CN115135180A

CN115135180A - Component for an article for use in an aerosol delivery system

Info

Publication number: CN115135180A
Application number: CN202080097136.2A
Authority: CN
Inventors: 安德烈·格里先科; 戴维·斯彭德洛夫
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2019-12-20
Filing date: 2020-12-21
Publication date: 2022-09-30
Also published as: IL293722A; AU2020410194A1; GB201918983D0; BR112022012275A2; US20230031144A1; WO2021123833A1; JP2023507157A; CA3162036A1; EP4076035A1; KR20220118506A; AU2020410194B2

Abstract

A component of an article for use in an aerosol delivery system comprises a body of fibrous material comprising first and second additive release components embedded within the body of fibrous material. The first and second additive release members each have a maximum diameter of about 1.5mm to about 2.5mm, and the first and second additive release members are separated by a distance of less than about 2.5 mm. An article comprising the component is also provided, as well as a system comprising the article and a non-combustible aerosol provision device for heating an aerosol-generating material of the article. A method of manufacture is also provided.

Description

Component for an article for use in an aerosol delivery system

Technical Field

The present invention relates to a component of an article for use in an aerosol delivery system, an aerosol delivery system comprising an article and a method of manufacturing a component of an article for use in an aerosol delivery system.

Background

Certain tobacco industry products produce aerosols that are inhaled by the user during use. For example, a tobacco heating device heats a smoke generating substrate (e.g., tobacco) by heating the substrate but not burning the substrate to form an aerosol. Such tobacco industry products typically include a mouthpiece through which the aerosol passes to the mouth of the user.

Disclosure of Invention

According to an embodiment of the invention, in a first aspect, there is provided a component of an article for use in an aerosol delivery system, the component comprising a body of fibrous material comprising first and second additive release members embedded within the body of fibrous material, wherein the first and second additive release members each have a maximum diameter of about 1.5mm to about 2.5mm and the first and second additive release members are separated by a distance of less than about 2.5 mm.

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

According to an embodiment of the invention, in a third aspect, there is provided a system comprising an article according to the second aspect and a non-combustible aerosol provision means for heating an aerosol-generating material of the article.

According to an embodiment of the invention, in a fourth aspect, there is provided a method of manufacturing a component of an article for use in an aerosol delivery system, the method comprising inserting first and second additive release components into a stream of fibrous material and forming the stream of fibrous material into a body of fibrous material comprising the first and second additive release components embedded within the body, wherein the first and second additive release components each have a maximum diameter of from about 1.5mm to about 2.5mm and the first and second additive release components are separated by a distance of less than about 2.5 mm.

Drawings

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

figure 1a is a side cross-sectional view of an article comprising a mouthpiece;

figure 1b is a cross-sectional view of the mouthpiece shown in figure 1 a;

figure 2 is a perspective view of a non-combustible aerosol provision device suitable for generating an aerosol from the aerosol-generating material of the article of figures 1a and 1 b;

FIG. 3 shows the device of FIG. 2 with the outer cover removed and the article absent;

FIG. 4 is a side view in partial cross-section of the device of FIG. 2;

FIG. 5 is an exploded view of the device of FIG. 2 with the outer cover omitted;

FIG. 6A is a cross-sectional view of a portion of the device of FIG. 2;

FIG. 6B is a close-up illustration of a region of the apparatus of FIG. 6A; and

figure 7 is a flow chart illustrating a method of manufacturing an article comprising a mouthpiece.

Detailed Description

As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user and includes:

combustible aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for cigarettes by hand or for homemade cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable materials);

a non-combustible aerosol provision system which releases compounds from an aerosol generating material without combusting the aerosol generating material, such as an electronic cigarette, a tobacco heating product and a mixing system, to generate an aerosol using a combination of aerosol generating materials; and

an aerosol-free delivery system that delivers at least one substance to a user orally, nasally, transdermally, or otherwise without forming an aerosol, including but not limited to lozenges, chewing gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco including snus or snus, wherein the at least one substance may or may not include nicotine.

According to the present disclosure, a "combustible" aerosol provision system is one in which the constituent aerosol-generating materials of the aerosol provision system (or components thereof) burn or ignite during use in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a combustible aerosol delivery system, such as a system selected from the group consisting of cigarettes, cigarillos and cigars.

In some embodiments, the present disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol modifier release component (e.g., a capsule, a thread, or a bead), or a paper (e.g., a plug wrap, a tipping paper, or a cigarette paper).

According to the present disclosure, a "non-combustible" aerosol provision system is one in which the constituent aerosol-generating materials of the aerosol provision system (or components thereof) do not burn or ignite in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible aerosol delivery system, e.g., a powered non-combustible aerosol delivery system.

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

In some embodiments, the non-combustible aerosol provision system is an aerosol generating material heating system, also referred to as a heated non-combustion system. One example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol provision system is a hybrid system that uses a combination of aerosol generating materials to generate an aerosol, wherein one or more of the aerosol generating materials may be heated. Each aerosol-generating material may for example be in the form of a solid, liquid or gel, and may or may not comprise nicotine. In some embodiments, the mixing system comprises a liquid or gel aerosol generating material and a solid aerosol generating material. The solid aerosol-generating material may comprise, for example, tobacco or non-tobacco products.

In general, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.

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

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

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

In some embodiments, a consumable for use with a non-combustible aerosol provision device may comprise an aerosol-generating material, an aerosol-generating material storage region, an aerosol-generating material transport component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, a filter, a mouthpiece and/or an aerosol modifier.

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

An active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropic agents, psychoactive substances. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, caffeine, a vitamin (e.g., B6 or B12 or C), melatonin, a cannabinoid, or a component, derivative, or combination thereof. The active substance may comprise one or more components, derivatives or extracts of tobacco, cannabis or other plants.

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

An aerosol generating material is a material that is capable of generating an aerosol, for example when heated, irradiated or energized in any other way. The aerosol-generating material may, for example, be in the form of a solid, liquid or gel, which may or may not contain an active and/or a flavourant. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., a non-fibrous). In some embodiments, the amorphous solid may be a dried gel. An amorphous solid is a solid material that can retain some fluid (e.g., liquid) within its interior. In some embodiments, the aerosol-generating material may, for example, comprise from about 50 wt%, 60 wt% or 70 wt% amorphous solids to about 90 wt%, 95 wt% or 100 wt% amorphous solids.

The aerosol-generating material may comprise one or more active substances and/or flavourings, one or more aerosol former materials, and optionally one or more other functional materials.

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

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

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

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

An aerosol-modifying agent is a substance, typically located downstream of an aerosol-generating region, that is configured to modify the generated aerosol, for example, by changing the taste, flavor, acidity, or other characteristics of the aerosol. The aerosol modifying agent may be disposed in an aerosol modifying agent releasing component operable to selectively release the aerosol modifying agent.

For example, the aerosol modifier may be an additive or an adsorbent. For example, the aerosol modifier may include one or more of a fragrance, a colorant, water, and a carbon sorbent. For example, the aerosol modifier may be a solid, liquid or gel. The aerosol modifier may be in the form of a powder, a thread or a granule. The aerosol modifier may be free of filter material.

A susceptor is a material that can be heated by penetration with a changing magnetic field (e.g., an alternating magnetic field). The susceptor may be an electrically conductive material such that penetration thereof with a varying magnetic field results in inductive heating of the heating material. The heating material may be a magnetic material such that its penetration with a varying magnetic field results in hysteresis heating of the heating material. The susceptor may be electrically conductive and magnetic such that the susceptor may be heated by two heating mechanisms. Herein, a device configured to generate a varying magnetic field is referred to as a magnetic field generator.

An aerosol generator is a device configured to cause an aerosol to be generated from an aerosol generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol generating material to thermal energy in order to release the one or more volatiles from the aerosol generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause aerosol to be generated from the aerosol generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure or electrostatic energy.

Induction heating is a process of heating an electrically conductive object by penetrating it with a varying magnetic field. The process is described by faraday's law of induction and ohm's law. The induction heater may comprise an electromagnet and means for passing a varying current (e.g. an alternating current) through the electromagnet. When the electromagnet and the object to be heated are appropriately positioned relative to each other such that the resultant varying magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are generated inside the object. The object has a resistance to the flow of current. Thus, when such an eddy current is generated in the object, it flows against the resistance of the object, causing the object to be heated. This process is known as joule, ohmic or resistive heating. An object that can be inductively heated is called a susceptor.

In one embodiment, the susceptor is in the form of a closed loop. It has been found that when the susceptor is in the form of a closed loop, the magnetic coupling between the susceptor and the electromagnet is enhanced in use, which results in greater or improved joule heating.

Hysteresis heating is a process of heating an object made of a magnetic material by penetrating the object with a varying magnetic field. Magnetic materials can be considered to include many atomic scale magnets or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipole aligns with the magnetic field. Thus, when a varying magnetic field (e.g., an alternating magnetic field generated by an electromagnet) penetrates a magnetic material, the orientation of the magnetic dipoles changes with the varying applied magnetic field. This reorientation of the magnetic dipoles results in the generation of heat in the magnetic material.

When an object is both electrically conductive and magnetic, penetrating the object with a varying magnetic field can cause both joule heating and hysteresis heating in the object. In addition, the use of magnetic materials may enhance the magnetic field, which may enhance joule heating.

In each of the above processes, since heat is generated within the object itself, rather than by an external heat source through thermal conduction, rapid temperature rise and more uniform heat distribution in the object can be achieved, particularly by selecting appropriate object materials and geometries, as well as appropriate varying magnetic field sizes and orientations relative to the object. Furthermore, since induction heating and hysteresis heating do not require a physical connection to be provided between the source of the varying magnetic field and the object, the design freedom and control over the heating profile can be greater and the cost can be lower.

Articles, such as consumables described herein, e.g., those in stick form, are generally named according to product length: "regular" (typically in the range of 68-75mm, e.g., from about 68mm to about 72mm), "short" or "mini" (68mm or less), "extra large" (typically in the range of 75-91mm, e.g., from about 79mm to about 88mm), "long" or "extra large" (typically in the range of 91-105mm, e.g., from about 94mm to about 101mm), and "extra long" (typically in the range of from about 110mm to about 121 mm).

It is also named according to product perimeter: "regular" (about 23-25mm), "wide" (greater than 25mm), "elongated" (about 22-23mm), "semi-elongated" (about 19-22mm), "ultra-elongated" (about 16-19mm) and "slightly elongated" (less than about 16 mm).

Thus, an oversized, ultra-elongated form of the article will, for example, have a length of about 83mm and a circumference of about 17 mm.

The article may comprise an aerosol-generating material and a downstream portion downstream of the aerosol-generating material, and each form may be produced with a different length of the downstream portion. The downstream portion length will typically be from about 30mm to 50 mm. The tipping paper joins the downstream portion to the aerosol-generating material and will typically have a greater length than the downstream portion, for example 3 to 10mm long, such that the tipping paper covers the downstream portion and overlaps the aerosol-generating material, for example in the form of a rod, to join the downstream portion to the rod.

The articles described herein and their aerosol-generating materials and downstream portions may be manufactured in, but are not limited to, any of the forms described above.

The terms "upstream" and "downstream" as used herein are relative terms defined with respect to the direction of mainstream aerosol drawn through the article or device in use.

The monofilament tow (filament tow) material described herein may comprise cellulose acetate tow. The monofilament tow may also be formed using other materials for forming fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), Polycaprolactone (PCL), poly (1-4 butylene succinate) (PBS), poly (butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers or combinations thereof. The monofilament tow may be plasticized with a suitable tow plasticizer, such as triacetin, in which the material is cellulose acetate tow, or the tow may be unplasticized. The tow may have any suitable gauge, such as fibers having a "Y" shape or other cross section (e.g., "X" shape), a denier per filament value of between 2.5 denier per filament and 15 denier per filament, such as between 8.0 denier per filament and 11.0 denier per filament, and a total denier value of 5000 to 50000, such as between 10000 and 40000.

The cross-section of the fiber may have an isoperimetric ratio L of 25 or less, 20 or less, or 15 or less ² Where L is the length of the perimeter of the cross-section and A is the area of the cross-section. For a given denier per filament value, such fibers have a relatively low surface area, which improves aerosol delivery to the consumer.

As used herein, the term "tobacco material" refers to any material that includes tobacco or derivatives thereof. 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, reconstituted tobacco, and/or tobacco extracts.

