KR20240100465A - Articles for use in aerosol delivery systems and methods of making articles for use in aerosol delivery systems - Google Patents

Abstract

The present disclosure relates to articles for use in aerosol delivery systems, where the article includes a substrate and a body of material. The substrate includes a first aerosol generating material. The body of material includes a second aerosol-generating material, and the substrate at least partially surrounds the body of material. The disclosure also relates to methods of making articles for use in aerosol delivery systems, kits of parts including articles and aerosol delivery devices, and packages of articles.

Description

Articles for use in aerosol delivery systems and methods of making articles for use in aerosol delivery systems

The present disclosure relates to articles for use in aerosol delivery systems. The disclosure also relates to methods of making articles for use in aerosol delivery systems, kits of parts including articles and aerosol delivery devices, and packages of articles.

Aerosol delivery systems produce an inhalable aerosol or vapor during use by releasing compounds from an aerosol-generating material. These may be referred to, for example, as non-combustible smoking articles, aerosol generating assemblies, or aerosol presentation devices.

According to some embodiments described herein, an article for use in an aerosol delivery system is provided, the article comprising: a substrate comprising a first aerosol-generating material; and a body of material comprising a second aerosol-generating material, wherein the substrate at least partially surrounds the body of material.

In some embodiments, the article further comprises a first sheet material, and preferably the substrate is attached to the first sheet material. In some embodiments, the substrate is attached to the first sheet material.

In some embodiments, the first sheet material and the substrate are arranged such that the substrate is provided on an interior surface of the first sheet material. In some embodiments, the first sheet material surrounds, or at least partially surrounds, the substrate.

In some embodiments, the edge of the substrate is spaced apart from the edge of the first sheet material such that no area of the first sheet material is covered by the substrate, preferably the edges are longitudinal edges of the substrate and the first sheet material. admit.

In some embodiments, the first sheet material forms the exterior surface of the article.

In some embodiments, the first sheet material has a permeability of up to 100 Coresta Units.

In some embodiments, the first sheet material has a thickness ranging from 20 to 100 microns.

In some embodiments, the second sheet material is attached to the first sheet material, for example by an adhesive.

In some embodiments, the substrate includes a second sheet material.

In some embodiments, the second sheet material is a cast sheet.

In some embodiments, the substrate is cast on the first sheet material. For example, a first sheet material may be provided, and a slurry comprising a first aerosol-generating material may be provided on the first sheet material and allowed to dry.

In some embodiments, the second sheet material includes the first aerosol generating material.

In some embodiments, the second sheet material is formed from a slurry comprising the first aerosol-generating material.

In some embodiments, the slurry is cast to form a second sheet of material.

In some embodiments, the first aerosol-generating material is attached to the surface of the second sheet material, and preferably is attached to the surface of the second sheet material.

In some embodiments, the second sheet material includes one or more of paper, card, and/or aerosol generating material.

In some embodiments, the second aerosol-generating material has a higher or lower density than the first aerosol-generating material.

In some embodiments, the density of one of the first and second aerosol-generating materials is at least about 25% higher than the density of the other of the first and second aerosol-generating materials. However, in other embodiments, the densities of the first and second aerosol generating materials are the same.

In some embodiments, one of the first and second aerosol-generating materials has a density of about 0.1 g/cm3 to about 1 g/cm3.

In some embodiments, the other of the first and second aerosol-generating materials has a density of about 0.4 g/cm3 to about 2 g/cm3.

In some embodiments, heating the article provides a relatively constant release of volatile compounds into the inhalable medium.

In some embodiments, the first aerosol generating material includes extruded tobacco.

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

In some embodiments, the second aerosol generating material includes one or more tobacco materials selected from the group consisting of lamina and recycled tobacco materials.

In some embodiments, at least one of the first and second aerosol generating materials includes a combination of tobacco lamina and regenerated tobacco material. In some embodiments, the lamina and recycled tobacco material are present in the aerosol-generating material in a ratio of 1:4 to 4:1 by weight.

In some embodiments, the first and second aerosol generating materials have equal levels of volatile compounds. In some embodiments, the volatile compound is nicotine.

In some embodiments, the release of volatile compounds from the first and second aerosol-generating materials is at the same rate when the materials reach a given temperature.

In some embodiments, the first and second aerosol generating materials are present in the article in a ratio of 1:10 to 10:1 by weight.

In some embodiments, the article has a weight ranging from 7 mg to 13 mg of the first and second aerosol-generating materials combined per mm length of the article, preferably 8 mg of the first and second aerosol-generating materials combined per mm length of the article. from 12 to 12, 9 to 11.5, 9 to 11 or 9.5 to 10.5 mg.

In some embodiments, the substrate surrounds the entire circumference of the body of material.

In some embodiments, the first sheet material surrounds a body of material. In some embodiments, the patch surrounds a body of material.

In some embodiments, the body of material includes a third sheet of material collected to form the body of material.

In some embodiments, the third sheet material is crimped and/or cut into strips.

In some embodiments, the substrate is in direct contact with the body of material.

In some embodiments, the body of material includes a tobacco stick. For example, the body of material may include shredded tobacco material molded into sticks. In some embodiments, the body of material includes cut rag tobacco formed into sticks.

In some embodiments, the substrate includes a first end spaced apart from the first end of the body of material.

In some embodiments, the substrate includes a second end opposite the first end of the substrate, the second end being spaced apart from the second end of the body of material.

In some embodiments, the substrate extends over a portion of the length of the body of material. In some embodiments, the patch extends the entire length of the body of material.

In some embodiments, the body of material extends over a portion of the length of the article. In some embodiments, the body of material extends over the entire length of the article.

In some embodiments, the first aerosol-generating material includes aerosol-generating material dust and/or aerosol-generating material fibers.

In some embodiments, the first aerosol-generating material includes extruded and/or compressed aerosol-generating material.

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

In some embodiments, the beads have a diameter ranging from 0.5 to 3 mm, preferably ranging from 1 to 2 mm.

In some embodiments, the first and/or second aerosol-generating material includes, consists of, or consists essentially of tobacco material.

In some embodiments, the second aerosol generating material includes shredded tobacco and/or reconstituted tobacco.

In some embodiments, the tobacco material of the first and/or second aerosol-generating material is derived only from tobacco lamina and not from other types of tobacco material.

In some embodiments, the first and/or second aerosol generating material includes tobacco lamina and regenerated tobacco.

In some embodiments, the first and second aerosol-generating materials together have an average nicotine content within the range of 0.5% to 2.5% by weight of the first and second aerosol-generating materials, and preferably in the range of 1% to 2.1%. It has a level.

In some embodiments, the total weight of aerosol-generating material in the article is in the range of 150 to 350 mg, preferably in the range of 200 to 300 mg, 220 to 280 mg, or 230 to 260 mg.

In some embodiments, the article has an amount ranging from 7 mg to 13 mg of aerosol-generating material (including first and second aerosol-generating materials) per mm length of the article, preferably of aerosol-generating material per mm length of the article. Includes a range of 8 to 12, 9 to 11.5, 9 to 11 or 9.5 to 10.5 mg.

In some embodiments, the first and/or second aerosol generating material is a solid material.

In some embodiments, the article does not include plastic.

In some embodiments, the article does not include cellulose acetate.

In some embodiments, the first and second aerosol-generating materials are made from the same aerosol-generating starter materials that are processed to have different morphologies.

In some embodiments, the substrate includes a third aerosol-generating material.

In some embodiments, the substrate includes a second sheet of material that includes first and/or third aerosol generating materials. For example, the second sheet material can be formed from a slurry comprising the first and/or third aerosol-generating materials.

In some embodiments, the first and/or third aerosol generating materials are applied to the surface of the second sheet material.

In some embodiments, the second sheet of material includes one of the first and third aerosol-generating materials, and the other of the first and third aerosol-generating materials is applied to the surface of the second sheet of material.

According to the present disclosure, a method of making an article for use in an aerosol presentation system is provided, the method comprising: providing a substrate comprising a first aerosol-generating material; and arranging the substrate such that the substrate at least partially surrounds a body of material comprising the second aerosol-generating material.

In some embodiments, the method further includes providing a first sheet material, and the substrate is attached to the first sheet material. In some embodiments, the substrate is attached to the first sheet material.

In some embodiments, the first sheet material forms the exterior surface of the article.

In some embodiments, the first sheet material has a permeability of up to 100 Coresta Units.

In some embodiments, the first sheet material has a thickness ranging from 20 to 100 microns.

In some embodiments, the second sheet material is attached to the first sheet material, for example by an adhesive.

In some embodiments, the body of material includes a tobacco stick. For example, the body of material may include shredded tobacco material molded into sticks. In some embodiments, the body of material includes cut rag tobacco formed into sticks.

In some embodiments, providing the first sheet material includes providing a web of the first sheet material.

In some embodiments, the method includes applying a substrate to a web of first sheet material.

In some embodiments, the substrate includes a second sheet material, preferably the second sheet material is a cast sheet.

In some embodiments, applying the substrate includes applying a web of a second sheet material to the web of first sheet material.

In some embodiments, applying the substrate includes applying a plurality of portions of the second sheet material to the web of the first sheet material.

In some embodiments, the plurality of portions of the second sheet material are spaced apart from each other on the web of the first sheet material.

In some embodiments, the portions of the second sheet material are discrete. The portions of the second sheet material may be spaced apart from each other in a direction along the delivery path of the web of the first sheet material.

In some embodiments, the first sheet material and the substrate are arranged such that the substrate is provided on an interior surface of the first sheet material. In some embodiments, the first sheet material surrounds, or at least partially surrounds, the substrate.

In some embodiments, the edge of the substrate is spaced apart from the edge of the first sheet material such that no area of the first sheet material is covered by the substrate, preferably the edges are longitudinal edges of the substrate and the first sheet material. admit.

In some embodiments, the second sheet material includes the first aerosol generating material.

In some embodiments, the second sheet material is formed from a slurry comprising the first aerosol-generating material.

In some embodiments, the slurry is cast to form a second sheet of material.

In some embodiments, the first aerosol-generating material is attached to the surface of the second sheet material, and preferably is attached to the surface of the second sheet material.

In some embodiments, the first aerosol-generating material is attached to the surface of the second sheet material before or after attaching the second sheet material to the first sheet material.

In some embodiments, the second sheet material includes one or more of paper, card, and/or aerosol generating material.

In some embodiments, the second aerosol-generating material has a higher or lower density than the first aerosol-generating material.

In some embodiments, the substrate surrounds the entire circumference of the body of material.

In some embodiments, the first sheet material surrounds a body of material. In some embodiments, the patch surrounds a body of material.

In some embodiments, the body of material includes a third sheet of material, and preferably, the method includes collecting the third sheet of material to form the body of material.

In some embodiments, the third sheet material is crimped and/or cut into strips.

In some embodiments, arranging the substrate includes arranging the substrate to directly contact the body of material.

In some embodiments, the body of material includes a tobacco stick. For example, the body of material may include shredded tobacco material molded into sticks. In some embodiments, the body of material includes cut rag tobacco formed into sticks.

In some embodiments, the substrate includes a first end spaced apart from the first end of the body of material, and preferably, the substrate includes a second end opposite the first end of the substrate, the second end spaced apart from the second end of the body of material.

In some embodiments, the substrate extends over a portion of the length of the body of material. In some embodiments, the patch extends the entire length of the body of material.

In some embodiments, the body of material extends over a portion of the length of the article. In some embodiments, the body of material extends over the entire length of the article.

In some embodiments, the first aerosol-generating material includes aerosol-generating material dust and/or aerosol-generating material fibers.

In some embodiments, the first aerosol-generating material includes extruded and/or compressed aerosol-generating material.

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

In some embodiments, the beads have a diameter ranging from 0.5 to 3 mm, preferably ranging from 1 to 2 mm.

In some embodiments, the first and/or second aerosol-generating material includes, consists of, or consists essentially of tobacco material.

In some embodiments, the second aerosol generating material includes shredded tobacco and/or reconstituted tobacco.

In some embodiments, the tobacco material of the first and/or second aerosol-generating material is derived only from tobacco lamina and not from other types of tobacco material.

In some embodiments, the first and/or second aerosol generating material includes tobacco lamina and regenerated tobacco.

In some embodiments, the first and second aerosol-generating materials together have an average nicotine content within the range of 0.5% to 2.5% by weight of the first and second aerosol-generating materials, and preferably in the range of 1% to 2.1%. It has a level.

In some embodiments, the total weight of aerosol-generating material in the article is in the range of 150 to 350 mg, preferably in the range of 200 to 300 mg, 220 to 280 mg, or 230 to 260 mg.

In some embodiments, the article has an aerosol-generating material in the range of 6 mg to 18 mg per mm length of the article, preferably 8 to 16, 10 to 14, 11 to 12 mg of aerosol-generating material per mm length of the article. Includes range.

