JP2024105585A - Aerosol-generating material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an aerosol-generating material, an article including the aerosol-generating material, a pack of articles, a consumable for use in an aerosol provision system, a non-combustible aerosol provision system, and various methods of producing the aerosol-generating material.

SOLUTION: An aerosol-generating material 3 includes a plurality of strands and/or strips of a tobacco material, and a plurality of strips of amorphous solid material. The plurality of strands and/or strips of tobacco material and the plurality of strips of amorphous solid material each have a length of at least about 5 mm. There is also described an article 1 including the aerosol-generating material, a pack of articles, a consumable for use in an aerosol provision system, a non-combustible aerosol provision system, and various methods of producing the aerosol-generating material.

SELECTED DRAWING: Figure 1

COPYRIGHT: (C)2024,JPO&INPIT

Description

The present invention relates to aerosol-generating materials, articles containing the aerosol-generating materials, packs of articles, consumables for use in aerosol delivery systems, non-combustible aerosol delivery systems, and methods of making the aerosol-generating materials.

background

Certain tobacco industry products generate an aerosol during use, which is inhaled by the user. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, to form an aerosol by non-combustion heating of the substrate. Such tobacco industry products include a mouthpiece through which the aerosol can pass to the user's mouth.

overview

According to some embodiments described herein, in a first aspect, an aerosol-generating material is provided, the aerosol-generating material comprising a plurality of strands and/or strips of tobacco material and a plurality of strips of amorphous solid material, each of the plurality of strands and/or strips of tobacco material and the plurality of strips of amorphous solid material having a length of at least about 5 mm.

According to some embodiments described herein, in a second aspect, there is provided an article comprising an aerosol-generating material according to the first aspect.

According to some embodiments described herein, in a third aspect, a pack is provided that includes a plurality of articles, each according to the second aspect above, wherein the number of strips of amorphous solid material varies by less than 40% between the articles in the pack, or by less than 30% between the articles in the pack, or by less than 20% between the articles in the pack.

According to some embodiments described herein, in a fourth aspect, there is provided a pack comprising a plurality of articles each according to the second aspect above, wherein the plurality of strips of amorphous solid material comprise a flavourant, optionally menthol, and wherein delivery of the flavourant from each of the plurality of articles during use varies by less than 50% between the articles in the pack, or varies by less than 20% between the articles in the pack.

According to some embodiments described herein, in a fifth aspect, there is provided a pack comprising a plurality of articles, each according to the second aspect above, wherein the plurality of strips of amorphous solid material comprise a flavourant, optionally menthol, and the total content of said flavourant in each of the plurality of articles in use has a standard deviation of less than 30% of the average content of said flavourant in said articles, or has a standard deviation of less than 20% of the average content of said flavourant in said articles, with at least 20% of the average flavourant being provided within the strips of amorphous solid material.

According to some embodiments described herein, in a sixth aspect, there is provided a pack comprising a plurality of articles, each according to the second aspect above, wherein the plurality of strips of amorphous solid material comprise a flavourant, optionally menthol, in a total amount of flavourant from 5 mg per article to 30 mg per article, or from 16 mg per article to 22 mg per article, or from 5 mg per article to 10 mg per article, or from 17 mg per article to 30 mg per article.

According to some embodiments described herein, in a seventh aspect, there is provided a pack comprising a plurality of articles each according to the second aspect above, wherein the plurality of strips of amorphous solid material comprise a flavourant, optionally menthol, and the standard deviation in the total amount of flavourant among the articles in the pack is less than 30% or 20% of the average total amount of flavourant by weight, and the amorphous solid comprises at least 50% of the average total amount of flavourant in each article.

According to some embodiments described herein, in an eighth aspect, a pack is provided comprising a plurality of articles, each according to the second aspect above, the articles comprising ventilation, and the standard deviation of the ventilation levels between the articles in the pack is less than 15%, or less than 10%, or less than 9%.

According to some embodiments described herein, in a ninth aspect, there is provided a pack comprising a plurality of articles, each according to the second aspect above, wherein the plurality of strips of amorphous solid material comprise an aerosol forming agent, optionally glycerol, and the total content of said aerosol forming agent in each of the plurality of articles in use has a standard deviation of less than 30% of the average content of said aerosol forming agent in said articles, or has a standard deviation of less than 25% of the average content of said aerosol forming agent in said articles, and at least 20% of the average aerosol forming agent is provided within the strips of amorphous solid material.

According to some embodiments described herein, in a tenth aspect, there is provided a consumable for use in an aerosol delivery system, the consumable comprising an article according to the second aspect.

According to some embodiments described herein, in an eleventh aspect, a non-combustible aerosol delivery system is provided, the non-combustible aerosol delivery system comprising a non-combustible aerosol delivery device and a consumable according to the fifth aspect, the device being arranged to heat an aerosol generating material of the consumable.

According to some embodiments described herein, in a twelfth aspect, there is provided a method of making an aerosol-generating material according to the first aspect, the method comprising cutting a sheet of amorphous solid material to form a plurality of strips of amorphous solid material having a cut length of at least about 5 mm.

According to some embodiments described herein, in a thirteenth aspect, there is provided a method of making an aerosol-generating material, the method including feeding a single thickness sheet of amorphous solid material to a cutting device and cutting the single thickness sheet.

According to some embodiments described herein, in a fourteenth aspect, there is provided a method of making an aerosol-generating material, the method including cutting a first portion of an amorphous solid material to form a first component including a plurality of strips of the amorphous solid material having a first length, and cutting a second portion of the amorphous solid material to form a second component including a plurality of strips of the amorphous solid material having a second length different from the first length.

According to some embodiments described herein, in a fifteenth aspect, there is provided a method of making an aerosol-generating material, the method comprising cutting a sheet of amorphous solid material to form a plurality of strips of amorphous solid material and mixing the plurality of strips of amorphous solid material with tobacco material, the cutting and mixing steps being performed within 12 hours of each other, or within 6 hours of each other, or within 2 hours of each other, or within 30 minutes of each other.

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

1 is a side cross-sectional view of an article for use with a non-combustion aerosol delivery device, including a mouthpiece. FIG. 1 is a side cross-sectional view of a further article for use with a non-combustion aerosol delivery device, in this example an article including a capsule-containing mouthpiece. FIG. 2b is a cross-sectional view of the capsule-containing mouthpiece shown in FIG. 2a. FIG. 2 is a perspective view of a non-combustion aerosol delivery device suitable for generating aerosols from the aerosol-forming materials of the articles of FIGS. 1, 2a, and 2b. FIG. 4 shows the device of FIG. 3 with the outer cover removed and no item present. FIG. 4 is a partial cross-sectional side view of the device of FIG. 3. FIG. 4 is an exploded view of the device of FIG. 3 with the outer cover omitted. FIG. 4 is a cross-sectional view of a portion of the device of FIG. FIG. 7B is an enlarged view of a region of the device of FIG. 7A. 1 is a flow chart illustrating a first method of producing an aerosol-forming material. 4 is a flow chart illustrating a second method of producing an aerosol-forming material.

Detailed Description

As used herein, the term "delivery system" is intended to encompass a system for delivering at least one substance to a user, including:
Combustible aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for rolled or hand-made cigarettes, whether based on tobacco, tobacco derivatives, puffed tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials;
Included are non-combustion aerosol delivery systems that release compounds from aerosol-generating materials without burning the aerosol-generating materials, such as electronic cigarettes, tobacco heating products, and mixing systems to generate an aerosol using a combination of aerosol-generating materials; and non-aerosol delivery systems that deliver at least one substance to a user orally, nasally, transdermally, or otherwise without forming an aerosol, whether or not the at least one substance contains nicotine, including oral products such as, but not limited to, lozenges, gums, patches, articles containing inhalable powders, and oral tobacco products, including snus or moist snuff.

According to this disclosure, a "flammable" aerosol delivery system is one in which an aerosol-generating component of the aerosol delivery system (or a component thereof) is combusted or burned during use to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a combustible aerosol delivery system, such as a system selected from the group consisting of a cigarette, a cigarillo, and a cigar.

In some embodiments, the present disclosure relates to components for use in combustible aerosol delivery systems, such as filters, filter rods, filter segments, tobacco rods, spills, aerosol modifier release components, such as capsules, threads or beads, or papers, such as plug wrap, tipping paper, or cigarette paper.

In accordance with the present disclosure, a "non-combustion" aerosol delivery system is one in which the aerosol-generating components of the aerosol delivery system (or components thereof) are not combusted or burned to facilitate delivery of at least one substance to a user.

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

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

In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

In some embodiments, the non-combustion aerosol delivery system is a mixing system that generates an aerosol using a combination of aerosol-generating materials, and one or more of the aerosol-generating materials may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form, and may or may not contain nicotine. In some embodiments, the mixing system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

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

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

In some embodiments, the non-combustion aerosol delivery system, such as the non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, a power source or a heat source. In some embodiments, the heat source includes a carbon substrate that can be excited to dissipate power in the form of heat to an aerosol-generating material or a heat transfer material in proximity to the heat source.

In some embodiments, the non-combustible aerosol delivery system can include an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and/or an aerosol modifier.

In some embodiments, consumables for use with a non-combustion aerosol delivery device can include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material delivery component, an aerosol generator, an aerosol generating area, a housing, a paper roll, a filter, a mouthpiece, and/or an aerosol modifier.

In some embodiments, the substance to be delivered can be an aerosol-generating material or a material that is not intended to be aerosolized. Where appropriate, either material can include one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and/or one or more other functional materials.

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

As used herein, an active substance can be a bioactive material, i.e. a material intended to achieve or promote a physiological response. An active substance can be selected from, for example, functional foods, nootropics, psychotropic drugs. An active substance can be naturally occurring or synthetically obtained. An active substance can include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. An active substance can include one or more components, derivatives, or extracts of tobacco extract, cannabis, or another botanical substance.

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

As described herein, the active material may include or be derived from one or more botanical materials or their components, derivatives, or extracts. As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, pods, husks, and the like. Alternatively, the material may include active compounds naturally present in the botanical material, synthetically obtained active compounds. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, sheets, and the like. Exemplary botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea, such as green or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, and the like. The mint may be selected from the group consisting of Mentha arvensis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrate c.v., Mentha piperita citrata c.v., Mentha niliaca ... , Mentha piperita c.v., Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v., and Mentha suaveolens mint types can be selected.

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

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

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

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

As used herein, the terms "flavor" and "flavoring agent" refer to materials that can be used, where local regulations permit, to produce a desired taste, aroma, or other somatic sensation in a product intended for adult consumers. Flavoring agents include naturally occurring flavor materials, botanical substances, extracts of botanical substances, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, peppermint, aniseed (aniseed), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, etc.). A, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberry, citrus fruits, drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang ylang , sage, fennel, wasabi, pimento, ginger, coriander, coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay leaf, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, turmeric, cilantro, myrtle, black currant, valerian, bell pepper, mace, Damian , marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. The flavorings may be imitation, synthetic or natural ingredients, or mixtures thereof. The flavorings may be in any suitable form, e.g., liquids such as oils, solids such as powders, or gases.

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

In some embodiments, the flavorings may include sensates intended to achieve somatic sensations that are chemically induced and perceived, usually by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of the olfactory or gustatory nerves, and these may include agents that provide a heating, cooling, tingling, or numbing effect. Suitable heating agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucalyptol, WS-3.

An aerosol-generating material is a material capable of generating an aerosol when excited, for example, by heating, irradiation, or in any other manner. The aerosol-generating material may be in the form of, for example, a solid, liquid, or gel, and may or may not contain actives and/or flavorings. In some embodiments, the aerosol-generating material may include an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can hold a fluid, such as a liquid, within it.

In some instances, the amorphous solid is
1 to 60% by weight of a gelling agent;
0.1 to 50% by weight of an aerosol forming material; and 0.1 to 80% by weight of a flavoring agent;
These weights are calculated on a dry weight basis.

In some further embodiments, the amorphous solid is
1 to 50 wt. % of a gelling agent;
0.1 to 50% by weight of an aerosol forming material; and 30 to 60% by weight of a flavoring agent;
These weights are calculated on a dry weight basis.

The amorphous solid material may be provided in the form of a sheet.

In some further embodiments, the amorphous solid is
an aerosol forming material in an amount of about 40-80% by weight of the amorphous solid;
a gelling agent and an optional filler (i.e., in some instances the filler is present in the amorphous solid and in other instances the filler is absent from the amorphous solid), the combined amount of the gelling agent and the filler being about 10-60% by weight of the amorphous solid (i.e., the gelling agent and the filler together make up about 10-60% by weight of the amorphous solid);
Optionally, the amorphous solid comprises an active and/or flavoring in an amount up to about 20% by weight of the amorphous solid (ie, the amorphous solid comprises 20% or less of the active by weight).

The amorphous solid material can be formed from a dried gel. The inventors have found that using these component ratios means that when the gel hardens, the flavour compounds are stable within the gel matrix, making it possible to achieve greater flavour loadings than non-gel compositions. The flavouring (e.g. menthol) is stable at high concentrations and the product has a good shelf life.

