JP2024540790A - Articles for use in non-combustion aerosol delivery systems - Google Patents

Abstract

Disclosed is an article (1) for use in a non-combustion based aerosol delivery system including an aerosol delivery device (100). The article includes a rod of aerosol-generating material (3) having a distal end (D) for insertion into the non-combustion based aerosol delivery device such that a heating element (103) of the device extends through said distal end and into the rod of aerosol-generating material. The article includes a cavity (20) extending longitudinally from said distal end into the aerosol-generating material for receiving the heating element. Also disclosed is a system including a non-combustion based aerosol delivery device having a heating element and an article according to the invention, as well as a method of making an article according to the invention.

Description

The present invention relates to an article for use in a non-combustion aerosol delivery system, a system including the article and a non-combustion aerosol delivery device, and a method for making the article according to the present invention.

Certain tobacco industry products generate an aerosol that is inhaled by a user during use. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, to form an aerosol by heating the substrate without burning it. Such tobacco industry products commonly include a mouthpiece through which the aerosol passes to reach the user's mouth.

Some embodiments described herein provide an article for use in a non-combustion aerosol delivery system including an aerosol delivery device, the article including a rod of aerosol-generating material having a distal end for insertion into the non-combustion aerosol delivery device, such that a heating element of the device extends through the distal end and into the rod of aerosol-generating material, the article including a cavity extending longitudinally from the distal end into the rod of aerosol-generating material for receiving the heating element.

The article of the invention may include a mouth end opposite the distal end, the mouth end being configured to be sandwiched between a user's lips when the distal end is inserted into the non-combustion aerosol delivery device.

The cooling segment may be located between the aerosol generating material and the mouth end.

The filtration segment may be located between the cooling segment and the mouth end.

The cavity may extend the entire length of the aerosol-generating material.

The cavity may be coaxial with the longitudinal axis of the article.

The aerosol generating material may include a tube.

The tube may include an inner surface, and the mold is formed on the inner surface extending longitudinally.

The mold may include a spiral groove or recess.

The mold may include linear grooves or recesses.

A plurality of cavities may extend into the aerosol generating material from the distal end.

One or more of the cavities may be disposed about the longitudinal axis.

One of the cavities may be coaxial with the longitudinal axis.

The or each cavity may have a non-circular cross-section.

The or each cavity may have a non-uniform cross-section in the longitudinal direction.

The or each cavity may be tapered in the longitudinal direction.

The or each cavity may taper narrowing away from the distal end.

The article may include a plug at the distal end. The plug may abut the aerosol-generating material.

The plug may have a passageway located corresponding to the cavity extending through the aerosol generating material. The passageway may be a slit or slot in the plug.

The plug may be formed from pleated and in some cases crimped paper.

The article of the present invention may include a layer of material on the inner wall of the cavity.

The layer of material may be a gel, an amorphous solid or a layer of sheet material such as paper.

The material layer may be a separate layer made of an aerosol-generating material different from the aerosol-generating material.

In some embodiments, the material layer may include a thermally conductive material. For example, the material layer may include a metal or metal alloy, a polymer ceramic, or graphite.

In some other embodiments described herein, a system is provided that includes a non-combustion aerosol delivery device having a heating element and an article including a rod of aerosol-generating material having a distal end for insertion into the non-combustion aerosol delivery device, such that the heating element of the device extends into the rod of aerosol-generating material through the distal end, and a cavity extends longitudinally from the distal end into the rod of aerosol-generating material to accommodate the heating element.

The heating element and the cavity may have the same cross-sectional shape.

The heating element may be fitted or interference-fitted into the cavity.

The heating element and the cavity may have different cross-sectional shapes such that when the heating element is received in the cavity, a pathway remains between the heating element and the inner wall of the aerosol generating material.

The heating element may have a circular cross-section, and the cavity may have a portion having a circular cross-section and at least one protrusion extending from the circular portion to form the heating element and the pathway.

The aerosol generating material may have a longitudinal axis and the cavity for housing the heating element may be a central cavity extending along the longitudinal axis.

There are a number of further cavities extending into the aerosol-generating material from the distal end, the further cavities surrounding the central cavity and forming an open passageway through the aerosol-generating material when a heating element is received in the central cavity.

Some embodiments described herein provide a method for making an article including a rod of aerosol-generating material having a distal end for insertion into a non-combustion aerosol delivery device, the method including extruding the aerosol-generating material through a die head onto a mandrel to form a cavity through which the aerosol-generating material extends.

The mandrel may be shaped to provide a cavity in the aerosol-generating material that corresponds to the shape of the mandrel.

In some other embodiments described herein, a method for making an article including an aerosol-generating material having a distal end for insertion into a non-combustion aerosol delivery device is provided that includes molding the aerosol-generating material around a former.

The former may be shaped to provide the aerosol-generating material with a cavity of a shape corresponding to the former.

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
1 is a cross-sectional side view of an article for use in a non-combustion based aerosol delivery device. 1 is a cross-sectional side view of an article for use in a non-combustion based aerosol delivery device according to another embodiment. 3 shows a cross section along line AA of the aerosol-generating material of the article of FIG. 1 or 2 in a different embodiment. 3 shows a cross section along line AA of the aerosol-generating material of the article of FIG. 1 or 2 in a different embodiment. 3 shows a cross section along line AA of the aerosol-generating material of the article of FIG. 1 or 2 in a different embodiment. 3 shows a cross section along line AA of the aerosol-generating material of the article of FIG. 1 or 2 in a different embodiment. 3 shows a cross section along line AA of the aerosol-generating material of the article of FIG. 1 or 2 in a different embodiment. FIG. 1 is a cross-sectional view of a non-combustion based aerosol delivery device. 5 is a simplified schematic diagram of the components within a housing of the aerosol delivery device shown in FIG. 4. FIG. 5 is a cross-sectional view of the non-combustion based aerosol delivery device shown in FIG. 4 with the article of FIG. 1 or 2 inserted into the device.