In some embodiments, the first and/or second aerosol generating material is a solid material.

In some embodiments, the article does not include plastic.

In some embodiments, the article does not include cellulose acetate.

In some embodiments, the first and second aerosol-generating materials are made from the same aerosol-generating starter materials that are processed to have different morphologies.

In some embodiments, the substrate includes a third aerosol-generating material.

In some embodiments, the substrate includes a second sheet of material that includes first and/or third aerosol generating materials. For example, the second sheet material can be formed from a slurry comprising the first and/or third aerosol-generating materials.

In some embodiments, the first and/or third aerosol generating materials are applied to the surface of the second sheet material.

In some embodiments, the second sheet of material includes one of the first and third aerosol-generating materials, and the other of the first and third aerosol-generating materials is applied to the surface of the second sheet of material.

According to the present disclosure, articles made according to the methods disclosed herein are also provided.

According to the present disclosure, a package comprising a plurality of articles as disclosed herein is also provided. In some embodiments, the package is hermetically sealed.

According to the present disclosure, a kit of parts comprising an article and an aerosol presentation device as disclosed herein is also provided.

In some embodiments, the aerosol presentation device includes a heating chamber for receiving an article for heating the first aerosol-generating material and the second aerosol-generating material.

Embodiments will now be described, by way of example only, with reference to the accompanying drawings.
1 is a side cross-sectional view of an embodiment of an article for use in an aerosol delivery system.
Figure 2 is a top view of the first sheet material of the article of Figure 1, with the first sheet material lying flat.
Figure 3 is a top view of the second sheet material of the article of Figure 1, with the second sheet material lying flat.
Figure 4 is a perspective view of an embodiment of the article of Figure 1;
Figure 5 is a plan view of the substrate of the article of Figure 1 with the substrate lying flat.
Figure 6 is a top view of an arrangement for use in the manufacture of the article of Figure 1, the arrangement comprising a first sheet material and a substrate.
Figure 7 is a perspective view of a bead of aerosol-generating material of the article of Figure 1;
Figure 8 is a cross-sectional side view of another embodiment of an article for use in an aerosol delivery system.
Figure 9 is a cross-sectional side view of another embodiment of an article for use in an aerosol delivery system.
Figure 10 is a cross-sectional view of an embodiment of a non-flammable aerosol delivery device.
Figure 11 is a simplified schematic diagram of components within the housing of the aerosol delivery device shown in Figure 10.
FIG. 12 is a cross-sectional view of the non-flammable aerosol delivery device shown in FIG. 10 with the article shown in FIG. 1 inserted into the device.
Figure 13 is a cross-sectional side view of another embodiment of an article for use in an aerosol delivery system.
Figure 14 is a block diagram illustrating a method of manufacturing an article for use in an aerosol delivery system.
Figure 15A is a top view of the first step of a method of manufacturing an article for use in an aerosol delivery device.
Figure 15B is a top view of the second step of a method of manufacturing an article for use in an aerosol delivery system.
Figure 15C is a top view of the third step of a method of manufacturing an article for use in an aerosol delivery system.
Figure 15D is a top view of the fourth step of a method of manufacturing consumables for use in an aerosol delivery system.
Figure 15E is a top view of the fifth step of a method of manufacturing an article for use in an aerosol delivery system.
Figure 15F is a cross-sectional side view of the sixth step of a method of making an article for use in an aerosol delivery system.
Figure 15G is a cross-sectional side view of the seventh step of a method of making an article for use in an aerosol delivery system.
Figure 16 is a schematic diagram of an apparatus for manufacturing articles for use in an aerosol delivery system.
Figure 17 is a cross-sectional side view of another embodiment of an article for use in an aerosol delivery system.
Figure 18 is a top view of the first sheet material and substrate of the article of Figure 1, with the first sheet material and substrate lying flat.

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

Combustible aerosol delivery systems, such as cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, regenerated tobacco, tobacco substitutes or other smokable materials) Tobacco for cigarettes, cigarillos, cigars, and pipes or for roll-your-own or make-your-own cigarettes;

non-flammable aerosol delivery systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as e-cigarettes, tobacco heating products and hybrid systems for generating an aerosol using a combination of aerosol-generating materials; and

at least one substance without forming an aerosol, including, but not limited to, oral products such as lozenges, gummies, patches and inhalable powders and oral cigarettes including snus or moist snuff. Non-aerosol delivery systems - where at least one substance may or may not contain nicotine - that deliver to the user orally, nasally, transdermally or otherwise.

According to the present disclosure, a “non-flammable” aerosol delivery system is one in which the constituent 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 it is noted that the presence of nicotine in the aerosol generating material is not a requirement. .

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

In some embodiments, the non-flammable aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol generating materials, one or more of which 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-flammable aerosol delivery system may include a non-flammable aerosol delivery device and consumables for use with the non-flammable aerosol delivery device.

In some embodiments, the present disclosure relates to consumables that include an aerosol generating material and are configured for use with non-flammable aerosol presentation devices. These consumables are sometimes 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 being drawn through the article or device in use. References to 'distal end' refer to the upstream end of the device, while 'proximal end' refers to the downstream end of the device.

In some embodiments, a non-flammable aerosol delivery system, such as a non-flammable aerosol delivery device, can include a power source and a controller. The power source may be, for example, an electric power source or an exothermic power source. In some embodiments, the heating 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 heating power source.

In some embodiments, a 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.

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

Consumables include the materials to be delivered. The substance to be delivered is an aerosol-generating material. As appropriate, the material may include one or more active ingredients, one or more flavors, one or more aerosol former materials, and/or one or more other functional materials.

In some embodiments, the substance to be delivered includes an active substance. As used herein, the active agent may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substances may be selected from, for example, nutraceuticals, nootropics, and psychoactives. 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 components, derivatives, or May include 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 noted 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” includes extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, bark, bark, etc. (but not limited to), any material derived from plants. Alternatively, the material may contain active compounds naturally present in herbal medicines obtained synthetically. Materials may be in the form of liquids, gases, solids, powders, dust, shredded particles, granules, pellets, shreds, strips, sheets, etc. You can. Examples of herbal medicines include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, and flax. ), ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin ), papaya, rose, sage, tea (e.g. green or black tea), thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaf. (bay leaves), cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elder. Elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom. blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm ), lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine ( theacrine, maca, ashwagandha, 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. c.v. (Mentha piperita citrata c.v.), Mentha piperita c.v., Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suablens 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 their components, derivatives or extracts, and the herbal medicine is tobacco.

In some embodiments, the active substance comprises or is derived from one or more herbal medicines or their components, derivatives or extracts, and the herbal medicine is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active agent comprises or is derived from one or more herbal medicines or their components, derivatives or extracts, and the herbal medicine is selected from rooibos and fennel.

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

As used herein, the terms “flavor” and “flavor” refer to ingredients that can be used to create a desired taste, aroma or other physical sensation in products for adult consumers, where local regulations allow. . These include naturally occurring flavoring ingredients, plants, extracts of plants, 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 Peppermint, Aniseed, Cinnamon, Turmeric, Indian Spices, Asian Spices, Herbs, Wintergreen, Cherry, Berry, Red Berries, cranberries, peaches, apples, oranges, mangoes, tangerines, lemons, limes, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumbers, blueberries, mulberry, citrus fruits, Drambuie, bourbon, scotch. , whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, cartcha, snuff, betel tree, shisha, pine, honeycomb essence, Rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cornac, jasmine, ylang-ylang, sage, fennel, horseradish, allspice, ginger, coriander, coffee, hemp, peppermint ( Mint oil, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazelnut, hibiscus, laurel, mate, orange skin, from any species of the genus Mentha. , roses, teas such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, turmeric, coriander, myrtle, cassis, varelian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carby, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugar and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives. , such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. These may be man-made, synthetic or natural ingredients or blends thereof. These may be in any suitable form, for example liquids such as oils, solids such as powders, or gases.

In some embodiments, the flavoring agent 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 flavor 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 bodily sensation that is generally chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of the directional or gustatory nerves. These may include agents that provide heating, cooling, tingling, and numbing effects. A suitable thermogenic agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol, WS-3.

Aerosol-generating materials may be or include “amorphous solids.” In some embodiments, the aerosol-generating material includes an aerosol-generating membrane that is an amorphous solid. Amorphous solids may be “monolithic solids.” Amorphous solids may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it. In some embodiments, the amorphous solid may include, for example, from about 50%, 60%, or 70% by weight of amorphous solid to about 90%, 95%, or 100% by weight of amorphous solid. Aerosol-generating materials may also be referred to as aerosol-capable materials.

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. An aerosol-generating material is incorporated into an article for use in an aerosol-generating system.

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, puffed tobacco, regenerated tobacco or tobacco substitutes. The tobacco material may include one or more of shredded tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, regenerated tobacco, and/or tobacco extract.

A consumable is an article that contains or consists of aerosol-generating materials, some or all of which are intended to be consumed during use by a user. The consumable may include one or more other components, such as an aerosol-generating material storage region, an aerosol-generating material delivery component, an aerosol-generating region, a housing, a wrapper, a mouthpiece, a filter, and/or an aerosol generating agent. The consumable may also include an aerosol generator, particularly a heating element that emits heat such that the aerosol generating material generates an aerosol upon use. The heater may include a material capable of being heated by electrical conduction, or a susceptor.

The aerosol-generating material 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-capable materials may be present on the substrate. The substrate is or includes, for example, paper, card, paperboard, cardboard, recycled aerosol-capable material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. can do.

The aerosol former material may include one or more ingredients capable of forming an aerosol. In some embodiments, the aerosol former material is glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillatate. , ethyl laurate, diethyl subrate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. It may contain more than one.

One or more other functional materials may include one or more of pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and/or antioxidants.

A consumable is an article that contains or consists of aerosol-generating materials, some or all of which are intended to be consumed during use by a user. The consumable may include one or more other components, such as an aerosol-generating material storage region, an aerosol-generating material delivery component, an aerosol-generating region, a housing, a wrapper, a mouthpiece, a filter, and/or an aerosol generating agent. Additionally, the consumable may include an aerosol generator, such as a heater, that 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 heatable by electrical conduction, or a susceptor.

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

Aerosol modifiers are substances, typically located downstream of the aerosol generating area, that are configured to modify the produced aerosol, for example by altering the taste, flavor, acidity or other properties of the aerosol. The aerosol modifier may be provided in 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 can be, for example, solid, liquid or gel. Aerosol modifiers may be in powder, thread or granular form. The aerosol modifier may be free of filtration material.

An aerosol generator is a device configured to produce 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 can be configured to subject the aerosol generating material to one or more of vibration, increased pressure, or electrostatic energy.

The filament tow materials described herein may include cellulose acetate fiber tow. Additionally, filament tows include polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), and poly(1-4 butanediol succinate). 4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials and polysaccharides. It can be formed using other materials used to form fibers, such as polymers or combinations thereof. The filament tow may be plasticized with a plasticizer suitable for the tow, such as triacetin if the material is a cellulose acetate tow, or the tow may be unplasticized. The tows can be of different cross sections such as 'Y' shape or 'X' shape, filamentary denier values of 2.5 to 15 denier per filament, for example 8.0 to 11.0 denier per filament and 5,000 to 50,000, e.g. It can have any suitable specification, such as fibers having total denier values between 10,000 and 40,000.

In the drawings described herein, like reference numbers are used to illustrate equivalent features, items or components.

1 is a side cross-sectional view of an article 1 for use in an aerosol delivery system including an aerosol delivery device 200 (see FIGS. 10-12).

Article 1 has an upstream or distal end ('D') and a downstream or proximal end (P'). In some embodiments, the proximal end (P) is positioned relatively closer to the mouthpiece 207 of the aerosol delivery device 200 than the distal end (D) during use. In another embodiment (not shown), the proximal end P of article 1 includes a mouthpiece. In some embodiments (not shown), the proximal end P of article 1 forms a mouthpiece.

It should be appreciated that the article 1 may be used with the aerosol delivery device 200 in either orientation, such that in some embodiments it does not matter which end of the article 1 is upstream and which is downstream. do.

The article (1) includes a substrate (2) and a body (3) of material. The substrate 2 at least partially surrounds the body 3 of material.

In this example, the substrate 2 is in the form of a patch 2.

The patch (2) comprises a first aerosol-generating material (4). The body of material (3) comprises a second aerosol-generating material (5).

In this example, the first sheet material 6 and the patch 2 are arranged such that the patch 2 is provided on the inner surface of the first sheet material 6. That is, the patch 2 is located radially inside the first sheet material 6. In some embodiments, first sheet material 6 surrounds, or at least partially surrounds, patch 2. However, in alternative embodiments (not shown), the patch 2 is positioned on the outer surface of the first sheet material 6 such that the first sheet material 6 is positioned radially inside the patch 2. It must be recognized that it can be provided on the table.

