

The sensory material 5a may not coat the entire inwardly and/or outwardly facing surface of the mouthpiece wrapper 5. Region 5b of the mouthpiece wrapper 5 may be free or substantially free of sensory material 5a. In other words, a portion of the surface area of the inwardly and/or outwardly facing surface may be free of sensory material 5a. By coating only certain portions of the inwardly and/or outwardly facing surface with sensory material and leaving the remaining portions free of sensory material, the manufacturing costs of the mouthpiece wrapper 5 may be reduced.

In some embodiments, the portion of the wrapper near the aerosol-generating material or the downstream end of the mouthpiece contains a sensate, and the portion of the wrapper near the other of the aerosol-generating material and the downstream end of the mouthpiece does not contain a sensate.

In some embodiments, less than about 90%, about 80%, about 70%, about 60%, about 50%, about 40%, about 30%, about 20%, or about 10% of the surface area of the inwardly and/or outwardly facing surfaces comprises sensate 5a. Sensate 5a may form a coating that extends along less than about 10%, about 20%, about 30%, about 40%, about 50%, about 60%, about 70%, about 80%, or about 90% of the inwardly and/or outwardly facing surfaces from the first end of the mouthpiece wrapper 5.

The concentration of sensate 5a may vary from the first end of the mouthpiece wrapper 5 to the portion of the mouthpiece 5 closest to the sensate. For example, the portion of the mouthpiece wrapper 5 closest to the aerosol-generating material 3 may contain a relatively low concentration of sensate 5a, while the portion of the mouthpiece wrapper 5 closer to the downstream end of the mouthpiece 2 may contain a relatively high concentration of sensate 5a. The concentration of sensate 5a may gradually increase from the portion of the mouthpiece wrapper 5 closest to the aerosol-generating material 3 to the portion of the mouthpiece wrapper 5 closer to the downstream end 2b of the mouthpiece 2.

The mouthpiece wrapper 5 may include at least one sensate 5a. When the mouthpiece wrapper 5 includes two or more sensate materials 5a, the inwardly and/or outwardly facing surface of the mouthpiece wrapper 5 includes a homogenous mixture of the sensate materials. Alternatively, the sensate materials may be disposed in separate, distinct regions on the inwardly and/or outwardly facing surface of the mouthpiece wrapper 5. The inclusion of two or more sensate materials can alter the sensory characteristics of the aerosol emitted by the aerosol-generating substrate 3 during use of the article 1, thereby enhancing the sensory characteristics of the aerosol.

The sensate 5a may be disposed to form a discontinuous coating on the inwardly and/or outwardly facing surfaces of the mouthpiece wrapper 5. A pattern may be formed by coating the sensate on the inwardly and outwardly facing surfaces of the mouthpiece wrapper 5. For example, the sensate 5a may be coated on the outwardly facing surface of the mouthpiece wrapper 5 as a series of discrete dots or lines of sensate.

As shown in FIG. 1b, the mouthpiece wrapper 5 includes a sensate disposed on a surface of the flat sheet of mouthpiece wrapper 5. The flat sheet of mouthpiece wrapper 5 may be wrapped around at least a portion of the mouthpiece 2 and at least a portion of the aerosol-generating material 3. This method may be used to manufacture an article 1 including the mouthpiece wrapper 5.

The mouthpiece wrapper 5 may be manufactured by applying a sensory material 5a to at least a portion of the mouthpiece wrapper 5. In some embodiments, at least a portion of the mouthpiece wrapper 5 is coated with the sensory material 5a. This may be done, for example, by printing the sensory material on the surface of the mouthpiece wrapper 5 or by dipping at least a portion of the mouthpiece wrapper 5 in the sensory material. Printing the sensory material on the surface of the mouthpiece wrapper 5 is advantageous because it may speed up the manufacture of the mouthpiece wrapper 5.

Preferably, the mouthpiece wrapper 5 is made from a non-porous material having a breathability of, for example, less than about 100 Coresta units, less than about 90 Coresta units, less than about 80 Coresta units, less than about 70 Coresta units, less than about 60 Coresta units, or less than about 50 Coresta units. In a preferred embodiment, the wrapper has a breathability of less than about 60 Coresta units. Forming the mouthpiece wrapper 5 from a non-porous material helps prevent leaching of the sensate from the mouthpiece wrapper 5 during storage or use of the article 1. For example, if the sensate is disposed on the outward-facing surface of the mouthpiece wrapper 5, the sensate will not be absorbed throughout the mouthpiece wrapper. This increases the shelf life of the article.

In some embodiments of one aspect of the present disclosure, there is provided a method for manufacturing an article for use in an aerosol generating device described herein, the method comprising coating at least a portion of a wrapper with a sensate. In some embodiments of one aspect of the present disclosure, there is provided an article for use in an aerosol generating device manufactured by this method.

In an embodiment according to an aspect of the present disclosure, a system is provided that includes an article for use in an aerosol-generating device as described herein and a device for heating an aerosol-generating material. The apparatus of the present invention may be configured to house at least a portion of an article for use in an aerosol-generating device that includes an aerosol-generating material, and to heat that portion of the article for use in an aerosol-generating device that includes an aerosol-generating material to generate an aerosol from the aerosol-generating material.

The device of the present invention may be configured to heat the aerosol-generating material to at least 200°C so that the temperature of the portion of the wrapper closest to the aerosol-generating material is at least about 60%, at least about 70%, at least about 80%, or at least about 90% higher than the temperature of the portion of the wrapper closest to the downstream end of the mouthpiece.

The device of the present invention may include a coil arranged to heat the portion of the article for use in an aerosol-generating device containing an aerosol-generating material.

Referring again to FIG. 1 , the aerosol-generating material 3, also referred to herein as the aerosol-generating substrate 3, includes at least one aerosol-forming material. In this example, the aerosol-forming material is glycerin. In other examples, the aerosol-forming material may be another material described herein, or a combination thereof. The aerosol-forming material has been found to improve the sensory performance of the article by assisting 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 an aerosol-generating material in an article for use in a non-combustion aerosol delivery system presents a problem in that as the aerosol-forming material aerosolizes 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, it transfers heat into the mouthpiece, which warms the exterior of the mouthpiece, including the area that contacts the consumer's lips during use. The temperature of the mouthpiece may be significantly higher than the temperature to which a consumer is accustomed when smoking, for example, a cigarette, which can be an undesirable effect of using such an aerosol-forming material.

