JP7771238B2 - Articles for use in aerosol delivery systems - Google Patents

Description

The present disclosure relates to articles for use in non-flammable aerosol delivery systems, non-flammable aerosol delivery systems including the articles, and methods of manufacturing articles for use in non-flammable aerosol delivery systems.

Certain tobacco industry products generate an aerosol during use, which is inhaled by the user. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, to form an aerosol through non-combustion heating of the substrate. Such tobacco industry products typically include a mouthpiece through which the aerosol passes to the user's mouth.

According to an embodiment of the present invention, in a first aspect, there is provided an article for use in a non-combustible aerosol delivery system, the article comprising a first aerosol-generating material and a component downstream of the first aerosol-generating material, the component comprising a tubular portion, the tubular portion comprising a wall containing a second aerosol-generating material.

According to an embodiment of the present invention, in a second aspect, there is provided an article for use in a non-combustible aerosol delivery system, the article comprising a first aerosol-generating material and a component downstream of the first aerosol-generating material, the component comprising a body of material, the body of material including a second aerosol-generating material.

According to an embodiment of the present invention, in a third aspect, there is provided a method of forming the article described in the first aspect, the method comprising applying an aerosol-generating material to a wall of the tubular portion.

According to an embodiment of the present invention, in a fourth aspect, there is provided a method of forming the article of the second aspect, the method comprising applying an aerosol-generating material to a body of material.

According to a further embodiment of the present invention, there is provided a non-combustible aerosol delivery system comprising an article according to the first or second aspect above and a non-combustible aerosol delivery device.

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

1 is a side cross-sectional view of an article for use with a non-combustion aerosol delivery device, the article including a mouthpiece including a tubular portion. FIG. 1 is a side cross-sectional view of an article for use with a non-combustible aerosol delivery device, in this example a mouthpiece including a hollow tubular element. FIG. 1 is a side cross-sectional view of an article for use with a non-combustible aerosol delivery device, in this example a mouthpiece including a capsule-containing mouthpiece. 3b is a cross-sectional view of the capsule-containing mouthpiece shown in FIG. 3a. FIG. FIG. 2 is a perspective view of a non-combustion aerosol delivery device suitable for generating aerosols from the aerosol-forming materials of the articles of FIGS. 1, 2, 3a, and 3b. FIG. 5 shows the device of FIG. 4 with the outer cover removed and no item present. FIG. 5 is a partial cross-sectional side view of the device of FIG. 4. FIG. 5 is an exploded view of the device of FIG. 4 with the outer cover omitted. FIG. 5 is a cross-sectional view of a portion of the device of FIG. 4. FIG. 8B is an enlarged view of a region of the device of FIG. 8A. 1 is a flow chart illustrating a method of manufacturing an article for use with a non-combustion aerosol delivery device.

Detailed Description
As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user, including:
combustible aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for hand-rolled or handmade cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials);
Included are non-combustion aerosol delivery systems that release compounds from aerosol-forming materials without burning them, such as electronic cigarettes, tobacco heating products, and mixing systems for generating aerosols using combinations of aerosol-forming materials, as well as aerosol-free delivery systems that deliver at least one substance to a user orally, nasally, transdermally, or otherwise without forming an aerosol, whether or not the at least one substance contains nicotine, including oral products such as, but not limited to, lozenges, gums, patches, articles containing inhalable powders, and oral tobacco products including snus or moist snuff.

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

In some embodiments, the delivery system is a combustible aerosol delivery system, such as a system selected from the group consisting of a cigarette, a cigarillo, and a cigar.

In some embodiments, the present disclosure relates to components for use in combustible aerosol delivery systems, such as filters, filter rods, filter segments, tobacco rods, spills, aerosol modifier-releasing components, such as capsules, threads or beads, or papers, such as plug wrap, tipping paper, or cigarette paper.

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

In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as a powered non-combustible aerosol delivery system.

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

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

In some embodiments, the non-combustion aerosol delivery system is a mixing system that generates an aerosol using a combination of aerosol-forming materials, and one or more of the aerosol-forming materials may be heated. Each of the aerosol-forming materials may be, for example, in solid, liquid, or gel form, and may or may not contain nicotine. In some embodiments, the mixing system includes a liquid or gel aerosol-forming material and a solid aerosol-forming material. The solid aerosol-forming material may include, for example, tobacco or a non-tobacco product.

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

In some embodiments, the present disclosure relates to consumables comprising aerosol-generating materials configured for use with non-combustible aerosol delivery devices. These consumables may also be referred to as articles throughout this disclosure.

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

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

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

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

As used herein, an active substance can be a bioactive material, i.e., a material intended to achieve or promote a physiological response. The active substance can be selected from, for example, functional foods, nootropics, and psychotropic drugs. The active substance can be naturally occurring or synthetically obtained. The active substance can include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance can include one or more components, derivatives, or extracts of tobacco extract, cannabis, or another botanical substance.

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

An aerosol-generating material is a material capable of generating an aerosol when excited, for example, by heating, irradiation, or in any other manner. The aerosol-generating material can be, for example, in the form of a solid, liquid, or gel, and may or may not contain active substances and/or flavorings. In some embodiments, the aerosol-generating material can comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid can be a dry gel. An amorphous solid is a solid material that can hold a fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material can comprise, for example, from about 50%, 60%, or 70% by weight of an amorphous solid to about 90%, 95%, or 100% by weight of an amorphous solid.

In certain embodiments, the aerosol-forming material comprises a cellulosic and/or non-cellulosic gelling agent, an active agent, and an acid-containing gelling agent.

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

In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginic acid, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginic acid, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, polydimethylsiloxane (PDMS), sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the gelling agent comprises alginic acid and/or pectin, which can be combined with a hardening agent (such as a calcium source) during the formation of the amorphous solid. In some cases, the amorphous solid can comprise calcium-crosslinked alginic acid and/or calcium-crosslinked pectin.

In some embodiments, the cellulosic gelling agent is selected from the group consisting of hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), acetylpropionylcellulose (CAP), and combinations thereof.

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

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

The aerosol-generating material may include an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monobasic acid, a dibasic acid, and a tribasic acid. In some such embodiments, the acid may contain at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid may be an alpha-keto acid.

In some such embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propionic acid, and pyruvic acid.

Preferably, the acid is lactic acid. In other embodiments, the acid is benzoic acid. In other embodiments, the acid can be an inorganic acid. In some of these embodiments, the acid can be a mineral acid. In some such embodiments, the acid can be at least one of sulfuric acid, hydrochloric acid, boric acid, and phosphoric acid. In some embodiments, the acid is levulinic acid.

In embodiments in which the aerosol-forming material includes nicotine, it is particularly preferred to include an acid. In such embodiments, the presence of an acid can stabilize dissolved species in the slurry from which the aerosol-forming material is formed. The presence of an acid can reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing nicotine loss during manufacturing.

In some embodiments, the aerosol-generating material comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabiclovarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabielsoin (CBE), and cannabicitran (CBT).

The aerosol-forming material may include one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

The aerosol-forming material may include cannabidiol (CBD).

The aerosol-forming material may include nicotine and cannabidiol (CBD).

Aerosol-forming materials may include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

In some embodiments, the amorphous solid comprises 1-60% by weight of a gelling agent, 0.1-50% by weight of an aerosol-forming material, and 0.1-80% by weight of a flavoring agent, these weights being calculated on a dry weight basis.

In some further embodiments, the amorphous solid comprises 1-50% by weight of a gelling agent, 0.1-50% by weight of an aerosol former, and 30-60% by weight of a flavoring agent, these weights being calculated on a dry weight basis.

In some further embodiments, the amorphous solid comprises an aerosol-forming material in an amount of about 40-80% by weight of the amorphous solid, a gelling agent, and an optional filler (i.e., in some instances, the filler is present in the amorphous solid and in other instances, the filler is absent from the amorphous solid), the combined amount of the gelling agent and filler being about 10-60% by weight of the amorphous solid (i.e., the gelling agent and filler together comprise about 10-60% by weight of the amorphous solid), and optionally, the amorphous solid comprises an active agent and/or flavoring agent in an amount of up to about 20% by weight of the amorphous solid (i.e., the amorphous solid comprises 20% or less by weight of the active agent).

Amorphous solid materials can be formed from dried gels. It has been found that using the component ratios discussed above means that once the gel hardens, the flavor compounds are stabilized within the gel matrix, allowing for greater flavor loading than non-gel compositions. The flavor (e.g., menthol) is stable at high concentrations, and the product has a good shelf life.

In some cases, the amorphous solid may have a thickness of about 0.015 mm to about 1.5 mm. Preferably, the thickness may be within the range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm, 0.3 mm, or 1 mm. The inventors have found that in some embodiments, a material having a thickness of 0.2 mm is particularly suitable. The amorphous solid may include two or more layers, and the thicknesses described herein refer to the combined thicknesses of those layers.

If the amorphous solid is too thick, heating efficiency is compromised, which has a negative impact on power consumption during use. Conversely, if the amorphous solid is too thin, it becomes difficult to manufacture and handle; very thin materials are more difficult to cast and can be fragile, compromising aerosol formation during use.

The amorphous solid can suitably contain from about 1%, 5%, 10%, 15%, 20%, 25%, 30%, or 35% to about 60%, 55%, 50%, 45%, 40%, or 35% by weight of gelling agent (all calculated on a dry weight basis). For example, the amorphous solid can contain 1-60%, 5-60%, 20-60%, 25-55%, 30-50%, 35-45%, 5-45%, 10-40%, or 20-35% by weight of gelling agent.

In some embodiments, the amorphous solid comprises alginic acid and pectin, and the ratio of alginic acid to pectin is between 1:1 and 10:1. The ratio of alginic acid to pectin is typically greater than 1:1, i.e., alginic acid is present in an amount greater than the amount of pectin. In examples, the ratio of alginic acid to pectin is between about 2:1 and 8:1, or between about 3:1 and 6:1, or about 4:1.

In some embodiments, the amorphous solid comprises a filler in an amount of 1-30% by weight of the amorphous solid, e.g., 5-25% by weight, or 10-20% by weight. In examples, the amorphous solid comprises a filler in an amount greater than 1%, 5%, or 8% by weight of the amorphous solid. In examples, the amorphous solid comprises a filler in an amount less than 40%, 30%, 20%, 15%, 12%, 10%, 5%, or 1% by weight of the amorphous solid. In other examples, the amorphous solid does not comprise a filler.

In examples, the amorphous solids comprise gelling agent and filler in an amount, combined, of about 10%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, or about 60% by weight. In examples, the amount of gelling agent and filler combined is less than or equal to 85%, 80%, 75%, 70%, 65%, or 60% by weight of the amorphous solids. In examples, the amorphous solids comprise gelling agent and filler in an amount, combined, of about 20-60%, 25-55%, 30-50%, or 35-45% by weight of the amorphous solids.

When present, the filler may include one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, e.g., molecular sieves. The filler may include one or more organic filler materials such as wood pulp, cellulose, and cellulose derivatives. In certain cases, the amorphous solid does not include calcium carbonate, such as chalk.

In some examples that include a filler, the filler may be fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler in an amorphous solid can increase the tensile strength of the material.

In some instances, the amorphous solid does not include tobacco fiber. In certain instances, the amorphous solid does not include fibrous material.

In some embodiments, the amorphous solid can comprise from about 0.1%, 0.5%, 1%, 3%, 5%, 7%, or 10% to about 80%, 50%, 45%, 40%, 35%, 30%, or 25% by weight of the aerosol-forming material (all calculated on a dry weight basis). For example, the amorphous solid can comprise 0.5-40%, 3-35%, or 10-25% by weight of the aerosol-forming material.

