JP7796773B2 - Aerosol-forming composition - Google Patents

Description

This application relates to aerosol-forming compositions, processes for making aerosol-forming compositions, and articles including aerosol-forming compositions.

background

In use, an aerosol-generating system generates an aerosol that is inhaled by a user. For example, a tobacco heating device heats an aerosol-generating material, such as tobacco, to form an aerosol by heating but not burning the aerosol-generating material. Some aerosol-generating systems include a susceptor configured to heat the aerosol-generating material and form the aerosol.

overview

According to a first aspect of the present disclosure, there is provided an aerosol-generating composition comprising an aerosol-generating material including a binder and an aerosol-forming agent, and at least one susceptor at least partially embedded in the aerosol-generating material.

In some embodiments, the aerosol-forming material is in the form of a slurry.

In some embodiments, the aerosol-generating material is in the form of a sheet or cut sheets.

In some embodiments, the susceptor includes multiple susceptor elements that can be heated by the penetration of a varying magnetic field.

In some embodiments, the plurality of susceptor elements are in the form of particles, loops, spheres, strands, and/or strips.

In some embodiments, the susceptor takes the form of a web or mesh.

In some embodiments, the susceptor takes the form of a fibrous sheet.

In some embodiments, the fibrous sheet includes a first surface, a second surface opposite the first surface, and a plurality of fibers extending from one or both of the first and/or second surfaces, and the aerosol-generating material contacts and at least partially covers at least one of the first and/or second surfaces such that one or more of the plurality of fibers are embedded in the aerosol-generating material.

In some embodiments, the susceptor includes one or more closed circuits of material that can be heated by the penetration of a varying magnetic field.

In some embodiments, the binder is selected from the group consisting of cellulosic binders, non-cellulosic binders, and mixtures thereof.

In some embodiments, the aerosol forming agent is selected from the group consisting of glycerol, propylene glycerol, and mixtures thereof.

In some embodiments, the aerosol-forming material includes a filler.

In some embodiments, the filler is wood pulp.

In some embodiments, the aerosol-generating material includes plant material.

In some embodiments, the plant material includes tobacco.

In some embodiments, the aerosol-forming material is reconstituted tobacco.

In some embodiments, the aerosol-forming material is substantially free of tobacco material.

According to a second aspect of the present disclosure, there is provided an aerosol-generating composition comprising a first aerosol-generating material including a binder and an aerosol-forming agent, a second aerosol-generating material, and at least one susceptor at least partially embedded in the first aerosol-generating material.

In some embodiments, the first aerosol-generating material includes plant material.

In some embodiments, the second aerosol-forming material comprises or consists of laminar tobacco and/or reconstituted tobacco.

In some embodiments, the first aerosol-forming material is substantially free of tobacco.

According to a third aspect of the present disclosure, there is provided a process for producing an aerosol-generating composition, the process comprising at least partially embedding a susceptor in an aerosol-generating material comprising a binder and an aerosol-forming agent.

In some embodiments, the process includes combining a binder, an aerosol-forming agent, and a susceptor to form a slurry of aerosol-generating material.

In some embodiments, the process includes curing the slurry to form a gel and, optionally, drying the gel to form the aerosol-generating material.

In some embodiments, the aerosol-generating material is in the form of a sheet, and the process further comprises cutting the sheet to form a plurality of separate portions of the aerosol-generating material.

In some embodiments, the discrete portions of aerosol-generating material comprise multiple strands or strips.

The aerosol-generating material may be prepared by the process of the third aspect.

According to a fourth aspect of the present disclosure, there is provided an aerosol-generating material including a binder and an aerosol-forming agent, and a susceptor at least partially embedded in the binder.

According to a fifth aspect of the present disclosure, there is provided a susceptor having at least partially embedded therein an aerosol-generating material comprising a binder and an aerosol-forming agent.

According to a sixth aspect of the present disclosure, there is provided an article for use in a non-flammable aerosol delivery system comprising an aerosol-forming composition according to the first aspect.

According to a seventh aspect of the present disclosure, there is provided a non-combustible aerosol delivery device for use with the article of the sixth aspect.

According to an eighth aspect of the present disclosure, there is provided a system comprising the article of the sixth aspect and the device of the seventh aspect.

According to a ninth aspect of the present disclosure, there is provided use of the aerosol-forming composition of the first aspect for generating an aerosol.

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

FIG. 1 is a perspective view of an article for use with a non-flammable aerosol delivery device. FIG. 1 is a process flow diagram illustrating a process for producing an aerosol-forming material. FIG. 1 is a process flow diagram illustrating a process for producing an aerosol-forming material. FIG. 1 is a perspective view of an aerosol-forming material. 4b is a cross-sectional side view of the aerosol-generating material shown in FIG. 4a. FIG. 1 is a perspective view of a further aerosol-forming material. 5b is a side cross-sectional view of the aerosol-generating material shown in FIG. 5a. FIG. 1 is a perspective view of a further aerosol-forming material. 6b is a cross-sectional side view of a further article for use with a non-combustion aerosol delivery device including the aerosol-forming material shown in FIG. 6a. FIG. 2 is a cross-sectional side view of an aerosol generation component. 6c is a cross-sectional side view of a further article for use with a non-combustion aerosol delivery device including the aerosol-generating component shown in FIG. 6c. 1 is a cross-sectional side view of a further article for use with a non-combustible aerosol delivery device. FIG. 1 is a schematic diagram of a non-combustible aerosol delivery device. FIG. 1 is a schematic diagram of a non-combustible aerosol delivery device. FIG. 1 is a schematic diagram of a non-combustible aerosol delivery device. FIG. 1 is a schematic diagram of a non-combustible 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;
Combustion 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;
a non-combustion aerosol delivery system that releases compounds from an aerosol-forming material without burning the aerosol-forming material, such as an electronic cigarette, tobacco heating product, or mixing system for generating an aerosol using a combination of aerosol-forming materials;
an aerosol-free delivery system that delivers at least one substance, which may or may not contain nicotine, to a user orally, nasally, transdermally, or otherwise, without forming an aerosol, including, but not limited to, oral products such as lozenges, gums, patches, articles containing inhalable powders, and oral tobacco products, including snus and moist snuff;
Includes.

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. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustion aerosol delivery system is a mixing system for generating an aerosol using a combination of aerosol-forming materials, and one or more of the aerosol-forming materials can be heated. Each of the aerosol-forming materials can 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 can 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 system.

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

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.

In some embodiments, a non-combustible aerosol delivery system, e.g., a non-combustible aerosol delivery device of the non-combustible aerosol delivery system, can include a power source and a controller. The power source can be, for example, a power source.

In some embodiments, the non-combustion aerosol delivery system includes an area for receiving an item for use in the non-combustion aerosol delivery system, an aerosol generator, an aerosol-generation area, a housing, a mouthpiece, a filter, and/or an aerosol modifier.

In some embodiments, an article for use with a non-combustible aerosol delivery device includes an aerosol-forming composition including an aerosol-forming material, an aerosol-forming composition storage region, an aerosol-forming composition transfer component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol modifier.

In the figures described herein, similar reference numerals are used to describe equivalent features, items or components.

Figure 1 is a perspective view of an article 1 for use in an aerosol delivery system.

Article 1 includes a mouthpiece 2 and an aerosol-generation section 3 connected to mouthpiece 2. In this example, aerosol-generation section 3 includes a cylindrical rod of an aerosol-generating composition. Article 1 includes an upstream end 2' and a downstream end 2" spaced apart from upstream end 2'.

The aerosol-forming composition includes an aerosol-forming material including a binder and an aerosol-forming agent, and one or more susceptors at least partially embedded in the aerosol-forming material.

An aerosol-forming material is a material capable of generating an aerosol when activated, for example, by heating, irradiation, or any other method. The aerosol-forming material can be in the form of a solid, liquid, or semi-solid, such as a gel, and may or may not contain an active substance and/or flavoring.

The aerosol-generating composition includes at least one aerosol-generating material. For example, the aerosol-generating material may include multiple aerosol-generating materials. The multiple aerosol-generating materials may be the same or different. For example, the aerosol-generating composition may include a first aerosol-generating material and a second aerosol-generating material. Additional (e.g., third, fourth, fifth, or more) aerosol-generating materials may also be included in the composition.

At least one of the aerosol-generating materials is an aerosol-generating material that includes a binder (which may be a gelling agent) and an aerosol-forming agent. Optionally, an active substance and/or a filler may also be present. Optionally, a solvent, such as water, is also present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent.

In some embodiments, the binder includes or is a gelling agent. The binder can include one or more compounds selected from the group including alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder includes one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the binder includes a hydrocolloid. In some cases, the binder includes alginate and/or pectin and may be combined with a hardening agent (calcium source), etc., during formation of the aerosol-forming material. In some cases, the aerosol-forming material may include calcium-crosslinked alginate and/or calcium-crosslinked pectin. The binder may include one or more compounds selected from cellulosic binders, non-cellulosic binders, guar gum, acacia gum, and mixtures thereof.

