KR20240015715A - Components for use in non-flammable aerosol delivery systems - Google Patents

Abstract

Components for use in non-flammable aerosol delivery systems. The component includes at least one spirally wound strip containing an aerosol-generating material. Articles, systems and methods for forming components are also described.

Description

Components for use in non-flammable aerosol delivery systems

The present invention provides components for use in a non-combustible aerosol provision system, articles for use in a non-combustible aerosol provision system, aerosol delivery systems, and uses in a non-combustible aerosol provision system. It is about how to form components for

Certain tobacco industry products produce aerosols that are inhaled by the user during use. For example, tobacco heating devices heat an aerosol generating substrate, such as a cigarette, to form an aerosol by heating the substrate without burning it. Such tobacco industry products typically include mouthpieces that pass the aerosol to reach the user's mouth.

According to embodiments described herein, in a first aspect, a component for use in a non-flammable aerosol delivery system is provided, the component comprising at least one spirally wound strip comprising an aerosol generating material. .

According to embodiments described herein, in a second aspect, a component for use in a non-flammable aerosol delivery system is provided, the component comprising a plurality of braids or spirally wound strips, the plurality of braids and /or at least one of the helically wound strips comprises an aerosol-generating material, and the component further comprises 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-flammable aerosol delivery device, the article comprising a component according to the first or second aspect above.

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

According to embodiments described herein, in a fifth aspect, a method of forming a component according to the first or second aspect is provided, the method comprising:

providing a source of strip material comprising aerosol generating material;

feeding the strip material toward a mandrel; and

and winding the strip material around the mandrel to form a spirally wound strip comprising the aerosol generating material.

Embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings:
1A is a side cross-sectional view of an article for use in a non-flammable aerosol delivery system, the article comprising a component having at least one spirally wound strip containing an aerosol generating material. Aerosol delivery devices are also illustrated, wherein the article and device form a system;
Figure 1B is a side view of the component of Figure 1A;
Figure 2A is a cross-sectional side view of an article for use in a non-flammable aerosol delivery system, the article comprising a component having a plurality of braided or spirally wound strips. Aerosol delivery devices are also illustrated, wherein the article and device form a system;
Figure 2B is a side view of the component of Figure 2A;
Figures 3a and 3b illustrate individual machine arrangements for forming the components of Figures 1b and 2b, respectively;
4 is a flow diagram illustrating a method of forming a component as described herein.

As used herein, the term “delivery system” is intended to include systems that deliver at least one substance to a user and includes:

Cigarettes, cigars (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable materials) Combustible aerosol delivery systems such as cigarettes, cigars, and tobacco for pipes or roll-your-own (ROY) or make-your-own (MYO) cigarettes. provision systems;

from aerosol-generating materials without burning them, such as electronic cigarettes, tobacco heating products, and hybrid systems that generate aerosols using a combination of aerosol-generating materials. non-combustible aerosol provision systems that release compounds; and

Oral products such as lozenges, gums, patches, articles containing inhalable powders, and oral tobacco, including snus or moist snuff. Products that deliver at least one substance, which may or may not contain nicotine, orally, nasally, transdermally or otherwise, without forming an aerosol to a user, including but not limited to products for use. Aerosol-free delivery systems.

According to the present disclosure, a “non-flammable” aerosol delivery system is one in which the aerosol-generating materials of the aerosol delivery system (or components thereof) do not combust or burn to facilitate delivery of at least one substance to a user.

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

In some embodiments, the non-flammable aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although the presence of nicotine in the aerosol generating material is not required. It is noteworthy that this is not the case.

In some embodiments, the non-flammable aerosol delivery system is an aerosol generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

In some embodiments, the non-flammable aerosol delivery system is a hybrid system for generating an aerosol using a combination of aerosol-generating materials, one or more of the aerosol-generating materials can be heated. Each of the aerosol-generating materials may be in the form of a solid, liquid or gel, for example, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. Solid aerosol-generating materials may include plant-based materials, such as tobacco or non-tobacco products.

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

In some embodiments, the present disclosure relates to consumables that include an aerosol generating material and are configured for use with a non-flammable aerosol presentation device. These supplies are sometimes also referred to as articles throughout this disclosure.

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

In some embodiments, a non-flammable aerosol delivery system, such as a non-flammable aerosol delivery device thereof, can include a power source and a controller. The power source may be, for example, an electric power source or a thermal power source. In some embodiments, the exothermic power source includes a carbon substrate that can be energized to distribute power in the form of heat to an aerosol generating material or heat transfer material proximate to the exothermic power source.

In some embodiments, the non-flammable aerosol delivery system includes a region for receiving consumables, an aerosol generator, an aerosol generation region, a housing, a mouthpiece, a filter, and/or an aerosol modifier. (aerosol-modifying agent).

In some embodiments, consumables for use with a non-flammable aerosol delivery device include aerosol-generating material, an aerosol-generating material storage region, an aerosol-generating material transport component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, and a filter. , a mouthpiece and/or an aerosol modifier.

In some embodiments, the consumable includes the material to be delivered. The material to be delivered may be an aerosol-generating material, or a material not intended to be aerosolized. Where appropriate, any one material may contain one or more active constituents, one or more flavors, one or more aerosol-former materials, and/or one or more other functional ingredients. It can be included.

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

As used herein, an active agent may be a physiologically active agent, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from nutraceuticals, nootropics, psychoactives, for example. The active substances may occur naturally or be obtained synthetically. The active substances are for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids. , or their components, derivatives, or combinations. The active substance may include one or more components, derivatives or extracts of tobacco, cannabis or other botanicals.

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

As mentioned herein, the active substance may comprise or be derived from one or more herbal medicines or their constituents, derivatives or extracts. As used herein, the term "botanical" means extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husk. , shells, etc., but are not limited to any material derived from plants. Alternatively, the material may contain active compounds naturally present in plant herbal medicines, obtained synthetically. This material can be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, etc. It can be. Exemplary botanicals include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint ( spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, laurel, licorice, matcha. , mate, orange peel, papaya, rose, sage, tea such as green or black tea, thyme, clove, cinnamon, coffee, aniseed. (anise, basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary) , saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant. , curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian. ), pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi ( carvi), verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana (damiana), guarana, chlorophyll, baobab, or any combination thereof. Mint can be selected from the following mint varieties: Mentha Arvensis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata. Mentha piperita citrata c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

In some embodiments, the active agent comprises or is derived from one or more herbal medicines, or components, derivatives or extracts thereof, and the herbal medicine is tobacco.

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

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

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

As used herein, the terms “flavour” and “flavourant” mean any substance that produces a desired taste, aroma or other somatosensory sensation in a product for adult consumers, where local regulations permit. Refers to materials that can be used to These include natural flavoring ingredients, herbal medicines, herbal extracts, synthetically obtained ingredients or combinations thereof (e.g. tobacco, cannabis, licorice, hydrangea, eugenol). ), Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint. mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen ( wintergreen, cherry, berry, redberry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit , papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon. , scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, caramel cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, Betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom ), cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi (wasabi), allspice, ginger, coriander, coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemon. Lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, laurel, mate, orange peel, rose, tea such as green or black tea, thyme (thyme), juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel. (lemon peel), mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitterness receptor site blockers, sensory receptor site activators Activators or stimulators, sugars and/or sugar substitutes (e.g. sucralose, acesulfame potassium, aspartame, saccharine, cyclamate) (lactose, sucrose, glucose, fructose, sorbitol or mannitol), and charcoal, chlorophyll, minerals, herbal medicines or Other additives such as breath freshening agents may be included. These may be man-made, synthetic or natural ingredients or blends thereof. They may be in any suitable form, liquid such as oil, solid such as powder, or gas.

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

In some embodiments, flavor is a sensation intended to achieve a somatosensory sensation that is typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves. They may contain sensates, and they may contain agents that provide a heating, cooling, tingling, or numbing effect. A suitable thermogenic agent may be, but is not limited to, vanillyl ethyl ether, and a suitable thermogenic agent may be, but not limited to, eucalyptol, 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. Aerosol-generating materials may be in the form of solids, liquids or gels, which may or may not contain active substances and/or flavoring agents. Aerosol generating materials can be incorporated into articles for use in aerosol generating systems.

As used herein, the term “tobacco material” refers to any material including tobacco, or derivatives or substitutes thereof. 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, and tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, regenerated tobacco, and/or tobacco extract. You can.