As shown in FIG. 1, 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. The mouthpiece includes a hollow tube 4, also referred to herein as a hollow tubular member. At the downstream end 2b, the mouthpiece 2 has a hollow tubular member 4 formed from filamentary tow, as shown in FIG. 1. 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. Additionally, 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 believed that this is due to directing the aerosol closer to the center of the mouthpiece 2, thereby reducing the transfer of heat from the aerosol to the exterior surface of the mouthpiece 2.

In another embodiment, the mouthpiece 2 does not include a hollow tubular member 4. In such an embodiment, the mouthpiece 2 may include a material (not shown) that allows fluid to pass between the aerosol-generating substrate 3 and the downstream end 2b of the mouthpiece 2. For example, the mouthpiece may include a porous material, such as a plug of filter material.

In this example, Article 1 has a circumference of approximately 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 of 15 mm to 25 mm. Because the article is heated to release the aerosol, improved heating efficiency can be achieved by using an article with a smaller circumference within this range, for example, a circumference of 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 of 19 mm to 23 mm, more preferably 20 mm to 22 mm, have been found to provide a good balance of efficient heating while effectively delivering aerosol.

The circumference of the mouthpiece 2 is substantially the same as the circumference of the rod 3 of aerosol-generating material, which allows for a smooth connection between these components. In this example, the circumference of the mouthpiece 2 is approximately 20.8 mm.

In the illustrated embodiment, the mouthpiece wrapper is wrapped around the entire length of the mouthpiece 2 and a portion of the rod 3 of aerosol-generating material, has adhesive on its inner surface, and connects the mouthpiece 2 to the rod 3. In this example, the tipping paper 5 extends 5 mm around the rod of aerosol-generating material, but may alternatively extend 3 mm to 10 mm, more preferably 4 mm to 6 mm, around 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 wrap used for the article 1, for example, 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 tipping paper that is flexible enough to wrap the article 1 while having acceptable tensile strength, and that adheres to itself along the paper's longitudinal hold-down seam. 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 1.0 mm or greater. 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 at any point around the circumference of the hollow tubular member 4, more preferably 1.0 mm or greater.

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 the good stiffness provided by high-density materials and the low thermal conductivity of low-density materials. For purposes of this invention, the "density" of the hollow tubular member 4 refers to the density of the filamentary tow 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, and the total volume can be calculated using appropriate measurements of the hollow tubular member 4, for example using a vernier caliper. If necessary, appropriate dimensions can also 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 preferred embodiments, 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 tow forming the hollow tubular member 4 preferably has 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 tow forming the hollow tubular member 4 has a denier per filament of 4 to 10, more preferably 4 to 9. In one example, the filamentary tow forming the hollow tubular member 4 is formed from cellulose acetate, e.g., an 8Y40,000 tow containing 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 the aerosol traveling through the mouthpiece 2 and into the consumer's mouth at a faster than desired rate, causing the aerosol to become too warm, for example reaching temperatures 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 approximately 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, although 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.

The pressure drop or pressure differential (also referred to as resistance to draw) across the mouthpiece, e.g., the portion of the article 1 downstream of the aerosol-generating material 3, is preferably less than about 40 _mmH2O . Such a pressure drop has been found to allow sufficient aerosol, including flavor compounds, to be transferred to the consumer through the mouthpiece 2. More preferably, the pressure drop across the mouthpiece 2 is less than about _{32 mmH2O} . In some embodiments, particularly improved aerosols have been achieved using mouthpieces 2 having a pressure drop of less than 31 _mmH2O , e.g., about 29 mmH2O, about 28 _mmH2O , or about 27.5 _mmH2O. Alternatively or additionally, the mouthpiece pressure drop is at least 10 _mmH2O , preferably at least 15 _mmH2O , and more preferably at least 20 _mmH2O . In some embodiments, the mouthpiece pressure drop may be between about 15 _mmH2O and 40 _mmH2O . These values allow the mouthpiece 2 to slow down 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 to, abutting, and upstream of the hollow tubular member 4 in this example. 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 less than 50 gsm, more preferably between about 20 gsm and 40 gsm. Preferably, the first plug wrapper 7 has a thickness of between 30 μm and 60 μm, more preferably between 30 μm and 45 μm. Preferably, the first plug wrapper 7 is a non-porous plug wrapper having a breathability 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 a breathability of, for example, greater 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 between about 5 mm and about 15 mm, more preferably between about 6 mm and about 12 mm, even more preferably between about 6 mm and about 12 mm, and most preferably about 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In this example, the length of the body of material 6 is 10 mm.

In this example, the body 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, for example, a denier per filament (d.p.f.) of 9.5 and a total denier of 12,000. In this example, the tow comprises plasticized cellulose acetate tow. The plasticizer used in the tow comprises approximately 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 example, for use in cigarettes. Alternatively, the body 6 can be formed from tow other than cellulose acetate, such as polylactic acid (PLA), other materials described herein for filamentary tow, or similar materials. Preferably, the tow is formed from cellulose acetate. The tow, whether formed from cellulose acetate or another material, 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 with a narrow surface area that reduces mouthpiece pressure drop than tows that are relatively coarse and thick and have lower 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 of material 6 is preferably at most 30,000, more preferably at most 28,000, and even more preferably at most 25,000. These total denier values provide the tow with a smaller percentage of the cross-sectional area of the mouthpiece 2, resulting in a lower pressure drop across the mouthpiece 2 than tows having higher total denier values. For adequate hardness of the body of material 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 to 12, and the total denier is 10,000 to 25,000. More preferably, the denier per filament is 6 to 10, and the total fineness is 11,000 to 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. values provided herein may be any of the d.p.f ... 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 abuts 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 multiple 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; however, in other examples, three, four, or more layers may be used to form triple, quadruple, or more stacked tubes. Other constructions, such as spirally wound paper layers, cardboard tubes, tubes formed using a composite paper-molding 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. This stiff plug wrapper and/or tipping paper is manufactured to have sufficient stiffness to withstand axial compression and bending movements that may occur during manufacturing 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 within these ranges to achieve an acceptable level of stiffness for the second hollow tubular member 8.

The second hollow tubular member 8 has a wall thickness of at least about 100 μm and not 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, measured in the same manner as the first hollow tubular member 4. 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 heated volatile components generated by the aerosol-generating material 3 flow. The second hollow tubular member 8 is hollow to provide a chamber for aerosol deposition, yet is rigid enough to withstand axial compressive forces and bending movements that may occur during manufacturing and while the article 1 is in use. The second hollow tubular member 8 provides physical movement between the aerosol-generating material 3 and the body of material 6. The physical movement provided by the second hollow tubular member 8 provides a temperature gradient along the length of the second hollow tubular member 8.