In some embodiments, the cellulosic binder is selected from the group consisting of hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

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

In some embodiments, the binder comprises one or more non-cellulosic binders (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-cellulose-based binder is alginic acid or agar.

In some examples, the binder is present in an amount of about 5-40 wt %, or 15-40 wt %, of the aerosol-forming material. That is, the aerosol-forming material includes the binder in an amount of about 5-40 wt %, or 15-40 wt %, based on the dry weight of the aerosol-forming material. In some examples, the aerosol-forming material includes the binder in an amount of about 20-40 wt %, or about 15-35 wt %, of the aerosol-forming material.

In some examples, the binder contains alginate in an amount of about 5-40 wt %, or about 15-40 wt %, of the aerosol-forming material. That is, the aerosol-forming material contains alginate in an amount of about 5-40 wt %, or about 15-40 wt %, of the aerosol-forming material by dry weight. In some examples, the aerosol-forming material contains alginate in an amount of about 20-40 wt %, or about 15-35 wt %, of the aerosol-forming material.

In some examples, the binder contains pectin in an amount of about 3-15 wt % of the aerosol-forming material. That is, the aerosol-forming material contains pectin in an amount of about 3-15 wt % of the aerosol-forming material, based on the dry weight of the aerosol-forming material. In some examples, the aerosol-forming material contains pectin in an amount of about 5-10 wt % of the aerosol-forming material.

In some examples, the binder contains guar gum in an amount of about 3 to 40 wt % of the aerosol-forming material. That is, the aerosol-forming material contains guar gum in an amount of about 3 to 40 wt % based on the dry weight of the aerosol-forming material. In some examples, the aerosol-forming material contains guar gum in an amount of about 5 to 10 wt % of the aerosol-forming material. In some examples, the aerosol-forming material contains guar gum in an amount of about 15 to 40 wt %, or about 20 to 40 wt %, or about 15 to 35 wt % of the aerosol-forming material.

In examples, the alginic acid is present in an amount of at least about 50 wt% of the binder. In examples, the aerosol-forming material includes alginic acid and pectin, and the ratio of alginic acid to pectin is 1:1 to 10:1. The ratio of alginic acid to pectin is typically greater than 1:1, i.e., the alginic acid is present in an amount greater than the amount of pectin. In examples, the ratio of alginic acid to pectin is about 2:1 to 8:1, or about 3:1 to 6:1, or approximately 4:1.

The aerosol-forming material can be formed by forming a slurry and then drying the slurry to form a solid. The inclusion of a binder in the slurry results in the aerosol-forming material being formed from a dried gel. It has been found that the inclusion of a binder in the aerosol-forming material stabilizes flavor compounds, such as menthol, within the gel matrix, allowing for higher flavor loadings than non-gel compositions. The flavoring (e.g., menthol) is stable at high concentrations, and the product has a good shelf life.

In some embodiments, the binder comprises alginic acid, and the binder is present in the aerosol-forming material in an amount of 10-30 wt %, 20-35 wt %, or 25-30 wt % of the slurry/aerosol-forming material (calculated on a dry weight basis). In some embodiments, alginic acid is the only binder present in the aerosol-forming material. In other embodiments, the binder comprises alginic acid and at least one additional binder, such as pectin.

The aerosol-forming material includes an aerosol-forming agent. An "aerosol-forming agent" (also referred to herein as an aerosol-forming agent material) is an agent that facilitates the generation of an aerosol. The aerosol-forming agent can facilitate the generation of an aerosol by promoting the initial vaporization and/or condensation of a gas into an inhalable solid and/or liquid aerosol. In some embodiments, the aerosol-forming agent can improve the delivery of flavorants from the aerosol-forming material. Generally, any suitable aerosol-forming agent 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.

The aerosol-forming agent may be present in the aerosol-forming material in an amount up to about 80 wt% of the aerosol-forming material, such as from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10% to about 80 wt%, 75 wt%, 70 wt%, 65 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of the aerosol-forming material. In some embodiments, the aerosol-forming material includes the aerosol-forming agent in an amount of about 40-80 wt%, 40-75 wt%, 50-70 wt%, or 55-65 wt%.

In some embodiments, the aerosol-forming agent can be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. 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, when present, can be present in an amount of 0.1-0.3% by weight of the composition.

The aerosol former may act as a plasticizer. In some cases, the aerosol former material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol former material consists essentially of or consists of glycerol. It has been established that if the plasticizer content is too high, the aerosol-generating material can absorb water, resulting in a material that does not produce a suitable consumption experience during use. It has been established that if the plasticizer content is too low, the aerosol-generating material can become brittle and easily break. The plasticizer content specified herein provides flexibility to the aerosol-generating material, allowing the sheet to be wound onto a bobbin, which may be useful in the manufacture of consumable products or allow the sheet to be transported before shredding.

The aerosol-forming agent can enhance the mouthfeel, and generally the sensory characteristics, of the aerosol generated by the aerosol-forming material when heated and inhaled by a user, particularly when the aerosol-forming material contains a relatively large amount (e.g., >40 wt%) of the aerosol-forming agent. The ability of the aerosol-forming material to retain large amounts of the aerosol-forming agent can reduce the need to add other components of the aerosol-forming material, such as expanded plant matter material, along with large amounts of the aerosol-forming agent, thereby improving manufacturing efficiency.

The aerosol-forming material may include a filler. The filler 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 cast 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 some cases, the aerosol-generating material comprises 5 to 50 wt%, 10 to 40 wt%, or 15 to 30 wt% of filler. In some such cases, the aerosol-generating material comprises at least 1 wt% of filler, e.g., at least 5 wt%, at least 10 wt%, at least 20 wt%, at least 30 wt%, at least 40 wt%, or at least 50 wt% of filler. In exemplary embodiments, the aerosol-generating material comprises 5 to 25 wt% of filler, including fibers. Preferably, the filler consists of fibers or is in the form of fibers.

In some embodiments, the aerosol-forming material contains less than 60 wt% filler, such as 1 wt% to 60 wt%, or 5 wt% to 50 wt%, or 5 wt% to 30 wt%, or 10 wt% to 20 wt%.

In other embodiments, the aerosol-forming material contains less than 20 wt%, preferably less than 10 wt%, or less than 5 wt%, of filler.

The filler may include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives (such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). Inorganic fillers, such as calcium carbonate or chalk, may also be used. In some embodiments, the aerosol-forming material does not include calcium carbonate, such as chalk.

Preferably, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or a cellulose derivative (e.g., methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). Without wishing to be bound by theory, it is believed that including a fibrous filler within the aerosol-generating material can increase the tensile strength of the material. Additionally, including a fibrous filler has been found to improve handling of the aerosol-generating material during manufacturing. In particular, the resulting aerosol-generating material has been found to be less "sticky" and, as a result, more easily shredded during manufacturing. Therefore, including a fibrous filler can increase manufacturing efficiency and reduce the likelihood of machine stoppages during shredding. Including a fibrous filler in the aerosol-generating material also means that the aerosol-generating material is less likely to clump together (e.g., clump) when shredded. When shredded aerosol-generating material is included in a consumable product, reducing clumping optimizes the distribution of the shredded aerosol-generating material within the consumable product. Therefore, having each consumable contain a similar amount of chopped aerosol-forming material likely improves the consistency of flavor loading within a batch of consumables and/or within a given consumable.

In some embodiments, the aerosol-generating material comprises the substance to be delivered. The substance to be delivered may include one or more active ingredients, one or more flavorings, one or more aerosol former materials, and/or one or more other functional materials.

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

As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, a dietary supplement, a nootropic, or a psychoactive substance. The active substance may be naturally derived or synthetically derived. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives (including, but not limited to, the corresponding acidic forms of these materials, where appropriate), or combinations thereof. The active substance may also include one or more components, derivatives, or extracts of tobacco, 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.

As described herein, the active substance may include or be derived from one or more botanical substances, or components, derivatives, or extracts thereof. 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, husks, shells, etc. Alternatively, the material may include synthetically derived active compounds naturally occurring in the botanical substance. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, shreds, strips, sheets, etc. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, kavi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint may be any of the following mint varieties: common mint (Mentha arvensis), grapefruit mint (Mentha c.v.), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), lime mint (Mentha piperita citrate c.v.), chocolate mint (Mentha piperita c.v.), curly mint (Mentha spicata crispa), wild mint (Mentha cordifolia), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), pennyroyal mint (Mentha It may be selected from Mentha pulegium, English spearmint (Mentha spicata c.v.), and apple mint (Mentha suaveolens).

In some embodiments, the active substance comprises or is derived from one or more botanical substances, or components, derivatives, or extracts thereof. The botanical substance can be tobacco material. Thus, in some embodiments, the aerosol-forming material can comprise tobacco material.