A consumable is an article that contains or consists of an aerosol-generating material that is intended to be partially or fully consumed during use by a user. The consumable may include one or more other components, such as an aerosol-generating material storage area, aerosol-generating material transport components, an aerosol-generating area, a housing, wrapper, mouthpiece, filter, and/or aerosol modifier. The consumable may also include an aerosol generator, such as a heater, which emits heat to cause the aerosol generating material to generate an aerosol upon use. The heater may comprise, for example, a combustible material, a material that can be heated by electrical conduction, or a susceptor.

A susceptor is a material that can be heated by penetration by a variable magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material such that penetration by a variable magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, such that penetration by a variable magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. A device configured to generate a variable magnetic field is referred to herein as a magnetic field generator.

Aerosol modifiers are substances that are typically located downstream of the aerosol generating area and are configured to modify the resulting aerosol, for example by changing the taste, flavor, acidity or other properties of the aerosol. The aerosol modifier may be provided to an aerosol modifier release component operable to selectively release the aerosol modifier.

Aerosol modifiers may be, for example, additives or adsorbents. Aerosol modifiers may include, for example, one or more of flavorants, colorants, water, and carbon adsorbents. Aerosol modifiers may be solid, liquid or gel, for example. Aerosol modifiers may be in powder, thread or granular form. Aerosol modifiers may be devoid of filtration 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 apply thermal energy to the aerosol-generating material to release one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from an aerosol generating material without heating. For example, an aerosol generator may be configured to apply one or more of vibration, increased pressure, or electrostatic energy to the aerosol generating material.

The filamentary tow material described herein may include cellulose acetate fiber tow. Filament tows also include polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), and poly(1-4 butanediol succinate). ); PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials and polysaccharide polymers, or combinations thereof The same can be formed using different materials used to form fibers. The filament tow may be plasticized with a plasticizer suitable for the tow, such as triacetin, where the material is a cellulose acetate tow, or the tow may be unplasticized. Tows may be fibers having a 'Y' shape or other cross-section, such as an ' It may have any suitable specification, for example total denier values from 10,000 to 40,000.

1A is a side cross-sectional view of an article 1a for use in a non-flammable aerosol delivery system, the article 1a comprising at least one helically-wound strip 3c comprising an aerosol-generating material. It includes a component (3) having. Figure 1A also schematically illustrates the aerosol presentation device 100.

The article 1a comprises a mouthpiece 2 and a component 3 connected to the mouthpiece 2 and also referred to as an aerosol generating section 3. In this example, the aerosol generating section 3 comprises a recess or cavity 3a extending into the component 3. In this example, 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 shown by the dashed line X-X'.

The recess or cavity 3a is formed by a hollow tube 3b. The hollow tube 3b is formed by a plurality of paper layers wound in parallel with butt seams. The helically wound strip 3c is wrapped around the hollow tube 3b, and in this example is glued to the tube 3b. In alternative examples, the hollow tube can be formed in other ways, such as spirally or helically wound paper layers (e.g., those described herein), cardboard tubes, molded pulp. tubes formed using a pulp or molded fiber type process, molded or extruded plastic tubes, or the like. The hollow tube 3b is manufactured to have sufficient rigidity to withstand axial compressive forces and bending moments that may occur during manufacturing and while the article 1a is in use. Manufacturing tolerances of the diameter of the cavity may be less than the tolerances typically associated with aerosol generating materials, for example less than 0.5 mm, or less than 0.4 mm, or less than 0.3 mm.

The aerosol generating material forming the spirally wound strip 3c in this example is a strip formed from recycled tobacco sheet material. In other examples, the spirally wound strip 3c may be a tobacco-free sheet material, an amorphous solid sheet material, a gelled sheet material, or a material having a layer thereon. It may be formed from other materials such as deposited paper materials. The helically wound strip 3c may be formed from a sheet material comprising an aerosol modifier, such as a flavoring agent, as defined herein. The aerosol-generating material may be laminated on a support material, for example, a support material formed of metal foil such as aluminum foil, paper, polylactide (PLA) material, starch-based sheet materials, etc. You can.

The helically wound strip may have a tensile strength of at least 4 N/15 mm. This can ensure that the strip 3c has sufficient tensile strength during the winding process used to wind the strip 3c around the tube 3b.

In this example, the recess or cavity 3a extends completely through the component 3. However, in other examples, recess or cavity 3a may extend only partially through component 3. The length of the recess or cavity 3a along the longitudinal axis may be shorter than the length of the component 3 along the longitudinal axis.

Device 100 includes a housing 101 and an area 102 for receiving an article 1a. Region 102 comprises an aerosol-generating element 103, in this case a heatable element, which generates an aerosol from the aerosol-generating material of the article 1a. 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 of the aerosol providing device 100 such that the aerosol generating element 103 enters the recess or cavity 3a. The article 1a is consumed by drawing mainstream aerosol through the downstream portion 2 of the article 1a, in this case the mouthpiece 2. Once the smoking session is complete, the aerosol-generating element 103 is removed from the aerosol-generating material 3.

In this example, component 3 has a circumference of approximately 22.7 mm. In alternative embodiments, component 3 may have any suitable circumference, for example from about 20 mm to about 26 mm.

Component 3 has a length of, for example, about 5 mm to about 20 mm, or about 8 mm to 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 with a length of 12 mm, the recess 3a may extend more than 9 mm into the body.

The maximum diameter of the recess or cavity 3a may be greater than 10%, or greater than 15%, or greater 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 component 3, for example between 10% and 40% of the diameter of component 3, or It may be 15% to 30% of the diameter of element 3.

The aerosol-generating material in any of the embodiments described herein may include the aerosol-generating material in sheet form, extruded form, or molded form. Aerosol-generating materials may include, for example, plant-based materials that are extruded and/or molded to form strips 3c. Extruded or molded cigarettes can be produced by the process described in International Patent Publication No. WO 2020/148538, the contents of which are incorporated herein by reference.

The recess or cavity 3a of the component 3 is at least filled with a second aerosol-generating material, which in the present case is referred to as the first aerosol-generating material, which may be the same or different from the aerosol-generating material forming the strip 3c. Can be partially charged.

In this example, a helically wound strip 3c is wound around the hollow tube 3b such that a gap 3d is provided between the edges of the strip 3c. This gap 3d creates a path through component 3, maximizing air flow across the surface of strip 3c for a given strip length, and thus exposing the air to the aerosol-generating materials contained in the strip. Let it happen. Optionally, the helically wound strip 3c may be the first of the two strips, with the second helically wound strip (not shown) also having a gap between the edges of the second strip. 1 can be wound around the spirally wound strip 3c. The second helically wound strip may lie at least partially on the first helically wound strip 3c and may lie over the entire width of the gap. This may allow air flow in the gap formed by the edges of the first strip 3c and the inner surface of the second strip. The size of the gap may range from about 0.5 mm to about 10 mm, or from about 1 mm to about 5 mm, between the edges of the first and/or second strip 3c. In other examples, the helically wound strip 3c may be tightly wound such that no gaps 3d exist, increasing the amount of strip material provided for a given length of the component. In other words, the helically wound strip 3c in this case may be the first of the two strips, and the second helically wound strip (not shown) is the first helically wound strip 3c. It can be wound around, tightly wound so that no gap exists, as described above, or wound with a gap.

The component 3 has a longitudinal axis Z-Z', when viewed laterally with respect to the longitudinal axis as shown in Figure 1b, the long edge of the helically wound strip, when projected onto the longitudinal axis of the component, constitutes Forms two angles with the longitudinal axis of the element. One of the angles is greater than 90 degrees and the other is less than 90 degrees. In some examples, the angle between the long edge of the helically wound strip and the longitudinal axis is less than 90 degrees, such as less than about 70 degrees, for example, less than about 60 degrees, or less than about 50 degrees.

Figure 3a illustrates a machine arrangement for forming component 3 of Figure 1b. A section of the hollow tube (3b) is rotated and fed/pulled in the direction of the arrow (X) along the mandrel (16). The hollow tube 3b may be formed, for example, of helically or spirally wound paper forming a core, which may be pre-formed or formed immediately prior to wrapping the core with strip material 14. there is. A source of first strip material 14 is provided, in this example comprising aerosol generating material. The first strip of material 14 is wound around the tube 3b as the tube 3b is rotated and moved forward. The first strip material 14 forms first helically wound strips 3c around the tube 3b. An optional second strip of material 15 is provided, in this case used to adhere the first strip of material 14 to the tube 3b. For example, the second strip material 15 is dipped into a reservoir of adhesive before reaching the hollow tube 3b and then bonded to the tube 3b and the first strip material 14 is bonded to the tube 3b. It may be a paper material used for The second strip material 15 forms second helically wound strips 3c around the tube 3b.