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

The aerosol-forming material can include one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material includes one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols, such as glycerol monoacetate, diacetate, or triacetate; and/or aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

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

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

Thus, in some embodiments, the amorphous solid or aerosol-generating material can include a colorant or pigment. The addition of a colorant or pigment can alter the appearance of the amorphous solid or aerosol-generating material. The presence of a colorant in the amorphous solid or aerosol-generating material can enhance the appearance of the amorphous solid and/or aerosol-generating material. When present, adding a colorant to the amorphous solid can match the color of the amorphous solid to other components of the aerosol-generating material or other components of an article comprising the amorphous solid.

Depending on the desired color of the amorphous solid or aerosol-generating material, various colorants can be used. The color of the amorphous solid or aerosol-generating material can be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated. Natural or synthetic colorants can be used, such as natural or synthetic dyes, food-grade colorants, and pharmaceutical-grade colorants. In certain embodiments, the colorant is caramel, which can impart a brown appearance to the amorphous solid or aerosol-generating material. In such embodiments, the color of the amorphous solid or aerosol-generating material can be similar to the color of other components (e.g., tobacco material) in the aerosol-generating material that includes the amorphous solid. In some embodiments, the colorant is added to the amorphous solid to make the amorphous solid visually indistinguishable from other components in the aerosol-generating material.

The colorant can be incorporated into the amorphous solid or aerosol-forming material during its formation (e.g., when forming a slurry containing the materials that will form the amorphous solid or aerosol-forming material), or can be added to the amorphous solid after its formation (e.g., by spraying it onto the amorphous solid or aerosol-forming material).

The materials described herein can be present on or in a support to form a substrate. The support can be or include, for example, paper, card, paperboard, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is present on one or either side of the material.

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

Aerosol modifiers are substances configured to modify the generated aerosol, for example, by changing the taste, flavor, acidity, or another property of the aerosol, and are typically located downstream of the aerosol-generation zone. The aerosol modifier can be provided in an aerosol modifier-releasing component operable to selectively release the aerosol modifier.

The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, strings, or granules. The aerosol modifier may not include a filtration material.

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

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

Induction heating is a process by which a conductive object is heated by the penetration of a varying magnetic field into the object. This process is explained by Faraday's law of electromagnetic induction and Ohm's law. An induction heater may include an electromagnet and a device for passing a varying current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are suitably positioned relative to one another so that the resulting varying magnetic field produced by the electromagnet penetrates the object, one or more eddy currents are generated within the object. The object has a resistance to the flow of current. Therefore, when such eddy currents are generated within the object, they flow against the object's electrical resistance, causing the object to heat. This process is called Joule, Ohmic, 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, magnetic coupling between the susceptor and the electromagnet during use is enhanced, resulting in greater or improved Joule heating.

Magnetic hysteresis heating is a process by which an object made from a magnetic material is heated by the penetration of a varying magnetic field into the object. A magnetic material can be thought of as containing many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipoles become aligned with the field. Thus, when a varying magnetic field, such as an alternating magnetic field provided by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes with the variation of the applied field. This changing orientation of the magnetic dipoles generates heat within the magnetic material.

When an object is both conductive and magnetic, a fluctuating magnetic field penetrating the object can cause both Joule heating and magnetic hysteresis heating in the object. Furthermore, the magnetic field can be reinforced by the use of magnetic materials, thereby promoting Joule heating.

In each of the above processes, because heat is generated within the object itself rather than from an external heat source via thermal conduction, rapid temperature rise and more uniform heat distribution in the object can be achieved, particularly by selecting a suitable object material and geometry, as well as a suitable 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 varying magnetic field source and the object, allowing for greater design freedom and control and lower costs compared to heating profiles.

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

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

Thus, a king-size, super slim format item would have, for example, a length of approximately 83 mm and a circumference of approximately 17 mm.

The article can include an aerosol-generating material and a downstream portion downstream of the aerosol-generating material, and each type can be made with a downstream portion of a different length. The length of the downstream portion is typically about 30 mm to 50 mm. Tipping paper connects the downstream portion to the aerosol-generating material, and the tipping paper typically has a length greater than the downstream portion, for example, 3 to 10 mm longer, so that the tipping paper covers the downstream portion, for example, overlapping the aerosol-generating material in the form of a rod, connecting the downstream portion to the rod.

The articles described herein and their aerosol-generating materials and downstream portions can be made in any of the formats described above, including but not limited to:

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

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

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 ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco leaf, reconstituted tobacco, and/or tobacco extract.

As described herein, an active substance can include or be derived from one or more botanical substances or their components, derivatives, or extracts. As used herein, the term "botanical substance" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruit, pollen, pods, husks, and the like. Alternatively, the material can include an active compound naturally present in the botanical substance or a synthetically obtained active compound. The material can be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, sheets, and the like. Exemplary botanicals include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed (aniseed), basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, and the like. Mints include Mentha arvensis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrate c.v., Mentha arvensis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrate c.v., or any combination thereof. The mint species can be selected from the following: Mentha piperita c.v., Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v., and Mentha suaveolens.

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

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

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

In some embodiments, the substance to be delivered includes a fragrance.

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

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

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

The same reference numbers are used throughout the figures described herein to describe equivalent features, items, or components.

FIG. 1 is a cross-sectional side view of an article 1 for use with a non-combustion aerosol delivery system. In this example and other examples described herein, the article may be a tobacco heating consumable.

Article 1 comprises component 2, in this example, mouthpiece 2, and aerosol-generating material 3, in this case a cylindrical rod of tobacco material, connected to mouthpiece 2. The aerosol-generating material 3 delivers an aerosol when heated, for example, in a non-combustible aerosol delivery device described herein, such as a non-combustible aerosol delivery device comprising a coil, forming a system. In other embodiments, article 1 can include its own heat source, forming an aerosol delivery system, without the need for a separate aerosol delivery device. Alternatively, component 2 can comprise a portion of article 1 that is downstream from aerosol-generating material 3 and is not positioned to be received in a user's mouth.

The aerosol-forming 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 glycerol. Alternatively, the aerosol-forming material can be another material described herein or a combination thereof. It has been found that the aerosol-forming material improves the sensory performance of the article by aiding in the transfer of compounds, such as fragrance compounds, from the aerosol-generating material to the consumer. However, a problem with adding such aerosol-forming materials to the aerosol-generating material in an article for use in a non-combustible aerosol delivery system is that when the aerosol-forming material is aerosolized upon heating, it can increase the mass of the aerosol delivered by the article, which, in turn, can maintain a higher temperature as the aerosol passes through the mouthpiece. As the aerosol passes through the mouthpiece, it transfers heat into the mouthpiece, thereby warming the exterior surface of the mouthpiece, including the area that contacts the consumer's lips during use. Mouthpiece temperatures may be significantly higher than a consumer may be accustomed to when smoking, for example, a conventional cigarette, and undesirable effects may be caused by the use of such aerosol-forming materials.

In this example, the mouthpiece includes a tubular portion 4a, which in this example is formed by a hollow tube and is also referred to as a cooling element. In this example, the mouthpiece 2 includes a body of material 6 downstream of the tubular portion 4a, which in this example is adjacent to and in abutting relationship with the tubular portion 4a. The body of material 6 and the tubular portion 4a each define a substantially cylindrical overall outer shape and share a common longitudinal axis.

The body of material 6 is wrapped in a first plug wrap 7. In this example, the tubular portion 4a and the body of material 6 are combined using a second plug wrap 9 that wraps around both sections. Tipping paper 5 is wrapped around a portion of the rod of aerosol-forming material 3 along the entire length of the mouthpiece 2, and the tipping paper 5 has adhesive on its inner surface to connect the mouthpiece 2 and the rod 3.

In this example, the tubular portion has a wall containing a second aerosol-generating material 4b, which is an aerosol-generating material described herein, such as an amorphous solid material described herein.

The second aerosol-generating material 4b includes at least one aerosol-forming material and may also include at least one aerosol modifier or other sensate material. The aerosol-forming material and/or aerosol modifier may be any aerosol-forming material or aerosol modifier described herein, or a combination thereof.

In this example, the second aerosol-generating material 4b is disposed on the inner wall of the tubular portion 4a.

When the aerosol generated from the aerosol-generating material 3, referred to herein as the first aerosol, is inhaled through the tubular portion 4a of the mouthpiece, heat from the first aerosol can aerosolize the aerosol-forming material of the second aerosol-generating material 4b to form a second aerosol. The second aerosol can include flavorings that can be additional to or complementary to the flavoring of the first aerosol.

For example, providing a second aerosol-generating material 4b in the tubular portion 4a can result in the generation of a second aerosol that enhances or complements the scent or appearance of the first aerosol.

The second aerosol-generating material 4b may include microcapsules configured to release the aerosol-generating material when exposed to a hot aerosol, such as the first aerosol. The microcapsules may include a wax shell or other material configured to decompose at the temperature of the first aerosol. Alternatively, the second aerosol-generating material 4b may include a coating on the tubular portion. Alternatively, the second aerosol-generating material 4b may include a sheet material in the form of an amorphous solid, for example, as described herein.

The second aerosol-generating material 4b can be applied to the tubular portion 4a by any suitable method and in any suitable form, such as by painting, spraying, printing, sprinkling, or gluing a solution, slurry, sheet, or particles. In one example, the second aerosol-generating material 4b is applied as a sheet material adhered to the inner surface of the tubular portion 4a. The sheet material can be adhered to the paper or other material forming the inner surface of the tubular portion 4a before the formation of the tubular portion 4a. The sheet can be applied as one or more strips extending through the tubular portion. The strips can have a width of, for example, 0.5 mm to 10 mm or 0.75 mm to 5 mm. Alternatively, the sheet can be applied over substantially the entire inner surface of the tubular portion 4a. In another example, the second aerosol-generating material 4b is sprayed as a liquid onto the material forming the inner surface of the tubular portion 4a. This can be done, for example, before, during, or after the formation of the tubular portion 4a. The second aerosol-generating material 4b can be sprayed as a liquid in a pattern of longitudinal stripes along the length of the tubular portion 4a, or in a spiral or swirling pattern across the interior surface of the tubular portion 4a.

In an alternative embodiment, the body of material 6 may include a second aerosol-generating material 4b instead of or in addition to the tubular portion 4a. For example, the second aerosol-generating material may be sprayed directly into the material forming the cylindrical body of material 6.

In this example, the tubular portion 4a is formed from multiple layers of paper that are wound in parallel and abutted at seams to form a hollow tube. In this example, the first and second paper layers are provided as a double tube, but in other examples, three, four, or more paper layers can be used to form triple, quadruple, or more tubes. Other constructions can also be used, such as spirally wound paper layers, cardboard tubes, tubes formed using a paper mache-type process, molded or extruded plastic tubes, etc.

The tubular portion 4a can also be formed using stiff plug wrap and/or tipping paper as the second plug wrap 9 and/or tipping paper 5 described herein, meaning that separate tubular elements are not required. The stiff plug wrap and/or tipping paper is manufactured to have sufficient rigidity to withstand axial compressive forces and bending moments that may occur during manufacturing and use of the article 1. For example, the stiff plug wrap and/or tipping paper can have a basis weight of 70 gsm to 120 gsm, more preferably 80 gsm to 110 gsm. Additionally or alternatively, the stiff plug wrap and/or tipping paper can have a thickness of 80 μm to 200 μm, more preferably 100 μm to 160 μm, or 120 μm to 150 μm. It may be desirable to have values within these ranges for both the second plug wrap 9 and the tipping paper 5 to achieve an acceptable overall stiffness level for the tubular portion 4a.