As used herein, the term "tobacco material" refers to any material containing tobacco or a derivative or substitute thereof. The tobacco material can take any suitable form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco, and/or tobacco extract.
In some embodiments, the active agent comprises or is derived from one or more botanical substances, or components, derivatives, or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

As used herein, the term "tobacco material" refers to material derived from a plant of the Nicotiana species. The selection of the plant of the Nicotiana species is not limited, and the type or types of tobacco used may vary. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, leaf tobacco, tobacco stems, reconstituted tobacco, and/or tobacco extract. As used herein, "leaf tobacco" means cut laminar tobacco.

In some embodiments, the tobacco material is selected from flue-cured or Virginia, burley, sun-cured, Maryland, dark (fire-cured), dark (air-cured), light (air-cured), Indian (air-cured), Red Russian, and rustica tobaccos, and mixtures thereof, as well as various other rare or specialty tobaccos (green or cured). Tobacco materials produced through any other type of tobacco processing that can modify the tobacco taste, such as fermented tobacco or genetic modification or hybridization techniques, are also within the scope of this disclosure. For example, it is contemplated that tobacco plants may be genetically engineered or hybridized to increase or decrease the production of a component, property, or attribute.

In some embodiments, the tobacco material is sun-cured tobacco selected from Indian Kurnool and Oriental tobaccos, including Izmir, Basma, Samsun, Katerini, Prelip, Komotini, Xanthi, and Yambol tobaccos. In some embodiments, the tobacco material is dark (air-cured) tobacco selected from Passanda, Cubano, Jatin, and Beski tobaccos. In some embodiments, the tobacco material is light (air-cured) tobacco selected from North Wisconsin and Galpao tobaccos.

In some embodiments, the tobacco material is selected from Brazilian tobacco, including Matafina and Bahia tobacco. In some embodiments, the tobacco material is selected from Criollo, Pilotto Cubano, Olor, Green River, Isabela DAC, White Pata, Elulu, Jatim, Madura, Kasturi, Connecticut Seed, Broadleaf, Connecticut, Pennsylvania, Italian (air-cured), Paraguayan (air-cured), and Wansucker tobacco.

For the preparation of smokeable/electronic smoking or smokeless tobacco products, plants of the Nicotiana species may be subjected to a curing method. Certain types of tobacco may be subjected to other types of curing methods, such as flue-curing or sun-drying. Preferably, but not necessarily, the cured harvested tobacco is aged.

Tobacco can be harvested at different stages of growth, for example, when the plant reaches a level of maturity and the lower leaves can be harvested while the upper leaves are still growing.

In some embodiments, at least a portion of a plant of the Nicotiana species (e.g., at least a portion of the tobacco material) is used in an immature form. That is, in some embodiments, the plant or at least a portion of the plant is harvested before reaching a stage normally considered ripe or mature.

In some embodiments, at least a portion of a plant of the Nicotiana species (e.g., at least a portion of the tobacco material) is used in a mature form. That is, in some embodiments, the plant or at least a portion of the plant is harvested when the plant (or plant portion) has reached a point traditionally considered ripe, overripe, or mature, and harvesting can be done using tobacco harvesting techniques traditionally used by farmers. Both Oriental and Burley tobacco plants can be harvested. Additionally, Virginia tobacco leaves can be harvested or picked according to the position of their petioles.

Nicotiana species may be selected for the content of various compounds present in the plants. For example, plants may be selected based on their production of relatively large amounts of one or more of the compounds desired to be isolated (i.e., volatile compounds of interest). In certain embodiments, Nicotiana species plants are specifically cultivated for their abundance of leaf surface compounds. Tobacco plants may be grown in greenhouses, growth chambers, or outdoor fields, or may be grown hydroponically.

Various parts or portions of the Nicotiana species plant may be utilized. In some embodiments, the whole plant or substantially the whole plant is harvested and used as is. As used herein, the term "substantially the whole plant" means that at least 90% of the plant is harvested, such as at least 95% of the plant, for example, at least 99% of the plant. Alternatively, in some embodiments, various parts or pieces of the plant are harvested or separated for further use after harvest. In some embodiments, the tobacco material is selected from the leaves, stems, petioles, and various combinations of these parts of the plant. Thus, the tobacco material of the present disclosure may include the whole Nicotiana species plant or any part of the plant.

The tobacco material may comprise or consist of reconstituted tobacco, tobacco lamina, paper reconstituted tobacco, extruded tobacco, band-cast reconstituted tobacco, band-cast reconstituted tobacco, or a combination of reconstituted tobacco and another form of tobacco, such as tobacco lamina or tobacco granules.

In some embodiments, the aerosol-forming material is substantially free of plant material. In particular, in some embodiments, the aerosol-forming material is substantially free of tobacco.

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

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, may be used to create a desired taste, aroma, or other somatosensory sensation in products for adult consumers. These materials may include naturally derived flavor materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese 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, etc.). Fruits: papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberries, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang Orchids, sage, fennel, wasabi, bell peppers, ginger, coriander, coffee, hemp, mint oil of any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, 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, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, Damian The ingredients may include other additives such as spices, 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. These ingredients may be imitation, synthetic, or natural ingredients, or mixtures thereof. These ingredients may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

In some embodiments, the flavoring includes menthol, spearmint, and/or peppermint. In some embodiments, the flavoring includes cucumber, blueberry, citrus, 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 aerosol-forming material may contain up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% flavoring. In some cases, the aerosol-forming material may contain at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% flavoring (all calculated on a dry weight basis). For example, the aerosol-forming material may contain 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% flavoring. In exemplary embodiments, the aerosol-forming material contains 35-50 wt% flavoring. In some cases, the flavoring includes, consists essentially of, or consists of menthol.

In some embodiments, the flavoring agent may include a sensory elicitor intended to achieve a somatosensory sensation typically perceived chemically induced by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and may include agents that provide heating, cooling, tingling, or anesthetic effects. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol WS-3.

The aerosol-forming composition may include an aerosol-forming material in the form of an "amorphous solid." The amorphous solid may be a "monolithic solid." In some embodiments, the aerosol-forming material may be a dry gel.

The aerosol-generating composition may include an aerosol-generating material in the form of an aerosol-generating film. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-forming agent, and one or more other ingredients, such as an active agent, to form a slurry, and then heating the slurry to volatilize at least some of the solvent and form the aerosol-generating film. The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent. The aerosol-generating film may be a continuous or discontinuous film, such as a construction of separate portions of film on a substrate. The aerosol-generating film may be substantially free of tobacco.

The aerosol-generating material may include or be a sheet, which may optionally be shredded to form shredded sheets. The sheet of aerosolizable material may be cut lengthwise and/or widthwise, e.g., in a cross-cut shredding process, to define a cut length of strands or strips of aerosolizable material in addition to a cut width.

The aerosol-generating composition can include any combination of the above aerosol-generating materials. For example, the aerosol-generating composition can include a mixture of aerosol-generating materials, at least one of which includes a binder and an aerosol-forming agent. In some embodiments, the aerosol-generating composition includes a (e.g., first) aerosol-generating material that includes a binder and an aerosol-forming agent, and a (e.g., second) different aerosol-generating material. For example, the second aerosol-generating material can be a plant material such as tobacco lamina.

Figure 2 shows an overview of a process for making an aerosol-generating material. An aerosol-generating composition can include the aerosol-generating material prepared by the process shown in Figure 2. The process includes forming a slurry including components of the aerosol-generating material or its precursor, solidifying the slurry to form a gel, and drying to form the aerosol-generating material. Optionally, the step of solidifying the gel can include applying a solidifying agent to the slurry. In some embodiments, the solidifying agent is sprayed onto the slurry, such as on top of the slurry.

In some embodiments, the solidifying agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof. In some embodiments, the solidifying agent comprises or consists of calcium formate and/or calcium lactate. In particular embodiments, the solidifying agent comprises or consists of calcium formate. It has been determined that the use of calcium formate as the solidifying agent typically results in aerosol-generating materials having higher tensile strength and higher resistance to elongation.

The total amount of hardening agent, such as a calcium source, may be 0.5 to 5 wt % (calculated on a dry weight basis). Preferably, the total amount may be from about 1 wt %, 2.5 wt %, or 4 wt % to about 4.8 wt % or 4.5 wt %. It has been found that adding too little hardening agent can result in an aerosol-forming material that does not stabilize the components of the aerosol-forming material, causing these components to drop out of the aerosol-forming material. It has been found that adding too much solidifying agent can result in an aerosol-forming material that is very sticky and therefore difficult to handle.

When the aerosol-forming material does not contain tobacco, a larger amount of hardener may need to be applied. Thus, in some cases, the total amount of hardener may be 0.5 to 12 wt%, such as 5 to 10 wt%, calculated on a dry weight basis. Preferably, the total amount may be from about 5 wt%, 6 wt%, or 7 wt% to about 12 wt% or 10 wt%. In this case, the aerosol-forming material typically does not contain tobacco.

The process involves forming a layer of the slurry. This typically involves spraying, casting, or extruding the slurry. In an example, the slurry layer is formed by electrostatically spraying the slurry. In an example, the slurry layer is formed by casting the slurry.

In some instances, all steps of the process occur at least partially simultaneously (e.g., during electrostatic spraying). In some instances, steps of the process occur sequentially.