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

A continuous rod is formed using a machine arrangement and a cutting arrangement 17 is provided for cutting the continuously formed rod into individual components 3 or groups of components 3 . The cutting arrangement comprises a plurality of blades, for example spinning circular blades, spaced longitudinally along the transport path of the rod. The cutting arrangement may be arranged to reciprocate along a path parallel to the transport path of the rod and cut the rod while moving in the same direction as the rod. For example, the cutting arrangement may be arranged to move with the rod at the same speed as the rod and cut the rod into segments while moving at the same speed as the rod. This can help 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, positioned immediately downstream and adjacent to the source of aerosol-generating material (3). In this example, the cooling section 8 is in abutting relationship with the source of aerosol-generating material. The mouthpiece 2 also comprises in this example 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 mouth end of the article 1 .

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

The cooling section 8 may have a radial wall thickness, which can be measured using, for example, a calliper. The wall thickness of the cooling section (8) for a given outer diameter of the cooling section defines the inner diameter of the cavity surrounded by the walls of the cooling section (8). Cooling section 8 may have a wall thickness of at least about 1.5 mm and up to about 2 mm. In this example, the cooling section 8 has a wall thickness of approximately 2 mm. Providing a cooling section (8) with a wall thickness within this range reduces the longitudinal displacement of the strands and/or strips of aerosol-generating material when the aerosol-generating device is inserted into the article, thereby reducing the Improves retention of sources of aerosol-generating materials.

The cooling section 8 is formed from a filament tow. A plurality of paper layers, cardboard tubes, paper layers wound in parallel, with butt seams or spirally wound to form the cooling section 8, using a papier-mache type process. Other configurations may be used, such as formed tubes, molded or extruded plastic tubes, or the like. Cooling section 8 is manufactured with sufficient rigidity to withstand axial compressive forces and bending moments that may occur during manufacturing and while the article 1 is in use.

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

In some embodiments, the density of the material forming cooling section 8 is greater than or equal to about 0.20 grams per cubic centimeter (g/cc), greater than or equal to about 0.25 g/cc, and is less than about 0.80 grams per cubic centimeter (g/cc), and more preferably less than 0.6 g/cc. In some embodiments, the density of the material forming cooling section 8 is 0.20 to 0.8 g/cc, more preferably 0.3 to 0.6 g/cc, or 0.4 g/cc to 0.6 g/cc or about 0.5 g. It is /cc. These densities have been found to provide a good balance between minimizing the overall weight of the article and the improved rigidity provided by a more dense material. For the purposes of the present invention, the “density” of the material forming the cooling section 8 refers to the density of the filament tows forming the element in which any plasticizer is incorporated. The density can 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, the total volume being the total volume of the cooling section 8 obtained using, for example, calipers. ) can be calculated using appropriate measurements of the material from which it is formed. If necessary, appropriate dimensions can be measured using a microscope.

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

The cooling section (8) is located around and defines an air gap in the mouthpiece (2), which serves as a cooling section. The air gap provides a chamber for flowing heated volatilized components generated by the load 3 of aerosol generating material. The cooling section 8 is hollow to provide a chamber for aerosol accumulation, but has sufficient rigidity to withstand axial compressive forces and bending moments that may occur during manufacturing and while the article 1 is in use. The cooling section (8) provides physical displacement between the aerosol-generating material (3) and the material body (6). The physical displacement provided by cooling section 8 may provide a thermal gradient over the length of cooling section 8.

Preferably, the mouthpiece 2 comprises a cavity with an internal volume greater than 110 mm3. It has been found that providing cavities above this volume allows for improved aerosol formation. More preferably, the mouthpiece 2 comprises a cavity formed for example within the cooling section 8 and having an internal volume of greater than 120 mm3, even more preferably greater than 130 mm3, to further enhance the aerosol. You can do it. In some examples, the internal cavity includes a volume of about 130 mm3 to about 230 mm3, for example about 134 mm3 or 227 mm3.

The cooling section (8) is configured to provide a temperature difference of at least 40° C. 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). It can be configured. Preferably, the cooling section (8) has a temperature of at least 60° C. between the heat-volatilized component entering the first upstream end of the cooling section (8) and the heat-volatilized component exiting the second downstream end of the cooling section (8). , preferably 80°C or higher, more preferably 100°C or higher. This temperature difference over the length of the cooling section 8 protects the temperature-sensitive material body 6 from the high temperatures of the aerosol-generating material 3 when the aerosol-generating material 3 is heated.

When in use, the aerosol generating section can exhibit a pressure drop of about 15 to about 40 mmH ₂ O. In some embodiments, the aerosol generating section exhibits a pressure drop across the aerosol generating section of about 15 to about 30 mmH ₂ O.

The aerosol-generating material can have a packing density within the aerosol-generating section of about 400 mg/cm3 to about 900 mg/cm3.

In this embodiment, a moisture impermeable wrapper 10 surrounds the rod of aerosol generating material and includes aluminum foil. In other embodiments, wrapper 10 includes a paper wrapper that optionally includes a barrier coating to render the material of the wrapper substantially impermeable to moisture. Aluminum foil has been found to be particularly effective in enhancing the formation of aerosols in aerosol-generating materials (3). In this example, the aluminum foil has a metal layer with a thickness of approximately 6 μm. In this example, the aluminum foil has a paper backing. However, in alternative arrangements, the aluminum foil may be of other thicknesses, for example between 4 μm and 16 μm. Aluminum foil also need not have a paper backing, but may have a backing formed of other materials, for example to help provide appropriate tensile strength to the foil, 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 can provide a wrapper with adequate structural integrity and heat transfer properties.

In this example, the moisture impermeable wrapper is also substantially impermeable to air. In alternative embodiments, the wrapper preferably has a permeability of less than 100 Coresta Units, more preferably less than 60 Coresta Units. Low permeability wrappers, for example having a permeability of less than 100 Coresta Units, more preferably less than 60 Coresta Units, have been found to improve aerosol formation in the aerosol generating material (3). The permeability of the wrapper 10 can be measured according to ISO 2965:2009 on determination of the air permeability of materials used as cigarette papers, filter plug wrap and filter bonding paper.

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

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

In this example, the material body 6 is formed from filament tow. In this example, the tow used for the material body 6 has a denier per filament (d.p.f.) of 5 and a total denier of 25,000. In this example, the tow includes plasticized cellulose acetate tow. Plasticizers used in tow make up about 9% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, different materials may be used to form the material body 6. For example, instead of a tow, the body 6 could be formed of paper, for example in a similar way to the paper filters known to be used in cigarettes. For example, paper or other cellulose-based material may be provided as one or more portions of sheet material that are folded and/or crimped to form body 6. The sheet material may have a basis weight of 15 gsm to 60 gsm, for example 20 to 50 gsm. For example, the sheet material can have a basis weight in any of the following ranges: 15 to 25 gsm, 25 to 30 gsm, 30 to 40 gsm, 40 to 45 gsm, and 45 to 50 gsm. Additionally or alternatively, the sheet material may have a width of 50 mm to 200 mm, such as 60 mm to 150 mm, or 80 mm to 150 mm. For example, the sheet material may have a basis weight of 20 to 50 gsm and a width of 80 mm to 150 mm. This can, for example, allow cellulose-based bodies to have appropriate pressure drops for articles having dimensions as described herein.

Alternatively, body 6 may be formed from tows other than cellulose acetate, such as polylactic acid (PLA), other materials described herein for filament tow, or similar materials. 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, to achieve a sufficiently uniform body of material 6, the tow is 12 d.p.f. or less, preferably 11 d.p.f. or less, even more preferably 10 d.p.f. It has a denier per filament below.

