CN118119292A

CN118119292A - Article for use in a non-combustible sol providing system

Info

Publication number: CN118119292A
Application number: CN202280053538.1A
Authority: CN
Inventors: J·坎贝尔; R·赫普沃斯; B·泰勒; M·霍奇森; M·法希姆阿什拉夫; B·迪米克
Original assignee: Nico Investment Trading Co ltd
Current assignee: Nico Investment Trading Co ltd
Priority date: 2021-06-18
Filing date: 2022-06-17
Publication date: 2024-05-31

Abstract

An article (1) for use in a non-combustible sol providing system comprising an aerosol providing device (100) is disclosed. The article comprises a rod of aerosol-generating material (3), the rod of aerosol-generating material (3) having a distal end (D) for insertion into the non-combustible aerosol-providing device such that a heating element (103) of the device extends into the rod of aerosol-generating material through said distal end. The article comprises a cavity (20), the cavity (20) extending from the distal end in a longitudinal direction into the rod of aerosol-generating material to receive the heating element. Also disclosed is a system comprising a non-combustible sol providing device with a heating element and an article according to the invention, as well as a method of manufacturing an article according to the invention.

Description

Article for use in a non-combustible sol providing system

Technical Field

The present invention relates to an article for use in a non-combustible sol providing system, a system comprising the article and a non-combustible sol providing device, and a method of manufacturing an article according to the invention.

Background

Certain tobacco industry products produce aerosols that are inhaled by a user during use. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, by heating, rather than incinerating, the substrate to form an aerosol. Such tobacco industry products typically include a mouthpiece through which the aerosol passes to reach the mouth of the user.

Disclosure of Invention

According to some embodiments described herein, there is provided an article for use in a non-combustible aerosol-providing system comprising an aerosol-providing device, the article comprising a rod of aerosol-generating material having a distal end for insertion into the non-combustible aerosol-providing device such that a heating element of the device extends into the rod of aerosol-generating material through the distal end, wherein the article comprises a cavity extending from the distal end into the rod of aerosol-generating material in a longitudinal direction to receive the heating element.

The article may include a mouth end opposite the distal end, the mouth end configured to be placed between the lips of a user when the distal end is inserted into the non-combustible sol providing device.

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

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

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 comprise a tube.

The tube may comprise an inner surface and a profile extending in a longitudinal direction may be formed in said surface.

The profile may comprise a helical groove or recess.

The profile may comprise a linear groove or recess.

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

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

One of the cavities may be coaxial with said longitudinal axis of the aerosol-generating material.

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 taper in the longitudinal direction.

The or each cavity may taper such that it narrows in a direction away from the distal end.

The article may comprise a filter rod (plug) at the distal end. The filter rod may abut the aerosol-generating material.

The filter rod may have a passageway positioned to correspond to a cavity extending in the aerosol-generating material. The passageway may be a slit or groove in the filter rod.

The filter rod may be formed from gathered paper, and in some examples, from curled paper.

The article may comprise a layer of material on an inner wall of the cavity.

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

The layer of material may be another layer of aerosol-generating material different from the aerosol-generating material.

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

According to some other embodiments described herein, there is provided a system comprising a non-combustible sol providing device having a heating element; and an article comprising a rod of aerosol-generating material having a distal end for insertion into the non-combustible aerosol-providing device such that a heating element of the device extends into the aerosol-generating material through the distal end, wherein a cavity extends into the rod of aerosol-generating material in a longitudinal direction from the distal end to receive the heating element.

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

The heating element may fit or be an interference fit in the cavity.

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

The pin may have a circular cross-section and the cavity may have a portion with a circular cross-section to receive the pin and at least one lobe extending from the circular portion to form the passageway.

The aerosol-generating material may have a longitudinal axis and the cavity to receive the heating element may be a central cavity extending along the longitudinal axis.

There may be a plurality of additional cavities extending from the distal end into the aerosol-generating material, wherein the additional cavities surround the central cavity and form an open passageway through the aerosol-generating material when a heating element is received in the central cavity.

According to some embodiments described herein, there is provided a method of manufacturing an article comprising a rod of aerosol generating material having a distal end for insertion into a non-combustible aerosol providing device, the method comprising extruding the aerosol generating material through a die head and over a mandrel to form a cavity extending through the aerosol generating material.

The mandrel may be shaped to provide a correspondingly shaped cavity in the aerosol-generating material.

According to some other embodiments described herein, there is provided a method of manufacturing an article comprising an aerosol-generating material having a distal end for insertion into a non-combustible aerosol-providing device, the method comprising moulding the aerosol-generating material around a precursor.

The precursor may be shaped to provide a correspondingly shaped cavity in the aerosol-generating material.

Drawings

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

FIG. 1 is a side cross-sectional view of an article for use with a non-combustible sol providing device;

FIG. 2 is a side cross-sectional view of an article for use with a non-combustible sol providing device according to another embodiment;

figures 3a to 3e each show a different embodiment of a cross-section of aerosol-generating material through the article of figures 1 or 2 taken along line A-A;

FIG. 4 is a cross-sectional view of a non-combustible sol providing device;

FIG. 5 is a simplified schematic of components within the housing of the aerosol provision device shown in FIG. 4;

Fig. 6 is a sectional view of the non-combustible sol providing device shown in fig. 4, in which the article shown in fig. 1 or 2 is inserted into the device.