Suitably, the amorphous solid can comprise from about 1%, 5%, 10%, 15%, 20%, 25%, 30%, or 35% to about 60%, 55%, 50%, 45%, 40%, or 35% by weight of gelling agent (all calculated on a dry weight basis). For example, the amorphous solid can comprise 1-60%, 5-60%, 20-60%, 25-55%, 30-50%, 35-45%, 1-50%, 5-45%, 10-40%, or 20-35% by weight of gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginic acid, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginic acid, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the gelling agent comprises alginic acid and/or pectin, which can be combined with a hardening agent (such as a calcium source) during the formation of the amorphous solid. In some cases, the amorphous solid can comprise calcium cross-linked alginic acid and/or calcium cross-linked pectin.

In some embodiments, the gelling agent comprises alginic acid, and the alginic acid is present in the amorphous solid in an amount of 5-40% by weight, e.g., 10-30% by weight (calculated on a dry weight basis) of the amorphous solid. In some embodiments, the alginic acid is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginic acid and at least one further gelling agent, e.g., pectin.

In some examples, the alginic acid is included in the gelling agent in an amount of about 5-40% or 15-40% by weight of the amorphous solid. That is, the amorphous solid includes alginic acid in an amount of about 5-40% or 15-40% by weight of the dry weight of the amorphous solid. In some examples, the amorphous solid includes alginic acid in an amount of about 20-40% or about 15%-35% by weight of the amorphous solid.

In some examples, pectin is included in the gelling agent in an amount of about 3-15% by weight of the amorphous solid. That is, the amorphous solid includes pectin in an amount of about 3-15% by dry weight of the amorphous solid. In some examples, the amorphous solid includes pectin in an amount of about 5-10% by weight of the amorphous solid.

In some examples, the guar gum is included in the gelling agent in an amount of about 3-40% by weight of the amorphous solid. That is, the amorphous solid includes guar gum in an amount of about 3-40% by weight of the dry weight of the amorphous solid. In some examples, the amorphous solid includes guar gum in an amount of about 5-10% by weight of the amorphous solid. In some examples, the amorphous solid includes guar gum in an amount of about 15-40% by weight, or about 20-40% by weight, or about 15-35% by weight of the amorphous solid.

In some examples, the alginic acid is present in an amount of at least about 50% by weight of the gelling agent. In examples, the amorphous solid comprises alginic acid and pectin, and the ratio of alginic acid to pectin is 1:1 to 10:1. The ratio of alginic acid to pectin is typically less than 1:1, i.e., the alginic acid is present in an amount greater than the amount of pectin. In examples, the ratio of alginic acid to pectin is about 2:1 to 8:1, or about 3:1 to 6:1, or about 4:1.

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

The gelling agent may include one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum, and mixtures thereof.

In some embodiments, the cellulosic gelling agent is selected from the group consisting of hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), acetylpropionylcellulose (CAP), and combinations thereof.
In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia gum.

In some embodiments, the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginic acid, and combinations thereof. In preferred embodiments, the non-cellulosic gelling agent is alginic acid or agar.

The amorphous solids may suitably comprise from about 0.1%, 0.5%, 1%, 3%, 5%, 7%, or 10% to about 80%, 50%, 45%, 40%, 35%, 30%, or 25% by weight of the aerosol-forming material (all calculated on a dry weight basis). For example, the amorphous solids may comprise from about 40-80%, 40-75%, 50-70%, or 55-65% by weight of the aerosol-forming material. The aerosol-forming material may act as a plasticizer. For example, the amorphous solids may comprise from 0.5-40%, 3-35%, or 10-25% by weight of the aerosol-forming material. In some cases, the aerosol-forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol-forming material comprises, consists essentially of, or consists of glycerol.

In some embodiments, the aerosol forming material includes one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols, such as glycerol monoacetate, diacetate, or triacetate, and/or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

The amorphous solid may include a flavoring. Suitably, the amorphous solid may include up to about 80%, 70%, 60%, 55%, 50%, or 45% by weight of flavoring.

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

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

In some cases, the amorphous solids may further include an emulsifier to emulsify the molten flavor during manufacture. For example, the amorphous solids may include from about 5% to about 15%, preferably about 10%, by weight of an emulsifier (calculated on a dry weight basis). The emulsifier may include gum acacia.

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

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

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

In some cases, the amorphous solid may contain no nicotine other than that derived from the tobacco extract.

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

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

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

The amorphous solid can be made from a gel, which can further include a solvent present at 0.1-50% by weight. However, the inventors have demonstrated that including a solvent in which the fragrance is soluble can reduce the stability of the gel and can lead to crystallization of the fragrance from the gel. Therefore, in some cases, the gel does not include a solvent in which the fragrance is soluble.

The amorphous solid may include a filler. Combined, the amorphous solid typically includes the gelling agent and the filler (if present) in an amount of about 10-60% by weight of the amorphous solid. In examples, the amorphous solid includes the filler in an amount of 1-15% by weight of the amorphous solid, such as 5%-15% or 8-12% by weight. In examples, the amorphous solid includes the filler in an amount greater than 1%, 5%, or 8% by weight of the amorphous solid. In some embodiments, the amorphous solid includes less than 60% by weight, such as 1%-60%, or 5%-50%, or 5%-30%, or 10%-20% by weight of the filler.

In other embodiments, the amorphous solid contains less than 40% by weight, less than 20% by weight, preferably less than 10% by weight or less than 5% by weight of filler. In some cases, the amorphous solid contains less than 1% by weight of filler, and in some cases, no filler.

When present, 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, e.g., molecular sieves. The filler may include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives. In certain cases, the amorphous solid does not include calcium carbonate, such as chalk.

In certain embodiments that include a filler, the filler is fibrous. For example, the filler can be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler in an amorphous solid can increase the tensile strength of the material.

In some embodiments, the amorphous solid comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabiclovarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), and cannabielsoin (CBE), cannabicitran (CBT).

The amorphous solid may include one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

The amorphous solid can include cannabidiol (CBD).

The amorphous solid can include nicotine and cannabidiol (CBD).

The amorphous solid can include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

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

In some examples, the amorphous solid in the form of a sheet can have a tensile strength of about 150 N/m to about 3000 N/m, e.g., 150 N/m to 2500 N/m, or 150 N/m to 2000 N/m, or 200 N/m to 1700 N/m, or 250 N/m to 1500 N/m, or 200 N/m to 900 N/m. In some examples where the amorphous solid does not include a filler, the amorphous solid can have a tensile strength of 150 N/m to 500 N/m, or 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. Such tensile strengths can be particularly suitable for embodiments where the amorphous solid material is formed as a sheet and then chopped and incorporated into an aerosol product article.

In some examples where the amorphous solid includes a filler, the amorphous solid may have a tensile strength of 150 N/m to 3000 N/m, e.g., 500 N/m to 1200 N/m, or 600 N/m to 900 N/m, or 700 N/m to 900 N/m, or about 800 N/m, or more. In some examples, the amorphous solid may have a tensile strength of greater than 500 N/m, greater than 1000 N/m, or greater than 1500 N/m. Such tensile strengths may be particularly suitable for embodiments in which the amorphous solid material is included in the aerosol product article as a rolled sheet, preferably in the form of a tube.

In certain embodiments, the amorphous solid comprises a gelling agent that includes a cellulosic and/or non-cellulosic gelling agent, an active agent, and an acid.

In some cases, the amorphous solid can consist essentially of, or consist of, a gelling agent, water, aerosol-forming material, flavoring, and optionally an active agent.

In some cases, the amorphous solid may consist essentially of or consist of gelling agents, water, aerosol-forming materials, flavorings, and optionally tobacco materials and/or a nicotine source.

The amorphous solid may contain one or more active agents and/or flavorings, one or more aerosol forming materials, and optionally one or more other functional materials.

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

The amorphous solid can include an acid. The acid can be an organic acid. In some of these embodiments, the acid can be at least one of a monobasic acid, a dibasic acid, and a tribasic acid. In some such embodiments, the acid can contain at least one carboxyl functional group. In some such embodiments, the acid can be at least one of an alpha-hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid can be an alpha-keto acid.

In some such embodiments, the acid can be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propionic acid, and pyruvic acid.

The acid is preferably lactic acid. In other embodiments, the acid is benzoic acid. In other embodiments, the acid can be an inorganic acid. In some of these embodiments, the acid can be a mineral acid. In some such embodiments, the acid can be at least one of sulfuric acid, hydrochloric acid, boric acid, and phosphoric acid. In some embodiments, the acid is levulinic acid.

In embodiments in which the amorphous solid includes nicotine, it is particularly preferred to contain an acid. In such embodiments, the presence of an acid can stabilize dissolved species in the slurry from which the aerosol-forming material is formed. The presence of an acid can reduce or substantially prevent evaporation of the nicotine during drying of the slurry, thereby reducing loss of nicotine during production.

The amorphous solid can include a colorant. The addition of a colorant can change the appearance of the amorphous solid. The presence of a colorant in the amorphous solid can enhance the appearance of the amorphous solid and the aerosol generating material. Adding a colorant to the amorphous solid can match the color of the amorphous solid to other components of the aerosol generating material or other components of an article comprising the amorphous solid.

Depending on the desired color of the amorphous solid, various colorants can be used. The color of the amorphous solid can be, for example, white, green, red, purple, blue, brown, or black. Other colors are contemplated. Natural or synthetic colorants can be used, such as natural or synthetic dyes, food grade colorants, and pharmaceutical grade colorants. In certain embodiments, the colorant is caramel, which can give the amorphous solid a brown appearance. In such embodiments, the color of the amorphous solid can be similar to the color of other components in the aerosol-generating material that includes the amorphous solid, such as the tobacco material. In some embodiments, the colorant is added to the amorphous solid to make the amorphous solid visually indistinguishable from other components in the aerosol-generating material.

The colorant can be incorporated during the formation of the amorphous solid (e.g., when forming a slurry containing the materials that will form the amorphous solid) or can be added to the amorphous solid after its formation (e.g., by spraying it onto the amorphous solid).

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

A consumable is an article that includes or consists of an aerosol-generating material, some or all of which is 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 area, an aerosol-generating material delivery component, an aerosol-generating area, a housing, a paper wrapper, a mouthpiece, a filter, and/or an aerosol modifier. The consumable may also include an aerosol generator, such as a heater that releases heat upon use to cause the aerosol-generating material to generate an aerosol. The heater may include, 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 varying magnetic field, such as an alternating magnetic field. The susceptor can be a conductive material, such that penetration of the conductive material by the varying magnetic field causes inductive heating of the heating material. The heating material can be a magnetic material, such that penetration of the magnetic material by the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor can be both conductive and magnetic, such that the susceptor can be heated by either heating mechanism. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

An aerosol modifier is a substance configured to modify the generated aerosol, for example by changing the taste, flavor, acidity, or another property of the aerosol, and is typically located downstream of the aerosol-generation zone. The aerosol modifier can be provided in an aerosol modifier-releasing component operable to selectively release the aerosol modifier.

The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a string, or granules. The aerosol modifier may not include a filtration material.

The aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to expose the aerosol-generating material to thermal energy to liberate one or more volatile substances from the aerosol-generating material and form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator can be configured to expose the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

Articles, e.g., rod-shaped articles, are often designated according to the length of the product as "regular" (typically 68-75 mm, e.g., in the range of about 68 mm to about 72 mm), "short" or "mini" (68 mm or less), "king size" (typically 75-91 mm, e.g., in the range of about 79 mm to about 88 mm), "long" or "super king" (typically 91-105 mm, e.g., in the range of about 94 mm to about 101 mm), and "ultra long" (typically in the range of about 110 mm to about 121 mm).

The articles are also designated according to the circumference of the product: "regular" (about 23-25 mm), "wide" (over 25 mm), "slim" (about 22-23 mm), "demi-slim" (about 19-22 mm), "super slim" (about 16-19 mm), and "micro-slim" (less than about 16 mm).

Thus, a king size, super slim format item, for example, has a length of about 83 mm and a circumference of about 17 mm.

Each format can be made with a different length of mouthpiece. The length of the mouthpiece is typically about 30mm to 50mm. Tipping paper connects the mouthpiece to the aerosol-generating material, and the tipping paper typically has a length greater than the mouthpiece, for example 3-10mm longer, so that the tipping paper covers the mouthpiece, for example overlapping the aerosol-generating material in the form of a rod, connecting the mouthpiece to the rod of substrate material.

The articles described herein, as well as the aerosol-generating materials and mouthpieces thereof, can be made in any of the formats described above, including, but not limited to, those described above.

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

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

As used herein, the term "tobacco material" refers to any material that includes tobacco or a derivative or substitute thereof. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco leaf, reconstituted tobacco, and/or tobacco extract.

In the tobacco materials described herein, the tobacco material may contain a filler component. The filler component is generally a non-tobacco component, i.e., a component that does not include tobacco-derived materials. The filler component may be a non-tobacco fiber, such as wood fiber or pulp or wheat fiber. The filler component may also be an inorganic material, such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, etc. The filler component may also be a non-tobacco casting material or a non-tobacco extrusion material. The filler component may be present in an amount of 0-20% by weight of the tobacco material, or in an amount of 1-10% by weight of the overall composition, e.g., of the aerosol-generating material described herein. In some embodiments, no filler component is present.

