CN117729857A

CN117729857A - Component for use in a non-combustible sol supply system

Info

Publication number: CN117729857A
Application number: CN202280043139.7A
Authority: CN
Inventors: 本杰明·泰勒; 马修·霍奇森; 巴里·迪米克; 理查德·赫普沃斯
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2021-06-18
Filing date: 2022-06-17
Publication date: 2024-03-19
Also published as: WO2022263865A1; EP4355132A1; BR112023026318A2; GB202108825D0; JP2024522659A; KR20240015715A

Abstract

A component for use in a non-combustible sol supply system. The component comprises at least one helically wound rod comprising aerosol-generating material. Articles, systems, and methods for forming the components are also described.

Description

Component for use in a non-combustible sol supply system

Technical Field

The present invention relates to a component for use in a non-combustible sol supply system, an article for use in a non-combustible sol supply system, an aerosol supply system and a method of forming a component for use in a non-combustible sol supply system.

Background

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

Disclosure of Invention

According to embodiments described herein, in a first aspect, there is provided a component for use in a non-combustible aerosol provision system, the component comprising at least one helically wound rod comprising an aerosol generating material.

According to embodiments described herein, in a second aspect, there is provided a component for use in a non-combustible sol supply system, the component comprising a plurality of braided or spirally wound strips, at least one of the plurality of braided and/or spirally wound strips comprising an aerosol-generating material, the component further comprising a cavity extending from a first end of the component.

According to embodiments described herein, in a third aspect, there is provided an article for use with a non-combustible sol supply device, the article comprising a component according to the first or second aspects above.

According to embodiments described herein, in a fourth aspect, there is provided a non-combustible aerosol provision system comprising an article according to the third aspect and an aerosol provision device for forming an aerosol from an aerosol-generating material.

According to an embodiment described herein, in a fifth aspect, there is provided a method of forming a component according to the first or second aspect above, the method comprising the steps of:

providing a source of a strip of material comprising an aerosol-generating material;

feeding the strip of material towards a mandrel; and

the strip of material is wound around the mandrel to form a helically wound strip comprising aerosol generating material.

Drawings

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

fig. 1a is a cross-sectional side view of an article for use in a non-combustible aerosol-supply system, the article comprising a component having at least one helically wound rod containing aerosol-generating material. Also shown is an aerosol supply device, the article and device forming a system;

FIG. 1b is a side view of the component of FIG. 1 a;

fig. 2a is a cross-sectional side view of an article in use in a non-combustible sol supply system, the article including a component having a plurality of spirally wound or woven strips. Also shown is an aerosol supply device, the article and device forming a system;

FIG. 2b is a side view of the component of FIG. 2 a;

fig. 3a and 3b show the respective mechanical means for forming the components of fig. 1b and 2b, respectively; and

fig. 4 is a flow chart showing a method of forming a component as described herein.

Detailed Description

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

combustible sol supply systems, for example, cigarettes, cigarillos, cigars, tobacco for pipes or for self-cigarettes or for self-made cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable materials);

A non-combustible aerosol supply system that releases a compound 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 produce an aerosol using a combination of aerosol-generating materials; and

an aerosol-free delivery system that delivers at least one substance orally, nasally, transdermally, or in another manner to a user without forming an aerosol, including but not limited to lozenges, chewing gums, patches, inhalable powder-containing products, and oral products, such as oral tobacco comprising snuff or snuff, wherein the at least one substance may or may not comprise nicotine.

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

In some embodiments, the delivery system is a non-combustible sol supply system, such as an electrical non-combustible sol supply system.

In some embodiments, the non-combustible aerosol supply system is an electronic cigarette, also referred to as an electronic cigarette device (vaping device) or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol generating material is not necessary.

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

In some embodiments, the non-combustible aerosol supply system is a hybrid system that uses a combination of aerosol-generating materials, one or more of which may be heated, to generate an aerosol. Each of these aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain 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 a plant-based material, such as tobacco or a non-tobacco product.

In general, a non-combustible sol supply system may include a non-combustible sol supply device and a consumable for use with the non-combustible sol supply 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 supply device. These consumables are sometimes referred to as articles throughout this disclosure.

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

In some embodiments, a non-combustible sol supply system, such as a non-combustible sol supply device thereof, may include a power source and a controller. For example, the power source may be an electrical power source or a exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate that may be energized to distribute power in the form of heat to the aerosol-generating material or to a heat transfer material proximate to the exothermic power source.

In some embodiments, the non-combustible aerosol supply system includes 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 supply device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material delivery component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol modifier.

In some embodiments, the consumable comprises a substance to be delivered. The substance to be delivered may be an aerosol generating material or a material that is not intended to be nebulized. Any of the materials may comprise one or more active ingredients, one or more flavors, one or more aerosol former materials, and/or one or more other functional materials, as appropriate.

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

An active substance as used herein may be a physiologically active substance, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropic agents and psychoactive agents. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise, for example, nicotine, caffeine, taurine, theophylline, vitamins such as B6 or B12 or C, melatonin, or components, derivatives or combinations thereof. The active substance may comprise one or more ingredients, derivatives or extracts of tobacco or another botanical preparation (botanical).

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

As noted herein, the active substance may comprise or be derived from one or more botanical preparations or components, derivatives or extracts thereof. As used herein, the term "botanical preparation" includes any material derived from a plant (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 a synthetically derived active compound naturally occurring in a plant preparation. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, sheets, etc. Examples of vegetable preparations are tobacco, eucalyptus, star anise, cocoa, fennel, lemon grass, peppermint, spearmint, louis (rooibos), chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay, licorice (licorce)), japanese green tea (matcha), mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, fennel (fennel), basil, bay leaf, cardamon (caramon), coriander (coriander), fennel, nutmeg, oregano, red pepper, rosemary, saffron, lavender, lemon peel, peppermint, juniper, presbyopia, vanilla, holly, perilla (beefsteak plant), turmeric root, sandalwood (sandalwood), coriander (cilantro), bergamot, orange flower, myrtle, cinnamon (cassis, blackcurrant), valerian, jamaica (pimento), cardamom (mace), shaggy-clock (damien), marjoram, olive, lemon vanilla (lemon balm), lemon basil, chive, amaranth (carvi), verbena, tarragon, geranium, mulberry, ginseng, theanine (thenine), matrine (tebuchan), maca, indian ginseng (ashwagandham), shaggon (damiana), guana, chlorophyll, bread tree, or any combination thereof. The mint may be selected from the following mint varieties: peppermint (mantha arvensis), ha Tepu lines of peppermint (mantha c.v., mentha variety), egypt peppermint (mantha nilla), peppermint (mantha piperita), spearmint variety (Mentha piperita citracta c.v.), peppermint variety (mantha piperita c.v.), spearmint (Mentha spicata crispa), heart mint (Mentha cardifolia), peppermint (Mentha longifolia), pineapple mint (Mentha suavevolens variegata), calyx mint (mantha pulegium), spearmint variety (mantha spicata c.v.), and apple mint (Mentha suaveolens).

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

In some embodiments, the active substance comprises or is derived from one or more botanical preparations or ingredients, derivatives or extracts thereof, and the botanical preparations are selected from eucalyptus, star anise and cocoa.

In some embodiments, the active substance comprises or is derived from one or more botanical agents or ingredients, derivatives or extracts thereof, and the botanical agents are selected from lewis and fennel.

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

As used herein, the terms "flavor" and "fragrance" refer to materials that can be used to create a desired taste, aroma, or other somatosensory sensation in an adult consumer's product, as permitted by local regulations. They may include naturally occurring flavor materials, botanical preparations, extracts of botanical preparations, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice (liquorice)), hydrangea (hydrangea), eugenol, japanese white bark magnolia leaf (Japanese white skip magnolia leaf), chamomile, fenugreek, clove, maple, japanese green tea, menthol, japanese mint, fennel (fennel), cinnamon, turmeric, indian spice, asian spice, herbal medicine, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, claimel citrus (clementine), lemon, lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, du Linbiao (dragbuie) wine, bourbon whiskey, scotch whiskey, juniper, agave, peppermint, lavender, aloe, cardamom, celery, cascara (cascara), nutmeg, sandalwood, bergamot, geranium, arabian tea (khat), nastile (naswar), betel (betel), broadleaf rosewood (shisha), pine, honey essence, rose oil, vanilla, lemon oil, orange flower, cherry flower, cinnamon, coriander, franchet, jasmine, ylang-ylang, sage, fennel, horseradish (wampee), multi-spice), ginger (tsumami), cinnamon (bergamot), and the like, coriander, coffee, peppermint oil from any of the genus boehmeria, eucalyptus, star anise, cocoa, lemon grass, lewy, flax, ginkgo, hazelnut, hibiscus, bay, mate, orange peel, rose, tea, such as green tea or black tea, thyme, juniper, presbya, basil, bay leaf, fennel, oregano, capsicum, rosemary, saffron, lemon peel, peppermint, perilla, turmeric root, myrtle, cinnamon (cassis, blackcurrant), valerian, jamaica (pimento), cardamom petals (mace), shawl flowers (damien), marjoram, olive, lemon vanilla (lemon balm), lemon basil, chives, amaranth (carvi), verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulators, sugar and/or sugar substitutes (e.g., sucralose, potassium acetamido sulfonate, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, plant preparations, or breath fresheners. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as oil, solid such as powder, or gas.

In some embodiments, the flavoring agent comprises menthol, spearmint, and/or peppermint. In some embodiments, the flavor includes a flavor component of cucumber, blueberry, citrus fruit, and/or raspberry. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring includes a flavoring component extracted from tobacco.

In some embodiments, the flavoring agents may include sensates (sensory) that are intended to achieve a somatosensory sensation that is generally chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve), in addition to or in lieu of aromatic or gustatory nerves, and these sensates may include agents that provide a thermal, cold, stinging, numbing effect. Suitable thermal effectors may be, but are not limited to, vanillyl ethyl ether and suitable coolants may be, but are not limited to, eucalyptus oil, WS-3.

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 be in the form of a solid, liquid or gel, which may or may not contain an active substance and/or a fragrance. The aerosol-generating material may be incorporated into an article for use in an aerosol-generating system.