Detailed Description

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

Combustible sol providing systems such as cigarettes, cigarillos, cigars, and tobacco for pipes or cigarettes or tobacco for self-cigarettes or homemade cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable materials);

A non-combustible aerosol-providing system, such as an electronic cigarette, a tobacco heating product, and a mixing system to generate an aerosol using a combination of aerosol-generating materials that releases a compound from the aerosol-generating material without combusting the aerosol-generating material; and

An aerosol-free delivery system for delivering at least one substance orally, nasally, transdermally, or in another manner that does not form an aerosol to a user, including but not limited to lozenges, chewing gums, patches, articles including inhalable powders, and oral products such as oral tobacco including snuff or wet snuff, wherein the at least one substance may or may not include nicotine.

According to the present disclosure, a "non-combustible" aerosol provision system is an aerosol provision system in which the constituent aerosol-generating materials (or components thereof) of the aerosol provision system are not combusted or incinerated to facilitate delivery of at least one substance to a user.

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

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

In some embodiments, the non-combustible sol providing system is an aerosol-generating material heating system, also referred to as a non-incinerating heating system. One example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate 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 the form of a solid, liquid or gel, and may or may not comprise nicotine. In some embodiments, the mixing system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, a tobacco or non-tobacco product.

Typically, a non-combustible sol providing system may include a non-combustible sol providing device and a consumable for use with the non-combustible sol providing device.

The present disclosure relates to consumables that include an aerosol-generating material and are configured for use with a non-combustible sol providing device. Throughout this disclosure, these consumables are sometimes referred to as articles.

The terms "upstream" and "downstream" as used herein are relative terms defined with respect to the direction of mainstream aerosol drawn through an article or device in use. Reference to "distal end" refers to the upstream end of the device, while "proximal end" refers to the downstream end of the device.

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

In some embodiments, the non-combustible aerosol provision system comprises a region for receiving a consumable, an aerosol generator, an aerosol generating region, a housing, a mouthpiece, a filter, and/or an aerosol modifier.

In some embodiments, a consumable for use with a non-combustible aerosol provision device may include an aerosol generating material, an aerosol generating material storage region, an aerosol generating material delivery member, an aerosol generator, an aerosol generating region, a housing, a packaging material, a filter, a mouthpiece, and/or an aerosol modifier.

The consumable comprises the substance to be delivered. The substance to be delivered is an aerosol-generating material. Where appropriate, the material may comprise one or more active ingredients, one or more fragrances, one or more aerosol-forming materials and/or one or more other functional materials.

In some embodiments, the substance to be delivered comprises an active substance. An active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropic agents, psychoactive substances. The active substance may be naturally occurring or synthetically obtained. The active may include, for example, nicotine, caffeine, taurine, caffeine, vitamins (such as B ₆ or B ₁₂ or C), melatonin, or components, derivatives, or combinations thereof. The active substance may comprise one or more components, derivatives or extracts of tobacco, or another plant (botanical). In some embodiments, the active comprises nicotine. In some embodiments, the active comprises caffeine, melatonin, or vitamin B ₁₂.

As referred to herein, an active substance may comprise or be derived from one or more plants or components, derivatives or extracts thereof. As used herein, the term "plant" includes any material derived from a plant including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, bark, hulls, and the like. Alternatively, the material may comprise an active compound naturally occurring in synthetically obtained plants. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, sheets, etc. Exemplary plants are tobacco, eucalyptus, star anise, cocoa, fennel, lemon grass, peppermint, spearmint, louis, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay, licorice (licorice of opa), green tea, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, fennel seed (fennel), basil, bay leaf, cardamon, coriander, cumin, nutmeg, oregano, capsicum, rosemary, saffron, lavender, lemon peel, peppermint, juniper, elder, vanilla, wintergreen, perilla, turmeric, sandalwood, coriander leaf, bergamot, orange flower, myrtle, blackcurrant, valerian, doramese, nutmeg, damiana (damien), marjoram, olive, lemon vanilla, lemon basil, chive, caraway, verbena, geranium, ginseng, mulberry, tea, nightshade, tea, macadamia, chlorophyll, macadamia, or any combination thereof. The peppermint can be selected from the following peppermint varieties: peppermint (MENTHA ARVENSIS), mentha piperita cultivar (Mentha c.v.), mentha aegypti (MENTHA NILIACA), mentha piperita (MENTHA PIPERITA), mentha piperita cultivar (MENTHAPIPERITA CITRATA c.v.), mentha piperita cultivar (MENTHA PIPERITA c.v.), spearmint (MENTHA SPICATA CRISPA), spearmint (Mentha cardifolia), spearmint (Mentha longifolia), macleaya She Fengli (Mentha suaveolens variegata), mentha pulegium (Mentha pulegium), spearmint cultivar (MENTHA SPICATA c.v.), and peppermint (Mentha suaveolens).