The total denier of the tow forming the material body 6 is preferably at most 30,000, more preferably at most 28,000 and even more preferably at most 25,000. These total denier values provide a toe that occupies a reduced proportion of the cross-sectional area of the mouthpiece 2, which results in a lower pressure drop across the mouthpiece 2 than toes with higher total denier values. For adequate rigidity of the material body 6, the tow preferably has a total denier of at least 8,000, more preferably at least 10,000. Preferably, the denier per filament is 5 to 12, while the total denier is 10,000 to 25,000. Preferably, the cross-sectional shape of the filaments of the tow is 'Y' shaped, but in other embodiments the same d.p.f. as provided herein may be used. and 'X' shaped filaments with total denier values may be used.

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

As shown in Figure 1A, the mouthpiece 2 of the article 1a has an upstream end 2a adjacent the rod 3 of aerosol-generating material, and a downstream end away from the rod 3 of aerosol-generating material. Includes 2b). At the downstream end 2b, the mouthpiece 2 has a hollow tubular element 4 formed from a filament tow. This has been found to advantageously significantly lower the temperature of the outer surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece, which is in contact with the consumer's mouth when the article 1 is in use. It has also been found that the use of the tubular element 4 significantly lowers the temperature of the external surface of the mouthpiece 2 even upstream of the tubular element 4 . Without wishing to be bound by theory, this is believed to be because the tubular element 4 channels the aerosol closer to the center of the mouthpiece 2 and thus reduces heat transfer from the aerosol to the outer surface of the mouthpiece 2. do.

The “wall thickness” of the hollow tubular element 4 corresponds to the thickness of the radial tube 4 wall. This can be measured, for example using a caliper. The wall thickness is advantageously greater than 0.9 mm, more preferably greater than or equal to 1.0 mm. Preferably, the wall thickness is substantially constant around the entire wall of the hollow tubular element 4. However, if the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9 mm, more preferably greater than or equal to 1.0 mm, at any point around the hollow tubular element 4. In this example, the wall thickness of the hollow tubular element 4 is approximately 1.3 mm.

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

Preferably, the density of the hollow tubular element 4 is at least about 0.25 grams per cubic centimeter (g/cc), more preferably at least about 0.3 g/cc. Preferably, the density of the hollow tubular element 4 is less than about 0.75 grams per cubic centimeter (g/cc), more preferably less than 0.6 g/cc. In some embodiments, the density of hollow tubular element 4 is 0.25 to 0.75 g/cc, more preferably 0.3 to 0.6 g/cc, more preferably 0.4 g/cc to 0.6 g/cc or about 0.5 g. It is /cc. These densities have been found to provide a good balance between the improved robustness provided by denser materials and the lower heat transfer properties of lower density materials. For the purposes of the present invention, “density” of the hollow tubular element 4 refers to the density of the filament tows forming the element with any plasticizer incorporated. The density can be determined by dividing the total weight of the hollow tubular element 4 by the total volume of the hollow tubular element 4, where the total volume is determined by taking appropriate measurements of the hollow tubular element 4, for example obtained using calipers. It can be calculated using If necessary, appropriate dimensions can be measured using a microscope.

The filament tows forming the hollow tubular element 4 preferably have a total denier of less than 45,000, more preferably less than 42,000. It has been found that this total denier allows the formation of tubular elements 4 that are not too dense. Preferably, the total denier is 20,000 or more, more preferably 25,000 or more. In preferred embodiments, the filament tow forming the hollow tubular element 4 has a total denier of 25,000 to 45,000, more preferably 35,000 to 45,000. Preferably, the cross-sectional shape of the filaments of the tow is 'Y' shaped, although other shapes such as 'X' shaped filaments may be used in other embodiments.

The filament tow forming the hollow tubular element 4 preferably has a denier per filament greater than 3. The denier per filament was found to allow the formation of tubular elements (4) that were not too dense. Preferably, the denier per filament is at least 4, more preferably at least 5. In preferred embodiments, the filament tow forming the hollow tubular element 4 has a denier per filament of 4 to 10, more preferably 4 to 9. In one example, the filament tow forming the hollow tubular element 4 has a 7.3Y36,000 tow formed from cellulose acetate and containing 18% of a plasticizer, such as triacetin.

The hollow tubular element 4 preferably has an inner diameter greater than 3.0 mm. Smaller diameters may increase the velocity of the aerosol passing through the mouthpiece 2 to the consumer's mouth more than desired, causing the aerosol to become too warm, reaching temperatures, for example, above 40°C or above 45°C. You can. More preferably, the hollow tubular element 4 has an inner diameter greater than 3.1 mm, even more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the internal diameter of the hollow tubular element 4 is about 4.7 mm.

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

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

A tipping paper (5) is wrapped around the entire length of the mouthpiece (2) and, in this example, over the entire length of the rod (3) of aerosol-generating material, connecting the mouthpiece (2) and the rod (3). It has adhesive on its inner surface. In this example, a rod (3) of aerosol-generating material is wrapped with a wrapper (10) forming a first wrapping material, and a tipping paper (5) of aerosol-generating material connects the mouthpiece (2) and the rod (3). forming an outer wrapping material that extends at least partially over the rod 3 of. In some examples, the tipping paper may only extend partially over the load of aerosol generating material.

The tipping paper (5) may extend by 5 mm above the rod of aerosol-generating material (3), or alternatively, to provide a secure attachment between the mouthpiece (2) and the rod (3). ) may extend upward by 3 mm to 10 mm, more preferably by 4 mm to 6 mm. The tipping paper may have a basis weight of greater than 20 gsm, such as greater than 25 gsm, or preferably greater than 30 gsm, such as 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% of the aerosol drawn through the article, for example 1% to 12%. These levels of ventilation help increase the concentration of aerosol that the user inhales at the mouth end 2b, aiding the aerosol cooling process. Ventilation is provided directly within the mouthpiece 2 of the article 1. In this example, ventilation is provided within the cooling section 8, which has been found to be particularly beneficial in aiding the aerosol generation process. Ventilation is provided via perforations 12 , which in the present case are formed as a single row of laser perforations positioned 13 mm from the downstream mouth end 2b of the mouthpiece 2 . In alternative embodiments, two or more rows of ventilation 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 within the mouthpiece at other locations, for example within the material body 6 or the first tubular element 4. Preferably, the article is configured such that the perforations are provided no more than about 28 mm from the upstream end of article 1, preferably between 20 mm and 28 mm from the upstream end of article 1. In this example, the holes are provided approximately 25 mm from the upstream end of the article.

Figure 2a is a side cross-sectional view of a further article 1b for use in a non-flammable aerosol delivery system, the additional article 1b comprising a component 3' having a plurality of braided or spirally wound strips 3c, 3e. ) includes. An aerosol delivery device is also shown, with the article and device forming a system. Figure 2b is a side view of component 3' of Figure 2a. In this example, 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 comprising an aerosol generating material. Includes. The component 3' extends from a first end of the component 3' and in this example also includes a cavity extending through the entire length of the component 3'. In this example, 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 first aerosol generating material as described herein. and a second aerosol-generating material as described. The second aerosol-generating material may be different from the first aerosol-generating material. In alternative embodiments, the second braided and/or spirally wound strip 3e is a paper strip used to adhere the first braided and/or spirally wound strip 3c to the tube 3b. You can. For example, at least one of the braided and/or helically wound strips may have an adhesive surface, for example the adhesive surface connects the other braided and/or helically wound strips of the component 3'. do.

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

A first gap 3d is provided between the edges of the first braid and/or helically wound strip 3c and a second gap 3d is provided between the edges of the second braid and/or helically wound strip 3e. A gap 3f is provided. These first and second gaps 3d, 3f provide helical air flow paths through the component 3'.

In alternative embodiments, at least one of the braided and/or helically wound strips 3c, 3e may comprise a spacer material, for example ridged and/or corrugated. It has a ridged and/or corrugated structure. This spacer material may allow the formation of air gaps in the component 3' and may serve, for example, as a layer between the inner and outer strips, each carrying an aerosol-generating material.

As described above in relation to component 3, when viewed from the side with respect to the longitudinal axis of component 3', at least one long edge of the braided and/or helically wound strips extends along the longitudinal axis of the component. When projected, it forms two angles with the longitudinal axis of the component. One of the angles is greater than 90 degrees and the other is less than 90 degrees. In some examples, the angle of less than 90 degrees between the longitudinal axis and a long edge of at least one of the braided and/or helically wound strips is less than about 70 degrees, such as less than about 60 degrees, or less than about 50 degrees.