As used herein, the term "tobacco material" refers to any material comprising tobacco or derivatives or substitutes thereof. The tobacco material may be in any suitable form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco stems, tobacco flakes, reconstituted tobacco, and/or tobacco extracts.

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 include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and/or an aerosol modifier. The consumable may also comprise an aerosol generator, for example a heater, which generates heat to cause the aerosol-generating material to generate an aerosol in use. The heater may for example comprise a combustible material, a material which is heatable by electrical conduction or a susceptor.

Susceptors are materials that can be heated by penetration with a varying magnetic field (e.g., an alternating magnetic field). The susceptor may be an electrically conductive material such that its penetration with a varying magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material such that penetration thereof with a varying magnetic field causes 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. Devices configured to generate a varying magnetic field are referred to herein as magnetic field generators.

An aerosol-modifying agent is a substance typically located downstream of the aerosol-generating region that is configured to modify the generated aerosol, for example by altering the taste, flavour, acidity or another characteristic of the aerosol. The aerosol modifier may be provided in an aerosol modifier release member operable to selectively release the aerosol modifier

The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may, for example, comprise one or more of a fragrance, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid or a gel. The aerosol modifiers may be in powder, strand or particulate form. The aerosol modifier may be free of filter material.

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

The filamentary tow material described herein may comprise cellulose acetate fiber tows. Other materials for forming the fibers may also be used to form the filament bundles, 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 filament bundles may be plasticized with a plasticizer suitable for the bundles, such as glyceryl triacetate, wherein the material is a cellulose acetate bundle, or the bundles may be non-plasticized. The tows may be of any suitable gauge, such as fibers having a "Y" shape, or other cross-section such as an "X" shape, having a filament denier value of from 2.5 to 15 denier per filament, such as from 8.0 to 11.0 denier per filament, and a total denier value of from 5,000 to 50,000, such as from 10,000 to 40,000.

Fig. 1a is a cross-sectional side view of an article 1a for use in a non-combustible aerosol supply system, the article 1a comprising a component 3 having at least one helically wound strip 3c, the helically wound strip 3c comprising an aerosol-generating material. Fig. 1a also schematically shows an aerosol provision device 100.

The article 1a comprises a mouthpiece 2 and a component 3, also referred to as an aerosol-generating section 3, connected to the mouthpiece 2. In the present embodiment, the aerosol-generating section 3 comprises a recess or cavity 3a extending into the component 3. In this embodiment, the recess or cavity 3a forms a channel extending through the entire length of the component 3. The article 1a is generally rod-shaped and has a longitudinal axis as indicated by the dashed line X-X'.

The recess or cavity 3a is formed by a hollow tube 3b. The hollow tube 3b is formed of a multi-layered paper wound in parallel with a butt seam. The spirally wound strip 3c is a wrap around the hollow tube 3b and in this embodiment is glued to the tube 3b. In alternative embodiments, the hollow tube may be formed in other ways, such as using a curled or spiral wound paper layer (such as those described herein), cardboard tube, a tube formed using a molded pulp or molded fiber process, a molded or extruded plastic tube, or the like. The hollow tube 3b is made rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and when the article 1a is used. The manufacturing tolerances of the cavity diameters may be lower than those typically associated with aerosol-generating materials, for example less than 0.5mm, or less than 0.4mm, or less than 0.3mm.

In this embodiment, the aerosol-generating material forming the spirally wound strip 3c is a strip formed from reconstituted tobacco sheet material. In other embodiments, the spiral-wound strip 3c may be formed of other materials, such as a non-tobacco sheet material, an amorphous solid sheet material, a gel sheet material, or a paper material having a material deposited thereon. The spirally wound strip 3c may be formed from a sheet material comprising an aerosol modifier, such as a fragrance as defined herein. For example, the aerosol-generating material may be laminated on a support material, such as a support material formed from a metal foil (such as aluminum foil), paper, polylactide (PLA) material, starch-based sheet material, or the like.

The spirally wound strip may have a tensile strength of at least 4N/15 mm. This ensures that the strip 3c has sufficient tensile strength during the winding process for winding the strip around the tube 3 b.

In this embodiment, the recess or cavity 3a extends all the way through the component 3. However, in other embodiments, the recess or cavity 3a may extend only partially through the component 3. The length of the recess or cavity 3a in the direction of the longitudinal axis may be smaller than the length of the component 3 along the longitudinal axis.

The device 100 comprises a housing 101 and a region 102 for receiving the article 1 a. The region 102 comprises an aerosol-generating element 103 (in the present case a heatable element) which generates an aerosol from the aerosol-generating material of the article 1 a. The recess or cavity 3a is arranged to receive at least a portion of the aerosol-generating element 103.

In use, the article 1a is pressed onto the aerosol-generating element 103 such that the aerosol-generating element 103 of the aerosol-supply device 100 enters the recess or cavity 3a. The product 1a is consumed by drawing the bulk stream of aerosol through the downstream portion 2 of the product 1a (in the present case the mouthpiece 2). Once the smoking period is completed, the aerosol-generating element 103 is removed from the aerosol-generating material 3.

In this embodiment, the circumference of the component 3 is about 22.7mm. In alternative embodiments, the member 3 may have any suitable circumference, for example between about 20mm and about 26 mm.

The component 3 has a length of, for example, between about 5mm and about 20mm or between about 8mm and about 15 mm. The recess or cavity 3a extends through at least 25%, 50% or 75% of the length of the component 3. For example, for a component 3 having a length of 12mm, the recess 3a may extend 9mm or more into the body.

The maximum diameter of the recess or cavity 3a may be more than 10%, or more than 15%, or more than 20% of the diameter of the component 3.

The maximum diameter of the recess 3a may be less than 60%, or less than 50%, or less than 40% of the diameter of the component 3, for example 10% to 40% of the diameter of the component 3 or 15% to 30% of the diameter of the component 3.

The aerosol-generating material in any of the embodiments described herein may comprise aerosol-generating material in sheet form or in extruded form or in molded form. The aerosol-generating material may for example comprise a plant-based material which is extruded and/or moulded to form the strip 3c. Extruded or molded tobacco can be produced by a process as described in international patent publication No. WO 2020148538, the contents of which are incorporated herein by reference.

The recess or cavity 3a in the component 3 may be at least partially filled with a second aerosol-generating material, which may be the same or different from the aerosol-generating material forming the rod 3c (in this case referred to as the first aerosol-generating material).

In the present embodiment, the spirally wound strip 3c is wound around the hollow tube 3b such that a gap 3d is provided between edges of the strip 3c. This gap 3d creates a path through the component 3 so that for a given length of the strip the airflow over the surface of the strip 3c is maximised and thus the air is exposed to the aerosol-generating material included in the strip. Alternatively, the spirally wound strip 3c may be a first strip of the two strips, and a second spirally wound strip (not shown) may be wound around the first spirally wound strip 3c, also with a gap between the edges of the second strip. The second helically wound strip may at least partially cover the first helically wound strip 3c and may cover the entire width of the gap. This may allow the air flow in the gap formed by the edge of the first strip 3c and the inner surface of the second strip. The size of the gap may range from about 0.5mm to about 10mm, or from about 1mm to about 5mm, between the edges of the first strip 3c and/or the second strip 3c. In other embodiments, the helically wound strip 3c may be tightly wound such that there is no gap 3d, thereby increasing the amount of strip material provided for a given length of component. Further, in this case, the spirally wound strip 3c may also be the first of the two strips, and a second spirally wound strip (not shown) may be wound around the first spirally wound strip 3c, tightly wound so that there is no gap or wound with a gap as described above.

The component 3 has a longitudinal axis Z-Z' and when viewed laterally of the longitudinal axis, as shown in fig. 1b, the long edges of the spirally wound strip form two angles with the longitudinal axis of the component when protruding onto said axis. One of the angles is greater than 90 degrees and the other is less than 90 degrees. In some embodiments, the angle between the long edge of the spirally wound strip and the longitudinal axis of less than 90 degrees is less than about 70 degrees, such as less than about 60 degrees or less than about 50 degrees.

Fig. 3a shows a mechanical device for forming the component 3 of fig. 1 b. While rotating, a section of the hollow tube 3b is fed/pulled along the mandrel 16 in the direction of arrow "X". The hollow tube 3b may be formed, for example, from a spirally or curly wound paper forming the core, and this may be preformed or formed immediately before winding the core with the strip material 14. A source of a first strip of material 14 is provided, which in this embodiment comprises an aerosol generating material. As the tube 3b rotates and moves forward, the first strip of material 14 is wound around the tube 3 b. The first strip of material 14 forms a first helically wound strip 3c around the tube 3 b. An optional second strip of material 15 is provided, in the present case for adhering the first strip of material 14 to the tube 3 b. For example, the second strip 15 of material may be a paper material which is immersed in a reservoir of adhesive before it reaches the hollow tube 3b and then adheres to the tube 3b and serves to adhere the first strip 14 of material to the tube 3 b. The second strip of material 15 forms a second helically wound strip 3c around the tube 3 b.

Preferably, the strip of material 14 has a width at least twice the diameter of the mandrel 16. Accordingly, the helically wound strip of component 3 preferably has a width that is at least 1.5 times the diameter of the recess or cavity 3 a. For example, the spiral wound strip width may be 2, 2.5, or 3 times the recess diameter.

A continuous rod is formed using mechanical means and cutting means 17 are provided to cut the continuously formed rod into individual parts 3 or groups of parts 3. The cutting device includes a plurality of blades, such as rotating circular blades, longitudinally spaced along the conveying path of the rod. The cutting device may be arranged to reciprocate along a path parallel to the conveying path of the rod and cut the rod while moving in the same direction as the rod. For example, the cutting device may be arranged to move alongside the rod at the same speed as the rod and to cut the rod into segments while moving at the same speed as the rod. This may help to provide a clean cut through the rod at an angle perpendicular to the rod's travel path.

The mouthpiece 2 comprises a cooling section 8, also referred to as a cooling element, located immediately downstream of and adjacent to the aerosol-generating material source 3. In this embodiment, the cooling section 8 is in abutting relationship with the source of aerosol-generating material. In this embodiment, the mouthpiece 2 further comprises a body of material 6 downstream of the cooling section 8, and a hollow tubular element 4 downstream of the body of material 6 at the mouthpiece end of the article 1.