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

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

In some embodiments, the active substance comprises or is derived from one or more plants or components, derivatives or extracts thereof, and the plants are selected from the group consisting of lewisi (rooibos) and fennel.

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

As used herein, the terms "fragrance" and "flavoring" refer to materials that can be used to create a desired taste, aroma, or other body sensation in a product for an adult consumer, as permitted by local regulations. They may include naturally occurring fragrance materials, plants, plant extracts, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice (Glycyrrhiza glabra), hydrangea, eugenol, japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, japanese mint, pimpinella seed (pimpinella), cinnamon bark, turmeric, indian spice, asian spice, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clematis orange, white cinnamon bark, turmeric, red pepper, orange, red pepper, orange, green orange, red pepper, green orange, green color, red pepper, green color, red color, green color, and white color, red color, green color, and white color, respectively lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruit, scotch whiskey, bouillon whiskey, scotch whiskey, juniper berry, tequila, rum, spearmint, peppermint, lavender, aloe, cardamom, celery, carica, nutmeg, and the like sandalwood, bergamot, geranium, arabian tea, naswale, betel nut, water tobacco, pine, honey essence, rose oil, vanilla, lemon oil, orange flowers, cherry blossom, cassia seed, caraway, cognac, jasmine flower, ylang, sage, fennel, horseradish, peppermint, ginger, coriander, coffee, peppermint oil from any of the genus mentha, eucalyptus, star anise, cocoa, lemon grass, lewy, flax, ginkgo, hazelnut, hibiscus, bay, yerba mate, orange peel, rose, tea such as green tea or black tea, thyme, juniper, elder flower, basil, bay leaves, cumin, oregano, capsicum, rosemary, saffron, lemon peel, peppermint, perilla, turmeric, coriander, myrtle, blackcurrant, lemon peel, peppermint, and black tea Valerian, spanish pepper, nutmeg dried skin, damiana, marjoram, olive, lemon vanilla, lemon basil, chives, celery, verbena, tarragon, limonene, thymol, camphene), odorants, bitter taste receptor site blockers, sensory receptor site activators or stimulators, sugar and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, plants, or breath fresheners. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, a liquid such as oil, a solid such as powder, or a gas.

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

In some embodiments, the fragrances may include sensates intended to achieve a somatosensory sensation that is chemically induced and perceived, typically by stimulating the fifth cranial nerve (trigeminal nerve), in addition to or in place of the aroma or gustatory nerve, and these sensates may include agents that provide heating, cooling, stinging, numbness effects. Suitable thermal effectors may be, but are not limited to, vanillyl ether, and suitable coolants may be, but are not limited to, eucalyptol, WS-3.

An aerosol-generating material is a material that is capable of generating an aerosol, for example, when heated, irradiated or excited in any other way. The aerosol-generating material may be in the form of a solid, liquid or gel, which may or may not contain an active substance and/or a flavouring agent. 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 that includes tobacco or derivatives or substitutes thereof. The tobacco material may be in any suitable form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fibers, cut filler, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco, and/or tobacco extracts. A consumable is an article comprising or consisting of an aerosol-generating material, part or all of which is intended to be consumed by a user during use. The consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol-generating area, a housing, a packaging material, a mouthpiece, a filter, and/or an aerosol modifier. The consumable may further comprise an aerosol generator, in particular a heating element, which in use emits heat to cause the aerosol-generating material to generate an aerosol. The heater may comprise a material or a susceptor that is capable of being heated by conduction.

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

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

For example, the aerosol modifier may be an additive or an adsorbent. The aerosol modifiers may, for example, include one or more of fragrances, colorants, water, and carbon adsorbents. 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, wire or particle. The aerosol modifier may be free of filter material.

An aerosol-generating device is a device configured to cause an aerosol to be generated from an aerosol-generating material. The aerosol-generating device comprises a heater configured to subject the aerosol-generating material to thermal energy so as to release one or more volatiles from the aerosol-generating material to form an aerosol.

The filamentary tow material described herein may comprise cellulose acetate tow. Other materials for forming the fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly (1-4 butylene succinate) (PBS), poly (butylene adipate terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof, may also be used to form the filament bundles. The filament bundles may be plasticized with a plasticizer suitable for the bundles (such as triacetin, wherein the material is cellulose acetate bundles), or the bundles may be unplasticized. The tows may have any suitable gauge, such as fibers having a "Y" shape or other cross-section (such as an "X" shape), a denier per filament value of between 2.5 and 15 denier per filament, for example between 8.0 and 11.0 denier per filament, and a total denier value of between 5000 and 50000 denier, for example between 10000 and 40000 denier.

In the drawings described herein, like reference numerals are used to describe equivalent features, objects or components.