In some embodiments, first sheet material 6 forms outer surface 1A of article 1. In this example, first sheet material 6 forms the generally cylindrical peripheral surface 1A of article 1.

Patch 2 comprises a second sheet material 7. In this example, the second sheet material 7 is a cast sheet. For example, the second sheet material 7 can be formed from a slurry that is cast (eg, by heating) to form the second sheet material 7 and then solidified.

In some embodiments, the slurry is cast and dried to form a second sheet material 7, which is subsequently attached to the first sheet material 6.

In other embodiments, the slurry is applied to the first sheet material 6 such that when the slurry dries, it forms a second sheet material 7 (e.g., patch 2) that adheres to the first sheet material 6. ) can be cast in the right place on the surface. The first aerosol-generating material 4 may be provided to the slurry before being applied to the first sheet material 6, or may be applied to or mixed with the slurry after the slurry has been applied to the first sheet material 6. .

1 to 6, the first aerosol-generating material 4 is attached to the first surface of the second sheet material 7. In this example, the first aerosol-generating material (4) is attached to the first surface of the second sheet material (7). For example, an adhesive (not shown) may be applied to either the first aerosol generating material 4 or the second sheet material 7 or both.

The first aerosol-generating material 4 may be loose aerosol-generating material (eg dust, fibers or beads/pellets/granules) attached to the second sheet material 7.

In some embodiments, second sheet material 7 includes one or more of paper, card, and/or aerosol generating material. The second sheet material 7 may comprise recycled tobacco.

In this example, the body 3 of material is a rod 3 comprising a second aerosol-generating material 5 . The body 3 of material may be a tobacco stick 3. For example, the body 3 of material may be a stick comprising shredded lamina tobacco and/or shredded remanufactured tobacco (eg shredded remanufactured tobacco sheets).

In another embodiment (not shown), the body 3 of material includes a third sheet of material collected to form the body 3 of material. The third sheet material may comprise a second aerosol-generating material 5, which may optionally include, consist of, or consist essentially of tobacco material. For example, the third sheet material may be recycled tobacco collected to form the body 3 of material.

In some embodiments, the third sheet material is crimped to facilitate collection of the third sheet material to form the body 3 of material.

In some embodiments, the third sheet material is cut into strips, and the strips are then formed into the body 3 of material.

In some embodiments, patch 2 is in direct contact with body 3 of material. This helps promote heat transfer between the patch 2 and the body 3 of material.

Patch 2 includes opposing first and second edges 2A, 2B. In this example, the first edge 2A of the patch 2 is spaced apart from the first end 3A of the body 3 of material, and the second edge 2B of the patch 2 is spaced apart from the first end 3A of the body 3 of material. ) is spaced apart from the second end (3B).

In this example, the first sheet of material 6 includes opposing first and second edges 6A, 6B. The patch 2 is positioned such that the first edge 2A of the patch 2 is close to but spaced apart from the first edge 6A of the first sheet of material 6 and the second edge 2B of the patch 2 ) can be positioned on the first sheet of material 6, close to but spaced apart from the second edge 6B of the first sheet of material 6. In an alternative embodiment, the first edge 2A of the patch 2 is aligned with the first edge 6A of the first sheet of material 6 and/or the second edge 2B of the patch 2 is It is aligned with the second edge 6B of the second material sheet 6.

In this example, patch 2 extends over a portion of the axial length of body 3 of material. However, it should be appreciated that in other embodiments the patch 2 extends over the entire axial length of the body 3 of material.

In this example, the body 3 of material extends over a portion of the length of the article 1 (shown by arrow 'X' in Figure 1). In an alternative embodiment, the body 3 of material extends over the entire length X of the article 1.

In some embodiments, patch 2 includes opposing third and fourth edges 2C, 2D and first sheet material 6 has opposing third and fourth edges 6C, 6D. ) includes. The third edge 2C of the patch 2 is a third edge of the first sheet material 6, such that the first sheet material 6 includes an area 8 not covered by the patch 2. 6C) can be separated from The region 8 may be arranged to overlap the fourth edge 6D of the first sheet material 6 and may be adhered to the outer surface of the first sheet material 6 . The area 8 not covered by the patch 2 facilitates adhesion of the inner surface of the area 8 of the first sheet material 6 to the outer surface of the first sheet material 6 .

The article 1 is configured to be heated by the aerosol providing device 200 such that the first and second aerosol generating materials 4, 5 are heated to generate an aerosol.

In this example, the first sheet material 6 has a permeability of at most 100 Coresta units, and preferably at most 90, 80, 70, 60 or 50 Coresta units. In some embodiments, first sheet material 6 is a porous material and may have a permeability greater than 100 Coresta units. Alternatively or additionally, the first sheet material 6 may include one or more slits or apertures to increase the permeability of the first sheet material 6.

In some embodiments, first sheet material 6 has a thickness ranging from 20 to 100 microns. It has been found that reducing the thickness of the first sheet material (6) helps facilitate heat transfer to the first and second aerosol generating materials (4, 5). In some embodiments, first sheet material 6 is a porous material.

Increasing heat transfer through the sheet material 6 advantageously improves the efficiency of heating the first and second aerosol-generating materials 4, 5.

In some embodiments, first sheet material 6 has a basis weight ranging from 20 to 50 gsm.

In some embodiments, the first and/or second aerosol generating material 4, 5 is a loose material.

In this example, the first aerosol-generating material 4 comprises extruded and/or compressed aerosol-generating material, as described in more detail below. However, it should be appreciated that in other embodiments, the first aerosol-generating material 4 may have a different form.

In some embodiments, the first and/or second aerosol-generating material 4, 5 includes beads. The beads may be cylindrical, or may have alternative shapes, such as spherical, pyramidal or cuboidal shapes.

In this example, the first aerosol-generating material 4 comprises beads 4.

In some embodiments, the beads 4 have a diameter (shown by arrow 'D' in Figure 7) ranging from 0.5 to 3 mm, preferably ranging from 1 to 2 mm.

In some embodiments, the beads 4 have an axial length (shown by arrow 'L' in Figure 7) ranging from 0.5 to 3 mm, preferably ranging from 1 to 2 mm.

In some embodiments, the beads 4 have a particle size in the range of 0.5 to 3 mm, preferably in the range of 1 to 2 mm.

In some embodiments, the first and/or second aerosol-generating material 4, 5 includes, consists of, or consists essentially of tobacco material.

In some embodiments, the tobacco material 4, 5 of the first and/or second aerosol-generating material is derived only from tobacco lamina and not from other types of tobacco material.

In some embodiments, the first and/or second aerosol generating material 4, 5 includes tobacco lamina and regenerated tobacco.

In some embodiments, the first and second aerosol-generating materials 4, 5 together are in the range of 0.5% to 2.5% by weight of the first and second aerosol-generating materials 4, 5, and preferably Typically, it has an average nicotine level in the range of 1% to 2.1%.

In some embodiments, the first aerosol-generating material 4 has a nicotine level in the range of 0.5% to 2.5% by weight of the first aerosol-generating material 4, and preferably in the range of 1% to 2.1%. have

In some embodiments, the second aerosol-generating material 5 has an average nicotine content within the range of 0.5% to 2.5% by weight of the second aerosol-generating material 5, and preferably in the range of 1% to 2.1%. It has a level.

In some embodiments, the aerosol-generating material of article 1 includes approximately 50% of first aerosol-generating material 4 and approximately 50% of second aerosol-generating material 5 by weight. Thus, for example, an article comprising 260 mg of aerosol-generating material may comprise 130 mg of the first aerosol-generating material 4 and 130 mg of the second aerosol-generating material 5.

In some embodiments, article 1 comprises about 20 to about 330 mg of first aerosol-generating material 4, and preferably about 50 to about 300 mg, or about 40 to about 125 mg of first aerosol-generating material. Includes material (4).

In some embodiments, article 2 comprises about 20 to about 330 mg of second aerosol-generating material 5, and preferably about 50 to about 300 mg, or about 40 to about 125 mg of second aerosol-generating material. Includes ingredients (5).

In some embodiments, the total mass of aerosol generating materials 4, 5 of article 1 is in the range of 80 to 350 mg, preferably in the range of about 120 to 330 mg, or about 150 to 300 mg. It is within.

In some embodiments, the total mass of tobacco of article 1 ranges from about 80 to 350 mg, preferably from about 120 to 330 mg, or from about 150 to 300 mg.

In some embodiments, the first and/or second aerosol-generating materials 4, 5 are solid materials.

In some embodiments, the first and second aerosol generating materials are different materials and/or have one or more different properties.

The article 1 may have an axial length (shown by arrow 'X' in Figure 1) of at least 10 mm, preferably of at least 12, 14, 16, 18, 20, 22 or 23 mm.

The article 1 may have an axial length of at most 36 mm, preferably at most 34, 32, 30, 28, 26, 24 or 23 mm.

The article 1 may have an axial length in the range of 10 to 36 mm, and preferably in the range of 14 to 32 mm, in the range of 20 to 26 mm, or in the range of 22 to 24 mm.

In some embodiments, one or more of the first sheet material 6, the second sheet material 7, the substrate 2, and/or the body 3 of material do not include plastic. This makes the article 1 more environmentally friendly and is also advantageous in embodiments where the entire article 1 is heated by the aerosol delivery device 200 (described below).

In some embodiments, the entire article 1 does not include plastic. In some embodiments, the body 3 of material or the entire article 1 does not include cellulose acetate.

In some embodiments, the first and/or second aerosol-generating materials 4, 5 may comprise, consist of, or consist essentially of plant-based materials. The plant material may be tobacco material. 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, puffed tobacco, regenerated tobacco or tobacco substitutes. The tobacco material may include one or more of shredded tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, regenerated tobacco, and/or tobacco extract.

In some embodiments, the first and/or second aerosol generating material 4 , 5 or another material (not shown) of the article 1, for example another material of the body 3 of the material 1 It may contain the above aerosol-forming materials. For example, the first and/or second aerosol-generating materials 4, 5 or the other materials may comprise one or more components 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 suberate), triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, It includes one or more of lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol former material may be glycerol or propylene glycol.

The first and/or second aerosol-generating material 4, 5 may be provided as a loose material. For example, the first aerosol-generating material 4 may be a loose material held in place in the substrate 2 by means of an adhesive or by being formed into a second sheet material 7 . The first and/or second aerosol-generating material 4, 5 may be, for example, discrete strands or particles of aerosol-generating material. Another example of loose aerosol-generating material are beads/pellets of aerosol-generating material, comprising aerosol-generating material that is extruded and then cut into beads/pellets. Another example of an aerosol-generating material is a sheet of aerosol-generating material cut into individual pieces, for example cut into individual strips of aerosol-generating material. The sheet of aerosol generating material may be a sheet of recycled tobacco.

For example, the body 3 of material may comprise sheets of a second aerosol-generating material collected to form the body 3 of material.

In some embodiments, article 1 further includes a third aerosol-generating material. In some such embodiments, the body 3 of material includes second and third aerosol-generating materials. For example, the body 3 of material may be formed from sheets/strips of one of the second or third aerosol-generating materials and beads/dust/of the other of the second or third aerosol-generating materials. Fibers can be applied to sheets/strips.

In another embodiment, substrate 2 includes first and third aerosol generating materials. For example, the second sheet material 7 of the substrate 2 may be formed from one of the first and third aerosol-generating materials, and beads of the other of the first and third aerosol-generating materials/ The dust/fibers may be applied to (eg glued to) the second sheet material 7 .

In this example, the second aerosol generating material 4 comprises shredded tobacco material (eg shredded lamina and/or shredded regenerated tobacco). The shredded tobacco material is formed into tobacco sticks (3). Patch 2 at least partially surrounds rod 3.

In this example, the first aerosol-generating material 4 comprises extruded and/or compressed tobacco. In these embodiments, the first aerosol-generating material 4 may comprise a single body of aerosol-generating material. However, in this example, the first aerosol-generating material 4 comprises a plurality of bodies of aerosol-generating material.

In this example, the first aerosol-generating material 4 comprises beads/pellets/granules of aerosol-generating material (hereinafter referred to as 'beads' of aerosol-generating material). The beads 4 may be extruded and/or compressed beads 4 .