In the tobacco materials described herein, the tobacco materials include aerosol-forming materials.

In some embodiments, the aerosol-forming material of the tobacco material can be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. Glycerol can be present in an amount of 10-20% by weight of the tobacco material, such as 13-16% by weight of the composition, i.e., the overall aerosol-generating materials described herein, or about 14% or 15% by weight of the composition. Propylene glycol, when present, can be present in an amount of 0.1-0.3% by weight of the composition.

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

The tobacco material may contain 10% to 90% by weight of tobacco leaf, e.g., tobacco flakes. In addition to providing any aerosol-forming material via the amorphous solid material, the tobacco material may be provided with an aerosol-forming material. For example, the aerosol-forming material described herein may be provided to the tobacco material in an amount of 2% to 20% by weight of the tobacco material, e.g., about 5% to about 15% by weight. When tobacco leaf is used, the aerosol former may include up to about 10% by weight of leaf tobacco. It has been found advantageously that this may be added in a greater weight percentage than another component of the tobacco material, such as reconstituted tobacco material, to achieve an overall level of aerosol-forming material of 10% to 20% by weight of the tobacco material. In some examples, the tobacco material consists essentially of leaf tobacco, e.g., flake tobacco.

The tobacco material described herein contains nicotine. The nicotine content may be 0.5-1.75% by weight of the tobacco material, for example 0.8-1.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material contains 10%-90% by weight of tobacco leaf and has a nicotine content of greater than 1.5% by weight of the tobacco leaf. Advantageously, it has been found that the use of tobacco leaf having a nicotine content greater than 1.5% in combination with a lower nicotine matrix, such as reconstituted tobacco, provides a tobacco material having a suitable nicotine level, yet with better sensory performance than reconstituted tobacco alone. Tobacco leaf, for example cut rag tobacco, may have a nicotine content of, for example, 1.5%-5% by weight of the tobacco leaf.

The tobacco material described herein may contain an aerosol modifying agent, such as any of the flavourings described herein. In one embodiment, the tobacco material contains menthol to form a mentholated article. The tobacco material may contain 3 mg to 20 mg of menthol, preferably 5 mg to 18 mg, more preferably 8 mg to 16 mg of menthol. In this example, the tobacco material comprises 16 mg of menthol. The tobacco material may contain 2% to 8% by weight of menthol, preferably 3% to 7% by weight of menthol, more preferably 4% to 5.5% by weight of menthol. In one embodiment, the tobacco material comprises 4.7% by weight of menthol. Such high levels of menthol loading may be achieved by using a high proportion of reconstituted tobacco material, for example greater than 50% by weight of the tobacco material. Alternatively or additionally, the menthol loading levels that can be achieved may be increased by using a larger amount of aerosol-forming material, such as tobacco material, for example greater than about 500 ^mm3 , or suitably greater than about 1000 ^mm3 of aerosol-forming material, such as tobacco material, is used.

In the compositions or aerosol-forming materials described herein, when amounts are given in weight percent, this refers to dry weight, unless specifically indicated to the contrary, for the avoidance of doubt. Thus, for the purposes of determining weight percent, any water that may be present in the tobacco material or any component thereof is completely disregarded. The moisture content of the tobacco materials described herein may vary, and may be, for example, 5-15% by weight. The moisture content of the tobacco materials described herein may vary, for example, according to the temperature, pressure, and humidity conditions in which the compositions are maintained. The moisture content may be determined by Karl Fischer analysis, as known to those skilled in the art. On the other hand, for the avoidance of doubt, even when the aerosol-forming material is a component of a liquid phase, such as glycerol or propylene glycol, any component other than water is included in the weight of the tobacco material. However, when an aerosol-forming material is provided within the tobacco component of the tobacco material or within a filler component of the tobacco material (if present), instead of or in addition to being added separately to the tobacco material, the aerosol-forming material is not included in the weight of the tobacco component or filler component, but is included in the weight of the "aerosol-forming material" in the weight percent defined herein. All other materials present in the tobacco component are included in the weight of the tobacco component, even if they are of non-tobacco origin (eg, non-tobacco fibers in the case of reconstituted tobacco).
In one embodiment, the tobacco material comprises a tobacco component as defined herein and an aerosol-forming material as defined herein. In one embodiment, the tobacco material consists essentially of a tobacco component as defined herein and an aerosol-forming material as defined herein. In one embodiment, the tobacco material consists of a tobacco component as defined herein and an aerosol-forming material as defined herein.

The reconstituted tobacco paper may be present in the tobacco component of the tobacco material described herein in an amount of 10% to 100% by weight of the tobacco component. In an embodiment, the reconstituted tobacco paper is present in an amount of 10% to 80% by weight or 20% to 70% by weight of the tobacco component. In a further embodiment, the tobacco component consists essentially of reconstituted tobacco paper or consists of reconstituted tobacco paper. In a preferred embodiment, the leaf or flake tobacco is present in the tobacco component of the tobacco material in an amount of at least 10% by weight of the tobacco component. For example, the leaf tobacco may be present in an amount of at least 10% by weight of the tobacco component, with the remainder of the tobacco component comprising reconstituted tobacco paper, banded cast reconstituted tobacco, or a combination of banded cast reconstituted tobacco and tobacco granules in another form. The leaf tobacco may be present in an amount of up to 40% or 60% of the tobacco material, with the remainder of the tobacco component comprising reconstituted tobacco paper, banded cast reconstituted tobacco, or a combination of banded cast reconstituted tobacco and tobacco granules in another form.

Reconstituted tobacco refers to tobacco material formed by a process in which tobacco raw materials are extracted with a solvent to give a residue extract containing soluble matter and fibrous material, and then the extract (usually after concentration, optionally after further processing) is recombined with fibrous material from the residue by depositing the extract on the fibrous material (usually after purification of the fibrous material, optionally with the addition of a portion of non-tobacco fiber). The recombination process is similar to the papermaking process.

The reconstituted tobacco paper can be any type of reconstituted tobacco paper known in the art. In certain embodiments, the reconstituted tobacco paper is made from raw materials including one or more of tobacco strips, tobacco stems, and whole tobacco. In further embodiments, the reconstituted tobacco paper is made from raw materials consisting of tobacco strips and/or whole tobacco, and tobacco stems. However, in other embodiments, shreds, fines, and husks can alternatively or additionally be used in the raw materials.

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

The figures described herein use the same reference numbers to describe equivalent features, items, or components.

Figure 1 is a cross-sectional side view of an article 1 for use in an aerosol delivery system.

The article 1 comprises a mouthpiece 2 and a cylindrical rod of aerosol-generating material 3 connected to the mouthpiece 2. In exemplary embodiments of the invention, the aerosol-generating material comprises a mixture of at least two separate components. In some embodiments, the aerosol-generating material comprises a plurality of strands and/or strips of tobacco material and a plurality of strips of amorphous solid material, each of the plurality of strands and/or strips of tobacco material and the plurality of strips of amorphous solid material having a length of at least about 5 mm. In some embodiments, the material properties and/or dimensions of the at least two components may be suitably selected to ensure that a relatively uniform mixture of the components is possible and to reduce separation or undermixing of the components during or after manufacture of the aerosol-generating material rod.

Although described above in the form of a rod, the aerosol-generating material can be provided in other forms, such as a plug, pouch, or packet of material within the article. The article can constitute a consumable for an aerosol delivery or delivery system, such as the non-combustible aerosol delivery or delivery system described herein.

In this example, the first component is a tobacco material and the second component is an amorphous solid material.

In some examples, the tobacco material comprises a paper reconstituted tobacco material. The tobacco material may alternatively or additionally comprise any of the forms described herein. The tobacco material preferably comprises 10% to 90% by weight of tobacco leaf, with the aerosol forming material being provided in an amount of up to about 10% by weight of the leaf tobacco. Such an aerosol forming agent may be provided in addition to the aerosol forming agent provided in the amorphous solid material. For example, 3% to 8%, or 4% to 7%, or 5% to 7% by weight of the tobacco material may be used as an aerosol forming agent. The remainder of the tobacco material may comprise paper reconstituted tobacco. In other examples, the tobacco material may comprise up to 100% tobacco leaf, for example up to 100% tobacco flakes, which may be in the form of cut rag tobacco. It may be advantageous to adjust the aerosol forming agent and/or water content of the tobacco flake material to avoid a material that is too dry and brittle. For example, the tobacco flakes may comprise 5% to 8% aerosol forming agent, such as glycerol, and/or 9% to 12% water.

In this example, the amorphous solid material is a dry gel that includes menthol. In alternative embodiments, the amorphous solid can have any composition described herein.

Advantageously, the inventors have found that improved articles can be made that include an aerosol-generating material that includes a first component that includes a tobacco material and a second component that includes an amorphous solid, the material having properties (e.g., density) and specifications (e.g., thickness, length, and cut width) that fall within the ranges described herein.

In some cases, the amorphous solid can have a thickness of about 0.015 mm to about 1.5 mm. Suitably, the thickness can be within the range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm, 0.3 mm, or 1 mm. The inventors have found that materials having a thickness of about 0.2 mm can be used. The amorphous solid can include two or more layers, and the thicknesses described herein refer to the combined thickness of these layers.

The thickness of the amorphous solid material can be measured using calipers or a microscope, such as a scanning electron microscope (SEM), known to those of skill in the art, or any other suitable technique known to those of skill in the art.

The inventors have demonstrated that if the amorphous solid is too thick, heating efficiency may be compromised. This may have a negative impact on power consumption during use, for example, power consumption to release the flavoring from the amorphous solid. Conversely, if the aerosol-forming amorphous solid is too thin, it may be difficult to manufacture and handle, and very thin materials are more difficult to cast and may be prone to breaking, impairing aerosol formation during use. The inventors have demonstrated that the thickness of the amorphous solid as defined herein optimizes material properties taking into account these trade-offs.

In some cases, the individual strips or sections of the amorphous solid have a minimum thickness of about 0.015 mm across their area. In some cases, the individual strips or sections of the amorphous solid have a minimum thickness of about 0.05 mm or about 0.1 mm across their area. In some cases, the individual strips or sections of the amorphous solid have a maximum thickness of about 1.0 mm across their area. In some cases, the individual strips or sections of the amorphous solid have a maximum thickness of about 0.5 mm or about 0.3 mm across their area.

The inventors have found that providing an amorphous solid material and a tobacco material having areal density values that differ from each other by less than a given percentage results in less segregation of the mixture of these materials. In some examples, the areal density of the amorphous solid material can be between 50% and 150% of the areal density of the tobacco material. For example, the areal density of the amorphous solid material can be between 60% and 140% of the areal density of the tobacco material, or between 70% and 110% of the areal density of the tobacco material, or between 80% and 120% of the areal density of the tobacco material.

For the avoidance of doubt, when areal density is referred to herein, it refers to the average areal density calculated for a given strip, section or sheet of amorphous solid material, the areal density being calculated by measuring the surface area and weight of a given strip, section or sheet of amorphous solid material.

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

In the embodiments described herein, the amorphous solid material can be incorporated into the article in the form of a sheet. Suitably, the amorphous solid material in the form of a sheet can be shredded and then incorporated into the article, and can be mixed with an aerosolizable material, such as a tobacco material (as described further below).

In further embodiments, the amorphous solid sheet can be further incorporated as a flat sheet, as a collected or bundled sheet, as a crimped sheet, or as a rolled sheet (i.e., in the form of a tube). In some such cases, the amorphous solid of these embodiments can be included in the aerosol product article as a sheet, such as a sheet circumscribing a rod of aerosolizable material (e.g., tobacco). For example, the amorphous solid sheet can be formed on a wrapping paper that circumscribing an aerosolizable material such as tobacco.

The amorphous solid in the form of a sheet can have any suitable areal density, such as from about 30 g/ ^m2 to about 150 g/ ^m2 . In some cases, the sheet can have a mass per unit area of from about 55 g/ ^m2 to about 135 g/ ^m2 , or from about 80 ^{to about 120 g/m2, or from about 70 to about 110 g/m2, or from about 100 g/m2 to about 125 g/m2 , or especially from} about 90 to about 110 g/m2, or preferably about 100 g/ ^m2 , 120 g/ ^m2 , or 110 g/ ^m2 . These ranges can provide a density similar to that of cut rag tobacco, and thus a mixture of these materials that does not readily separate. Such areal densities can be particularly suitable when the amorphous solid material is included in the aerosol product as shredded sheets (discussed further below). In some cases, the sheet can have a weight per unit area of about 30-70 g/m ² , 40-60 g/m ² , or 25-60 g/m ² and can be used to wrap aerosolizable materials such as cigarettes.

The density of the tobacco material affects the rate at which heat is transferred through the material, with lower densities, e.g., below 700 mg/cc, allowing heat to transfer through the material more slowly and therefore more sustained aerosol release.

The tobacco material may include a reconstituted tobacco material, such as a paper reconstituted tobacco material, having a density of less than about 700 mg/cc. For example, the aerosol-forming material 3 may include a reconstituted tobacco material having a density of less than about 600 mg/cc. Alternatively or additionally, the aerosol-forming material 3 may include a reconstituted tobacco material having a density of at least 350 mg/cc.