The cooling section 8 comprises a hollow channel having an inner diameter of between about 1mm to about 4mm, for example between about 2mm to about 4 mm. In this embodiment, the hollow passage has an inner diameter of about 3 mm. The hollow channel extends along the entire length of the cooling section 8. In this embodiment, the cooling section 8 comprises a single hollow channel. In alternative embodiments, the cooling section may comprise a plurality of channels, for example 2, 3 or 4 channels. In this example, the single hollow channel is substantially cylindrical, although in alternative embodiments, other channel geometries/cross-sections may be used. The channel may be, for example, a cylinder, an elliptical cylinder, a hyperbolic cylinder, or a parabolic cylinder. The hollow channel may provide a space in which the aerosol drawn into the cooling section 8 may expand and cool.

The cooling section 8 may have a wall thickness in the radial direction, which may be measured, for example, using calipers. For a given outer diameter of the cooling section, the wall thickness of the cooling section 8 defines the inner diameter of the cavity surrounded by the wall of the cooling section 8. The cooling section 8 may have a wall thickness of at least about 1.5mm and up to about 2 mm. In this embodiment, the cooling section 8 has a wall thickness of about 2 mm. Providing a cooling section 8 with a wall thickness in this range improves the retention of the source of aerosol-generating material in the aerosol-generating section in use by reducing the longitudinal displacement of the strands and/or strips of aerosol-generating material when the aerosol generator is inserted into the article.

The cooling section 8 is formed from a filiform filament bundle. Other configurations may be used, such as multiple paper layers with butt seams wound in parallel to form the cooling section 8; or a spirally wound paper layer, a cardboard tube, a tube formed using a paper-in-machine (papier-mach) process, a molded or extruded plastic tube, or the like. The cooling section 8 is made rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and when the article 1 is used.

The wall material of the cooling section 8 may be relatively non-porous such that at least 90% of the aerosol generated by the aerosol-generating material 3 passes longitudinally through the one or more hollow channels, rather than through the wall material of the cooling section 8. For example, at least 92% or at least 95% of the aerosol generated by the aerosol-generating material 3 may pass longitudinally through the one or more hollow channels.

In some embodiments, the material forming the cooling section 8 has a density of at least about 0.20g/cm ³ (g/cc) of at least about 0.25g/cc, the material forming the cooling section 8 having a density of less than about 0.80g/cm ³ (g/cc), more preferably less than 0.6g/cc. In some embodiments, the material forming the cooling section 8 has a density of 0.20 to 0.8g/cc, more preferably 0.3 to 0.6g/cc, or 0.4g/cc to 0.6g/c c or about 0.5g/cc. These densities have been found to provide a good balance between the improved hardness provided by the denser material and minimizing the total weight of the article. For the purposes of the present invention, the "density" of the material forming the cooling section 8 refers to the density of any filament strand forming the element incorporating any plasticizer. The density may be determined by dividing the total weight of the material forming the cooling section 8 by the total volume of the material forming the cooling section 8, wherein the total volume may be calculated using appropriate measurements taken (e.g., using pliers) of the material forming the cooling section 8. A microscope may be used to measure the appropriate dimensions, if necessary.

Preferably, the length of the cooling section 8 is less than about 30mm. More preferably, the length of the cooling section 8 is less than about 25mm. Still more preferably, the length of the cooling section 8 is less than about 20mm. Additionally or alternatively, the length of the cooling section 8 is preferably at least about 10mm. Preferably, the length of the cooling section 8 is at least about 15mm. In some preferred embodiments, the length of the cooling section 8 is from about 15mm to about 20mm, more preferably from about 16mm to about 19mm. In this embodiment, the length of the cooling section 8 is 19mm.

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

Preferably, the mouthpiece 2 comprises a mouthpiece having a diameter of more than 110mm ³ A cavity of the internal volume. It has been found that providing at least this volume of cavity enables the formation of an improved aerosol. More preferably, the mouthpiece 2 comprises a cavity, for example formed in the cooling section 8, having a length of more than 120mm ³ And still more preferably greater than 130mm ³ Allowing further improvements in aerosols. In some casesIn an embodiment, the internal cavity is included at about 130mm ³ To about 230mm ³ Volume therebetween, e.g. about 134mm ³ Or 227mm ³ 。

The cooling section 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 cooling section 8 and the heated volatile components exiting the second downstream end of the cooling section 8. The cooling section 8 is preferably configured to provide a temperature difference between the heated volatilized component entering the first upstream end of the cooling section 8 and the heated volatilized component exiting the second downstream end of the cooling section 8 of at least 60 degrees celsius, preferably at least 80 degrees celsius, and more preferably at least 100 degrees celsius. This temperature difference over the length of the cooling section 8 protects the temperature sensitive body of the material 6 from the high temperature of the aerosol-generating material 3 (when it is heated).

When used, the aerosol-generating segment may exhibit about 15 to about 40mm H ₂ Pressure drop of O. In some embodiments, the aerosol-generating section has about 15 to about 30mm H on the aerosol-generating section ₂ Pressure drop of O.

The aerosol-generating material may have a content of about 400mg/cm in the aerosol-generating section ³ To about 900mg/cm ³ Filling density between.

In this embodiment, the moisture impermeable wrapper 10 surrounds the rod of aerosol generating material and comprises aluminium foil. In other embodiments, the wrapper 10 comprises a paper wrapper, optionally including a barrier coating to render the material of the wrapper substantially impermeable to moisture vapor. Aluminum foil has been found to be particularly effective in enhancing aerosol formation within the aerosol-generating material 3. In this embodiment, the aluminum foil has a metal layer with a thickness of about 6 μm. In this embodiment, the aluminum foil has a paper backing. However, in alternative arrangements, the aluminium foil may have other thicknesses, for example between 4 μm and 16 μm. 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 proper tensile strength, or it may have no backing material. Metal layers or foils other than aluminum may also be used. The total thickness of the wrapper is preferably between 20 μm and 60 μm, more preferably between 30 μm and 50 μm, which may provide the wrapper with suitable structural integrity and heat transfer characteristics.

In this embodiment, the moisture impermeable wrapper 10 is also substantially impermeable to air. In alternative embodiments, the wrapper 10 preferably has a permeability of less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that a low permeability wrapper, for example having a permeability of less than 100 Coresta units, more preferably less than 60 Coresta units, results in improved aerosol formation in the aerosol-generating material 3. The permeability of the wrapper 10 may be measured according to ISO2965:2009, which relates to the determination of the air permeability of materials used as cigarette paper, filter plug wrap and filter joint paper.

The body of material 6 and the hollow tubular element 4 each define a generally cylindrical overall external shape and have a common longitudinal axis. The body of material 6 is wrapped in a first plug wrap 7. Preferably, the first plug wrap 7 has a basis weight of less than 50gsm, more preferably between about 20gsm and 40 gsm. Preferably, the first plug wrap 7 has a thickness between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. Preferably, the first plug wrap 7 is a non-porous plug wrap, e.g. having a permeability of less than 100 Coresta units (e.g. less than 50 Coresta units). However, in other embodiments, the first plug wrap 7 may be a porous plug wrap, for example having a permeability of greater than 200 Coresta units.

Preferably, the length of the body of material 6 is less than about 15mm. More preferably, the length of the body of material 6 is less than about 12mm. Additionally, or alternatively, the length of the body of material 6 is at least about 5mm. Preferably, the length of the body of material 6 is at least about 8mm. In some preferred embodiments, the length of the body of material 6 is from about 5mm to about 15mm, more preferably from about 6mm to about 12mm, even more preferably from about 6mm to about 12mm, most preferably about 6mm, 7mm, 8mm, 9mm or 10mm. In the present embodiment, the length of the material body 6 is 10mm.

In this embodiment, the body of material 6 is formed from a filiform tow. In this embodiment, the tow for the material body 6 has a denier per filament (d.p.f.) of 5 and a total denier of 25,000. In this embodiment, the tow comprises plasticized cellulose acetate tow. The plasticizer for the tow was about 9wt% of the tow. In this example, the plasticizer is glyceryl triacetate. In other embodiments, different materials may be used to form the material body 6. For example, the body 6 may be formed of paper instead of tow, for example in a similar manner to paper filters known for cigarettes. For example, paper or other cellulosic material may be provided as one or more portions of sheet material that are folded and/or rolled to form the body 6. The sheet material may have a basis weight of from 15gsm to 60gsm, for example between 20 and 50 gsm. The sheet material may for example have a basis weight in any range between 15 and 25gsm, between 25 and 30gsm, between 30 and 40gsm, between 40 and 45gsm and between 45 and 50 gsm. Additionally or alternatively, the sheet material may have a width of between 50mm and 200mm, for example between 60mm and 150mm, or between 80mm and 150 mm. For example, the sheet material may have a basis weight between 20 and 50gsm and a width between 80mm and 150 mm. For example, this may enable the cellulosic body to have a suitable pressure drop for an article having the dimensions as described herein.

Alternatively, the body 6 may be formed from tows other than cellulose acetate, such as polylactic acid (PLA), other materials described herein for filamentous tows, or the like. The tow is preferably formed from cellulose acetate. The tow, whether formed from cellulose acetate or other materials, preferably has a d.p.f. of at least 5. Preferably, in order to achieve a sufficiently homogeneous material body 6, the tows have a denier per filament of not more than 12d.p.f., preferably not more than 11 d.p.f., still more preferably not more than 10d.p.f.

The total denier of the tows forming the material body 6 is preferably at most 30,000, more preferably at most 28,000, still more preferably at most 25,000. These total denier values provide a reduced proportion of the tow occupying the cross-sectional area of the mouthpiece 2, which results in a lower pressure drop across the mouthpiece 2 than a tow with a higher total denier value. For proper stiffness of the material body 6, the tows preferably have a total denier of at least 8,000, more preferably at least 10,000. Preferably, the denier per filament is from 5 to 12 and the total denier is from 10,000 to 25,000. Preferably, the filament cross-sectional shape of the tow is "Y" shaped, although in other embodiments other shapes such as "X" shaped filaments having the same d.p.f. and total denier values as provided herein may be used.