Optionally, one of the first aerosol-generating materials (4, 5) has a higher density than the other of the first and second aerosol-generating materials (4, 5). This has been found to cause denser aerosol-generating materials to heat more slowly when subjected to a given heating power. This means that the initially less dense material (e.g. second aerosol-generating material 5) produces one or more volatile compounds at a higher rate than the more dense material (e.g. first aerosol-generating material 4). means that it will release substances (e.g. nicotine). This also means that a less dense material (e.g. the second aerosol-generating material 5) absorbs the volatile compound(s) more rapidly than a more dense material (e.g. the first aerosol-generating material 4). This means that it will be relatively depleted. However, as the less dense material (e.g., the second aerosol-generating material (5)) begins to be relatively depleted of the volatile compound(s), the more dense material (e.g., the first aerosol-generating material (5)) 4)) will begin to reach a temperature at which it will begin to release volatile compound(s) at a higher rate. The effect of this is a more consistent release of volatile compound(s) over the period of consumption of the article 1, with the less dense material (e.g. the second aerosol-generating material 5) being used throughout the consumption of the article 1. Releasing a greater proportion of the volatile compound(s) towards the beginning, the denser material (e.g. first aerosol-generating material 4) releases more volatile compound(s) towards the end of consumption of the article 1. emits a greater proportion of This is particularly advantageous because the article 1 can be made relatively small and still achieve relatively consistent and/or sufficient release of volatile compound(s) over the consumption period.

In some embodiments, the one or more volatile compound(s) released by the first aerosol-generating material (4) is the same as the volatile compound(s) released by the second aerosol-generating material (5).

In some embodiments, the first aerosol-generating material 4 is configured such that the density of the first aerosol-generating material 4 is higher than the density of the second aerosol-generating material 5 (without subsequent expansion or with relatively low/minimal expansion). aerosol-generating materials that have been compressed or extruded (by expansion).

In some embodiments, the second aerosol generating material 5 is: tobacco lamina; Contains one or more of tobacco stems or regenerated tobacco. In one such embodiment, the second aerosol-generating material 5 comprises a mixture of tobacco lamina and regenerated tobacco. The second aerosol-generating material 5 may comprise shredded or cut material. However, in other embodiments, the second aerosol-generating material 5 has a lower density than the first aerosol-generating material 4 (e.g., has a lower compression than the first aerosol-generating material 4). , which may optionally also be extruded or compressed). For example, the body of material 3 may comprise an extruded/compressed body of a second aerosol generating material 5 .

In some embodiments, the first and second aerosol generating materials 4, 5 may comprise the same material, for example tobacco, but are processed to have different densities. In one such embodiment, the first and second aerosol generating materials 4, 5 may be of different shapes. For example, the second aerosol-generating material 5 may be shredded material (e.g. shredded lamina tobacco and/or shredded recyclable tobacco) formed into the body 3, while the first aerosol-generating material The material 4 can be compressed or extruded (without or with minimal expansion) such that the first aerosol-generating material 4 has a higher density than the second aerosol-generating material 5 .

For example, the first aerosol-generating material 4 may be in the form of extruded/compressed beads of aerosol-generating material (e.g. tobacco or other material) and the second aerosol-generating material 5 may be, for example , strands or strips of aerosol-generating material (eg, tobacco or other material); Sheets of aerosol-generating material collected into plugs or cut into strips; rods of aerosol-generating material (e.g., rods formed from cut rag tobacco); or it may be in the form of a tobacco lamina and/or stem material formed into a plug. However, it should be appreciated that the first, second and/or third aerosol generating materials 4, 5 may alternatively have the same form (eg both are cutting lag tobacco).

It should be appreciated that in alternative embodiments, the density of the first aerosol-generating material 4 is lower than the density of the second aerosol-generating material 5 . In another embodiment, the densities of the first and second aerosol-generating materials 4, 5 are the same.

In some embodiments, the first aerosol-generating material 4 has at least one additional different property than the second aerosol-generating material 5. The different properties include the type of materials forming the first and second aerosol-generating materials 4, 5 (including their recipe when each of the aerosol-generating materials 4, 5 is made from more than one material). , size, moisture content, amount (by weight), material or materials, or ratio. In some embodiments, the first and second aerosol-generating materials 4, 5 do not have different properties other than being in different shapes.

The first and/or second aerosol-generating material 4, 5 may comprise a plurality of strands or strips of aerosol-generating material. For example, the first and/or second aerosol-generating material 4, 5 may comprise a plurality of strands or strips of an aerosol-capable material and/or a plurality of strands or strips of an amorphous solid.

The first and/or second aerosol-generating materials 4, 5 may comprise plant-based materials, such as tobacco materials. The first and/or second aerosol-generating material 4, 5 may be a sheet or shredded sheet of aerosol-enabled material, including plant-based material such as tobacco material. The sheet material can be processed such that the second aerosol-generating material (5) has a higher density than the first aerosol-generating material (4).

Plant-based materials may be particulate or granular. In some embodiments, the plant-based material is a powder. Alternatively or additionally, the plant-based material may include strips, strands or fibers of tobacco. For example, where tobacco material is provided, the 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 tobacco material of the first and/or second aerosol-generating material 4, 5 may comprise tobacco obtained from any part of the tobacco plant. In some embodiments, the tobacco material includes tobacco leaves.

The sheets or shredded sheets may include from 5% to about 90% tobacco leaves by weight.

In some embodiments, both the first and/or second aerosol-generating material 4, 5 comprises, consists of, or consists essentially of tobacco material.

In some embodiments, the first and/or second aerosol-generating material 4, 5 comprises a sheet or shredded sheet of aerosol-enabled material comprising an aerosol-forming 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 comprises about 5% to about 40% by dry weight of the sheet or shredded sheet, about 10% to about 30% by dry weight of the sheet or shredded sheet, or about 10% to about 30% by dry weight of the sheet or shredded sheet. It is provided in an amount of about 10% to about 20% based on the dry weight of the sheet.

The first and/or second aerosol-generating materials 4, 5 may comprise fillers. Fillers are generally non-tobacco components, that is, components that do not contain ingredients derived from tobacco. 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. You can. The filler may be wood fiber or non-tobacco fiber such as pulp or wheat fiber. The filler may be a material comprising cellulose, or the material comprises a derivative of cellulose. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material. In some embodiments, the first and/or second aerosol generating materials 4, 5 are in the form of sheets containing filler or shredded sheets.

The first and/or second aerosol generating materials 4, 5 may include an aerosol modifier, such as any of the flavors described herein. In one embodiment, the first and/or second aerosol generating materials 4, 5 comprise menthol. When the first and/or second aerosol generating materials 4, 5 are incorporated into an article 1 for use in an aerosol delivery system, the article may be referred to as a menthol-containing consumable or article 1. The first and/or second aerosol generating materials 4, 5 may comprise 0.5 mg to 20 mg menthol, 0.7 mg to 20 mg menthol, 1 mg to 18 mg or 8 mg to 16 mg menthol. there is.

In some embodiments, article 1 includes an aerosol-generating composition that includes an aerosol-generating material. The aerosol-generating material may comprise a first and/or second aerosol-generating material 4, 5 (and/or a third aerosol-generating material).

An aerosol-generating material is a material that is capable of generating an aerosol, for example, when heated, irradiated, or energized in any other way. The aerosol-generating material (e.g., the first and/or second aerosol-generating material 4, 5) may be in the form of, for example, a solid, liquid, semi-solid (such as a gel), which comprises the active substance and /or may or may not have flavours.

The aerosol-generating material (eg, first and/or second aerosol-generating material 4, 5) may include a binder and an aerosol former. Optionally, activators and/or fillers may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material (e.g., first and/or second aerosol-generating material 4, 5) is substantially free of plant material. In particular, in some embodiments, the aerosol-generating material (e.g., first and/or second aerosol-generating material 4, 5) is substantially tobacco-free.

In some embodiments, the composition of the first and/or second aerosol-generating materials 4, 5 includes an aerosol-forming “amorphous solid.” Amorphous solids may be “monolithic solids.” In some embodiments, the amorphous solid may be a dried gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material may comprise, for example, about 50%, 60%, or 70% amorphous solids by weight to about 90%, 95%, or 100% amorphous solids by weight. Amorphous solids may be substantially non-fibrous.

In some examples, the amorphous solid is:

- 1 to 60 wt% of gelling agent;

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

- Contains from 0.1 to 80 wt% of flavor;

These weights are calculated on a dry weight basis.

In some further embodiments, the amorphous solid is:

- 1 to 50 wt% of gelling agent;

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

- Contains 30 to 60 wt% of flavor;

These weights are calculated on a dry weight basis.

The aerosol-generating material (eg, first and/or second aerosol-generating material 4, 5) may be or include an aerosol-generating membrane. An aerosol-generating membrane is formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol former, and one or more other ingredients, such as active materials, to form a slurry, and then heating the slurry to form an aerosol-generating membrane. It can be formed by volatilizing at least a portion of. The slurry can be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent. The aerosol-generating membrane may be a continuous membrane or a discontinuous membrane, such as an arrangement of discrete portions of the membrane on a support. The aerosol-generating membrane can be substantially tobacco-free.

The aerosol-generating membrane may be a sheet or include a sheet that can be selectively fractured to form a fractured sheet.

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

In each of the embodiments of article 1 described herein, the article may comprise such first and/or second aerosol-generating materials 4, 5 (and/or third aerosol-generating materials), and such aerosol It may include a production composition.

Amorphous solid materials may be provided in sheet or broken sheet form. The amorphous solid material can take the form of sheets or shredded sheets of aerosol-capable material.

In some embodiments, the aerosol-generating material, e.g., the first or second aerosol-generating material 4, 5, comprises about 10 to about 50 wt% aerosol former material; About 15 to about 60 wt% gelling agent; and optionally a filler; Weight percent values are calculated on a dry weight basis.

The first and/or second aerosol generating materials 4, 5 may comprise recycled paper tobacco material. The composition may alternatively or additionally include any of the forms described herein. The first and/or second aerosol generating materials 4, 5 may comprise sheets or shredded sheets comprising tobacco material comprising 10% to 90% by weight of tobacco leaves, wherein the aerosol former The material is provided in an amount of up to about 20% by weight sheet or shredded sheet, with the remainder of the tobacco material comprising paper recycled tobacco.

If the first and/or second aerosol-generating material 4, 5 comprises an amorphous solid material, the amorphous solid material may be a dried gel comprising menthol.

In some embodiments, the first and/or second aerosol-generating material 4, 5 comprises extruded aerosol-generating material that is then cut into beads of pellets.

Referring now to FIG. 8 , an alternative article 1 to an aerosol delivery device 200 is shown. The article 1 has similar features to the article 1 described above in relation to FIGS. 1 to 7 , the similar features bearing the same reference numerals, and any of the variations of the features described herein. You can have it. The difference is that instead of the first aerosol-generating material 4 being applied to the surface of the second sheet material 7, the substrate 2 comprises a second sheet material 7 comprising the first aerosol-generating material 4. It means doing it. For example, the second sheet of material 7 may be formed from the first aerosol-generating material 4 . The first aerosol-generating material (4) may be integral with the second sheet material (7).

In one such embodiment, the second sheet material 7 is formed from a slurry, where the first aerosol-generating material 4 is provided as a slurry, and then the second sheet material 7 is formed from the slurry. For example, the second sheet material 7 can be cast from a slurry comprising the first aerosol-generating material 4.

In another embodiment (not shown), the second sheet material 7 comprises the first aerosol-generating material 4 (e.g., formed from a slurry comprising the first aerosol-generating material 4). , where the third aerosol-generating material is applied to the surface of the second sheet material 7 (e.g. held in place by an adhesive).

Referring now to Figure 9, another article 1 for aerosol delivery device 200 is shown. The article 1 has similar features to the article 1 described above in relation to FIGS. 1 to 7 , the similar features bearing the same reference numerals, and any of the variations of the features described herein. You can have it. The difference is that the substrate 2 in the embodiment of Figure 9 extends over the entire axial length of the article 1 (shown by arrow 'X'). In this embodiment, both the second sheet material 7 and the first aerosol generating material 4 extend over substantially the entire axial length X of the article 1. However, in alternative embodiments, the second sheet material 7 may extend over substantially the entire axial length It should be recognized that 1) can only extend over a part of the axial length.

Embodiments in which the first aerosol-generating material (4) extends over the entire axial length (X) of the article (1) (or the entire axial length of the body (3) of the material) It provides the advantage of increasing the amount of aerosol that can be generated for a given axial length (X) of the article (1) and the amount of generating material (4).

Embodiments in which the first aerosol-generating material 4 spans only a portion of the total axial length ) and also provides the advantage of helping to reduce the likelihood of the first aerosol generating material 4 falling off from the ends P, D of the article 1.

Referring now to Figures 10-12, an embodiment of an aerosol delivery device 200 is shown.

The article 1 is configured for use in an aerosol providing device 200 (see Figure 10) comprising an aerosol generator in the form of a heating element 203 for heating the article 1. In this example, the heating element 203 at least partially surrounds the heating area 202, eg the heating chamber 202. Heating element 203 may be heated resistively and/or inductively.

In other embodiments (not shown), the heating element 203 instead includes a blade or pin for insertion into the article 1, e.g. It can be inserted through In other embodiments (not shown), the consumable 1 may comprise a heating element, which may for example be embedded in the body 3 of material.