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

The article 1 has an upstream or distal end "D" and a downstream or proximal end "P". The proximal end P comprises the mouthpiece 2 and the distal end D comprises an aerosol-generating section connected to the mouthpiece 2. In this example, the aerosol-generating section comprises a source of aerosol-generating material 3 in the form of a rod. The aerosol-generating material 3 may comprise a plurality of strands or strips of aerosol-generating material 3. For example, the aerosol-generating material 3 may comprise a plurality of strands or strands of nebulizable material, and/or a plurality of strands or strands of amorphous solid.

In the present example, the aerosol-generating material 3 comprises a plurality of strands and/or strips of aerosol-generating material and is constrained by the wrapper 4. In this example, the packaging material 4 is a moisture vapor impermeable packaging material.

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 ribbons may be arranged generally such that their longitudinal dimensions are aligned 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 alternative embodiments, the rod of aerosol-generating material 3 may have any suitable circumference, for example between about 20mm and about 26 mm.

The article 1 is configured for use in a non-combustible sol providing device 100 (see fig. 4), the non-combustible sol providing device 100 comprising an aerosol generator, such as a blade or pin, in the form of a heating element 103 for insertion into an aerosol-generating material 3 of an aerosol-generating section, as will be described in more detail below.

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

The cooling section 5 comprises a hollow channel having an inner diameter of between about 1mm and about 4mm, for example between about 2mm and about 4 mm. In this example, the hollow passage 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 comprises a single hollow channel. In alternative embodiments, the cooling section 5 may comprise a plurality of channels, for example 2, 3 or 4 channels. In this example, the single hollow channel is substantially cylindrical, although in alternative embodiments, other channel geometries/cross-sections may be used. The hollow channel may provide a space into which the aerosol drawn into the cooling section 5 may expand and cool. In all embodiments, the cooling section 5 is configured to limit the cross-sectional area of the one or more hollow channels to limit tobacco displacement into the cooling section 5 in use.

When the heating element 103 is inserted into the rod of aerosol-generating material 3, the moisture-impermeable packaging material 4 may have a lower friction with the aerosol-generating material 3, which may result in easier longitudinal displacement of the strip and/or ribbon of aerosol-generating material 3 into the cooling section 5. By providing the cooling section 5 directly adjacent to the source of aerosol-generating material 3 and comprising an inner channel having a diameter in this range, the longitudinal displacement of the strip and/or ribbon 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. In use, reducing the displacement of the aerosol-generating material 3 may advantageously result in a more consistent packing density of the aerosol-generating material 3 along the length of the rod, which may result in more consistent and improved aerosol generation.

The cooling section 5 may have a wall thickness in the radial direction. For a given outer diameter of the cooling section, the wall thickness of the cooling section 5 defines the inner diameter of the chamber enclosed by the wall of the cooling section 5. The cooling section 5 may have a wall thickness of at least about 1.5mm and up to about 2 mm. In this example, the cooling section 5 has a wall thickness of about 2 mm. By providing the cooling section 5 with a wall thickness in this range, in use, the retention of the source of aerosol-generating material 3 in the aerosol-generating section is improved by reducing the longitudinal displacement of the wire and/or ribbon of aerosol-generating material 3 when the aerosol generator is inserted into the article 1.

The cooling section 5 is formed from a filiform filament bundle. Other structures may be used, such as parallel wound multi-ply paper with butt seams to form the cooling section 5; or spirally wound paper layers, cardboard tubes, or use of coagulated pulp (papier-) Pipes, molded or extruded plastic pipes or the like formed by the process. The cooling section 5 is manufactured with a stiffness sufficient to withstand axial compression forces and bending moments that may occur during manufacture and when the article 1 is in use.

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

In some examples, the mouthpiece 2 includes a cavity having an internal volume greater than 110mm ³. It has been found that providing a cavity of at least this volume enables the formation of an improved aerosol. In certain examples, the mouthpiece 2 comprises a cavity, e.g., formed within the cooling section 5, having an internal volume of greater than 110mm ³ or greater than 130mm ³, allowing for further improvements in aerosol. In some examples, the internal cavity includes a volume between about 130mm ³ and about 230mm ³ (e.g., about 134mm ³ or 227mm ³).

The cooling section 5 may be configured to provide a temperature difference of at least 40 degrees celsius between the heated volatile components entering the first upstream end of the cooling section 5 and the heated volatile components exiting the second downstream end of the cooling section 5. The cooling section 5 may be configured to provide a temperature difference of at least 60 degrees celsius, or at least 80 degrees celsius, or at least 100 degrees celsius, between the heated volatile components entering the first upstream end of the cooling section 5 and the heated volatile components exiting the second downstream end of the cooling section 5. This temperature difference across the length of the cooling section 8 protects the body of temperature sensitive material 6 from the high temperature of the aerosol-generating material 3 as it is heated.

When used, the aerosol-generating section may exhibit a pressure drop of from about 15 to about 40mmH ₂ O. In some embodiments, the aerosol-generating section exhibits a pressure drop across the aerosol-generating section of from about 15 to about 30mmH ₂ O.