Preferably, the mouthpiece 2 includes a cavity having an internal volume greater than 450 ^mm . It has been found that providing a cavity of at least this volume results in good aerosol formation. Because heated volatile components would otherwise result in a warm aerosol, such a cavity size provides sufficient space within the mouthpiece 2 to cool the volatile components, thereby exposing the aerosol-generating material 3 to higher temperatures than would otherwise be present. In this example, the cavity is formed by the second hollow tubular member 8, but in alternative configurations, it could 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 500 ^mm , and even more preferably greater than 550 ^mm , further enhancing aerosol formation. In some examples, the internal cavity includes a volume of about 550 ^mm to about 750 ^mm , e.g., about 600 ^mm or 700 ^mm .

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 along the length of the second hollow tubular member 8 protects the temperature-sensitive body 6 from the high temperatures of the aerosol-generating material 3 when heated.

In other articles, the second hollow tubular member 8 may be replaced by another cooling member, for example a member formed from a 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 30 μm to 60 μm, more preferably between 35 μm and 45 μm. The second plug wrapper 9 is preferably a non-porous plug wrapper having a breathability 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 a breathability of, for example, greater than 200 Coresta units.

In this example, the aerosol-generating material 3 is enclosed in a wrapper 10. The wrapper 10 may be, for example, a paper or paper-backed foil wrapper. In this example, the wrapper 10 is substantially airtight. In another embodiment, the wrapper 10 preferably has a breathability of less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that wrappers with low breathability, for example less than 100 Coresta units, more preferably less than 60 Coresta units, result in improved aerosol formation at the aerosol-generating material 3. Without wishing to be bound by any theory, this is believed to be due to reduced loss of aerosol compounds through the wrapper 10. The breathability of the wrapper 10 can be measured in accordance with ISO 2965:2009, which relates to the measurement of air permeability of materials used as cigarette paper, 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 aerosol formation within the aerosol-generating material 3. In this example, the aluminum foil has a metal layer approximately 6 μm thick. In this example, the aluminum foil has a backing. However, in alternative configurations, the aluminum foil may have other thicknesses, for example, a thickness of 4 μm to 16 μm. The aluminum foil also does not require a backing, but may have a backing formed from another material that, for example, helps to provide the foil with adequate tensile strength, or may have no backing at all. Metal layers or foils other than aluminum may also be used. The total thickness of the wrapper is preferably 20 μm to 60 μm, more preferably 30 μm to 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, 3,000 to 10,000 gram-force or 3,000 to 4,500 gram-force.

In addition to or alternatively to applying a sensate 5a as described herein to the mouthpiece wrapper 5, a sensate as described herein can be applied to the wrapper 10 that encases the aerosol-generating material. For example, the sensate can be applied to the wrapper 10 as a coating and/or impregnated into the material of the wrapper 10. The sensate can be encapsulated in microcapsules, which can be used, for example, as a coating on the wrapper 10 or can be contained within the fibrous structure of the wrapper 10. In these embodiments, the wrapper can include a metal foil, such as aluminum foil. The aluminum foil can be provided with a paper backing, as described above.

The article has a ventilation level of approximately 75% of the aerosol drawn through the article. In another embodiment, the article may have a ventilation level of 50% to 80%, e.g., 65% to 75%, of the aerosol drawn through the article. These levels of ventilation assist in slowing 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. Ventilation is provided directly within the mouthpiece 2 of the article 1. In this example, ventilation is provided within the second hollow tubular member 8, which has been found to be particularly beneficial in assisting the aerosol generation process. Ventilation is provided via first and second parallel rows of perforations 12, in this case formed as laser drilling, located 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 within the mouthpiece, such as within 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, more preferably at least 10% by weight, of the aerosol-generating substrate. Preferably, the aerosol-forming material comprises less than 25% by weight, more preferably less than 20% by weight, for example, 10% to 20%, 12% to 18%, or 13% to 16% of the aerosol-generating substrate.

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 approximately 10 mm to 100 mm. In some embodiments, the length of the aerosol-generating material is preferably in the range of approximately 25 mm to 50 mm, more preferably in the range of approximately 30 mm to 45 mm, and even more preferably in the range of approximately 30 mm to 40 mm.

The volume of the aerosol-generating material 3 provided may vary from about 200 ^mm to about 4300 ^mm , preferably from about 500 ^mm to 1500 ^mm , and more preferably from about 1000 ^mm to about 1300 ^mm . Providing these volumes of aerosol-generating material, for example from about 1000 ^mm to about 1300 ^mm , has been shown to advantageously achieve 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, about 200 mg to 400 mg, preferably about 230 mg to 360 mg, and more preferably about 250 mg to 360 mg. In some embodiments, the aerosol-generating substrate may be about 250 mg to about 380 mg, about 300 mg to about 360 mg, about 320 mg to about 350 mg, or about 330 mg to about 350 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. Preferably, the aerosol-generating material includes a tobacco component.

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

The aerosol-generating material 3 may include reconstituted tobacco material having a density of less than about 700 milligrams per cubic centimeter (mg/cc). Such tobacco materials have been found to be particularly effective in providing an aerosol-generating material that can heat up quickly to release an aerosol compared to denser materials. For example, the inventors have tested the heating properties of various aerosol-generating materials, including band-cast reconstituted tobacco material and paper reconstituted tobacco material. For each given aerosol-generating material, during the application of heat to the material, there exists a specific zero heat flow temperature below which the net heat flow becomes endothermic, i.e., more heat enters the material than exits it, and above which the net heat flow becomes exothermic, i.e., more heat exits the material than enters it. Materials with densities less than 700 mg/cc have low zero heat flow temperatures. Because a significant portion of the heat flow exiting the material is via the formation of an aerosol, having a low zero heat flow temperature has a beneficial effect on the time it takes to initially release an aerosol from the aerosol-generating material. For example, aerosol-generating materials with densities less than 700 mg/cc were found to have zero heat flow temperatures below 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 is transferred through the material; low densities, e.g., less than 700 mg/cc, result in a slower rate of heat transfer through the material, thus allowing for more sustained aerosol release.

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

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 approximately 1.7 mm). Preferably, the shredded tobacco has a cut width of at least 18 pieces per inch (approximately 7.1 pieces per centimeter, equivalent to a cut width of approximately 1.4 mm), more preferably at least 20 pieces per inch (7.9 pieces per centimeter, equivalent to a cut width of approximately 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 approximately 1.15 mm). Preferably, the shredded tobacco has a cut width of at least 40 pieces per inch (approximately 15.7 pieces per centimeter, equivalent to a cut width of approximately 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. The shredded tobacco can be formed from a mixture of tobacco material forms, such as a mixture with one or more of reconstituted tobacco, leaf tobacco, extruded tobacco, and band-cast tobacco. Preferably, the tobacco material comprises reconstituted tobacco or a mixture of reconstituted tobacco and leaf tobacco.