In Figure 10, the components of an embodiment of an aerosol presentation device 200 are shown in a simplified manner. In particular, elements of the aerosol presentation device 200 are not shown to scale in FIG. 10 . Elements that are not relevant to the understanding of this embodiment have been omitted to simplify FIG. 10.

In the example of FIG. 10 , aerosol delivery device 200 is a non-flammable aerosol delivery device 200 . Non-flammable aerosol delivery device 200 includes a housing 201 comprising an area 202 for receiving an article 1.

When the article 1 is received within the heating zone 202 , at least a portion of the article 1 is brought into thermal proximity with the heater 203 . Accordingly, at least a portion of the aerosol generating material 4, 5 is in thermal proximity to the heater 203. In some embodiments, heater 203 is spaced apart from article 1, for example, surrounds article 1 but has a larger diameter and is spaced apart from article 1. In other embodiments, the heater 203 is in direct contact with the article 1, for example contacting the outer surface of the first sheet material 6 of the article. In another embodiment, the heater 203 includes blades or pins that contact the interior of the article 1, for example, the body 3 of material and/or the substrate 2.

When the article 1 is heated, the first and/or second aerosol-generating materials 4, 5 will release one or more volatile compounds and may release a range of volatile compounds at different temperatures. By controlling the maximum operating temperature of the electrically heated aerosol generation system 200, the selective release of undesirable compounds can be controlled by preventing the release of selected volatile compounds.

As shown in Figure 11, within the housing 201 there is an electrical energy supply 204, for example a rechargeable lithium ion battery. Controller 205 is connected to heater 203, electrical energy supply 204, and user interface 206, for example buttons or displays. The controller 205 controls the power supplied to the heater 203 to adjust the temperature of the heater 203. Typically, the aerosol-forming substrate is heated to a temperature of 250 to 450 degrees Celsius.

Figure 12 is a schematic cross-sectional view of a non-flammable aerosol delivery device 200 of the type shown in Figure 10, wherein an article 1 is received in a heating region 202 of the device 200 for heating by a heater 203. do. Non-flammable aerosol presentation device 200 is illustrated as containing an aerosol-generating article 1 for consumption of the aerosol-generating article 1 by a user.

The housing 201 of the non-flammable aerosol delivery device 200 defines an open, cavity-shaped area 202 at the proximal end (or mouth end) for receiving the aerosol-generating article 1 for consumption by a user. do.

In this example, the aerosol presentation device 200 is configured to block the remainder of the device 200 to allow access to the area 202 so that the article 1 may be of interest to and removed from the area 202. It includes a mouthpiece 207 that is detachable from. Once article 1 is provided in area 202, mouthpiece 207 can be reattached. In some embodiments, mouthpiece 207 is removably attached to housing 201 of device 200, for example by a screw thread or bayonet connection.

When a user inhales with mouthpiece 207, air is drawn into article 1 and volatile substances condense to form an inhalable aerosol. This aerosol is delivered to the user's mouth through the mouthpiece 207 of the device 200.

It should be appreciated that in other embodiments, the mouthpiece 207 of device 200 may be omitted. In some embodiments, article 1 may form a mouthpiece and may contact the user's mouth.

In the embodiments described above, the body 3 of material extends between the ends P and D of the article 1 . However, it should be recognized that in alternative embodiments (not shown) the article 1 may comprise one or more additional segments, for example an additional segment upstream or downstream of the body 3 of material. .

For example, an alternative embodiment of the article 1 is shown in FIG. 13 , which further comprises a cooling section 25 , also referred to as a cooling element, positioned immediately downstream of the body 3 of material. In this example, cooling element 25 is immediately downstream and adjacent to body 3 of material. In some such embodiments, cooling element 25 is in abutting relationship with body 3 of material. Additionally or alternatively, the article 1 may comprise an additional body 26 of material downstream of the cooling element 25 . The additional body 26 of material may contain flavoring and/or filtration material and/or may be provided to obscure the view of the cooling element 25 .

Cooling element 25 includes a hollow channel having an internal diameter of about 1 mm to about 4 mm, for example about 2 mm to about 4 mm. The hollow channel may have an internal diameter of approximately 3 mm. The hollow channel extends along the entire length of the cooling element 25 . Cooling element 25 may comprise a single hollow channel. In alternative embodiments, cooling element 25 may include multiple channels, for example two, three, or four channels. The single hollow channel may be substantially cylindrical, but in alternative embodiments other channel geometries/cross-sections may be used. The hollow channel may provide a space in which aerosol drawn into the cooling element 25 can expand and cool. The cooling element 25 may be configured, in use, to limit the cross-sectional area of the hollow channel(s), thereby limiting tobacco displacement within the cooling element 25 .

Cooling element 25 may have a wall thickness in the radial direction. For a given outer diameter of the cooling element 25 , the wall thickness of the cooling element 25 defines the inner diameter for the chamber surrounded by the walls of the cooling element 25 . Cooling element 25 may have a wall thickness of at least about 1.5 mm and up to about 2 mm. In this example, the cooling element 25 has a wall thickness of approximately 2 mm.

Cooling element 25 may be formed from a filamentary tow. Other configurations, such as multiple layers of paper rolled in parallel with butted seams to form the cooling element 25; or spirally wound layers of paper, cardboard tubes, papermaking ( ) Tubes formed using a type process, molded or extruded plastic tubes, etc. can be used. Cooling element 25 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 element 25 is relatively thick such that at least 90% of the aerosols generated by the aerosol-generating material 3 pass longitudinally through one or more hollow channels rather than through the wall material of the cooling element 25. -Can be porous. For example, at least 92% or at least 95% of the aerosol generated by the first and/or second aerosol generating material 4, 5 may pass longitudinally through one or more hollow channels.

The cooling element 25 provides a temperature difference of at least 40 degrees Celsius between the heated volatilized component entering the first upstream end of the cooling element 25 and the heated volatilized component exiting the second downstream end of the cooling element 25. It can be configured to provide. The cooling element 25 has a temperature of at least 60 degrees Celsius between the heated volatilized component entering the first upstream end of the cooling element 25 and the heated volatilized component exiting the second downstream end of the cooling element 25, or It may be configured to provide a temperature difference of at least 80 degrees Celsius, or at least 100 degrees Celsius. This temperature difference across the length of the cooling element 25 protects the body 26 of temperature-sensitive material from the higher temperatures of the aerosol-generating materials 4, 5 when heated.

The body 26 of material defines a substantially cylindrical overall outer shape and is wrapped with a plug wrap 28. Plug wrap 28 may have a basis weight of less than 50 gsm, or about 20 gsm to 40 gsm. Plug wrap 28 may have a thickness of 30 μm to 60 μm, or 35 μm to 45 μm. Plug wrap 28 may be a non-porous plug wrap, for example having a permeability of less than 100 Coresta units, for example less than 50 Coresta units. However, in other embodiments, plug wrap 28 may be a porous plug wrap with a permeability of, for example, greater than 100 Coresta units or greater than 200 Coresta units.

Cooling element 25 and/or body 26 of material may form a mouthpiece for article 1 configured to be received within a user's mouth. It should be appreciated that in some embodiments, mouthpiece 207 of device 200 may be omitted.

In some embodiments, tipping paper (not shown) is wrapped around the cooling element 25 and the body 26 of the material, and also a first sheet of material surrounding the substrate 2 and the body 3 of the material. (6) and can be connected to these components by adhesive. Accordingly, the tipping paper connects the cooling element 25 and the body 26 of the material to the body 3 of the material. In other embodiments, the tipping paper is omitted and, instead, the first sheet material 6 is extended to surround the cooling element 25 and the body 26 of the material to connect these components to the body 3 and the material 26. Connect to substrate (2).

Referring now to FIG. 15 , a block diagram is shown illustrating an example embodiment of a method 100 of manufacturing an article 1 for an aerosol delivery device.

Method 100 includes providing a substrate comprising first aerosol-generating material 4 (S1). The method 100 also includes a step S2 of arranging the substrate 2 such that the substrate 2 at least partially surrounds the body 3 of material comprising the second aerosol-generating material 5 . In this example, substrate 2 is patch 2.

In some embodiments, method 100 further includes providing a first sheet material 6, and the substrate 2 is attached to the first sheet material 6. Optionally, the first sheet material 6 forms the outer surface 1A of the article 1.

In some embodiments, the first sheet material 6 has a permeability of up to 100 Coresta units, and preferably up to 90, 80, 70, 60 or 50 Coresta units.

In some embodiments, first sheet material 6 has a thickness ranging from 20 to 100 microns.

In some embodiments, the body 3 of material includes a tobacco stick. For example, the body 3 of material may comprise shredded or cut tobacco material shaped into sticks. In some embodiments, the body 3 of material includes cut rag tobacco formed into sticks.

In some embodiments, providing the first sheet material 6 includes providing a web of first sheet material 6. For example, the method may include providing a continuous web of first sheet material 6. The web may be fed along a transport path. The web of first sheet material 6 may be supplied from a reel.

In some embodiments, the method includes applying a substrate (2) to a web of first sheet material (6).

In some embodiments, substrate 2 includes a second sheet material 7. In one such embodiment, the second sheet material 7 is formed from a slurry. The second sheet material 7 may be a cast sheet.

In some embodiments, the second sheet material 7 is attached to the first sheet material 6, for example by an adhesive.

In some embodiments, method 100 includes applying a web of second sheet material 7 to a web of first sheet material 6. For example, continuous webs of first and second sheet materials 6, 7 can be merged and glued together.

In some embodiments, method 100 includes applying a plurality of portions of second sheet material 7 to a web of first sheet material 6. A plurality of portions of the second sheet material 7 may be spaced apart from each other on the web of the first sheet material 6 . In some embodiments, portions of second sheet material 7 are discrete. The portions of the second sheet material 7 can be spaced apart from each other in a direction along the transfer path of the web of the first sheet material 6 .

In some embodiments, the third sheet material 6 and the substrate 2 are arranged such that once wrapped around the body 3 of the material the substrate 2 is provided on the interior surface of the first sheet material 6. are arranged. In some embodiments, first sheet material 6 surrounds, or at least partially surrounds, substrate 2.

In some embodiments, substrate 2 includes opposing third and fourth edges 2C, 2D, and first sheet material 6 has opposing third and fourth edges 6C, 6D. ) includes. The third edge 2C of the patch 2 is a third edge of the first sheet material 6, such that the first sheet material 6 includes an area 8 not covered by the patch 2. 6C) can be separated from The region 8 may be arranged to overlap the fourth edge 6D of the first sheet material 6 and may be adhered to the outer surface of the first sheet material 6 . The area 8 not covered by the patch 2 facilitates adhesion of the inner surface of the area 8 of the first sheet material 6 to the outer surface of the first sheet material 6 . Method 100 may include applying adhesive to area 8 .

In some embodiments, second sheet material 7 includes first aerosol generating material 4. For example, the second sheet of material 7 may be formed from the first aerosol-generating material 4 . The first aerosol-generating material (4) may be integral with the second sheet material (7). In one such embodiment, the second sheet material 7 is formed from a slurry, where the first aerosol-generating material 4 is provided as a slurry, and then the second sheet material 7 is formed from the slurry. For example, the second sheet material 7 can be cast from a slurry comprising the first aerosol-generating material 4.

In some embodiments, the first aerosol-generating material 4 is attached to the surface of the second sheet material 7, and preferably is attached to the surface of the second sheet material 7.

The first aerosol-generating material may be attached to the surface of the second sheet material 7 before or after attaching the second sheet material 7 to the first sheet material 6.

The first aerosol-generating material 4 can be applied as a slurry or as a slurry to the first sheet material 6, which is then dried to form a layer on the first sheet material 6.

In some embodiments, second sheet material 7 includes one or more of paper, card, and/or aerosol generating material.

Method 100 may include forming a body 3 of material and then wrapping a first sheet material 6 and a substrate 2 around the body 3 of material. In another embodiment, the body 3 of material can be formed, for example, by wrapping the first sheet material 6 and the substrate 2 around the body 3 at the same time, for example, by wrapping the first sheet material 6 and the substrate 2 around the body 3 It is formed by supplying the first sheet material 6 and the substrate through the garniture together with the material formed in 3).

In some embodiments, substrate 2 surrounds the entire circumference of body 3 of material. In some embodiments, first sheet material 6 surrounds body 3 of material. In some embodiments, patch 2 surrounds body 3 of material.

In some embodiments, the first and/or second aerosol-generating material 4, 5 includes, consists of, or consists essentially of tobacco material.

In this example, the first aerosol generating material 4 comprises extruded tobacco beads.

In some embodiments, the second aerosol-generating material 5 includes shredded tobacco and/or reconstituted tobacco.

The first and second aerosol-generating materials 4, 5 and the body 3 of the material comprise any of the features described above, including those described above with respect to FIGS. 1 to 14. It should be recognized that it may have various characteristics and/or forms.