Regardless of the material used to form the body 6, the pressure drop across the body 6 may be, for example, between 0.3 and 5mmWG/mm body length 6, for example between 0.5 and 2mmWG/mm body length 6. The pressure drop may be, for example, between 0.5 and 1mmWG/mm in length, between 1 and 1.5mmWG/mm in length, or between 1.5 and 2mmWG/mm in length. The total pressure drop over the body 6 may be, for example, between 3 and 8mmWG, or between 4 and 7mmWG. The total pressure drop over the body 6 may be about 5, 6 or 7mmWG.

As shown in fig. 1a, the mouthpiece 2 of the article 1a comprises an upstream end 2a adjacent to the rod 3 of aerosol-generating material and a downstream end 2b remote from the rod 3 of aerosol-generating material. At the downstream end 2b, the mouthpiece 2 has a hollow tubular element 4 formed of a filiform tow. Advantageously, it has been found that this significantly reduces the temperature of the outer surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece, which is in contact with the mouth of the consumer, when the article 1 is in use. Furthermore, it has been found that the use of the tubular element 4 significantly reduces the outer surface (even upstream of the tubular element 4) temperature of the mouthpiece 2. Without wishing to be bound by theory, it is assumed that this is due to the tubular element 4 leading the aerosol closer to the centre of the mouthpiece 2 and thus reducing the transfer of heat from the aerosol to the outer surface of the mouthpiece 2.

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 may be measured, for example, using calipers. The wall thickness is advantageously greater than 0.9mm, and 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 the case where the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9mm, more preferably 1.0mm or greater, at any point around the hollow tubular element 4. In this embodiment, the wall thickness of the hollow tubular element 4 is about 1.3mm.

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

Preferably, the hollow tubular element 4 has a density of at least about 0.25g/cm ³ (g/cc), more preferably at least about 0.3g/cc. Preferably, the hollow tubular element 4 has a density of less than about 0.75g/cm ³ (g/cc), more preferably less than 0.6g/cc. In some embodiments, the hollow tubular element 4 has a density of between 0.25 and 0.75g/cc, more preferably between 0.3 and 0.6g/cc, and more preferably between 0.4 and 0.6g/cc or about 0.5g/cc. These densities have been found to provide a good balance between the improved hardness provided by denser materials and the lower heat transfer characteristics of lower density materials. For the purposes of the present invention, the "density" of the hollow tubular element 4 refers to the density of the filiform strands forming the element with any incorporated plasticizer. 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 suitable measurements of the hollow tubular element 4, e.g. using calipers. A microscope may be used to measure the appropriate dimensions, if necessary.

The filament bundles forming the hollow tubular member 4 preferably have a total denier of less than 45,000, more preferably less than 42,000. This total denier has been found to allow the formation of less dense tubular elements 4. Preferably the total denier is at least 20,000, more preferably at least 25,000. In a preferred embodiment, the total denier of the filament bundles forming the hollow tubular member 4 is between 25,000 and 45,000, more preferably between 35,000 and 45,000. Preferably, the cross-sectional shape of the tow filaments is "Y" shaped, although in other embodiments other shapes such as "X" shaped filaments may be used.

The filament bundles forming the hollow tubular member 4 preferably have a denier per filament of greater than 3. It has been found that such denier per filament allows the formation of a less dense tubular element 4. Preferably the denier per filament is at least 4, more preferably at least 5. In a preferred embodiment, the filament bundles forming the hollow tubular member 4 have a denier per filament of between 4 and 10, more preferably between 4 and 9. In one embodiment, the filiform strands forming the hollow tubular element 4 have 7.3Y36,000 strands formed from cellulose acetate and containing 18% of a plasticizer, such as glyceryl triacetate.

The hollow tubular element 4 preferably has an inner diameter greater than 3.0 mm. A smaller diameter than this may cause the velocity of the aerosol through the mouthpiece 2 to the consumer's mouth to increase beyond the desired velocity such that the aerosol becomes too hot, for example to 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, and 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 4.7mm.

The hollow tubular element 4 preferably comprises 15 to 22wt% of plasticizer. For cellulose acetate tow, the plasticizer is preferably glyceryl triacetate, although other plasticizers such as polyethylene glycol (PEG) may be used. More preferably, the hollow tubular element 4 comprises 16wt% to 20wt% of plasticizer, for example about 17%, about 18% or about 19% plasticizer.

In the present embodiment, the first hollow tubular element 4, the material body 6 and the cooling section 8 are joined together using a second plug wrap 9 wound around all three sections. Preferably, the second plug wrap 9 has a basis weight of less than 50gsm, more preferably between about 20gsm and 45 gsm. Preferably, the second plug wrap 9 has a thickness between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The second plug wrap 9 is preferably a non-porous plug wrap having a permeability of less than 100 Coresta units (e.g., less than 50 Coresta units). However, in alternative embodiments, the second plug wrap 9 may be a porous plug wrap, for example having a permeability of greater than 200 Coresta units.

The tipping paper 5 is wrapped over the entire length of the mouthpiece 2 and in this embodiment over the entire length of the rod of aerosol-generating material 3 and has adhesive on its inner surface to connect the mouthpiece 2 and the rod 3. In the present embodiment, the rod 3 of aerosol-generating material is wrapped in a wrapper 10, which forms the first wrapper and the tipping paper 5 forms an outer wrapper which extends at least partially over the rod 3 of aerosol-generating material to connect the mouthpiece 2 and the rod 3. In some embodiments, the tipping paper may extend only partially over the rod of aerosol-generating material.

The tipping paper 5 may extend 5mm above the rod of aerosol-generating material 3, or it may alternatively extend between 3mm and 10mm, or more preferably between 4mm and 6mm, above the rod 3, so as to provide a secure attachment between the mouthpiece 2 and the rod 3. The tipping paper may have a basis weight of greater than 20gsm, for example greater than 25gsm, or preferably greater than 30gsm, for example 37 gsm.

The article has a ventilation level of about 10% of the aerosol drawn through the article. In alternative embodiments, the article may have a ventilation level of 1% to 20%, such as 1% to 12%, of the aerosol drawn through the article. Ventilation at these levels helps to increase the consistency of the aerosol inhaled by the user at the mouth end 2b, while at the same time helping the aerosol cooling process. Ventilation is provided directly into the mouthpiece 2 of the article 1. In the present embodiment ventilation is provided into the cooling section 8, which ventilation has been found to be particularly advantageous in assisting the aerosol-generating process. Ventilation is provided via the perforations 12, which perforations 12 are in the present case formed as a single row of laser perforations, positioned 13mm from the downstream mouth end 2b of the mouthpiece 2. In alternative embodiments, two or more rows of vent perforations may be provided. These perforations pass through the tipping paper 5, the second plug wrap 9 and the cooling section 8. In alternative embodiments ventilation may be provided into the mouthpiece at other locations, for example into the material body 6 or the first tubular element 4. Preferably, the article is configured such that the perforations are disposed about 28mm or less from the upstream end of the article 1, preferably between 20mm and 28mm from the upstream end of the article 1. In this embodiment, an aperture of about 25mm from the upstream end of the article is provided.

Fig. 2a is a cross-sectional side view of another article 1b in use in a non-combustible sol supply system, the other article 1b comprising a component 3' having a plurality of helically wound or braided strips 3c, 3 e. Also shown is an aerosol provision device 100, the article and device forming a system. Fig. 2b is a side view of the part 3' of fig. 2 a. In this embodiment, the component 3' comprises a plurality of braided or spirally wound strips 3c, 3e, at least one of the plurality of braided and/or spirally wound strips containing aerosol-generating material. The component 3' includes a cavity extending from a first end of the component 3', and in this embodiment, the cavity also extends through the entire length of the component 3'. In the present embodiment, the first braided and/or spirally wound strip 3c comprises a first aerosol-generating material as described herein, and the second braided and/or spirally wound strip 3e comprises a second aerosol-generating material as described herein. The second aerosol-generating material may be different to the first aerosol-generating material. In alternative embodiments, the second braided and/or spirally wound strip 3e may be a paper strip for adhering the first braided and/or spirally wound strip 3c to the tube 3 b. For example, at least one of the braided and/or spirally wound strips may have a gluing surface, e.g. wherein the gluing surface connects other braided and/or spirally wound strips in the component 3'.

The braided and/or spirally wound strip 3c comprising the first aerosol-generating material is arranged closer to the cavity 3a than the at least one braided and/or spirally wound strip comprising the second aerosol-generating material.

A first gap 3d is provided between the edges of the first braided and/or spirally wound strip 3c and a second gap 3f is provided between the edges of the second braided and/or spirally wound strip 3 e. These first gap 3d and second gap 3f provide a helical air flow path through the component 3'.

In alternative embodiments, at least one of the braided and/or spirally wound strips 3c, 3e may comprise a spacer material, for example wherein the spacer material has a ridged and/or corrugated structure. The spacer material may allow an air gap to be formed in the component 3' and may for example be provided as a layer between an inner and an outer strip, each strip containing an aerosol generating material.

As described above in relation to the component 3, the long edge of at least one braided and/or spirally wound strip forms two angles with the longitudinal axis of the component when projected onto said axis, when seen laterally from the longitudinal axis of the component 3'. One of the angles is greater than 90 degrees and the other is less than 90 degrees. In some embodiments, the angle of less than 90 degrees between the long edge of at least one of the braided and/or spirally wound strips and the longitudinal axis is less than about 70 degrees, such as less than about 60 degrees, or less than about 50 degrees.

Figure 3b shows a mechanical device for forming the part 3' of figure 2 b. A mandrel 16 is provided along which the material forming part 3' is fed/pulled in the direction of arrow "X". The spindle 16 may be static, for example. A source of a first strip of material 14 is provided, which in this embodiment comprises an aerosol generating material. The source of the first strip of material 14 (e.g., a spool of material) is wound around the mandrel 16 by moving the spool around the mandrel 16 as the mandrel moves forward. The first strip of material 14 forms a first helically wound strip 3c around the mandrel. A second strip of material 15 is likewise provided on the bobbin, in the present case for bonding to the first strip of material 14 and for providing rigidity to the first strip of material 14. For example, the second strip of material 15 may be a paper material that is immersed in a reservoir of adhesive so that the adhesive is present on its outer surface before it reaches the mandrel and then adheres to the first strip of material 14. The bobbin of the second strip of material 15 is moved around the mandrel such that the second strip of material 15 forms a second helically wound strip 3c around the tube 3 b.