The tobacco material described herein 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 wood fiber or a non-tobacco fiber such as 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, or magnesium carbonate. 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 some embodiments, no filler component is included.

In the tobacco materials described herein, the tobacco material includes an aerosol-forming material. In this context, an "aerosol-forming material" is a chemical that facilitates the generation of an aerosol. The aerosol-forming material may facilitate the generation of an aerosol by promoting the initial evaporation and/or condensation of a gas 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-forming material or forming agent may be included in the aerosol-generating materials of the present invention, including those described herein. Other suitable aerosol-forming materials 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 hydrocarbons; acids such as lactic acid; glycerin derivatives; esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate or myristates including ethyl myristate and isopropyl myristate; and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate. In some embodiments, the aerosol-forming material may be glycerin, propylene glycol, or a mixture of glycerin and propylene glycol. Glycerin may be present in an amount of 10-20% by weight of the tobacco material, e.g., 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 any component, such as any component comprising tobacco material and/or filler material, if any. Alternatively or additionally, the aerosol-forming material may be added separately to the tobacco material. In either case, the total amount of aerosol-forming material in the tobacco material may be as described herein.

The tobacco material may comprise 10-90% by weight of tobacco leaf, with the aerosol-forming material being provided in an amount of about 10% by weight of the tobacco leaf. It has been found advantageous to add a higher weight percentage of the aerosol-forming material to another component of the tobacco material, such as reconstituted tobacco, to achieve a total amount of aerosol-forming material of 10%-20% by weight of the tobacco material.

The tobacco material described herein contains nicotine. The nicotine content may be 0.5-1.75% by weight of the tobacco material, for example, 0.8-1.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material comprises 10-90% by weight of tobacco leaf having a nicotine content greater than 1.5% by weight of the tobacco leaf. In a preferred embodiment, the tobacco material comprises tobacco leaf in an amount of about 10% to about 30% by weight of the tobacco component. It has been found advantageous to use tobacco leaf having a nicotine content greater than 1.5% in combination with a low-nicotine-based material, such as reconstituted tobacco, to obtain a tobacco material that contains an adequate amount of nicotine but has better sensory performance than reconstituted tobacco alone. Tobacco leaf, e.g., shredded tobacco, may have a nicotine content of, for example, 1.5%-5% by weight of the tobacco leaf.

The tobacco material described herein may also include an aerosol modifying agent, such as any of the flavorants 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 menthol loadings are achieved by using a high percentage of reconstituted tobacco material, e.g., greater than 50% by weight of tobacco material. Alternatively or additionally, the use of a high-volume aerosol-generating material, e.g., tobacco material, can increase the menthol loading achieved when aerosol-generating material, e.g., tobacco material, greater than about 500 ^mm³ , or preferably greater than 1000 ^mm³, is used.

For the avoidance of doubt, when amounts are expressed in terms of weight percent in the compositions described herein, this refers to a dry weight basis unless otherwise specified. Accordingly, any water present in the tobacco material or any of its components is completely disregarded for purposes of measuring weight percent. The moisture content of the tobacco material described herein may vary, e.g., from 5 to 15 weight percent. The moisture content of the tobacco material described herein may vary depending, for example, on the temperature, pressure, and humidity conditions under which the composition is maintained. Moisture content may be measured by Karl-Fisher analysis, as known to those skilled in the art. For the avoidance of doubt, all components other than water are included in the weight of the tobacco material, even if the aerosol-forming material is a liquid-phase component, such as glycerin or propylene glycol. However, if an aerosol-forming material is provided in the tobacco components of the tobacco material or in the filler element (if any) of the tobacco material instead of or in addition to being added separately to the tobacco material, the aerosol-forming material is not included in the weight of the tobacco composition or filler element, but is included in the weight of the "aerosol-forming material" in the weight percents specified herein. All other components present in the tobacco composition, even if they are non-tobacco-derived (e.g., non-tobacco fiber in the case of reconstituted tobacco), are included by weight of the tobacco component.

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

Reconstituted tobacco is present in the tobacco component of the tobacco material described herein in an amount of 10% to 100% by weight of the tobacco component. Preferably, the tobacco component comprises reconstituted tobacco material in an amount of about 70% to 90% by weight of the tobacco component. In some embodiments, reconstituted tobacco is present in an amount of 10% to 80% or 20% to 70% by weight of the tobacco component. In other embodiments, the tobacco component consists essentially of reconstituted tobacco or consists of reconstituted tobacco. In a preferred embodiment, leaf tobacco is present in the tobacco component of the tobacco material in an amount of at least about 10% by weight of the tobacco component. For example, leaf tobacco may be present in an amount of at least 10% by weight of the tobacco component, with the remainder of the tobacco component comprising a combination of reconstituted tobacco, band-cast tobacco, or band-cast reconstituted tobacco and another form of tobacco, such as tobacco particles.

In preferred embodiments, the tobacco component may comprise reconstituted tobacco material in an amount of about 70% to about 90% by weight of the tobacco component. In some embodiments, leaf tobacco is present in an amount of about 10% to about 30% by weight of the tobacco component.

Reconstituted tobacco refers to tobacco material formed by a process in which raw tobacco 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 removal of 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 raw materials including one or more of tobacco strips, tobacco stems, and whole leaf tobacco. In other embodiments, the reconstituted tobacco is produced from raw materials consisting of tobacco strips and/or whole leaf tobacco and tobacco stems. However, in other embodiments, waste, fines, and rice husk may alternatively or additionally be employed in the raw materials.

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

Figure 2a is a side cross-sectional view of another article 1' including a capsule-containing mouthpiece 2'. Figure 2b is a cross-sectional view of the capsule-containing mouthpiece taken along line A-A' in Figure 2a. The article 1 and capsule-containing mouthpiece 2' are the same as the article 1 and mouthpiece 2 illustrated in Figure 1, except that the aerosol modifier is provided within the body of material 6, in this example in the form of capsules 11, and an oil-resistant first plug wrapper 7' surrounds the body of material 6. In some embodiments, the aerosol modifier may be encapsulated within a capsule. In other examples, the aerosol modifier may be provided in other forms, such as a material infused 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. According to some embodiments, the body of material includes the aerosol modifier disposed therein.