The tubular portion 4a preferably has a wall thickness of at least about 100 μm to about 1.5 mm, preferably 100 μm to 1 mm, more preferably 150 μm to 500 μm, or about 300 μm. In this example, the tubular portion 4a has a wall thickness of about 290 μm. The "wall thickness" of the tubular portion 4a corresponds to the wall thickness of the tubular portion 4a in the radial direction. This can be measured, for example, using calipers.

In this example, Article 1 has a circumference of approximately 21 mm (i.e., the Article is in a demi-slim format). Preferably, Article 1 has an aerosol-generating material rod with a circumference greater than 19 mm. This has been found to provide a sufficient circumference to generate improved, sustained aerosol over a typical aerosol generation session, which is desirable for consumers. When the article is heated, heat is transferred through the aerosol-generating material rod 3, volatilizing the rod's components, and circumferences greater than 19 mm have been found to be particularly effective at generating aerosol in this manner. Because the article is heated to release the aerosol, improved heating efficiency can be achieved by using an article with a circumference less than approximately 23 mm. To maintain a suitable product length while achieving improved aerosol through heating, a rod circumference greater than 19 mm but less than 23 mm is preferred. In some examples, the rod circumference can be between 20 mm and 22 mm, which has been found to provide a good balance between efficient heating and effective aerosol delivery.

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

In some examples, article 1 can be configured so that there is a separation distance (i.e., a minimum distance) between the heater and tubular portion 4a of non-combustion aerosol delivery device 100. This prevents heat from the heater from damaging the material forming tubular portion 4a.

The minimum distance between the heater and the tubular portion 4a of the non-combustion aerosol delivery device 100 can be 3 mm or more. In some examples, the minimum distance between the heater and the tubular portion 4a of the non-combustion aerosol delivery device 100 can be within a range of 3 mm to 10 mm, for example, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm.

The separation distance between the heating element and the tubular portion 4a of the non-combustible aerosol delivery device 100 can be achieved, for example, by adjusting the length of the aerosol-generating material rod 3.

In this example, the tipping paper 5 extends 5 mm above the aerosol-forming material rod 3, but alternatively, it may extend 3 mm to 10 mm, or more preferably 4 mm to 6 mm, above the rod 3 to provide a secure attachment between the mouthpiece 2 and the rod 3. The tipping paper 5 may have a basis weight greater than that of the plug wrap used in the article 1, for example, 40 gsm to 80 gsm, more preferably 50 gsm to 70 gsm, in this example 58 gsm. It has been found that these basis weight ranges result in tipping paper that has acceptable tensile strength while being flexible enough to wrap around the article 1 and adhere to itself along the paper's longitudinal lap seam. After being wrapped around the mouthpiece 2, the tipping paper 5 has a circumference of approximately 21 mm.

The first plug wrap 7 preferably has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. The first plug wrap 7 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The first plug wrap 7 is preferably a non-porous plug wrap, for example, having a permeability of less than 100 Coresta units, for example, less than 50 Coresta units. However, in other embodiments, the first plug wrap 7 can be a porous plug wrap, for example, having a permeability of greater than 200 Coresta units.

The length of the material body 6 is preferably less than approximately 20 mm. In this example, the length of the material body 6 is 16 mm.

In this example, the body of material 6 is formed from filament tow. In this example, the tow used in the body of material 6 has a denier per filament (d.p.f.) of 8.4 and a total denier of 21,000. Alternatively, the tow can 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 of material 6. For example, rather than tow, the body of material 6 can be formed from paper, for example, in a manner similar to paper filters known for use in cigarettes. Alternatively, the body of material 6 can be formed from a tow other than cellulose acetate, such as polylactic acid (PLA), other materials described herein with respect to filament tow, or similar materials. The tow, 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 denier per filament values provide tows with relatively coarse, thick fibers that have less surface area, resulting in a lower pressure drop across the mouthpiece 2 than tows with lower d.p.f. values. To achieve a sufficiently uniform body of material 6, the tow preferably 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 tows that occupy 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 a body of material 6 of appropriate stiffness, the tow preferably has a total denier of at least 8,000, more preferably at least 10,000. The denier per filament is preferably 5-12, with a total denier of 10,000-25,000. More preferably, the denier per filament is 6-10, with a total denier of 11,000-22,000. The cross-sectional shape of the filaments in the tow is preferably "Y" shaped, although other shapes, such as "X" shaped filaments, having the same d.p.f. and total denier values provided herein may be used in other embodiments.

The cross-section of the fiber can have an isoperimetric ratio ^L2 /A of 25 or less, 20 or less, or 15 or less, where L is the perimeter of the cross-section and A is the area of the cross-section. Such fibers have a relatively small surface area for a given value of denier per filament, thereby improving aerosol delivery to the consumer.

The length of the tubular portion 4a is preferably less than about 50 mm. More preferably, the length of the tubular portion 4a is less than about 40 mm. Even more preferably, the length of the tubular portion 4a is less than about 30 mm. Additionally or alternatively, the length of the tubular portion 4a is preferably at least about 10 mm. The length of the tubular portion 4a is preferably at least about 15 mm. In some preferred embodiments, the length of the tubular portion 4a 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 tubular portion 4a is 25 mm.

The second plug wrap 9 preferably has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 45 gsm. The second plug wrap 9 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The second plug wrap 9 is preferably a non-porous plug wrap having a permeability of less than 100 Coresta units, for example less than 50 Coresta units. However, in alternative embodiments, the second plug wrap 9 may be a porous plug wrap having a permeability of, for example, greater than 200 Coresta units.

The tubular portion 4a surrounds and defines a cavity within the mouthpiece 2, 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 tubular portion 4a is hollow, providing a chamber for the aerosol accumulation that is still rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and use of the article 1. The tubular portion 4a provides a physical displacement between the aerosol-generating material 3 and the body of material 6. The physical displacement provided by the tubular portion 4a provides a temperature gradient across the length of the tubular portion 4a.

Preferably, the mouthpiece 2 includes a cavity having an internal volume greater than 450 ^mm³ . It has been found that providing a cavity of at least this volume allows for improved aerosol formation. Such a cavity size provides sufficient space within the mouthpiece 2 to allow heated volatile components to cool, which would otherwise result in an aerosol that is too warm, and thus allows for exposure of the aerosol-generating material 3 to higher temperatures than would otherwise be possible. In this example, the cavity is formed by the tubular portion 4a, but in alternative configurations, it could be formed within a different portion of the mouthpiece 2. More preferably, the mouthpiece 2 includes a cavity formed, for example, within the tubular portion 4a, which has an internal volume greater than 500 ^mm³ , and even more preferably greater than 550 ^mm³ , allowing for further aerosol improvement. In some examples, the internal cavity includes a volume of about 550 ^mm³ to about 750 ^mm³ , for example, about 600 ^mm³ or 700 ^mm³ .

The tubular portion 4a can be configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile components entering the first upstream end of the tubular portion 4a and the heated volatile components exiting the second downstream end of the tubular portion 4a. The tubular portion 4a is preferably configured to provide a temperature difference of at least 60 degrees Celsius, preferably at least 80 degrees Celsius, and more preferably at least 100 degrees Celsius between the heated volatile components entering the first upstream end of the tubular portion 4a and the heated volatile components exiting the second downstream end of the tubular portion 4a. This temperature difference along the length of the tubular portion 4a protects the temperature-sensitive body 6 from the high temperatures of the aerosol-generating material 3 when heated.

In an alternative article, the tubular portion 4a may be replaced by an alternative cooling element, for example an element formed from a body of material that performs the function of cooling the aerosol while allowing the aerosol to pass longitudinally.

The mouthpiece 2 of the article 1 has an upstream end 3a adjacent to the aerosol-generating substrate 3 and a downstream end 2b remote from the aerosol-generating substrate 3.

Preferably, the pressure drop or pressure differential (also referred to as resistance to draw) across the mouthpiece, e.g., the portion of article 1 downstream of the aerosol-forming material 3, is less than about _{40 mmH2O} . Such a pressure drop has been found to allow sufficient aerosol containing desirable compounds, such as flavor compounds, to pass through the mouthpiece 2 to the consumer. More preferably, the pressure drop across the mouthpiece 2 is less than about 32 _mmH2O . In some embodiments, particularly improved aerosols are achieved using a mouthpiece 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 pressure drop across the mouthpiece can be at least 10 mmH2O, preferably at least 15 _mmH2O , and more preferably at least 20 _mmH2O . In some embodiments, the pressure drop across the mouthpiece can 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, thus allowing time for the aerosol's temperature to decrease before it reaches the downstream end 2b of the mouthpiece 2.

In this example, the aerosol-generating material 3 is wound within a paper wrapper 10. The paper wrapper 10 may be, for example, a paper or paper-backed foil wrapper. In this example, the paper wrapper 10 is substantially impermeable to air. In an alternative embodiment, the paper wrapper 10 preferably has a permeability of less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that a low-permeability paper wrapper, for example, having a permeability of less than 100 Coresta units, more preferably less than 60 Coresta units, results in improved aerosol formation within the aerosol-generating material 3. Without wishing to be bound by theory, it is hypothesized that this is due to reduced loss of aerosol compounds within the paper wrapper 10. The permeability of the paper wrapper 10 may be measured in accordance with ISO 2965:2009, Determination of the Air Permeability of Materials Used as Cigarette Paper, Filter Plug Wrap, and Filter Bonding Paper.

In this embodiment, the paper wrapper 10 comprises aluminum foil. Aluminum foil has been found to be particularly effective in promoting the formation of an aerosol within the aerosol-generating material 3. In this example, the aluminum foil has a metal layer having a thickness of approximately 6 μm. In this example, the aluminum foil has a paper backing. However, in alternative configurations, the aluminum foil can be other thicknesses, for example, from 4 μm to 16 μm. The aluminum foil also need not have a paper backing, and can have a backing formed from other materials, for example to help provide the foil with adequate tensile strength, or can have no backing material at all. Metal layers or foils other than aluminum can also be used. The total thickness of the paper wrapper is preferably 20 μm to 60 μm, more preferably 30 μm to 50 μm, to provide a paper wrapper with adequate structural integrity and heat transfer properties. The pulling force that can be applied to the web before it breaks can be greater than 3,000 grams force, for example, 3,000 to 10,000 grams force, or 3,000 to 4,500 grams force.

In some examples, the web 10 surrounding the aerosol-generating material includes a citrate salt, such as sodium citrate and/or potassium citrate. In such examples, the web 10 may have a citrate content of 2% by weight or less, or 1% by weight or less. Reducing the citrate content of the web can help reduce any visible discoloration of the web during use.

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

The wrapping paper 10 can be formed from a material with a high inherent permeability level, an inherently porous material, or any material with a final permeability level achieved by providing permeable sections or zones in the wrapping paper 10. Providing a permeable wrapping paper 10 provides a path for air to enter the smoking article. The wrapping paper can be made permeable so that the amount of air entering the article through the rod of aerosol-generating material is relatively greater than the amount of air entering the article through the vent zone 12 in the mouthpiece. Articles having this configuration can produce a more flavorful aerosol and provide greater user satisfaction.