In this embodiment, the respective bobbins of first 14 and second 15 strips of material are arranged to rotate in opposite directions about the mandrel 16. Thus, at least one of the braided and/or spirally wound strips is arranged in a left-hand spiral pattern, and at least one of the plurality of braided strips is arranged in a right-hand spiral pattern. This results in a woven arrangement of strips. A cutting device 17 is provided which is identical to the cutting device described with reference to fig. 3 a.

Fig. 4 is a flow chart showing a method of forming a component 3, 3' as described herein. In step S201, a source of a strip of material comprising aerosol-generating material is provided. This may be provided for example on a wire drum. In step S202, a strip of material is fed towards the mandrel. In step S203, a strip of material is wound around a mandrel to form a helically wound strip comprising aerosol-generating material. As described above, this can be achieved by rotating the mandrel (with an optional hollow tube) or by moving a wire drum of material around the mandrel.

The aerosol-generating material 3 according to some of the embodiments described herein may be provided in the form of a sheet or slice comprising a first surface and a second surface opposite the first surface. The dimensions of the first and second surfaces are congruent. The first and second surfaces of the sheet or slice may have any shape. For example, the first and second surfaces may be square, rectangular, oblong or circular. Irregular shapes are also contemplated.

The first and/or second surfaces of the sheet or slice may be relatively uniform (e.g., they may be relatively smooth) or they may be non-uniform or irregular. For example, the first and/or second surfaces of the sheet may be textured or patterned to define a relatively rough surface. In some embodiments, the first and/or second surface is relatively rough.

The smoothness of the first and second surfaces may be affected by a variety of factors, such as the areal density of the sheet or slice, the nature of the components comprising the aerosol-generating material, or whether the material surfaces have been manipulated, such as embossed, scored or otherwise altered to impart a pattern or texture thereto.

The width or cut width of the strands or strips of material 14, 15 may be between 1mm and 15 mm. For example, the width may be between 5mm and 12 mm. Preferably, the strands or strips of material 14, 15 have a width that is 1.5 times greater than the diameter of the cavity 3 a. For example, the strands or strips of material 14, 15 may have a width that is 2, 2.5, 3, or 4 times greater than the diameter of the cavity. This ratio of strip width to cavity diameter may result in a more resilient structure of the component 3'.

The strips of material 14, 15 may be formed from a sheet of aerosol-generating material. The sheet of aerosol-generating material has a thickness of at least about 100 μm. The sheet may have a thickness of at least about 120 μm, 140 μm, 160 μm, 180 μm, or 200 μm. In some embodiments, the sheet has a thickness of about 150 μm to about 300 μm, about 151 μm to about 299 μm, about 152 μm to about 298 μm, about 153 μm to about 297 μm, about 154 μm to about 296 μm, about 155 μm to about 295 μm, about 156 μm to about 294 μm, about 157 μm to about 293 μm, about 158 μm to about 292 μm, about 159 μm to about 291 μm, or about 160 μm to about 290 μm. In some embodiments, the sheet has a thickness of about 170 μm to about 280 μm, about 180 μm to about 270 μm, about 190 μm to about 260 μm, about 200 μm to about 250 μm, or about 210 μm to about 240 μm.

The sheet thickness may be different between the first and second surfaces. In some embodiments, a single strip or sheet of aerosol-generating material has a minimum thickness of about 100 μm over its area. In some cases, the individual strips or sheets of aerosol-generating material have a minimum thickness of about 0.05mm or about 0.1mm over their area. In some cases, the individual strips of aerosol-generating material have a maximum thickness of about 1.0mm over their area. In some cases, a single strip or sheet of aerosol-generating material has a maximum thickness of about 0.5mm or about 0.3mm over its area.

The sheet thickness can be determined using ISO 534:2011 "Paper and cardboard-thickness determination (Paper and Board-Determination of Thickness)".

If the sheet of aerosol-generating material is too thick, heating efficiency may be compromised. This may adversely affect the power consumption in use, for example the power consumption of releasing flavour from an aerosol-generating material. Conversely, if the aerosol-generating material is too thin, it may be difficult to manufacture and handle; very thin materials can be more difficult to cast and can be brittle, compromising aerosol formation in use.

It is assumed that if the sheet of aerosol-generating material is too thin (e.g. less than 100 μm), it may be necessary to increase the cut width of the sheet to achieve sufficient tensile strength.

Provided that it has a thickness of at least about 100 μm together with a thickness of about 100g/m ² To about 250g/m ² Is less prone to tearing, splitting or otherwise deforming during its manufacture. A thickness of at least about 100 μm may have a positive impact on the overall structural integrity and strength of the sheet or shredded sheet. For example, it may have good tensile strength and thus be relatively easy to process.

The thickness of the sheet is also believed to have an effect on its areal density. That is, increasing the thickness of the sheet may increase the areal density of the sheet.

Conversely, reducing the thickness of the sheet may reduce the areal density of the sheet. For the avoidance of doubt, where reference is made herein to an area density, this refers to the average area density calculated for a given strip, strand, sheet or sheet of aerosol-generating material, calculated by measuring the surface area and weight of the given strip, strand, sheet or sheet of aerosol-generating material.

The sheet of aerosol-generating material has a mass density of about 100g/m ² To about 250g/m ² Is a high density of the area of the substrate. The sheet may have a weight of about 110g/m ² To about 240g/m ² About 120g/m ² To about 230g/m ² About 130g/m ² To about 220g/m ² Or about 140g/m ² To about 210g/m ² Is a high density of the area of the substrate. In some embodiments, the sheet has about 130g/m ² To about 190g/m ² About 140g/m ² To about 180g/m ² About 150g/m ² To about 170g/m ² Is a high density of the area of the substrate. In a preferred embodiment, the sheet has a weight of about 160g/m ² Is a high density of the area of the substrate.

Considered to be about 100g/m ² To about 250g/m ² Is effective in the strength and flexibility of the sheet.

The flexibility of a sheet is believed to depend at least in part on the thickness and area density of the sheet. Thicker sheets may be less flexible than thinner sheets. Moreover, the greater the areal density of the sheet, the less flexible the sheet. The combined thickness and areal density of the aerosol-generating materials described herein are believed to provide a relatively flexible sheet. This flexibility may yield various advantages when incorporating aerosol-generating materials into articles used in non-combustible sol supply devices. For example, when the aerosol generator is inserted into the aerosol-generating material, the strands or strips can easily deform and bend, thereby facilitating insertion of the aerosol generator (e.g., heater) into the material and also improving retention of the aerosol generator by the aerosol-generating material.

The areal density of the sheet of aerosol-generating material affects the roughness of the first and second surfaces of the sheet or shredded sheet. By varying the area density, the roughness of the first and/or second surface may be adjusted.

The average bulk density of a sheet of aerosol-generating material may be calculated from the sheet thickness and the sheet area density. The average bulk density may be greater than about 0.2g/cm ³ About 0.3g/cm ³ Or about 0.4g/cm ³ . In some embodiments, the average bulk density is about 0.2g/cm ³ To about 1g/cm ³ About 0.3g/cm ³ To about 0.9g/cm ³ About 0.4g/cm ³ To about 0.9g/cm ³ About 0.5g/cm ³ To about 0.9g/cm ³ Or about 0.6g/cm ³ To about 0.9g/cm ³ 。

According to one aspect of the present disclosure, there is provided an aerosol-generating material comprising a sheet of aerosol-generating material comprising a tobacco material, an aerosol-former material and a binder, wherein the sheet has a content of more than about 0.4g/cm ³ Is a density of (3). In some embodiments, the density is about 0.4g/cm ³ To about 2.9g/cm ³ About 0.4g/cm ³ To about 1g/cm ³ About 0.6cm ³ To about 1.6cm ³ Or about 1.6cm ³ To about 2.9cm ³ 。

The sheet may have a tensile strength of at least 4N/15 mm. When the sheet has a tensile strength of less than 4N/15mm, the sheet may tear, break or otherwise deform during its manufacture and/or subsequent incorporation into an article used in a non-combustible sol supply system. Tensile strength can be measured using ISO 1924:2008.

The aerosol-generating material comprises tobacco material. The sheet of aerosol-generating material comprises tobacco material.

The tobacco material may be particulate or granular material. In some embodiments, the tobacco material is a powder. Alternatively or additionally, the tobacco material may comprise a rod, strand or fiber of tobacco. For example, the tobacco material may include particles, granules, fibers, strands, and/or strands of tobacco. In some embodiments, the tobacco material consists of microparticles or particles of the tobacco material.

The density of the tobacco material has an effect on the rate of heat conduction through the material, with lower densities, such as those below 900mg/cc, conducting heat through the material more slowly, and thus being able to release the aerosol more continuously.

The tobacco material may comprise reconstituted tobacco material having a density of less than about 900mg/cc, such as paper reconstituted tobacco material. For example, the aerosol-generating material comprises reconstituted tobacco material having a density of less than about 800 mg/cc. Alternatively or additionally, the aerosol-generating material may comprise reconstituted tobacco material having a density of at least 350 mg/cc.

The reconstituted tobacco material may be provided in the form of a shredded sheet. The sheet of reconstituted tobacco material may have any suitable thickness. The reconstituted tobacco material may have a thickness of at least about 0.145mm, such as at least about 0.15mm, or at least about 0.16 mm. The reconstituted tobacco material may have a maximum thickness of about 0.30mm or 0.25mm, for example the reconstituted tobacco material may have a thickness of less than about 0.22mm or less than about 0.2mm. In some embodiments, the reconstituted tobacco material may have an average thickness in the range of 0.175mm to 0.195 mm.

In some embodiments, the tobacco is a particulate tobacco material. Each particle of particulate tobacco material may have a maximum size. As used herein, the term "maximum dimension" refers to the longest straight line distance from any point on the surface of a tobacco particle or particle to any other surface point on the same tobacco particle or particle surface. The maximum size of the particles of particulate tobacco material can be measured using a Scanning Electron Microscope (SEM).

The largest dimension of each particle of tobacco material can be up to about 200 μm. In some embodiments, each particle of the tobacco material has a maximum dimension of up to about 150 μm.