The tobacco material may be provided in the form of cut rag tobacco. The cut rag tobacco may have a cut width of at least 15 cuts per inch (approximately 5.9 cuts per cm, equivalent to a cut width of approximately 1.7 mm). The cut rag tobacco preferably has a cut width of at least 18 cuts per inch (approximately 7.1 cuts per cm, equivalent to a cut width of approximately 1.4 mm), more preferably at least 20 cuts per inch (approximately 7.9 cuts per cm, equivalent to a cut width of approximately 1.27 mm). In one example, the cut rag tobacco has a cut width of 22 cuts per inch (approximately 8.7 cuts per cm, equivalent to a cut width of approximately 1.15 mm). The cut rag tobacco preferably has a cut width of no more than 40 cuts per inch (approximately 15.7 cuts per cm, equivalent to a cut width of approximately 0.64 mm). It has been found that a cut width of 0.5 mm to 2.0 mm, for example 0.6 to 1.7 mm or 0.6 mm to 1.5 mm, provides a preferred tobacco material with respect to the surface area to volume ratio of the rod of aerosol-generating material 3, as well as the overall density and pressure drop, especially when heated. The cut rag tobacco can be formed from a mixture of tobacco material forms, such as one or more of reconstituted tobacco, leaf tobacco, extruded tobacco, and band-cast tobacco. The tobacco material preferably comprises reconstituted tobacco or a mixture of reconstituted tobacco and leaf tobacco.

The tobacco material can have any suitable thickness. The tobacco material can have a thickness of at least about 0.145 mm, such as at least about 0.15 mm, or at least about 0.16 mm. The tobacco material can have a maximum thickness of about 0.25 mm, for example, the tobacco material can have a thickness of less than about 0.22 mm or less than about 0.2 mm. In some embodiments, the tobacco material can have an average thickness in the range of 0.175 mm to 0.195 mm. Such thicknesses can be particularly suitable when the tobacco material is a reconstituted tobacco material.

It may be desirable to provide an aerosol-generating material that includes a mixture of at least two components, such as a first component that includes a tobacco material as described herein and a second component that includes an amorphous solid material. Such an aerosol-generating material may provide an aerosol having a desirable flavor profile during use, since the inclusion of the amorphous solid material component may introduce additional flavors into the aerosol-generating material. The flavors provided within the amorphous solid material may be more stably retained within the amorphous solid material as compared to flavors that are added directly to the tobacco material, resulting in a more consistent flavor profile among articles made according to the present invention.

As discussed above, it has been advantageously found that tobacco materials having a density of at least 350 mg/cc and less than about 700 mg/cc provide a more sustained aerosol release. To provide an aerosol with a consistent flavor profile, the amorphous solid material components of the aerosol-generating material should be uniformly dispersed throughout the rod. Advantageously, the inventors have found that this can be accomplished by casting the amorphous solid material to have a thickness as described herein and processing the amorphous solid material as described below to ensure uniform distribution throughout the aerosol-generating material to provide an amorphous solid material with an areal density similar to that of the tobacco material.

Advantageously, the inventors have found that when the amorphous solid material in the form of a sheet is chopped, a sufficiently uniform mixture of the tobacco material components and the amorphous solid material components can be achieved. The chopped amorphous solid material preferably has a cut width of 0.75 mm to 2 mm, for example 1 mm to 1.5 mm. The amorphous solid material strands formed by chopping can be cut widthwise, for example by a cross-cut chopping process, to define a chop length of the chopped amorphous solid material in addition to the chop width. The chop length of the chopped amorphous solid material is preferably at least 5 mm, for example at least 10 mm, or at least 20 mm. The chop length of the chopped amorphous solid material can be less than 60 mm, less than 50 mm, or less than 40 mm. Advantageously, the inventors have found that in order to achieve a uniform mixture of the chopped amorphous solid material with cut rag tobacco, it is preferable for the chopped amorphous solid material to have a non-uniform cut length. For example, the distribution of cut lengths can be multimodal, e.g., bimodal. In some examples, a first portion of the amorphous solid material can be cut to a first length, a second portion of the amorphous solid material can be cut to a second length, and the cut materials can be mixed together to form a plurality of strands or strips of amorphous solid material having a bimodal distribution of lengths. In some examples, the first cut length can be between 30 mm and 50 mm, or between 35 mm and 45 mm, or about 40 mm, and the second cut length can be between 10 mm and 30 mm, or between 15 mm and 25 mm, or about 20 mm. The number of cut lengths can be selected to match the number of modes in the length distribution of the shredded tobacco material. Strands of amorphous material having different cut lengths can be mixed together in a ratio selected to match the length distribution of the shredded tobacco material. The inventors have found that by matching the strand and/or strip length distribution of the amorphous solid material to the strand length distribution of the tobacco material, a more uniform mixture of the amorphous solid and the tobacco material can be obtained.

Although referred to as the cut length, the length of the piece or strip of amorphous solid material may alternatively or additionally be determined by a dimension of the material determined during its manufacture, e.g., the width of a sheet of material as manufactured.

In some embodiments, a plurality of strips of amorphous solid material are provided, and at least one of the plurality of strips of amorphous solid material has a length greater than about 10 mm. At least one of the plurality of strips of amorphous solid material may alternatively or additionally have a length of about 10 mm to about 60 mm or about 20 mm to about 50 mm. Each of the plurality of strips of amorphous solid material may have a length of about 10 mm to about 60 mm or about 20 mm to about 50 mm.

The rod of aerosol-generating material preferably comprises a first component comprising tobacco material in an amount of 50% to 98%, e.g., 80% to 95%, for example provided as cut rag tobacco, and a second component comprising shredded amorphous solid material in an amount of 2% to 50%, e.g., 5% to 20%.

The inventors have found that it may be advantageous to produce rods of aerosol-generating material from a relatively low amount of chopped amorphous solid material within the ranges described herein with a relatively high level of aerosol-forming agent within the ranges described herein, such that fewer strips of amorphous solid material are required for a given aerosol-forming agent content in the aerosol-generating material. This may be beneficial in production because, compared to the amorphous solid material, relatively more tobacco material may come into contact with components of the production machinery, thereby reducing the possibility of material clumping and/or formation of blockages on the machinery during production. For example, the amount of aerosol-forming agent, such as glycerol, in the amorphous solid material may account for 20% to 70% by weight of the amorphous solid material, e.g., 25% to 55%, 30% to 40%, or 45% to 55% by weight.

Advantageously, the inventors have found that aerosol-generating materials according to the present disclosure can have a more uniform distribution of chopped amorphous solid material throughout the aerosol-generating material. For example, the standard deviation in weight percent inclusion level of the amorphous solid strips in the aerosol-generating material (expressed as a percentage of the average) between consumables made using the aerosol-generating materials described herein can be less than 35% or less than 30% by weight of the aerosol-generating material based on measurements of 10 consumables, where each consumable contains about 650 mg of aerosol-generating material. Table 1a shows the inclusion percentages achieved for three aerosol-generating materials: material A having an average amorphous solid content of 4.6307%, material B having an average amorphous solid content of 10.625%, and material C having an average amorphous solid content of 19.722%. For example, it has been found that for average amorphous solid contents of greater than 10%, a standard deviation of less than 30% as a percentage of the average can be achieved. This measurement is performed by carefully opening the consumable aerosol-generating material rod and manually separating the amorphous solid material from the tobacco material.

Exemplary aerosol-generating materials were made according to the present disclosure, and chemical analyses known to those skilled in the art were performed on samples of each exemplary aerosol-generating material to determine the total nicotine, glycerol, and water content of the material. Ten 10 g samples were taken from a batch of aerosol-generating material for chemical analysis, and the process was repeated ten times to obtain the average nicotine, glycerol, and water content, as well as their standard deviations, within the batches of aerosol-generating material produced by the methods described herein.

Each of the exemplary aerosol-generating materials 1-3 contained 100% leaf tobacco as the tobacco material component and was made to different specifications with respect to the inclusion level of the amorphous solid material component and the composition of the amorphous solid material. The tobacco material contained 4.5% glycerol by weight of the tobacco material. Table 1b shows that in the aerosol-generating materials made according to the present disclosure, in all cases the standard deviation of the total glycerol content within a given batch of material was less than 35%, or less than 30%, or less than 25% of the mean.

In cases where the amorphous solid material includes flavorings, the total flavorings in the article may include the flavorings provided in the amorphous solid material, and optionally additional flavorings added to the tobacco material or present in components of the article other than the aerosol-forming material 3. The total flavoring content of the article may be determined by disassembling the article into its component parts and performing chemical analyses known to those skilled in the art to determine the flavoring content of each component, and thereby the total flavoring content. In examples where the amorphous solid includes flavorings, the total flavoring content of the article may be between 5 mg and 30 mg per article, e.g., between 16 mg and 22 mg per article, or between 5 mg and 10 mg per article, or between 17 mg and 30 mg per article. The amorphous solid may include a total flavoring content of at least 20%.

Articles including aerosol-generating materials according to the present disclosure were made such that the aerosol-generating material included 5%, 12%, or 20% by weight of amorphous solids, with 35% by weight of menthol as the flavoring. Table 2 shows the menthol content in mg per article for articles including aerosol-generating materials. The standard deviation of the menthol content was determined by analyzing 10 articles made from each batch of aerosol-generating material. As shown, the total menthol content within each article can vary from article to article, with a standard deviation of less than 20% of the average menthol content in mg.

The aerosol-generating material may be provided in the form of a rod having a first end and a second end. The portion of the rod between the first end and a longitudinal position midway between the first end and the second end of the rod may comprise 20% to 80% of the amorphous solid material in the rod.

In this example, the mouthpiece 2 includes a body of material 6 upstream of the hollow tubular element 4, which in this example is adjacent to and in abutting relationship with the hollow tubular element 4. The body of material 6 and the hollow tubular element 4 each define a substantially cylindrical overall outer shape and share a common longitudinal axis. The body of material 6 is wrapped in a first plug wrap 7. The first plug wrap 7 preferably has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. The first plug wrap 7 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The first plug wrap 7 is preferably a non-porous plug wrap, for example having a permeability of less than 100 Coresta units, for example less than 50 Coresta units. However, in other embodiments, the first plug wrap 7 may be a porous plug wrap, for example having a permeability of greater than 200 Coresta units.

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

In this example, the body of material 6 is formed from filament tow. In this example, the tow used in the body of material 6 has a denier per filament (d.p.f.) of 8.4 and a total denier of 21,000. Alternatively, the tow can have, for example, a denier per filament (d.p.f.) of 9.5 and a total denier of 12,000. In this example, the tow includes a plasticized cellulose acetate tow. The plasticizer used in the tow comprises about 7% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, different materials can be used to form the body of material 6. For example, rather than tow, the body 6 can be formed from paper, for example, in a manner similar to paper filters known for use in cigarettes. Alternatively, the body 6 can be formed from a tow other than cellulose acetate, for example polylactic acid (PLA), other materials described herein with respect to filament tow, or similar materials. The tow, whether formed from cellulose acetate or other materials, preferably has a d.p.f. of at least 5, more preferably at least 6, and even more preferably at least 7. These denier per filament values provide tows with relatively coarse, thick fibers with less surface area, resulting in a lower pressure drop across the mouthpiece 2 than tows with lower d.p.f. values. To achieve a sufficiently uniform body of material 6, it is preferred that the tow has a denier per filament of 12 d.p.f. or less, preferably 11 d.p.f. or less, and even more preferably 10 d.p.f. or less.

The total denier of the tows forming the body of material 6 is preferably at most 30,000, more preferably at most 28,000, and even more preferably at most 25,000. These total denier values provide the tows to occupy a smaller percentage of the cross-sectional area of the mouthpiece 2, resulting in a lower pressure drop in the mouthpiece 2 than tows having higher total denier values. For a body of material 6 of suitable stiffness, the tows preferably have a total denier of at least 8,000, more preferably at least 10,000. The denier per filament is preferably 5-12, and the total denier is preferably 10,000-25,000. More preferably, the denier per filament is 6-10, and the total denier is 11,000-22,000. The cross-sectional shape of the filaments of the tow is preferably "Y" shaped, although other shapes such as "X" shaped filaments having the same d.p.f. and total denier values provided herein may be used in other embodiments.

As shown in FIG. 1, the mouthpiece 2 of the article 1 comprises an upstream end 2a adjacent the rod of aerosol-generating material 3 and a downstream end 2b remote from the rod of aerosol-generating material 3. The mouthpiece 2 has a hollow tubular element 4 formed from filament tow at the downstream end 2b. Advantageously, this has been found to significantly reduce the temperature of the outer surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece that contacts the consumer's mouth when the article 1 is in use. In addition, the use of the tubular element 4 has also been found to significantly reduce the temperature of the outer surface of the mouthpiece 2 upstream of the tubular element 4. Without wishing to be bound by theory, it is hypothesized that this is due to the tubular element 4 causing the aerosol to pass closer to the center of the mouthpiece 2, thus reducing the transfer of heat from the aerosol to the outer surface of the mouthpiece 2.