As described herein, the active material may include or be derived from one or more botanical materials or components, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, hulls, husks, and the like. Alternatively, the material may comprise active compounds naturally occurring in vegetable materials, which are obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, flakes, or the like. Examples of vegetable materials are tobacco, eucalyptus, star anise, hemp, cocoa, Indian hemp, fennel, lemongrass, mint, spearmint, black leaf tea, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay, licorice (glycyrrhiza uralensis), matcha, mate, orange peel, papaya, rose, sage, tea (e.g. green or black tea), thyme, clove, cinnamon, coffee, anise (anise), basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderberry, vanilla, wintergreen, perilla, turmeric, santalum, sandalwood, caraway, bergamot, orange flower, myrtle, black currant, valerian, spanish pepper, nutmeg, dammar, kale, marylang, olive, lemon mint, lemon balm, welsh onion, parsley, verbena, tarragon, geranium, mulberry, ginseng, theanine, theophylline, maca, indian ginseng, damnacanthus, guanna, chlorophyll, sinomenium or any combination thereof. The mint may be selected from the following mint varieties: mentha arvensis (Mentha arvensis), Mentha arvensis c.v. (Mentha c.v.), egyptian mint (Mentha niliacea), peppermint (Mentha piperita), lemon peppermint c.v. (Mentha piperita cirtrata c.v.), peppermint c.v. (Mentha piperita c.v), spearmint (Mentha spicata crispa), peppermint (Mentha carinata), spearmint (memzhai longifolia), spearmint (memzha longifolia), spearmint (Mentha suaveolens vagata), spearmint (Mentha pulegium), spearmint c.v. (Mentha spicata c.v.) and apple mint (Mentha sualoriensis).

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

In some embodiments, the active substance comprises or is derived from one or more botanical materials or components, derivatives or extracts thereof, and the botanical material is selected from eucalyptus, anise, cocoa, and hemp.

In some embodiments, the active substance comprises or is derived from one or more botanical materials or components, derivatives or extracts thereof, and the botanical material is selected from black leaf tea and anise.

In some embodiments, the substance to be delivered comprises a flavoring agent.

As used herein, the terms "flavoring agent" and "aroma" refer to a material that, where local regulations permit, may be used to produce a desired taste, aroma, or other somatic sensation in a product for an adult consumer. They may include naturally occurring flavoring materials, plant materials, extracts of plant materials, synthetically obtained materials, or combinations thereof (e.g., tobacco, Indian hemp, licorice (licorice root), hydrangea, eugenol, japanese magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, japanese mint, anise (anise), cinnamon, turmeric, indian spice, asian spice, herb, wintergreen, cherry, berry, raspberry, cranberry, peach, apple, orange, mango, citrus fruit, lemon, lime, tropical fruits, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, red plum, bourbon whisky, scotch whisky, gin, agave, rum, spearmint, lavender, aloe, cardamom, celery, sophora alopecuroide, nutmeg, sandalwood, bergamot, geranium, arabic tea, sorghum, betel leaf, hookah, pine, honey essence, rose oil, vanilla, lemon oil, orange blossom, cherry blossom, cinnamon, caraway, brandy, jasmine, ylang, sage, fennel, horseradish, allspice, ginger, coriander, coffee, hemp, peppermint oil from any species of mentha, eucalyptus, aniseed, cocoa, citronella, red leaf tea, flax, ginkgo, hazelnut, hibiscus, bay, natural indigo, orange peel, rose, tea (such as green tea or black tea), thyme, juniper, elderberry, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak, turmeric, coriander, myrtle, black currant, valerian, spanish pepper, nutmeg, dammar, marjoram, olives, lemon mint, lemon basil, shallot, parsley, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives, such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. They may be imitation, synthetic or natural ingredients or mixtures thereof. They 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 agent comprises menthol, spearmint, and/or peppermint. In some embodiments, the flavoring agent comprises a flavor component of cucumber, blueberry, citrus fruit, and/or raspberry. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring agent comprises a flavoring ingredient extracted from tobacco. In some embodiments, the flavoring agent comprises a flavoring ingredient extracted from Indian hemp.

In some embodiments, the flavoring agent may include sensates intended to achieve somatic sensations that are generally chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), which may include agents that provide heating, cooling, tingling, numbing effects in addition to or in place of the aromatic or gustatory nerves. A suitable thermogenic agent may be, but is not limited to, vanillyl ether, and a suitable coolant may be, but is not limited to, eucalyptol, WS _-3 。

In the drawings described herein, like reference numerals are used to designate equivalent features, articles, or components.

Fig. 1a is a side cross-sectional view of an article 1 for use in an aerosol provision system, the article comprising a component 2, in this example a mouthpiece 2, at least a portion of which is arranged to be received in the mouth of a user. Figure 1b is a cross-sectional view of the mouthpiece shown in figure 1a through line a-a' thereof. In an alternative example, the component 2 may comprise a portion of the article 1 that is not arranged to be received in the mouth of a user.

The article 1 comprises a cylindrical rod of aerosol-generating material 3, in this case a tobacco material, connected to a mouthpiece 2. The mouthpiece 2 comprises a segment 6 having a longitudinal axis "X" and a cross-sectional area measured perpendicular to the longitudinal axis. Herein, the terms "longitudinal" and "longitudinally" refer to directions along the longitudinal axis X of the article 1, while the terms "transverse" and "laterally" refer to directions substantially perpendicular to the longitudinal axis X of the article 1.

In this example, the segment 6 comprises a body of material. In this example, the body of material is in the shape of a cylinder. A first breakable capsule 11a and a second breakable capsule 11b are disposed in the body of material. The body of material is preferably substantially uniform in density throughout the cylinder. Preferably, the length of the body of material 6 is less than about 15 mm. More preferably, the length of the body of material 6 is less than about 10 mm. In addition, or as an alternative, the length of the body of material 6 is at least about 5 mm. Preferably, the length of the body of material 6 is at least about 6 mm. In some preferred embodiments, the length of the body of material 6 is about 5mm to about 15mm, more preferably about 6mm to about 12mm, even more preferably about 6mm to about 10mm, most preferably about 6mm, 7mm, 8mm, 9mm or 10 mm. In this example, the length of the body 6 of material is 10 mm.

In this example, the body of material 6 is formed from a monofilament tow. In this example, the tow used in the body 6 of material has an individual filament denier of 8.4 and a total denier of 21000. Alternatively, the tow may, for example, have a denier per filament (d.p.f.) of 9.5 and a total denier of 12000. As another alternative, the tow may have a denier per filament of 6 and a total denier of 17000, or a denier per filament of 8.0 and a total denier of 15000. In this example, the tow comprises plasticized cellulose acetate tow. The plasticizer used in the tow comprises about 8% by weight of the tow, but may be between about 5% and about 12%. In this example, the plasticizer is triacetin. In other examples, the body 6 may be formed from a tow other than cellulose acetate, such as polylactic acid (PLA), other materials described herein for monofilament tows, or the like. The tow is preferably formed of cellulose acetate.

For a given tow specification (e.g., 8.4Y21000), it is known to generate a tow capacity curve representing the pressure drop of a length of rod formed by using tow for each of the tow weight ranges. Parameters such as rod length and circumference, wrapper thickness, and tow plasticizer level are specified and combined with tow specifications to produce a tow capacity curve that gives an indication of pressure drop that will be provided by different tow weights between the minimum and maximum weight achievable using standard filter rod forming machinery. Such tow capacity curves may be calculated using software available from tow suppliers, for example. It has been found to be particularly advantageous to use a body 6 of material comprising a filament bundle, wherein the weight of the filament bundle is in the range of about 10% to about 30% of the range between the minimum weight and the maximum weight of the bundle capacity curve produced by the filament bundle for each millimeter of the length of the body 6 of material. This may provide an acceptable balance between providing sufficient tow weight to avoid shrinkage after the body 6 has been formed, providing an acceptable pressure drop, while also helping to place the capsules within the tow (e.g., for capsules of the size described herein).

In other examples, different materials may be used to form the body of material 6. For example, the body 6 may be formed from paper rather than tow, for example in a similar manner to paper filters known for cigarettes. Alternatively, the body 6 may be formed from a tow other than cellulose acetate, such as polylactic acid (PLA), other materials described herein for monofilament tows, or the like. Whether formed of cellulose acetate or other material, the tow preferably has a denier per filament of at least 5, more preferably at least 6, and even more preferably at least 7. These values of denier per filament provide a tow having relatively coarse fibers with a lower surface area, which results in a lower pressure drop across the mouthpiece 2 than a tow having a lower value of denier per filament. Preferably, to achieve a sufficiently uniform body of material, the tow has a denier per filament of no greater than 12 denier per filament, preferably no greater than 11 denier per filament, and still more preferably no greater than 10 denier per filament.

The total denier of the tow forming the body 6 of material is preferably at most 30000, more preferably at most 28000, still more preferably at most 25000. These values of total denier provide a reduced proportion of the tow occupying the cross-sectional area of the mouthpiece 2, which results in lower resistance to draw than tow having a higher total denier value, and therefore a lower pressure drop across the mouthpiece 2. For a suitable stiffness of the body 6 of material, the tow preferably has a total denier of at least 8000, more preferably at least 10000. Preferably, the filament denier is between 5 and 12 and the total denier is between 10000 and 20000. More preferably, the filament denier is between 6 and 10 and the total denier is between 11000 and 22000. Preferably, the cross-sectional shape of the filament bundle is "Y" shaped, and in other embodiments, other shapes, such as "X" shaped filaments, having the same denier per filament and total denier values as provided herein, may also be used.

In this example, the aerosol modifier is provided in the form of

capsules

11a, 11b within the body 6 of material and the first oil resistant forming paper 7 surrounds the body 6 of material. The body 6 of material is in the form of a cylinder having a longitudinal axis, and the

capsules

11a, 11b are embedded within the body 6 of material such that the

capsules

11a, 11b are surrounded by the material forming the body 6. The

capsules

11a, 11b have an outer shell that encapsulates a liquid aerosol modifier. The maximum cross-sectional area of the capsule, measured perpendicular to the longitudinal axis, is less than about 28% of the cross-sectional area of the body of material 6, measured perpendicular to the longitudinal axis.

Providing a plurality of capsules, each having a cross-sectional area of less than about 28% of the cross-sectional area of the portion of the mouthpiece 2 in which the

capsules

11a, 11b are disposed, has the advantage that the pressure drop across the mouthpiece 2 can be reduced compared to a single capsule having a larger cross-sectional area, and sufficient space remains around the capsule for the aerosol to pass through, without the body 6 of material removing a significant amount of the aerosol mass as it passes through the mouthpiece 2.

The maximum cross-sectional area of each of the

capsules

11a, 11b at its maximum cross-section is less than 35%, more preferably less than about 28%,and still more preferably less than about 25%. For example, each of the

capsules

11a, 11b within the body 6 has a maximum cross-sectional area at its maximum cross-section of between about 5% and about 24%, or between about 9% and about 22%, or between about 14% and about 21%. For example, for a spherical capsule having a diameter of 2.5mm, the maximum cross-sectional area of the capsule is 4.91mm ² . For a mouthpiece 2 as described herein having a circumference of about 17mm, the body 6 of material has an outer circumference of about 16.8mm, and the radius of this component would be 2.67mm, corresponding to 22.46mm ² Cross-sectional area of (a). In this example, the maximum capsule cross-sectional area is about 21% of the cross-sectional area of the mouthpiece 2. For a mouthpiece 2 having a circumference of 21mm as described herein, the body 6 of material has an outer circumference of 20.8mm and the radius of this component would be 3.31mm, corresponding to 34.43mm ² Cross-sectional area of (a). In this example, the capsule cross-sectional area is 14.3% of the cross-sectional area of the mouthpiece 2. As another example, if the capsule has a diameter of 2mm, its maximum cross-sectional area would be 3.14mm ² . In this case, the cross-sectional area of the capsule will be about 14% of the cross-sectional area of the body 6 of material having a circumference of about 16.8mm and about 9% of the cross-sectional area of the body 6 of material having a circumference of about 20.8 mm. In the present example, each of the

capsules

11a, 11b has a diameter of 2.5 mm.

Each of the

capsules

11a, 11b may comprise a breakable capsule, such as a capsule having a solid breakable shell enclosing a liquid payload. In the present example, two

capsules

11a, 11b are used. The

capsules

11a, 11b are completely embedded within the body 6 of material, in other words the

capsules

11a, 11b are completely surrounded by the material forming the body 6. In other examples, more than two breakable capsules may be provided within the body of material 6, such as 3, 4, 5, or more breakable capsules. The length of the body of material 6 may be increased to accommodate the number of capsules required. The

individual capsules

11a, 11b may be identical to each other or may differ from each other in terms of size and/or capsule payload. In other examples, multiple bodies 6 of material may be provided, wherein each body contains two or more capsules.