The capsule 11 may comprise a frangible capsule, for example a capsule having a solid, frangible shell enclosing a liquid payload. In this example, a single capsule 11 is used. The capsule 11 is fully embedded within the body of material. In other words, the capsule 11 is completely 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 the required number of capsules. 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.

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

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

In this example, the capsule 11 is positioned at the longitudinal center within the material body 6. That is, the capsule 11 is positioned so that its center is 4 mm away from both ends of the material body 6. In other examples, the capsule 11 may be positioned at a position other than the longitudinal center of the material body 6, i.e., closer to the downstream end of the material body 6 than the upstream end, or closer to the upstream end of the material body 6 than the downstream end. Preferably, the mouthpiece 2' is configured so 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 2b, taken through line A-A' in Figure 2a. Figure 2b shows the capsule 11, body of material 6, first and second plug wrappers 7', and tipping paper 5. In this example, the capsule 11 is centered on the longitudinal axis (not shown) of the mouthpiece 2'. The first and second plug wrappers 7', 9, and tipping paper 5 are concentrically arranged around the body of material 6.

The frangible capsule 11 has a core-shell structure. That is, 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 the aerosol modifier, during use.

In some cases, the barrier material (also referred to as the encapsulant) is frangible. The capsule can be 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; more specifically, the shell can be ruptured by pressure applied by the user's fingers when the user wishes to release the capsule's core.

In some cases, the barrier material is heat resistant. That is, in some cases, the barrier does not 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 ranging from 30°C to 100°C, for example, 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, which melts or ruptures 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.

Capsules according to the present invention include a core and a shell, as described above. The capsules may exhibit a crush strength of about 4.5 N to about 40 N, more preferably about 5 N to about 30 N or about 28 N (e.g., about 9.8 N to about 24.5 N). Capsule crush strength can be measured using a gauge that removes the capsule from the body 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 have a diameter of at least about 0.4 mm, 0.6 mm, 0.9 mm, 1.0 mm, 1.2 mm, 1.4 mm, 1.6 mm, 1.8 mm, 1.9 mm, 2.0 mm, 2.2 mm, 2.4 mm, 2.6 mm, 2.8 ...
The capsules may have a diameter of 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 capsules may have a diameter of about 0.4 mm to about 10.0 mm, about 0.8 mm to about 6.0 mm, about 2.5 mm to about 5.5 mm, or 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.

In some embodiments, the body of material is cylindrically shaped having a longitudinal axis, the capsule is embedded within the body of material such that the capsule is surrounded on all sides by the material forming the body of material, the capsule has a shell encapsulating the liquid aerosol modifier, and the maximum cross-sectional area of the capsule measured perpendicular to the longitudinal axis is less than 28% of the cross-sectional area of the body of material measured perpendicular to the longitudinal axis.

The cross-sectional area of capsule 11 at its largest cross-sectional area is, in some embodiments, less than 28%, more preferably less than 27%, and even more preferably less than 25% of the cross-sectional area of the portion of mouthpiece 2' in which capsule 11 is located. For example, for a spherical capsule having a diameter of 3.0 mm, the maximum cross-sectional area of the capsule is 7.07 ^mm² . As described herein, for a mouthpiece 2' having a circumference of 21 mm, the body of material 6 has an outer periphery of 20.8 mm, resulting in a radius of 3.31 mm, corresponding to a cross-sectional area of 34.43 ^mm² . The cross-sectional area of the capsule is, in this example, 20.5% of the cross-sectional area of mouthpiece 2'. As another example, if the capsule has a diameter of 3.2 mm, its maximum cross-sectional area is 8.04 ^mm² . In this case, the cross-sectional area of the capsule is 23.4% of the cross-sectional area of body of material 6. A capsule having a maximum cross-sectional area that is 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, leaving adequate space for the aerosol around the capsule so that the aerosol can pass through the mouthpiece 2' without the body of material 6 removing any significant amounts of bulk aerosol as it passes through the mouthpiece 2'.

Preferably, the pressure drop or pressure differential (also known as resistance to draw), measured as the opening pressure drop (i.e., ventilation opening open), decreases by less than 8 _mmH2O when the capsule is broken. More preferably, the opening pressure drop decreases by less than 6 _mmH2O , and more preferably by less than 5 _mmH2O . These values are measured as averages obtained across at least 80 articles made with the same design. Such small pressure drop changes mean that other aspects of 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.

In some embodiments, when the aerosol-forming material 3 is heated to provide an aerosol, for example, in a non-combustion aerosol delivery device described herein, the portion of the mouthpiece 2 in which the capsule is located reaches a temperature of 58-70°C during use of the system to generate an aerosol. As a result of this temperature, the contents of the capsule are sufficiently warmed to promote volatilization of the capsule's contents, e.g., aerosol-generating agent, into the aerosol formed by the system as the aerosol passes through the mouthpiece 2. Warming of the contents of the capsule 11 may occur before the capsule 11 is broken, for example, so that upon breakage, the contents are more likely to be released into the aerosol passing through the mouthpiece. Alternatively, the contents of the capsule 11 may be warmed to this temperature after the capsule 11 is broken, again resulting in greater release of the contents into the aerosol. A mouthpiece temperature in the range of 58-70°C has been found to be advantageous as it is high enough to make the capsule contents more likely to be released, but low enough so that the outer surface of the portion of the mouthpiece 2 where the capsule is located reaches a temperature that would be uncomfortable for a consumer to touch in order to rupture the capsule 11 by squeezing the mouthpiece 2.

The temperature of the portion of the mouthpiece 2 where the capsule 11 is located can be measured using a digital thermometer with a piercing probe positioned so that the probe passes through the wall of the mouthpiece 2 (which is sealed around the probe to limit the amount of outside air that can get into the mouthpiece) and enters the mouthpiece 2 near the location of the capsule 11. Similarly, a temperature probe can be placed on the exterior surface of the mouthpiece 2 to measure the temperature of the exterior surface.

Table 1.0 below shows the temperature at the capsule location in mouthpiece 2 of an article used in an aerosol delivery system during the first five puffs. Data is shown for the article when heated using a coil heating device as described herein with reference to Figures 3-7 using a "standard" heating profile, and for the same article when heated using the same device using a "boost" heating profile. The "boost" heating profile is user selectable and allows for higher temperatures.

As shown in Table 1.0, the temperature of the mouthpiece 2 where the capsule 11 is located reaches a maximum of 61.5°C for the "Standard" heating profile and a maximum of 63.8°C for the "Boost" heating profile. A maximum temperature in the range of 58°C to 70°C, preferably in the range of 59°C to 65°C, and more preferably in the range of 60°C to 65°C, has been found to be advantageous in that it aids in volatilizing the contents of the capsule 11 and maintains a suitable exterior temperature of the mouthpiece 2.