The article has a ventilation level of approximately 75% of the aerosol inhaled through the article. In alternative embodiments, the article can have a ventilation level of 50% to 80%, for example 65% to 75%, of the aerosol inhaled through the article. These levels of ventilation help slow the flow of aerosol inhaled through the mouthpiece 2, thereby allowing the aerosol to cool sufficiently before reaching the downstream end 2b of the mouthpiece 2. Ventilation is provided directly into the mouthpiece 2 of the article 1. In this example, ventilation is provided into the tubular portion 4a, 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, which in this case are formed as laser drillings 17.925 mm and 18.625 mm from the downstream mouth end 2b of the mouthpiece 2, respectively. These perforations pass through the tipping paper 5, the second plug wrap 9, and the tubular portion 4a. In alternative embodiments, ventilation can be provided elsewhere within the mouthpiece.

Alternatively, ventilation can be provided through a single row of perforations, e.g., laser perforations, into the portion of the article in which the tubular portion is located. This has been found to result in improved aerosol formation, believed to be due to the fact that for a given ventilation level, the airflow through the perforations is more uniform than with multiple rows of perforations.

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

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

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

The volume of the aerosol-forming material 3 provided can 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 aerosol-forming material in these volumes, for example from about 1000 ^mm to about 1300 ^mm , has been shown to advantageously provide a superior aerosol with improved visibility and perceptibility compared to that achieved with volumes selected at the lower end of this range.

The mass of the aerosol-forming material 3 provided can 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. Advantageously, providing a larger mass of aerosol-forming material has been found to result in improved sensory performance compared to aerosols generated from tobacco material with smaller masses.

The aerosol-forming material or substrate is preferably formed from a tobacco material as described herein, including a tobacco component.

In the tobacco materials described herein, the tobacco component preferably contains reconstituted tobacco. The tobacco component may also contain leaf tobacco, extruded tobacco, and/or band-cast tobacco.

The aerosol-generating material 3 can 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 at providing aerosol-generating materials that can be rapidly heated to release an aerosol, compared to materials with higher densities. For example, the inventors tested the properties of various aerosol-generating materials when heated, including band-cast reconstituted tobacco material and paper reconstituted tobacco material. For each given aerosol-generating material, a specific zero heat flow temperature was found to exist; while heat is being applied to the material, below this zero heat flow temperature, the net heat flow is endothermic, meaning that more heat enters the material than leaves it; above this zero heat flow temperature, the net heat flow is exothermic, meaning that more heat enters the material than leaves it. Materials with densities less than 700 mg/cc had lower zero heat flow temperatures. Because the majority of the heat flow exiting the material is due to the formation of the aerosol, having a lower zero heat flow temperature has a beneficial effect on the time it takes to initially release the aerosol from the aerosol-generating material. For example, it has been found that aerosol-generating materials with densities less than 700 mg/cc have zero heat flow temperatures less than 164°C, compared to materials with densities greater than 700 mg/cc having zero heat flow temperatures greater than 164°C.

The density of the aerosol-generating material also affects the rate at which heat is conducted through the material; at lower densities, e.g., below 700 mg/cc, heat will conduct through the material more slowly, thus allowing for a more sustained aerosol release.

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

The tobacco material can be provided in the form of cut rag tobacco. The cut rag tobacco can have a cut width of at least 15 notches per inch (approximately 5.9 notches per cm, equivalent to a cut width of approximately 1.7 mm). The cut rag tobacco preferably has a cut width of at least 18 notches per inch (approximately 7.1 notches per cm, equivalent to a cut width of approximately 1.4 mm), more preferably at least 20 notches per inch (approximately 7.9 notches per cm, equivalent to a cut width of approximately 1.27 mm). In one example, the cut rag tobacco has a cut width of 22 notches per inch (approximately 8.7 notches per cm, equivalent to a cut width of approximately 1.15 mm). Preferably, the cut rag tobacco has a cut width of no more than 40 notches per inch (approximately 15.7 notches per cm, equivalent to a cut width of approximately 0.64 mm). It has been found that 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, results in a tobacco material that is favorable, particularly in terms of the surface area to volume ratio when heated, and the overall density and pressure drop of the substrate 3. The cut rag tobacco can be formed from a mixture of tobacco material forms, for example, a mixture of 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.

In the tobacco materials described herein, the tobacco material may contain a filler component. The filler component is generally a non-tobacco component, i.e., a component that does not contain tobacco-derived materials. The filler component may be a non-tobacco fiber, such as wood fiber or pulp or wheat fiber. The filler component may also be an inorganic material, such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, or magnesium carbonate. The filler component may also be a non-tobacco casting material or a non-tobacco extrusion material. The filler component may be present in an amount of 0-20% by weight of the tobacco material, or in an amount of 1-10% by weight of the composition. In some embodiments, no filler component is present.

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

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

The tobacco material may contain 10% to 90% by weight of tobacco leaf, with the aerosol-forming material being provided in an amount of up to about 10% by weight of the tobacco leaf. Advantageously, it has been found that this can be added in a greater weight percentage than another component of the tobacco material, such as reconstituted tobacco material, to achieve an overall level of aerosol-forming material of 10% to 20% by weight of the tobacco material.

The tobacco material described herein contains nicotine. The nicotine content can be 0.5 to 1.75% by weight of the tobacco material, for example, 0.8 to 1.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material contains 10% to 90% by weight of tobacco leaf and has a nicotine content greater than 1.5% by weight of the tobacco leaf. Advantageously, it has been found that using tobacco leaf having a nicotine content greater than 1.5% in combination with a lower nicotine base material, such as reconstituted tobacco, provides a tobacco material with an appropriate nicotine level yet with better sensory performance than reconstituted tobacco alone. Tobacco leaf, for example, cut rag tobacco, can have a nicotine content of 1.5% to 5% by weight of the tobacco leaf.

The tobacco materials described herein can contain an aerosol modifying agent, such as any of the flavorings described herein. In one embodiment, the tobacco material contains menthol to form a mentholated article. The tobacco material can contain 3 mg to 20 mg of menthol, preferably 5 mg to 18 mg, and more preferably 8 mg to 16 mg. In this example, the tobacco material contains 16 mg of menthol. The tobacco material can contain 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 contains 4.7% by weight of menthol. Such high levels of menthol loading can be achieved by using a high proportion of reconstituted tobacco material, for example, greater than 50% by weight of the tobacco material. Alternatively or additionally, the achievable menthol loading level can be increased by using a larger amount of aerosol-forming material, e.g., tobacco material, e.g., greater than about 500 ^mm3 , or preferably greater than about 1000 ^mm3 , of aerosol-forming material, such as tobacco material.

For the compositions described herein, when amounts are given in weight percent, this refers to dry basis weight unless specifically indicated to the contrary. Therefore, for purposes of determining weight percent, any water that may be present in the tobacco material or any of its components is completely disregarded. The moisture content of the tobacco materials described herein may vary and may be, for example, 5-15% by weight. The moisture content of the tobacco materials described herein may vary, for example, according to the temperature, pressure, and humidity conditions under which the compositions are maintained. The moisture content may be determined by Karl Fischer analysis, as known to those skilled in the art. For the avoidance of doubt, however, even when the aerosol-forming material is a liquid-phase component, such as glycerol or propylene glycol, all components other than water are included in the weight of the tobacco material. However, when an aerosol-forming material is provided within the tobacco component of the tobacco material or within a filler component (if present) of the tobacco material instead of or in addition to being added separately to the tobacco material, the aerosol-forming material is not included in the weight of the tobacco component or filler component, but is included in the weight of the "aerosol-forming material" at the weight percent defined herein. All other materials present in the tobacco component are included in the weight of the tobacco component, even if they are of non-tobacco origin (e.g., non-tobacco fiber in the case of reconstituted tobacco).

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

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

Reconstituted tobacco refers to tobacco material formed by a process in which tobacco raw material is extracted with a solvent to give a residue extract containing solubles and fibrous material, and the extract (usually after concentration, optionally after further processing) is then recombined with fibrous material from the residue by depositing the extract on the fibrous material (usually after purification of the fibrous material, optionally with the addition of a portion of non-tobacco fiber). The recombination process is similar to the papermaking process.

The reconstituted tobacco can be any type of reconstituted tobacco known in the art. In certain embodiments, the reconstituted tobacco is made from raw materials including one or more of tobacco strip, tobacco stem, and whole leaf tobacco. In further embodiments, the reconstituted tobacco is made from raw materials consisting of tobacco strip and/or whole leaf tobacco, and tobacco stem. However, in other embodiments, shreds, granules, and husks can alternatively or additionally be used as raw materials.

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

FIG. 2 is a cross-sectional side view of a further article 1' that includes a component 2', in this example, a mouthpiece 2', that includes a hollow tubular element 8. The mouthpiece 2' is substantially similar to the mouthpiece 2 described above, except that the mouthpiece 2' has a hollow tubular element 8 formed from filament tow at its downstream end 2b. In particular, the mouthpiece 2' includes a tubular portion 4 having a wall that includes a second aerosol-generating material, as described with reference to FIG. 1. The second aerosol-generating material is an aerosol-generating material described herein, such as an amorphous solid material described herein. In this example, the tubular portion 4a, body of material 6, and hollow tubular element 8 are combined using a second plug wrap 9 wrapped around all three sections. In an alternative example, the component 2' can constitute a portion of the article 1' that is downstream of the aerosol-generating material 3 and is not positioned to be received in the user's mouth.

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

Typically, the portion of the mouthpiece that contacts the consumer's lips is a paper tube, which is hollow or surrounds a cylinder of filter material. Advantageously, it has been found that providing a hollow tubular element 8 significantly reduces the temperature of the outer surface of the mouthpiece 2' at the downstream end 2b of the mouthpiece that contacts the consumer's mouth when the article 1' is in use. In addition, it has been found that the use of a hollow tubular element 8 also significantly reduces the temperature of the outer surface of the mouthpiece 2' upstream of the hollow tubular element 8. Without wishing to be bound by theory, it is hypothesized that this is due to the hollow tubular element 8 causing the aerosol to pass closer to the center of the mouthpiece 2', thus reducing the transfer of heat from the aerosol to the outer surface of the mouthpiece 2'.

The hollow tubular element 8 may also, or alternatively, include a second aerosol-generating material 4b, as described above. In this example, the hollow tubular element 8 is formed from a filament tow. In alternative embodiments, the hollow tubular element may be formed using any of the structures described herein for the tubular portion 4a.

The "wall thickness" of the hollow tubular element 8 corresponds to the thickness of the wall of the tube 8 in the radial direction. This can be measured in the same manner as for the tubular portion. Advantageously, the wall thickness is greater than 0.9 mm, more preferably 1.0 mm or greater. The wall thickness is preferably substantially constant throughout the wall of the hollow tubular element 8. However, if the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9 mm, more preferably 1.0 mm or greater, at any point around the hollow tubular element 8.

In some embodiments, the length of the hollow tubular element 8 is less than about 20 mm. For example, the length of the hollow tubular element 8 can be less than about 15 mm. The length of the hollow tubular element 8 can also be less than about 10 mm. Additionally or alternatively, the length of the hollow tubular element 8 can be at least about 5 mm. Preferably, the length of the hollow tubular element 8 is at least about 6 mm. In some preferred embodiments, the length of the hollow tubular element 8 is between about 5 mm and about 20 mm, e.g., between about 6 mm and about 10 mm, or between about 6 mm and about 8 mm, e.g., about 6 mm, 7 mm, or about 8 mm. In this example, the length of the hollow tubular element 8 is 6 mm.

In some embodiments, it may be particularly advantageous to use a hollow tubular element 8 having a length greater than about 10 mm, for example, from about 10 mm to about 30 mm or from about 12 mm to about 25 mm. It has been found that a consumer's lips are likely to extend about 12 mm from the mouth end of the article 1 in some cases when inhaling aerosol from the article 1, and therefore having a hollow tubular element 4 having a length of at least 10 mm or at least 12 mm means that most of the consumer's lips will surround this element 8.