The

capsules

11a, 11b have a core-shell structure. In other words, the capsules each include a shell that encapsulates a liquid agent, such as a fragrance or other agent, which may be any of the fragrances or aerosol modifiers described herein. The user may rupture the outer shell of the capsule to release the flavourant or other agent into the body 6 of material, the mouthpiece also comprising a second forming paper 9 and tipping paper 5. The first forming paper 7 may comprise a barrier coating to render the material of the forming paper substantially impermeable to the liquid payload of the capsule 11. In the present example, the first forming paper 7 is oil-resistant forming paper. Alternatively or additionally, the second forming paper 9 and/or tipping paper 5 may comprise a barrier coating to render the material of the forming paper and/or tipping paper substantially impermeable to the liquid payload of the

capsules

11a, 11 b.

In this example, the

capsules

11a, 11b are spherical and each has a diameter of about 2.5 mm. In other examples, other shapes and sizes of capsules may be used. The total combined weight of the

capsules

11a, 11b may be in the range of about 10mg to about 50 mg.

In this example, the

capsules

11a, 11b are located in a longitudinally central position within the body 6 of material. In this example, the capsule 11a is positioned with its center 2.75mm from the upstream end of the body of material 6, and the capsule 11b is axially aligned, adjacent and in abutting relationship with the capsule 11a with its center 2.75mm from the downstream end of the body of material 6. Thus, the point directly between the

capsules

11a, 11b of 2.5mm diameter is 4mm from each end of the body 6 of material. In other examples, each of the

capsules

11a, 11b may be located at a position other than a longitudinally central position in the body of material 6, i.e., closer to a downstream end of the body of material 6 than to an upstream end, or closer to an upstream end of the body of material 6 than to a downstream end. In other examples, the

capsules

11a and 11b may not be laterally aligned and may be offset from each other in a direction along line a-a' of fig. 1 (i.e., in a direction perpendicular to the longitudinal axis X of the article). Preferably, the mouthpiece 2 is configured such that the

capsules

11a, 11b and the ventilation holes 12 are longitudinally offset from each other in the mouthpiece 2.

In figure 1b a cross section of the mouthpiece 2 is shown, this cross section being taken through line a-a' of figure 1 a. Figure 1b shows a capsule 11b, a body of material 6, first and second forming

papers

7, 9 and tipping paper 5. In this example, the capsule 11b is centred on the longitudinal axis (not shown) of the mouthpiece 2. The first and second forming

papers

7, 9 and the tipping paper 5 are arranged concentrically around the body 6 of material.

In this case, the capsule 11a is substantially identical to the capsule 11 b. However, in other embodiments, the

capsules

11a and 11b may differ in structure, shell composition, additive composition, diameter, or any other feature described herein.

The

breakable capsules

11a, 11b have a core-shell structure. That is, the encapsulating or barrier material creates an outer shell around the core that includes the aerosol modifier. The shell structure retards migration of the aerosol modifier during storage of the article 1, but allows controlled release of the aerosol modifier (also referred to as aerosol modifier) during use.

In some cases, the barrier material (also referred to herein as an encapsulant material) is frangible. The capsule is crushed or otherwise broken or ruptured by a user to release the encapsulated aerosol modifier. Typically, the capsule is broken immediately before heating begins, but the user may choose when to release the aerosol modifier. The term "breakable capsule" refers to a capsule in which the shell can be broken by pressure to release the core; more specifically, when the user wishes to release the core of the capsule, the shell can be ruptured under the pressure exerted by the user's finger.

In some cases, the barrier material is heat resistant. That is, in some cases, the barrier material will not rupture, melt, or otherwise fail at the temperatures reached at the capsule site during operation of the aerosol provision device. Illustratively, the capsule located in the mouthpiece may be exposed to a temperature in the range of, for example, 30 ℃ to 100 ℃, and the barrier material may continue to retain the liquid core up to at least about 50 ℃ to about 120 ℃.

In other cases, the capsules release the core composition upon heating, e.g., by melting of the barrier material or by rupture of the barrier material as a result of capsule swelling.

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

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

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

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

Preferably, when both capsules rupture, the pressure drop or differential pressure (also referred to as resistance to draw) across the article, measured as open pressure drop (i.e., vent opening), decreases by less than about 15mmH ₂ And O. More preferably, the reduction in open pressure drop is less than about 10mmH ₂ O, and more preferably less than about 8mmH ₂ O or less than about 6mmH ₂ And O. These values are as follows80 fewer articles made of the same design were measured. This small variation in pressure drop means that other aspects of the product design, such as setting the correct ventilation level for a given pressure drop of the product, can be achieved whether or not the consumer chooses to break the capsule.

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

Suitably, the gelling agent may be, for example, a polysaccharide or cellulose gelling agent, gelatin, gum, gel, wax or a mixture thereof. Suitable polysaccharides include alginates, dextrans, maltodextrins, cyclodextrins, and pectins. Suitable alginates include, for example, salts of alginic acid, esterified alginates or glycerol alginates. Salts of alginic acid include ammonium alginate, triethanolamine alginate, and group I or II metal ion alginates, such as sodium alginate, potassium alginate, calcium alginate, and magnesium alginate. Esterified alginates include propylene glycol alginate and glycerol alginate. In one embodiment, the barrier material is sodium alginate and/or calcium alginate. Suitable cellulosic materials include methyl cellulose, ethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, cellulose acetate and cellulose ethers. The gelling agent may comprise one or more modified starches. The gelling agent may comprise carrageenan. Suitable gums include agar, gellan, gum arabic, pullulan, mannan gum, terminalia subgenera gum, tragacanth gum, karaya gum, locust bean gum, gum arabic, guar gum, quince seed and xanthan gum. Suitable gels include agar, agarose, carrageenan, carbofuran and furcellaran. Suitable waxes include carnauba wax. In some cases, the gelling agent may include carrageenan and/or gellan gum; these gelling agents are particularly suitable to be added as gelling agents, since the pressure required to break the resulting capsules is particularly suitable.

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

The barrier material may comprise a colorant which facilitates positioning of the capsule within the aerosol-generating device during the manufacturing process of the aerosol-generating device. The colorant is preferably selected from the group consisting of colorants and pigments.

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

The barrier material may also comprise at least one plasticizer, which may be glycerol, sorbitol, maltitol, triacetin, polyethylene glycol, propylene glycol or another polyol having plasticizing properties, and optionally one of the monobasic, dibasic or tribasic acid types, in particular citric acid, fumaric acid, malic acid, etc. The amount of plasticizer is from 1% to 30% by weight, preferably from 2% to 15% by weight, even more preferably from 3% to 10% by weight of the total dry weight of the shell

The barrier material may also include one or more filler materials. Suitable filler materials include starch derivatives, such as dextrin, maltodextrin, cyclodextrin (α, β or γ), or cellulose derivatives, such as Hydroxypropylmethylcellulose (HPMC), Hydroxypropylcellulose (HPC), Methylcellulose (MC), carboxymethylcellulose (CMC), polyvinyl alcohol, polyols or mixtures thereof. Dextrin is a preferred filler. The amount of filler in the casing is at most 98.5%, preferably from 25% to 95%, more preferably from 40% to 80%, even more preferably from 50% to 60% by weight of the total dry weight of the casing.

The capsule shell may additionally include a hydrophobic outer layer that reduces the susceptibility of the capsule to moisture-induced degradation. The hydrophobic outer layer is suitably selected from the group comprising waxes, in particular carnauba wax, candelilla wax or beeswax, polyethylene glycol, shellac (in alcohol or aqueous solution), ethyl cellulose, hydroxypropyl methyl cellulose, hydroxypropyl cellulose, latex compositions, polyvinyl alcohol, or combinations thereof. More preferably, the at least one moisture barrier is ethyl cellulose or a mixture of ethyl cellulose and shellac.

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

The flavour may suitably be licorice, rose oil, vanilla, lemon oil, orange oil, mint flavour, suitably menthol and/or mint oil from any species of the genus mentha, for example peppermint and/or spearmint oil, or lavender, fennel or fennel.

In some cases, the flavorant includes menthol.

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

In some cases, the core may comprise at least about 25% w/w perfume (based on the total weight of the core), suitably at least about 30% w/w perfume, 35% w/w perfume, 40% w/w perfume, 45% w/w perfume or 50% w/w perfume. In some cases, the core may comprise less than or equal to about 75% w/w perfume (based on the total weight of the core), suitably less than or equal to about 65% w/w perfume, 55% w/w perfume, or 50% w/w perfume. Illustratively, the capsules may comprise perfume in an amount in the range of 25-75% w/w (based on the total weight of the core), about 35-60% w/w or about 40-55% w/w.

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

In some cases, the consumable comprises at least about 7mg of the aerosol modifier, suitably at least about 8mg of the aerosol modifier, 10mg of the aerosol modifier, 12mg of the aerosol modifier or 15mg of the aerosol modifier. The core may also include a solvent that dissolves the aerosol modifier.

Any suitable solvent may be used.

Where the aerosol modifier comprises a perfume, the solvent may suitably comprise short or medium chain fats and oils. For example, the solvent may comprise a triglyceride, such as a C2-C12 triglyceride, suitably a C6-C10 triglyceride or a Cs-C12 triglyceride. For example, the solvent may include medium chain triglycerides (MCT-C8-C12), which may be derived from palm oil and/or coconut oil.

Esters may be formed with caprylic and/or capric acid. For example, the solvent may include a medium chain triglyceride that is caprylic acid triglyceride and/or capric acid triglyceride. For example, the solvent may include the compound in CAS registry No. 73398-61-5, 65381-09-1, 85409-09-2. The medium chain triglycerides are odorless and tasteless.

The hydrophilic-lipophilic balance (HLB) of the solvent may be in the range 9 to 13, suitably 10 to 12. The process of making the capsules comprises co-extrusion, optionally followed by centrifugation and curing and/or drying. The content of WO 2007/010407a2 is hereby incorporated by reference in its entirety.

In some embodiments, when heating the aerosol generating material 3 to provide an aerosol, for example within a non-combustible aerosol provision device as described herein, the portion of the mouthpiece 2 in which the capsule is located reaches a temperature of between 58 degrees celsius and 70 degrees celsius during use of the system to generate an aerosol. As a result of this temperature, the capsule contents are heated sufficiently to promote volatilization of the capsule contents (e.g., aerosol modifier) into the aerosol formed by the system as the aerosol passes through the mouthpiece 2. Heating the contents of the

capsules

11a, 11b may for example take place before the

capsules

11a, 11b have ruptured, so that when the

capsules

11a, 11b rupture, the capsule contents are more easily released into the aerosol passing through the mouthpiece 2. Alternatively, the contents of the

capsules

11a, 11b may be heated to this temperature after the

capsules

11a, 11b have been ruptured, again resulting in increased release of the contents into the aerosol. Advantageously, it has been found that a mouthpiece temperature in the range of 58 to 70 degrees celsius is high enough that the capsule contents can be more easily released, but low enough that the outer surface of the portion of the mouthpiece 2 in which the capsule is located does not reach an uncomfortable temperature for the consumer to touch in order to rupture the

capsules

11a, 11b by squeezing on the mouthpiece 2.

The temperature of the portion of the mouthpiece 2 where the

capsules

11a, 11b are located may be measured using a digital thermometer with a penetrating probe arranged so that the probe enters the mouthpiece 2 through the walls of the mouthpiece 2 (forming a seal to limit the amount of outside air that may leak around the probe into the mouthpiece) and is located near the location of the

capsules

11a, 11b, for example between the

capsules

11a, 11 b. Similarly, a temperature probe may be placed on the outer surface of the mouthpiece 2 to measure the temperature of the outer surface.

Table 2.0 below shows the temperature at the location of the capsule in the mouthpiece 2 of the article used in the aerosol provision system during the first 5 puffs. The "standard" heating profile is used to provide data for an article when heated using a coil heating apparatus as described herein with reference to fig. 2-6, and the "enhanced" heating profile is used to provide data for the same article when heated using the same apparatus. The "boost" heating profile is user selectable and allows higher heating temperatures to be achieved.

As shown in table 2.0, the temperature of the mouthpiece 2 at the location of the capsule 11b reached a maximum temperature of 61.5 ℃ under the "standard" heating curve and a maximum temperature of 63.8 ℃ under the "enhanced" heating curve. It has been found that a maximum temperature in the range of 58 ℃ to 70 ℃, preferably in the range of 59 ℃ to 65 ℃, more preferably in the range of 60 ℃ to 65 ℃ is particularly advantageous with respect to helping the evaporation of the contents of the

capsule

11a, 11b while maintaining a suitable outer surface temperature of the mouthpiece 2.