The population of particles of tobacco material may have a particle size distribution (D90) of at least about 100 μm. In some embodiments, the population of particles of tobacco material has a particle size distribution (D90) of about 110 μm, at least about 120 μm, at least about 130 μm, at least about 140 μm, or at least about μm. In one embodiment, the population of particles of tobacco material has a particle size distribution (D90) of about 150 μm. Screening analysis may also be used to determine the particle size distribution of particles of tobacco material.

A particle size distribution (D90) of at least about 100 μm is believed to contribute to the tensile strength of the aerosol-generating material sheet.

Particle size distribution (D90) of less than 100 μm may provide a sheet of aerosol-generating material with good tensile strength. However, including such fine particles of tobacco material in the sheet increases its density. Such higher densities can reduce the filling value of the tobacco material when incorporating the sheet into an article for use in a non-combustible sol supply system. Advantageously, a satisfactory balance between tensile strength and suitable density (and thus filling value) can be achieved when the particle size distribution (D90) is at least about 100 μm.

The particle size of the particulate tobacco material may also affect the roughness of the sheet of aerosol-generating material. It is speculated that forming the sheet of aerosol-generating material by introducing relatively large particles of tobacco material reduces the density of the sheet of aerosol-generating material.

The tobacco material may include tobacco obtained from any portion of a tobacco plant. In some embodiments, the tobacco material comprises tobacco leaves. The sheet may comprise from 5wt% to about 90wt% tobacco leaf.

The tobacco material may include tobacco flakes (lamina tabacco) and/or tobacco stems, such as mid-rib stems (midrib stems). The tobacco sheet may be present in an amount of 0wt% to about 100wt%, about 20wt% to about 100wt%, about 40wt% to about 95wt%, about 45wt% to about 90wt%, about 50wt% to about 85wt%, or about 55wt% to about 80wt% of the sheet and/or tobacco material. In some embodiments, the tobacco material consists of or consists essentially of tobacco sheet material.

The tobacco material may comprise tobacco stems in an amount of from 0wt% to about 100wt%, from about 0wt% to about 50wt%, from about 0wt% to about 25wt%, from about 0wt% to about 20wt%, from about 5wt% to about 15wt% of the sheet or shredded sheet.

In some embodiments, the tobacco material comprises a combination of tobacco lamina and tobacco stems. In some embodiments, the tobacco material may comprise tobacco flakes in an amount of about 40wt% to about 95wt% and tobacco stems in an amount of about 5wt% to about 60wt%, or tobacco flakes in an amount of about 60wt% to about 95wt% and tobacco stems in an amount of about 5wt% to about 40wt%, or tobacco flakes in an amount of about 80wt% to about 95wt% and tobacco stems in an amount of about 5wt% to about 20wt% of the aerosol-generating material sheet.

The incorporation of tobacco stems can reduce the viscosity of the aerosol-generating material. Incorporating tobacco material comprising tobacco stems into aerosol-generating materials may increase their burst strength.

The sheet or shredded sheet of aerosol-generating material may have a burst strength of at least about 75g, at least about 100g, or at least about 200 g.

If the burst strength is too low, the sheet may be relatively brittle. Thus, sheet breakage may occur during the process of manufacturing the aerosol-generating material. For example, when the sheet is shredded by a cutting process to form a shredded sheet, the sheet may chip or break into pieces or fragments upon cutting.

The tobacco materials described herein contain nicotine. The nicotine content is 0.1 to 3wt% of the tobacco material and may be, for example, 0.5 to 2.5wt% of the tobacco material. Additionally or alternatively, the tobacco material comprises between 10wt% and 90wt% tobacco leaves having a nicotine content of the tobacco leaves of greater than about 1wt% or about 1.5 wt%. Tobacco leaves (e.g., cut tobacco) may, for example, have a nicotine content of between 1wt% and 5wt% of the tobacco leaves.

The aerosol-generating material sheet may comprise nicotine in an amount of between about 0.1% to about 3% by weight of the sheet or the chopped sheet.

Paper reconstituted tobacco may also be present in the aerosol-generating material described herein. Paper reconstituted tobacco refers to tobacco material formed by the following process: the 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, and optionally after further processing) with fibrous material from the residue (typically after refining of the fibrous material, and optionally adding a portion of non-tobacco fibers) by depositing the extract onto the fibrous material. The process of recombination is similar to the paper making process.

The paper reconstituted tobacco may be any type of paper reconstituted tobacco known in the art. In one embodiment, the paper reconstituted tobacco is made from a raw material comprising one or more of tobacco rod, tobacco stem and whole leaf tobacco. In a further embodiment, the paper reconstituted tobacco is made from a raw material consisting of tobacco rod and/or whole leaf tobacco and tobacco stems. However, in other embodiments, crushed material, fines and wind sorting (winnowing) may alternatively or additionally be used in the feedstock.

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

In embodiments, the paper reconstituted tobacco is present in an amount of 5wt% to 90wt%, 10wt% to 80wt%, or 20wt% to 70wt% of the aerosol-generating material.

The aerosol generating material comprises an aerosol former material. The aerosol former material comprises one or more components capable of forming an aerosol. The aerosol former material comprises one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, meso-erythritol, ethyl vanillic acid, ethyl laurate, diethyl suberate, triethyl citrate, glyceryl triacetate, glyceryl diacetate mixture, benzyl benzoate, benzyl phenyl acetate, glyceryl tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. Preferably, the aerosol former material is glycerol or propylene glycol.

The sheet of aerosol-generating material comprises an aerosol-former material. The aerosol former material is provided in an amount up to about 50wt% on a dry weight sheet or chopped sheet basis. In some embodiments, the aerosol former material is provided in an amount of about 5wt% to about 40wt% based on dry weight sheet or shredded sheet, about 10wt% to about 30wt% based on dry weight sheet, or about 10wt% to about 20wt% based on dry weight sheet or shredded sheet.

The sheet may also contain water. The sheet of aerosol-generating material may comprise water in an amount of less than about 15wt%, less than about 10wt%, or less than about 5wt% of the aerosol-generating material. In some embodiments, the aerosol-generating material comprises water in an amount between about 0wt% and about 15wt% or between about 5wt% and about 15wt% of the aerosol-generating material.

The sheet of aerosol-generating material may comprise a total amount of water and aerosol-former material of less than about 30wt% of the sheet of aerosol-generating material or less than about 25wt% of the sheet of aerosol-generating material. It is believed that incorporating water and aerosol former material in an amount of less than about 30wt% of the sheet of aerosol-generating material into the sheet of aerosol-generating material may advantageously reduce sheet tackiness. This may improve the ease with which the aerosol-generating material may be handled during processing. For example, a sheet of aerosol-generating material may be more easily rolled up to form a bobbin of material and then unrolled without the layers of sheet material sticking together. Reducing tackiness may also reduce the tendency of strands or strips of shredded material to bunch or adhere together, further improving processing efficiency and quality of the final product.

The sheet comprises an adhesive. The adhesive is arranged to adhere the components of the aerosol-generating material from the thermoformed sheet or the shredded sheet. The binder may at least partially coat the surface of the tobacco material. Where the tobacco material is in particulate form, the binder may at least partially coat the surfaces of the tobacco particles and bind them together.

The binder may be selected from one or more compounds selected from the group comprising: alginate, pectin, starch (and derivatives thereof), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder includes one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the binder comprises alginate and/or pectin or carrageenan. In a preferred embodiment, the binder comprises guar gum.

The binder may be present in an amount of from about 1wt% to about 20wt% of the sheet or shredded sheet, or in an amount of from 1wt% to about 10wt% of the sheet of aerosol-generating material. For example, the binder may be present in an amount of about 1wt%, 2wt%, 3wt%, 4wt%, 5wt%, 6wt%, 7wt%, 8wt%, 9wt%, or 10wt% of the aerosol-generating material sheet.

The aerosol-generating material may comprise a filler. In some embodiments, the sheet comprises a filler. Fillers are typically non-tobacco components, i.e., components that do not include tobacco-derived ingredients. The filler may comprise one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may be non-tobacco fibres such as wood fibres or pulp or wheat fibres. The filler may be a material comprising cellulose or a material comprising cellulose derivatives. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material.

In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood, wood pulp, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that including fibrous fillers may increase the tensile strength of the material.

The filler may also contribute to the texture of the sheet of aerosol-generating material. For example, a fibrous filler, such as wood or wood pulp, may provide a sheet of aerosol-generating material having relatively rough first and second surfaces. Conversely, a non-fibrous particulate filler, such as powdered chalk, may provide a sheet of aerosol generating material having relatively smooth first and second surfaces. In some embodiments, the aerosol-generating material comprises a combination of different filler materials.

The filler component may be present in an amount of 0wt% to 20wt% of the sheet or shredded sheet, or 1wt% to 10wt% of the sheet or shredded sheet. In some embodiments, the filler component is absent.

The filler may help to improve the conventional structural properties of the aerosol-generating material, such as its tensile strength and burst strength.

In the compositions described herein, when amounts are given in wt%, for the avoidance of doubt, this refers to on a dry weight basis unless specifically indicated to the contrary. Thus, any water that may be present in the aerosol-generating material or any component thereof is completely ignored for the purpose of determining wt%. The water content of the aerosol-generating material described herein may vary and may be, for example, from 5wt% to 15wt%. The water content of the aerosol-generating materials described herein may vary depending on, for example, the temperature, pressure, and humidity conditions under which the composition is maintained. The water content may 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-former material is a component of the liquid phase, such as glycerol or propylene glycol, any component other than water is included in the weight of the aerosol-generating material. However, when the aerosol-former material is provided in the tobacco component of the aerosol-generating material, or in the filler component of the aerosol-generating material (if present), the aerosol-former material is not included in the weight of the tobacco component or filler component, but is included in the weight of the "aerosol-former material" at wt% as defined herein, instead of or in addition to being added separately to the aerosol-generating material. All other ingredients present in the tobacco component are included in the weight of the tobacco component, even if not of tobacco origin (e.g., non-tobacco fibers in the case of paper reconstituted tobacco).