In this embodiment, the moisture vapor impermeable packaging material 4 restraining the stem of aerosol-generating material 3 comprises aluminum foil. In other embodiments, the packaging material 4 comprises a paper packaging material, optionally comprising a barrier coating, to render the material of the packaging material 4 substantially impermeable to moisture. 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 paper backing. However, in alternative arrangements, the aluminium foil may be of other thickness, for example between 4 μm and 16 μm thick. The aluminum foil also need not have a paper backing, but may have a backing formed of other materials, for example, to help provide the foil with suitable tensile strength, or it may have no backing material. Metal layers or foils other than aluminum may also be used. The total thickness of the packaging material may be between 20 μm and 60 μm, or between 30 μm and 50 μm, which may provide the packaging material with suitable structural integrity and heat transfer characteristics. The tensile force that may be applied to the packaging material before the packaging material breaks may be greater than 3000 grams force, for example between 3000 and 10000 grams force or between 3000 and 4500 grams force. When the wrapper comprises a paper or paper backing, i.e., a cellulose-based 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 40gsm to about 70gsm, which may provide improved stiffness to the rod of aerosol-generating material 3. The improved stiffness provided by the wrapper 4 having a basis weight in this range may make the rod of aerosol-generating material 3 more resistant to wrinkling or other deformation under the forces to which the article is subjected in use (e.g. when the article is inserted into the device and/or the heat generator is inserted into the article 1).

In this example, the moisture vapor impermeable packaging material 4 is also substantially impermeable to air. In alternative embodiments, the packaging material 4 has a permeability of less than 100Coresta units, or less than 60Coresta units. It has been found that a low permeability packaging material (e.g. having a permeability of less than 100Coresta units or less than 60Coresta units) results in an improved aerosol formation in the aerosol-generating material 3. Without wishing to be bound by theory, it is hypothesized that this is due to the reduced loss of aerosol compounds through the packaging material 10. The permeability of the wrapper 10 may be measured in accordance with ISO2965:2009 with respect to the determination of the air permeability of the materials used as cigarette paper, filter rod forming paper and filter tipping paper.

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

As shown in fig. 1, the mouthpiece 2 of the article 1 comprises an upstream end 2a adjacent to the rod of aerosol-generating material 3. At the proximal end, the mouthpiece 2 has a hollow tubular element 7 formed of a filiform tow. Advantageously, it was found that this significantly reduces the temperature of the outer surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece which comes into contact with the mouth of the consumer when the article 1 is in use. In addition, it has been found that the use of the tubular element 7 significantly reduces the temperature of the outer surface of the mouthpiece 2 further upstream of the tubular element 7. Without wishing to be bound by theory, it is assumed that this is due to the tubular element 7 guiding the aerosol closer to the centre of the mouthpiece 2 and thus reducing the heat transfer from the aerosol to the outer surface of the mouthpiece 2.

The "wall thickness" of the hollow tubular element 7 corresponds to the wall thickness of the tube 7 in the radial direction. The wall thickness may be measured, for example, using calipers. The wall thickness is advantageously greater than 0.9mm and may be 1.0mm or more. In some examples, the wall thickness is substantially constant around the entire wall of the hollow tubular element 7. However, in the case where the wall thickness is not substantially constant, the wall thickness may be greater than 0.9mm, or 1.0mm or more, at any point around the hollow tubular element 7. In this example, the wall thickness of the hollow tubular element 4 is about 1.3mm.

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

The article 1 has a ventilation level of about 10% of the aerosol drawn through the article 1. In alternative embodiments, the article 1 may have a level of ventilation between 1% and 20% (e.g., between 1% and 12%) of aerosol drawn through the article 1. Ventilation at these levels helps to increase the consistency of aerosol inhaled by the user at the mouth end 2b while helping the aerosol cooling process. Ventilation is provided directly into the mouthpiece 2 of the article 1. In the present example, ventilation is provided into the cooling section 5, which has been found to be particularly beneficial in facilitating the aerosol-generating process. Ventilation is provided via perforations 10, in this case perforations 10 are formed as a single row of laser perforations positioned 13mm from the downstream mouth end portion 2b of mouthpiece 2. In alternative embodiments, two or more rows of ventilation perforations 10 may be provided. These perforations 10 pass through the tipping paper 9, the second plug wrap 11 and the cooling zone 5. In alternative embodiments, ventilation may be provided into the mouthpiece 2 at other locations, for example into the body of material 6 or the first tubular element 7. The article 1 may be configured such that the perforations 10 are provided about 28mm or less from the upstream end of the article 1, preferably between 20mm and 28mm from the upstream end of the article 1. In this example, the orifice is provided about 25mm from the upstream end of the article 1.

The aerosol-generating material 3 comprises a plant-based material, such as a tobacco material. The aerosol-generating material 3 may be a sheet or chip of nebulizable material comprising a plant-based material, such as a tobacco material.

The plant based material may be a granular or granular material. In some embodiments, the plant-based material is a powder. Alternatively or additionally, the tobacco material may comprise strips, ribbons or fibers of tobacco. For example, the tobacco material may include particles, granules, fibers, strips, and/or ribbons of tobacco. In some embodiments, the tobacco material consists of particles or granules of tobacco material.