TABLE 2.0

The

capsules

11a, 11b are breakable by an external force applied to the mouthpiece 2, for example by the consumer squeezing the mouthpiece 2 using their fingers or other mechanism. As mentioned above, the portion of the mouthpiece in which the capsule is located is arranged to reach a temperature of greater than 58 ℃ during use of the aerosol provision system to generate an aerosol. Preferably, the burst strength of the

capsules

11a, 11b is between 1500 and 4000 gram-force when positioned within the mouthpiece 2 and prior to heating the aerosol-generating material 3. Preferably, the burst strength of the

capsules

11a, 11b is between 1000 and 4000 gram-force when located within the mouthpiece 2 and within 30 seconds of generating an aerosol using the aerosol provision system. Thus, despite being subjected to temperatures above 58 ℃, for example between 58 ℃ and 70 ℃, the

capsules

11a, 11b are able to maintain burst strength within a range that has been found to enable the capsules to be easily crushed by the consumer, while providing the consumer with sufficient tactile feedback that the

capsules

11a, 11b have ruptured. Maintaining such burst strength is achieved by selecting a suitable gelling agent for the capsule, as described herein, such as a polysaccharide, including, for example, gum arabic, gellan gum, gum arabic, xanthan gum, or carrageenan, alone or in combination with gelatin. In addition, a suitable wall thickness of the capsule shell should be selected.

Suitably, the burst strength of the capsule, when located within the mouthpiece and prior to heating the aerosol generating material, is between 2000 grams force and 3500 grams force, or between 2500 grams force and 3500 grams force. Suitably, the burst strength of the capsule when positioned within the mouthpiece and within 30 seconds of generating an aerosol using the system is between 1500 grams force and 4000 grams force, or between 1750 grams force and 3000 grams force. In one example, the average burst strength of the capsule is about 3175 grams force when positioned within the mouthpiece and prior to heating the aerosol-generating material, and about 2345 grams force when positioned within the mouthpiece and within 30 seconds of generating an aerosol using the system.

The burst strength of the capsule can be tested using a force measuring instrument such as a texture analyzer. Xtplus type texture analyser can be used with a circular metal probe having a diameter of 6mm centred on the position of the capsule (i.e. 12mm from the mouth end of the mouthpiece 2). The test speed of the probe may be 0.3mm/s, while a pre-test speed of 5.00mm/s and a post-test speed of 10mm/s may be used. The force used may be 5000 g. Using standard testing equipment, the articles tested can be smoked using a Borgwaldt a14 syringe drive unit, following the known canadian department of health strong puff protocol (55 ml of puff volume applied every 30 seconds for 2 seconds). Three puffs can be performed using this puff protocol, and the capsule burst strength is measured within 30 seconds of the third puff.

The aerosol generating material 3 provides an aerosol when heated within a non-combustible aerosol supply device, for example a non-combustible aerosol supply device comprising a coil, for example as described herein, thereby forming a system. In other embodiments, the article 1 may include its own heat source, thereby forming an aerosol provision system without the need for a separate aerosol provision device.

The aerosol-generating material 3, also referred to herein as aerosol-generating substrate 3, comprises at least one aerosol-forming material. In this example, the aerosol-forming material is glycerol. In alternative examples, the aerosol-forming material may be another material as described herein or a combination thereof. It has been found that aerosol-forming materials improve the organoleptic properties of the article by helping to transfer compounds (e.g. flavour compounds) from the aerosol-generating material to the consumer. However, a problem with adding such aerosol-forming materials to aerosol-generating materials within articles for use in non-combustible aerosol delivery systems may be that the aerosol-forming material may increase the mass of aerosol delivered by the article as it aerosolizes upon heating, and this increased mass may be maintained at a higher temperature as it passes through the mouthpiece. As it passes through the mouthpiece, the aerosol transfers heat into the mouthpiece, and this warms the outer surface of the mouthpiece, including the areas in contact with the lips of the consumer during use. The mouthpiece temperature may be significantly higher than the temperature to which a consumer may be accustomed when smoking, for example, a conventional cigarette, and this may be an undesirable effect resulting from the use of such aerosol-forming materials.

The mouthpiece portion that contacts the lips of the consumer is typically a paper tube that is hollow or cylindrical surrounding the filter material.

As shown in figure 1a, the mouthpiece 2 of the article 1 comprises an upstream end 2a proximal to the aerosol-generating substrate 3 and a downstream end 2b distal to the aerosol-generating substrate 3. At the downstream end 2b, the mouthpiece 2 has a hollow tubular element 4 formed from a monofilament tow. It has been advantageously found that this significantly reduces the temperature of the outer surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece which comes into contact with the mouth of the consumer when the article 1 is in use. In addition, the use of the tubular element 4 has also been found to significantly reduce the temperature of the outer surface of the mouthpiece 2 even upstream of the tubular element 4. Without wishing to be bound by theory, it is hypothesized that this is due to the tubular element 4 guiding the aerosol closer to the centre of the mouthpiece 2 and thus reducing the heat transfer from the aerosol to the outer surface of the mouthpiece 2.

The body of material 6 and the hollow tubular element 4 each define a substantially cylindrical overall profile and share a common longitudinal axis. The body of material 6 is wrapped in a first forming paper 7. Preferably, the first forming paper 7 has a basis weight of less than 50gsm, more preferably about 20gsm to 40 gsm. Preferably, the first forming paper 7 has a thickness of 30 μm to 60 μm, more preferably 35 μm to 45 μm. Preferably, the first forming paper 7 is a non-porous forming paper, for example having a permeability of less than 100Coresta units, for example less than 50Coresta units. However, in other embodiments, the first forming paper 7 may be a porous forming paper, for example having a permeability of more than 200Coresta units.

In this example, the article 1 has an outer perimeter of about 17mm (i.e., the article is in ultrathin form). In other examples, the article may be provided in any form described herein, for example having an outer perimeter of 15mm to 25 mm.

The outer circumference of the mouthpiece 2 is substantially the same as the outer circumference of the rod 3 of aerosol-generating material so that there is a smooth transition between these components. In this example, the outer circumference of the mouthpiece 2 is about 16.8 mm. The tipping paper 5 is wrapped around the entire length of the mouthpiece 2 and over a portion of the rod 3 of aerosol-generating material and has adhesive on its inner surface to join the mouthpiece 2 and rod 3. In the present example, the tipping paper 5 extends 5mm over the rod 3 of aerosol-generating material, but it may alternatively extend 3mm to 10mm, or more preferably 4mm to 6mm, over the rod 3 to provide a secure attachment between the mouthpiece 2 and the rod 3. The basis weight of the tipping paper 5 may be higher than the basis weight of the plug wrap used in the article 1, for example a basis weight of 40gsm to 80gsm, more preferably 50gsm to 70gsm, and in this example 58 gsm. It has been found that these basis weight ranges result in tipping paper having acceptable tensile strength, while being flexible enough to wrap around the article 1 and adhere to itself along the longitudinal lap seam on the paper. The outer circumference of the tipping paper 5, once wrapped around the mouthpiece 2, is about 21 mm.

The "wall thickness" of the hollow tubular element 4 corresponds to the thickness of the wall of the tube 4 in the radial direction. This can be measured, for example, using a caliper. The wall thickness is advantageously greater than 0.9mm, more preferably 1.0mm or greater. Preferably, the wall thickness is substantially constant around the entire wall of the hollow tubular element 4, however, in case the wall thickness is not substantially constant, the wall thickness is preferably larger than 0.9mm, more preferably 1.0mm or more at any point around the hollow tubular element 4.

Preferably, the length of the hollow tubular element 4 is less than about 20 mm. More preferably, the hollow tubular element 4 has a length of less than about 15 mm. More preferably, the length of the hollow tubular element 4 is less than about 10 mm. Additionally, or alternatively, the length of the hollow tubular element 4 is at least about 5 mm. Preferably, the length of the hollow tubular element 4 is at least about 6 mm. In some preferred embodiments, the length of hollow tubular element 4 is from about 5mm to about 20mm, more preferably from about 6mm to about 10mm, even more preferably from about 6mm to about 8mm, most preferably about 6mm, 7mm or about 8 mm. In the present example, the hollow tubular element 4 has a length of 6 mm.

In some embodiments, it may be particularly advantageous to use a hollow tubular element 4 having a length greater than about 10mm, for example about 10mm to about 30mm or about 12mm to about 25 mm. It has been found that when the aerosol is drawn through the article 1, the lips of the consumer may in some cases extend from the mouth end of the article 1 to about 12mm, so a hollow tubular element 4 having a length of at least 10mm or at least 12mm means that the majority of the lips of the consumer surround this element 4.

Preferably, the hollow tubular member 4 has a density of at least about 0.25 grams per cubic centimeter (g/cc), more preferably at least about 0.3 g/cc. Preferably, the hollow tubular member 4 has a density of less than about 0.75 grams per cubic centimeter (g/cc), more preferably less than 0.6 g/cc. In some embodiments, the hollow tubular member 4 has a density of 0.25g/cc to 0.75g/cc, more preferably 0.3g/cc to 0.6g/cc, more preferably 0.4g/cc to 0.6g/cc or about 0.5 g/cc. These densities have been found to provide a good balance between the improved robustness provided by the denser material and the lower heat transfer properties of the lower density material. For the purposes of the present invention, the "density" of hollow tubular element 4 refers to the density of the monofilament strands forming the element, in which any plasticizer is incorporated. The density may be determined by dividing the total weight of the hollow tubular element 4 by the total volume of the hollow tubular element 4, wherein the total volume may be calculated using a suitable measurement of the hollow tubular element 4, e.g. using a caliper. If necessary, a microscope may be used to measure the appropriate dimensions.

The filament bundle forming the hollow tubular element 4 preferably has a total denier of less than 45000, more preferably less than 42000. It has been found that this total denier allows the formation of a less dense tubular element 4. Preferably, the total denier is at least 20000, more preferably at least 25000. In a preferred embodiment, the filament bundle forming hollow tubular element 4 has a total denier of from 25000 to 45000, more preferably from 35000 to 45000. Preferably, the cross-sectional shape of the filament bundle is "Y" shaped, but other shapes, such as "X" shaped monofilaments, may be used in other embodiments.

The filament bundle forming the hollow tubular member 4 preferably has a denier per filament of greater than 3. This filament denier has been found to allow the formation of less dense tubular members 4. Preferably, the filament denier is at least 4, more preferably at least 5. In a preferred embodiment, the filament bundle forming hollow tubular member 4 has a denier per filament of from 4 to 10, more preferably from 4 to 9. In one example, the monofilament tow forming hollow tubular element 4 has an 8Y40000 tow formed of cellulose acetate and comprising 18% plasticizer (e.g., triacetin).

The hollow tubular element 4 preferably has an inner diameter greater than 3.0 mm. A smaller diameter than this may result in the velocity of the aerosol through the mouthpiece 2 to the mouth of the consumer increasing more than desired, such that the aerosol becomes too hot, for example reaching a temperature of greater than 40 ℃ or greater than 45 ℃. More preferably, the hollow tubular element 4 has an inner diameter greater than 3.1mm, still more preferably greater than 3.5mm or 3.6 mm. In one embodiment, the inner diameter of the hollow tubular element 4 is about 3.9 mm.

The hollow tubular element 4 preferably comprises from 15 to 22% by weight of a plasticizer. For cellulose acetate tow, the plasticizer is preferably triacetin, but other plasticizers, such as polyethylene glycol (PEG), may also be used. More preferably, the tubular element 4 comprises from 16% to 20% by weight of plasticizer, for example about 17%, about 18% or about 19% of plasticizer.

The pressure drop or pressure differential across the mouthpiece (also known as the resistance to draw), e.g. the portion of the article 1 downstream of the aerosol-generating material 3, is preferably less than about 40mmH ₂ And (O). It has been found that such a pressure drop allows sufficient aerosol, including the desired compound (e.g. flavour compound), to pass through the mouthpiece 2 to the consumer. More preferably, the pressure drop across the mouthpiece 2 is less than about 32mmH ₂ And (O). In some embodiments, a composition having less than 31mmH has been used ₂ The mouthpiece 2 with a pressure drop of O achieves a particularly improved aerosol, for example of about 29mmH ₂ O, about 28mmH ₂ O or about 27.5mmH ₂ And O. Alternatively or additionally, the mouthpiece pressure drop may be at least 10mmH ₂ O, preferably at least 15mmH ₂ O, more preferably at least 20mmH ₂ And O. In some embodiments, the mouthpiece pressure drop may be about 15mmH ₂ O and 40mmH ₂ And O is between. These values enable the mouthpiece 2 to slow the aerosol as it passes through the mouthpiece 2 so that the temperature of the aerosol has time to decrease before reaching the downstream end 2b of the mouthpiece 2.