The aerosol-generating material may contain 1-60 wt% gelling agent, 0.1-70 wt% aerosol former material, 5-50% filler in the form of fibers, and 0.1-80 wt% flavoring and/or active substance.

The aerosol-generating material may comprise 10-40 wt% gelling agent, 10-70 wt% aerosol former material, 20-40 wt% filler, and optionally 10-50 wt% flavoring.

In an embodiment, the aerosol-forming material comprises alginate in an amount of 32.8 wt%, glycerol in an amount of 19.2 wt%, and menthol in an amount of 48 wt%.

In one embodiment, the aerosol-forming material comprises alginate in an amount of 26.2 wt%, glycerol in an amount of 15.4 wt%, menthol in an amount of 38.4 wt%, and fiber (derived from wood pulp) in an amount of 20 wt%.

In an embodiment, the aerosol-forming material comprises alginate in an amount of 32 wt%, pectin in an amount of 8 wt%, and glycerol in an amount of 60 wt%.

In an embodiment, the aerosol-forming material comprises alginate in an amount of 24 wt%, pectin in an amount of 6 wt%, cellulose fiber in an amount of 10 wt%, and glycerol in an amount of 60 wt%.

In an embodiment, the aerosol-forming material comprises carboxymethyl cellulose (CMC) in an amount of about 7 wt%, cellulose fibers (derived from wood pulp) in an amount of about 43 wt%, and glycerol in an amount of about 50 wt%.

The aerosol-generating composition includes at least one susceptor that can be heated using induction heating.

Induction heating is a process of heating a conductive object (such as a susceptor) by electromagnetic induction. A magnetic field generator can include an induction element, e.g., one or more inductor coils, and a device for passing a variable current, such as an alternating current, through the induction element. The varying current in the induction element generates a variable magnetic field. The variable magnetic field penetrates a susceptor appropriately positioned relative to the induction element and generates eddy currents within the susceptor. The susceptor has an electrical resistance to the eddy currents, and the flow of eddy currents against this resistance heats the susceptor by Joule heating. If the susceptor contains a ferromagnetic material, such as iron, nickel, or cobalt, heat can also be generated by magnetic hysteresis losses in the susceptor, i.e., by varying the orientation of magnetic dipoles in the magnetic material as a result of alignment with the varying magnetic fields. In induction heating, heat is generated within the susceptor, allowing for faster heating than, for example, heating by conduction. Furthermore, no physical contact is required between the induction heater and the susceptor, allowing for greater flexibility in construction and application.

The susceptor is at least partially embedded in the aerosol-generating material.

The aerosol-generating composition can include one or more aerosol-generating materials described herein. One or more susceptor materials can be embedded in one or more of the aerosol-generating materials.

The susceptor can be in the form of a rod, strand, strip, continuous sheet, or discontinuous sheet such as a mesh or web. The composition can include a single susceptor at least partially embedded in the aerosol-generating material. For example, the susceptor can be in the form of a continuous sheet embedded in the sheet of aerosol-generating material. In such an embodiment, the susceptor sheet can be completely embedded within the aerosol-generating sheet. The sheet of aerosol-generating material can be a flat sheet.

The susceptor sheet can be incorporated into an aerosol-generation section of an article for use with a non-combustion aerosol delivery system. The aerosol-generation section can be in the form of, for example, a rod. The susceptor sheet can have a cross-sectional area that is about 1% to about 25% of the total cross-sectional area of the aerosol-generation section.

In some embodiments, the susceptor sheet can have a thickness of about 150 μm to about 300 μm. Such a sheet can have flexibility that allows it to be easily handled.

The susceptor can take the form of a fibrous sheet including a plurality of fibers made from a material heatable by the penetration of a fluctuating magnetic field. The fibrous sheet can include a first surface, a second surface opposite the first surface, and a plurality of fibers extending from one or both of the first and/or second surfaces, with the aerosol-generating material contacting and at least partially covering at least one of the first and/or second surfaces such that one or more of the plurality of fibers are embedded in the aerosol-generating material. Such fibrous sheets typically have a high surface area-to-volume ratio, which can increase the rate of heat transfer from the fibrous material to the aerosol-generating material in which it is embedded.

The susceptor may take the form of a closed circuit of magnetically conductive material, which, in use, may improve magnetic coupling between the susceptor and the magnetic field generator of the aerosol delivery device, resulting in higher or improved heating.

When the aerosol-generating composition includes an aerosol-generating material in sheet form and susceptors are embedded in the aerosol-generating material, the sheet can be cut or shredded to form an aerosol-generating composition including multiple strands or strips of aerosol-generating material with embedded susceptors.

The susceptor can include or consist of multiple separate susceptor elements made from a material that can be heated by the penetration of a varying magnetic field. For example, the susceptor can include multiple strands or strips. In some embodiments, the susceptor elements are particulate or granular. The particulates can have a wide variety of shapes. The susceptor elements can take the form of, for example, beads, flakes, particles, shards, rods, tubes, plates, coils, rings, or loops. The susceptor elements can be uniformly dispersed throughout the aerosol-generating material. This can allow for uniform heating of the aerosol-generating material.

The susceptor elements can be magnetically aligned with one another. That is, the magnetic dipoles within the susceptor elements can be magnetically aligned with one another. When the susceptor elements are magnetically aligned with one another, this can improve the electromagnetic coupling between the susceptor elements and the magnetic field generator of the aerosol delivery device.

The susceptor is at least partially embedded in the aerosol-generating material. In some embodiments, the susceptor is fully embedded within the aerosol-generating material such that it is completely surrounded by the aerosol-generating material. The susceptor may be in direct contact with the aerosol-generating material. At least partially embedding the susceptor in the aerosol-generating material allows for a faster rate of heat transfer between the susceptor material and the aerosol-generating material. This can improve the rate at which the aerosol-generating material heats up and generates aerosol during use.

In some embodiments, the aerosol-generating composition may include two or more susceptors. All of the susceptors may be at least partially embedded in the aerosol-generating material. Alternatively, one or more of the susceptors may be at least partially embedded in the aerosol-generating material. For example, the aerosol-generating composition may include a first susceptor in the form of a continuous sheet completely embedded in the aerosol-generating material, and a second susceptor including a plurality of discrete susceptor elements as described herein.

The susceptor can be embedded in the aerosol-generating material by any suitable means. The aerosol-generating material can be added to a slurry formed during the manufacture of the aerosol-generating material according to the processes described herein. For example, the aerosol-generating material can be combined with a binder and an aerosol-forming agent in a slurry. The slurry can then be dried to produce an aerosol-generating material having at least a partial embedded susceptor.

Figure 3 illustrates one such process for embedding a susceptor in an aerosol-generating material. The process includes forming a slurry containing components of the aerosol-generating material or its precursor and a susceptor, forming a layer of the slurry, curing the slurry to form a gel, and drying to form the aerosol-generating material with the susceptor embedded therein. Optionally, curing the slurry includes adding a curing agent to the slurry, as described above with respect to preparing the aerosol-generating material.

In some embodiments, the susceptor is at least partially embedded in the aerosol-generating material by pressing a surface of the susceptor against the surface of the aerosol-generating material with sufficient pressure to embed the susceptor in the aerosol-generating material. For example, the aerosol-generating material can be in the form of a sheet of aerosol-generating material including a flat surface and a susceptor, and the susceptor can be in any form and can be pressed against the flat surface with sufficient force to at least partially embed the susceptor in the flat surface of the aerosol-generating material.

Because the susceptor is at least partially embedded in the aerosol-generating material, when incorporated into an article for use in a non-combustion aerosol delivery system, it may not be necessary to heat the aerosol-generating material using a separate susceptor.

A percentage of the susceptor may be completely embedded in the aerosol-generating material. When a susceptor is completely embedded in the aerosol-generating material, it is surrounded by and in direct contact with the aerosol-generating material. At least about 40%, 50%, 60%, 70%, 80%, 90%, or about 100% of the surface area of the susceptor can be completely surrounded by and in direct contact with the aerosol-generating material.

A percentage of the susceptors may be only partially embedded in the aerosol-generating material. When the susceptors are partially embedded in the aerosol-generating material, at least a portion of the susceptor elements are not in direct contact with the aerosol-generating material. At least about 40%, 50%, 60%, 70%, 80%, 90%, or about 100% of the susceptors may be partially surrounded by and in direct contact with the aerosol-generating material.

The aerosol-generating composition includes at least one aerosol-generating material. The aerosol-generating composition can consist of an aerosol-generating material and a susceptor. In some embodiments, the aerosol-generating composition includes a mixture of two or more different aerosol-generating materials. For example, the aerosol-generating material may include a first aerosol-generating material and a second aerosol-generating material. In such embodiments, the susceptor is embedded in one or more of the aerosol-generating materials.

In embodiments, the aerosol-generating composition includes first and second aerosol-generating materials, the first aerosol-generating material including a binder and an aerosol-forming agent, and a susceptor at least partially embedded in the first aerosol-generating material. The second aerosol-generating material can be any of the aerosol-generating materials described herein. For example, the second aerosol-generating material can be reconstituted tobacco or laminar tobacco.