As used herein, the term "delivery system" is intended to encompass a system that provides at least one substance to a user, including:
Combustion-based aerosol delivery systems, such as cigarettes, cigarillos, cigars and pipes or tobacco for roll-your-own or homemade cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smoking materials);
non-combustion aerosol delivery systems that release a compound from an aerosol-generating material without burning the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems that generate an aerosol using a combination of aerosol-generating materials; and aerosol-free delivery systems that orally, nasally, transdermally, or otherwise deliver at least one of the above substances, with or without nicotine, to a user, including, but not limited to, lozenges, gums, patches, articles containing patch-inhalable powders, and oral products, such as oral tobacco products, including snus or moist snus.

For purposes of this disclosure, a "non-combustion" aerosol delivery system is one that does not combust or burn the constituent aerosol-generating materials of the aerosol delivery system (or its components) to facilitate delivery of at least one substance to a user.

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

In some embodiments, the non-combustion based 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 hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which 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 hybrid 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.

A non-combustion aerosol delivery system typically includes a non-combustion aerosol delivery device and consumables for use with the non-combustion aerosol delivery device.

This disclosure relates to consumables that include an aerosol generating material and are configured for use in non-combustion based aerosol delivery devices. These consumables may also be referred to as articles throughout this disclosure.

As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction of mainstream aerosol drawn through an article or device during use. References to the "distal end" mean upstream of the device, whereas references to the "proximal end" mean downstream of the device.

In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, a power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that is energized to deliver power in the form of heat to an aerosol generating material or a thermally conductive material proximate to the heat generating power source.

In some embodiments, the non-combustion aerosol delivery system includes a region for containing a consumable, an aerosol generator, an aerosol-generating region, a housing, a mouthpiece, and a filter and/or an aerosol modifier.

In some embodiments, consumables for use in non-combustion based aerosol delivery systems may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transport component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol modifier.

The consumable includes a substance to be delivered. The substance to be delivered is an aerosol-generating material. Optionally, the generating material may 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 provided comprises an active agent. An active agent as used herein is a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active agent may be selected from, for example, a dietary supplement, a nootropic, or a psychotropic drug. The active agent may be naturally occurring or synthetically derived. The active agent may comprise, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or mixtures thereof. The active agent may comprise one or more components, derivatives, or extracts of tobacco, cannabis, or other plants. In some embodiments, the active agent comprises nicotine. In some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

As described herein, the active agent may include or be derived from a plant or its components, derivatives, or extracts. As used herein, the term "plant" includes, but is not limited to, any material derived from a plant, such as extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, pods, etc. Alternatively, the material may include active compounds naturally occurring in the plant or synthetically derived. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, pieces, strips, sheets, etc. Examples of plants include tobacco, eucalyptus, cornstarch, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, 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, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, sedge, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiene, oregano, olive, lemon balm, lemon basil, chives, fennel, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following mint species: mentha, moroccan mint, egyptian mint, peppermint, cologne mint, candy mint, curly mint, kentucky kernel mint, horse mint, pineapple mint, pennyroyal mint, english spearmint, and malva.

In some embodiments, the active agent may include or be derived from a plant or one or more of its components, derivatives, or extracts, and the plant is tobacco.

In some embodiments, the active agent may include or be derived from one or more of a plant or its components, derivatives or extracts, the plant being selected from eucalyptus, tallow tree, cocoa and hemp.

In some embodiments, the composition may comprise or be derived from one or more plants or components, derivatives or extracts thereof, the plants being selected from rooibos and fennel.

In some embodiments, the substance includes a flavoring agent.

As used herein, the terms "flavoring agent" and "flavoring agent" are used as permitted by local ordinance to produce a taste, odor or other somatosensory stimulus desired by the adult consumer. They include naturally occurring flavoring materials, plants, plant extracts, synthetically derived materials or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, and the like). Roots, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey extract, 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, peppermint oil from any species of the genus Mentha, eucalyptus, burdock, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay, 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, scutellaria, curcuma, cilantro, myrtle, black currant, valerian, pimento, melon .... , damien, origanum, olive, lemon balm, lemon basil, chives, fennel, 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, mannitol, etc.), and other additives such as charcoal, chlorophyll, minerals, botanicals or breath fresheners. They may be mimics, synthetic or natural ingredients or blends thereof. They may be in any suitable form, e.g. liquids such as oils, solids such as powders or gases.

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

In some embodiments, the flavoring agent may include a sensory agent that is chemically induced and recognized by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the aroma or taste nerves, and may include agents that impart heating, cooling, tingling, or numbing sensations. A suitable heating agent is, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent is, but is not limited to, eucalyptol, WS-3.

An aerosol-generating material is a material that can generate an aerosol when excited, for example, by heating, irradiation, or in some other way. The aerosol-generating material may be in the form of a solid, liquid, or gel, which may or may not contain active substances and/or flavorants. The aerosol-generating material is incorporated into an article for use in an aerosol generating system.

As used herein, the term "tobacco material" refers to any material containing tobacco or a derivative or substitute thereof. The tobacco material may be in any suitable form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may include one or more of powdered tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract.

A consumable is an article that contains or consists of an aerosol-generating material that is intended to be consumed in whole or in part by a user during use. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and/or an aerosol modifier. A consumable may also include an aerosol generator, particularly a heating element, that radiates heat so that the aerosol-generating material generates an aerosol during use. A heater may include a material or susceptor that can be heated by electrical conduction.