The aerosol-generating material herein may comprise an aerosol-modifying agent, such as any of the flavours described herein. In one embodiment, the aerosol-generating material comprises menthol. When the aerosol-generating material is incorporated into an article for use in an aerosol-supply system, the article may be referred to as a menthol article. The aerosol-generating material may comprise from 0.5mg to 20mg of menthol, from 0.7mg to 20mg of menthol, between 1mg to 18mg or between 8mg to 16mg of menthol. In this embodiment, the aerosol-generating material comprises 16mg menthol. The aerosol-generating material may comprise between 1 and 8wt% menthol, preferably between 3 and 7wt% menthol and more preferably between 4 and 5.5wt% menthol. In one embodiment, the aerosol-generating material comprises 4.7wt% menthol. Such high levels of menthol loading may be achieved using a high percentage of reconstituted tobacco material, such as greater than 50wt% tobacco material. Alternatively or additionally, the use of a large amount of, for example, tobacco material may increase the menthol loading level that may be achieved, for example, when greater than about 500mm is used ³ Or suitably greater than about 1000mm ³ Such as tobacco material.

In some embodiments, the composition comprises an aerosol-forming "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may comprise a dry gel. Amorphous solids are solid materials that can retain some fluid (e.g., liquid) therein.

In some embodiments, the amorphous solid comprises:

-1-60wt% of a gelling agent;

-0.1wt% to 50wt% of an aerosol former material; and

0.1-80wt% of a flavoring agent;

wherein these weights are calculated on a dry weight basis.

In some further embodiments, the amorphous solid comprises:

-1-50wt% of a gelling agent;

-0.1wt% to 50wt% of an aerosol former material; and

-30-60wt% of a flavour;

wherein these weights are calculated on a dry weight basis.

The amorphous solid material may be provided in sheet form or in chopped sheet form. The amorphous solid material may take the same form as the sheet of aerosol-generating material described previously.

Suitably, the amorphous solid may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt% or 35wt% of the gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1 to 50wt%, 5 to 45wt%, 10 to 40wt%, or 20 to 35wt% of the gellant. In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group consisting of: alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the gelling agent includes alginate and/or pectin, and may be combined with a hardening agent (e.g., a calcium source) during the formation of the amorphous solid. In some cases, the amorphous solid may include calcium-crosslinked alginate and/or calcium-crosslinked pectin.

In some embodiments, the gelling agent comprises an alginate, and the alginate is present in the amorphous solid in an amount of 10-30wt% (calculated on dry weight) of the amorphous solid. In some embodiments, the alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises an alginate and at least one additional gelling agent, such as pectin.

In some embodiments, the amorphous solid may include a gelling agent comprising carrageenan.

Suitably, the amorphous solid may comprise from about 0.1wt%, 0.5wt%, 1wt%, 3wt%, 5wt%, 7wt%, or 10% to about 50wt%, 45wt%, 40wt%, 35wt%, 30wt%, or 25wt% aerosol former material (all calculated on a dry weight basis). Aerosol former materials may be used as plasticizers. For example, the amorphous solid may comprise 0.5 to 40wt%, 3 to 35wt% or 10 to 25wt% aerosol former material. In some cases, the aerosol former material comprises one or more compounds selected from the group consisting of: erythritol, propylene glycol, glycerol, glyceryl triacetate, sorbitol, and xylitol. In some cases, the aerosol former material comprises, consists essentially of, or consists of glycerin.

The amorphous solid includes a flavoring agent. Suitably, the amorphous solid may comprise up to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt% or 45wt% of flavour.

In some cases, the amorphous solid may include at least about 0.1wt%, 1wt%, 10wt%, 20wt%, 30wt%, 35wt%, or 40wt% flavoring (all on a dry weight basis).

For example, the amorphous solids may include 1-80wt%, 10-80wt%, 20-70wt%, 30-60wt%, 35-55wt%, or 30-45wt% flavoring. In some cases, the flavoring agent comprises, consists essentially of, or consists of menthol.

In some cases, the amorphous solid may additionally contain an emulsifier that emulsifies the molten flavor during the manufacturing process. For example, the amorphous solid may include from about 5wt% to about 15wt% of an emulsifier (calculated on a dry weight basis), suitably about 10wt%. The emulsifier may comprise gum arabic.

In some embodiments, the amorphous solid is a hydrogel and comprises less than about 20wt% water, calculated on a wet weight basis. In some cases, the hydrogel may comprise less than about 15wt%, 12wt%, or 10wt% water, calculated on a wet weight basis. In some cases, the hydrogel may include at least about 1wt%, 2wt%, or at least about 5Wt% Water (WWB).

In some embodiments, the amorphous solid further comprises an active substance. For example, in some cases, the amorphous solid additionally includes tobacco material and/or nicotine. In some cases, the amorphous solid may include 5-60wt% (calculated on a dry weight basis) of tobacco material and/or nicotine. In some cases, the amorphous solid may include from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt%, or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of the active material. In some cases, the amorphous solid may include from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt%, or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry basis) of tobacco material. For example, the amorphous solids may include 10wt% to 50wt%, 15wt% to 40wt%, or 20wt% to 35wt% of the tobacco material. In some cases, the amorphous solid may include from about 1wt%, 2wt%, 3wt%, or 4wt% to about 20wt%, 18wt%, 15wt%, or 12wt% (calculated on a dry weight basis) nicotine. For example, the amorphous solid may comprise 1-20wt%, 2-18wt% or 3-12wt% nicotine.

In some cases, the amorphous solid includes an active substance, such as a tobacco extract. In some cases, the amorphous solid may comprise 5-60wt% (calculated on a dry weight basis) of the tobacco extract. In some cases, the amorphous solid may include from about 5wt%, 10wt%, 15wt%, 20wt%, or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of tobacco extract. For example, the amorphous solids may include 10-50wt%, 15-40wt%, or 20-35wt% tobacco extract. The tobacco extract may contain a concentration of nicotine such that the amorphous solids comprise 1wt%, 1.5wt%, 2wt%, or 2.5wt% to about 6wt%, 5wt%, 4.5wt%, or 4wt% (calculated on a dry weight basis) nicotine.

In some cases, nicotine may not be present in the amorphous solid other than nicotine derived from the tobacco extract.

In some embodiments, the amorphous solid does not comprise tobacco material but does comprise nicotine. In some such cases, the amorphous solid may include from about 1wt%, 2wt%, 3wt%, or 4wt% to about 20wt%, 18wt%, 15wt%, or 12wt% (calculated on a dry weight basis) nicotine. For example, the amorphous solid may comprise 1-20wt%, 2-18wt% or 3-12wt% nicotine.

In some cases, the total content of actives and/or flavors may be at least about 0.1wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt%, or 30wt%. In some cases, the total content of actives and/or flavors may be less than about 90wt%, 80wt%, 70wt%, 60wt%, 50wt%, or 40wt% (all calculated on a dry weight basis).

In some cases, the total content of tobacco material, nicotine, and flavoring agent may be at least about 0.1wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt%, or 30wt%. In some cases, the total content of actives and/or flavors may be less than about 90wt%, 80wt%, 70wt%, 60wt%, 50wt%, or 40wt% (all calculated on a dry weight basis).

The amorphous solid may be made of a gel, and such a gel may additionally contain a solvent in an amount of 0.1 to 50wt%. However, inclusion of a solvent in which the flavoring agent is soluble may reduce gel stability and the flavoring agent may crystallize out of the gel. Thus, in some cases, the gel does not include a solvent in which the flavoring agent is soluble.

In some embodiments, the amorphous solid comprises less than 60wt% filler, for example 1wt% to 60wt%, or 5wt% to 50wt%, or 5wt% to 30wt%, or 10wt% to 20wt%.

In other embodiments, the amorphous solid comprises less than 20wt%, suitably less than 10wt% or less than 5wt% filler. In some cases, the amorphous solid includes less than 1wt% filler, and in some cases, no filler.

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

In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler such as wood pulp, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that including fibrous fillers in the amorphous solids may increase the tensile strength of the material.

In some embodiments, the amorphous solid does not comprise tobacco fibers.

In some embodiments, the amorphous solid in sheet form may have a tensile strength of about 200N/m to about 1500N/m. In some embodiments, for example when the amorphous solid does not contain a filler, the amorphous solid may have a tensile strength of 200N/m to 400N/m, or 200N/m to 300N/m, or about 250N/m. Such tensile strength may be particularly suitable for embodiments in which the amorphous solid material is formed into a sheet and then shredded and incorporated into an aerosol-generating article.

In some embodiments, for example when the amorphous solid includes a filler, the amorphous solid may have a tensile strength of 600N/m to 1500N/m, or 700N/m to 900N/m, or about 800N/m. Such tensile strength may be particularly suitable for embodiments in which the amorphous solid material is included in an aerosol-generating article (as a rolled sheet, suitably in the form of a tube).

In some cases, the amorphous solid may consist essentially of, or consist of, a gelling agent, water, an aerosol former material, a flavor, and optionally an active.

In some cases, the amorphous solid may consist essentially of or consist of a gelling agent, water, aerosol former material, flavor, and optionally tobacco material and/or nicotine source.

The amorphous solid may include one or more active substances and/or flavours, one or more aerosol former materials, and optionally one or more other functional materials.

The aerosol-generating material may comprise paper reconstituted tobacco material. The composition may alternatively or additionally comprise tobacco in any of the forms described herein. The aerosol-generating material may comprise a sheet comprising tobacco material comprising between 10wt% and 90wt% tobacco leaves, wherein the aerosol-former material is provided in an amount of up to about 20wt% of the sheet or shredded sheet, and the remainder of the tobacco material comprises paper reconstituted tobacco.

When the aerosol-generating material comprises an amorphous solid material, the amorphous solid material may be a dry gel comprising menthol. In alternative embodiments, the amorphous solid may have any composition as described herein.

Improved articles may be prepared that comprise an aerosol-generating material comprising a first component comprising a sheet of aerosol-generating material and a second component comprising an amorphous solid, wherein material properties (e.g., density) and specifications (e.g., thickness, length, and cut width) fall within the ranges described herein.

In some cases, the amorphous solid may have a thickness of about 0.015mm to about 1.0 mm. Suitably, the thickness may be in the range of about 0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3 mm. A material having a thickness of about 0.09mm may be used. The amorphous solid may include more than one layer, and the thicknesses described herein refer to the total thickness of those layers.

The thickness of the amorphous solid material may be measured using calipers or a microscope, such as a Scanning Electron Microscope (SEM), as known to those skilled in the art, or any other suitable technique known to those skilled in the art.