Figure 4a is a perspective view of a sheet of aerosol-generating material 4 and a susceptor in the form of a plurality of susceptor elements 5 at least partially embedded in the aerosol-generating material 4. In this embodiment, the susceptor elements take the form of closed loops at least partially embedded in the sheet of aerosol-generating material.

Figure 4b shows a cross-sectional side view of the sheet of aerosol-generating material 4 shown in Figure 4. The sheet includes a first surface 6a and a second surface 6b. Susceptor elements 7 are at least partially embedded in and dispersed throughout the sheet of aerosol-generating material 4. Some of the susceptor elements 7 are completely surrounded by the aerosol-generating material, while others protrude from the first surface 6a or the second surface 6b of the sheet of aerosol-generating material 4.

Figure 5a is a perspective view of a sheet of aerosol-generating material 44 and a susceptor 55 (shown by a dotted line) completely embedded in the sheet of aerosol-generating material 44. The susceptor 55 takes the form of a flat, continuous sheet of material. In other embodiments, the susceptor 55 can take the form of a flat mesh or web. Such a configuration can improve adhesion between the aerosol-generating material 44 and the susceptor 55.

Figure 5b is a cross-sectional side view of a sheet of aerosol-generating material 44 and a susceptor 55 (shown using a dotted line) completely embedded in the center of the sheet of aerosol-generating material 44.

The sheets of aerosol-generating material 4, 44 shown in Figures 4a, 4b, 5a, and 5b can be chopped to form chopped sheets of aerosol-generating material having embedded susceptors. The chopped sheets can be incorporated into the aerosol-generating section of article 1 for use with a non-combustible aerosol delivery device.

Alternatively, in some embodiments, a sheet of aerosol-forming material may be used as an inner wrap in an article for use in a non-combustible aerosol delivery device. For example, the aerosol-forming material may be a continuous sheet of material surrounding a rod containing other aerosol-forming materials of the aerosol-forming composition, such as plant material (e.g., lamina and/or reconstituted tobacco).

Figure 6a is a perspective view of a sheet of aerosol-generating material that has been chopped to form discrete portions 8 of aerosol-generating material. Susceptor elements 7 are embedded in the discrete portions 8 of aerosol-generating material.

Figure 6b is a cross-sectional side view of an article 1a for use with a non-combustion aerosol delivery device, including a mouthpiece 2a, an aerosol-generating section 3a, and the discrete portions 8 of aerosol-generating material shown in Figure 6a. The discrete portions 8 of aerosol-generating material are longitudinally aligned with one another.

FIG. 6c is a side cross-sectional view of a susceptor-containing aerosol-generating component 555a, including three susceptor elements 555 joined by portions of joining material 666. The three susceptor elements are in the form of spheres, and the portions of joining material 666 are in the form of strands. Both the susceptor elements 555 and the portions of joining material 666 are embedded in the aerosol-generating material 444, such that the aerosol-generating material completely surrounds the susceptor elements 555 and the portions of joining material 666. The susceptor elements 555 can be made of any material that can be heated by exposure to a fluctuating magnetic field. The portions of joining material 666 can also be made of such a material. While three susceptor elements are shown, in some embodiments, the component 555a can include additional susceptor elements. The portions of material 666 can be relatively flexible and relatively weak to allow them to be easily cut. The aerosol-generating component 555a can be formed from a continuous reel including multiple aerosol-generating components 555a joined together by an additional section of material 666. The aerosol-generating components 555a can be cut to a desired length by cutting the section of joined material 666.

Figure 6d is a cross-sectional side view of article 1b for use with a non-combustion aerosol delivery device including aerosol-generating components, including mouthpiece 2b, aerosol-generating section 3b, and aerosol-generating component 555a, as shown in Figure 6c. The aerosol-generating composition also includes other aerosol materials (not shown).

Figure 7 shows a side cross-sectional view of the article 1 shown in Figure 1. The article 1 includes a mouthpiece 2 and an aerosol-generating section 3 connected to the mouthpiece 2. In this example, the aerosol-generating section 3 includes a cylindrical rod of aerosol-generating composition 3. The article 1 includes an upstream end 2' and a downstream end 2'' distal to the rod of aerosol-generating material 3.

In this example, the cylindrical rod of aerosol-forming composition includes multiple strands and/or strips of aerosol-forming material 3 and is surrounded by a wrapper 9. In this example, wrapper 9 is a moisture-impermeable wrapper.

Multiple strands or strips of aerosol-generating material may be aligned within the aerosol-generating section so that their longitudinal dimensions are aligned parallel to the longitudinal axis X-X' of the article 1. Alternatively, the strands or strips may be arranged so that their aligned longitudinal dimensions are generally transverse to the longitudinal axis of the article.

At least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 95% of the plurality of strands or strips may be arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. A majority of the strands or strips may be arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. In some embodiments, about 95% to about 100% of the plurality of strands or strips are arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. In some embodiments, substantially all of the strands or strips are arranged within the aerosol-generation section of the article such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the aerosol-generation section.

The mouthpiece 2 includes a cooling section 10, also referred to as a cooling element, positioned immediately downstream of and adjacent to the source of aerosol-forming composition 3. In this example, the cooling section 10 is in abutting relationship with the source of aerosol-forming material. In this example, the mouthpiece 2 also includes a body of material 11 downstream of the cooling section 10, and a hollow tubular element 12 at the mouth end of the article 1 downstream of the body of material 11.

The cooling section 10 includes a hollow channel having an inner diameter of about 1 mm to about 4 mm, for example, about 2 mm to about 4 mm. In this example, the hollow channel has an inner diameter of about 3 mm. The hollow channel extends along the entire length of the cooling section 10. In this example, the cooling section 10 includes a single hollow channel. In alternative embodiments, the cooling section may include multiple channels, for example, two, three, or four channels. In this example, the single hollow channel is substantially cylindrical, although other channel shapes/cross-sections may be used in alternative embodiments. The hollow channel may provide space in which aerosol drawn into the cooling section 10 can expand and cool. In all embodiments, the cooling section is configured to limit the cross-sectional area of the hollow channel and limit the displacement of tobacco into the cooling section during use.

The cooling section 10 preferably has a radial wall thickness, which can be measured, for example, with calipers. The wall thickness of the cooling section 10 for a given outer diameter of the cooling section defines the inner diameter of the cavity enclosed by the walls of the cooling section 10. The cooling section 10 can have a wall thickness of at least 1.5 mm and up to about 2 mm. In this example, the cooling section 10 has a wall thickness of about 2 mm. The inventors have advantageously found that providing a cooling section 10 with a wall thickness within this range improves retention of the source of aerosol-generating material in the aerosol-generating section during use by reducing longitudinal displacement of strands and/or strips of aerosol-generating material when the aerosol generator is inserted into an article.

The cooling section 10 is formed from filament tow. Multiple paper layers wound in parallel and butt-sewn to form the cooling section 10 may also be used, or other configurations may be used, such as spirally wound paper, cardboard tubes, tubes formed using a papier-mâché process, molded or extruded plastic tubes, or the like. The cooling section 10 is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacturing and use of the article 1.

The wall material of the cooling section 10 may be relatively non-porous, such that at least 90% of the aerosol generated by the aerosol-generating material 3 passes longitudinally through the one or more hollow channels rather than through the wall material of the cooling section 10. For example, at least 92% or at least 95% of the aerosol generated by the aerosol-generating material 3 may pass longitudinally through the one or more hollow channels.

The filament tows forming the cooling section 10 preferably have a total fineness of less than 45,000, more preferably less than 42,000. This total fineness has been found to allow for the formation of a cooling section 10 that is not too dense. The total fineness is preferably at least 20,000, more preferably at least 25,000. In preferred embodiments, the filament tows forming the cooling section 10 have a total fineness 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 cooling section 10 preferably has a monofilament fineness greater than 3. This monofilament fineness has been found to enable the formation of tubular elements 12 that are not too dense. The monofilament fineness is preferably at least 4, more preferably at least 5. In a preferred embodiment, the filament tow forming the hollow tubular elements 12 has a monofilament fineness of 4 to 10, more preferably 4 to 9. In one example, the filament tow forming the cooling section 10 has a Y40,000 tow formed from cellulose acetate and includes 18% plasticizer, such as triacetin.

The density of the material forming the cooling section 10 is preferably at least about 0.20 grams per cubic centimeter (g/cc), and more preferably at least about 0.25 g/cc. The density of the material forming the cooling section 10 is preferably less than about 0.80 grams per cubic centimeter (g/cc), and more preferably less than about 0.6 g/cc. In some embodiments, the density of the material forming the cooling section 10 is 0.20 to 0.8 g/cc, more preferably 0.3 to 0.6 g/cc, or 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 afforded by a higher density material and minimizing the overall weight of the article. For purposes of this invention, the "density" of the material forming the cooling section 10 refers to the density of any filament tows forming the element into which any plasticizer is incorporated. Density can be determined by dividing the total weight of the material forming the cooling section 10 by the total volume of the material forming the cooling section 10, which can be calculated using appropriate measurements of the material forming the cooling section 10, for example, obtained using calipers. If necessary, appropriate dimensions can be measured using a microscope.