The density of the hollow tubular element 8 is preferably at least about 0.25 grams per cubic centimeter (g/cc), more preferably at least about 0.3 g/cc. The density of the hollow tubular element 8 is preferably less than 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 element 8 is 0.25 to 0.75 g/cc, more preferably 0.3 to 0.6 g/cc, more preferably 0.4 g/cc to 0.6 g/cc, or about 0.5 g/cc. These densities have been found to provide a good balance between the improved stiffness imparted by higher density materials and the lower heat transfer characteristics of lower density materials. For purposes of this invention, the "density" of the hollow tubular element 8 refers to the density of the filament tow forming the element in which any plasticizer is incorporated. The density can be determined by dividing the total weight of the hollow tubular elements 8 by the total volume of the hollow tubular elements 8, and the total volume can be calculated using appropriate measurements of the hollow tubular elements 8, for example obtained using calipers. If necessary, appropriate dimensions can be measured using a microscope.

The filament tow forming the hollow tubular element 8 preferably has a total denier of less than 45,000, more preferably less than 42,000. This total denier has been found to allow for the formation of hollow tubular elements 8 that are not too dense. The total denier is preferably at least 20,000, more preferably at least 25,000. In preferred embodiments, the filament tow forming the hollow tubular element 8 has a total denier of 25,000 to 45,000, more preferably 35,000 to 45,000. The cross-sectional shape of the filaments in the tow is preferably "Y" shaped, although other shapes, such as "X" shaped filaments, can be used in other embodiments.

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

Preferably, the hollow tubular element 8 has an inner diameter greater than 3.0 mm. A smaller diameter may undesirably increase the velocity of the aerosol passing through the mouthpiece 2' and into the consumer's mouth, resulting in the aerosol becoming too warm, for example reaching temperatures greater than 40°C or greater than 45°C. More preferably, the hollow tubular element 8 has an inner diameter greater than 3.1 mm, and even more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the inner diameter of the hollow tubular element 8 is approximately 3.9 mm.

The hollow tubular element 8 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 hollow tubular element 8 contains 16% to 20% by weight of plasticizer, for example, about 17%, about 18%, or about 19%.

In this example, tubular portion 4a is the first hollow tubular element, and hollow tubular element 8 is the second hollow tubular element.

In this example, ventilation is provided into the tubular portion 4a, as described in connection with FIG. 1. In alternative embodiments, ventilation may be provided elsewhere into the mouthpiece, for example into the body of material 6 or the hollow tubular element 8.

3a is a side cross-sectional view of a further article 1" including a capsule-containing component 2", in this example, a mouthpiece 2". FIG. 3b is a cross-sectional view of the capsule-containing mouthpiece shown in FIG. 3a taken along line A-A' in FIG. 3a. Article 1" and capsule-containing mouthpiece 2" are the same as article 1 and mouthpiece 2 shown in FIG. 1, except that the aerosol modifier is provided within body 6, in this example in the form of capsules 11, and an oil-resistant first plug wrap 7' surrounds body 6. In particular, mouthpiece 2" includes tubular portion 4 having a wall containing a second aerosol-generating material, as described with reference to FIG. 1. The second aerosol-generating material is an aerosol-generating material as described herein, for example, an amorphous solid material as described herein. In other examples, the aerosol modifier can be provided in other forms, such as infused within body 6 or provided on a thread; for example, the thread can hold a flavoring or other aerosol modifier, which can also be disposed within body 6. Alternatively, component 2" may comprise a portion of article 1" that is downstream of aerosol-forming material 3 and that is not positioned to be received in the mouth of a user.

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

The capsule 11 has a core-shell structure. In other words, the capsule 11 comprises a shell encasing a liquid agent, such as a flavoring or other agent, which may be any one of the flavorings or aerosol-modifying agents described herein. The capsule shell can be ruptured by the user to release the flavoring or other agent into the body of material 6. The first plug wrap 7' may comprise a barrier coating that renders the plug wrap material substantially impermeable to the liquid payload of the capsule 11. Alternatively or additionally, the second plug wrap 9 and/or tipping paper 5 may comprise a barrier coating that renders the plug wrap and/or tipping paper material substantially impermeable to the liquid payload of the capsule 11.

In this example, capsule 11 is spherical and has a diameter of approximately 3 mm. In other examples, capsules of 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 a longitudinally central position within the body of material 6. That is, the capsule 11 is positioned so that its center is 4 mm from each end of the body of material 6. In other examples, the capsule 11 can be positioned at a position other than a longitudinally central position within the body of material 6, that is, closer to the downstream end of the body of material 6 than the upstream end, or closer to the upstream end of the body of material 6 than the downstream end. The mouthpiece 2" is preferably configured so that the capsule 11 and the vent hole 12 are longitudinally offset from each other within the mouthpiece 2".

A cross-sectional view of the mouthpiece 2" is shown in Figure 3b, taken along line A-A' in Figure 3a. Figure 3b shows the capsule 11, the body of material 6, the first and second plug wraps 7' and 9, and the tipping paper 5. In this example, the capsule 11 is located centrally on the longitudinal axis (not shown) of the mouthpiece 2". The first and second plug wraps 7' and 9, and the tipping paper 5 are arranged concentrically around the body of material 6.

The rupturable capsule 11 has a core-shell structure, i.e., the encapsulating or barrier material creates 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 herein as the encapsulating material) is frangible. The capsule is crushed or otherwise broken or destroyed by the user to release the encapsulated aerosol modifier. Typically, the capsule is broken just before heating begins, but the user can choose when to release the aerosol modifier. The term "breakable capsule" refers to a capsule whose shell can be broken by pressure to release the core; more specifically, the shell can be ruptured under 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, melt, or otherwise collapse at temperatures reached at the capsule site during operation of the aerosol delivery device. Illustratively, a capsule disposed within a mouthpiece can be exposed to temperatures in the range of, for example, 30°C to 100°C, and the barrier material can continue to retain the liquid core up to at least about 50°C to 120°C.

In other cases, the capsules release the core composition when heated, for example by melting the barrier material or by expanding the capsule and rupturing the barrier material.

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

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

Capsules according to the present invention comprise the core described above and a shell. The capsules may exhibit a crushing 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 burst strength can be measured when the capsule is removed from the body of material 6, using a force gauge to measure the force at which the capsule bursts when pressed between two flat metal plates. A suitable measuring device is a Sauter FK50 force gauge with a flat-headed attachment that can be used to press the capsule against a flat, hard surface with a surface similar to the attachment.

The capsules can be substantially spherical and can have a diameter of at least about 0.4 mm, 0.6 mm, 0.8 mm, 1.0 mm, 2.0 mm, 2.5 mm, 2.8 mm, or 3.0 mm. The capsule diameter can be less than about 10.0 mm, 8.0 mm, 7.0 mm, 6.0 mm, 5.5 mm, 5.0 mm, 4.5 mm, 4.0 mm, 3.5 mm, or 3.2 mm. Illustratively, the capsule diameter can be within the range 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 can 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 cross-sectional area of capsule 11 at its maximum cross-sectional area is 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 provided. 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 . For the mouthpiece 2" described herein having a circumference of 21 mm, the body of material 6 has a circumference of 20.8 mm, and the radius of this component is 3.31 mm, corresponding to a cross-sectional area of 34.43 ^mm2 . In this example, the cross-sectional area of the capsule is 20.5% of the cross-sectional area of the mouthpiece 2". As another example, if the capsule had a diameter of 3.2 mm, its maximum cross-sectional area would be 8.04 ^mm2 . In this case, the cross-sectional area of the capsule would be 23.4% of the cross-sectional area of the body of material 6. Having a maximum cross-sectional area of the capsule that is less than 28% of the cross-sectional area of the part of the mouthpiece 2" in which the capsule 11 is provided has the advantage, compared to a capsule with a larger cross-sectional area, that the pressure drop in the mouthpiece 2" is reduced, sufficient space is left around the capsule for the aerosol to pass through, and the body of material 6 does not remove as much aerosol mass as it passes through the mouthpiece 2".

When the capsule is broken, the pressure drop or pressure differential (also called resistance to draw) across the article, measured as the opening pressure drop (i.e., with the vent opening open), preferably drops by less than 8 mm _H2O . More preferably, the opening pressure drop drops by less than 6 mm _H2O , and more preferably by less than 5 mm _H2O . These values are measured as an average achieved by at least 80 articles made with the same design. Such small changes in pressure drop mean that other aspects of the product design, such as setting the correct vent level for a given product pressure drop, can be achieved whether or not the consumer chooses to break the capsule.

For a given tow specification (e.g., 8.4Y21000), it is known to generate a tow performance curve that represents the pressure drop across the length of a rod formed using the tow for each of a wide range of tow weights. Parameters such as rod length and circumference, web thickness, and tow plasticizer level are specified and combined with the tow specification to generate a tow performance curve that indicates the pressure drop that would be provided by different tow weights between the minimum and maximum weights achievable using standard filter rod forming machinery. Such tow performance curves can be calculated, for example, using software available from tow suppliers. It has been found particularly advantageous to use a body 6 including a filament tow having a weight per mm of body 6 length that is about 10% to about 30% of the range between the minimum and maximum weights of the tow performance curve generated for the filament tow. This provides a tow weight sufficient to avoid shrinkage after the body 6 is formed, providing an acceptable balance of providing an acceptable pressure drop while also assisting capsule placement within the tow for capsules of the sizes described herein.

In some embodiments, when the aerosol-generating material 3 is heated to deliver an aerosol, for example, in the non-combustible aerosol delivery devices described herein, the portion of the mouthpiece 2 in which the capsule is located reaches a temperature of 58-70 degrees Celsius during use of the system to generate the aerosol. As a result of this temperature, the capsule contents are sufficiently warmed to promote volatilization of the capsule contents, e.g., an aerosol modifier, into the aerosol formed by the system as the aerosol passes through the mouthpiece 2. Warming the contents of the capsule 11 can occur, for example, before the capsule 11 is broken, so that when the capsule 11 is broken, the contents of the capsule 11 are more readily released into the aerosol passing through the mouthpiece 2. Alternatively, the contents of the capsule 11 can be warmed to this temperature after the capsule 11 is broken, again increasing the release of the contents into the aerosol. It has been found that a mouthpiece temperature in the range of 58-70 degrees Celsius is advantageously high enough to allow the capsule contents to be released more easily, but low enough so that the outer surface of the portion of the mouthpiece 2 where the capsule is located does not reach an uncomfortable temperature 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 an invasive probe positioned so that the probe enters the mouthpiece 2 through the wall of the mouthpiece 2 (forming a seal to limit the amount of outside air that can leak around the probe into the mouthpiece) and is located adjacent to 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 in the mouthpiece 2 of an article used with an aerosol delivery system during the first five puffs. Data is provided for an article heated using a "standard" heating profile with the coil heating device described herein with reference to Figures 3-7, and for the same article heated using the same device with a "boost" heating profile. The "boost" heating profile is user selectable and allows for higher heating temperatures to be achieved.