Figure 3b illustrates a machine arrangement for forming component 3' of Figure 2b. A mandrel 16 is provided and the material forming the component 3' is fed/pulled along the mandrel 16 in the direction of arrow X. The mandrel 16 may for example be static. In this example a source of first strip material 14 comprising aerosol generating material is provided. A source of first strip material 14, for example a bobbin of material, is wound around the mandrel 16 by moving the bobbin 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 also provided on the bobbin, in this case bonded to the first strip of material 14 and used to provide rigidity. For example, the second strip of material 15 may be a paper material that is dipped into a reservoir of adhesive and then glued to the first strip of material 14 so that the adhesive is present on its outer surface before reaching the mandrel. The bobbin of second strip material 15 is moved around the mandrel causing the second strip material 15 to form a second helically wound strip 3c around tube 3b.

In this example the individual bobbins of the first and second strip materials 14 , 15 are arranged to rotate in opposite directions about the mandrel 16 . As a result, at least one of the braided and/or spirally wound strips is arranged in a left handed helical pattern, and at least one of the plurality of braided strips is arranged in a right handed helical pattern. ) are arranged as follows. This creates a braided arrangement of strips. A cutting arrangement 17 identical to that described with reference to Figure 3a is provided.

4 is a flow diagram illustrating a method of forming components 3, 3' as described herein. In step S201, a source of strip material containing aerosol generating material is provided. This may be provided on a bobbin, for example. In step S202, strip material is fed toward the mandrel. In step S203, the strip material is wound around the mandrel to form a spirally wound strip containing the aerosol generating material. As mentioned above, this can be accomplished by rotating the mandrel (optionally with a hollow tube) or moving bobbins 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 cut sheet comprising a first surface and a second surface opposite the first surface. The dimensions of the first and second surfaces are the same. The first and second surfaces of the sheet or cut sheet may have any shape. For example, the first and second surfaces can be square, rectangular, oval, or circular. Irregular shapes are also envisioned.

The first and/or second surfaces of the sheet or cut sheet may be relatively uniform (eg, relatively smooth), uneven, 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 surfaces are relatively rough.

The smoothness of the first and second surfaces may be determined by the areal density of the sheet or cut sheet, the nature of the components that make up the aerosol-generating material, or whether the surfaces of the material have been treated, for example embossed to impart a pattern or texture. ), scoring, or other changes may be affected by a number of factors.

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

The material strips 14, 15 may be formed from sheets of aerosol generating material. The sheet of aerosol-generating material has a thickness of about 100 μm or more. The sheet may have a thickness of about 120 μm, 140 μm, 160 μm, 180 μm, or 200 μm or more. In some embodiments, the sheet has a length 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 155 μm. It has a thickness of from about 156 μm to about 294 μm, from about 157 μm to about 293 μm, from about 158 μm to about 292 μm, from about 159 μm to about 291 μm, or from 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. has

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

The thickness of the sheet can be determined using ISO 534:2011 “Paper and Board—Determination of Thickness”.

If the sheet of aerosol generating material is too thick, heating efficiency may be reduced. This may have a negative impact on power consumption during use, for example for flavor release from aerosol-generating materials. Conversely, if the aerosol-generating material is too thin, manufacturing and handling may be difficult; Very thin materials can be more difficult to mold and can be brittle, which can reduce aerosol formation in use.

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

It is assumed that sheets having a thickness of about 100 μm or more with an areal density of about 100 g/m 2 to about 250 g/m 2 are less likely to tear, split, or otherwise deform during manufacturing. Thicknesses greater than about 100 μm can have a positive effect on the overall structural integrity and strength of the sheet or shredded sheet. For example, it may have good tensile strength and therefore be relatively easy to process.

The thickness of the sheet is also believed to be related to areal density. In other words, increasing the thickness of the sheet can increase the areal density of the sheet.

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

The sheet of aerosol generating material has an areal density of about 100 g/m2 to about 250 g/m2. The sheet may weigh from about 110 g/m2 to about 240 g/m2, from about 120 g/m2 to about 230 g/m2, from about 130 g/m2 to about 220 g/m2, or from about 140 g/m2 to about 210 g/m2. It can have an areal density of . In some embodiments, the sheet has an areal density of from about 130 g/m2 to about 190 g/m2, from about 140 g/m2 to about 180 g/m2, or from about 150 g/m2 to about 170 g/m2. In a preferred embodiment, the sheet has an areal density of about 160 g/m2.

An areal density of about 100 g/m2 to 250 g/m2 is believed to contribute to the strength and flexibility of the sheet.

The flexibility of the sheet is believed to depend at least in part on the thickness and areal density of the sheet. Thicker sheets may be less flexible than thinner sheets. Additionally, the greater the areal density of the sheet, the less flexible the sheet becomes. It is believed that the combined thickness and areal density of the aerosol generating materials described herein provide a relatively flexible sheet. This flexibility can lead to a variety of advantages when aerosol-generating materials are incorporated into articles for use in non-flammable aerosol-presenting devices. For example, the strands or strips can be easily deformed and bent when the aerosol generator is inserted into the aerosol-generating material, thus facilitating insertion of the aerosol generator (e.g., heater) into the material and also facilitating the aerosol-generating material. Improves the holding power of the aerosol generator by the material.

The areal density of a sheet of aerosol generating material affects the roughness of the first and second surfaces of the sheet or shredded sheet. By changing the areal density, the roughness of the first and/or second surfaces can be adjusted.

The average volume density of a sheet of aerosol generating material can be calculated from the thickness of the sheet and the areal density of the sheet. The average bulk density may be greater than about 0.2 g/cm3, about 0.3 g/cm3, or about 0.4 g/cm3. In some embodiments, the average bulk density is from about 0.2 g/cm3 to about 1 g/cm3, about 0.3 g/cm3 to about 0.9 g/cm3, about 0.4 g/cm3 to about 0.9 g/cm3, about 0.5 g/cm3. cm3 to about 0.9 g/cm3, or about 0.6 g/cm3 to about 0.9 g/cm3.

According to one aspect of the present disclosure, there is provided an aerosol-generating material comprising a sheet of aerosol-generating material comprising tobacco material, an aerosol former material, and a binder, wherein the sheet has a density greater than about 0.4 g/cm3. In some embodiments, the density is from about 0.4 g/cm3 to about 2.9 g/cm3, about 0.4 g/cm3 to about 1 g/cm3, about 0.6 g/cm3 to about 1.6 g/cm3, or about 1.6 g/cm3. to about 2.9 g/cm3.

The sheet may have a tensile strength of at least 4 N/15 mm. If the sheet has a tensile strength of less than 4 N/15 mm, the sheet is likely to tear, break or deform during manufacturing and/or subsequent integration into an article for use in a non-flammable aerosol delivery system. Tensile strength can be measured using ISO 1924:2008.

Aerosol-generating materials include tobacco materials. The sheet of aerosol generating material includes tobacco material.

Tobacco material may be particulate or granular material. In some embodiments, the tobacco material is a powder. Alternatively or additionally, the tobacco material may include strips, strands or fibers of tobacco. For example, tobacco material may include particles, granules, fibers, strips and/or strands of tobacco. In some embodiments, the tobacco material consists of particles or granules of tobacco material.

The density of the tobacco material affects the rate at which heat is conducted through the material, with lower densities (e.g., densities less than 900 mg/cc) conducting heat through the material more slowly and thus producing a lower volume of the aerosol. Enables continuous release.

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

Recycled tobacco material may be provided in the form of shredded sheets. Sheets of recycled tobacco material may have any suitable thickness. The regenerated tobacco material may have a thickness of at least about 0.145 mm, for example at least about 0.15 mm, or at least about 0.16 mm. The regenerated tobacco material may have a maximum thickness of about 0.30 mm or 0.25 mm, for example the thickness of the regenerated tobacco material may be less than about 0.22 mm, or less than about 0.2 mm. In some embodiments, the regenerated tobacco material may have an average thickness ranging from 0.175 mm to 0.195 mm.

In some embodiments, the tobacco is particulate tobacco material. Each particle of particulate tobacco material can have a maximum dimension. As used herein, the term “maximum dimension” refers to the longest straight line distance from the surface of a tobacco particle or any point on the particle surface to the surface of the same tobacco particle or any other point on the particle surface. The maximum dimensions of particles of particulate tobacco material can be measured using scanning electron microscopy (SEM).

The maximum dimension of each particle of tobacco material may be up to about 200 μm. In some embodiments, the largest dimension of each particle of tobacco material is at most about 150 μm.