In some embodiments, the body 3 of material includes a third sheet material (not shown), and preferably the method 100 comprises a third sheet material to form the body 3 of material. Includes collecting steps. The third sheet material can optionally be crimped and/or cut into strips.

In some embodiments, the body 3 of material includes a tobacco stick. For example, the body 3 of material may comprise shredded tobacco material molded into sticks. In some embodiments, the body 3 of material includes cut rag tobacco formed into sticks.

In some embodiments, article 1 includes a third aerosol-generating material. For example, the substrate 2 or body 3 of material may comprise a third aerosol-generating material. In some embodiments, substrate 2 includes a second sheet material 7 comprising first and/or third aerosol generating materials. For example, the second sheet material 7 may be formed from a slurry comprising the first and/or third aerosol-generating materials. In some embodiments, the first and/or third aerosol generating materials are applied to the surface of the second sheet material 7. In some embodiments, the second sheet of material 7 includes one of the first and third aerosol-generating materials, and the other of the first and third aerosol-generating materials is of the second sheet of material 7. Applied to the surface.

Referring now to Figures 15A-15G, an embodiment of a method of manufacturing an article 1 for an aerosol presentation device 200 is shown. An example of an apparatus 300 for performing the method is shown in Figure 16.

In the first step (shown in Figure 15a), a continuous web W1 of second sheet material 7 is provided. In this example, the second sheet material 7 comprises a strip of paper. The continuous web (W1) may be supplied from the first reel (S1).

In the second step (shown in Figure 15b), the first aerosol-generating material 4 is applied to the surface of the web W1 of the second sheet material 7. For example, an adhesive may be applied to the web W1 and/or the first aerosol-generating material 4 such that the first aerosol-generating material 4 adheres to the web W1. In this example, the device 300 includes an applicator 301 which sprays adhesive onto the web W1 and then sprays the first aerosol-generating material under the influence of gravity, for example using a hopper. (4) is supplied. In another embodiment, the first aerosol generating material 4 may be pneumatically supplied and optionally sprayed onto the web W1.

The first aerosol-generating material 4 may be supplied as loose aerosol-generating material 4, for example loose beads/fibers/dust of the first aerosol-generating material 4.

The second sheet material 7 and the first aerosol generating material 4 may together form the substrate 2 .

It should be appreciated that in an alternative embodiment, the second sheet of material 7 comprises the first aerosol generating material 4. For example, the second sheet material 7 can be cast from a slurry comprising the first aerosol-generating material 4.

In the third step (shown in Figure 15c), a plurality of successive cuts are provided in the web W1 to form a plurality of individual portions of the substrate 2. In this example, web W1 is cut along successive cutting lines Z1-Z1 (shown in Figure 15C). Cuts may be formed using cutting device 302. For example, cutting device 302 may include a cutting drum, one or more cutting knives, or one or more lasers. In some embodiments, each individual part forms an individual patch 2.

In the fourth step (shown in Figure 15D), a plurality of individual parts of the substrate 2 are spaced apart from each other. In this example, device 300 includes a first belt conveyor 303 and a second belt conveyor 304 that operates at a faster speed than the first belt conveyor 303. Individual portions of the substrate 2 are conveyed from the first belt conveyor 303 to the second belt conveyor 304, where each individual portion of the substrate 2 is accelerated and the upstream portions of the substrate 2 is separated from In an alternative embodiment (not shown), individual parts of substrate 2 are spaced apart using spacing drums. In another embodiment, the individual parts of the substrate 2 are not spaced apart from each other.

In the fifth step (shown in Figure 15e), the individual parts of the substrate 2 are glued to the web W2 of the first sheet material 6. As web W2 passes along the conveying path, individual portions of substrate 2 are fed from second belt conveyor 304 onto web W2 of first sheet material 6. The web W2 may be supplied from the second reel S2.

The adhesive may be applied to the web W2 of the first sheet material 6 and/or to the substrate 2 (eg applied to the second sheet material 7 of the substrate 2).

In this example, the adhesive is applied by an adhesive applicator 305. The adhesive applicator 305 may be configured to spray adhesive onto the first sheet material 6 and/or the substrate 2 as it is fed along the transport path and passes the adhesive applicator 305, or Alternatively, the adhesive may be applied using one or more brushes or rollers. In another embodiment, the adhesive is pre-applied to the web W2 or substrate 2 as a hot melt adhesive, and the fifth step includes heating the adhesive to activate the adhesive.

In the sixth step (shown in Figure 15f), the web W2 of the first sheet material 6 with the individual parts of the substrate 2 on top is combined with the second aerosol-generating material 5 to form a continuous rod ( R) is formed.

In this example, the second aerosol generating material 5 is a tobacco material fed from the tobacco supply section S3. Tobacco may include, for example, shredded tobacco. In other embodiments, the tobacco material may include tobacco sheets (eg, recycled tobacco) that are collected to form a body 3 of material.

In this example, a web (W2) of first sheet material (6) with individual parts of substrate (2) on top is combined with a second aerosol-generating material (5) in a wrapping device (306).

In one embodiment, the wrapping device 306 includes, for example, a garniture tongue 307, a garniture belt (not shown), and a belt drive (not shown) that drives the garniture belt (not shown). ) may include. The belt drive may include, for example, one or more pulleys or wheels driven by an electric motor to drive the garnish belt. The garnish belt extends through the garnish tongue 307. A web W2 (hereinafter 'arrangement') of first sheet material 6 with individual parts of substrate 2 thereon, such that the action of the belt drive feeds the arrangement through garniture tongue 307, It is placed on the garnish belt. Garniture tongue 307 includes a first portion (not shown) that is shaped to form the arrangement into a U-shape as it passes through garnish tongue 307. The second aerosol generating material 5 is supplied to the garnish tongue 307 to be received in the U-shaped portion of the arrangement of the web W2 and the substrate 2.

The U-shaped arrangement then causes the second longitudinal edge of the garniture tongue 307 to be shaped to fold the first longitudinal edge (not shown) of the web W2 over an opposing second longitudinal edge (not shown). The arrangement passing through the portion (not shown) and exiting the garnish tongue 307 is formed in a cylindrical shape. In this example, the first longitudinal edge of web W2 is positioned so that the uncovered area 8 of web W2 is attached to the outer surface of web W2 to form a cylindrical shape. Close to the unused area (8). In some embodiments, the first portion of the component tongue 307 is generally U-shaped in cross-section and the second portion of the garnish tongue 307 is generally O-shaped in cross-section.

When the second aerosol-generating material 5 passes through the garnish tongue 307, it is formed into a body 3 of material. In this example, the second aerosol-generating material 5 is formed in a cylindrical shape. However, it should be recognized that in alternative embodiments the body 3 of material may have a different shape, for example having a square, rectangular, oval or triangular cross-section.

In some embodiments, wrapping device 306 further includes an adhesive applicator (not shown) configured to apply a line of adhesive to web W2 (e.g., to uncovered area 8); Accordingly, as the web W2 passes the second portion (not shown) of the garnish tongue 307, the first longitudinal edge is folded over the opposing second longitudinal edge of the web W2 and the adhesive It is glued in place by a line of Thus, a continuous rod R is formed comprising a body 3 of material circumscribed intermittently by individual parts of the substrate 2 and continuously circumscribed by the first wrapping material 6 .

In alternative embodiments (not shown), the wrapping device 306 includes, for example, a first wrapping material 6, a substrate 2 and a second aerosol generating material 5 such that the components are combined into a rod. ) has a different arrangement comprising one or more drums or conveyor belts configured to convey the parts.

In the seventh step (shown in Figure 15g), the continuous bar R is cut to form individual articles 1 or to form multiple length articles 1, which are then (with additional components) It may be subsequently cut to form individual articles 1 (optionally before or after being combined). In this example, the continuous rod R is cut along the dashed line Zz-Z2 (shown in Figure 15f) by a cutting device 308, for example a cutting drum, a reciprocating blade/knife or a laser.

Accordingly, the method described above is a continuous process, in which a continuous bar R is formed, and then the ends of the continuous bar R are repeatedly cut to form a plurality of articles 1.

Providing the first aerosol-generating material 4 on the substrate 2 enables more accurate positioning of the first aerosol-generating material 4 and thus more consistent manufacturing of the articles 1. It turned out that it does.

It should be recognized that the various steps of the method described above may be modified, performed in a different order, or omitted entirely. For example, in one alternative embodiment, the steps of cutting and spacing individual parts of the substrate 2 may be omitted. Instead, the first aerosol generating material 4 is applied to the web W1 of the second sheet material 7 and then combined with the web W2 of the first sheet material 6 and subsequently wrapping. fed through device 306 to form article 1, wherein substrate 2 is formed of a body 3 of material (e.g., to produce article 1 of the configuration shown in FIG. 9). It extends between the first end and the second end.

In another alternative, the body 3 of material is preformed, and then an arrangement of the substrate 2 and the first sheet material 6 is wrapped around the body 3 of material. In some embodiments (not shown), the individual portions of the first sheet material 6 are formed each having a respective portion of the substrate 2 attached thereto, wherein the individual portions of the first sheet material 6 The parts and the individual parts of the substrate 2 are each wrapped around a respective body 3 of material.

Referring now to FIGS. 17 and 18 , an alternative article 1 to the aerosol delivery device 200 is shown. The article 1 has similar features to the article 1 described above in relation to FIGS. 1 to 7 , the similar features bearing the same reference numerals, and any of the variations of the features described herein. You can have it. The difference is that the substrate 2 does not comprise a second sheet material 7. Instead, the first aerosol-generating material 4 is attached directly to the first sheet material 6. In this example, the first aerosol-generating material 4 is applied to the first sheet material 6 in discrete areas. However, in other embodiments (not shown), the first aerosol generating material 4 is continuous over the entire length of the first sheet material 6 between its first and second edges 6A, 6B. It is applied as. The first aerosol-generating material (4) forms a substrate (2) attached to the first wrapping material (6).

In the articles 1 shown in FIGS. 1 , 8 , 9 , 13 , 15g and 17 , the body 3 of material is shown to be compressed radially inward in the region of the substrate 2 . That is, when the substrate 2 and the first sheet material 6 are wrapped around the body 3 of material, the substrate 2 deforms the body 3 radially inward to form the body 3 of material 3. ) is compressed. However, in other embodiments, less material is provided in the portion of the body 3 of material wrapped around the substrate 2 in order to accommodate the substrate 2 without the body 3 being compressed. . In one such embodiment, the body 3 of material receiving the substrate 2 may be provided with a circumferential groove. In other embodiments, the body 3 of material is a cylindrical rod, and the substrate 2 and the first sheet material 6 are such that the cylindrical rod is not or substantially compressed by the substrate 2. is wrapped around the body 3.

In all of the above examples, the first and/or second aerosol-generating material (4, 5) may comprise, consist of or consist essentially of extruded or compressed bodies of tobacco material, preferably comprising: Extruded or compressed bodies of tobacco material contain beads of tobacco material.

In each of the above examples, the first and/or second aerosol generating material 4, 5 may comprise, consist of or consist essentially of reconstituted tobacco, preferably shredded sheets of reconstituted tobacco. Includes.

In all of the above examples, the first and/or second aerosol-generating material 4, 5 may comprise, consist of, or consist essentially of lamina tobacco.

In all of the above examples, the first and/or second aerosol generating material 4 , 5 may comprise, consist of or consist essentially of recycled tobacco and lamina tobacco, preferably recycled. Tobacco and lamina tobacco are mixed together.

In all of the above examples, the body 3 of material may comprise, consist of, or consist essentially of sheets of aerosol-generating material collected to form the body 3 of material, preferably The sheet material is crimped. Preferably, the sheet is a sheet of recycled tobacco.

In all of the above examples, the first and/or second aerosol-generating material 4, 5 may comprise, consist of, or consist essentially of sheets of aerosol-generating material cut into strips. Preferably, the sheet is a sheet of recycled tobacco. For example, the second aerosol-generating material 5 can then be cut into strips arranged to form a body 3 of material.

In all of the above examples, the first and/or second aerosol generating material 4, 5 may comprise tobacco material, wherein the tobacco material is made only from tobacco lamina and not from other types of tobacco material. It doesn't work.

In all of the above examples, the first and second aerosol-generating materials 4, 5 are made from the same aerosol-generating starter materials that are processed to have different morphologies.

In each of the examples of articles described above (including each of the articles shown in FIGS. 1-9, 12, 13, 15G, and 17), first and second aerosol-generating materials 4, 5 ) may have different densities. Alternatively, the aerosol-generating materials of the article may be the same or different. In other embodiments, the densities of the first and second aerosol-generating materials 4, 5 may be the same.

In some embodiments, the article further includes a third aerosol-generating material that may have a different density than the first and/or second aerosol-generating material.