The length of the cooling section 10 is preferably less than about 30 mm. More preferably, the length of the cooling section 10 is less than about 25 mm. Even more preferably, the length of the cooling section 10 is less than about 20 mm. Additionally or alternatively, the length of the cooling section 10 is preferably at least about 10 mm. Preferably, the length of the cooling section 10 is at least about 15 mm. In some preferred embodiments, the length of the cooling section 10 is between about 15 mm and about 20 mm, more preferably between about 16 mm and about 19 mm. In this example, the length of the cooling section 10 is 19 mm.

The cooling section 10 is disposed around and defines a cavity within the mouthpiece 2 that acts as the cooling section. The cavity provides a chamber through which heated volatile components generated by the rod of aerosol-generating material 3 flow. The cooling section 10 is hollow and provides an aerosol accumulation chamber that is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and use of the article 1. The cooling section 10 provides a physical displacement between the aerosol-generating material 3 and the body of material 11. The physical displacement provided by the cooling section 10 provides a thermal gradient across the length of the cooling section 10.

Preferably, the mouthpiece 2 includes a cavity having an internal volume greater than 110 mm ^3. It has been found that providing a cavity of at least this volume allows for improved aerosol formation. More preferably, the mouthpiece 2 includes a cavity (e.g., a cavity formed within the cooling section 10) having an internal volume greater than 110 mm ³ , and even more preferably greater than 130 mm ³ , thereby further improving the aerosol. In some examples, the internal cavity includes a volume of between about 130 mm ³ and about 230 mm ³ , e.g., about 134 mm ³ or 227 mm ³ .

The cooling section 10 can be configured to provide a temperature difference of at least 40°C between the heated volatile components entering the first upstream end of the cooling section 10 and the heated volatile components exiting the second downstream end of the cooling section 10. The cooling section 10 is preferably configured to provide a temperature difference of at least 60°C, more preferably at least 80°C, and even more preferably at least 100°C between the heated volatile components entering the first upstream end of the cooling section 10 and the heated volatile components exiting the second downstream end of the cooling section 10. This temperature difference across the length of the cooling section 10 protects the temperature-sensitive body of material 11 from the high temperatures of the aerosol-generating material 3 when heated.

In use, the aerosol-generation section may exhibit a pressure drop of about 15 to about 40 mm H ₂ O. In some embodiments, the aerosol-generation section exhibits a pressure drop across the aerosol-generation section of about 15 to about 30 mm H 2 O.

The aerosol-generating material may have a packing density within the aerosol-generating section of about 400 mg/cm3 to about 900 mg/cm3. Higher packing densities may increase pressure drop.

At least about 70% of the volume of the aerosol-generating section is filled with aerosol-generating material. In some embodiments, about 75% to about 85% of the volume of the cavity is filled with aerosol-generating material.

In this embodiment, the moisture-impermeable wrapper 9 surrounding the rod of aerosol-forming material comprises aluminum foil. In other embodiments, the wrapper 9 comprises a paper wrapper, optionally including a barrier coating that renders the wrapper material substantially moisture-impermeable. Aluminum foil has been found to be particularly effective in promoting aerosol formation within the aerosol-forming 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 have other thicknesses, for example, a thickness of 4 μm to 16 μm. The aluminum foil also need not have a paper backing and can have a backing formed from another material, 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 wrapper is preferably 20 μm to 60 μm, more preferably 30 μm to 50 μm, which can provide a wrapper with adequate structural integrity and heat transfer properties. The pulling force that can be applied to the wrapper before it breaks can be greater than 3,000 grams of force, for example, 3,000 to 10,000 grams of force, or 3,000 to 4,500 grams of force. If the wrapper comprises paper or a paper backing, i.e., a cellulose-based material, the wrapper can have a basis weight greater than about 30 gsm. For example, the wrapper can have a basis weight in the range of about 40 gsm to about 70 gsm. Such a basis weight imparts high stiffness to the rod of aerosol-generating material. The high stiffness imparted by a wrapper having a basis weight in this range can make the rod of aerosol-generating material 3 more resistant to wrinkling or other deformation due to forces experienced by the article during use. Providing a rod of aerosol-generating material with high stiffness can be advantageous when multiple strands or strips of aerosol-generating material are aligned within the aerosol-generation section with their longitudinal dimensions aligned parallel to the longitudinal axis. This is because the longitudinally aligned strands or strips of aerosol-generating material can provide the rod of aerosol-generating material with less stiffness than when the strands or strips are not aligned. The increased stiffness of the rod of aerosol-generating material can enable the article to withstand the increased forces to which the article is subjected during use.

In this example, the moisture-impermeable wrapper 9 is also substantially impermeable to air. In an alternative embodiment, the wrapper 9 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 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, this is hypothesized to be due to reduced loss of aerosol compound in the wrapper 9. The permeability of the wrapper 9 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 body of material 11 and the hollow tubular element 12 each define a substantially cylindrical overall outer shape and share a common longitudinal axis. The body of material 11 is rolled up within the first plug wrap 13. The first plug wrap 13 preferably has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. The first plug wrap 13 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The first plug wrap 13 is preferably a non-porous plug wrap, e.g., having a permeability of less than 100 Coresta units, e.g., less than 50 Coresta units. However, in other embodiments, the first plug wrap 13 can be a porous plug wrap, e.g., having a permeability of greater than 200 Coresta units.

The length of the body of material 11 is preferably less than about 15 mm. More preferably, the length of the body of material 11 is less than about 12 mm. Additionally or alternatively, the length of the body of material 11 is at least about 5 mm. Preferably, the length of the body of material 11 is at least about 8 mm. In some preferred embodiments, the length of the body of material 11 is between about 5 mm and about 15 mm, more preferably between about 6 mm and about 12 mm, even more preferably between about 6 mm and about 12 mm, and most preferably about 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In this example, the length of the body of material 11 is 10 mm.

In this example, the body of material 11 is formed from filament tow. In this example, the tow used in the body of material 11 has a denier fineness (d.p.f.) of 5 and a total fineness of 25,000. In this example, the tow comprises plasticized cellulose acetate tow. The plasticizer used in the tow accounts for approximately 9% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, a different material can be used to form the body of material 11. For example, rather than tow, the body 11 can be formed from paper, for example, in a manner similar to paper filters known for use in cigarettes. For example, the paper or other cellulose-based material can be provided as one or more portions of a sheet material that is folded and/or corrugated to form the body 11. The sheet material can have a basis weight of 15 gsm to 60 gsm, for example, 20 to 50 gsm. The sheet material may have a basis weight ranging from, for example, 15 to 25 gsm, 25 to 30 gsm, 30 to 40 gsm, 40 to 45 gsm, and 45 to 50 gsm. Additionally or alternatively, the sheet material may have a width ranging from 50 mm to 200 mm, e.g., from 60 mm to 150 mm or from 80 mm to 150 mm. For example, the sheet material may have a basis weight of 20 to 50 gsm and a width of 80 mm to 150 mm. This may allow, for example, the cellulose-based body to have an appropriate pressure drop for an article having the dimensions described herein.

Alternatively, the body 11 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 is preferably formed from cellulose acetate. Whether formed from cellulose acetate or another material, the tow preferably has a d.p.f. of at least 5. To achieve a sufficiently uniform body 11 of material, the tow preferably has a monofilament fineness 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 fineness of the tow forming the body of material 11 is preferably at most 30,000, more preferably at most 28,000, and even more preferably at most 25,000. These total fineness values provide the tow with a smaller percentage of the cross-sectional area of the mouthpiece 2, resulting in a lower pressure drop across the mouthpiece 2 than tows with higher total fineness values. For a body of material 11 of appropriate stiffness, the tow preferably has a total fineness of at least 8,000, more preferably at least 10,000. The single fineness is preferably 5 to 12, and the total fineness is preferably 10,000 to 25,000. The cross-sectional shape of the filaments of the tow is preferably "Y" shaped, although other shapes, such as "X" shaped filaments, having the same d.p.f. and total fineness values provided herein may be used in other embodiments.

Regardless of the material used to form the body 11, the pressure drop across the body 11 can be, for example, 0.3 to 5 mmWG per mm of body 11 length, e.g., 0.5 to 2 mmWG per mm of body 11 length. The pressure drop can be, for example, 0.5 to 1 mmWG/mm of length, 1 to 1.5 mmWG/mm of length, or 1.5 to 2 mmWG/mm of length. The total pressure drop across the body 11 can be, for example, 3 to 8 mmWG, or 4 to 7 mmWG. The total pressure drop across the body 11 can be approximately 5, 6, or 7 mmWG.