The density of the tobacco material has an effect on the rate of heat conduction through the material, with lower densities (e.g., those below 900 mg/cc) conducting heat through the material more slowly and thus achieving a more sustained release of the aerosol.

The tobacco material can include reconstituted tobacco material having a density of less than about 900mg/cc, e.g., paper reconstituted tobacco material. For example, the aerosol-generating material 3 comprises reconstituted tobacco material having a density of less than about 800 mg/cc. Alternatively or additionally, the aerosol-generating material may comprise reconstituted tobacco material having a density of at least 350 mg/cc.

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

The aerosol-generating material 3 may comprise an aerosol precursor material. The aerosol precursor material comprises one or more components capable of forming an aerosol. The aerosol precursor material comprises one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, endocrythritol, ethyl vanillic acid, ethyl laurate, diethyl suberate, triethyl citrate, glyceryl triacetate, glyceryl diacetate mixture, benzyl benzoate, benzyl phenylacetate, glyceryl tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol precursor material may be glycerol or propylene glycol.

The pieces or fragments of nebulizable material comprise aerosol precursor material. The aerosol precursor material is provided in an amount up to about 50% by weight of the sheet or shredded sheet on a dry weight basis. In some embodiments, the aerosol precursor material is provided in an amount of from about 5% to about 40% by weight of the sheet or shredded sheet on a dry weight basis, from about 10% to about 30% by weight of the sheet or shredded sheet on a dry weight basis, or from about 10% to about 20% by weight of the sheet or shredded sheet on a dry weight basis.

The aerosol-generating material 3 may comprise a filler. In some embodiments, the sheet or chip includes a filler. Fillers are typically non-tobacco components, i.e., components that do not include tobacco-derived ingredients. The filler may include one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may be non-tobacco fibers, such as wood fibers, or pulp or wheat fibers. The filler may be a material comprising cellulose or a material comprising cellulose derivatives. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material.

The aerosol-generating material 3 herein may comprise an aerosol-modifying agent, such as any of the fragrances described herein. In one embodiment, the aerosol-generating material 3 comprises menthol. When the aerosol-generating material 3 is incorporated into an article 1 for use in an aerosol-providing system, the article may be referred to as a menthol article 1. The aerosol-generating material 3 may comprise from 0.5mg to 20mg of menthol, from 0.7mg to 20mg of menthol, between 1mg and 18mg or between 8mg and 16mg of menthol.

In some embodiments, the composition includes an aerosol-forming "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fiber). In some embodiments, the amorphous solid may comprise a xerogel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, therein.

In some examples, the amorphous solid comprises:

-1-60 wt% of a gelling agent;

-0.1-50 wt% of an aerosol precursor material; and

-0.1-80 Wt% of a fragrance;

Wherein these weights are calculated on a dry weight basis.

In some further embodiments, the amorphous solid comprises:

-1-50 wt% of a gelling agent;

-0.1-50 wt% of an aerosol precursor material; and

-30-60 Wt% of a fragrance;

Wherein these weights are calculated on a dry weight basis.

The amorphous solid material may be provided in the form of flakes or chips. The amorphous solid material may take the same form as the flakes or chips of nebulizable material.

The aerosol-generating material 3 may comprise paper reconstituted tobacco material. The composition may alternatively or additionally comprise any of the forms of tobacco described herein. The aerosol-generating material 3 may comprise a sheet or chip comprising tobacco material comprising between 10 and 90% by weight tobacco leaf, wherein the aerosol-precursor material is provided in an amount of up to about 20% by weight of the sheet or chip, and the remainder of the tobacco material comprises paper reconstituted tobacco.

In case the aerosol-generating material 3 comprises an amorphous solid material, the amorphous solid material may be a xerogel comprising menthol.

In fig. 4, the components of an embodiment of the non-combustible sol providing device 100 are shown in a simplified manner. In particular, in fig. 4, the elements of the non-combustible sol providing device 100 are not drawn to scale. Elements not relevant to understanding the embodiment are omitted to simplify fig. 4.

As shown in fig. 4, the non-combustible sol providing device 100 comprises a non-combustible sol providing device having a housing 101, the housing 101 comprising a region 102 for receiving the article 1.

The region 102 is arranged to receive the object 1. When the article 1 is received in the region 102, at least a portion of the aerosol-generating material 3 is in thermal proximity with the heater 103. At least a portion of the aerosol-generating material 3 may be in direct contact with the heater 103 when the article 1 is fully received in the region 102. The aerosol-forming material 3 will release a range of volatile compounds at different temperatures. By controlling the maximum operating temperature of the electrically heated aerosol-generating system 100, the selective release of undesirable compounds may be controlled by preventing the release of selected volatile compounds.

As shown in fig. 5, there is an electrical energy supply 104, such as a rechargeable lithium ion battery, within the housing 101. The controller 105 is connected to the heater 103, the power supply 104, and a user interface 106, such as a button or display. The controller 105 controls the power supplied to the heater 103 so as to adjust the temperature of the heater 103. Typically, the aerosol-forming substrate is heated to a temperature between 250 and 450 degrees celsius.