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

An aerosol modifier is a substance that is typically located downstream of the aerosol-generation region and configured to modify the generated aerosol, for example by changing the taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided within an aerosol modifier-releasing component that is 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 flavorant, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, liquid, or gel. The aerosol modifier may be a powder, string, or granules. The aerosol modifier may not include a filtration material.

The aerosol-generating device is an apparatus configured to generate an aerosol from an aerosol-generating material. The aerosol-generating device includes a heater configured to expose the aerosol-generating material to thermal energy to release one or more volatile substances from the aerosol-generating material to form an aerosol.

The filamentary tow material described herein may include cellulose acetate fiber tow. The filamentary tow material may 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, paper, aliphatic polyester materials, and polysaccharide polymers or combinations thereof. The filamentary tow material may be plasticized with a plasticizer suitable for the filter material, such as triacetin, if the filter material is cellulose acetate tow, or may be unplasticized. The tows can be of any suitable specification, such as other cross sections such as "Y" or "X", fibers having a single yarn fineness of 2.5 to 15, e.g., a single yarn fineness of 8.0 to 11.0, and a total fineness value of 5,000 to 50,000, e.g., 10,000 to 40,000.

The same reference numbers are used in the drawings throughout this specification to indicate equivalent features, items or components.

Figure 1 is a side cross-sectional view of an article 1 for use in an aerosol delivery system including an aerosol delivery device 100 (see Figures 4-6).

The article 1 has an upstream or distal end "D" and a downstream or proximal end "P". The proximal end P includes a mouthpiece 2 and the distal end D includes an aerosol-generating section connected to the mouthpiece 2. In this example, the aerosol-generating section includes a rod-shaped source of aerosol-generating material 3. The aerosol-generating material 3 may include multiple strands or strips of aerosol-generating material 3. For example, the aerosol-generating material 3 may include multiple strands or strips of an aerosolizable material and/or multiple strands or strips of an amorphous solid.

In this example, the aerosol-generating material 3 includes multiple strands and/or strips of aerosol-generating material and is surrounded by a wrapper 4. In this example, the wrapper 4 is a moisture-impermeable wrapper.

The multiple strands or strips of aerosol-generating material 3 may be aligned within the aerosol-generating section such that their longitudinal dimensions are aligned parallel to the longitudinal axis X-X' of the article 1. Alternatively, the strands or strips may be generally arranged such that their longitudinal dimensions are transverse to the longitudinal axis of the article 1.

In this example, the rod of aerosol-generating material 3 has a circumference of about 22.7 mm. In other embodiments, the rod of aerosol-generating material 3 may have any suitable circumference, for example, a circumference of about 20 mm to about 26 mm.

The article 1 is configured for use in a non-combustion based aerosol delivery device 100 (see FIG. 4) that includes an aerosol generator in the form of a heating element 103, such as a blade or pin, for insertion into an aerosol-generating material 3 of an aerosol-generating section, as described in more detail below.

The mouthpiece 2 includes a cooling section 5, also referred to as a cooling member, located immediately downstream and adjacent to the source of aerosol-generating material 3. In this example, the cooling section 5 is in abutting relationship with the source of aerosol-generating material 3. The mouthpiece 2 also includes a body of material 6, in this example downstream of the cooling section 5, and a hollow tubular member 7 at the mouth end 2 of the article 1 and downstream of the body of material 6.

The cooling section 5 includes a hollow channel having an inner diameter of about 1 mm to about 4 mm, for example about 2 mm to about 4 mm. In this example, the hollow channel has an inner diameter of about 3 mm. The hollow channel extends along the entire length of the cooling section 5. In this example, the cooling section 5 includes a single hollow channel. In other embodiments, the cooling section may include multiple channels, for example, two, three or four channels. In this example, the single hollow channel is substantially cylindrical, although other channel shapes/cross sections may be used in other embodiments. The hollow channel provides a space within which aerosol drawn into the cooling section 5 can expand and cool. In all embodiments, the cooling section 5 is configured to restrict the cross-sectional area of one or more hollow channels to restrict the movement of tobacco into the cooling section 5 in use.

The moisture impermeable wrapper 4 has low friction with the aerosol-generating material 3, which results in greater longitudinal slippage of the strands and/or strips of aerosol-generating material 3 within the cooling section 5 when the heating element 103 is inserted into the rod of aerosol-generating material 3. By providing the cooling section 5 directly adjacent to the source of aerosol-generating material 3 and including an inner flow passage having a diameter in this range, longitudinal slippage of the strands and/or strips of aerosol-generating material 3 is reduced when the heating element 103 of the device 100 is inserted into the rod of aerosol-generating material 3. Reducing slippage of the aerosol-generating material in use has the advantage of resulting in a more consistent packing density of the aerosol-generating material 3 along the length of the rod, which results in more consistent and better aerosol generation.

The cooling section 5 may have a wall thickness in the radial direction. The wall thickness of the cooling section 5 defines the inner diameter of the chamber enclosed by the walls of the cooling section 5 when the cooling section has a given outer shape. The cooling section 5 may have a wall thickness of at least about 1.5 mm and at most about 2 mm. In this example, the cooling section 5 has a wall thickness of about 2 mm. Providing a cooling section 5 with a wall thickness within this range improves retention of the source of aerosol-generating material 3 within the aerosol-generating section during use by reducing longitudinal displacement of the strands and/or strips of aerosol-generating material 3 when the aerosol generator is inserted into the article 1.