If the amorphous solid is too thick, heating efficiency may be impaired. This may adversely affect the power consumption in use, for example the power consumption of releasing flavour from an amorphous solid. Conversely, if the amorphous solids forming the aerosol are too thin, it may be difficult to manufacture and handle; very thin materials may be more difficult to cast and may be brittle, compromising aerosol formation when in use. In some cases, individual strips or sheets of amorphous solid have a minimum thickness of about 0.015 over their area. In some cases, individual strips or sheets of amorphous solid have a minimum thickness of about 0.05mm or about 0.1mm over their area. In some cases, individual strips or sheets of amorphous solid have a maximum thickness of about 1.0mm over their area. In some cases, individual strips or sheets of amorphous solid have a maximum thickness of about 0.5mm or about 0.3mm over their area.

In some cases, the amorphous solid thickness may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1% in its area.

Providing sheets of amorphous solid material and aerosol-generating material having area density values that differ from each other by less than a given percentage results in less separation in a mixture of these materials. In some embodiments, the area density of the amorphous solid material may be between 50% and 150% of the area density of the aerosol-generating material. For example, the area density of the amorphous solid material may be between 60% and 140% of the density of the aerosol-generating material, or between 70% and 110% of the area density of the aerosol-generating material, or between 80% and 120% of the area density of the aerosol-generating material.

In embodiments described herein, the amorphous solid material may be incorporated into the article in sheet form. The amorphous solid material in sheet form may be shredded and then incorporated into an article, suitably mixed with an aerosol-generating material (e.g., a sheet of aerosol-generating material as described herein).

In further embodiments, the amorphous solid sheet may be additionally bonded as a planar sheet, as an aggregated or bunched sheet, as a coiled sheet, or as a rolled sheet (i.e., in the form of a tube). In some such cases, the amorphous solids of these embodiments may be included in an aerosol-generating article as a sheet, such as a sheet surrounding a rod comprising an aerosol-generating material. For example, the amorphous solid sheet may be formed on a wrapper surrounding an aerosol-generating material such as tobacco.

The amorphous solid in sheet form may have any suitable areal density, for example about 30g/m ² To about 150g/m ² . In some cases, the sheet may have about 55g/m ² To about 135g/m ² Or about 80 to about 120g/m ² Or about 70 to about 110g/m ² Or specifically about 90 to about 110g/m ² Or suitably about 100g/m ² Is a mass per unit area. These ranges may provide a density similar to that of cut tobacco (cut rag tobacco) and may thus provide a mixture of these substances that will not readily separate. Such area densities may be particularly suitable when amorphous solid materials are included as shredded sheets in aerosol-generating articles (described further below). In some cases, the sheet may have a weight of about 30 to 70g/m ² 40 to 60g/m ² Or 25 to 60g/m ² And may be used to encapsulate an aerosol-generating material, such as the aerosol-generating materials described herein.

The aerosol-generating material may comprise a blend of an aerosol-generating material as described herein and an amorphous solid material. Such an aerosol-generating material may provide an aerosol with a desired flavour profile in use, as additional flavour may be incorporated into the aerosol-generating material by inclusion in the amorphous solid material component. The flavoring provided in the amorphous solid material may be more stably retained within the amorphous solid material than the flavoring added directly to the tobacco material, resulting in a more consistent flavor profile between articles produced according to the present disclosure.

As noted above, it is advantageously found that tobacco materials having a density of at least 350mg/cc and less than about 900mg/cc, preferably between about 600mg/cc and about 900mg/cc, result in a more sustained release of the aerosol. In order to provide an aerosol with a consistent flavour profile, the amorphous solid material component of the aerosol-generating material should be evenly distributed throughout the rod. This may be achieved by casting the amorphous solid material to have a thickness as described herein to provide an amorphous solid material having an area density similar to that of the tobacco material, and processing the amorphous solid material as described below to ensure uniform distribution throughout the aerosol-generating material.

As mentioned above, optionally the aerosol-generating material comprises a plurality of amorphous solid material strips. When the aerosol-generating section comprises a plurality of strands and/or ribbons of aerosol-generating material sheet and a plurality of amorphous solid material ribbons, the material properties and/or dimensions of the at least two components may be otherwise suitably selected to ensure that relatively uniform mixing of the components is possible and to reduce separation or unmixement of the components during or after manufacture of the rod of aerosol-generating material.

The longitudinal dimension of the plurality of strands or strips may be substantially the same as the length of the aerosol-generating section. The plurality of strands and/or strips may have a length of at least about 5 mm.

The various embodiments described herein are provided solely to aid in the understanding and teaching of the claimed features. These embodiments are provided as representative examples of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that the advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be used and 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 the appropriate combination of the elements, components, features, parts, steps, means, etc. disclosed, in addition to those specifically described herein. Furthermore, the present disclosure may include other inventions not presently claimed but which may be claimed in the future.

Claims

1. A component for use in a non-combustible sol supply system, the component comprising at least one helically wound rod containing aerosol generating material.

2. The component of claim 1, further comprising a cavity extending from the first end of the component.

3. The component of claim 2, wherein the at least one helically wound strip has a width that is at least 1.5 times the inner diameter of the cavity, or at least 2 times the inner diameter of the cavity, or at least 3 times the inner diameter of the cavity, or at least 4 times the inner diameter of the cavity.

4. A component according to any one of claims 1 to 3, wherein the component has a longitudinal axis and the long edge of the helically wound strip protruding onto the axis forms an angle with the axis of less than about 70 degrees, such as less than about 60 degrees or less than about 50 degrees.

5. A component for use in a non-combustible sol supply system, the component comprising a plurality of braided or spiral wound strips, at least one of the plurality of braided and/or spiral wound strips comprising an aerosol-generating material, the component further comprising a cavity extending from a first end of the component.

6. The component of claim 5, wherein at least one of the plurality of braided or spirally wound strips has a width that is at least 1.5 times an inner diameter of the cavity, or at least 2 times an inner diameter of the cavity, or at least 3 times an inner diameter of the cavity, or at least 4 times an inner diameter of the cavity.

7. The component of claim 5 or 6, wherein the component has a longitudinal axis and an edge of at least one of the plurality of braid or spiral wound strips protruding onto the longitudinal axis forms an angle with the axis of less than about 70 degrees, such as less than about 60 degrees or less than about 50 degrees.

8. A component according to any one of claims 5 to 7, wherein the aerosol-generating material comprises a plant-based material, such as a tobacco material and/or an amorphous solid material.

9. A component according to any one of claims 5 to 8, wherein the aerosol-generating material is laminated to a support material.

10. A component according to any one of claims 5 to 9, wherein at least one woven and/or spiral wound strip comprises a first aerosol-generating material and the component further comprises at least one woven and/or spiral wound strip comprising a second aerosol-generating material.

11. A component according to claim 10, wherein the at least one woven and/or spirally wound strip comprising the first aerosol-generating material is arranged closer to the cavity than the at least one woven and/or spirally wound strip comprising the second aerosol-generating material.

12. The component of any of claims 5 to 11, wherein the diameter of the cavity has a manufacturing tolerance of less than 0.5mm, or less than 0.4mm, or less than 0.3mm.

13. The component of any one of claims 5 to 12, wherein the cavity is surrounded by a hollow tube and the braiding and/or spirally wound strips are arranged around the hollow tube.

14. The component of any one of claims 1 to 13, wherein at least one of the braided and/or spirally wound strips comprises a spacer material, wherein the spacer material has a ridge-like structure and/or a corrugated structure.

15. A component according to claim 14, wherein the spacer material is arranged around at least one of a braided and/or spiral wound strip comprising aerosol generating material, optionally wherein the arrangement of spacer material provides an airflow path through the component.

16. The component of any one of claims 1 to 15, wherein at least one of the braided and/or spirally wound strips comprises a gluing surface, optionally wherein the gluing surface connects other braided and/or spirally wound strips in the component.

17. The component of claim 16, wherein the bonding surface comprises an adhesive or binder, optionally wherein the adhesive or binder is selected from a starch-based adhesive or binder, a gum-based adhesive or binder, a polysaccharide-based adhesive or binder, or a carboxymethyl cellulose-based adhesive or binder.

18. The component of any one of claims 1 to 17, wherein at least one of the braided strips and/or the spirally wound strips is arranged in a left-hand spiral pattern, and wherein at least one of the plurality of braided strips is arranged in a right-hand spiral pattern.

19. The component of any one of claims 1 to 18, wherein at least one of the braided and/or spirally wound strips comprises a tensile strength of at least 4N/15mm, or wherein each of the braided and/or spirally wound strips comprises a tensile strength of at least 4N/15 mm.

20. An article for use in a non-combustible sol supply system, the article comprising a component according to any one of claims 1 to 19 and a downstream portion downstream of the component.

21. A non-combustible aerosol provision system comprising an article according to claim 20 and an aerosol provision device for forming an aerosol from an aerosol-generating material.

22. A method of forming a component according to any one of claims 1 to 19, comprising the steps of:

feeding the strip of material towards a mandrel; and

the strip of material is wound around the mandrel to form a helically wound strip comprising aerosol-generating material.

23. The method of claim 22, further comprising the step of: providing a source of spacer material; and winding the spacer material around the mandrel to provide a layer of spacer material in the component.

24. The method of claim 22 or 23, wherein the width of the strip of material is at least a multiple of the mandrel diameter, or at least 2 times the mandrel diameter, or at least 3 times the mandrel diameter, or at least 4 times the mandrel inner diameter.

25. The method of claim 22 or 23, further comprising disposing a tube on the mandrel, and wherein the winding step comprises winding the strip of material around the tube.

26. A method according to any one of claims 22 to 25, wherein the strip of material comprising aerosol-generating material is a first strip of material, and the method comprises: providing a source of a second strip of material;

feeding the second strip of material towards a mandrel; and

the second strip of material is wound around the mandrel to form a second helically wound strip.

27. The method of claim 26, wherein the step of winding the first strip of material is performed in a first direction, and wherein the step of winding the second strip of material is performed in a second direction, the winding step forming a spiral pattern of the first strip of material and the second strip of material, the spiral pattern comprising at least one left-hand spiral and at least one right-hand spiral.