In the present example, the hollow tubular element 4 is a first hollow tubular element 4, and the mouthpiece comprises a second hollow tubular element 8, also referred to as a cooling element, which is located upstream of the first hollow tubular element 4. In this example, the second hollow tubular element 8 is located upstream of the body 6 of material, adjacent to and in abutting relationship with the body 6 of material. The body of material 6 and the second hollow tubular element 8 each define a substantially cylindrical overall profile and share a common longitudinal axis. The second hollow tubular element 8 is formed from a plurality of paper layers which are wound in parallel and have butt seams to form the tubular element 8. In the present example, the first and second paper layers are provided in a double tube, but in other examples, 3, 4 or more paper layers may be used to form a 3, 4 or more tube. Other configurations may be used, such as spiral wraps of paper, cardboard tubes, tubes formed using a paper machine type process, molded or extruded plastic tubes, and the like. The second hollow tubular member 8 may also be formed using stiff plug wrap and/or tipping paper into the second plug wrap 9 and/or tipping paper 5 described herein, which means that a separate tubular member is not required. Stiff plug wrap and/or tipping paper is manufactured to have sufficient stiffness to withstand axial compression forces and bending moments that may occur during manufacture and when the article 1 is used. For example, the stiff plug wrap and/or tipping paper may have a basis weight of from 70gsm to 120gsm, more preferably from 80gsm to 110 gsm. Additionally or alternatively, the stiff plug wrap and/or tipping paper may have a thickness of from 80 μm to 200 μm, more preferably from 100 μm to 160 μm, or from 120 μm to 150 μm. It may be desirable for both the second forming paper 9 and the tipping paper 5 to have values within these ranges to achieve an acceptable level of overall stiffness for the second hollow tubular element 8.

The second hollow tubular member 8 preferably has a wall thickness of at least about 100 μm and up to about 1.5mm, preferably 100 μm to 1mm, more preferably 150 μm to 500 μm, or about 300 μm, which can be measured in the same manner as the wall thickness of the first hollow tubular member 4. In the present example, the second hollow tubular element 8 has a wall thickness of approximately 290 μm.

In other embodiments, the second hollow tubular element 8 has a wall thickness of at least about 325 μm and up to about 2mm, preferably 500 μm to 1.5mm, more preferably 750 μm to 1 mm. For example, the second hollow tubular element 8 may have a wall thickness of about 1 mm.

In some embodiments, the wall thickness of the second hollow tubular element 8 is at least 325 microns, preferably at least 400 microns, 500 microns, 600 microns, 700 microns, 800 microns, 900 microns or 1000 microns. In some embodiments, the wall thickness of the second hollow tubular element 8 is at least 1250 micrometers or 1500 micrometers.

In some embodiments, the second hollow tubular element 8 has a wall thickness of less than 2000 microns, preferably less than 1500 microns.

The increased wall thickness of the second hollow tubular element 8 means that it has a greater thermal mass, which has been found to help reduce the temperature of the aerosol passing through the second hollow tubular element 8 and reduce the surface temperature of the mouthpiece at a location downstream of the second hollow tubular element 8.

This is believed to be because the larger thermal mass of the second hollow tubular element 8 allows the second hollow tubular element 8 to absorb more heat from the aerosol than a second hollow tubular element 8 having a thinner wall thickness. The increased thickness of the second hollow tubular element 8 also directs the aerosol centrally within the mouthpiece so that less heat from the aerosol is transferred to the exterior of the mouthpiece, for example the exterior of the body of material.

In some embodiments, the permeability of the second hollow tubular element 8 is at least 100Coresta units, preferably at least 150 or 200Coresta units.

It has been found that the relatively high permeability of the second hollow tubular element 8 increases the amount of heat transferred from the aerosol to the tubular portion and thus reduces the temperature of the aerosol. It has also been found that the permeability of the second hollow tubular element 8 increases the amount of moisture transferred from the aerosol to the second hollow tubular element 8, which has been found to improve the sensation of the aerosol in the mouth of the user. The high permeability of the second hollow tubular element 8 also makes it easier to use a laser to cut the vent holes, which means that a lower power laser can be used.

In some examples, the article 1 may be configured such that there is a separation (i.e., a minimum distance) between the heater of the non-combustible aerosol provision device 100 and the second hollow tubular element 8. This prevents heat from the heater from damaging the material forming the second hollow tubular element 8.

The minimum distance between the heater of the non-combustible aerosol provision device 100 and the second hollow tubular element 8 may be 3mm or more. In some examples, the minimum distance between the heater of the non-combustible aerosol provision device 100 and the second hollow tubular element 8 may be in the range of 3mm to 10mm, such as 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm or 10 mm.

The spacing between the heating element of the non-combustible aerosol provision device 100 and the second hollow tubular element 8 may be achieved by, for example, adjusting the length of the aerosol-generating material 21.

Preferably, the length of the second hollow tubular element 8 is less than about 50 mm. More preferably, the length of the second hollow tubular element 8 is less than about 40 mm. More preferably, the length of the second hollow tubular element 8 is less than about 30 mm. In addition, or as an alternative, the length of the second hollow tubular element 8 is preferably at least about 10 mm. Preferably, the length of the second hollow tubular element 8 is at least about 15 mm. In some preferred embodiments, the length of the second hollow tubular element 8 is from about 20mm to about 30mm, more preferably from about 22mm to about 28mm, even more preferably from about 24mm to about 26mm, most preferably about 25 mm. In the present example, the length of the second hollow tubular element 8 is 25 mm.

A second hollow tubular element 8 is positioned around the mouthpiece 2 and defines an air gap within the mouthpiece which acts as a cooling segment. The air gap provides a chamber through which the heated volatile components generated by the aerosol-generating material 3 flow. The second hollow tubular element 8 is hollow to provide a chamber for aerosol accumulation, but is also sufficiently rigid to withstand axial compression forces and bending moments that may occur during manufacture and when the article 1 is in use. The second hollow tubular element 8 provides physical displacement between the aerosol-generating material 3 and the body 6 of material. The physical displacement provided by the second hollow tubular element 8 will provide a thermal gradient over the length of the second hollow tubular element 8.

Preferably, the mouthpiece 2 comprises a mouthpiece having a diameter greater than 450mm ³ The internal volume of (a). It has been found that providing a cavity of at least this volume enables improved aerosol formation. Such cavity dimensions provide sufficient space within the mouthpiece 2 to allow the heated volatile components to cool, thus allowing the aerosol-generating material 3 to be exposed to higher temperatures than would otherwise be possible, asWhich may cause the aerosol to be too hot. In the present example, the cavity is formed by the second hollow tubular element 8, but in an alternative arrangement it may be formed within a different part of the mouthpiece 2. More preferably, the mouthpiece 2 comprises a cavity, for example formed within the second hollow tubular element 8, having a diameter greater than 500mm ³ And still more preferably greater than 550mm ³ Allowing further improvement of the aerosol. In some examples, the internal cavity comprises about 550mm ³ To about 750mm ³ E.g. about 600mm ³ Or 700mm ³ 。

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

In alternative articles, the second hollow tubular element 8 may be replaced by an alternative cooling element, for example an element formed by a body of material which allows the aerosol to pass longitudinally therethrough and which also performs the function of cooling the aerosol.

In some examples, the aerosol generating material described herein is a first aerosol generating material and the second hollow tubular element 8 may comprise a second aerosol generating material. The second hollow tubular element 8 may comprise a wall comprising the second aerosol-generating material. For example, the second aerosol-generating material 4b may be disposed on an inner wall of the second hollow tubular element 8.

The second aerosol-generating material comprises at least one aerosol former material and may also comprise at least one aerosol modifier, or other sensory material. The aerosol former material and/or aerosol modifier may be any aerosol former material or aerosol modifier, or combination thereof, as described herein.

When an aerosol generated from the aerosol generating material 3, referred to herein as a first aerosol, is drawn through the second hollow tubular element 8 of the mouthpiece, heat from the first aerosol may aerosolise the aerosol forming material of the second aerosol generating material to form a second aerosol. The second aerosol may include a flavorant, which may be additional or complementary to the flavor of the first aerosol.

Providing a second aerosol-generating material on the second hollow tubular member 8 may result in the generation of a second aerosol which enhances or supplements the flavour or visual appearance of the first aerosol.

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

In this example, the aerosol-generating material 3 is wrapped in a wrapper 10. The packaging material 10 may be, for example, a paper or paper-backed foil packaging material. In this example, the packaging material 10 is substantially gas impermeable. In an alternative embodiment, the wrapper 10 preferably has a permeability of less than 100Coresta units, more preferably less than 60Coresta units. It has been found that a low permeability wrapper, for example having a permeability of less than 100Coresta units, more preferably less than 60Coresta units, results in an improved aerosol formation in the aerosol-generating material 3. Without wishing to be bound by theory, it is hypothesized that this is due to the reduced loss of aerosol compound through the packaging material 10. The permeability of the wrapper 10 may be measured according to ISO2965:2009 with respect to determining the air permeability of materials used as cigarette paper, filter plug paper and filter tipping paper.

In the present embodiment, the packaging material 10 includes an aluminum foil. Aluminium foil has been found to be particularly effective in enhancing the formation of aerosol within the aerosol-generating material 3. In this example, the aluminum foil has a metal layer with a thickness of about 6 μm. In this example, the aluminum foil has a paper backing. However, in alternative arrangements, the aluminium foil may be of other thicknesses, for example 4 to 16 μm thick. The aluminum foil also need not have a paper backing, but may have a backing formed of other materials, for example, to help provide the foil with adequate tensile strength, or it may not have a backing material. Metal layers or foils other than aluminum may also be used. The total thickness of the packaging material is preferably 20 μm to 60 μm, more preferably 30 μm to 50 μm, which may provide a packaging material with suitable structural integrity and heat transfer characteristics. The tension applied to the packaging material may be greater than 3000 grams-force, such as 3000 to 10000 grams-force or 3000 to 4500 grams-force, before the packaging material ruptures.

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

The article has a ventilation level of about 75% of the aerosol drawn through the article. In alternative embodiments, the article may have a ventilation level of between 50% and 80%, for example 65% to 75%, of the aerosol drawn through the article. These horizontal downdrafts help slow the flow of aerosol drawn through the mouthpiece 2, enabling the aerosol to cool sufficiently before it reaches the downstream end 2b of the mouthpiece 2. The ventilation is provided directly into the mouthpiece 2 of the article 1. In the present example, ventilation is provided into the second hollow tubular element 8, which has been found to be particularly beneficial in assisting the aerosol-generating process. Ventilation is provided via parallel first and second rows of perforations 12, formed in this case as laser perforations, at locations 17.925mm and 18.625mm respectively from the downstream mouth end 2b of the mouthpiece 2. These perforations pass through the tipping paper 5, the second forming paper 9 and the second hollow tubular element 8. In alternative embodiments, ventilation may be provided into the mouthpiece at other locations, for example into the body of material 6 or the first tubular element 4.

Alternatively, ventilation may be provided via a single row of perforations, such as laser perforations, into the portion of the article in which the hollow tubular element is located. This has been found to result in improved aerosol formation, which is believed to be due to the fact that for a given ventilation level, the airflow through the perforations is more uniform than an airflow having a plurality of rows of perforations.

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

In some examples, the wrapper 10 surrounding the aerosol generating material has a high level of permeability, for example greater than about 1000Coresta units, or greater than about 1500Coresta units, or greater than about 2000Coresta units. The permeability of the wrapper 10 may be measured according to ISO2965:2009 for determining the air permeability of materials used as cigarette paper, filter plug wrap and filter tipping paper.

The packaging material 10 may be formed of a material having a high intrinsic permeability level (an inherently porous material), or may be formed of a material having any intrinsic permeability level, wherein the final permeability level is achieved by providing the packaging material 10 with a permeable zone or region. The provision of the permeable wrapper 10 provides a path for air to enter the smoking article. The packaging material may have a permeability of: so that the amount of air entering the article through the rod of aerosol-generating material is relatively greater than the amount of air entering the article through the ventilation zone 12 in the mouthpiece. An article having such an arrangement may produce a more flavoured aerosol that may be more satisfactory to the user.

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

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

The volume of aerosol-generating material 3 provided may be from about 200mm ³ To about 4300mm ³ Preferably from about 500mm ³ To 1500mm ³ More preferably from about 1000mm ³ To about 1300mm ³ . Providing these volumes of aerosol-generating material, for example from about 1000mm ³ To about 1300mm ³ It has been advantageously shown that excellent aerosols are achieved, with greater visibility and sensory properties than aerosols achieved with volumes selected from the lower end of the range.

The mass of aerosol-generating material 3 provided may be greater than 200mg, for example from about 200mg to 400mg, preferably from about 230mg to 360mg, more preferably from about 250mg to 360 mg. It has been advantageously found that providing a higher quality aerosol generating material achieves improved sensory properties compared to aerosols generated from lower quality tobacco materials.