As shown in Table 1.0, the temperature of the mouthpiece 2 at the location of the capsule 11 reaches a maximum temperature of 61.5°C under the "standard" heating profile and a maximum temperature of 63.8°C under 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 particularly advantageous in terms of aiding in the volatilization of the contents of the capsule 11 while maintaining a suitable exterior surface 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 squeezing the mouthpiece 2 using their fingers or another mechanism. As described above, the portion of the mouthpiece in which the capsule is disposed is configured to reach a temperature greater than 58°C during use of the aerosol delivery system to generate an aerosol. The capsule 11 disposed within the mouthpiece 2 prior to heating of the aerosol-generating material 3 preferably has a burst strength of 1,500 to 4,000 grams of force. The capsule 11 disposed within the mouthpiece 2 within 30 seconds of using the aerosol delivery system to generate an aerosol preferably has a burst strength of 1,000 to 4,000 grams of force. Therefore, it has been found that the capsule 11 can maintain its burst strength regardless of whether it is exposed to temperatures greater than 58°C, for example, temperatures between 58°C and 70°C, and within this burst strength range, the capsule 11 can be easily crushed by a consumer while providing sufficient tactile feedback to the consumer that the capsule 11 has been broken. Maintaining such burst strength is achieved by selecting an appropriate gelling agent for the capsule, such as polysaccharides including gum arabic, gellan gum, acacia gum, xanthan gum, or carrageenan, alone or in combination with gelatin, as described herein. In addition, a suitable wall thickness should be selected for the capsule shell.

The burst strength of a capsule placed in the mouthpiece before heating the aerosol-generating material is preferably 2000 to 3500 grams force, or 2500 to 3500 grams force. The burst strength of a capsule placed in the mouthpiece within 30 seconds of using the system to generate an aerosol is preferably 1500 to 4000 grams force, or 1750 to 3000 grams force. In one example, the average burst strength of capsules placed in the mouthpiece before heating the aerosol-generating material is approximately 3175 grams force, and the average burst strength of capsules placed in the mouthpiece within 30 seconds of using the system to generate an aerosol is approximately 2345 grams force.

Capsule burst strength can be tested using a force-measuring instrument such as a Texture Analyser. For these burst strengths, a Type TA. XTPlus Texture Analyser was used, with a 6 mm diameter circular metal probe positioned at the center of the capsule site (i.e., 12 mm from the mouth end of the mouthpiece 2). The probe test speed was 0.3 mm/sec, with a pre-test speed of 5.00 mm/sec and a post-test speed of 10 mm/sec. The force used was 5000 g. Tested articles were puffed using standard testing equipment according to the well-known Health Canada smoking regime (55 ml puffs applied for 2 seconds every 30 seconds) using a Borgwaldt A14 syringe drive unit. Three puffs were taken using this regime, and capsule burst strength was measured within 30 seconds of the third puff. The article tested was similar to article 1" shown in Figures 3a and 3b described herein, except that it had an 8 mm hollow tubular element 8 at the mouth end formed from two layers of paper laminated together, the layers wrapped parallel to each other and abutting at a seam, and had a total thickness of 300 μm. The capsule was 3 mm in diameter and placed within an 8 mm long body 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 buffering agent, a colorant, and a plasticizer.

The gelling agent may suitably be, for example, a polysaccharide or cellulose gelling agent, gelatin, gum, gel, wax, or a mixture thereof. Suitable polysaccharides include alginic acid, dextran, maltodextrin, cyclodextrin, and pectin. Suitable alginic acids include, for example, alginate salts, alginic acid esters, or glyceryl alginate. Alginate salts include ammonium alginate, triethanolamine alginate, and metal ion alginates of Group I or Group II, such as sodium, potassium, calcium, and magnesium alginate. Alginic acid esters include propylene glycol alginate and glyceryl alginate. In one embodiment, the barrier material includes sodium alginate and/or calcium alginate. Suitable cellulose 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, gum ghatti, tragacanth gum, karaya, locust bean, acacia gum, guar, quince seed, and xanthan gum. Suitable gels include agar, agarose, carrageenan, fucoidan, and furcellaran. Suitable waxes include carnauba wax. In some cases, the gelling agent can include carrageenan and/or gellan gum, which are particularly suitable for inclusion as gelling agents to provide a suitable pressure needed to rupture the resulting capsules.

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

The barrier material may contain a colorant that makes it easier to identify the location of the capsule within the aerosol generating device during the manufacturing process of the aerosol generating device. The colorant is preferably selected from dyes and pigments.

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

The barrier material may further comprise at least one plasticizer, which may be glycerol, sorbitol, maltitol, triacetin, polyethylene glycol, propylene glycol, or another polyalcohol with plasticizing properties, and optionally an acid of the mono-, di-, or tri-acid type, in particular citric acid, fumaric acid, malic acid, etc. 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 may also contain one or more filler materials. Suitable filler materials include starch derivatives such as dextrin, maltodextrin, cyclodextrin (α, β, or γ), cellulose derivatives such as hydroxypropylmethylcellulose (HPMC), hydroxypropylcellulose (HPC), methylcellulose (MC), carboxymethylcellulose (CMC), polyvinyl alcohol, polyols, or mixtures thereof. Dextrin is a preferred filler. The amount of filler in the shell is at most 98.5% by weight of the total dry weight of the shell, preferably 25 to 95% by weight, more preferably 40 to 80% by weight, and even more preferably 50 to 60% by weight.

The capsule shell may further comprise a hydrophobic outer layer that reduces the capsule's susceptibility to moisture-induced degradation. The hydrophobic outer layer is preferably selected from the group consisting of waxes, particularly carnauba wax, candelilla wax, or beeswax, carbowax, shellac (in alcoholic or aqueous solutions), ethyl cellulose, hydroxypropyl methylcellulose, hydroxypropyl cellulose, latex compositions, polyvinyl alcohol, or combinations thereof. More preferably, the at least one moisture barrier is ethyl cellulose or a mixture of ethyl cellulose and shellac.

The capsule core includes an aerosol modifier. The aerosol modifier can be any volatile substance that modifies at least one property of the aerosol. For example, the aerosol substance can modify the pH, sensory properties, moisture content, delivery characteristics, or flavor. In some cases, the aerosol modifier can be selected from an acid, a base, water, or a flavoring. In some embodiments, the aerosol modifier includes one or more flavorings.

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

In some cases, the flavoring includes menthol.

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

In some cases, the core can contain at least about 25% w/w flavoring (based on the total weight of the core), preferably at least about 30% w/w flavoring, 35% w/w flavoring, 40% w/w flavoring, 45% w/w flavoring, or 50% w/w flavoring. In some cases, the core can contain up to about 75% w/w flavoring (based on the total weight of the core), preferably up to about 65% w/w flavoring, 55% w/w flavoring, or 50% w/w flavoring. Illustratively, the capsule can contain an amount of flavoring in the range of 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. The core may also contain a solvent in which the aerosol modifier is dissolved.

Any suitable solvent can be used.

When the aerosol modifier includes a flavoring, the solvent can preferably include short- or medium-chain fats and oils. For example, the solvent can include a triester of glycerol, such as a C2-C12 triglyceride, preferably a C6-C10 triglyceride, or a Cs-C12 triglyceride. For example, the solvent can include a medium-chain triglyceride (MCT-C8-C12), which can be derived from palm oil and/or coconut oil.

Esters can be formed with caprylic acid and/or capric acid. For example, the solvent can include medium-chain triglycerides of glyceryl tricaprylate and/or glyceryl tricaprate. For example, the solvent can include compounds identified by CAS Registry Numbers 73398-61-5, 65381-09-1, and 85409-09-2. Such medium-chain triglycerides are odorless and tasteless.

The hydrophilic-lipophilic balance (HLB) of the solvent may be in the range of 9 to 13, preferably 10 to 12. A method for making the capsules involves co-extrusion, optionally followed by centrifugation and hardening and/or drying. The contents of WO 2007/010407 are incorporated by reference in their entirety.

In the examples described above, the mouthpieces 2, 2', 2" each comprise a single body of material 6. In other examples, the mouthpieces of Figures 1, 2, or 3a and 3b may comprise multiple bodies of material. The mouthpieces 2, 2', 2" may comprise cavities between the bodies of material.

In some examples, the mouthpiece 2, 2', 2" downstream of the aerosol-generating material 3 can comprise a paper wrapper, such as a first plug wrap 7 or a second plug wrap 9, or tipping paper 5, where the paper wrapper includes an aerosol modifier or other sensate material as described herein. The aerosol modifier can be disposed on an inward-facing or outward-facing surface of the mouthpiece paper wrapper. For example, the aerosol modifier or other sensate material can be provided on an area of the paper wrapper that will contact the consumer's lips during use, such as the outward-facing surface of the tipping paper 5. By disposing the aerosol modifier or other sensate material on the outward-facing surface of the mouthpiece paper wrapper, the aerosol modifier or other sensate material can be delivered to the consumer's lips during use. Delivery of the aerosol modifier or other sensate material to the consumer's lips during use of the article can be an aerosol. The organoleptic properties (e.g., taste) of the aerosol generated by the generation substrate 3 can be modified or an alternative sensory experience can be otherwise provided to the consumer. For example, the aerosol modifier or other sensate material can impart a flavor to the aerosol generated by the aerosol-generating substrate 3. The aerosol modifier or other sensate material can be at least partially water-soluble so that it can be transferred to the user by the consumer's saliva. The aerosol modifier or other sensate material can be volatilized by the heat generated by the aerosol delivery system, thereby facilitating transfer of the aerosol modifier to the aerosol generated by the aerosol-generating substrate 3. Suitable sensate materials can include flavors described herein, cooling agents such as sucralose, or menthol.

A non-combustion aerosol delivery device is used to heat the aerosol-generating material 3 of the articles 1, 1', 1" described herein. Preferably, the non-combustion aerosol delivery device comprises a coil, as this has been found to allow for improved heat transfer to the articles 1, 1', 1" compared to other configurations.

In some examples, the coil is configured to cause heating of at least one conductive heating element during use, thereby enabling thermal energy to be conducted from the at least one conductive heating element to the aerosol-forming material, thereby causing heating of the aerosol-forming material.

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

The device may include heating element(s), for example, conductive heating element(s), which may be positioned or positionable relative to the coil to enable such heating of the heating element(s). The heating element(s) may be in a fixed position relative to the coil. Alternatively, at least one heating element, for example, at least one conductive heating element, may be included within article 1, 1', 1" for insertion into the heating section of the device, with article 1, 1', 1" also comprising aerosol-generating material 3 and removable from the heating section after use. Alternatively, both the device and such article 1, 1', 1" may comprise at least one respective heating element, for example, at least one conductive heating element, and the coil may be for causing heating of the heating element(s) of each of the device and article when the article is within the heating section.

In some examples, the coil is helical. In some examples, the coil surrounds at least a portion of a heated section of a device configured to receive the aerosol-generating material. In some examples, the coil is a helical coil that surrounds at least a portion of the heated section.

In some examples, the device includes a conductive heating element at least partially surrounding the heating section, and the coil is a helical coil surrounding at least a portion of the conductive heating element. In some examples, the conductive heating element is tubular. In some examples, the coil is an inductor coil.

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

The use of a coil described herein in a device to cause heating of the aerosol-generating material has been found to enhance the resulting aerosol. For example, consumers have reported that the aerosol generated by a device including a coil such as that described herein feels closer to that generated in a factory-made cigarette (FMC) product than aerosols obtained with other non-combustion aerosol delivery systems. While not wishing to be bound by theory, it is hypothesized that this is a result of the reduced time to reach the required heating temperature when a coil is used, the higher heating temperatures achievable when a coil is used, and/or the fact that coils allow such systems to simultaneously heat a relatively large volume of aerosol-generating material, resulting in aerosol temperatures similar to FMC aerosol temperatures. In FMC products, hot aerosols are generated by burning coals, which heat the tobacco in the tobacco rod behind the coals as the aerosol is drawn through the rod. This hot aerosol is understood to liberate flavor compounds from the tobacco in the rod behind the burning coals. The coil-containing devices described herein are also believed to be capable of heating aerosol-forming materials, such as the tobacco materials described herein, to release flavor compounds, resulting in aerosols that are reportedly more similar to FMC aerosols. Particular aerosol improvements can be achieved by using the coil-containing devices to heat articles comprising rods of aerosol-forming material having a circumference greater than 19 mm, for example, from about 19 mm to about 23 mm.