The capsule 11 can be broken by an external force applied to the mouthpiece 2, for example, by a consumer crushing the mouthpiece 2 using a finger or other mechanism. As described above, the portion of the mouthpiece in which the capsule is located is positioned to reach a temperature of greater than 58°C during use of the aerosol delivery system to generate an aerosol. Preferably, the capsule 11, when placed in the mouthpiece 2 and prior to heating of the aerosol-forming material 3, has a burst strength of 1,500 to 4,000 grams-force. Preferably, the capsule 11, when placed in the mouthpiece 2 and after using the aerosol delivery system to generate an aerosol for less than 30 seconds, has a burst strength of 1,000 to 4,000 grams-force. As a result, even when exposed to temperatures greater than 58°C, e.g., 58°C to 70°C, the capsule 11 can maintain a burst strength within a range known to allow a consumer to easily crush the capsule 11, and still provide the consumer with sufficient tactile feedback that the capsule 11 has been broken. Maintaining such burst strength can be achieved by selecting a suitable gelling agent for the capsule as described herein, such as gum arabic, gellan gum, acacia gum, xanthan gum, or polysaccharides, including carrageenan, either alone or in combination with gelatin. Additionally, the capsule wall should be selected to have a suitable thickness.

Preferably, the capsules have a burst strength of 2000 to 3500 grams force or 2500 to 3500 grams force when placed in the mouthpiece and before the aerosol-forming material is heated. Preferably, the burst strength of the capsules when placed in the mouthpiece and after the aerosol delivery system is used to generate an aerosol for 30 seconds or less is 1500 to 4000 grams force or 1750 to 3000 grams force. In one example, the average burst strength of the capsules when placed in the mouthpiece and before the aerosol-forming material is heated is approximately 3175 grams force, and the average burst strength of the capsules when placed in the mouthpiece and after the aerosol delivery system is used to generate an aerosol for 30 seconds or less is approximately 2345 grams force.

The burst strength of the capsules can be tested using a load-measuring device such as a Texture Analyser. For the present burst strength test, a Type TA.XTPlus Texture Analyser was used with a 6 mm diameter circular metal probe centered at the capsule location (i.e., 12 mm from the mouth end of the mouthpiece 2). The test speed of the probe was 0.3 mm/sec, a pre-test speed of 5.00 mm/sec was used, and a post-test speed of 10 mm/sec was used. The load used was 5000 g. The tested article was then slid into the syringe using a Borgwaldt A14 Syringe drive unit.
The known Health Canada Intense puffing regime (55 ml puff volume for 2 seconds every 30 seconds) was followed using standard testing equipment. Three puffs were administered using this regime, and the capsule burst strength was measured within 30 seconds of the third puff. The tested article was identical to Article 1 shown in Figures 1a and 1b and described in more detail below, except that it had an 8 mm hollow tubular member 4 at the mouth end formed from two layers of paper wound parallel to each other with abutted seams and bonded together to a total thickness of 300 μm. The capsule was a 3 mm diameter capsule placed within an 8 mm length of cellulose acetate tow with a tow specification of 9.5Y12,000 and a target of 9% triacetin plasticizer.

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

Preferably, 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 some embodiments, 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 gum, acacia gum, guar, quince seed gum, and xanthan gum. Suitable gels include agar, agarose, carrageenan, fleudan, and fructosellan. 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 capsules is particularly suitable.

Barrier materials 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 within the aerosol generating device during the manufacturing process of the aerosol generating device. The colorant is preferably selected from colorants 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 mono-, di-, or tri-acid acid, such as citric acid, fumaric acid, or malic acid. The amount of plasticizer ranges from 1 to 30% by weight, preferably from 2 to 15% by weight, and even more preferably from 3 to 10% by weight, of the total dry weight of the shell.

The barrier material also contains one or more filler materials. Suitable filler materials include starch derivatives such as dextrin, maltodextrin, cyclodextrin (alpha, beta, or gamma), cellulose derivatives such as hydroxypropylmethylcellulose (HPMC), hydroxypropylcellulose (HPC), methylcellulose (MC), carboxymethylcellulose (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 to 95% by weight, more preferably 40 to 80% by weight, and even more preferably 50 to 60% by weight, based on the total dry weight of the shell.

The capsule shell may additionally comprise a hydrophobic outer layer to prevent the capsule from being disintegrated by moisture. The hydrophobic outer layer is preferably selected from the group including waxes, especially 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 substance that alters at least one property of the aerosol. For example, the aerosol substance may alter the pH, sensory characteristics, moisture content, delivery characteristics, or flavor. In some embodiments, the aerosol modifier may be selected from acids, bases, water, or flavoring agents. In some embodiments, the aerosol modifier includes one or more flavoring agents.

The flavouring may be licorice, rose oil, vanilla, lemon oil, orange oil, a mint flavouring, preferably menthol and/or peppermint oil from any species of the Mentha genus, such as peppermint oil and/or spearmint oil, 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 contain at least about 25% w/w flavorant (based on the total weight of the core), preferably at least about 30% w/w, 35% w/w, 40% w/w, 45% w/w, or 50% w/w flavorant. In some cases, the core may contain up to about 75% w/w flavorant (based on the total weight of the core), preferably up to about 65% w/w, 55% w/w, or 50% w/w flavorant. Specifically, the capsule may contain 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.

Capsules may contain at least about 2 mg, 3 mg, or 4 mg of aerosol modifier, preferably at least about 4.5 mg, 5 mg, 5.5 mg, 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 includes a flavoring agent, the solvent may preferably include a short- or medium-chain fat. For example, the solvent may include a triester of glycerin, such as a C2-C12 triglyceride, preferably a C6-C10 triglyceride or a Cs-C12 triglyceride. For example, the solvent may include a medium-chain triglyceride (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, and 85409-09-2. Such medium-chain triglycerides are tasteless and odorless.

The hydrophilic-lipophilic balance (HLB) of the solvent may be in the range of 9 to 13, preferably 1 to 12. The capsules may be produced by extrusion, optionally followed by centrifugation and hardening and/or drying. The contents of International Application Publication No. 2007/010407 A2 are incorporated by reference in their entirety.

In the above example, mouthpieces 2, 2' each include a single body of material 6. In other examples, either the mouthpiece of Figure 1 or Figures 2a and 2b may include multiple bodies of material. 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 a 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 inner or outer facing surface of the mouthpiece wrapper. For example, the aerosol modifier may be provided in an area of the wrapper, such as the outer facing surface of the tipping paper 5, that contacts the consumer's lips during use. By disposing the aerosol modifier on the outer 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 a 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 the heat generated by the aerosol delivery system, which makes it easier for the aerosol modifier to migrate into the aerosol generated by the aerosol-generating substrate 3.