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

In the tobacco materials described herein, the tobacco component preferably comprises paper reconstituted tobacco. The tobacco component may also comprise tobacco, extruded tobacco, and/or bandcast tobacco.

The aerosol-generating material 3 may comprise reconstituted tobacco material having a density of less than about 700 milligrams per cubic centimeter (mg/cc). It has been found that such tobacco materials are particularly effective in providing an aerosol generating material which can be heated rapidly to release an aerosol, as compared to more dense materials. For example, the inventors tested the properties of various aerosol-generating materials (e.g., tape-type reconstituted tobacco material and paper reconstituted tobacco material) upon heating. It has been found that for each given aerosol-generating material there is a certain zero heat flow temperature below which the net heat flow is endothermic, in other words, more heat enters the material than leaves the material, and above which the net heat flow is exothermic, in other words, more heat leaves the material than enters the material when heat is applied to it. Materials with densities less than 700mg/cc have lower zero heat flux temperatures. Since a significant portion of the heat flow out of the material is via the formation of the aerosol, having a lower zero heat flow temperature has a beneficial effect on the time it takes to first release the aerosol from the aerosol generating material. For example, an aerosol-generating material having a density of less than 700mg/cc was found to have a zero heat flow temperature of less than I64 ℃ compared to a material having a density of more than 700mg/cc and a zero heat flow temperature of greater than I64 ℃.

The density of the aerosol-generating material also has an effect on the rate of heat conduction through the material, with lower densities (e.g. densities below 700 mg/cc) conducting heat more slowly through the material and thus enabling a more sustained release of aerosol.

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

The tobacco material may be provided in the form of cut pieces of tobacco. The cut pieces of tobacco may have a cut width of at least 15 cuts/inch (about 5.9 cuts/cm, corresponding to a cut width of about 1.7 mm). Preferably, the cut pieces of tobacco have a cut width of at least 18 cuts/inch (about 7.1 cuts/cm, corresponding to a cut width of about 1.4 mm), more preferably at least 20 cuts/inch (about 7.9 cuts/cm, corresponding to a cut width of about 1.27 mm). In one example, the cut pieces of tobacco have a cut width of 22 cuts per inch (about 8.7 cuts/cm, corresponding to a cut width of about 1.15 mm). Preferably, the cut pieces of tobacco have a cut width equal to or less than 40 cuts/inch (about 15.7 cuts/cm, corresponding to a cut width of about 0.64 mm). It has been found that a cut width of between 0.5mm and 2.0mm, for example between 0.6mm and 1.5mm, or between 0.6mm and 1.7mm, produces a tobacco material which is preferred in terms of surface area to volume ratio, in particular when heated, and in terms of overall density and pressure drop of the substrate 3. The cut pieces of tobacco may be formed from a blend in the form of tobacco material, such as a blend of one or more of paper reconstituted tobacco, tobacco leaf, extruded tobacco, and bandcast tobacco. Preferably, the tobacco material comprises paper reconstituted tobacco or a mixture of paper reconstituted tobacco and tobacco leaf.

In the tobacco materials described herein, the tobacco material may comprise a filler component. The filler component is typically a non-tobacco component, i.e., a component that does not include tobacco-derived materials. The filler component may be a non-tobacco fibre, such as wood fibre or pulp or wheat fibre. The filler component may also be an inorganic material such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate. The filler component may also be a cast material other than tobacco or an extruded material other than tobacco. The filler component may be present in an amount of 0 to 20% by weight of the tobacco material, or in an amount of 1 to 10% by weight of the composition. In some embodiments, no filler component is present.

In the tobacco materials described herein, the tobacco material comprises an aerosol-forming material. In this context, an "aerosol-forming material" is an agent that facilitates aerosol generation. The aerosol-forming material may facilitate the generation of an aerosol by promoting the initial evaporation and/or condensation of a gas into an inhalable solid and/or liquid aerosol. In some embodiments, the aerosol-forming material may improve the delivery of flavour from the aerosol-generating material. In general, any suitable aerosol-forming material or agent may be included in the aerosol-generating materials of the present invention, including those described herein.

Other suitable aerosol-forming materials include, but are not limited to: polyols, such as sorbitol, glycerol and glycols, such as propylene glycol or triethylene glycol; non-polyhydric alcohols, 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 myristate, including ethyl myristate and isopropyl myristate, and aliphatic carboxylic acid esters, such as methyl stearate, dimethyl dodecanoate and dimethyl tetradecanedioate. In some embodiments, the aerosol-forming material may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. The glycerin may be present in an amount of 10% to 20% by weight of the tobacco material, for example in an amount of 13% to 16% by weight of the composition, or in an amount of about 14% or 15% by weight of the composition. Propylene glycol, if present, may be present in an amount of 0.1% to 0.3% by weight of the composition.

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

The tobacco material may comprise between 10% and 90% by weight of tobacco leaf, wherein the aerosol-forming material is provided in an amount of up to about 10% by weight of the tobacco leaf. In order to achieve an overall level of aerosol-forming material of between 10% and 20% by weight of the tobacco material, it has been advantageously found that this can be added to another ingredient of the tobacco material, for example reconstituted tobacco material, in a higher weight percentage.

The tobacco material described herein comprises nicotine. The nicotine content is from 0.5% to 1.75% by weight of the tobacco material, for example can be from 0.8% to 1.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material comprises 10 to 90% by weight of tobacco leaves having a nicotine content of more than 1.5% by weight of the tobacco leaves. It has been advantageously found that the use of tobacco leaves having a nicotine content of greater than 1.5% in combination with a low nicotine based material (e.g., paper reconstituted tobacco) provides a tobacco material having a suitable nicotine level but better organoleptic properties than paper reconstituted tobacco alone. The tobacco leaves, e.g. cut pieces of tobacco, may for example have a nicotine content of between 1.5% and 5% by weight of the tobacco leaves.

The tobacco material described herein can comprise an aerosol modifier, such as any of the flavorants described herein. In one embodiment, the tobacco material comprises menthol, thereby forming a menthol-alcoholized article. The tobacco material may comprise from 3mg to 20mg of menthol, preferably between 5mg and 18mg, more preferably between 8mg and 16mg of menthol. In this example, the tobacco material includes 16mg of menthol. The tobacco material may comprise between 2% and 8% by weight menthol, preferably between 3% and 7% by weight menthol, more preferably between 4% and 5.5% by weight menthol. In one embodiment, the tobacco material comprises 4.7% by weight menthol. Such high levels of menthol loading can be achieved using a high percentage of reconstituted tobacco material, for example greater than 50% by weight of the tobacco material. Alternatively or additionally, e.g. in the use of transformersAt about 500mm ³ Or suitably greater than about 1000mm ³ In the case of aerosol-generating materials (e.g. tobacco materials), the use of high volumes of aerosol-generating material (e.g. tobacco material) may increase the loading level of menthol that can be achieved.

In the compositions described herein, wherein amounts are given in% by weight, for the avoidance of doubt, this is on a dry weight basis unless explicitly stated to the contrary. Thus, any water that may be present in the tobacco material or any of its components is completely ignored for the purpose of determining weight%. The moisture content of the tobacco material described herein can vary and can be, for example, from 5% to 15% by weight. The moisture content of the tobacco material described herein can vary depending on, for example, the temperature, pressure, and humidity conditions at which the composition is maintained. The water content can be determined by karl-fischer analysis, as known to those skilled in the art. On the other hand, for the avoidance of doubt, even when the aerosol-forming material is a component of the liquid phase (e.g. glycerol or propylene glycol), any component other than water is included in the weight of the tobacco material. However, when the aerosol-forming material is provided in the tobacco component of a tobacco material or in the filler component (if present) of a tobacco material, the aerosol-forming material is not included in the weight of the tobacco component or filler component, but is included in the weight of the "aerosol-forming material" in weight% as defined herein, instead of or in addition to being added separately to the tobacco material. All other materials present in the tobacco component are included in the weight of the tobacco component, even if of non-tobacco origin (e.g., non-tobacco fibers in the case of paper reconstituted tobacco).

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

The paper reconstituted tobacco is present in the tobacco component of the tobacco material described herein in an amount of 10% to 100% by weight of the tobacco component. In these embodiments, the paper reconstituted tobacco is present in an amount of 10% to 80% by weight of the tobacco component, or 20% to 70% by weight. In another embodiment, the tobacco component consists essentially of, or consists of, paper reconstituted tobacco. In a preferred embodiment, the tobacco leaf is present in the tobacco component of the tobacco material in an amount of at least 10% by weight of the tobacco component. For example, the tobacco leaf can be present in an amount of at least 10% by weight of the tobacco component, with the remainder of the tobacco component comprising paper reconstituted tobacco, bandcast reconstituted tobacco, or a combination of bandcast reconstituted tobacco and other forms of tobacco (e.g., tobacco particles).

Paper reconstituted tobacco refers to tobacco material formed by a process in which tobacco raw material is extracted with a solvent to provide an extract of solubles and a residue comprising fibrous material, and then the extract is recombined (typically after concentration, optionally after further processing) with fibrous material from the residue (typically after refining of the fibrous material, optionally with addition of a portion of non-tobacco fibres) by depositing the extract onto the fibrous material. The reconstitution process is similar to the papermaking process.

The paper reconstituted tobacco can be any type of paper reconstituted tobacco known in the art. In a particular embodiment, the paper reconstituted tobacco is made from a raw material comprising one or more of tobacco rod, tobacco stalk, and whole leaf tobacco. In another embodiment, the paper reconstituted tobacco is made from a tobacco rod and/or a raw material consisting of whole leaf tobacco and tobacco stems.

However, in other embodiments, fines and winnings may alternatively or additionally be used in the feedstock.

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

In the above example, the mouthpiece 2 comprises a single body 6 of material. In other examples, the mouthpiece of figure 1a may comprise multiple bodies of material. The mouthpiece 2 may comprise a cavity between multiple bodies of material.

In some examples, the mouthpiece 2 downstream of the aerosol-generating material 3 may comprise a wrapper material, for example a first or second formed

paper

7, 9 or tipping paper 5, which comprises an aerosol-modifying agent as described herein. The aerosol modifier may be disposed on an inward or outward facing surface of the mouthpiece wrapper. For example, the aerosol-modifying agent may be disposed on a region of the wrapper, such as the outwardly facing surface of the tipping paper 5, which is in contact with the lips of the consumer during use. By disposing the aerosol modifying agent on the outwardly facing surface of the mouthpiece wrapper, the aerosol modifying agent may be transferred to the lips of the consumer during use. Transferring the aerosol-modifying agent to the lips of the consumer during use of the article may modify the sensory characteristics (e.g. taste) of the aerosol generated by the aerosol-generating substrate 3 or otherwise provide the consumer with an alternative sensory experience. For example, the aerosol-modifying agent may impart a flavour to an aerosol generated by the aerosol-generating substrate 3. The aerosol-modifying agent may be at least partially water soluble such that it is transferred to the user via the saliva of the consumer. The aerosol modifier may be an aerosol modifier that is volatilized by heat generated by the aerosol provision system. This may facilitate transfer of the aerosol-modifying agent to the aerosol generated by the aerosol-generating substrate 3. Suitable sensory materials may be a flavoring agent as described herein, sucralose, or a cooling agent such as menthol and the like.

The aerosol-generating material 3 of the article 1 described herein is heated using a non-combustible aerosol provision device. The non-flammable aerosol provision device preferably comprises a coil, as it has been found that this enables improved heat transfer to the article 1 compared to other arrangements.

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

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

The device may comprise one or more heating elements, for example one or more electrically conductive heating elements, and the one or more heating elements may be suitably positioned or positionable relative to the coil to enable such heating of the one or more heating elements. The one or more heating elements may be in a fixed position relative to the coil. Alternatively, the at least one heating element, for example at least one electrically conductive heating element, may be comprised in the article 1 for insertion into a heating region of the device, wherein the article 1 further comprises the aerosol generating material 3 and is removable from the heating region after use. Alternatively, both the apparatus and such an article 1 may comprise at least one respective heating element, for example at least one electrically conductive heating element, and the coil may cause heating of one or more heating elements of each of the apparatus and the article when the article is in the heating region.

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

In some examples, the apparatus includes an electrically conductive heating element at least partially surrounding the heating region, and the coil is a helical coil surrounding at least a portion of the electrically conductive heating element. In some examples, the electrically conductive heating element is tubular. In some examples, the coil is an inductive coil.

In some examples, the use of coils enables the non-combustible aerosol delivery devices to reach operating temperatures faster than non-coil aerosol delivery devices. For example, a non-combustible aerosol delivery device comprising a coil as described above may reach an operating temperature such that a first puff may be provided in less than 30 seconds, more preferably in less than 25 seconds, from the start of a device heating program. In some examples, the device may reach the operating temperature within about 20 seconds from the start of the device heating program.