The cooling section 5 is formed from filamentary tow. Other configurations may be used, such as tubes formed using parallel or spirally wound paper layers with seams joined to form the cooling section 5, cardboard tubes, molded or extruded plastic tubes of a paper-compound mold process, or the like. The cooling section 5 is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacture and use of the article 1.

The wall material of the cooling section 5 may be relatively non-porous such that at least 90% of the aerosol emitted by the aerosol-generating material 3 passes longitudinally through the one or more hollow channels rather than through the wall material of the cooling section 5. For example, at least 92% or at least 95% of the aerosol emitted by the aerosol-generating material 3 may pass through the one or more hollow channels.

In some examples, the mouthpiece 2 includes a cavity having an internal volume of greater than 110 ^mm3 . It has been found that providing a cavity of at least this volume allows for good aerosol formation. The mouthpiece 2 includes a cavity, for example formed in the cooling section 5, having an internal volume of greater than 110 ^mm3 , or greater than 130 ^mm3 , further improving aerosol. In some examples, the internal cavity includes a volume of between about 130 ^mm3 and about 230 ^mm3 , for example about 134 ^mm3 or 227 ^mm3 .

The cooling section 5 may be configured to provide a temperature difference of at least 40°C between the heated and volatilized components entering the first upstream end of the cooling section 5 and the heated and volatilized components exiting the second downstream end of the cooling section 5. The cooling section 5 is preferably configured to provide a temperature difference of at least 60°C, preferably at least 80°C, and more preferably at least 100°C between the heated and volatilized components entering the first upstream end of the cooling section 5 and the heated and volatilized components exiting the second downstream end of the cooling section 5. This temperature difference over the length of the cooling section 5 protects the temperature sensitive body of material 6 from the high temperatures of the aerosol generating material 3 when heated.

In use the aerosol-generation section may exhibit a pressure drop of about 15 to about 40 mmH ₂ O. In some embodiments the aerosol-generation section exhibits an aerosol-generation section pressure drop of about 15 to about 30 mmH ₂ O.

In this embodiment, the moisture-impermeable wrapper 4 surrounding the rod of aerosol-generating material 3 comprises aluminum foil. In other embodiments, the wrapper 4 comprises a paper wrapper, optionally including a barrier coating that renders the wrapper material substantially moisture-impermeable. Aluminum foil has been found to be particularly effective in enhancing aerosol formation 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 backing. However, in alternative configurations, the aluminum foil may be of other thicknesses, for example, between 4 μm and 16 μm. The aluminum foil may also not require a backing, but may have a backing material formed from other materials that, for example, help provide the foil with adequate tensile strength, or may have no backing material. Metal layers or foils other than aluminum may also be used. The total thickness of the wrapper is preferably between 20 μm and 60 μm, or between 30 μm and 50 μm, which is sufficient to provide the wrapper with suitable structural integrity and heat transfer properties. The tension that can be applied to the wrapper before it breaks is greater than 3,000 gf, for example, 3,000 to 10,000 gf or 3,000 to 4,500 gf. If the wrapper comprises paper or a paper backing, i.e., a cellulosic material, the wrapper may have a basis weight of greater than about 30 gsm. For example, the wrapper 4 may have a basis weight in the range of about 40 gsm to about 70 gsm, which improves the stiffness of the rod of aerosol-generating material 3. The improved stiffness provided by a wrapper 4 having a basis weight in this range allows the rod of aerosol-generating material 3 to resist crushing or other deformation due to forces experienced by the article during use, for example, when the article is inserted into a device and/or a heat generator is inserted into the article.

In this example, the moisture-impermeable wrapper 4 is also substantially air-tight. In another embodiment, the wrapper 4 has an air permeability of less than 100 Coresta units, for example less than 60 Coresta units. It has been found that wrappers with low air permeability, for example less than 100 Coresta units, more preferably less than 60 Coresta units, result in improved aerosol formation at the aerosol-generating material 3. Without wishing to be bound by any theory, it is hypothesized that this is due to less loss of aerosol compounds through the wrapper 10. The air permeability of the wrapper 10 can be measured according to ISO 2965:2009 for measurement of air permeability of materials used as cigarette papers, filter plug wrappers and filter bonding papers.

The body of material 6 generally defines a substantially cylindrical outer shape and is encased in a first plug wrapper 8. The first plug wrapper 8 may have a basis weight of less than 50 gsm or between about 20 gsm and 40 gsm. The first plug wrapper 8 may have a thickness of between 30 μm and 60 μm or between 35 μm and 45 μm. The first plug wrapper 8 may be a non-porous plug wrapper, for example having an air permeability of less than 100 Coresta units, for example less than 50 Coresta units. However, in other embodiments the first plug wrapper 8 may be a porous plug wrapper, for example having an air permeability of greater than 200 Coresta units.

As shown in FIG. 1, the mouthpiece 2 of the article 1 includes an upstream end 2a adjacent a rod 3 of aerosol-generating material. At the proximal end, the mouthpiece 2 has a hollow tubular member 7 formed from filamentary tow. This has been advantageously discovered to significantly reduce the temperature of the exterior surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece which contacts the consumer's lips during use of the article 1. Additionally, it has been found that the use of the tubular member 7 significantly reduces the temperature of the exterior surface of the mouthpiece 2 even upstream of the tubular member 7. While not wishing to be bound by any theory, it is hypothesized that this is due to the tubular member 7 directing the aerosol closer to the center of the mouthpiece 2, thus reducing the transfer of heat from the aerosol to the exterior surface of the mouthpiece 2.