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

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

A particle size distribution (D90) of less than 100 μm can provide sheets of aerosol-generating material with good tensile strength. However, including such fine particles of tobacco material in the sheet can increase density. If the sheet is incorporated into an article for use in a non-flammable aerosol delivery system, this higher density may reduce the fill-value of the tobacco material. Advantageously, a balance between satisfactory tensile strength and suitable density (and therefore fill value) can be achieved when the particle size distribution (D90) is about 100 μm or greater.

The particle size of the particulate tobacco material can also affect the roughness of the sheet of aerosol-generating material. It is assumed that forming a sheet of aerosol-generating material by incorporating relatively large particles of tobacco material reduces the density of the sheet of aerosol-generating material.

Tobacco material may include tobacco obtained from any part of the tobacco plant. In some embodiments, the tobacco material includes tobacco leaves. The sheet may include from 5% to about 90% tobacco leaves by weight.

Tobacco material may include lamina tobacco and/or tobacco stems, such as midrib stems. The leaf tobacco may comprise from 0% to about 100%, from about 20% to about 100%, from about 40% to about 100%, from about 40% to about 95%, by weight of the sheet and/or tobacco material. It may be present in an amount of from 45% to about 90% by weight, from about 50% to about 85% by weight, or from about 55% to about 80% by weight. In some embodiments, the tobacco material consists of or consists essentially of leaf tobacco material.

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

In some embodiments, the tobacco material includes a combination of leaves and tobacco stems. In some embodiments, the tobacco material includes from about 40% to about 95% of the leaves and from about 5% to about 60% of the stems by weight, or about 60% by weight, based on the sheet of aerosol-generating material. to about 95% by weight of leaves and from about 5% to about 40% by weight of stems, or from about 80% to about 95% by weight of leaves and from about 5% to about 20% by weight. It may include the stem of.

Including a stem may reduce the adhesion of the aerosol-generating material. Incorporating tobacco material, including stem tobacco, into an aerosol-generating material can increase burst strength.

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

If the bursting strength is too low, the sheet may become relatively brittle. As a result, breaks in the sheet may occur during the process of manufacturing the aerosol generating material. For example, if a sheet is shredded by a cutting process to form a shredded sheet, the sheet may break or break into pieces or fragments upon cutting.

The tobacco materials described herein contain nicotine. The nicotine content may be 0.1 to 3% by weight of the tobacco material, for example 0.5 to 2.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material has from 10% to 90% by weight of tobacco leaves with a nicotine content greater than about 1% or about 1.5% by weight of the tobacco leaves. For example, tobacco leaves, such as cut rag tobacco, can have a nicotine content of 1% to 5% by weight of the tobacco leaves.

Sheets of aerosol-generating material may include nicotine in an amount from about 0.1% to about 3% by weight of the sheet or shredded sheet.

Paper recycled tobacco may also be present in the aerosol generating materials described herein. Paper recycled tobacco is extracted by extracting the tobacco feedstock with a solvent to obtain a residue containing soluble extract and fibrous material, and then depositing the extract on the fibrous material (usually the extract after concentration, optionally after further processing). refers to tobacco material formed by a process of recombining the fibrous material with the fibrous material from the residue (usually after purification of the fibrous material, optionally with the addition of a portion of non-tobacco fibres). The recombination process is similar to the process of manufacturing paper.

Paper recycled cigarettes can be any type of paper recycled cigarette known in the art. In certain embodiments, paper recycled tobacco is made from a feedstock comprising one or more of tobacco strips, tobacco stems, and whole leaf tobacco. In a further embodiment, paper recycled tobacco is made from a feedstock consisting of tobacco strips and/or whole leaf tobacco, and tobacco stems. However, in other embodiments, scraps, fines and winnowings may alternatively or additionally be used as feedstock.

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

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

Aerosol-generating materials include aerosol former materials. The aerosol former material includes one or more ingredients capable of forming an aerosol. Aerosol former materials include glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3 -1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, diethyl suberate ( diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin , 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 includes an aerosol former material. The aerosol former material is provided in an amount of up to about 50% by dry weight of the sheet or shredded sheet. In some embodiments, the aerosol former material is present in an amount of from about 5% to about 40% by weight, based on the dry weight of the sheet or shredded sheet, or from about 10% to about 30% by weight, based on the dry weight of the sheet or shredded sheet. % by weight, or in an amount of from about 10% to about 20% by weight based on the dry weight of the sheet or shredded sheet.

The sheet may also contain water. The sheet of aerosol-generating material may include water in an amount of less than about 15%, less than about 10%, or less than about 5% by weight of the aerosol-generating material. In some embodiments, the aerosol-generating material includes water in an amount from about 0% to about 15%, or from about 5% to about 15% by weight of the aerosol-generating material.

The sheet of aerosol-generating material may include water and aerosol former material in a total amount of less than about 30% by weight of the sheet of aerosol-generating material or less than about 25% by weight of the sheet of aerosol-generating material. It is believed that including water and aerosol former material in a sheet of aerosol-generating material in an amount of less than about 30% by weight of the sheet of aerosol-generating material may advantageously reduce the tackiness of the sheet. This can improve the ease with which aerosol-generating materials can be handled during processing. For example, after rolling a sheet of aerosol generating material to form a bobbin of material, it may become easier to unroll the bobbin without the sheet layers sticking together. Reduction in stickiness can also reduce the tendency of strands or strips of shredded material to clump or stick together, thus further improving processing efficiency and quality of the final product.

The sheets or shredded sheets contain a binder. The binder is arranged to bind the components of the aerosol-generating material to form a sheet or shredded sheet. The binder may at least partially coat the surface of the tobacco material. When the tobacco material is in particulate form, the binder can at least partially coat the surface of the tobacco particles to bind them together.

Binders include alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol. alcohol), and combinations thereof. For example, in some embodiments, the binder is alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan. , xanthan gum, guar gum, carrangeenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. Contains one or more In some cases, the binder includes alginate and/or pectin or carrageenan. In a preferred embodiment, the binder includes guar gum.

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

Aerosol-generating materials may include fillers. In some embodiments, the sheet includes filler. Fillers are generally non-tobacco components, that is, components that do not contain ingredients of tobacco origin. The filler may include one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may be a non-tobacco fiber such as wood fiber, pulp or wheat fiber. The filler may be a material containing cellulose or a material containing a derivative of cellulose. The filler component may also be a non-tobacco casting material or a non-tobacco extrusion material.

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

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

The filler component may be present in an amount of 0 to 20% by weight of the sheet or shredded sheet, or 1 to 10% by weight of the sheet or shredded sheet. In some embodiments, no filler components are present.

Fillers can help improve general structural properties of aerosol-generating materials, such as tensile strength and bursting strength.

In the compositions described herein, amounts are given in weight percent and, for the avoidance of doubt, refer to dry weight basis unless specifically indicated to the contrary. Accordingly, any water that may be present in the aerosol-generating material or any component thereof is completely ignored in the determination of weight percent. The moisture content of the aerosol-generating materials described herein can vary, for example, from 5 to 15 weight percent. The moisture content of the aerosol-generating materials described herein may vary depending, for example, on the temperature, pressure and humidity conditions in which the compositions are maintained. Moisture content can be determined by Karl-Fisher analysis as known to those skilled in the art. Meanwhile, for the avoidance of doubt, any component other than water is included in the weight of the aerosol-forming material, even if the aerosol-forming material is a liquid component such as glycerol or propylene glycol. However, if the aerosol-generating material is provided with the tobacco component of the aerosol-generating material, or the filler component (if present) of the aerosol-generating material, instead of or in addition to being added separately to the aerosol-generating material, the aerosol-forming material may be added to the tobacco component of the aerosol-generating material. It is not included in the weight of the ingredients or filler ingredients, but is included in the weight of the "aerosol former material" in weight percent as defined herein. All other constituents present in the tobacco component are included in the weight of the tobacco component, even if they are of non-tobacco origin (e.g. non-tobacco fibers in the case of recycled paper tobacco).