Fig. 6 is a schematic cross-sectional view of a non-combustible sol providing device 100 of the type shown in fig. 4, wherein a heater 103 is inserted into the aerosol-generating material 3 of the article 1. The non-combustible sol providing device 100 is shown engaged with the aerosol-generating article 1 for consumption of the aerosol-generating article 1 by a user.

The housing 101 of the non-combustible sol providing device 100 defines a region 102 in the form of a cavity, the region 102 being 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 assembly comprising a heater 103. The heater 103 is held by a heater mount (not shown) such that the active heating area of the heater is located within the cavity. When the aerosol-generating article 1 is fully received within the cavity, the effective heating area of the heater 103 is positioned within the aerosol-generating section of the aerosol-generating article 1.

The heater 103 is configured for insertion into the aerosol-generating material 3. As the article 1 is pushed into the device 100, the conical point of the heater 103 engages with the aerosol-generating material 3. By applying a force to the article 1, the heater 103 penetrates into the aerosol-generating material 3. When the article 1 is properly engaged with the non-combustible sol providing device 100, the heater 103 is inserted into the aerosol generating material 3. When the heater 103 is actuated, the aerosol-generating material 3 is heated and a volatile substance is generated or emitted. As the user smokes the mouth 2, air is drawn into the article 1 and the volatile material condenses to form an inhalable aerosol. The aerosol passes through the mouthpiece 2 of the article 1 and into the mouth of the user.

Regardless of the composition of the aerosol-generating material 3, embodiments of the invention provide the aerosol-generating material 3 with a cavity 20 extending in a longitudinal direction from the distal end D in a direction towards the proximal end P, such that the heating element 103 of the device 100 is received in the cavity 20 when the object 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 shape. In other embodiments, the cavity 20 may be offset from the longitudinal axis X-X' and/or include a plurality of cavities 20, one or more of which cavities 20 may receive the heating element 103 when the article 1 is inserted into the device 100.

The one or more cavities 20 may extend the entire length of the aerosol-generating material 3. Alternatively, some or all of the cavities 20 may extend part of the length of the aerosol-generating material 3.

In an embodiment of the invention, the inner surface 21 of the cavity 20, i.e. the inner wall 21 of the aerosol-generating material 3, may be profiled or have a flow path adapted to increase the surface area of the aerosol-generating material 3 and the contact time between the aerosol and the aerosol-generating material 3. For example, the inner wall 21 may have a rifling-type pattern, such as a spiral groove or recess, formed therein. The heating element 103 of the device 100 may have a complementary shape to enable the article 1 to be rotated during insertion to effectively screw 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 requiring any rotation and independent of any profile that may be cut into the inner wall 21. For example, in another embodiment, the inner wall 21 of the aerosol-generating material 3 may have a linear groove or recess, which may extend in the longitudinal direction between the upstream and downstream ends of the article 1.

Although the or each cavity 20 may have a circular cross-section as shown in the cross-sectional view of fig. 3a, other cross-sections are possible. For example, the cross-section of the cavity 20 may be in the shape of a groove as shown in fig. 3b, or a star as shown in fig. 3 c. The cross-section of the cavity 20 may also have some other non-circular cross-section. In these embodiments, the heating element 103 may be cylindrical, i.e. in the form of a pin, to avoid having to orient the heating element 103 and the cavity 20 with each other prior to insertion. However, it is possible that both 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 a snug fit or an interference fit within the cavity 20. In certain embodiments, the heating element 103 may have a size slightly larger than the size of the cavity 20, such that the aerosol-generating material 3 is compressed or deformed by the heating element 103 during 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 or otherwise delimited by a layer of a material other than the aerosol-generating material. For example, a layer of amorphous solid, and/or gel and/or sheet material, such as paper, or another layer of aerosol-generating material different from the first layer, may be provided on the inner wall 21. One or more cavities in the aerosol-generating material thus extend through the second layer of material. The inner material layer may have a lower coefficient of friction than the aerosol-generating material to allow the heating element 103 to slide more easily into the cavity 20.

In a particular embodiment, the liner extends across at least a portion of the inner wall 21 of the cavity 20 to separate the heating element 103 from the aerosol-generating material 3 by the liner. The liner may be formed of a thermally conductive material such that it improves the uniformity of heating of the aerosol-generating material 3 and the aerosol-generating material will be heated more uniformly. Hygiene is also improved because the heating element 103 is not in direct contact with the aerosol-generating material 3 and is therefore not attachable to the aerosol-generating material 3. Breakage of the aerosol-generating material 3 is also minimized or prevented.

Specific examples of thermally conductive materials considered suitable for the bushing include metals or metal alloys, polymeric ceramics, or graphite. It will be appreciated that the cavity 20 may be lined and take different forms or shapes, such as those shown with reference to fig. 3.