Providing different densities of the first and second aerosol generating materials 4, 5 means that when both materials are exposed to the same heating, the higher density material heats more slowly and thus the higher density material This means that it releases its volatile compounds (e.g. nicotine) at a slower rate than lower density materials. In some embodiments, the first aerosol-generating material 4 heats more slowly than the second aerosol-generating material 5 when exposed to the same heating, such that the second aerosol-generating material 5) and has a greater density than the second aerosol-generating material (5) so as to release its volatile compounds (e.g. nicotine) at a slower rate (however, in other embodiments, the second aerosol-generating material ( The opposite may be true, such that 5) has a higher density than the first aerosol-generating material 4). Accordingly, combining aerosol-generating materials with different densities provides a more consistent and longer-lasting release of volatile compound(s). In some embodiments, different densities of aerosol-generating materials are optionally combined with separate heating of these materials at different times and/or different temperatures, e.g., to reduce the volatile compound(s) over the period of consumption of the article. Allows the provision of more customized releases of Alternatively, it may be desirable to have a more rapid or greater release of volatile substances towards the start of consumption of the article to provide the user with a greater initial impact from use. The ability to control aerosol generation and volatile compound release can be particularly advantageous because articles can be made relatively small while still achieving a particular desired release of volatile compound(s) over the consumption period.

In some embodiments, one of the first and second aerosol-generating materials (4, 5) has a density that is at least about 25% greater than the density of the other of the first and second aerosol-generating materials (4, 5), and optionally has a density that is at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, or 75% higher. said one of the first and second aerosol-generating materials (4, 5) has a density of about 200% less than the density of the other of the first and second aerosol-generating materials (4, 5), and optionally, about 150% , may have densities up to 125%, 100%, or 75% higher. In some embodiments, one of the first and second aerosol-generating materials 4, 5 has a density that is about 25% to about 75% greater than the density of the other of the first and second aerosol-generating materials 4, 5. has a higher density.

In some embodiments, said one of the first and second aerosol generating materials 4, 5 has a weight of at least about 0.4 g/cm3, and optionally at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1. , have a density of 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3. Said one of the first and second aerosol generating materials 4, 5 has an aerosol content of less than about 2 g/cm3, and optionally about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, It may have a density of less than or equal to 0.9, 0.8, 0.7, 0.6 or 0.5 g/cm3. In some embodiments, the density of one of the first and second aerosol generating materials 4, 5 is between about 0.4 and 1.99 g/cm3.

In some embodiments, the other of the first and second aerosol generating materials 4, 5 has at least about 0.1 g/cm3, and optionally at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8. or has a density of 0.9 g/cm3. The other of the first and second aerosol generating materials 4, 5 has an amount of less than or equal to about 1 g/cm3, and optionally less than or equal to about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3 or 0.2 g/cm3. It can have a density of In some embodiments, the density of the other of the first and second aerosol generating materials 4, 5 is about 0.1 to 0.9 g/cm3.

In some embodiments, the first and second aerosol-generating materials 4, 5 include the same components. Therefore, upon heating, they will release very similar aerosols, potentially with the same content of active substance and/or flavor, etc. Their different densities allow the aerosol to be generated from the two materials at different rates and/or at different times during heating.

In other embodiments, the first and second aerosol-generating materials 4, 5 comprise different components (and may have the same or different densities). Therefore, upon heating, they will release different aerosols, potentially with different compositions of active substances and/or flavours, etc. Their different densities allow different aerosols to be generated from the two materials at different rates and/or at different times during heating, potentially providing an aerosol that varies over the period of use.

In some embodiments, the first aerosol-generating material 4 and the second aerosol-generating material 5 each comprise plant material, for example tobacco. Tobacco will contain volatile components including nicotine, aroma and flavors. Tobacco includes any type of tobacco and tobacco leaves, lamina, stem, stalk, ribs, scraps and shorts or mixtures of two or more of these. It can be any part of the tobacco plant. Suitable tobacco materials include the following types: Virginia or flue-cured tobacco, Burley tobacco, Oriental tobacco, or tobacco materials optionally including those listed herein. A blend of them. Tobacco may be expanded such as dry-ice expanded tobacco (DIET) or processed by any other means. In some embodiments, the tobacco material may be recycled tobacco material. Tobacco may be pre-processed or unprocessed, for example solid stems (SS); shredded dried stems (SDS); steam treated stems (STS); Or it may be any combination thereof. Tobacco material may be fermented, cured, uncured, toasted, or otherwise pretreated.

The first and second aerosol generating materials 4, 5 may comprise different tobacco. Optionally, the cigarettes may be identical but provided in different forms, such that one of the first aerosol generating materials (4, 5) has a greater density than the other of the first and second aerosol generating materials (4, 5). has

In some embodiments, the first aerosol-generating material 4 has at least one (additional) different property than the second aerosol-generating material 5 . The different properties include the shape, size and moisture content of the materials forming the first and second aerosol-generating materials 4, 5 (including their recipe when each of the aerosol-generating materials is prepared from more than one material). It can be one or more of the following: , amount (by weight), material or materials, or ratio. In some embodiments, the first and second aerosol-generating materials 4, 5 do not have different properties other than their different densities. In other embodiments, the densities of the first and second aerosol generating materials are the same.

In some embodiments, the second aerosol generating material 5 comprises one or more tobacco in the form of a cutting lag. This tobacco material may be lamina or recycled tobacco material. In some embodiments, the second aerosol generating material 5 is a blend comprising both lamina and regenerated tobacco. For example, the ratio of laminae to regenerated tobacco may be from about 1:4 to about 4:1.

In some embodiments, the first aerosol-generating material 4 has a greater density than the second aerosol-generating material 5. In some embodiments, this denser first aerosol-generating material 4 may comprise particles, or may be in the form of beads or one or more sheets. Each bead or sheet may be formed from agglomerated smaller particles. However, it should be recognized that in other embodiments the second aerosol-generating material 5 may be more dense than the first aerosol-generating material 4 and may be in the form of, for example, beads or one or more sheets. do. In some embodiments, both the first and second aerosol-generating materials 4, 5 may be in the form of beads or one or more sheets, and optionally, the first and second aerosol-generating materials 4, 5) can be processed to have a higher density than the other of the first and second aerosol generating materials 4, 5). In some embodiments, beads 4, 5 may be cast from sheet material.

As used herein, the term “beads” is intended to include beads, pellets, or other discrete small units that have been shaped, molded, compressed, or otherwise fashioned into a desired shape. The beads may have smooth, regular external shapes (eg, spheres, cylinders, ovoids, etc.) and/or they may have irregular external shapes.

In some embodiments, the beads have a diameter (e.g., as measured by sieving) of at least about 0.5 mm, and optionally at least about 1, 1.5, 2, 2.5 or 3 mm. The beads may have a diameter (e.g., as measured by sieving) of no more than about 5 mm, and optionally no more than about 4.5, 4, 3.5, 3, 2.5, 2, or 1.5 mm. In some embodiments, the diameter of each bead may range from about 0.5 mm to about 3 mm, or from about 1 mm to about 2 mm. The size of the beads may refer to their average size, such as number or volume average size.

In some embodiments, the desired density of the aerosol-generating material 4, 5 is achieved or controlled through the formulation of the material and/or the method(s) with which the material is processed. Coagulation, and especially processes involving agglomeration following the application of some compressive force, will tend to increase the density of the material.

Accordingly, in some embodiments, the first and/or second aerosol-generating material 4, 5 comprises particles of agglomerated material.

In the case of a sheet material, the sheet may be formed from particles of material that are combined and selectively compressed to form a sheet with desired dimensions and densities.

In some embodiments, beads or pellets may be formed using a so-called marumarising process.

In some embodiments, agglomeration is by pelleting. Pelletization is an agglomeration process that converts fine particles of material, selectively with excipients, into free-flowing units called pellets. Depending on the type of equipment and processes selected, pellet formation and growth can occur in a number of ways. These pellets can be formed by agitation, where the particles are rolled and tumbled in the presence of appropriate amounts of liquid, forming agglomerates. Balling may involve the use of devices such as fans, disks, drums or mixers to produce pellets. Compression pelletizing is a form of pressure agglomeration, where the particles are forced together by mechanical forces, optionally using formulation aids. Compression forces mean that the formed pellets have increased density compared to the starting material.

In some embodiments, agglomeration is by extrusion. In some embodiments, pellets formed by pelletizing can be extruded to form higher density extrudates.

The particles to be extruded may have a size selected to produce a denser aerosol-generating material (e.g., a denser first or second aerosol-generating material 4, 5), which facilitates heat transfer and release of volatile components within the material. will affect.

Extrusion involves feeding a composition (also referred to as a precursor composition) through a die to produce the extruded product. The process applies pressure combined with shear forces to the composition.

Extrusion can be performed using one of the main classes of extruders: screw, sieve and basket, roll, ram, and pin barrel extruders. . Single screw or twin screw extruders can be used. Forming tobacco beads by extrusion has the advantage that this processing combines compression, mixing, conditioning, homogenization and shaping of the composition.

In some embodiments, during extrusion, a free-flowing composition comprising particles, such as tobacco particles, is exposed to elevated pressure and temperature and forced through an orifice, such as a forming nozzle or die, to form an extrudate. In some embodiments, the extrudate has a rod-shaped shape, and the extrudate can be cut into segments of desired length.

In some embodiments, the composition is exposed to temperatures within the extruder of from about 40°C to about 150°C, or from about 80°C to about 130°C, or from about 60°C to about 95°C. In some embodiments, including embodiments using dual extrusion, the precursor composition is exposed to temperatures from about 70° C. to about 95° C. within the extruder. In some embodiments, including embodiments using a single extrusion, the precursor composition is exposed to temperatures from about 60° C. to about 80° C. within the extruder.

The composition may be exposed to pressures (immediately before the die or nozzle) ranging from about 2 bar to about 100 bar, or from about 5 bar to about 60 bar, depending on the design of the die or nozzle being used. The higher the pressure, the more dense the extrudate is likely to be. Accordingly, the extrusion process can be tailored to provide extruded aerosol-generating material with a desired density.

In some embodiments where tobacco particles are extruded, due to the relatively high density of the extrudate and the relatively open surface of the tobacco particles within the extrudate, the tobacco beads formed from the extrudate exhibit good heat and mass transfer, flavor and It has a positive effect on the release of tobacco components such as nicotine.

In some embodiments, extrusion may be a generally dry process and the composition includes an aerosol that produces dry or substantially dry particles. The composition may optionally include other particulate materials including, for example, bases, diluents, solid aerosol formers, solid flavor modifiers, etc.

In some embodiments, liquids can be added to the composition before or during the extrusion process. For example, water can be added as a processing aid, for example, to help dissolve or solubilize the components of the composition, or to aid binding or flocculation. Alternatively or additionally, wetting agents may be added to the composition.

In some embodiments, the liquid may be an aerosol former material such as glycerol or others discussed herein. When liquid is added to the composition in this way, not only is the liquid applied on the surface, but as a result of the extruder pressure combined with intensive mixing by high shear forces, the extrudate is impregnated with liquid. If the liquid is an aerosol former material, this may result in high availability of the aerosol former material in the resulting beads to enhance evaporation of volatile components.

In some embodiments, the amount of aerosol former material incorporated into the extruded beads can be up to about 30% by weight and even up to about 40% by weight. In general, such large amounts of aerosol former material can make the composition difficult to handle. However, this is less of a problem when extrusion causes the particles to be impregnated with an aerosol former material. If the beads generate an aerosol in addition to releasing volatile components, it may be desirable to include an aerosol former material in an amount such as at least about 10% by weight or at least about 20% by weight. If the primary function of the beads is to release volatile components carried by the beads into the existing aerosol or airflow, lower amounts of aerosol former material, such as up to about 5% by weight, may be sufficient.

In some embodiments, the agglomerates do not include a binder or bonding additive. For example, extruded beads may not require a binder to maintain their structural integrity. In other embodiments, the agglomerates include a binder or bonding additive. Bonding additives may be selected to assist in the formation of a coherent structure by helping the particles adhere to each other and to other ingredients in the composition. Suitable binding additives include, for example, thermoreversible gelling agents such as gelatin, starches, polysaccharides, pectins, alginates, wood pulp, celluloses, and cellulose derivatives such as carboxymethylcellulose. do.

In some embodiments, if desired, processing by extrusion is sufficient to provide higher densities of the first or second aerosol-generating material 4, 5. However, in other embodiments, the extrudate may be further processed to increase the density of the first or second aerosol-generating material 4, 5.

For example, in some embodiments, the extruded aerosol-generating material undergoes spheronization. In spheronization, extruded cylindrically shaped particles are broken into uniform lengths and gradually transformed into spherical shapes due to plastic deformation. If the extrudate is first broken into uniform lengths, the spheronization step will produce spheres with uniform diameter.

According to one specific example of the embodiments discussed herein, samples of the first aerosol-generating material 4 were generated as follows (however, in some embodiments, the samples may be generated as follows, which instead it is used for the second aerosol-generating material 5 and/or the third aerosol-generating material).