The "wall thickness" of the hollow tubular member 7 corresponds to the thickness of the wall of the tube 7 in the radial direction. This is measured, for example, using a vernier caliper. The wall thickness is advantageously greater than 0.9 mm, and may be 1.0 mm or greater. In some examples, the wall thickness is substantially constant around the entire wall of the hollow tubular member 7. However, if the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9 mm or greater than 1.0 mm anywhere around the circumference of the hollow tubular member 7. In this example, the wall thickness of the hollow tubular member 7 is approximately 1.3 mm.

The tipping paper 9 is wrapped around the entire length of the mouthpiece 2 and over part of the rod of aerosol-generating material, has adhesive on its inner surface and connects the mouthpiece 2 to the rod 3. In this example, the rod of aerosol-generating material 3 is wrapped in a wrapper 4 forming a first wrapper, and the tipping paper 9 forms an outer wrapper that extends over at least part of the rod of aerosol-generating material 3 to connect the mouthpiece 2 to the rod 3. In some examples the tipping paper 9 may extend over only part of the rod of aerosol-generating material 3.

The ventilation level of the aerosol of the article 1 drawn through the article 1 is about 10%. In another embodiment, the ventilation level of the aerosol of the article 1 drawn through the article 1 is 1% to 20%, for example 1% to 12%. These levels of ventilation help to increase the uniformity of the aerosol inhaled by the user at the mouth end 2b and aid in the aerosol cooling process. The ventilation is provided directly in the mouthpiece 2 of the article 1. In this example, the ventilation is provided in the cooling section 5, which has been found to be particularly beneficial in aiding the aerosol generation process. The ventilation is provided by perforation, in this example as a single row of laser perforations located 13 mm downstream from the mouth end 2b of the mouthpiece 2. In another embodiment, two or more rows of ventilation perforations 10 may be provided. These perforations 10 pass through the tipping paper 9, the second plug wrapper 11 and the cooling section 5. In another embodiment, the ventilation can be provided in other locations of the mouthpiece 2, for example in the body of material 6 or the first tubular member 7. The perforations of the article 1 are provided approximately 28 mm or less from the upstream end of the article 1, preferably 20 mm to 28 mm from the upstream end of the article 1. In this example, the opening is provided approximately 25 mm from the upstream end of the article 1.

The aerosol-generating material 3 includes a plant-based material such as tobacco. The aerosol-generating material 3 may be a sheet or shredded sheet of aerosolizable material including a plant-based material such as tobacco.

The plant-based material may be a particulate or granular material. In some embodiments, the plant-based material is a powder. Alternatively or additionally, the tobacco material may comprise tobacco flakes, strands or fibers. For example, the tobacco material may comprise tobacco particulates, particles, fibers, flakes and/or strands. In some embodiments, the tobacco material comprises particulates or granules of tobacco material.

The density of the tobacco material affects the rate at which heat is transferred to the tobacco material; at lower densities, such as 900 mg/cc, heat is transferred more slowly into the material, thus allowing for a more sustained release of the aerosol.

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

The tobacco material may include tobacco obtained from any part of the tobacco plant. In some embodiments, the tobacco material includes tobacco leaf.

The sheet or shredded sheet may contain from 5% to about 90% by weight tobacco leaf.

The aerosol-generating material 3 may include an aerosol-forming material. The aerosol-forming material includes one or more components capable of forming an aerosol. The aerosol-forming material includes 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 phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol-forming material may be glycerol or propylene glycol.

The sheet or engraved sheet of aerosolizable material includes an aerosol forming material. The aerosol forming material is provided in an amount of about 50% or less by dry weight basis by weight of the sheet or engraved sheet. The aerosol forming material is provided in an amount of about 5% to about 40% by dry weight basis by weight of the sheet or engraved sheet, about 10% to about 30% by dry weight basis by weight of the sheet or engraved sheet, or about 10% to about 20% by dry weight basis by weight of the sheet or engraved sheet.

The aerosol-generating material 3 may include a filler material. In some embodiments, the sheet or shredded sheet includes a filler material. The filler material is generally a non-tobacco component, i.e., a component that does not include components derived from tobacco. The filler material may include one or more suitable inorganic adsorbents such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and molecular sieves. The filler material may be non-tobacco fibers such as wood fibers or pulp or wheat fibers. It may be a material that includes cellulose or a material that includes a derivative of cellulose. The filler material component may be a non-tobacco cast material or a non-tobacco extruded material.

The aerosol-generating material 3 herein may include an aerosol modifying agent, such as any of the flavorants described herein. In one embodiment, the aerosol-generating material 3 includes menthol. When the aerosol-generating material 3 is incorporated into an article for use in an aerosol delivery system, the article may be referred to as a mentholated article. The aerosol-forming material 3 may include 0.5 mg to 20 mg of menthol, 0.7 mg to 20 mg of menthol, 1 mg to 18 mg, or 8 mg to 16 mg of menthol.

In some embodiments, the composition may include an aerosol-forming "amorphous solid," which is alternatively referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may include a dry gel. An amorphous solid is a solid material that holds a fluid, such as a liquid, within its interior.

In some cases, the amorphous solid is
- 1 to 60 wt. % of a gelling agent,
-0.1 to 50 wt % aerosol forming agent and -0.1 to 80 wt % flavoring agent, these weights being calculated on a dry weight basis.

In some other examples, the amorphous solid is
- 1 to 50 wt. % of a gelling agent,
-0.1 to 50 wt % aerosol forming agent and -30 to 60 wt % flavoring agent, these weights being calculated on a dry weight basis.

The amorphous solid material may be provided in the form of a sheet or an engraved sheet. The amorphous solid material may be in the same form as the sheet or engraved sheet of the aerosolizable material.