It has been found that the use of a coil as described herein in the device to cause heating of the aerosol generating material enhances the aerosol generated. For example, consumers have reported that aerosols produced by devices including coils such as described herein are perceptually closer to aerosols generated in factory smoke production (FMC) products than aerosols produced by other non-combustible aerosol delivery systems. Without wishing to be bound by theory, it is hypothesized that this is a result of the reduced time to reach the required heating temperature when using the coil, the higher heating temperature achievable when using the coil, and/or the fact that the coil enables such a system to simultaneously heat a relatively large volume of aerosol-generating material, resulting in an aerosol temperature similar to the FMC aerosol temperature. In FMC products, as the aerosol is drawn through the tobacco rod, the burning coal produces a hot aerosol that heats the tobacco in the tobacco rod behind the coal. This hot aerosol is understood to release flavor compounds from the tobacco in the tobacco rod behind the burning coal. Devices comprising a coil as described herein are believed to be also capable of heating an aerosol generating material, such as a tobacco material as described herein, to release flavour compounds to produce an aerosol which has been reported to more closely resemble an FMC aerosol.

Using an aerosol provision system comprising a coil as described herein, for example an induction coil that heats at least some of the aerosol generating material to at least 200 ℃, more preferably at least 220 ℃, may enable an aerosol to be generated from the aerosol generating material with specific characteristics that are believed to more closely resemble those of an FMC product. For example, when an aerosol-generating material comprising nicotine is heated using an induction heater for a period of two seconds (to at least 250 ℃), during which period at an airflow of at least 1.50L/m, one or more of the following characteristics have been observed:

at least 10 μ g of nicotine is aerosolized from the aerosol-generating material;

the weight ratio of aerosol-forming material to nicotine in the aerosol produced is at least about 2.5:1, suitably at least 8.5: 1;

at least 100 μ g of the aerosol-forming material may be aerosolised from the aerosol-generating material;

the average particle or droplet size in the aerosol produced is less than about 1000 nm; and

the aerosol density is at least 0.1 μ g/cc.

In some cases, during this period of time, at least 10 μ g of nicotine, suitably at least 30 μ g or 40 μ g of nicotine, is aerosolized from the aerosol-generating material under an airflow of at least 1.50L/m. In some cases, less than about 200 μ g of nicotine, suitably less than about 150 μ g or less than about 125 μ g of nicotine, is aerosolized from the aerosol-generating material under an airflow of at least 1.50L/m during the time period.

In some cases, the aerosol comprises at least 100 μ g of aerosol-forming material, suitably at least 200 μ g, 500 μ g or 1mg of aerosol-forming material is aerosolized from the aerosol-generating material under an airflow of at least 1.50L/m during the period of time. Suitably, the aerosol-forming material may comprise or consist of glycerol.

As defined herein, the term "average particle or droplet size" refers to the average size of the solid or liquid component of an aerosol (i.e., the component suspended in a gas). Where the aerosol comprises suspended liquid droplets and suspended solid particles, the term refers to the average size of all the ingredients together.

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

In some cases, the aerosol generated during the time period has a density of at least 0.1 μ g/cc. In some cases, the aerosol density is at least 0.2 μ g/cc, 0.3 μ g/cc, or 0.4 μ g/cc. In some cases, the aerosol density is less than about 2.5 μ g/cc, 2.0 μ g/cc, 1.5 μ g/cc, or 1.0 μ g/cc.

The non-combustible aerosol provision device is preferably arranged to heat the aerosol-generating material 3 of the article 1 to a maximum temperature of at least 160 ℃. Preferably, the non-combustible aerosol provision device is arranged to heat the aerosol-forming material 3 of the article 1 at least once to a maximum temperature of at least about 200 ℃, or at least about 220 ℃, or at least about 240 ℃, more preferably at least about 270 ℃ during a heating process by the non-combustible aerosol provision device.

Using an aerosol provision system comprising a coil as described herein, for example an induction coil that heats at least some of the aerosol generating material to at least 200 ℃, more preferably at least 220 ℃, may enable an aerosol to be generated from the aerosol generating material in the article 1 as described herein, which aerosol has a higher temperature than previous devices as it leaves the mouth end of the mouthpiece 2, thereby facilitating the generation of an aerosol that is believed to be closer to the FMC product. For example, the maximum aerosol temperature measured at the mouth end of the article 1 may preferably be greater than 50 ℃, more preferably greater than 55 ℃, still more preferably greater than 56 ℃ or 57 ℃, additionally or alternatively the maximum aerosol temperature measured at the mouth end of the article 1 may be less than 62 ℃, more preferably less than 60 ℃, and more preferably less than 59 ℃. In some embodiments, the maximum aerosol temperature measured at the mouth end of the article 1 may preferably be between 50 ℃ and 62 ℃, more preferably between 56 ℃ and 60 ℃.

Fig. 2 shows an example of a non-combustible aerosol provision device 100 for generating an aerosol from an aerosol-generating medium/material, such as the aerosol-generating material 3 of the article 1 described herein. In general terms, the device 100 may be used to heat a replaceable article 110 comprising an aerosol-generating medium, such as the article 1 described herein, to generate an aerosol or other inhalable medium for inhalation by a user of the device 100. The device 100 and the replaceable article 110 together form a system.

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

The device 100 of this example includes a first end member 106 that includes a cover 108 that is movable relative to the first end member 106 to close the opening 104 when no article 110 is in place. In fig. 2, the cover 108 is shown in an open configuration, however the cover 108 may be moved into a closed configuration. For example, the user may cause cover 108 to slide in the direction of arrow "B".

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

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

Fig. 3 depicts the device 100 of fig. 2 with the outer cover 102 removed and the article 110 absent. The device 100 defines a longitudinal axis 134.

As shown in fig. 3, the first end member 106 is disposed at one end of the device 100 and the second end member 116 is disposed at an opposite end of the device 100. Together, the first end member 106 and the second end member 116 at least partially define an end face of the device 100. For example, a bottom surface of the second end member 116 at least partially defines a bottom surface of the device 100. The edge of the outer cover 102 may also define a portion of the end face. In this example, the cover 108 also defines a portion of the top surface of the device 100.

The end of the device closest to the opening 104 may be referred to as the proximal end (or mouth end) of the device 100, since it is closest to the user's mouth in use. In use, a user inserts the article 110 into the opening 104, operating the user control 112 to begin heating the aerosol-generating material and drawing an aerosol generated in the device. This causes the aerosol to flow through the device 100 along a flow path toward the proximal end of the device 100.

The other end of the device furthest from the mouth 104 may be referred to as the distal end of the device 100, as in use it is the end furthest from the mouth of the user. When a user draws on the aerosol generated in the device, the aerosol flows away from the distal end of the device 100.

The apparatus 100 also includes a power supply 118. The power source 118 may be, for example, a battery, such as a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (e.g., lithium ion batteries), nickel batteries (e.g., nickel cadmium batteries), and alkaline batteries. The battery is electrically coupled to the heating assembly to supply electrical energy when required and to heat the aerosol generating material under the control of a controller (not shown). In this example, the batteries are connected to a central support 120 that holds the batteries 118 in place.

The device also includes at least one electronics module 122. The electronic module 122 may include, for example, a Printed Circuit Board (PCB). The PCB 122 may support at least one controller, such as a processor, and memory. PCB 122 may also include one or more electrical tracks to electrically connect various electronic components of device 100 together. For example, the battery terminals may be electrically connected to the PCB 122 so that power may be distributed throughout the device 100. The receptacle 114 may also be electrically coupled to the battery via an electrical rail.

In the example apparatus 100, the heating assembly is an induction heating assembly and includes various components for heating the aerosol-generating material of the article 110 via an induction heating process. Induction heating is a process of heating an electrically conductive object (e.g., a susceptor) by electromagnetic induction. The induction heating assembly may comprise an induction element, such as one or more induction coils, and means for passing a varying current (e.g. an alternating current) through the induction element. A varying current in the inductive element generates a varying magnetic field. The varying magnetic field penetrates a susceptor, which is suitably positioned relative to the inductive element, and generates eddy currents within the susceptor. The susceptor has an electrical resistance to eddy currents, so that a flow of eddy currents against this resistance causes the susceptor to be heated by joule heating. In case the susceptor comprises a ferromagnetic material (e.g. iron, nickel or cobalt), heat may also be generated by hysteresis losses in the susceptor (i.e. by the varying orientation of the magnetic dipoles in the magnetic material as a result of their alignment with the varying magnetic field). In induction heating, heat is generated inside the susceptor, allowing for rapid heating, as compared to heating, for example, by conduction. Furthermore, no physical contact between the induction heater and the susceptor is required, allowing for enhanced freedom in construction and application.

The induction heating assembly of the example apparatus 100 includes a susceptor arrangement 132 (referred to herein as a "susceptor"), a first induction coil 124 and a second induction coil 126. First inductor winding 124 and second inductor winding 126 are made of a conductive material. In this example, the first inductor coil 124 and the second inductor coil 126 are made of litz wire/cable that is wound in a spiral fashion to provide spiral inductor coils 124, 126. Litz wire comprises a plurality of individual wires which are individually insulated and twisted together to form a single wire. Litz wire is designed to reduce skin effect losses in the conductor. In the example apparatus 100, the first inductor winding 124 and the second inductor winding 126 are made of copper litz wire having a rectangular cross section. In other examples, the litz wire may have a cross-section of other shapes, such as circular.

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

It will be appreciated that in some examples, first inductor 124 and second inductor 126 may have at least one characteristic that is different from one another. For example, first inductor 124 may have at least one different characteristic than second inductor 126. More specifically, in one example, the first inductor 124 may have a different inductance value than the second inductor 126. In fig. 3, first inductor 124 and second inductor 126 have different lengths such that first inductor 124 is wound on a smaller segment of susceptor 132 than second inductor 126. Thus, first inductor 124 may include a different number of turns than second inductor 126 (assuming that the spacing between the individual turns is substantially the same). In yet another example, first inductor winding 124 may be made of a different material than second inductor winding 126. In some examples, first inductor winding 124 and second inductor winding 126 may be substantially identical.

In this example, first inductor coil 124 and second inductor coil 126 are wound in opposite directions. This may be useful when the inductor is operating at different times. For example, initially, first induction coil 124 may operate to heat a first section/portion of article 110, and at a later time, second induction coil 126 may operate to heat a second section/portion of the article. Winding the coils in opposite directions helps to reduce the current induced in the non-operating coils when used in conjunction with a particular type of control circuit. In fig. 3, the first inductor winding 124 is a right-hand spiral and the second inductor winding 126 is a left-hand spiral. However, in another embodiment, the inductor coils 124, 126 may be wound in the same direction, or the first inductor coil 124 may be a left-handed spiral and the second inductor coil 126 may be a right-handed spiral.

The susceptor 132 of this example is hollow, thus defining a reservoir within which the aerosol-generating material is received. For example, the article 110 may be inserted into the susceptor 132. In this example, the susceptor 120 is tubular with a circular cross-section.

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

In some examples, the susceptor 132 may include at least two materials capable of being heated at two different frequencies for selectively aerosolizing the at least two materials. For example, a first segment of the susceptor 132 (which is heated by the first inductive coil 124) may comprise a first material, and a second segment of the susceptor 132 heated by the second inductive coil 126 may comprise a second, different material. In another example, the first segment may include a first material and a second material, where the first material and the second material may be heated differently based on operation of the first induction coil 124. The first and second materials may be adjacent along an axis defined by the susceptor 132, or may form different layers within the susceptor 132. Similarly, the second segment may include a third material and a fourth material, where the third material and the fourth material may be heated differently based on the operation of the second induction coil 126. The third and fourth materials may be adjacent along an axis defined by the susceptor 132, or may form different layers within the susceptor 132. For example, the third material may be the same as the first material, and the fourth material may be the same as the second material. Alternatively, each material may be different. The susceptor may comprise, for example, carbon steel or aluminum.

The apparatus 100 of fig. 3 also includes an insulating member 128, which may be generally tubular and at least partially surrounds the susceptor 132. The insulating member 128 may be constructed of any insulating material, such as plastic. In this particular example, the insulating member is composed of Polyetheretherketone (PEEK). The insulating member 128 may help insulate various components of the apparatus 100 from heat generated in the susceptor 132.

Insulating member 128 may also fully or partially support first inductor winding 124 and second inductor winding 126. For example, as shown in fig. 3, first inductor winding 124 and second inductor winding 126 are positioned around insulating member 128 and are in contact with a radially outward surface of insulating member 128. In some examples, insulating member 128 does not abut first inductor winding 124 and second inductor winding 126. For example, there may be a small gap between the outer surface of insulating member 128 and the inner surfaces of first inductor winding 124 and second inductor winding 126.