In this example, the article 1 has a circumference of about 21 mm (i.e., the article is in a demi-slim format). In other examples, the article can be provided in any of the formats described herein, for example having a circumference of 15 mm to 25 mm. Improved heating efficiency can be achieved by using an article having a smaller circumference within this range, for example a circumference of less than 23 mm, when the article is heated to release the aerosol. It has been found that article circumferences greater than 19 mm are also particularly effective for achieving improved aerosol upon heating while maintaining a suitable product length. It has been found that articles having a circumference of 19 mm to 23 mm, more preferably 20 mm to 22 mm, provide a good balance that allows efficient heating while providing effective aerosol delivery.

The circumference of the mouthpiece 2 is substantially the same as the circumference of the rod of aerosol-generating material 3, so that the transition between these components is smooth. In this example, the circumference of the mouthpiece 2 is about 20.8 mm. A tipping paper 5 is wrapped over a portion of the rod of aerosol-generating material 3 over the entire length of the mouthpiece 2, the tipping paper 5 having an adhesive on its inner surface to connect the mouthpiece 2 and the rod 3. In this example, the tipping paper 5 extends 5 mm over the rod of aerosol-generating material 3, but alternatively it can extend 3 mm to 10 mm, or more preferably 4 mm to 6 mm, over the rod 3 to provide a secure attachment between the mouthpiece 2 and the rod 3. The tipping paper 5 can have a basis weight greater than that of the plug wrap used in the article 1, for example, a basis weight of 40 gsm to 80 gsm, more preferably 50 gsm to 70 gsm, in this example 58 gsm. It has been found that these basis weight ranges result in a tipping paper that has acceptable tensile strength while being flexible enough to wrap the article 1 around itself and attach it along the longitudinal lap seam of the paper. After being wrapped around the mouthpiece 2, the circumference of the tipping paper 5 is approximately 21 mm.

The "wall thickness" of the hollow tubular element 4 corresponds to the thickness of the wall of the tube 4 in the radial direction. This can be measured, for example, using calipers. Advantageously, the wall thickness is greater than 0.9 mm, more preferably equal to or greater than 1.0 mm. The wall thickness is preferably substantially constant throughout the wall of the hollow tubular element 4. However, if the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9 mm, more preferably equal to or greater than 1.0 mm, at any point around the hollow tubular element 4.

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

The density of the hollow tubular element 4 is preferably at least about 0.25 grams per cubic centimeter (g/cc), more preferably at least about 0.3 g/cc. The density of the hollow tubular element 4 is preferably less than about 0.75 grams per cubic centimeter (g/cc), more preferably less than 0.6 g/cc. In some embodiments, the density of the hollow tubular element 4 is 0.25 to 0.75 g/cc, more preferably 0.3 to 0.6 g/cc, more preferably 0.4 g/cc to 0.6 g/cc or about 0.5 g/cc. These densities have been found to provide a good balance between the improved stiffness provided by the higher density material and the lower heat transfer characteristics of the lower density material. For purposes of this invention, the "density" of the hollow tubular element 4 refers to the density of the filament tow forming the element in which any plasticizer is incorporated. The density can be determined by dividing the total weight of the hollow tubular elements 4 by the total volume of the hollow tubular elements 4, and the total volume can be calculated using suitable measurements of the hollow tubular elements 4, for example obtained using calipers. If necessary, suitable dimensions can be measured using a microscope.

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

The filament tows forming the hollow tubular elements 4 preferably have a denier per filament greater than 3. This denier per filament has been found to allow for the formation of tubular elements 4 that are not too dense. The denier per filament is preferably at least 4, more preferably at least 5. In a preferred embodiment, the filament tows forming the hollow tubular elements 4 have a denier per filament between 4 and 10, more preferably between 4 and 9. In one example, the filament tows forming the hollow tubular elements 4 have an 8Y40,000 tow formed from cellulose acetate and containing 18% plasticizer, e.g., triacetin.

The hollow tubular element 4 preferably has an inner diameter of greater than 3.0 mm. A smaller diameter may increase the velocity of the aerosol passing through the mouthpiece 2 to the consumer's mouth more than desired, resulting in the aerosol becoming too warm, for example reaching a temperature of greater than 40° C. or greater than 45° C. The hollow tubular element 4 more preferably has an inner diameter of greater than 3.1 mm, even more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the inner diameter of the hollow tubular element 4 is about 3.9 mm.

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

In this example, the hollow tubular element 4 is a first hollow tubular element 4, and the mouthpiece includes a second hollow tubular element 8, also called a cooling element, upstream of the first hollow tubular element 4. In this example, the second hollow tubular element 8 is located upstream of the body of material 6, adjacent to the body of material 6, and in abutting relationship therewith. The body of material 6 and the second hollow tubular element 8 each define a substantially cylindrical overall outer shape and share a common longitudinal axis. The second hollow tubular element 8 is formed from a plurality of layers of paper that are wound in parallel and abut at seams to form the tubular element 8. In this example, the first and second paper layers are provided as a double tube, but in other examples three, four or more paper layers can be used to form triple, quadruple or more tubes. Other constructions can be used, such as spirally wound paper layers, cardboard tubes, tubes formed using a paper mache type process, molded or extruded plastic tubes, etc. The second hollow tubular element 8 can also be formed using stiff plug wrap and/or tipping paper as the second plug wrap 9 and/or tipping paper 5 described herein, meaning that a separate tubular element is not required. The stiff plug wrap and/or tipping paper is manufactured to have sufficient stiffness to withstand axial compressive forces and bending moments that may occur during manufacture and use of the article 1. For example, the stiff plug wrap and/or tipping paper can have a basis weight of 70 gsm to 120 gsm, more preferably 80 gsm to 110 gsm. Additionally or alternatively, the stiff plug wrap and/or tipping paper can have a thickness of 80 μm to 200 μm, more preferably 100 μm to 160 μm, or 120 μm to 150 μm. It may be desirable to have values within these ranges for both the second plug wrap 9 and the tipping paper 5 to achieve an acceptable overall stiffness level for the second hollow tubular element 8.

The second hollow tubular element 8 preferably has a wall thickness that can be measured in the same manner as the first hollow tubular element 4, with the wall thickness of the second hollow tubular element 8 being at least about 100 μm to a maximum of about 1.5 mm, preferably 100 μm to 1 mm, more preferably 150 μm to 500 μm, or about 300 μm. In this example, the second hollow tubular element 8 has a wall thickness of about 290 μm.

The length of the second hollow tubular element 8 is preferably less than about 50 mm. More preferably, the length of the second hollow tubular element 8 is less than about 40 mm. Even more preferably, the length of the second hollow tubular element 8 is less than about 30 mm. Additionally or alternatively, the length of the second hollow tubular element 8 is preferably at least about 10 mm. The length of the second hollow tubular element 8 is preferably at least about 15 mm. In some preferred embodiments, the length of the second hollow tubular element 8 is about 20 mm to about 30 mm, more preferably about 22 mm to about 28 mm, even more preferably about 24 mm to about 26 mm, and most preferably about 25 mm. In this example, the length of the second hollow tubular element 8 is 25 mm.

The second hollow tubular element 8 is positioned around and defines a cavity in the mouthpiece 2 that acts as a cooling segment. The cavity provides a chamber through which the heated volatile components generated by the aerosol-generating material 3 flow. The second hollow tubular element 8 is hollow and provides a chamber for the aerosol accumulation that is still rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and use of the article 1. The second hollow tubular element 8 provides a physical displacement between the aerosol-generating material 3 and the body of material 6. The physical displacement provided by the second hollow tubular element 8 provides a temperature gradient over the length of the second hollow tubular element 8.

Preferably, the mouthpiece 2 comprises a cavity having an internal volume greater than 450 mm ^3. It has been found that providing a cavity of at least this volume allows for improved aerosol formation. Such a cavity size provides sufficient space within the mouthpiece 2 to allow the heated volatile components to cool, as a too-warm aerosol would result, and thus allows exposure of the aerosol-generating material 3 to higher temperatures than would otherwise be possible. In this example, the cavity is formed by the second hollow tubular element 8, but in alternative configurations it may be formed within a different part of the mouthpiece 2. More preferably, the mouthpiece 2 comprises a cavity, for example formed within the second hollow tubular element 8, which has an internal volume greater than 500 mm ³ , even more preferably greater than 550 mm ³ , allowing further improvement of the aerosol. In some examples, the internal cavity comprises a volume of about 550 mm ³ to about 750 mm ³ , for example about 600 mm ³ or 700 mm ³ .

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

In an alternative article, the second hollow tubular element 8 may be replaced by an alternative cooling element, for example an element formed from a body of material that performs the function of cooling the aerosol while allowing the aerosol to pass longitudinally.

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

In this example, the aerosol-generating material 3 is wound into a paper wrapper 10. The paper wrapper 10 can be, for example, a paper or paper-backed foil wrapper. In this example, the paper wrapper 10 is substantially impermeable to air. In an alternative embodiment, the paper wrapper 10 has a permeability of preferably less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that a low-permeability paper wrapper, for example having a permeability of less than 100 Coresta units, more preferably less than 60 Coresta units, results in improved aerosol formation in the aerosol-generating material 3. Without wishing to be bound by theory, it is hypothesized that this is due to reduced loss of aerosol compounds in the paper wrapper 10. The permeability of the paper wrapper 10 can be measured according to ISO 2965:2009 for determining the air permeability of materials used as cigarette paper, filter plug wrap, and filter bonding paper.

In this embodiment, the paper wrapper 10 comprises an aluminum foil. Aluminum foil has been found to be particularly effective in promoting the formation of an aerosol within the aerosol-generating material 3. In this example, the aluminum foil has a metal layer having a thickness of about 6 μm. In this example, the aluminum foil has a paper backing. However, in alternative configurations, the aluminum foil can be of other thicknesses, for example, between 4 μm and 16 μm. The aluminum foil also need not have a paper backing, and can have a backing formed from other materials, or no backing material, for example to help provide the foil with suitable tensile strength. Metal layers or foils other than aluminum can also be used. The total thickness of the paper wrapper is preferably between 20 μm and 60 μm, more preferably between 30 μm and 50 μm, to provide a paper wrapper with suitable structural integrity and heat transfer properties. The pulling force that can be applied to the web before it breaks can be greater than 3,000 grams force, for example, between 3,000 and 10,000 grams force, or between 3,000 and 4,500 grams force.

The article has an aeration level of about 75% of the aerosol drawn through the article. In alternative embodiments, the article can have an aeration level of 50% to 80%, such as 65% to 75%, of the aerosol drawn through the article. In some examples, the standard deviation of the aeration level within a batch of articles made according to the present disclosure is less than 5%, or less than 4%, or less than 3%. For purposes of determining the standard deviation of the aeration level, a batch refers to at least 10 articles made to the same specifications. For example, those articles provided in a pack of articles can be used as a basis for measurement. Such a standard deviation can be achieved by improved mixing of the tobacco material and the amorphous solid material in the aerosol-generating material made according to the present invention, because the improved mixing results in a more consistent pack of aerosol-generating material in the article.

These levels of ventilation help to slow down the flow of aerosol inhaled through the mouthpiece 2, thereby allowing the aerosol to cool sufficiently before reaching the downstream end 2b of the mouthpiece 2. Ventilation is provided directly into the mouthpiece 2 of the article 1. In this example, ventilation is provided into the second hollow tubular element 8, which has been found to be particularly beneficial in supporting the aerosol generation process. Ventilation is provided through first and second parallel rows of perforations 12, in this case formed as laser perforations 17.925 mm and 18.625 mm away from the downstream mouth end 2b of the mouthpiece 2, respectively. These perforations pass through the tipping paper 5, the second plug wrap 9, and the second hollow tubular element 8. In alternative embodiments, ventilation can be provided elsewhere into the mouthpiece, for example into the body of material 6 or the first tubular element 4.

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

The volume of the aerosol-generating material 3 provided may vary from ^about 200 mm to about 4300 ^mm , preferably from ^about 500 mm to 1500 ^mm , and more preferably from ^about 1000 mm to about 1300 ^mm . Providing aerosol-generating material in these volumes, for example ^from about 1000 mm to about 1300 ^mm , has been shown to advantageously provide superior aerosols with improved visibility and sensory performance when compared to those provided with volumes selected from the lower end of this range.

The mass of aerosol-generating material 3 provided may be greater than 200 mg, for example between about 200 mg and 400 mg, preferably between about 230 mg and 360 mg, more preferably between about 250 mg and 360 mg. Advantageously, providing a greater mass of aerosol-generating material has been found to result in improved sensory performance when compared to aerosols generated from smaller masses of tobacco material.

2a is a side cross-sectional view of a further article 1' including a capsule-containing mouthpiece 2'. FIG. 2b is a cross-sectional view of the capsule-containing mouthpiece shown in FIG. 2a taken along line A-A' in FIG. 2a. The article 1' and the encapsulated mouthpiece 2' are the same as the article 1 and mouthpiece 2 shown in FIG. 1, except that the aerosol modifier is provided within the body of material 6, in this example in the form of a capsule 11, and an oil-resistant first plug wrap 7' surrounds the body of material 6. In other examples, the aerosol modifier can be provided in other forms, such as a material injected into the body of material 6 or provided to a thread, for example the thread can hold a flavoring or other aerosol modifier, and the aerosol modifier can also be disposed within the body of material 6.