The use of an aerosol delivery system including a coil as described herein, such as 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, can enable the generation of aerosols from the aerosol-generating material with specific properties that are believed to be more similar to those of FMC products. For example, when an induction heater is used to heat an aerosol-generating material containing nicotine that is heated to at least 250°C for a period of 2 seconds under an air flow of at least 1.50 L/m during this period, one or more of the following properties are observed:

At least 10 μg of nicotine is aerosolized from the aerosol-forming material.

The aerosol-forming material produces an aerosol with a weight ratio of at least about 2.5:1 to nicotine, preferably at least 8.5:1.

At least 100 μg of aerosol-forming material can be aerosolized from the aerosol-generating material.

The average particle or droplet size in the generated aerosol is less than approximately 1000 nm.

Aerosol density is at least 0.1 μg/cc.

In some cases, at least 10 μg of nicotine, preferably at least 30 μg or 40 μg of nicotine, is aerosolized from the aerosol-forming material under an airflow of at least 1.50 L/m during the period. In some cases, 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-forming material under an airflow of at least 1.50 L/m during the period.

In some cases, 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 period. Preferably, the aerosol-forming material can include or consist of glycerol.

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

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

In some cases, the aerosol density generated during the period is 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.

Preferably, the non-combustion aerosol delivery device is arranged to heat the aerosol-forming material 3 of the article 1, 1', 1" to a maximum temperature of at least 160°C. Preferably, the non-combustion aerosol delivery device is arranged to heat the aerosol-forming material 3 of the article 1, 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 process by the non-combustion aerosol delivery device.

Use of an aerosol delivery system including a coil described herein, such as 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, can enable the generation of aerosols from the aerosol-generating material in the articles 1, 1', 1" described herein that have a higher temperature when the aerosol leaves the mouth end of the mouthpiece 2, 2', 2" than previous devices, which can contribute to the generation of aerosols that are considered more similar to FMC products. For example, the maximum aerosol temperature measured at the mouth end of the articles 1, 1', 1" can be 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', 1" can be less than 62°C, more preferably less than 60°C, and more preferably less than 59°C. In some embodiments, the maximum aerosol temperature measured at the mouth end of the articles 1, 1', 1" can be preferably between 50°C and 62°C, more preferably between 56°C and 60°C.

Figure 4 shows an example of a non-combustion aerosol delivery device 100 for generating aerosol from an aerosol-generating medium/material, such as the aerosol-generating material 3 of articles 1, 1', and 1" described herein. In summary, device 100 can be used to heat a replaceable article 110 comprising an aerosol-generating medium, such as articles 1, 1', and 1" described herein, to generate an aerosol or other inhalable medium that is inhaled by a user of device 100. Device 100 and replaceable article 110 together form a system.

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

The device 100 in this example includes a first end member 106 having a lid 108 movable relative to the first end member 106 to close the opening 104 when the item 110 is not in place. In FIG. 4, the lid 108 is shown in an open configuration, but the lid 108 can also be moved to a closed configuration. For example, a user can slide the lid 108 in the direction of arrow "B."

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

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

Figure 5 shows the device 100 of Figure 4 with the outer cover 102 removed and without the article 110 present. The device 100 defines a longitudinal axis 134.

As shown in FIG. 5 , 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 end member 106 and the second end member 116 together at least partially define an end surface of the device 100. For example, the bottom surface of the second end member 116 at least partially defines the bottom surface of the device 100. An edge of the outer cover 102 can also define a portion of the end surface. In this example, the lid 108 also defines a portion of the top surface of the device 100.

The end of the device nearest the opening 104 can be referred to as the proximal end (or mouth end) of the device 100, as it is closest to the user's mouth during use. In use, the user inserts the item 110 into the opening 104, operates the user control 112 to initiate heating of the aerosol-generating material, and inhales the aerosol generated within the device. This causes the aerosol to flow along the flow path through the device 100 toward the proximal end of the device 100.

The other end of the device furthest from the opening 104 can be referred to as the distal end of the device 100, as it is the end farthest from the user's mouth during use. When a user inhales the aerosol generated within the device, the aerosol flows away from the distal end of the device 100.

Device 100 further includes a power source 118. Power source 118 can be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (e.g., lithium-ion batteries), nickel batteries (e.g., nickel-cadmium batteries), and alkaline batteries. The battery is electrically coupled to the heating assembly to provide power for heating the aerosol-generating material when needed under the control of a controller (not shown). In this example, the battery is connected to a central support 120, which holds 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 at least one controller, such as a processor, and memory. The PCB 122 may also include one or more electrical tracks for electrically connecting together various electronic components of the device 100. For example, battery terminals may be electrically connected to the PCB 122 so that power can be distributed throughout the device 100. The socket 114 may also be electrically coupled to a battery via the electrical tracks.

In the exemplary device 100, the heating assembly is an induction heating assembly and includes various components for heating the aerosol-generating material of the article 110 by an induction heating process. Induction heating is a process of heating an electrical conductor (such as a susceptor) by electromagnetic induction. The induction heating assembly can include an induction element, such as 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 suitably positioned relative to the induction element and generates eddy currents in the susceptor. The susceptor has an electrical resistance to the eddy currents, and 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 can also be generated by magnetic hysteresis losses in the susceptor, i.e., by the varying orientation of magnetic dipoles in the magnetic material as a result of alignment with the varying magnetic field. In induction heating, heat is generated within the susceptor, allowing for rapid heating, as compared to, for example, conduction heating. Furthermore, no physical contact between the induction heater and the susceptor is required, allowing for greater freedom in terms of design and application.

The induction heating assembly of the exemplary device 100 includes a susceptor structure 132 (referred to herein as the "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first inductor coil 124 and the second inductor coil 126 are made from an electrically conductive material. In this example, the first inductor coil 124 and the second inductor coil 126 are made from litz wire/cable that is helically wound to provide the helical inductor coils 124, 126. Litz wire includes multiple individual wires that are individually insulated and twisted together to form a single wire. Litz wire is designed to reduce skin effect losses in the conductor. In the exemplary device 100, the first inductor coil 124 and the second inductor coil 126 are made from copper litz wire having a square cross-section. In other examples, the litz wire can have other cross-section shapes, 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 along the longitudinal axis 134 of the device 100 (i.e., the first inductor coil 124 and the second inductor coil 126 do not overlap). The susceptor structure 132 can comprise a single susceptor or two or more separate susceptors. Ends 130 of the first inductor coil 124 and the second inductor coil 126 can be connected to the PCB 122.

It will be appreciated that in some examples, the first inductor coil 124 and the second inductor coil 126 can have at least one characteristic that differs from one another. For example, the first inductor coil 124 can have at least one characteristic that differs from the second inductor coil 126. More specifically, in one example, the first inductor coil 124 can have a different inductance value than the second inductor coil 126. In FIG. 5 , the first inductor coil 124 and the second inductor coil 126 are of different lengths, and thus the first inductor coil 124 is wound on a smaller section of the susceptor 132 than the second inductor coil 126. Thus, the first inductor coil 124 can include 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 can be made of a different material than the second inductor coil 126. In some examples, the first inductor coil 124 and the second inductor coil 126 can be substantially identical.

In this example, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. This can be useful when the inductor coils are active at different times. For example, the first inductor coil 124 can be activated first to heat a first section/portion of the item 110, and the second inductor coil 126 can be activated later to heat a second section/portion of the item 110. Winding the coils in opposite directions helps reduce current induced in inactive coils when used with certain types of control circuitry. In FIG. 5, 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 can be wound in the same direction, or the first inductor coil 124 can be a left-handed spiral and the second inductor coil 126 can be a right-handed spiral.

The susceptor 132 in this example is hollow, thus defining a receptacle in which the aerosol-generating material is received. For example, the article 110 can be inserted into the susceptor 132. In this example, the susceptor 120 is tubular and has a circular cross-section.

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

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

The device 100 of FIG. 5 further includes an insulating member 128, which may be generally tubular and may at least partially surround the susceptor 132. The insulating member 128 may be constructed from any insulating material, such as, for example, plastic. In this particular example, the insulating member is constructed from polyetheretherketone (PEEK). The insulating member 128 may help insulate various components of the device 100 from heat generated within the susceptor 132.

The insulating member 128 can also fully or partially support the first inductor coil 124 and the second inductor coil 126. For example, as shown in FIG. 5 , the first inductor coil 124 and the second inductor coil 126 are disposed around the insulating member 128 and contact the radially outward surface of the insulating member 128. In some examples, the insulating member 128 does not abut the first inductor coil 124 and the second inductor coil 126. For example, there can be a slight gap between the outer surface of the insulating member 128 and the inner surfaces of the first inductor coil 124 and the second inductor coil 126.

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

Figure 6 shows a partial cross-sectional side view of device 100. In this example, the outer cover 102 is present. The rectangular cross-sectional shapes of first inductor coil 124 and second inductor coil 126 can be more clearly seen.

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

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

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

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

Figure 7 is an exploded view of the device 100 of Figure 6, with the outer cover 102 omitted.

Figure 8A shows a cross-sectional view of a portion of the device 100 of Figure 6. Figure 8B shows an enlarged view of a region of Figure 8A. Figures 8A and 8B show the article 110 received within the susceptor 132, with the article 110 sized so that the outer surface of the article 110 abuts the inner surface of the susceptor 132. This ensures the most efficient heating. The article 110 in this example comprises an aerosol-generating material 110a. The aerosol-generating material 110a is disposed within the susceptor 132. The article 110 may also comprise other components, such as a filter, packaging material, and/or cooling structure.

FIG. 8B shows that the outer surface of the susceptor 132 is spaced 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 approximately 3 mm to 4 mm, approximately 3 to 3.5 mm, or approximately 3.25 mm.

FIG. 8B further shows that the outer surface of the insulating member 128 is spaced from the inner surfaces of the inductor coils 124, 126 by a distance 152 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 152 is approximately 0.05 mm. In another example, the distance 152 is substantially 0 mm, such that the inductor coils 124, 126 abut and contact the insulating member 128.

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

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

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

In use, the articles 1, 1', 1" described herein can be inserted into a non-combustible aerosol delivery device, such as device 100 described with reference to Figures 3-7. At least a portion of the mouthpiece 2, 2', 2" of the article 1, 1', 1" protrudes from the non-combustible aerosol delivery device 100 and can be placed in the mouth of a user. An aerosol is generated by heating an aerosol-forming material 3 using device 100. The aerosol generated by the aerosol-forming material 3 passes through mouthpiece 2 to the mouth of the user.

When articles 1, 1', 1" are inserted into device 100, the minimum distance between one or more components of the heater assembly and the tubular element of article 1, 1', 1" can be in the range of 3 mm to 10 mm, for example, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm.

The articles 1, 1', 1" described herein have particular advantages when used in conjunction with a non-combustion aerosol delivery device, such as the device 100 described with reference to Figures 3-7. In particular, it has been surprisingly found that the first tubular element 4 formed from filament tow significantly affects the temperature of the outer surface of the mouthpiece 2 of the article 1, 1', 1". For example, it has been found that when a hollow tubular element 8 formed from filament tow is wound within an outer web, such as tipping paper 5, the outer surface of the outer web at a longitudinal position corresponding to the location of the hollow tubular element 8 reaches a maximum temperature during use of less than 42°C, preferably less than 40°C, and more preferably less than 38°C or less than 36°C.