The aerosol generating materials herein may include an aerosol modifier, such as any of the flavors described herein. In one embodiment, the aerosol generating material includes menthol. When an aerosol-generating material is incorporated into an article for use in an aerosol delivery system, the article may be referred to as a menthol-containing article. The aerosol-generating material may include 0.5 mg to 20 mg menthol, 0.7 mg to 20 mg menthol, 1 mg to 18 mg menthol, or 8 mg to 16 mg menthol. In this example, the aerosol generating material includes 16 mg of menthol. The aerosol-generating material may comprise 1% to 8% menthol by weight, preferably 3% to 7% menthol, more preferably 4% to 5.5% menthol. In one embodiment, the aerosol-generating material includes 4.7% menthol by weight. Such high levels of menthol loading can be achieved using a high percentage of recycled tobacco material, for example more than 50% by weight of the tobacco material. Alternatively or additionally, for example, the use of large quantities of tobacco material may increase the level of menthol loading that can be achieved, for example greater than about 500 mm3, suitably greater than about 1000 mm3 of aerosol-generating material, such as Tobacco materials are used.

In some embodiments, the composition includes 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 dried gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it.

In some examples, amorphous solids include:

- 1 to 60% by weight of gelling agent;

- 0.1 to 50% by weight of aerosol former material; and

- 0.1 to 80% by weight of flavor;

Here, these weights are calculated on a dry weight basis.

In some further embodiments, the amorphous solid includes:

- 1 to 50% by weight of gelling agent;

- 0.1 to 50% by weight of aerosol former material; and

- 30 to 60% by weight of flavor;

Here, these weights are calculated on a dry weight basis.

Amorphous solid materials may be provided in sheet or broken sheet form. The amorphous solid material can take the same form as a sheet of aerosol-generating material previously described.

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

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

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

Suitably, the amorphous solid is from about 0.1%, 0.5%, 1%, 3%, 5%, 7% or 10% by weight to about 50%, 45%, 40%, 35% by weight. %, 30% or 25% by weight of aerosol former material (all calculated on a dry weight basis). The aerosol former material can act as a plasticizer. For example, the amorphous solid may include 0.5 to 40 weight percent, 3 to 35 weight percent, or 10 to 25 weight percent aerosol former material. In some cases, the aerosol former material includes one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol former material includes, consists essentially of, or consists of glycerol.

The amorphous solid contains flavor. Suitably, the amorphous solid may comprise up to about 80%, 70%, 60%, 55%, 50%, or 45% by weight of flavor.

In some cases, the amorphous solid may include about 0.1%, 1%, 10%, 20%, 30%, 35%, or 40% by weight of flavor (all calculated on a dry weight basis). You can.

For example, the amorphous solid may include 1 to 80%, 10 to 80%, 20 to 70%, 30 to 60%, 35 to 55%, or 30 to 45% by weight of flavor. . In some cases, the flavor includes, consists essentially of, or consists of menthol.

In some cases, the amorphous solid may additionally include an emulsifier to emulsify the molten flavor during manufacturing. For example, the amorphous solid may comprise from about 5% to about 15% by weight, suitably about 10% by weight of emulsifier (calculated on a dry weight basis). Emulsifiers may include acacia gum.

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

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

In some cases, the amorphous solid includes an active substance such as tobacco extract. In some cases, the amorphous solid may include 5 to 60 weight percent (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid is from about 5%, 10%, 15%, 20% or 25% by weight to about 60%, 50%, 45%, 40%, 35% or It may comprise 30% by weight (calculated on dry weight basis) of tobacco extract. For example, the amorphous solid may include 10 to 50 weight percent, 15 to 40 weight percent, or 20 to 35 weight percent tobacco extract. The tobacco extract is an amorphous solid comprising from 1%, 1.5%, 2% or 2.5% to about 6%, 5%, 4.5% or 4% nicotine by weight (calculated on dry weight basis). It can hold nicotine in a concentration that allows it to be used.

In some cases, the amorphous solid may be free of nicotine other than nicotine originating from tobacco extract.

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

In some cases, the total content of active substance and/or flavor may be about 0.1%, 1%, 5%, 10%, 20%, 25%, or 30% by weight or more. In some cases, the total content of active substance and/or flavor may be less than about 90%, 80%, 70%, 60%, 50% or 40% by weight (all calculated on a dry weight basis). there is.

In some cases, the total content of tobacco material, nicotine and flavor may be about 0.1%, 1%, 5%, 10%, 20%, 25% or 30% by weight or more. In some cases, the total content of active substance and/or flavor may be less than about 90%, 80%, 70%, 60%, 50% or 40% by weight (all calculated on a dry weight basis). there is.

Amorphous solids can be prepared into gels, and these gels can additionally contain 0.1 to 50% by weight of a solvent. However, inclusion of a solvent in which the flavor dissolves may reduce gel stability and the flavor may crystallize from the gel. As such, in some cases, the gel does not contain a solvent in which the flavor is dissolved.

In some embodiments, the amorphous solid contains less than 60% filler by weight, such as 1% to 60% by weight, or 5% to 50% by weight, or 5% to 30% by weight, or 10% to 20% by weight. Contains % filler.

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

Fillers, if present, may be calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecules. It may contain one or more inorganic filler materials 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 include calcium carbonate, such as chalk.

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

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

In some examples, the amorphous solid in sheet form can have a tensile strength of about 200 N/m to about 1500 N/m. In some instances where the amorphous solid does not include a filler, the amorphous solid can have a tensile strength of 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. Such tensile strengths may be particularly suitable for embodiments where the amorphous solid material is formed as a sheet and then broken and incorporated into an aerosol-generating article.

In some examples, such as when the amorphous solid includes a filler, the amorphous solid may have a tensile strength of 600 N/m to 1500 N/m, or 700 N/m to 900 N/m, or about 800 N/m. You can. Such tensile strengths may be particularly suitable for embodiments where the amorphous solid material is included in the 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 be composed of, a gelling agent, water, aerosol former material, flavor, and optionally an active agent.

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

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

Aerosol-generating materials may include paper recycled tobacco materials. The composition may alternatively or additionally include any of the tobacco forms described herein. The aerosol-generating material may include a sheet comprising tobacco material comprising 10% to 90% tobacco leaves by weight, wherein the aerosol former material is provided in an amount of up to about 20% by weight of the sheet or shredded sheet. , the rest of the tobacco materials include paper recycled cigarettes.

When the aerosol-generating material includes an amorphous solid material, the amorphous solid material may be a dried gel containing menthol. In alternative embodiments, the amorphous solid can have any composition as described herein.

An improved article can be produced comprising an aerosol-generating material comprising a first component comprising a sheet of aerosol-generating material and a second component comprising an amorphous solid, the material properties (e.g., density) and specifications (e.g., thickness, length and cut width) are within the ranges set forth herein.

In some cases, the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may range from about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. Materials about 0.09 mm thick can be used. An amorphous solid may include more than one layer, and the thickness described herein refers to the total thickness of those layers.

The thickness of an amorphous solid material can be measured using a microscope such as a caliper or 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 reduced. This may have a negative impact on power consumption during use, for example for flavor release from amorphous solids. Conversely, if the aerosol-forming amorphous solid is too thin, it can be difficult to manufacture and handle; Very thin materials can be more difficult to mold and can be brittle, which can reduce aerosol formation in use. In some cases, an individual strip or piece of amorphous solid has a minimum thickness of about 0.015 mm over its area. In some cases, an individual strip or piece of amorphous solid has a minimum thickness of about 0.05 mm or about 0.1 mm over its area. In some cases, an individual strip or piece of amorphous solid has a maximum thickness of about 1.0 mm over its area. In some cases, an individual strip or piece of amorphous solid has a maximum thickness of about 0.5 mm or about 0.3 mm over its area.

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

Providing sheets of amorphous solid material and aerosol-generating material with areal density values that differ from each other by less than a given percentage results in less segregation in the mixture of these materials. In some examples, the areal density of the amorphous solid material can be between 50% and 150% of the areal density of the aerosol-generating material. For example, the areal density of the amorphous solid material is 60% to 140% of the density of the aerosol-generating material, or 70% to 110% of the areal density of the aerosol-generating material, or 80% to 120% of the areal density of the aerosol-generating material. It can be.

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 incorporated into an article after being broken up and suitably mixed with an aerosol-generating material, such as a sheet of aerosol-generating material described herein.

In further embodiments, the amorphous solid sheet may additionally be incorporated as a planar sheet, gathered or bunched sheet, crimped sheet, or rolled sheet (i.e., in the form of a tube). You can. In some such cases, the amorphous solids of these embodiments may be included in the aerosol-generating article as a sheet, such as a sheet surrounding a rod containing the aerosol-generating material. For example, an amorphous solid sheet can be formed on a wrapping paper surrounding an aerosol-generating material, such as a cigarette.