A 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, thereby allowing thermal energy to 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 induction 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 induction heating of the at least one electrically conductive heating element, may be referred to as an "induction coil" or "inductor coil."

The device may include one or more heating elements, such as one or more 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, such as at least one conductive heating element, may be included in an article 1, 1' for insertion into the heating zone of the device, the article 1, 1' including the aerosol-generating material 3, and removed from the heating zone after use. Alternatively, the device and such article 1, 1' may each include at least one heating element, such as at least one conductive heating element, and the coil may cause heating of the one or more heating elements of the device and article, respectively, when the article is in the heating zone.

In some cases, the coil is helical. In some cases, the coil surrounds at least a portion of a heating region of a device configured to contain the aerosol-generating material. In some cases, 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 instances, the use of a coil allows a non-combustion aerosol delivery device to reach 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 operating temperature so that the first puff can be provided in less than 30 seconds, preferably less than 25 seconds, from activation of the device heating program. In some instances, the device can reach operating temperature in about 20 seconds from activation of the device heating program.

The use of a coil such as that described herein in a device 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 (FMCs) than aerosols produced by other non-combustion aerosol delivery systems. While not wishing to be bound by any theory, this is presumed to be due to the reduced time required to reach the required heating temperature when using a coil, the higher heating temperatures achieved when using a coil, and/or the coil 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 FMCs. 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. This hot aerosol is understood to release flavor compounds from the tobacco in the rod behind the burning ember. It is believed that devices including coils such as those 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, it is possible to generate an aerosol from the aerosol-generating material having certain characteristics that are believed to be more similar to the aerosols of FMC products. For example, when an aerosol-generating material containing nicotine is heated to at least 250°C for 2 seconds using an induction heater, one or more of the following characteristics have been observed:
At least 10 μg of nicotine is aerosolized from the aerosol-generating material;
the weight ratio of aerosol-forming material to nicotine in the generated aerosol is at least about 2.5:1, preferably at least 8.5:1;
At least 100 μg of 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 during the two second period under an airflow of at least 1.50 L/m. 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 during the two second period under an airflow of at least 1.50 L/m.

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

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

In some cases, the average particle size or droplet size of the generated aerosol may be less than 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 aerosol density 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.

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, higher temperatures of aerosol can be generated from the aerosol-generating material of the articles 1, 1' described herein than previous devices that contribute to the generation of aerosols that are considered more akin to FMC products when the aerosol exits the mouth end of the mouthpiece 2, 2'. For example, the maximum aerosol temperature measured at the mouth end of the articles 1, 1' is preferably greater than 50°C, more preferably greater than 55°C, and even more preferably greater than 56°C or 57°C. Additionally or alternatively, the maximum aerosol temperature measured at the mouth end of the articles 1, 1' is less than 62°C, more preferably less than 60°C, and more preferably less than 59°C. In some embodiments, the maximum aerosol temperature measured at the mouth end of the articles 1, 1' is preferably between 50°C and 62°C, more preferably between 56°C and 60°C.

Figure 3 shows an example of a non-combustion aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium/material, such as the aerosol-generating material 3 of articles 1, 1' described herein. In general, device 100 may be used to heat an exchangeable article 110 containing an aerosol-generating medium, such as articles 1, 1' described herein, to generate an aerosol or other inhalable medium that is inhaled by a user of device 100. Device 100 and exchangeable article 110 together form a system.

Device 100 includes a housing 102 (in the form of an outer cover) that surrounds and contains the various components of device 100. Device 100 has an opening 104 at one end through which an item 110 is inserted for heating by the heating assembly. In use, 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. While the lid 108 is shown in an open configuration in FIG. 3, the lid 108 may also be moved to a closed configuration. For example, a user slides the lid 108 in the direction of arrow "B."

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

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

Figure 4 shows the device 100 of Figure 3 with the outer cover 102 removed and the item 110 absent. The device 100 defines a longitudinal axis 134.

As shown in FIG. 4 , the first end member 106 is disposed at one end of the device 100, and the 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. The 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 nearest the opening 104 is also known as the proximal end (or mouth end) of the device 100 because it is closest to the user's mouth during use. In use, the 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 it is the end that faces 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 122. 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 the various electronic components of the device 100 together. 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 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 for heating an electrically conductive object (such as a susceptor) by electromagnetic induction. The induction heating assembly may include an induction element, e.g., one or more inductor coils, and a device for passing a varying current, such as an alternating current, through the induction element. The varying current in the induction element generates a varying magnetic field. The varying magnetic field penetrates a susceptor, preferably positioned relative to the induction element, and generates eddy currents inside the susceptor. The susceptor has an electrical resistance to the eddy currents, and therefore, 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 within the susceptor, i.e., by changes in the orientation of the magnetic dipoles of the magnetic material as a result of matching the varying magnetic field. With induction heating, heat is generated inside the susceptor, allowing for faster heating than with conduction heating, for example. Furthermore, there is no need for any physical contact between the induction heater and the susceptor, allowing for greater flexibility in design and application.

The induction heating assembly of the example device 100 includes a susceptor structure 132 (hereinafter "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first and second inductor coils 124, 126 are made from an electrically conductive material. In this example, the first and second inductor coils 124, 126 are made from Litz wire/cable, which is wound in a spiral to provide the helical inductor coils 124, 126. Litz wire includes multiple individual wires, which 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 cross sections, such as circular.

The first inductor coil 124 is configured to generate a first varying magnetic field for heating a first section of the susceptor 132, and the second inductor coil 126 is configured to generate a second varying magnetic field for heating a second section of the susceptor 132. In this example, the first inductor coil 124 is adjacent to the second inductor coil 126 in a direction along the longitudinal axis 134 of the device 100 (i.e., the first 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.

It should be appreciated that 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. 4, the first and second inductor coils 124, 126 are different lengths such that the first inductor coil 124 is wound around 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 the spacing between 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 the second inductor coil 126 may be activated later 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 circuitry. In FIG. 4, 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 receptacle within which the aerosol-generating material is contained. 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, which 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 first and second materials, which 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 third and fourth materials, which 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 comprise, for example, carbon steel or aluminum.

The device 100 of FIG. 4 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 plastic. In this particular example, the insulating member is constructed from polyetheretherketone (PEEK). The insulating member 128 serves to insulate the 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. 4, 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 cases, 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 5 is a side view, partially in cross section, of device 100. Outer cover 102 is shown in this example. The rectangular cross-sectional shapes of first and second inductor coils 124, 126 are more clearly visible.