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

Accordingly, the first position is on the outer surface of the portion of the mouthpiece 2 where the first tubular element 4 is arranged, and the second and third positions are on the outer surface of the portion of the mouthpiece 2 where the material body 6 is arranged.

A control article was tested in comparison to the filament tow tubular element 4 described herein, where the filament tow tubular element 4 was replaced with a well-known spirally wound paper tube having the same structure as the second hollow tubular element 8 described herein, but measuring 6 mm in length instead of 25 mm.

Tests were performed on the first five puffs on the article so that the approximate maximum temperature could be observed, as temperatures generally peak by the fifth puff and begin to decline. Each sample was tested five times, and the temperature provided is the average of these five tests. Standard testing equipment was used to apply the well-known Health Canada smoking regime (55 ml puffs applied for 2 seconds every 30 seconds).

As shown in the table below, it was surprisingly found that the use of tubular element 4 formed from filament tow reduced the temperature of the outer surface of mouthpiece 2 compared to the control article at every puff and every test position on mouthpiece 2. Tubular element 4 formed from filament tow was particularly effective in reducing the temperature at the first probe position, where the consumer's lips would be placed when using article 1. In particular, the temperature of the outer surface of mouthpiece 2 at the first probe position decreased by more than 7°C for the first three puffs and by more than 5°C for the fourth and fifth puffs.

9 illustrates a method of manufacturing an article for use in a non-combustible aerosol delivery system, in this case involving the formation of two such articles.

In step S101, aerosol-generating material is applied to the wall of at least one tubular portion 4 or at least one body of material 6. If the tubular portion 4 or body of material 6 is to be located at the mouth end of the final mouthpiece, a single element can be provided, which can be cut into two pieces in step S105. Otherwise, two elements should be provided, so that there is one element per final mouthpiece. In step S102, a mouthpiece rod is formed comprising at least one tubular portion 4 or body of material.

In step S103, first and second aerosol-generating material portions, each containing an aerosol-forming material, are positioned adjacent to respective first and second longitudinal ends of the mouthpiece rod. For example, a hollow tubular element rod may include a double-length first hollow tubular element 8 positioned between respective first and second bodies of material 6. A tubular portion 4 is positioned at the outer end of each body of material 6, and the first and second aerosol-generating material portions are positioned adjacent to the outer ends of these tubular portions 4. The mouthpiece rod is then wrapped in a second plug wrap as described herein.

In step S104, the first and second aerosol-generating material portions are connected to the mouthpiece rod. In this example, this is accomplished by wrapping tipping paper 5, as described herein, around at least a portion of the mouthpiece rod and each of the aerosol-generating material portions 3. In this example, the tipping paper 5 extends longitudinally across the outer surface of each of the aerosol-generating material portions 3 by approximately 5 mm.

In step S105, the mouthpiece is cut to form first and second articles, each comprising a mouthpiece having at least one tubular portion or at least one body of material. For example, a first hollow tubular element 8, twice the length of the mouthpiece rod, is cut approximately halfway along its length to form first and second substantially identical articles.

In some embodiments, a non-combustible aerosol delivery system is provided that includes an aerosol modifying component and a heater, the heater operable to heat the aerosol-generating material during use so that the aerosol-generating material provides an aerosol. The aerosol modifying component includes first and second capsules. The first capsule is disposed in a first portion of the aerosol modifying component, and the second capsule is disposed in a second portion of the aerosol modifying component downstream from the first portion.

A first portion of the aerosol-modifying component is heated to a first temperature during operation of the heater to generate an aerosol, and a second portion is heated to a second temperature during operation of the heater to generate an aerosol, the second temperature being at least 4 degrees Celsius lower than the first temperature. Preferably, the second temperature is at least 5, 6, 7, 8, 9, or 10 degrees Celsius lower than the first temperature.

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

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

The first capsule contains an aerosol modifier. The second capsule also contains an aerosol modifier, which may be the same as or different from the aerosol modifier in the first capsule. In some embodiments, a user can selectively rupture the first and second capsules by applying an external force to the aerosol modifying component, releasing the aerosol modifier from each capsule.

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

The aerosol modifiers for the first and second capsules can be selected based on this temperature difference. For example, the first capsule can contain a first aerosol modifier that has a lower vapor pressure than the second aerosol modifier in the second capsule. If both capsules were heated to the same temperature, the higher vapor pressure of the aerosol modifier in the second capsule would mean that a greater amount of the second aerosol modifier would volatilize compared to the aerosol modifier in the first capsule. However, because the second capsule is heated to a lower temperature, this effect is less pronounced, and therefore, when the first and second capsules, respectively, are ruptured, a more uniform amount of the aerosol modifier in the first and second capsules volatilizes.

In some embodiments, the first and second capsules have the same aerosol modification profile, meaning that both capsules contain the same type of aerosol modifying agent in the same amount, and therefore, when both capsules are heated to the same temperature and broken, both capsules should cause the same modification of the aerosol. However, because the first capsule is heated to a higher temperature than the second capsule, more of the aerosol modifying agent in the first capsule volatilizes, for example, compared to the agent in the second capsule, and therefore causes more significant aerosol modification than the second capsule. Thus, even though both capsules are the same, which may make manufacturing the aerosol modifying component easier and/or cheaper, a user can decide whether to break the first capsule to cause more significant aerosol modification, or the second capsule to cause less significant aerosol modification, or both capsules to cause the greatest aerosol modification.

In some embodiments, both the first and second capsules contain a first and second aerosol modifier. The first aerosol modifier has a lower vapor pressure than the second aerosol modifier. Thus, when the second capsule is ruptured, a greater proportion of the second aerosol modifier evaporates relative to the first aerosol modifier compared to when the hotter first capsule is ruptured during use of the system to generate an aerosol. Thus, the same capsule can be used to generate different modifications of the aerosol based on the capsule's location within the first or second portion of the aerosol modifying component.

The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not intended to be exhaustive and/or exclusive. The advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein should not be construed as limitations on the scope of the invention, as defined by the claims, or on the equivalents of the claims, and it should be understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. It is preferred that the various embodiments of the present invention may include, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, the present disclosure may include other inventions not claimed herein but which may be claimed in the future.

Claims (36)

1. An article for use in a non-flammable aerosol delivery system, comprising:
a first aerosol-forming material; and
a downstream portion including a downstream component of the first aerosol-forming material; and
and tipping paper connecting the downstream portion to the first aerosol-generating material ;
the component comprises a body of material, the body of material including a second aerosol-forming material;
the component comprises a tubular portion with a wall, the tubular portion defining a cavity within the component, the cavity having an internal volume greater than 450 ^mm3 ;
The article, wherein the tipping paper covers the downstream portion and overlaps the first aerosol-forming material . The article of claim 1, wherein the tubular portion is located at the downstream end of the component. The article described in claim 1 or 2, wherein the tubular portion is located at the upstream end of the component. The article described in any one of claims 1 to 3, wherein the second aerosol-generating material is located on the inner wall of the tubular portion. The article described in any one of claims 1 to 4, wherein the tubular portion comprises a hollow tubular element. The article of claim 5, wherein the hollow tubular element is formed from a filament tow. The article described in claim 5, wherein the hollow tubular element is formed as a paper tube made from at least two layers of paper. The article of claim 5, 6, or 7, wherein the hollow tubular element is formed from a material having a density of 0.25 g/cc to 0.75 g/cc, or 0.25 g/cc to 0.65 g/cc, or 0.35 g/cc to 0.65 g/cc. The article described in any one of claims 5 to 8, wherein the hollow tubular element has an inner diameter greater than 3.0 mm or greater than 3.5 mm. The article described in any one of claims 5 to 9, wherein the hollow tubular element has a minimum wall thickness of greater than 0.9 mm. The article described in any one of claims 5 to 10, wherein the hollow tubular element constitutes a first hollow tubular element, and the component further constitutes a second hollow tubular element. The article of claim 11, wherein the second hollow tubular element is located at an end of the component opposite the first hollow tubular element. The article of claim 11 or 12, wherein the component further comprises a cylindrical body of material disposed between the first hollow tubular element and the second hollow tubular element. The article described in any one of claims 11 to 13, wherein the second hollow tubular element is formed from a filament tow. The article described in any one of claims 11 to 13, wherein the second hollow tubular element is formed as a paper tube made from at least two layers of paper. The article described in any one of claims 11 to 15, wherein the second hollow tubular element has a length greater than about 10 mm or greater than about 12 mm. The article of claim 7 or 15, wherein the at least two layers of paper each include a butt seam. The article described in claim 7, 15, or 17, wherein the at least two layers of paper are concentrically wound. The article described in any one of claims 7, 15, 17, and 18, wherein the total thickness of the paper tube is within the range of about 50 micrometers to about 500 micrometers, about 100 to about 400 micrometers, or about 200 micrometers to about 350 micrometers. The article of claim 1, wherein the body of material is cylindrical and formed from filament tow. The article of claim 20, wherein the filament tow has a weight per mm of the length of the body of material that is about 10% to about 30% of the range between the minimum and maximum weights of a tow performance curve generated for the filament tow. The article of any one of claims 1 to 21, wherein the second aerosol-forming material comprises a flavoring and/or an amorphous solid. The article of any one of claims 1 to 22, wherein the second aerosol-generating material comprises microcapsules. The article of claim 23, wherein the microcapsules contain an aerosol-forming additive. The article of claim 24, wherein the microcapsules are configured to release the aerosol-forming additive upon the application of heat. The article described in any one of claims 1 to 25, wherein the component is provided with ventilation. The article of claim 26, wherein the level of ventilation through the component is less than 50% of the volume of aerosol passing through the component, or in the range of 45% to 65%, or 40% to 60% of the volume of aerosol passing through the component. The article of claim 26 or 27, wherein the ventilation is provided by ventilation apertures in the tubular portion. The article described in any one of claims 26 to 28, wherein the ventilation is provided by an essentially porous material. The article of any one of claims 1 to 29, wherein the second aerosol-generating material comprises at least one of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The article of claim 30, wherein the second aerosol-forming material comprises at least 10%, at least 15%, or at least 20% by weight of the aerosol-forming material. The article described in any one of claims 1 to 31, wherein the first aerosol-forming material is wrapped in a paper wrapper having a permeability level greater than about 2000 Coresta units. An article according to any one of claims 1 to 32;
a non-combustible aerosol delivery system comprising: a non-combustible aerosol delivery device; The non-combustion aerosol delivery system of claim 33, wherein the non-combustion aerosol delivery device includes a heater. The non-combustion aerosol delivery system of claim 34, wherein the system is configured such that when the article is inserted into the non-combustion aerosol delivery device, the minimum distance between the heater and the tubular portion of the article is at least about 3 mm. 36. The non-combustion aerosol delivery system of claim 34 or 35, wherein the article further comprises an aerosol modifying component, the heater is operable to heat the first aerosol-generating material during use so that the first aerosol-generating material provides an aerosol, the aerosol modifying component is located downstream of the aerosol-generating material, the aerosol modifying component comprises: a first capsule located within a first portion of the aerosol modifying component, the first portion of the aerosol modifying component being heated to a first temperature during operation of the heater to generate the aerosol; and a second capsule located within a second portion of the aerosol modifying component downstream of the first portion, the second portion being heated to a second temperature during operation of the heater to generate the aerosol, the second temperature being at least 4 degrees Celsius lower than the first temperature.