The aerosol-generating material 3 may comprise reconstituted tobacco paper. The composition may alternatively or additionally comprise tobacco in any form as described herein. The aerosol-generating material 3 may comprise a sheet or shredded sheet comprising tobacco material comprising 10-90% by weight of tobacco leaves, the aerosol-forming material being provided in an amount of about 20% by weight of the sheet or shredded sheet, with the remainder of the tobacco material comprising reconstituted tobacco paper.

When the aerosol-generating material 3 contains an amorphous solid material, the amorphous solid material may be a dry gel containing menthol.

The components of one embodiment of a non-combustion aerosol delivery device 100 are shown in a simplified manner in FIG. 4. Notably, the elements of the non-combustion aerosol delivery device 100 are not drawn to scale in FIG. 4. Elements that are not relevant to an understanding of this embodiment have been omitted to simplify FIG. 4.

As shown in FIG. 4, the non-combustion aerosol delivery device 100 includes a non-combustion aerosol delivery device having a housing 101 including an area 102 for receiving an item 1.

The area 102 is arranged to accommodate the item 1. When the item 1 is accommodated in the area 102, at least a portion of the aerosol-generating material 3 is in thermal proximity to the heater 103. When the item 1 is fully accommodated in the area 102, at least a portion of the aerosol-generating material 3 is in direct contact with the heater 103. The aerosol-generating substrate 3 emits a series of volatile components at different temperatures. By controlling the maximum operating temperature of the electrically heated aerosol-generating system 100, selective emission of undesirable components is controlled by preventing the emission of selected volatile components.

As shown in FIG. 5, within the housing 101 is an electrical energy supply 104, e.g., rechargeable lithium ion. A controller 105 is connected to the heater 103, the electrical energy supply 104, and a user interface 106, e.g., buttons or a display. The controller 105 controls the power supplied to the heater 103 to regulate the temperature of the heater. Typically, the aerosol-forming substrate is heated to a temperature of 250-450°C.

Figure 6 is a schematic cross-sectional view of a non-combustion aerosol delivery device of the type shown in Figure 4 in which a heater 103 is inserted within the aerosol-generating material 3 of the article 1. The non-combustion aerosol delivery device 100 is shown engaged with an aerosol-generating article 1 for consumption of the aerosol-generating article 1 by a user.

The housing 101 of the non-combustion based aerosol delivery device 100 defines a cavity-shaped region 102, open at a proximal end (or mouth end) for receiving the aerosol generating article 1 for consumption. The distal end of the cavity is spanned by a heating arrangement including a heater 103. The heater 103 is held by a heater attachment such that an active heating area of the heater is located within the cavity. The active heating area of the heater 103 is located within the aerosol generating section of the aerosol generating article 1 when the aerosol generating article 1 is fully received within the cavity.

The heater 103 is configured to be inserted into the aerosol-generating material 3. When the article 1 is pushed into the device 100, the tapered tip of the heater 103 engages the aerosol-generating material 3. Applying force to the article 1 causes the heater to penetrate into the aerosol-generating material 3. When the article 1 is properly engaged with the non-combustion aerosol delivery device 100, the heater 103 is inserted into the aerosol-generating material 3. Activation of the heater 103 heats the aerosol-generating material 3 and generates or releases volatile substances. When the user inhales through the mouthpiece 2, air is drawn into the article 1 and the volatile components condense, forming an inhalable aerosol. The aerosol passes through the mouthpiece 2 of the article 1 and travels into the user's mouth.

Regardless of the composition of the aerosol-generating material 3, embodiments of the present invention provide an aerosol-generating material 3 having a cavity 20 extending longitudinally from a distal end D toward a proximal end P such that a heating element 103 of the device 100 is received in the cavity when the article 1 is inserted into the device 100.

In some embodiments, the cavity 20 is coaxial with the longitudinal axis X-X' of the article, and the aerosol-generating material 3 may be tubular. In other embodiments, the cavity 20 may be offset from the longitudinal axis X-X' and/or may include multiple cavities 20, one or more of which accommodate the heating element 103 when the article 1 is inserted into the device 100.

One or more of the cavities 20 may extend the entire length of the aerosol-generating material 3. Alternatively, some or all of the cavities 20 may extend only through a portion of the aerosol-generating material.

In an embodiment of the present invention, the inner surface 21 of the cavity 20, i.e., the inner wall 21 of the aerosol-generating material 3, may be patterned or have channels formed therein to increase the surface area of the aerosol-generating material 3 and the contact time of the aerosol with the aerosol-generating material 3. For example, the inner wall 21 may have a rifle pattern formed therein, such as a spiral groove or recess. The heating element 103 of the device 100 may have a complementary shape such that the article 1 is rotated upon insertion, effectively screwing the aerosol-generating material 3 onto the heating element 103. In other embodiments, the heating element 103 may be a pin or blade that slides into the cavity 20 without the need for any rotation and regardless of a pattern cut into the inner wall 21. For example, in another embodiment, the inner wall 21 of the aerosol-generating material 3 may have a straight groove or groove that may extend longitudinally between the upstream and downstream ends of the article 1.

The or each cavity 20 has a circular cross-section as shown in the cross-sectional view of FIG. 3a, although other cross-sectional shapes are possible. For example, the cross-section of the cavity 20 may be slot-shaped as shown in FIG. 3b or star-shaped as shown in FIG. 3c, or may have some other non-circular cross-section. In these embodiments, the heating element 103 may be cylindrical or pin-shaped so that the heating element 103 and the cavity do not need to be oriented prior to insertion. However, the heating element 103 and the cavity 20 may have the same cross-sectional shape.

Regardless of the shape of the cavity 20 and regardless of whether the cavity 20 and the heating element 103 have the same cross-sectional shape, the heating element 103 may be snapped or interference-fitted into the cavity 20. In certain embodiments, the heating element 103 may be slightly larger than the cavity 20 such that the aerosol-generating material 3 is compressed or deformed by the heating element 103 upon insertion into the device 100.