In a particular example, the susceptor 132, the insulating member 128, and the first and second

inductive coils

124, 126 are coaxial about a central longitudinal axis of the susceptor 132.

Fig. 4 shows a side view of the device 100 in partial cross-section. In this example there is an outer cover 102. The rectangular cross-sectional shape of first inductor winding 124 and second inductor winding 126 is more clearly visible.

The apparatus 100 also includes a support 136 that engages an end of the susceptor 132 to hold the susceptor 132 in place. The support 136 is connected to the second end member 116.

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

The device 100 further comprises a second cap 140 and a spring 142, which is arranged towards the distal end of the device 100. A spring 142 allows the second cover 140 to be opened to provide access to the susceptor 132. The user may open the second cover 140 to clean the susceptor 132 and/or support 136.

The device 100 also includes an expansion chamber 144 that extends away from the proximal end of the susceptor 132 toward the opening 104 of the device. Located at least partially within the expansion chamber 144 is a retaining clip 146 to abut and retain the article 110 when the article 110 is received within the device 100. Expansion chamber 144 is connected to end member 106.

Fig. 5 is an exploded view of the device 100 of fig. 4 with the outer cover 102 omitted.

Fig. 6A depicts a cross-section of a portion of the device 100 of fig. 4. Fig. 6B depicts a close-up of a region of fig. 6A. Fig. 6A and 6B illustrate the article 110 received within the susceptor 132, wherein the article 110 is sized such that an outer surface of the article 110 abuts an inner surface of the susceptor 132. This ensures that heating is most efficient. The article 110 of this example comprises an aerosol-generating material 110 a. The aerosol-generating material 110a is positioned within the susceptor 132. The article 110 may also include other components, such as filters, wrappers, and/or cooling structures.

Figure 6B shows that the outer surface of the susceptor 132 is spaced apart from the inner surfaces of the inductor coils 124, 126 by a distance 150, measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 150 is about 3mm to 4mm, about 3mm to 3.5mm, or about 3.25 mm.

Figure 6B also shows that the outer surface of the insulating member 128 is spaced from the inner surfaces of the

inductive coils

124, 126 by a distance 152, measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 152 is about 0.05 mm. In another example, the distance 152 is substantially 0mm such that the

inductive coils

124, 126 abut and contact the insulating member 128.

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

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

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

In use, the article 1 described herein may be inserted into a non-combustible aerosol delivery device, such as the device 100 described with reference to fig. 2-6. At least a portion of the mouthpiece 2 of the article 1 protrudes from the non-combustible aerosol provision device 100 and may be placed into the mouth of a user. The aerosol is generated by heating the aerosol generating material 3 using the apparatus 100. The aerosol generated by the aerosol-generating material 3 passes through the mouthpiece 2 to the mouth of the user.

The minimum distance between one or more components of the heater assembly and the tubular element of the article 1 when the article 1 is inserted into the apparatus 100 may be in the range 3mm to 10mm, for example 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm or 10 mm.

The article 1 described herein has particular advantages, for example when used with a non-flammable aerosol delivery device, such as the device 100 described with reference to fig. 2 to 6. In particular, it has been surprisingly found that the first tubular element 4 formed by monofilament tows has a significant effect on the temperature of the outer surface of the mouthpiece 2 of the article 1. For example, where a hollow tubular element 4 formed from a monofilament tow is wrapped in an outer wrapper (e.g. tipping paper 5), it has been found that during use the outer surface of the outer wrapper at a longitudinal position corresponding to the position of the hollow tubular element 4 reaches a maximum temperature of less than 42 ℃, suitably less than 40 ℃, more suitably less than 38 ℃ or less than 36 ℃.

Table 3.0 below shows the temperature of the outer surface of the article 1 as described herein with reference to fig. 1a and 1b when heated using the apparatus 100 described herein with reference to fig. 2 to 6. The first, second and third temperature measurement probes serve as corresponding first, second and third positions along the mouthpiece 2 of the article 1. The first position (numbered position 1 in table 2.0) was at 4mm from the downstream end 2b of the mouthpiece 2, the second position (numbered position 2 in table 2.0) was at 8mm from the downstream end 2b of the mouthpiece 2, and the third position (numbered position 3 in table 2.0) was at 12mm from the downstream end 2b of the mouthpiece 2.

Thus, the first position is on the outer surface of the portion of the mouthpiece 2 in which the first tubular element 4 is disposed, while the second and third positions are on the outer surface of the portion of the mouthpiece 2 in which the body of material 6 is disposed.

The control article was tested to compare with the monofilament bundle tubular member 4 described herein and replace the monofilament bundle tubular member 4 with a known helically wound paper tube of the same construction as the second hollow tubular member 8 described herein but having a length of 6mm instead of 25 mm.

The test was performed on the first 5 puffs on the article, as by the 5 th puff, the temperature typically peaked and began to drop such that an approximate maximum temperature was observed. Each sample was tested 5 times and the temperature provided was the average of these 5 tests. The known canadian ministry of health strong puff regime (55 ml puff volume applied every 30 seconds for 2 seconds) was applied using standard test equipment.

As shown in the table below, it was surprisingly found that the use of a tubular element 4 formed from monofilament tow reduces the outer surface temperature of the mouthpiece 2 in each puff and at each test position on the mouthpiece 2 compared to the control article. The tubular element 4 formed by the monofilament tow is particularly effective in reducing the temperature at the first probe location where the lips of the consumer will be positioned when using the article 1. In particular, the outer surface temperature of the mouthpiece 2 at the first probe position decreased by more than 7 ℃ in the first three puffs, and by more than 5 ℃ in the fourth and fifth puffs.

TABLE 3.0

Fig. 7 illustrates a method of making an article as described herein.

At step S101, at least two additive release components are received in a feed mechanism configured to dispense the additive release components into the stream of fibrous tow material at predetermined longitudinal intervals. In the present example, the fibrous tow material comprises cellulose acetate tow and the additive release member comprises

rupturable capsules

11a, 11 b. In this example, the feed mechanism includes a horizontally oriented disk assembly for receiving breakable capsules, and a vertically oriented rotary delivery wheel for delivering the capsules into the fiber tow stream.

Known machines for inserting capsules into a stream of fibrous tow material may be modified to effect insertion of at least two rupturable capsules of the invention.

At step S102, at least two additive release components are dispensed from a feed mechanism into a stream of fiber tow material. In step S103, the fiber tow, now containing at least two additive-releasing components, is passed through a decoration and a wrapping paper to form a rod. In the present case, the paper wrapper comprises an oil resistant plug wrap 7.

In step S104, the rod is cut to form a cigarette rod comprising at least two additive releasing components. In an optional further step, the formed cigarette rod may be combined with further cigarette segments and/or sources of aerosol-generating material to form an article.

The various embodiments described herein are intended only to aid in understanding and teaching the claimed features. These embodiments are provided merely as representative samples of embodiments and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on equivalents to the claims, that other embodiments may be utilized, and that modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, suitable combinations of the disclosed elements, components, features, parts, steps, devices, etc., other than those specifically described herein. Additionally, this disclosure may include other inventions not presently claimed, but which may be claimed in the future.

Claims

1. A component of an article for use in an aerosol delivery system, the component comprising a body of fibrous material comprising first and second additive release components embedded within the body of fibrous material, wherein the first and second additive release components each have a maximum diameter of about 1.5mm to about 2.5mm and the first and second additive release components are separated by a distance of less than about 2.5 mm.

2. The component of claim 1 wherein the first and second additive-releasing components are separated by a distance of less than about 2.0mm, less than about 1.5mm, or less than about 1.0 mm.

3. The component of claim 1 or 2, wherein a longitudinal spacing between a center of the first additive release member and a center of the second additive release member is at least about 0.75mm, at least about 1.0mm, at least about 1.5mm, at least about 2.0mm, or at least about 2.5 mm.

4. The component of claim 1, 2 or 3, wherein the first and second additive release members are each disposed along a longitudinal axis of the component.

5. The component of claim 1, 2 or 3 wherein the center of at least one of the first and second additive release members is offset from the longitudinal axis of the component by at least about 2 mm.

6. The component of any one of claims 1 to 5 wherein a maximum spacing between centers of each of the first and second additive release members is less than about 2.5mm, less than about 2.0mm, less than about 1.5mm, less than about 1.0mm, or less than about 0.8 mm.

7. The component of any one of claims 1 to 6, wherein each of the first and second additive-releasing components contains an additive, and the total mass of additive contained in the first and second additive-releasing components is 10 to 14 mg.

8. The component of any one of claims 1 to 7, wherein the total volume of the first and second additive-releasing components is about 2mm ³ To about 12mm ³ 。

9. The component of any one of claims 1 to 8, wherein a diameter of the first additive release component is different from a diameter of the second additive release component.

10. The component of any one of claims 1 to 9, wherein each of the first and second additive-releasing components comprises a capsule.

11. The component of claim 10, wherein each of the first and second additive-releasing components comprises a housing and an additive enclosed within the housing.

12. The component of claim 11, wherein the outer shell is rupturable to release the additive encapsulated therein.

13. The component of any one of claims 1 to 12, wherein the first and second additive-releasing components are substantially spherical.

14. The component of any one of claims 1 to 13, wherein the additive contained within the first and second additive-releasing components comprises an aerosol-modifying agent.

15. The component of any one of claims 1 to 14, wherein the first additive release component comprises a first aerosol-modifying agent and the second additive release component comprises a second aerosol-modifying agent.

16. The component of any one of claims 1 to 15, further comprising a third additive-releasing component.

17. A component according to any one of claims 1 to 16, wherein the fibrous material comprises monofilament tows.

18. The component of claim 17, wherein the monofilament bundle comprises, for each millimeter of length of the body of material, a weight of: the weight is in a range between about 10% and about 30% of a range between a minimum weight and a maximum weight of a tow capacity curve generated for the monofilament tow.

19. An article for use in an aerosol delivery system, the article comprising:

an aerosol generating material; and

the component of any one of claims 1 to 18.

20. An article according to claim 19, wherein the aerosol generating material comprises a tobacco material.

21. The article of claim 19 or 20, wherein the article is substantially cylindrical in shape.

22. The article of claim 21, wherein the article has a circumference in the range of 15mm to 23 mm.

23. The article of any one of claims 19 to 22, further comprising an aerosol cooling segment.

24. The article of claim 23, wherein the aerosol-cooling segment comprises a wall comprising an aerosol-generating material.

25. The article of claim 23, wherein the aerosol-cooling segment comprises a cavity surrounded by a paper tube, and wherein the paper tube has a wall thickness of at least 325 microns and/or a permeability of at least 100Coresta units.

26. An article according to any one of claims 19 to 24, further comprising a hollow tubular element, wherein the hollow tubular element is arranged at an end of the article distal to the aerosol generating material, and wherein the hollow tubular element comprises a length of greater than about 10mm or greater than about 12 mm.

27. An article according to any one of claims 19 to 26, wherein the aerosol-generating material is wrapped with a wrapper having a permeability level of greater than about 2000Coresta units, and wherein the component comprises at least one ventilation area.

28. An article according to any one of claims 19 to 27, wherein the component is arranged downstream of the aerosol-generating material and comprises at least one ventilation area, wherein a first airflow path is defined in which air drawn through the article at its downstream end passes through the aerosol-generating material, and a second airflow path is defined in which air drawn through the article at its downstream end passes through the at least one ventilation area in the component into the article, and the resistance to draw of the second airflow path is greater than the resistance to draw of the first airflow path.

29. The article of any one of claims 19 to 27, wherein the component comprises at least one ventilation area, and wherein a ventilation level provided by the at least one ventilation area is in a range of 45% to 65% of a volume of aerosol passing through the component, or in a range of 40% to 60% of a volume of aerosol passing through the component.

30. A system comprising an article according to any of claims 19 to 29, and a non-combustible aerosol provision device for heating the aerosol generating material of the article.

31. The system of claim 30, comprising the article of claim 23 or 24, wherein the article is configured such that when the article is inserted into the non-combustible aerosol provision device, a minimum distance between a heater of the non-combustible aerosol provision device and the aerosol cooling section is at least about 3 mm.

32. A method of manufacturing a component of an article for use in an aerosol delivery system, the method comprising:

inserting a first additive release element and a second additive release element into the stream of fibrous material; and

forming the stream of fibrous material into a body of fibrous material, the body of fibrous material comprising the first and second additive release components embedded within the body, wherein the first and second additive release components each have a maximum diameter of about 1.5mm to about 2.5mm, and the first and second additive release components are separated by a distance of less than about 2.5 mm.