The amorphous solid in sheet form may have any suitable areal density, such as from about 30 g/m2 to about 150 g/m2. In some cases, the sheet has a weight of about 55 g/m2 to about 135 g/m2, or about 80 to about 120 g/m2, or about 70 to about 110 g/m2, or especially about 90 to about 110 g/m2, Or, suitably, it may have a mass per unit area of about 100 g/m2. These ranges can provide densities similar to those of cut lag tobacco, resulting in a mixture of these materials that does not easily separate. Such areal densities may be particularly suitable where the amorphous solid material is included in the aerosol-generating article as a broken sheet (discussed further below). In some cases, the sheet may have a mass per unit area of about 30 to 70 g/m2, 40 to 60 g/m2, or 25 to 60 g/m2, and may be comprised of an aerosol-generating material, such as an aerosol-generating material described herein. Can be used to wrap .

The aerosol-generating material may include a blend of aerosol-generating material and an amorphous solid material as described herein. Such aerosol-generating materials can provide aerosols with a desirable flavor profile upon use, as additional flavors may be introduced into the aerosol-generating materials by inclusion in the amorphous solid material components. Flavors provided to the amorphous solid material can remain more stable within the amorphous solid material compared to flavors added directly to the tobacco material, resulting in a more consistent flavor profile between articles produced according to the present disclosure.

As mentioned above, it has been found that tobacco materials having a density of greater than 350 mg/cc and less than about 900 mg/cc, preferably between about 600 mg/cc and about 900 mg/cc, advantageously result in more sustained aerosol emissions. lost. To provide an aerosol with a consistent flavor profile, the amorphous solid material component of the aerosol generating material must be evenly distributed throughout the load. This involves casting the amorphous solid material to have a thickness as described herein to provide an amorphous solid material with an areal density similar to that of the tobacco material, and to ensure uniform distribution throughout the aerosol generating material, as described below. This can be achieved by processing the amorphous solid material as described.

As mentioned above, optionally the aerosol generating material includes a plurality of strips of amorphous solid material. When the aerosol-generating section comprises a plurality of strands and/or strips of a sheet of aerosol-generating material and a plurality of strips of an amorphous solid material, it ensures that relatively homogeneous mixing of the components is possible, The material properties and/or dimensions of the at least two components may be appropriately selected in different ways to reduce separation or un-mixing of the components during or after production of the rod.

The longitudinal dimension of the plurality of strands or strips may be substantially equal to the length of the aerosol generating section. The plurality of strands and/or strips may have a length of about 5 mm or more.

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

Claims (27)

As a component for use in a non-combustible aerosol provision system,
The component comprises at least one helically-wound strip comprising an aerosol-generating material,
Components for use in non-flammable aerosol delivery systems. According to claim 1,
further comprising a cavity extending from the first end of the component,
Components for use in non-flammable aerosol delivery systems. According to clause 2,
The width of the at least one helically wound strip 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. ,
Components for use in non-flammable aerosol delivery systems. According to any one of claims 1 to 3,
The component has a longitudinal axis, and a long edge of the helically wound strip projected onto the longitudinal axis makes an angle with the longitudinal axis of less than about 70 degrees, for example less than about 60 degrees, or less than about 50 degrees. forming,
Components for use in non-flammable aerosol delivery systems. 1. A component for use in a non-flammable aerosol delivery system, comprising:
The component comprises 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, and the component comprises an aerosol-generating material. further comprising a cavity extending from the first end,
Components for use in non-flammable aerosol delivery systems. According to clause 5,
The width of at least one of the plurality of braided or spirally wound strips 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,
Components for use in non-flammable aerosol delivery systems. According to paragraph 5 or 6
The component has a longitudinal axis, and edges of the plurality of braided or spirally wound strips projected onto the longitudinal axis have an angle with the longitudinal axis of less than about 70 degrees, for example less than about 60 degrees, or less than about 50 degrees. forming an angle of
Components for use in non-flammable aerosol delivery systems. According to any one of claims 5 to 7,
The aerosol-generating material includes plant-based materials such as tobacco material and/or amorphous solid material.
Components for use in non-flammable aerosol delivery systems. According to any one of claims 5 to 8,
wherein the aerosol generating material is laminated on a support material,
Components for use in non-flammable aerosol delivery systems. According to any one of claims 5 to 9,
The at least one braided and/or spirally wound strip comprises a first aerosol generating material, and the component further comprises at least one braided and/or spirally wound strip comprising a second aerosol generating material. doing,
Components for use in non-flammable aerosol delivery systems. According to claim 10,
The at least one braided and/or spirally wound strip comprising the first aerosol generating material is closer to the cavity than the at least one braided and/or spirally wound strip comprising the second aerosol generating material. arranged,
Components for use in non-flammable aerosol delivery systems. The method according to any one of claims 5 to 11,
The manufacturing tolerance of the diameter of the cavity is less than 0.5 mm, or less than 0.4 mm, or less than 0.3 mm,
Components for use in non-flammable aerosol delivery systems. The method according to any one of claims 5 to 12,
The cavity is surrounded by a hollow tube, and the braided and/or spirally wound strips are arranged around the hollow tube.
Components for use in non-flammable aerosol delivery systems. The method according to any one of claims 1 to 13,
At least one of the braided and/or helically wound strips includes a spacer material, the spacer material having a ridged and/or corrugated structure,
Components for use in non-flammable aerosol delivery systems. According to claim 14,
wherein the spacer material is arranged around at least one of the braided and/or helically wound strips comprising the aerosol generating material, optionally wherein the arrangement of the spacer material provides an air flow path through the component.
Components for use in non-flammable aerosol delivery systems. The method according to any one of claims 1 to 15,
At least one of the braided and/or spirally wound strips comprises an adhesive surface, optionally the adhesive surface connecting other braided and/or spirally wound strips of the component.
Components for use in non-flammable aerosol delivery systems. According to claim 16,
The adhesive surface comprises an adhesive or binder, optionally the adhesive or binder is a starch-based adhesive or binder, a gum-based adhesive or binder, a polysaccharide-based adhesive or binder. (polysaccharide-based adhesive or binder), or carboxymethyl cellulose based adhesive or binder,
Components for use in non-flammable aerosol delivery systems. The method according to any one of claims 1 to 17,
At least one of the braided and/or spirally wound strips is arranged in a left handed helical pattern, and at least one of the plurality of braided strips is in a right handed helical pattern. ), arranged as
Components for use in non-flammable aerosol delivery systems. The method according to any one of claims 1 to 18,
At least one of the braided and/or spirally wound strips comprises a tensile strength of at least 4 N/15 mm, or each of the braided and/or spirally wound strips comprises a tensile strength of at least 4 N/15 mm. doing,
Components for use in non-flammable aerosol delivery systems. An article for use in a non-flammable aerosol delivery system, comprising:
Comprising a component according to any one of claims 1 to 19 and a downstream part downstream of said component.
Articles for use in non-flammable aerosol delivery systems. Comprising an aerosol provision device for forming an aerosol from the article according to claim 20 and said aerosol generating material.
Non-flammable aerosol delivery system. 19. A method of forming a component according to any one of claims 1 to 19, comprising:
providing a source of strip material comprising aerosol generating material;
feeding the strip material toward a mandrel; and
Wrapping the strip material around the mandrel to form a spirally wound strip comprising aerosol generating material,
How to form components. According to clause 22,
providing a source of spacer material, and winding the spacer material around the mandrel to provide a layer of spacer material to the component.
How to form components. The method of claim 22 or 23,
the width of the strip material is at least twice the diameter of the mandrel, or at least twice the diameter of the mandrel, or at least three times the diameter of the mandrel, or at least four times the inner diameter of the mandrel,
How to form components. The method of claim 22 or 23,
further comprising providing a tube on the mandrel, wherein the winding step includes winding the strip material around the tube.
How to form components. The method according to any one of claims 22 to 25,
The strip of material comprising the aerosol-generating material is a first strip of material, and the method includes:
providing a source of second strip material;
feeding the second strip of material toward the mandrel; and
and winding the second strip of material around the mandrel to form a second helically wound strip.
How to form components. According to clause 26,
Winding the first strip of material is performed in a first direction, winding the second strip of material is performed in a second direction, and winding the first and second strips of material in a spiral pattern. forming a helical pattern comprising at least one left-handed helix and at least one right-handed helix,
How to form components.