In any embodiment of the invention, the inner wall 21 of the cavity 20 of the aerosol-generating material 3 may be coated with or otherwise adhered to a layer of a material different from the aerosol-generating material. For example, a layer of sheet material such as an amorphous solid and/or gel and/or paper or another layer of an aerosol-generating material different from the first may be disposed on the inner wall 21. One or more cavities of the aerosol-generating material may thus extend through this second layer. The inner material layer may have a low coefficient of friction compared to the aerosol-generating material so that the heating element 103 slides more easily into the cavity 20.

In certain embodiments, a liner extends across at least a portion of the inner wall 21 of the cavity 20 such that the heating element 103 is separated from the aerosol-generating material 3 by the liner. The liner may be formed from a heat-conducting material such that it improves the uniformity of heating of the aerosol-generating material 3, such that the aerosol-generating material is heated more uniformly. Hygiene is also improved as the heating element 103 is no longer in direct contact with, and therefore no longer adheres to, the aerosol-generating material 3. Crushing of the aerosol-generating material 3 is also minimized or avoided.

Specific examples of heat transfer materials that may be suitable for the liner include metals or metal alloys, polymer ceramics, or graphite. Of course, the cavity 20 may be lined and may take on different configurations or shapes, such as those shown in FIG. 3.

In some embodiments of the invention, the heating element 103 and the cavity 20 into which it is inserted have different cross sections such that the entire heating element 103 does not fill the cavity 20, leaving one or more paths for the aerosol to flow between the inner wall of the aerosol-generating material 3 and the heating element 103. It is also understood that there may be multiple cavities 20, only one or a portion of which may be occupied by the heating element 103, leaving other paths for the aerosol to flow freely through the aerosol-generating material 3. By adjusting the size of the paths relative to the size of the heating element 103 or by providing additional cavities 20 not occupied by the heating element 103, the resistance to draw of the aerosol-generating material 3 may be adjusted and optimized for a particular product or market. Figure 3e shows a structure with five cavities, configured such that the heating element is housed in the central cavity coaxial with the longitudinal axis X-X'. The remaining cavities form flow paths through the aerosol-generating material and may be the same or different size or shape as the central cavity housing the heating element 103 of the device 100.

In some embodiments, the aerosol flow path is formed as an integral part of the cavity 20 in which the heating element 103 is housed. In particular, the heating element 103 and the cavity 20 have different cross-sectional shapes to form a path between the heating element 103 and the inner wall of the aerosol-generating material 3. In certain embodiments, the heating element 103 is cylindrical, i.e., in the form of a pin, while the cavity 20 has a keyhole-shaped cross-section with a substantially circular section and a protrusion 21a extending therefrom, as shown in FIG. 3d, in which the heating element 103 is housed in the substantially circular section of the cavity 20, with the remaining protrusion 21a remaining open to form a free path for the aerosol flow through the aerosol-generating material 3. The size of the protrusion 21a and/or the number of protrusions 21a may be determined based on the resistance of draw required.

In any of the embodiments of the invention, one or more cavities 20 of the aerosol-generating material 3 may not be uniform along their length. For example, their shape may vary along the length of the aerosol-generating material 3, or the cavities 20 may be tapered. For example, the cavities 20 may narrow in the direction extending away from the distal end of the aerosol-generating material 3.

In either embodiment, the aerosol-generating material 3 may be extruded through a die. In this method, the die may be provided with a mandrel over which the aerosol-generating material 3 is extruded to form a cavity 20 in the aerosol-generating material 3. The mandrel may be cylindrical, but may also be of other shapes or configurations to form a cavity of the required cross-sectional shape in the aerosol-generating material 3.

In another embodiment, the aerosol-generating material 3 may be formed by a molding process by placing the aerosol-generating material in a mold and curing the aerosol-generating material to retain the shape of the mold. The mold may have an internal core shaped to form a cavity 20 within the aerosol-generating material.

In any embodiment of the present invention, the article 1 may include a plug 25 at the distal end D, as shown in FIG. 2. In this embodiment, the heating element 103 is inserted into the aerosol-generating material 3 through the plug 25. The plug 25 may have one or more holes extending therethrough, the one or more holes being positioned to correspond to one or more cavities 20 in the aerosol-generating material 3 such that the heating element 103 of the device 100 passes through the holes in the plug 25 before passing through the one or more cavities 20 in the aerosol-generating material 3. The one or more holes in the plug 25 may have a cross-sectional shape that is the same as or different from the cross-sectional shape of the cavity 20 in the aerosol-generating material 3.

The plug 25 can be made of an elastically compressible material such that it deforms in response to the heating element 103 being pushed through the plug. The hole in the plug 25 reduces the force required to insert the heating element 103 through the plug 25. The hole in the plug 25 can have a cross-sectional shape that complements the cross-sectional shape of the heating element 103. For example, if the heating element 103 is a pin and has a cylindrical cross-section, the hole in the plug 25 can also be cylindrical. Alternatively, if the heating element 103 is a blade, the hole in the plug 25 can be formed as a slot.

The plug 25 may wipe the heating element 103 when it is removed. Ideally therefore the size of the hole in the plug 25 is slightly smaller than the heating element 103 so that the material of the plug 25 comes into contact with the heating element 103 when it is removed to perform the wiping function.

The plug 25 may be formed from paper. In particular, the plug 25 may be formed from one or more pleated sheets of paper or one or more pleated and crimped sheets of paper. The degree of pleating of the paper adjusts the resistance to insertion of the heating element 103 through the plug. A tightly crinkled paper plug provides a greater resistance to insertion of the heating element 103 relative to a more loosely crinkled paper plug 25.