As shown in FIG. 7 , the mouthpiece 2 of the article 1 has an upstream end 2' adjacent the rod of aerosol-forming material 3 and a downstream end 2" remote from the rod of aerosol-forming material 3. The mouthpiece 2 has a hollow tubular element 12 formed from filament tow at the downstream end 2". This has been found to advantageously significantly reduce the temperature of the outer surface of the mouthpiece 2 at the downstream end 2" of the mouthpiece that contacts the consumer's mouth when the article 1 is in use. In addition, the use of the tubular element 12 has also been found to significantly reduce the temperature of the outer surface of the mouthpiece 2 further upstream of the tubular element 12. Without wishing to be bound by theory, it is hypothesized that this is due to the tubular element 12 causing the aerosol to pass closer to the center of the mouthpiece 2, thereby reducing heat transfer from the aerosol to the outer surface of the mouthpiece 2.

The "wall thickness" of the hollow tubular element 12 corresponds to the thickness of the wall of the tube 10 in the radial direction. This can be measured, for example, using calipers. 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 12. 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 12. In this example, the wall thickness of the hollow tubular element 12 is approximately 1.3 mm.

The length of the hollow tubular element 12 is preferably less than about 20 mm. More preferably, the length of the hollow tubular element 12 is less than about 15 mm. Even more preferably, the length of the hollow tubular element 12 is less than about 10 mm. Additionally or alternatively, the length of the hollow tubular element 12 is at least about 5 mm. Preferably, the length of the hollow tubular element 12 is at least about 6 mm. In some preferred embodiments, the length of the hollow tubular element 12 is between about 5 mm and about 20 mm, more preferably between about 6 mm and about 10 mm, even more preferably between about 6 mm and about 8 mm, and most preferably about 6 mm, 7 mm, or about 8 mm. In this example, the length of the hollow tubular element 12 is 7 mm.

The density of the hollow tubular element 12 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 12 is preferably less than about 0.75 grams per cubic centimeter (g/cc), more preferably less than about 0.6 g/cc. In some embodiments, the density of the hollow tubular element 12 is 0.25 to 0.75 g/cc, more preferably 0.3 to 0.6 g/cc, more preferably 0.4 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 12 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 12 by the total volume of the hollow tubular elements 12, and the total volume can be calculated using appropriate measurements of the hollow tubular elements 12, for example, obtained using calipers. If necessary, appropriate dimensions can be measured using a microscope.

The filament tow forming the hollow tubular element 12 preferably has a total fineness of less than 45,000, more preferably less than 42,000. This total fineness has been found to allow for the formation of a tubular element 12 that is not too dense. The total fineness is preferably at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filament tow forming the hollow tubular element 12 has a total fineness 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 12 preferably has a monofilament fineness greater than 3. This monofilament fineness has been found to allow for the formation of a tubular element 12 that is not too dense. Preferably, the monofilament fineness is at least 4, more preferably at least 5. In a preferred embodiment, the filament tow forming the hollow tubular element 12 has a monofilament fineness of 4 to 10, more preferably 4 to 9. In one example, the filament tow forming the hollow tubular element 12 has a 7.3Y36,000 tow formed from cellulose acetate and includes 18% plasticizer, such as triacetin.

Preferably, the hollow tubular element 12 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 12 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 12 is approximately 4.7 mm.

The hollow tubular element 12 preferably contains 15% to 22% by weight of plasticizer. In the case of cellulose acetate tow, the plasticizer is preferably triacetin, although other plasticizers such as polyethylene glycol (PEG) can also be used. More preferably, the tubular element 12 contains 16% to 20% by weight of plasticizer, for example, about 17%, about 18%, or about 19%.

In this example, the first hollow tubular element 12, the body of material 11, and the cooling section 10 are combined using a second plug wrap 14 wrapped around all three sections. The second plug wrap 14 preferably has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 45 gsm. The second plug wrap 14 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The second plug wrap 14 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 an alternative embodiment, the second plug wrap 14 can be a porous plug wrap, for example, having a permeability of greater than 200 Coresta units.

In this example, Article 1 has a circumference of approximately 23 mm. In other examples, the article may be provided in any of the formats described herein, for example, having a circumference of 20 mm to 26 mm. Because the article is heated to release the aerosol, improved heating efficiency can be achieved using an article having a smaller circumference within this range, for example, a circumference less than 23 mm. It has also been found that an article circumference greater than 19 mm is particularly effective for achieving improved aerosol upon heating while maintaining an adequate product length. Articles having a circumference of 20 mm to 24 mm, more preferably 20 mm to 23 mm, have been found to provide a good balance between effective aerosol delivery and allowing efficient heating.

Tipping paper 15 is wrapped around the entire length of mouthpiece 2 and over a portion of the rod of aerosol-generating material 3 and has adhesive on its inner surface, connecting mouthpiece 2 and rod 3. In this example, the rod of aerosol-generating material 3 is wrapped in wrapper 9, which forms a first wrapping material, and tipping paper 15 forms an outer wrapping material that extends at least partially over the rod of aerosol-generating material 3 and connects mouthpiece 2 and rod 3. In some examples, the tipping paper can extend only partially over the rod of aerosol-generating material.

In this example, the tipping paper 15 extends 5 mm over the rod of aerosol-forming material 3, but it may alternatively extend 3 mm to 10 mm, or more preferably 4 mm to 6 mm, over the rod 3 to securely attach the mouthpiece 2 to the rod 3. The tipping paper may have a basis weight of more than 20 gsm, for example more than 25 gsm, or preferably more than 30 gsm, for example 37 gsm. Basis weights in these ranges have been found to provide tipping paper with acceptable tensile strength yet sufficient flexibility 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 15 has a circumference of approximately 23 mm.

The article has a ventilation level of approximately 10% of the aerosol drawn through the article. In alternative embodiments, the article may have a ventilation level of 1% to 20%, for example 1% to 12%, of the aerosol drawn through the article. These levels of ventilation help to increase the concentration of aerosol inhaled by the user at the mouth end 2'' and aid in the aerosol cooling process. The ventilation is provided directly in the mouthpiece 2 of the article 1. In this example, the ventilation is provided in the cooling section 10, which has been found to be particularly advantageous in aiding the aerosol generation process. The ventilation is provided by perforations 16, in this case formed as a single row of laser perforations located 13 mm from the mouth end 2'' downstream of the mouthpiece 2. In alternative embodiments, more than one row of ventilation perforations may be provided. These perforations pass through the tipping paper 15, the second plug wrap 14, and the cooling section 10. In alternative embodiments, the vent may be provided at other locations on the mouthpiece, such as in the body of material 11 or the first tubular element 12. The article is preferably configured so that the perforations are provided no more than about 28 mm from the upstream end of the article 1, preferably between 20 mm and 28 mm from the upstream end of the article 1. In this example, the opening is provided about 25 mm from the upstream end of the article.

Item 1 is suitable for use with a non-combustible aerosol delivery device.

Figure 8 shows an example of a non-combustible aerosol delivery device 17 for use with the articles described herein, having a proximal end 17a and a distal end 17b.

In general, device 17 can be used to cause an article including a susceptor and an aerosol-generating material, such as article 1 described herein, to generate an aerosol that is inhaled by a user of device 17. Device 17 and article 1 together form a system.

Device 17 comprises a magnetic field generator including a coil 18 configured to generate a varying magnetic field. The varying magnetic field generates heat in a susceptor within article 1, which in turn heats the resulting aerosol to form an aerosol.

Device 17 comprises a housing 17a that encloses and houses the various components of device 17. Device 17 has an opening 19 at one end through which item 1 can be inserted. In use, item 1 can be fully or partially inserted into the heating assembly.

Device 17 may also include a user-actuable control element 20, such as a button or switch, that, when pressed, operates device 17. For example, a user may turn device 17 on by operating switch 20.

Device 17 may also include an electrical component such as a socket/port 21 capable of receiving a cable for charging device 17's power source 22. For example, socket 21 may be a charging port, such as a USB charging port.

In use, a user inserts item 1 into opening 19 and operates user control 20 to initiate heating of the aerosol-generating material, utilizing the aerosol generated within the device. This causes the aerosol to flow through device 17 along the flow path toward proximal end 17' of device 17.

The other end of the device, furthest from the opening 19, may be known as the distal end 17'' of the device 17, as this is the end furthest from the user's mouth during use. When a user utilizes the aerosol generated within the device, the aerosol flows away from the distal end 17'' of the device 17.

The power source 22 may 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 magnetic field generator to provide power under the control of a controller (not shown) when the aerosol-generating material needs to be heated.

The device further includes at least one electronics module 23. The electronics module 23 may include, for example, a printed circuit board (PCB). The PCB 23 may support at least one controller, such as a processor and memory. The PCB 23 may also include one or more electrical tracks for electrically connecting the various electronic components of the device 17 together. For example, battery terminals (not shown) may be electrically connected to the PCB 23 so that power can be distributed throughout the device 17. The socket 21 may also be electrically coupled to a battery via electrical tracks.

Device 17 includes a magnetic field generator including a coil 18 configured to inductively heat a susceptor within article 1.