Three sample formulations with and without binders are shown in Table 1, with amounts expressed as percent wet weight basis (WWB).

Tobacco was ground to produce a fine powder, taking care not to overheat the tobacco. The ground tobacco particles were sieved to select those having the desired size, for example, particle sizes less than 250 μm, less than 100 μm or less than 60 μm.

Next, all dry (non-liquid) components of the formulation were combined and mixed or blended in a mixer. In this particular example, the mixture was mixed for 1 minute at speeds up to 75 RPM. This was to ensure that the dry ingredients were homogeneously distributed within the mixture.

Next, half of the glycerol and half of the water were added to the dry mixture and mixed. Specifically, the mixture was mixed at 75 RPM for an additional 1 minute. The remaining glycerol and water were then added and mixed again at 75 RPM for 1 minute. Mixing was then continued until the mixture had a friable consistency that could be pressed into clumps, to ensure that a homogeneous mixture was achieved. In this particular example, additional mixing continued for 3 minutes.

The mixture was then extruded using Caleva Multilab. The extruder was operated at approximately 1500 rpm to produce extrudates of lengths similar to spaghetti.

When the extrudate came out of the extruder, it broke into pieces of various lengths. These pieces were then spheronized. Spheronization was performed until spherical beads were formed. In this case, the extrudate was initially spheronized in a Kaleva Multilab operating at 2,500 RPM for 1 minute, and then the beads were checked for any defects. Spheronization was then continued for an additional 1 to 2 minutes. This spheronization step broke the extruded tobacco into individual pieces to form dense spherical beads.

In the final step, the spheronized beads were dried in an oven at 65° C. for periods of 30 minutes. After each drying period, the beads were weighed and drying was stopped when the desired moisture weight loss was achieved. Typically, such drying will take about 1 hour.

In some embodiments, the other of the first and/or second aerosol generating materials 4, 5 is in the form of discrete particles or in the form of an agglomerate of particles. These particles may share various properties, such as particle size, with the (more dense) of the first and second aerosol generating materials 4, 5, but will have a lower density. As described above, there are various ways to adjust the density of the aerosol-generating material 4, 5, such as formulating and/or processing the material into particles, beads or pellets.

In some embodiments, the other of the first and second aerosol generating materials 4, 5 comprises a combination of 60% regenerated tobacco and 40% lamina tobacco, the material having a density of about 0.1 to about 0.9. It is in the range of g/cm³. Other (dense) aerosol-generating materials 4, 5 include about 30 to about 90% tobacco with densities ranging from about 0.4 to about 1.99 g/cm³. The amount of aerosol-forming material included in the first and/or second aerosol-generating materials 4, 5 may be from about 8 to about 15%. The (more dense) of the first aerosol generating materials 4, 5 may comprise generally spherical beads with a particle size of about 0.5 to about 3 mm. In some embodiments, the aerosol-generating material of the article comprises approximately 50% of the first aerosol-generating material (4) and approximately 50% of the second aerosol-generating material (5) by weight. Thus, for example, an article comprising 260 mg of aerosol-generating material may comprise 130 mg of the first aerosol-generating material 4 and 130 mg of the second aerosol-generating material 5.

In some embodiments where the aerosol-generating material includes tobacco, the tobacco is present in an amount from about 10% to about 90% by weight of the aerosol-generating material.

In some embodiments, the cigarette has at least about 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, based on the weight of the aerosol generating material. %, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, or at least about 35% May be present in cigarette quantities.

In some embodiments, the cigarette is about 90%, 89%, 88%, 87%, 86%, 85%, 84%, 83%, 82%, 81%, 80%, based on the weight of the aerosol generating material. , 75%, 70%, 65%, 60%, 55%, 50%, 45% or less, or about 40% or less of the tobacco amount.

Tobacco described herein may contain nicotine. In some embodiments, the nicotine content is 0.5% to 2% by weight of tobacco, for example, can be 0.5 to 1.75% by weight of tobacco, 0.8 to 1.2% by weight of tobacco, or 0.8 to 1.75% by weight of tobacco. there is. In some embodiments, the nicotine content may be 0.8 to 1% by weight of the tobacco.

In some embodiments, the first and second aerosol generating materials 4, 5 have the same nicotine content.

In some embodiments, the first and second aerosol-generating materials 4, 5 include one or more volatile components. In some embodiments, the first and second aerosol generating materials 4, 5 have the same volatile component content.

In some embodiments, the first and/or second aerosol generating materials 4, 5 include tobacco. For example, the first and/or second aerosol generating materials 4, 5 may comprise about 80 to about 350 mg of tobacco. In some specific embodiments, the aerosol-generating material of the article or consumable is 130 mg of a second aerosol-generating material 5 comprising, for example, a blend of lamina and regenerated tobacco, and, for example, a higher density tobacco. It has a weight of 260 mg comprising a combination of 130 mg of first aerosol generating material (4) comprising beads.

In some embodiments, the article includes regions of aerosol-generating material, where each region includes an equal amount of aerosol-generating material containing tobacco. In alternative embodiments, the areas may contain different amounts of cigarettes. When the total amount of tobacco is from about 80 to about 350 mg, one area of the aerosol-generating material comprises from about 20 to about 330 mg, or from about 50 to about 300 mg, or from about 40 to about 125 mg of tobacco, and the aerosol Other areas of product material include from about 20 to about 330 mg, or from about 30 to about 300 mg, or from about 40 to about 125 mg of tobacco.

According to the present disclosure, there is also provided a kit of parts comprising an aerosol presentation device 200 and an article 1 according to any of the examples described herein.

According to the present disclosure, there is also provided a package (not shown) comprising a plurality of articles according to any of the examples described herein. In some embodiments, the package is hermetically sealed. The package may include a container including a body and a cover, and a space for accommodating a plurality of articles is provided within the container body. The lid may be, for example, a hinged lid, a snap-fit lid, or a lid connected by screw threads.

The various embodiments described herein are presented merely to aid understanding and teach 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 subject to limitations on the scope of the invention as defined by the claims or equivalents of the claims. 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 suitably include or consist of appropriate combinations of other disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein. Or, it may consist essentially of these elements. Additionally, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims (49)

An article for use in an aerosol delivery system, comprising:
The above goods are:
A substrate comprising a first aerosol-generating material; and
comprising a body of material comprising a second aerosol-generating material;
An article for use in an aerosol delivery system, wherein the substrate at least partially surrounds the body of the material. According to paragraph 1,
An article for use in an aerosol delivery system, further comprising a first sheet material, preferably wherein the substrate is attached to the first sheet material. According to paragraph 2,
An article for use in an aerosol delivery system, wherein the first sheet material forms an exterior surface of the article. According to paragraph 2 or 3,
An article for use in an aerosol delivery system, wherein the first sheet material has a permeability of up to 100 Coresta Units. According to any one of claims 1 to 4,
An article for use in an aerosol delivery system, wherein the substrate comprises a second sheet material. According to clause 5,
An article for use in an aerosol delivery system, wherein the second sheet material is a cast sheet. According to claim 5 or 6,
An article for use in an aerosol delivery system, wherein the second sheet material comprises the first aerosol generating material. In clause 7,
An article for use in an aerosol delivery system, wherein the second sheet material is formed from a slurry comprising the first aerosol generating material. According to claim 5 or 6,
An article for use in an aerosol delivery system, wherein the first aerosol generating material is attached to a surface of the second sheet material, preferably attached to the surface of the second sheet material. According to any one of claims 5 to 9,
An article for use in an aerosol delivery system, wherein the second sheet material comprises one or more of paper, card, and/or aerosol generating material. According to any one of claims 1 to 10,
An article for use in an aerosol delivery system, wherein the second aerosol-generating material has a higher or lower density than the first aerosol-generating material. According to any one of claims 1 to 11,
An article for use in an aerosol delivery system, wherein the body of material includes a third sheet material collected to form the body of material. According to clause 12,
An article for use in an aerosol delivery system, wherein the third sheet material is crimped and/or cut into strips. According to any one of claims 1 to 13,
An article for use in an aerosol delivery system, wherein the substrate is in direct contact with the body of the material. According to any one of claims 1 to 14,
An article for use in an aerosol delivery system, wherein the substrate includes a first end spaced apart from a first end of the body of material. According to clause 15,
The article for use in an aerosol delivery system, wherein the substrate includes a second end opposite the first end of the substrate, the second end spaced apart from the second end of the body of material. According to any one of claims 1 to 16,
An article for use in an aerosol delivery system, wherein the first aerosol-generating material comprises aerosol-generating material dust and/or aerosol-generating material fibers. According to any one of claims 1 to 17,
An article for use in an aerosol delivery system, wherein the first aerosol-generating material comprises extruded and/or compressed aerosol-generating material. According to any one of claims 1 to 18,
An article for use in an aerosol delivery system, wherein the first aerosol generating material comprises beads. According to any one of claims 1 to 19,
An article for use in an aerosol delivery system, wherein the first aerosol-generating material and/or the second aerosol-generating material comprises, consists of, or consists essentially of tobacco material. According to any one of claims 1 to 20,
An article for use in an aerosol delivery system, wherein the substrate comprises a third aerosol generating material. 1. A method of manufacturing an article for use in an aerosol delivery system, comprising:
The above method is,
providing a substrate comprising a first aerosol-generating material; and
A method of making an article comprising arranging the substrate such that the substrate at least partially surrounds a body of material comprising a second aerosol-generating material. According to clause 22,
A method of manufacturing an article further comprising providing a first sheet material, wherein the substrate is attached to the first sheet material. According to clause 23,
The method of claim 1, wherein the first sheet material forms an exterior surface of the article. According to claim 23 or 24,
A method of making an article, wherein the first sheet material has a permeability of up to 100 Coresta units. According to any one of claims 23 to 25,
A method of making an article, wherein providing the first sheet material includes providing a web of the first sheet material. According to clause 26,
A method of making an article comprising applying the substrate to the web of first sheet material. According to any one of claims 22 to 27,
A method of making an article, wherein the substrate comprises a second sheet material, preferably the second sheet material is a cast sheet. According to clause 28,
28. The method of claim 27, wherein applying the substrate comprises applying the web of the second sheet material to the web of the first sheet material. According to clause 28,
28. The method of claim 27, wherein applying the substrate comprises applying a plurality of portions of a second sheet material to the web of the first sheet material. According to clause 30,
A method of manufacturing an article, wherein the plurality of portions of the second sheet material are spaced apart from one another on a web of the first sheet material. According to any one of claims 28 to 31,
The method of claim 1, wherein the second sheet material comprises the first aerosol generating material. According to clause 32,
wherein the second sheet material is formed from a slurry comprising the first aerosol-generating material. According to any one of claims 28 to 31,
The method of claim 1, wherein the first aerosol-generating material is attached to a surface of the second sheet material, and preferably is attached to the surface of the second sheet material. According to any one of claims 28 to 34,
The method of claim 1, wherein the second sheet material comprises one or more of paper, card, and/or aerosol generating material. According to any one of claims 22 to 35,
wherein the second aerosol-generating material has a higher or lower density than the first aerosol-generating material. According to any one of claims 22 to 36,
The method of manufacturing an article, wherein the body of material includes a third sheet material, and preferably, the method comprises collecting the third sheet material to form the body of material. According to clause 37,
The method of claim 1 , wherein the third sheet material is crimped and/or cut into strips. The method according to any one of claims 22 to 38,
A method of manufacturing an article, wherein arranging the substrate comprises arranging the substrate in direct contact with the body of material. According to any one of claims 22 to 39,
The substrate comprises a first end spaced apart from the first end of the body of material, and preferably, the substrate comprises a second end opposite the first end of the substrate, the second end comprising the first end of the body of the material. A method of manufacturing an article spaced apart from a second end of a body of material. According to any one of claims 22 to 40,
A method of making an article, wherein the first aerosol-generating material comprises aerosol-generating material dust and/or aerosol-generating material fibers. According to any one of claims 22 to 41,
A method of making an article, wherein the first aerosol-generating material comprises an extruded and/or compressed aerosol-generating material. According to any one of claims 22 to 42,
A method of making an article, wherein the first aerosol generating material comprises beads. According to any one of claims 22 to 43,
A method of making an article, wherein the first aerosol-generating material and/or the second aerosol-generating material comprises, consists of, or consists essentially of tobacco material. According to any one of claims 22 to 44,
A method of making an article, wherein the substrate comprises a third aerosol-generating material. An article manufactured according to the method of any one of claims 22 to 45. A package comprising a plurality of articles according to any one of claims 1 to 21 or 46,
Preferably, the package is hermetically sealed. A kit of parts comprising the article of any one of claims 1 to 21 or 46 and an aerosol delivery device. According to clause 48,
The kit of parts, wherein the aerosol presentation device includes a heating chamber for receiving articles for heating the first aerosol-generating material and the second aerosol-generating material.