When the heating element 103 is housed in the aerosol generating material 3, the item 1 is more securely held by the plug 25. This makes the item 1 less likely to slip out of the device 100 during use, making the item 1 and device 100 easier and safer to use.

The various embodiments described herein are provided merely to aid in the understanding and teaching of the claimed features. These embodiments are merely representative examples and are not intended to be comprehensive or exclusive. It is to be understood that the advantages, embodiments, examples, features, features, structures, and/or other aspects of the present disclosure should not be construed as limiting the present disclosure to the claims as set forth herein or to the equivalents of the claims, but that other embodiments may be utilized or modified without departing from the scope and/or spirit of the present disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of the disclosed components, ingredients, features, parts, steps, means, or other combinations. The present disclosure also includes other inventions not currently claimed but which may be claimed in the future.

Claims (38)

An article for use in a non-combustion aerosol delivery system including an aerosol delivery device, the article including a rod of aerosol-generating material having a distal end for insertion into the non-combustion aerosol delivery device, such that a heating element of the device extends into the rod of aerosol-generating material through the distal end, the article including a cavity extending longitudinally from the distal end into the rod of aerosol-generating material for receiving the heating element. The article of claim 1, further comprising a mouth end opposite the distal end, the mouth end being configured to be sandwiched between a user's lips when the distal end is inserted into the non-combustion aerosol delivery device. The article of claim 2, wherein the cooling segment is located between the aerosol generating material and the mouth end. The article of claim 3, wherein the filtering segment is located between the cooling segment and the mouth end. The article according to any one of claims 1 to 4, characterized in that the cavity extends the entire length of the aerosol-generating material. The article of any one of claims 1 to 5, wherein the cavity is coaxial with the longitudinal axis of the article. The article of claim 6, characterized in that the aerosol-generating material includes a tube. The article of claim 7, wherein the tube includes an inner surface, and the mold is formed on the inner surface extending in a longitudinal direction. The article of claim 8, characterized in that the mold includes a spiral groove or recess. The article of claim 8, characterized in that the mold includes linear grooves or recesses. The article of any one of claims 1 to 10, wherein a plurality of cavities extend from the distal end into the aerosol-generating material. The article of claim 11, wherein one or more of the cavities are disposed about the longitudinal axis. The article of claim 11 or 12, wherein one of the cavities is coaxial with the longitudinal axis. An article according to any one of claims 1 to 13, characterized in that the or each cavity has a non-circular cross-section. An article according to any one of claims 1 to 14, characterized in that the or each cavity has a non-uniform cross-section in the longitudinal direction. The article of claim 15, wherein the or each cavity is longitudinally tapered. The article of claim 16, wherein the or each cavity tapers narrowly away from the distal end. The article of any one of claims 1 to 17, further comprising a plug at the distal end. The article according to claim 18, characterized in that the plug abuts against the aerosol-generating material. 20. The article of claim 18 or 19, further comprising a passage in the plug that corresponds to the cavity extending through the aerosol generating material. The article of claim 20, wherein the passage is a slit or slot in the plug. The article of any one of claims 18 to 21, characterized in that the plug is formed from pleated and selectively crimped paper. The article of any one of claims 1 to 22, characterized in that the inner wall of the cavity includes a layer of material. The article of claim 23, wherein the layer of material is a layer of a gel, an amorphous solid, or a sheet of material such as paper. The article of claim 24, characterized in that the material layer is a separate layer of an aerosol-generating material different from the aerosol-generating material. The article of claim 23, wherein the material layer comprises a thermally conductive material. 27. The article of claim 26, wherein the material layer comprises a metal or metal alloy, a polymer ceramic, or graphite. A system including a non-combustion aerosol delivery device having a heating element and an article including a rod of aerosol-generating material having a distal end for insertion into the non-combustion aerosol delivery device, such that the heating element of the device extends into the rod of aerosol-generating material through the distal end, a cavity extending longitudinally from the distal end into the rod of aerosol-generating material to accommodate the heating element. The system of claim 28, wherein the heating element and the cavity have the same cross-sectional shape. The system of claim 28 or 29, wherein the heating element is fitted or interference-fitted into the cavity. 29. The system of claim 28, wherein the heating element and the cavity have different cross-sectional shapes such that a path remains between the heating element and an inner wall of the aerosol generating material when the heating element is received in the cavity. 32. The system of claim 31, wherein the cavity has a portion having a cross-section complementary to a cross-section of the heating element, the heating element being received in the portion, and the cavity further has at least one protrusion extending from the portion and forming the passageway. The system of any one of claims 28 to 32, wherein the aerosol generating material has a longitudinal axis and the cavity for housing the heating element is a central cavity extending along the longitudinal axis. 34. The system of claim 33, further comprising a plurality of additional cavities extending from the distal end into the aerosol-generating material, the additional cavities surrounding the central cavity and forming an open passageway through the aerosol-generating material when a heating element is received in the central cavity. A method of manufacturing an article comprising a rod of aerosol-generating material having a distal end for insertion into a non-combustion aerosol delivery device, the method comprising extruding the aerosol-generating material through a die head onto a mandrel to form a cavity extending through the aerosol-generating material. The method of claim 35, wherein the mandrel is shaped to provide the aerosol-generating material with a cavity shaped to correspond to the mandrel. A method for producing an article comprising an aerosol-generating material having a distal end for insertion into a non-combustion aerosol delivery device, comprising molding the aerosol-generating material around a former. The method of claim 36, wherein the former is configured to provide the aerosol-generating material with a cavity having a shape corresponding to the former.

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