Coil 18 is an inductor coil. Inductor coils are made from a conductive material. In this example, the inductor coil is made from litz wire/cable that is spirally wound to form a helical inductor coil. 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 exemplary device 17, the inductor coil is made from copper, and the litz wire has a rectangular cross-section. In other examples, the litz wire may have other cross-section shapes, such as circular.

The inductor coil 18 is configured to generate a first varying magnetic field for heating the susceptor of the article. The inductor coil 18 can be connected to the PCB 23.

The device includes an inductor coil support tube 24. The coil support tube 24 is defined by an outer surface and an inner surface. The outer surface of the coil support tube supports the inductor coil of the magnetic field generator 18. The inner surface defines a cavity into which the item 1 can be inserted. The tube 24 is preferably made from a material that is not heatable by penetration by a fluctuating magnetic field. This prevents the inductor from heating the tube during use and also reduces power consumption.

Referring to FIG. 9 , device 17b includes two magnetic field generators, including first inductor coil 18a and second inductor coil 18b. First inductor coil 18a is configured to generate a first varying magnetic field for heating a susceptor in article 1, and second inductor coil 18b is configured to generate a second varying magnetic field for heating a second susceptor. In this example, first inductor coil 18a is adjacent to second inductor coil 18b in a direction along the longitudinal axis of device 17b (i.e., first inductor coil 18a and second inductor coil 18b do not overlap). First inductor coil 18a and second inductor coil 18b can be connected to a PCB. The first and second coils are supported by a coil support tube 24'.

It will be appreciated that in some examples, the first inductor coil 18a and the second inductor coil 18b can have at least one characteristic that differs from one another. For example, the first inductor coil 18a can have at least one characteristic that differs from the second inductor coil 18b. More specifically, in one example, the first inductor coil 18a can have a different inductance value than the second inductor coil 18b. The first inductor coil 18a and the second inductor coil 18b can be different lengths. Thus, the first inductor coil 18a can include a different number of turns than the second inductor coil 18b (assuming the spacing between individual turns is substantially the same). In yet another example, the first inductor coil 18a can be made of a different material than the second inductor coil 18b. In some examples, the first inductor coil 18a and the second inductor coil 18b can be substantially identical.

In this example, the first inductor coil 18a and the second inductor coil 18b are wound in opposite directions. This can be useful when the inductor coils are active at different times. For example, initially, the first inductor coil 18a may be operating to heat a first section/portion of an article, and at a later time, the second inductor coil 18b may be operating to heat a second section/portion of the article. Winding the coils in opposite directions can help reduce current buildup in inactive coils when used in conjunction with certain types of control circuitry. In FIG. 9, the first inductor coil 18a is a right-handed spiral and the second inductor coil 18b is a left-handed spiral. However, in other embodiments, the inductor coils 18a and 18b can be wound in the same direction, or the first inductor coil 18a can be a left-handed spiral and the second inductor coil 18b can be a right-handed spiral.

In use, the article 1 described herein can be inserted into a non-combustible aerosol delivery device, such as devices 17 and 17b described with reference to Figures 10 and 11. At least a portion of the mouthpiece 2 of the article 1 protrudes from the non-combustible aerosol delivery device 17, 17b and can be placed in the mouth of a user. An aerosol is generated by using the device 17, 17b to heat an aerosol-generating section 3 containing an aerosol-generating composition including an aerosol-generating material and a susceptor at least partially embedded in the aerosol-generating material. The aerosol generated by the aerosol-generating material passes through the mouthpiece 2 and into the user's mouth.

Referring to FIG. 10, the magnetic field generator comprises a single coil 18. The magnetic field generator is configured to inductively heat the susceptor in the aerosol-generation section 3 by generating a varying magnetic field.

The outer surface of the article 1 can be dimensioned so that the outer surface of the article 1 abuts the inner surface of the coil support tube 24. This ensures that the aerosol generation section is closer to the coil 17 and therefore heating is most efficient.

Figure 11 shows an article 1 described herein received within the coil support tube 24' of device 17b. The magnetic field generator includes two coils 18a and 18b, which allows different portions of the aerosol-generation section 3 to be heated at different times and/or to different temperatures.

The various embodiments described herein are presented solely as an aid in 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. It is understood that 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 equivalents thereof, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. The various embodiments of the present invention may suitably 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. Additionally, the present disclosure may include other inventions not claimed herein but which may be claimed in the future.

Claims (33)

A cut or shredded sheet of an aerosol-forming composition comprising a plurality of strands or strips of an aerosol-forming material, including a binder and an aerosol-forming agent, and at least one susceptor at least partially embedded in the aerosol-forming material. 10. The cut or shredded sheet of the aerosol-forming composition of claim 1, wherein the aerosol-forming material is in the form of a dry slurry. A cut or shredded sheet of the aerosol-forming composition of claim 1, wherein the aerosol-forming material is in the form of a sheet or cut sheets. A cut or shredded sheet of the aerosol-forming composition of claim 1, wherein the susceptor comprises a plurality of susceptor elements that are heatable by the penetration of a fluctuating magnetic field. The cut or shredded sheet of aerosol-forming composition of claim 4, wherein the plurality of susceptor elements are in the form of particles, loops, spheres, strands, and/or strips. A cut or shredded sheet of the aerosol-forming composition of claim 1, wherein the susceptor is in the form of a web or mesh. A cut or shredded sheet of the aerosol-forming composition of claim 1, wherein the susceptor is in the form of a fibrous sheet. The cut or shredded sheet of an aerosol-forming composition according to claim 7, wherein the fibrous sheet comprises a first surface, a second surface opposite the first surface, and a plurality of fibers extending from one or both of the first surface and/or the second surface, and the aerosol-forming material contacts and at least partially covers at least one of the first surface and/or the second surface such that one or more of the plurality of fibers are embedded in the aerosol-forming material. A cut or shredded sheet of the aerosol-forming composition of claim 1, wherein the susceptor comprises one or more closed circuits of material that can be heated by the penetration of a fluctuating magnetic field. A cut or shredded sheet of the aerosol-forming composition of claim 1, wherein the binder is selected from the group consisting of cellulosic binders, non-cellulosic binders, and mixtures thereof. A cut or shredded sheet of the aerosol-forming composition of claim 1, wherein the aerosol-forming agent is selected from the group consisting of glycerol, propylene glycerol, and mixtures thereof. A cut or shredded sheet of the aerosol-forming composition of claim 1, wherein the aerosol-forming material includes a filler. A cut or shredded sheet of the aerosol-forming composition of claim 12, wherein the filler is wood pulp. A cut or shredded sheet of the aerosol-forming composition of claim 1, wherein the aerosol-forming material comprises plant material. A cut or shredded sheet of the aerosol-forming composition of claim 14, wherein the plant material comprises tobacco. A cut or shredded sheet of the aerosol-forming composition of claim 1, wherein the aerosol-forming material is reconstituted tobacco. A cut or shredded sheet of the aerosol-forming composition of claim 1, wherein the aerosol-forming material is substantially free of tobacco material. A cut or shredded sheet of an aerosol-generating composition comprising strands or strips of a first aerosol-generating material comprising a binder and an aerosol-forming agent, a second aerosol-generating material, and at least one susceptor at least partially embedded in the first aerosol-generating material. The cut or shredded sheet of the aerosol-forming composition of claim 18, wherein the first aerosol-forming material comprises a plant material. 20. A cut or shredded sheet of the aerosol-forming composition of claim 18 or 19, wherein the second aerosol-forming material comprises or consists of laminar tobacco and/or reconstituted tobacco. The cut or shredded sheet of an aerosol-forming composition described in claim 18, wherein the first aerosol-forming material is substantially free of tobacco. A process for producing an aerosol-generating composition comprising a plurality of strands or strips of an aerosol-generating material, the process comprising at least partially embedding a susceptor in the aerosol-generating material comprising a binder and an aerosol-forming agent. The process comprises:
23. The process of claim 22, comprising combining a binder, an aerosol-forming agent, and the susceptor to form a slurry of aerosol-generating material. The process of claim 23 , wherein the process includes setting the slurry to form a gel and, optionally, drying the gel to form the aerosol-generating material. 25. The process of claim 22 or 24, wherein the aerosol-generating material is in the form of a sheet, and the process further comprises cutting the sheet to form a plurality of separate portions of aerosol-generating material. The process of claim 25, wherein the discrete portions of aerosol-generating material comprise multiple strands or strips. An aerosol-generating material prepared by the process of claim 22. A plurality of strands or strips of aerosol-generating material comprising a binder and an aerosol-forming agent, and a susceptor at least partially embedded in the binder. A susceptor at least partially embedded in a cut or chopped sheet of aerosol-generating material in the form of multiple strands or strips comprising a binder and an aerosol-forming agent. An article for use with a non-combustible aerosol delivery device, the article comprising a cut or shredded sheet of the aerosol-forming composition of claim 1 or the aerosol-forming material of claim 27. A non-combustible aerosol delivery device for use with the article of claim 30. A system comprising the non-combustible aerosol delivery device described in claim 31 and the article described in claim 30. 10. Use of a cut or shredded sheet of the aerosol-forming composition of claim 1 to generate an aerosol.