The capsule 11 may constitute a breakable capsule, e.g., a capsule having a solid, brittle shell surrounding a liquid payload. In this example, a single capsule 11 is used. The capsule 11 is entirely embedded within the body of material 6. In other words, the capsule 11 is completely surrounded by the material forming the body 6. In other examples, multiple breakable capsules, e.g., two, three, or more breakable capsules, may be disposed within the body of material 6. The length of the body of material 6 may be increased to accommodate the number of capsules required. In examples where multiple capsules are used, the individual capsules may be the same as one another or may differ from one another in terms of size and/or capsule payload. In other examples, multiple bodies of material 6 may be provided, each housing one or more capsules.

The capsule 11 has a core-shell structure. In other words, the capsule 11 comprises a shell that encases a liquid agent, such as a flavorant or other agent, which may be any one of the flavorants or aerosol modifiers described herein. The capsule shell can be burst by the user to release the flavorant or other agent into the body of material 6. The first plug wrap 7' may constitute a barrier coating for making the plug wrap material substantially impermeable to the liquid payload of the capsule 11. Alternatively or additionally, the second plug wrap 9 and/or the tipping paper 5 may constitute a barrier coating for making the plug wrap and/or tipping paper material substantially impermeable to the liquid payload of the capsule 11.

In this example, capsule 11 is spherical and has a diameter of about 3 mm. In other examples, capsules of other shapes and sizes may be used. The total weight of capsule 11 may be in the range of about 10 mg to about 50 mg.

In this example, the capsule 11 is located at a longitudinally central position within the body of material 6. That is, the capsule 11 is located such that its centre is 4mm away from each end of the body of material 6. In other examples, the capsule 11 may be located at a position other than a longitudinally central position within the body of material 6, i.e. closer to the downstream end of the body of material 6 than the upstream end, or closer to the upstream end of the body of material 6 than the downstream end. The mouthpiece 2' is preferably configured such that the capsule 11 and the vent 12 are longitudinally offset from one another within the mouthpiece 2'.
A cross-sectional view of the mouthpiece 2' is shown in Figure 2b, taken along line A-A' in Figure 2a. Figure 2b shows the capsule 11, the body of material 6, the first and second plug wraps 7' and 9, and the tipping paper 5. In this example, the capsule 11 is centrally located about the longitudinal axis (not shown) of the mouthpiece 2'. The first and second plug wraps 7' and 9, and the tipping paper 5 are concentrically arranged around the body of material 6.

The breakable capsule 11 has a core-shell structure, i.e., the encapsulating or barrier material creates a shell around a core containing the aerosol modifier. The shell structure prevents migration of the aerosol modifier during storage of the article 1', but allows for controlled release of the aerosol modifier, also called the aerosol modifier, during use.

In some cases, the barrier material (also referred to herein as the encapsulating material) is frangible. The capsule is crushed or otherwise broken or destroyed by the user to release the encapsulated aerosol modifier. Typically, the capsule is broken just before heating is initiated, but the user can choose when to release the aerosol modifier. The term "breakable capsule" refers to a capsule whose shell can be broken by pressure to release the core, and more specifically, the shell can be ruptured under pressure applied by the user's finger when the user wishes to release the capsule's core.

In some cases, the barrier material is heat resistant; that is, in some cases, the barrier does not burst, melt, or otherwise collapse at temperatures reached at the capsule site during operation of the aerosol delivery device. Illustratively, a capsule disposed within a mouthpiece can be exposed to temperatures in the range of, for example, 30°C to 100°C, and the barrier material can continue to retain the liquid core up to at least about 50°C to 120°C.

In other cases, the capsule releases the core composition when heated, for example by melting the barrier material or by expanding the capsule and rupturing the barrier material.

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

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

The capsule according to the present invention comprises a core as described above and a shell. The capsule can exhibit a crush strength of about 4.5N to about 40N, more preferably about 5N to about 30N or about 28N (e.g., about 9.8N to about 24.5N). The capsule burst strength can be measured when the capsule is removed from the body of material 6, using a force gauge to measure the force with which the capsule is pressed between two flat metal plates to burst. A suitable measuring device is a Sauter FK50 force gauge with a flat head attachment that can be used to press the capsule against a flat, hard surface with a surface similar to the attachment.

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

In some embodiments, the cross-sectional area of the capsule 11 at its maximum cross-sectional area is less than 28%, more preferably less than 27%, and even more preferably less than 25% of the cross-sectional area of the portion of the mouthpiece 2' in which the capsule 11 is provided. For example, for a spherical capsule with a diameter of 3.0 mm, the maximum cross-sectional area of the capsule is ^7.07 mm2. For a mouthpiece 2' with a circumference of 21 mm as described herein, the body of material 6 has an outer circumference of 20.8 mm, the radius of this component is 3.31 mm, corresponding to a cross-sectional area of ^34.43 mm2. The cross-sectional area of the capsule is, in this example, 20.5% of the cross-sectional area of the mouthpiece 2'. As another example, if the capsule had a diameter of 3.2 mm, its maximum cross-sectional area would be 8.04 ^mm2 . In this case, the cross-sectional area of the capsule would be 23.4% of the cross-sectional area of the body of material 6. The maximum cross-sectional area of the capsule being less than 28% of the cross-sectional area of the portion of the mouthpiece 2' in which the capsule 11 is provided has the advantage, compared to a capsule having a larger cross-sectional area, that the pressure drop in the mouthpiece 2' is reduced, sufficient space remains around the capsule for the aerosol to pass through, and the body of material 6 does not remove a large amount of aerosol mass as it passes through the mouthpiece 2'.

When the capsule is broken, the pressure drop or pressure differential (also called resistance to draw) across the article, measured as the opening pressure drop (i.e., with the vent opening open), preferably drops by less than ₈ mmH2O. More preferably, the opening pressure drop drops by less than ₆ mmH2O, more preferably less than ₅ mmH2O. These values are measured as an average achieved by at least 80 articles made with the same design. Such small changes in pressure drop mean that other aspects of the product design, such as setting the correct vent level for a given product pressure drop, can be achieved whether or not the consumer chooses to break the capsule.

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

Suitably, the gelling agent of the capsule may be, for example, a polysaccharide or cellulosic gelling agent, gelatin, gum, gel, wax, or mixtures thereof. Suitable polysaccharides include alginic acid, dextran, maltodextrin, cyclodextrin, and pectin. Suitable alginic acids include, for example, alginates, ester alginates, or glyceryl alginates. Alginates include ammonium alginate, triethanolamine alginate, and metal ion alginates of Group I or Group II, such as sodium, potassium, calcium, and magnesium alginates. Ester alginates include propylene glycol alginate and glyceryl alginate. In one embodiment, the barrier material includes sodium alginate and/or calcium alginate. Suitable cellulosic materials include methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, cellulose acetate, and cellulose ethers. The gelling agent may include one or more modified starches. The gelling agent may include carrageenan. Suitable gums include agar, gellan gum, gum arabic, pullulan gum, mannan gum, gum ghatti, gum tragacanth, karaya, locust bean, acacia gum, guar, quince seed, and xanthan gum. Suitable gels include agar, agarose, carrageenan, fucoidan, and furcellan. Suitable waxes include carnauba wax. In some cases, the gelling agent may include carrageenan and/or gellan gum, which are particularly suitable for inclusion as gelling agents such that the pressure required to break the resulting capsule is particularly suitable.

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

The barrier material may include a colorant that makes it easier to locate the capsule in the aerosol generating device during the manufacturing process of the aerosol generating device. The colorant is preferably selected from among dyes and pigments.

The barrier material may further include at least one buffering agent, such as a citrate or phosphate compound.

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

The barrier material may also include one or more filler materials. Suitable filler materials include starch derivatives such as dextrin, maltodextrin, cyclodextrin (alpha, beta, or gamma), or cellulose derivatives such as hydroxypropylmethylcellulose (HPMC), hydroxypropylcellulose (HPC), methylcellulose (MC), carboxymethylcellulose (CMC), polyvinyl alcohol, polyols, or mixtures thereof. Dextrin is a preferred filler. The amount of filler in the shell is at most 98.5% by weight, preferably 25-95% by weight, more preferably 40-80% by weight, even more preferably 50-60% by weight of the total dry weight of the shell.

The capsule shell may further comprise a hydrophobic outer layer that reduces the susceptibility of the capsule to moisture-induced deterioration. The hydrophobic outer layer is preferably selected from the group including wax, particularly carnauba wax, candelilla wax, or beeswax, carbowax, shellac (in alcoholic or aqueous solutions), ethyl cellulose, hydroxypropyl methylcellulose, hydroxylpropyl cellulose, latex compositions, polyvinyl alcohol, or combinations thereof. More preferably, the at least one moisture barrier is ethyl cellulose or a mixture of ethyl cellulose and shellac.

The capsule core includes an aerosol modifier. The aerosol modifier can be any volatile substance that modifies at least one property of the aerosol. For example, the aerosol substance can modify the pH, sensory properties, moisture content, delivery characteristics, or flavor. In some cases, the aerosol modifier can be selected from an acid, a base, water, or a flavoring. In some embodiments, the aerosol modifier includes one or more flavorings.

The flavouring may suitably be liquorice, rose oil, vanilla, lemon oil, orange oil, mint flavouring from any species of the genus Mentha, such as peppermint oil and/or spearmint oil, preferably menthol, and/or mint oil, or lavender, fennel, or anise.

In some cases, the flavoring includes menthol.

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

In some cases, the core can include at least about 25% w/w flavoring (based on the total weight of the core), preferably at least about 30% w/w flavoring, 35% w/w flavoring, 40% w/w flavoring, 45% w/w flavoring, or 50% w/w flavoring. In some cases, the core can include no more than about 75% w/w flavoring (based on the total weight of the core), preferably no more than about 65% w/w flavoring, no more than 55% w/w flavoring, or no more than 50% w/w flavoring. Illustratively, the capsule can include an amount of flavoring in the range of 25-75% w/w (based on the total weight of the core), about 35-60% w/w, or about 40-55% w/w.

The capsule can contain at least about 2 mg, 3 mg, or 4 mg of aerosol modifier, preferably at least about 4.5 mg of aerosol modifier, 5 mg of aerosol modifier, 5.5 mg of aerosol modifier, or 6 mg of aerosol modifier.

In some cases, the consumable contains at least about 7 mg of aerosol modifier, preferably at least about 8 mg of aerosol modifier, 10 mg of aerosol modifier, 12 mg of aerosol modifier, or 15 mg of aerosol modifier. The core may also contain a solvent in which the aerosol modifier is dissolved.

Any suitable solvent may be used.

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

Esters can be formed with caprylic acid and/or capric acid. For example, the solvent can include medium chain triglycerides of glyceryl tricaprylate and/or glyceryl tricaprate. For example, the solvent can include compounds identified by CAS Registry Numbers 73398-61-5, 65381-09-1, 85409-09-2. Such medium chain triglycerides are odorless and tasteless.

The hydrophilic lipophilic balance (HLB) of the solvent may be in the range of 9 to 13, preferably 10 to 12. The method of making the capsules includes co-extrusion, optionally followed by centrifugation and hardening and/or drying. The contents of WO 2007/010407 are incorporated by reference in their entirety.

In the examples described above, the mouthpieces 2, 2' each comprise a single body of material 6. In other examples, the mouthpieces of Fig. 1 or Figs. 2a and 2b may comprise multiple bodies of material. The mouthpieces 2, 2' may comprise cavities between the bodies of material.

In some examples, the mouthpiece 2, 2' downstream of the aerosol-generating material 3 can comprise a wrapper, such as the first plug wrap 7 or the second plug wrap 9, or a tipping paper 5, which wrapper includes an aerosol modifier or other sensate material as described herein. The aerosol modifier can be disposed on an inward or outward surface of the mouthpiece wrapper. For example, the aerosol modifier or other sensate material can be provided on an area of the wrapper that contacts the consumer's lips during use, such as the outward surface of the tipping paper 5. By disposing the aerosol modifier or other sensate material on the outward surface of the mouthpiece wrapper, the aerosol modifier or other sensate material can be delivered to the consumer's lips during use. The delivery of the aerosol modifier or other sensate material to the consumer's lips during use of the article can modify the organoleptic properties (e.g., taste) of the aerosol generated by the aerosol-generating substrate 3 or can otherwise provide the consumer with an alternative sensory experience. For example, the aerosol modifier or other sensate material may provide a flavor to the aerosol generated by the aerosol-generating substrate 3. The aerosol modifier or other sensate material may be at least partially water-soluble so as to be transferred to the user by the consumer's saliva. The aerosol modifier or other sensate material may be volatilized by heat generated by the aerosol delivery system. This may facilitate transfer of the aerosol modifier to the aerosol generated by the aerosol-generating substrate 3. Suitable sensate materials may include flavors as described herein, cooling agents such as sucralose, or menthol.