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 provide 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 placed within the device 100. The expansion chamber 144 is connected to the end member 106.

Figure 6 is an exploded view of the device 100 of Figure 5 with the outer cover 102 removed.

Figure 7A shows a cross section of a portion of the device 100 of Figure 5. Figure 7B is an enlarged view of a region of Figure 7A. Figures 7A and 7B show an article 110 contained within a susceptor 132, with the article 110 sized so that its outer surface abuts the inner surface of the susceptor 132, thereby providing the most efficient heating. In this example, the article 110 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 wrap and/or a cooling structure.

Figure 7B shows that the outer surface of the susceptor 132 is separated from the inner surfaces 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.

FIG. 7B further shows 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 is approximately 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 approximately 0.025 mm to 1 mm, or approximately 0.05 mm.

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

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

In use, the article 1, 1' described herein is inserted into a non-combustion aerosol delivery device, such as the device 100 described with reference to Figures 3-7. 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 in the user's mouth. An aerosol is generated by heating the aerosol-generating material 3 using the device 100. The aerosol generated by the aerosol-generating material 3 travels through the mouthpiece 2 and into the user's mouth.

The articles 1, 1' described herein are particularly advantageous when used in non-combustion aerosol delivery devices, such as the device 100 described with reference to Figures 3-7. 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 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 at a longitudinal position corresponding to the position of the hollow tubular member 4 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.

Table 2.0 below shows the temperature of the outer surface of the article 1 described with reference to Figure 1 when heated using the device 100 described with reference to Figures 3-7. 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 2.0) was 4 mm from the downstream end 2b of the mouthpiece 2, the second position (numbered as Position 2 in Table 2.0) was 8 mm from the downstream end 2b of the mouthpiece 2, and the third position (numbered as Position 3 in Table 2.0) was 12 mm from the downstream end 2b of the mouthpiece 2.

Accordingly, the first position was the outer surface of the portion of the mouthpiece 2 where the first tubular member 4 was located, and the second and third positions were the outer surfaces of the portion of the mouthpiece 2 where 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-wound 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 peaks 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 (55 ml 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 a 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 decreased by more than 7°C after the first three puffs and by more than 5°C after the fourth and fifth puffs.

FIG. 8 illustrates a method of manufacturing an article for use in a non-combustion aerosol delivery system. In step S101, first and second portions of aerosol-generating material, each containing 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 then 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 approximately 5 mm over the outer surface of each portion 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, which 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 twice the length of the mouthpiece rod, 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 understanding and teaching the claimed features. These embodiments are merely representative examples and are not intended to be comprehensive or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and/or other aspects of the present disclosure should not be construed as limiting the disclosure to the exact scope of the claims or to the equivalents thereof, and 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 elements, components, features, parts, steps, means, or other combinations. The present disclosure also encompasses other inventions not currently claimed but which may be claimed in the future.

Claims (24)

1. An article for use in a non-combustion based aerosol delivery system, the article comprising:
A mouthpiece and
an aerosol-generating material;
a mouthpiece wrapper;
the mouthpiece wrapper includes a sensate, the mouthpiece wrapper having an inwardly facing surface and an outwardly facing surface, the sensate being present on at least a portion of the outwardly facing surface of the mouthpiece wrapper, and the mouthpiece wrapper being positioned to extend around at least a portion of the aerosol-generating material and at least a portion of the mouthpiece of the article;
Goods. The article of claim 1, wherein the mouthpiece includes an upstream end and a downstream end, and the mouthpiece wrapper is positioned to wrap around and surround the mouthpiece of the article in the region between the upstream and downstream ends of the mouthpiece. The article of claim 2, wherein the mouthpiece wrapper is configured so that, when the mouthpiece wrapper is wrapped around the mouthpiece of the article, a portion of the mouthpiece wrapper near the downstream end of the mouthpiece is positioned to contact the consumer's lips. The article of claim 2 or 3, wherein the sensate is disposed on the mouthpiece wrapper such that, when the mouthpiece wrapper is wrapped around the article, the sensate is positioned to transfer to the consumer's lips. The article of any one of claims 1 to 4, wherein the sensate is present on at least a portion of the inwardly facing and outwardly facing surfaces of the mouthpiece wrapper. The article of claim 5, wherein the inwardly facing surface and/or the outwardly facing surface of the mouthpiece wrapper contains a sensate in an amount of 0.02 g/m2 to 0.2 g/m2. The article of claim 5 or 6, wherein less than 90%, less than 80%, less than 70%, less than 60%, less than 50%, less than 40%, less than 30%, less than 20%, or less than 10% of the surface area of the inwardly facing and/or outwardly facing surface comprises a sensate. An article as claimed in any one of claims 1 to 7, wherein the mouthpiece wrapper is impregnated with the sensate and/or the sensate is provided in encapsulated form. The article of any one of claims 1 to 8, wherein the sensory material includes a flavoring agent. The article of any one of claims 1 to 9, wherein the mouthpiece wrapper has a breathability of less than 100 Coresta units, less than 90 Coresta units, less than 80 Coresta units, less than 70 Coresta units, or less than 60 Coresta units. The article of any one of claims 1 to 10, wherein the sensory material includes an aerosol modifying agent. The article described in claim 11, characterized in that the aerosol modifying agent is configured to volatilize when heated. The article of any one of claims 1 to 12, wherein the mouthpiece wrapper is for use with an article having a circumference of at least 19 mm. The article of any one of claims 1 to 13, wherein the mouthpiece wrapper comprises aluminum foil. The article of any one of claims 1 to 14, wherein one or more regions of the mouthpiece wrapper are free or substantially free of the sensate. The article of any one of claims 1 to 15, wherein the concentration of the sensate varies between the first end and the second end of the mouthpiece wrapper. The article of any one of claims 1 to 16, wherein the mouthpiece wrapper comprises two or more sensates. The article of claim 1, wherein the article includes an area for containing an aerosol-generating material. The article of claim 18, wherein the area for containing the aerosol-generating material is a storage area for storing the aerosol-generating material. The article described in claim 18 or 19, wherein the aerosol-generating material is in the form of a liquid or gel. The article described in any one of claims 18 to 20, characterized in that the article includes an aerosol-generating member. The article described in claim 21, wherein the aerosol-generating member is a heater. The article of claim 22, wherein the heater is configured to heat the aerosol-generating material to at least 200°C. The article of claim 22 or 23, wherein the heater includes a coil.