According to embodiments described herein, a pack may be provided that includes a plurality of articles described herein. The number of the plurality of strips of amorphous solid material in each article may vary by less than 40% between the articles in the pack, or by less than 30% between the articles in the pack, or by less than 20% between the articles in the pack. Alternatively or additionally, the plurality of strips of amorphous solid material in each article in the pack may include a flavoring, and the delivery of the flavoring from each of the plurality of articles during use varies by less than 50% between the articles in the pack, or by less than 20% between the articles in the pack. For example, the standard deviation of the inclusion level of the flavoring in weight percent between the articles in the pack may be less than 50%, or less than 30%, or less than 20%, of the average, e.g., 5% to 50%, or 5% to 30%, or 10% to 25%. The flavoring level may be determined by chemical analysis known to those skilled in the art, and the standard deviation may be determined for a batch of at least 10 articles, e.g., a pack of articles.

3 shows an example of a non-combustion aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium/material, such as the aerosol-generating material 3 of the articles 1, 1' described herein. In summary, the device 100 can be used to heat a replaceable article 110 comprising an aerosol-generating medium, such as the articles 1, 1' described herein, to generate an aerosol or other inhalable medium that is inhaled by a user of the device 100. The device 100 and the replaceable article 110 together form a system.

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

The device 100 in this example includes a first end member 106 with a lid 108 movable relative to the first end member 106 to close the opening 104 when the article 110 is not in place. In FIG. 3, the lid 108 is shown in an open configuration, but the lid 108 can also be moved to a closed configuration. For example, a user can slide the lid 108 in the direction of arrow "B."

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

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

Figure 4 shows the device 100 of Figure 3 with the outer cover 102 removed and without the article 110 present. The device 100 defines a longitudinal axis 134.

As shown in FIG. 4, the first end member 106 is disposed at one end of the device 100 and the second end member 116 is disposed at an opposite end of the device 100. The first end member 106 and the second end member 116 together at least partially define an end surface of the device 100. For example, the bottom surface of the second end member 116 at least partially defines the bottom surface of the device 100. An edge of the outer cover 102 can also define a portion of the end surface. In this example, the lid 108 also defines a portion of the top surface of the device 100.

The end of the device closest to the opening 104 can be referred to as the proximal end (or mouth end) of the device 100 because it is closest to the user's mouth during use. During use, the user inserts the article 110 into the opening 104, operates the user control 112 to initiate heating of the aerosol-generating material, and inhales the aerosol generated within the device. This causes the aerosol to flow along the flow path through the device 100 toward the proximal end of the device 100.

The other end of the device furthest from the opening 104 can be referred to as the distal end of the device 100 because it is the end furthest from the user's mouth during use. When a user inhales the aerosol generated within the device, the aerosol flows away from the distal end of the device 100.

The device 100 further comprises a power source 118. The power source 118 can be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium ion batteries), nickel batteries (such as nickel cadmium batteries), and alkaline batteries. The battery is electrically coupled to the heating assembly to provide power to heat the aerosol-generating material when needed under the control of a controller (not shown). In this example, the battery is connected to a central support 120, which holds the battery 118 in place.

The device further comprises at least one electronic module 122. The electronic module 122 may comprise, for example, a printed circuit board (PCB). The PCB 122 may support at least one controller, such as a processor, and a memory. The PCB 122 may also comprise one or more electrical tracks for electrically connecting together various electronic components of the device 100. For example, a battery terminal may be electrically connected to the PCB 122 so that power may be distributed throughout the device 100. The socket 114 may also be electrically coupled to a battery via the electrical tracks.

In the exemplary device 100, the heating assembly is an induction heating assembly, comprising various components for heating the aerosol-generating material of the article 110 by an induction heating process. Induction heating is a process of heating an electrical conductor (such as a susceptor) by electromagnetic induction. The induction heating assembly may comprise an induction element, for example one or more inductor coils, and a device for passing a varying current, such as an alternating current, through the induction element. The varying current in the induction element produces a varying magnetic field. The varying magnetic field penetrates a susceptor suitably positioned relative to the induction element and generates eddy currents in the susceptor. The susceptor has an electrical resistance to the eddy currents, and thus the susceptor is heated by Joule heating due to the flow of eddy currents against this resistance. If the susceptor comprises a ferromagnetic material, such as iron, nickel, or cobalt, heat can also be generated by magnetic hysteresis losses in the susceptor, i.e., by the varying orientation of magnetic dipoles in the magnetic material as a result of alignment with the varying magnetic field. In induction heating, heat is generated within the susceptor, which allows for rapid heating, as compared to, for example, heating by conduction. Furthermore, no physical contact between the induction heater and the susceptor is required, allowing for more freedom in terms of construction and application.

The induction heating assembly of the exemplary device 100 includes a susceptor structure 132 (referred to herein as a "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first inductor coil 124 and the second inductor coil 126 are made from an electrically conductive material. In this example, the first inductor coil 124 and the second inductor coil 126 are made from a Litz wire/cable that is wound in a helical shape to provide the helical inductor coils 124, 126. The Litz wire includes multiple individual wires that are individually insulated and twisted together to form a single wire. The Litz wire is designed to reduce the skin effect losses of the conductor. In the exemplary device 100, the first inductor coil 124 and the second inductor coil 126 are made from copper Litz wire with a square cross section. In other examples, the Litz wire can have other shaped cross sections, such as circular.

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

It will be appreciated that in some examples, the first inductor coil 124 and the second inductor coil 126 can have at least one characteristic that is different from each other. For example, the first inductor coil 124 can have at least one characteristic that is different from the second inductor coil 126. More specifically, in one example, the first inductor coil 124 can have a different inductance value than the second inductor coil 126. In FIG. 4, the first inductor coil 124 and the second inductor coil 126 are of different lengths, and thus the first inductor coil 124 is wound on a smaller section of the susceptor 132 than the second inductor coil 126. Thus, the first inductor coil 124 can include a different number of turns than the second inductor coil 126 (assuming that the spacing between the individual turns is substantially the same). In yet another example, the first inductor coil 124 can be made of a different material than the second inductor coil 126. In some examples, the first inductor coil 124 and the second inductor coil 126 can be substantially identical.

In this example, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. This can be useful when the inductor coils are active at different times. For example, the first inductor coil 124 can be activated first to heat a first section/portion of the article 110, and the second inductor coil 126 can be activated later to heat a second section/portion of the article 110. Winding the coils in opposite directions helps reduce the current induced in the inactive coils when used with certain types of control circuits. In FIG. 4, the first inductor coil 124 is a right-handed spiral and the second inductor coil 126 is a left-handed spiral. However, in other embodiments, the inductor coils 124, 126 can be wound in the same direction, or the first inductor coil 124 can be a left-handed spiral and the second inductor coil 126 can be a right-handed spiral.

The susceptor 132 in this example is hollow and thus defines a receptacle in which the aerosol generating material is received. For example, the article 110 can be inserted into the susceptor 132. In this example, the susceptor 120 is tubular and has a circular cross-section.

The susceptor 132 can be made from one or more materials. Preferably, the susceptor 132 comprises carbon steel and has a nickel or cobalt coating.

In some examples, the susceptor 132 can include at least two materials, which can be heated at two different frequencies for selective aerosolization of the at least two materials. For example, a first section of the susceptor 132 (heated by the first inductor coil 124) can include a first material, and a second section of the susceptor 132 (heated by the second inductor coil 126) can include a second, different material. In another example, the first section can include a first and a second material, which can be heated differently based on the operation of the first inductor coil 124. The first and second materials can be adjacent along an axis defined by the susceptor 132 or can form different layers within the susceptor 132. Similarly, the second section can include a third and a fourth material, which can be heated differently based on the operation of the second inductor coil 126. The third and fourth materials can be adjacent along an axis defined by the susceptor 132 or can form different layers within the susceptor 132. For example, the third material can be the same as the first material and the fourth material can be the same as the second material. Alternatively, each of these materials can be different. The susceptor can include, for example, carbon steel or aluminum.

4 further includes an insulating member 128, which may be generally tubular and may at least partially surround the susceptor 132. The insulating member 128 may be constructed from any insulating material, such as, for example, plastic. In this particular example, the insulating member is constructed from polyetheretherketone (PEEK). The insulating member 128 may help insulate various components of the device 100 from heat generated within the susceptor 132.

The insulating member 128 may also fully or partially support the first inductor coil 124 and the second inductor coil 126. For example, as shown in FIG. 4, the first inductor coil 124 and the second inductor coil 126 are disposed around the insulating member 128 and contact the radially outward surface of the insulating member 128. In some examples, the insulating member 128 does not abut the first inductor coil 124 and the second inductor coil 126. For example, there may be a slight gap between the outer surface of the insulating member 128 and the inner surfaces of the first inductor coil 124 and the second inductor coil 126.

In a particular example, the susceptor 132, the insulating member 128, and the first and second inductor coils 124 and 126 are coaxial about a central longitudinal axis of the susceptor 132.

Figure 5 shows a partial cross-sectional side view of device 100. In this example, outer cover 102 is present. The rectangular cross-sectional shapes of first inductor coil 124 and second inductor coil 126 can be seen more clearly.

The device 100 further includes a support 136 for engaging one end of the susceptor 132 to hold the susceptor 132 in place. The support 136 is connected to the second end member 116.

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

The device 100 further comprises a second lid/cap 140 and a spring 142 disposed at the distal end of the device 100. The spring 142 allows the second lid 140 to be opened to provide access to the susceptor 132. A user can open the second lid 140 to clean the susceptor 132 and/or the support 136.

The device 100 further comprises an expansion chamber 144 extending away from the proximal end of the susceptor 132 toward the opening 104 of the device. A retaining clip 146 is at least partially disposed within the expansion chamber 144 to abut and hold the article 110 when received within the device 100. The expansion chamber 144 is connected to the end member 106.

Figure 6 is an exploded view of the device 100 of Figure 5, with the outer cover 102 omitted.

7A shows a cross-sectional view of a portion of the device 100 of FIG. 5. FIG. 7B shows an enlarged view of a region of FIG. 7A. FIGS. 7A and 7B show the article 110 received within the susceptor 132, with the article 110 sized so that the outer surface of the article 110 abuts the inner surface of the susceptor 132. This ensures that heating is most efficient. The article 110 in this example comprises an aerosol-generating material 110a. The aerosol-generating material 110a is disposed within the susceptor 132. The article 110 may also comprise other components, such as a filter, packaging material, and/or cooling structure.

FIG. 7B shows that the outer surface of the susceptor 132 is spaced from the inner surface of the inductor coils 124, 126 by a distance 150 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 150 is about 3 mm to 4 mm, about 3 to 3.5 mm, or about 3.25 mm.

7B further illustrates that the outer surface of the insulating member 128 is spaced from the inner surface of the inductor coils 124, 126 by a distance 152 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 152 is about 0.05 mm. In another example, the distance 152 is substantially 0 mm, such that the inductor coils 124, 126 are in abutting contact with the insulating member 128.

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

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

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

In use, the article 1, 1' described herein can be inserted into a non-combustion aerosol delivery device, such as the device 100 described with reference to Figures 3-7. At least a portion of the mouthpiece 2, 2' of the article 1, 1' protrudes from the non-combustion aerosol delivery device 100 and can be placed in the mouth of a user. An aerosol is generated by heating an aerosol-generating material 3 using the device 100. The aerosol generated by the aerosol-generating material 3 passes through the mouthpiece 2 to the mouth of the user.

Figure 8 illustrates a first method of producing an aerosol generating material, such as an aerosol generating material for use in an article for use in a non-combustible aerosol delivery system.

In step S101, a single thickness of amorphous solid material in the form of a sheet is fed into the shredder. This can be achieved, for example, by providing a bobbin of amorphous solid sheet material that can be fed into the shredder in a continuous manner. Alternatively, individual portions of amorphous solid material in the form of sheets, such as sheets known to those skilled in the art as flags, can be fed into the shredder. The inventors have surprisingly found that there are benefits to amorphous solid material in the form of a sheet chopped to a single sheet thickness, as opposed to conventional tobacco cutting processes in which several sheets of leaf material are fed into the cutter simultaneously. Feeding multiple thicknesses of amorphous solid sheet material into the shredder in a single pass tends to result in an uneven distribution of material in the final aerosol-generating material, as the multiple thicknesses of sheet material may sometimes adhere to each other and form agglomerates. Alternatively, multiple thicknesses of amorphous solid sheet material can be fed into the shredder in a single pass, for example if the amorphous solid sheet has a relatively low "stickiness" and the formation of agglomerates is avoided.

In step S102, the single thickness of amorphous solid material is chopped to obtain a strip of amorphous solid material having a defined cut width. Optionally, the amorphous solid material can be subjected to a second cutting step, such as a cross-cut chopping process, to obtain a defined cut length.

In step S103, the strip of amorphous solid material obtained in step S102 is mixed with tobacco material. Advantageously, the inventors have found that it is preferable that mixing of the chopped amorphous solid material with the tobacco material should be performed as soon as possible after step S102. The inventors have found that when the chopped amorphous solid material is stored for an extended period of time, agglomerations of amorphous solid fragments may form within the chopped material, and thus, when the chopped amorphous solid material is mixed with tobacco material and used to form an article as described herein, the agglomerations of the amorphous solid material will result in a non-uniform distribution of the amorphous solid material among the article and within the individual rods of aerosol-generating material.

In some embodiments, the shredded amorphous solid material is incorporated into the tobacco material less than 12 hours, such as less than 6 hours, or less than 4 hours, or less than 2 hours, or less than 1 hour, after the cutting step. Optionally, the shredded amorphous solid material can be provided to the tobacco material in an online process, such that the time from shredding the amorphous solid material to incorporating the shredded material into the tobacco material to form the final aerosol-generating material can be less than 30 seconds, such as less than 20 seconds or less than 10 seconds.

In some embodiments, a method of making an aerosol-generating material includes cutting a sheet of amorphous solid material to form a plurality of strips of amorphous solid material having a cut length of at least about 5 mm, or at least about 10 mm, or at least about 20 mm. In some embodiments, the method includes cutting a sheet of amorphous solid material to form a plurality of strips of amorphous solid material each having a cut length of about 5 mm to about 60 mm, or about 10 mm to about 55 mm, or about 20 mm to about 50 mm.

The mixing step may be carried out using a rotary drum blender rotating at an RPM of, for example, 5-30 RPM, for example, 10-15 RPM. The drum diameter may be 0.8 m to 1.2 m, with 5 sets (optional) of 10-20 pins protruding from the inner wall of the drum towards the center of the drum, the pins having a length of 5% to 15%, for example about 10%, of the drum diameter, with the pins of each set spaced longitudinally along the length of the drum, and each set spaced circumferentially. The drum angle of its central axis during the mixing operation may be about 10-30 degrees (open side up) from the horizontal. Batches of 5-20 kg total, typically 8-10 kg solids, may be mixed in such a drum, with mixing times of 30 seconds to 10 minutes, for example, 30 seconds to 2 minutes.

Alternatively, the mixing step can be integrated into the standard primary manufacturing process for tobacco material, for example using add-back lines and flavour mixing cylinders. This method can be adapted for larger volumes of material. A continuous rotating drum blender fed by two metering conveyors can be used, each conveyor delivering one component (tobacco material or chopped amorphous solid material, e.g. shredded gel) at the correct relative rate kg/hr to achieve the desired content level of amorphous solids in the aerosol-generating material. The components are mixed in the rotating drum blender during the passage and collected at the outlet. Typical dimensions and operating conditions of the continuous rotating drum blender are RPM of 12-15 RPM, drum diameter of 0.6-0.8 m, drum length of 2.0-3.0 m. Residence time of the material in the drum can be 30-120 seconds (typically 40-70 seconds).

9 illustrates a second method of producing an aerosol-generating material, e.g., for use in an article for use in a non-combustion aerosol delivery system. The second method can be performed using the equipment described in connection with the first method above, and those skilled in the art will recognize that the steps of the first and second methods can be combined as appropriate. The second method includes a step (S201) of cutting a first portion of the amorphous solid material to form a first component including a plurality of strips of the amorphous solid material having a first length. The method also includes a step (S202) of cutting a second portion of the amorphous solid material to form a second component including a plurality of strips of the amorphous solid material having a second length different from the first length. In step S203, the cut strips of the amorphous solid material are mixed with tobacco material including strips and/or strands of tobacco material. Using two or more different lengths of amorphous solid material can allow the size of the strips of amorphous solid material to more closely match the material size distribution of the tobacco material to obtain a better mix of the amorphous solid and tobacco material.

The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and/or exclusive. The advantages, embodiments, examples, features, structures, and/or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or equivalents of the claims, and it should be understood that other embodiments can be utilized and modifications can be made without departing from the scope of the claimed invention. It is preferred that the various embodiments of the present invention can include, consist of, or essentially consist of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein. In addition, the present disclosure can include other inventions not claimed herein but which may be claimed in the future.

Claims (49)

An aerosol-generating material comprising a plurality of strands and/or strips of tobacco material and a plurality of strips of amorphous solid material, wherein the plurality of strands and/or strips of tobacco material and the plurality of strips of amorphous solid material each have a length of at least about 5 mm. The aerosol-generating material of claim 1, wherein the plurality of strips of amorphous solid material have an areal density of about 55 to about 135 grams per square meter, or about 80 to about 100 grams per square meter, or about 100 to 125 grams per square meter. The aerosol-generating material of claim 1 or 2, wherein the tobacco material comprises an aerosol-forming agent in an amount of less than 10% by weight of the tobacco material. The aerosol-forming material of claim 1, 2, or 3, wherein the areal density of the plurality of strips of amorphous solid material is between 70% and 110% of the areal density of the tobacco material. The aerosol-forming material of any one of claims 1 to 4, wherein the tobacco material comprises reconstituted tobacco material. The aerosol-forming material according to any one of claims 1 to 5, wherein the tobacco material comprises paper regenerated tobacco material. The aerosol-forming material of claim 5 or 6, wherein the reconstituted tobacco material has an areal density of between 80 grams per square meter and 120 grams per square meter. The aerosol-generating material of any one of claims 1 to 7, wherein the strips of amorphous solid material have a non-uniform length distribution. The aerosol generating material of claim 8, wherein the length distribution of the plurality of strips of the amorphous solid material is multimodal. The aerosol-generating material of claim 8 or 9, wherein the plurality of strands and/or strips of tobacco material have a multimodal distribution of lengths. The aerosol-generating material of any one of claims 1 to 10, wherein the length distribution of the plurality of strands and/or strips of tobacco material and the length distribution of the plurality of strips of amorphous solid material have the same number of modes. 11. The aerosol generating material of claim 10, wherein the number of modes in the length distribution of the plurality of strips of amorphous solid is selected to match the number of modes in the length distribution of strands and/or strips of the amorphous solid material. The aerosol-generating material of any one of claims 1 to 12, wherein at least one of the plurality of strips of amorphous solid material has a length greater than about 10 mm. The aerosol generating material of any one of claims 1 to 13, wherein 50% to 90% of the plurality of strips of the amorphous solid have a length of 35 mm to 45 mm. The aerosol generating material of claim 14, wherein 60% to 85% of the plurality of strips of the amorphous solid have a length of 35 mm to 45 mm. The aerosol-generating material of claim 14 or 15, wherein at least 50% of the remaining strips of amorphous solid have a length between 10 mm and 30 mm. The aerosol-generating material of any one of claims 1 to 16, wherein at least one of the plurality of strips of amorphous solid material has a length of about 10 mm to about 60 mm or about 20 mm to about 50 mm. The aerosol-generating material of any one of claims 1 to 17, wherein each of the plurality of strips of amorphous solid material has a length of about 10 mm to about 60 mm or about 20 mm to about 50 mm. The aerosol-generating material of any one of claims 1 to 18, wherein the strip of amorphous solid material has an average cut width of 0.75 mm to 2 mm. The aerosol-generating material of any one of claims 1 to 19, wherein the strip of amorphous solid material has an average cut width of 0.8 mm to 1.75 mm. The aerosol-generating material of any one of claims 1 to 20, wherein the strip of amorphous solid material has an average cut width of 1 mm to 1.5 mm. The aerosol generating material according to any one of claims 1 to 21, wherein the aerosol generating material comprises an aerosol forming agent, optionally glycerol, and/or optionally the amorphous solid material, in an amount of 10% to 20% by weight of the aerosol generating material. The aerosol-forming material of any one of claims 1 to 22, wherein the tobacco material comprises water in an amount of 5% to 10% by weight or 7.5% to 9.5% by weight. 23. The aerosol generating material of claim 22, wherein the standard deviation in the aerosol forming agent content of the aerosol generating material among at least ten 10 gram samples is less than 30% or less than 25% of the average aerosol forming agent content in the aerosol generating material. An article comprising the aerosol-generating material according to any one of claims 1 to 24. 26. The article of claim 25, wherein the plurality of strips of amorphous solid material contain a flavoring, optionally menthol, and the delivery of the flavoring from the article during use varies by less than 50% between the article and another article of the same batch. The article of claim 25 or 26, wherein the aerosol-generating material comprises an aerosol former, optionally glycerol, in an amount of 10% to 15% by weight or 12% to 14% by weight. A pack comprising a plurality of articles each according to any one of claims 25 to 27, wherein the number of strips of amorphous solid material varies by less than 40% between the articles in the pack, or by less than 30% between the articles in the pack, or by less than 20% between the articles in the pack. A pack comprising a plurality of articles each according to any one of claims 25 to 27, wherein the plurality of strips of amorphous solid material comprise a flavourant, optionally menthol, and wherein delivery of the flavourant from each of the plurality of articles during use varies by less than 50% between the articles within the pack, or varies by less than 20% between the articles within the pack. A pack comprising a plurality of articles each according to any one of claims 25 to 27, wherein the plurality of strips of amorphous solid material comprise a flavouring, optionally menthol, and wherein the total content of the flavouring in each of the plurality of articles in use has a standard deviation of less than 30% of the average content of the flavouring in the article, or has a standard deviation of less than 20% of the average content of the flavouring in the article, and at least 20% of the average flavouring is provided within the strips of amorphous solid material. A pack comprising a plurality of articles, each according to any one of claims 25 to 27, wherein the plurality of strips of amorphous solid material comprise a flavourant, optionally menthol, in a total amount of flavourant from 5 mg per article to 30 mg per article, or from 16 mg per article to 22 mg per article, or from 5 mg per article to 10 mg per article, or from 17 mg per article to 30 mg per article. A pack comprising a plurality of articles each according to any one of claims 25 to 27, wherein the plurality of strips of amorphous solid material comprise a flavouring, optionally menthol, the standard deviation in the total amount of flavouring between the articles in the pack being less than 30% or 20% by weight of the average total amount of flavouring, and the amorphous solid comprising at least 50% of the average total amount of flavouring in each article. A pack containing a plurality of articles, each of which is described in any one of claims 25 to 27, wherein the articles include ventilation, and the standard deviation of the ventilation level between the articles in the pack is less than 15%, or less than 10%, or less than 9%. A pack comprising a plurality of articles, each of which is described in any one of claims 25 to 27, wherein the plurality of strips of amorphous solid material comprise an aerosol forming agent, optionally glycerol, and wherein the total content of the aerosol forming agent in each of the plurality of articles in use has a standard deviation of less than 30% of the average content of the aerosol forming agent in the article, or has a standard deviation of less than 25% of the average content of the aerosol forming agent in the article, and at least 20% of the average aerosol forming agent is provided within the strips of amorphous solid material. A consumable for use in an aerosol delivery system, the consumable comprising an article according to any one of claims 25 to 27. The consumable of claim 35, wherein the aerosol-generating material is provided in the form of a rod having a first end and a second end, and a portion of the rod between the first end and a longitudinal position intermediate the first end and the second end of the rod comprises 20% to 80% of the amorphous solid material within the rod. A non-combustion aerosol delivery system comprising a non-combustion aerosol delivery device and a consumable according to claim 35 or 36, the device being arranged to heat the aerosol generating material of the consumable. A method of making the aerosol-generating material of any one of claims 1 to 24, comprising cutting a sheet of amorphous solid material to form a plurality of strips of amorphous solid material having a cut length of at least about 5 mm. A method of making an aerosol-generating material, the method comprising feeding a single thickness sheet of amorphous solid material into a cutting device to form a plurality of strips of amorphous solid material. The method of claim 38 or 39, comprising cutting a plurality of strips of the amorphous solid material across the width of the strips, optionally the strips of amorphous solid material are cut widthwise and lengthwise in one step. 1. A method of making an aerosol-forming material, comprising:
cutting a first portion of the amorphous solid material to form a first component comprising a plurality of strips of the amorphous solid material having a first length;
and cutting a second portion of the amorphous solid material to form a second component comprising a plurality of strips of amorphous solid material having a second length different from the first length. 42. The method of claim 41, wherein the first component and the second component are mixed to form a plurality of strips of amorphous solid material having a non-uniform length distribution. The method of any one of claims 38 to 42, further comprising a mixing step, in which the strip of amorphous solid material is mixed with a tobacco material. A method of making an aerosol-generating material, comprising cutting a sheet of amorphous solid material to form a plurality of strips of amorphous solid material, and mixing the plurality of strips of amorphous solid material with tobacco material, wherein the cutting and mixing steps are performed within 12 hours of each other, or within 6 hours of each other, or within 2 hours of each other, or within 30 seconds of each other. The method of claim 44, wherein a plurality of strips of the amorphous solid material are transported between the cutting step and the mixing step. The method of any one of claims 38 to 45, wherein the amorphous solid material is cut in a shredder to form strips, and optionally the shredder is a cross-cut shredder. The method of claim 46, wherein the shredder is configured to produce a plurality of strips of material having a wide range of lengths. An aerosol-generating material obtainable by the method of any one of claims 38 to 47, wherein the amorphous solid comprises an aerosol-forming agent, optionally glycerol, and the standard deviation of the aerosol-forming agent content of "N" 10 gram samples of the aerosol-generating material is less than 30% or less than 25% of the mean, where "N" is 10 or greater. An aerosol-generating material obtainable by the method of any one of claims 38 to 47, wherein the amorphous solid comprises a flavorant, optionally menthol, and the standard deviation of the flavorant content of "N" 10 gram samples of the aerosol-generating material is less than 30% or less than 25% of the mean, where "N" is 10 or greater.

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