In some embodiments of the invention, the heating element 103 and the cavity 20 into which the heating element 103 is inserted have different cross-sections, such that the heating element 103 does not completely fill the cavity 20, leaving one or more passages for the flow of aerosol between the inner wall of the aerosol-generating material 3 and the heating element 103. It will also be appreciated that there may be a plurality of cavities 20, one or some of the plurality of cavities 20 being occupied by the heating element 103, leaving other channels free to allow aerosol to flow through the aerosol-generating material 3. By controlling the size of the passageway with respect to the size of the heating element 103, or by providing an additional cavity 20 not occupied by the heating element 103, the resistance to drawing through the aerosol-generating material 3 can be controlled and optimised for a particular product or market. Fig. 3e shows an arrangement in which there are five cavities, the heating element being configured to be received in a central cavity coaxial with the longitudinal axis X-X'. The remaining cavities form a flow path through the aerosol-generating material and may have the same or a different size or shape than the central cavity 20 of the heating element 103 of the receiving device 100.

In some embodiments, the passageway for aerosol flow is formed as an integral part of the cavity 20 in which the heating element 103 is received. In particular, the heating element 103 and the cavity 20 have different cross-sectional shapes to form a passageway between the heating element 103 and the inner wall of the aerosol-generating material 3. In a particular embodiment, the heating element 103 may be cylindrical, i.e. in the form of a pin, but the cavity 20 has a cross-section in the form of a keyhole shape having a substantially circular cross-section with the lobes 21a extending therefrom, as shown in fig. 3d, such that the heating element 103 is received in the substantially circular cross-section of the cavity 20 leaving the remaining lobes 21a open to form a free passage for aerosol flow through the aerosol-generating material 3. The size of the lobes 21a and/or the number of lobes 21a may be determined based on the desired resistance to draw.

In any of the embodiments of the present invention, one or more of the cavities 20 in the aerosol-generating material 3 may be non-uniform along their length. For example, their shape may vary along the length of the aerosol-generating material 3, or the cavity 20 may taper. For example, the cavity 20 may narrow in a direction extending away from the distal end of the aerosol-generating material 3.

In any embodiment, the aerosol-generating material 3 may be extruded through a die. In this manufacturing method, the mould may be provided with a mandrel over which the aerosol-generating material 3 is extruded so as to form the cavity 20 in the aerosol-generating material 3. The mandrel may be cylindrical, but it may have other shapes or configurations to form a cavity of a desired cross-sectional shape within the aerosol-generating material 3.

In an alternative embodiment, the aerosol-generating material 3 may be formed during the moulding process by placing it within a mould and allowing it to solidify to retain the shape of the mould. The mould may have an inner core shaped to form a cavity 20 within the aerosol-generating material 3.

In any embodiment of the invention, the article 1 may comprise a filter rod 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 filter rod 25. The filter rod 25 may have one or more holes extending through the filter rod 25. The one or more holes may be positioned to correspond to the one or more cavities 20 in the aerosol-generating material 3 such that the heating element 103 of the device 100 passes through the one or more holes in the filter rod 25 before entering the one or more cavities 20 in the aerosol-generating material 3. The one or more holes in the filter rod 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 filter rod 25 may be made of a resiliently compressible material such that the filter rod 25 will deform in response to the heating element 103 being pushed through the filter rod 25. The holes in the filter rod 25 may reduce the force required to insert the heating element 103 through the filter rod 25. The holes in the filter rod 25 may have a cross-sectional shape that is complementary to 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 holes in the filter rod 25 may also be cylindrical. Alternatively, if the heating element 103 is a vane, the holes in the filter rod 25 may be shaped as slots.

The filter rod 25 may wipe the heating element 103 during extraction. Thus, desirably, the size of the holes in the filter rod 25 is slightly smaller than the size of the heating element 103, such that the material of the filter rod 25 will contact the surface of the heating element 103 to perform a wiping function during extraction.

The filter rod 25 may be formed of paper. In particular, the filter rod 25 may be formed from one or more sheets of paper in a gathered and curled form. The degree of paper accumulation controls the resistance to insertion of the heating element 103 through the filter rod 25. The tightly packed paper filter rods 25 will have a greater resistance to insertion of the heating element 103 with respect to the more loosely packed paper filter rods 25.

Once the heating element 103 is received in the aerosol-generating material 3, the article 1 is also more securely held by the filter rod 25. This makes the article 1 and the device 100 easier to use and also safer, as the article 1 may be less likely to be dislodged from the device 100 during use.

The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided as representative examples of embodiments only, and are not exhaustive and/or exclusive. It will be understood that the advantages, embodiments, examples, functions, features, structures and/or other aspects described herein are not to be considered limiting the scope of the invention as defined by the claims or limiting equivalents of the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope of the invention as defined by the claims. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, the appropriate combinations of the disclosed elements, components, features, parts, steps, means, and the like, in addition to those specifically described herein. In addition, the present disclosure may include other inventions not presently claimed but which may be claimed in the future.

Claims

1. An article for use in a non-combustible aerosol-providing system comprising an aerosol-providing device, the article comprising a rod of aerosol-generating material having a distal end for insertion into the non-combustible aerosol-providing device such that a heating element of the device extends into the rod of aerosol-generating material through the distal end, wherein the article comprises a cavity extending from the distal end into the rod of aerosol-generating material in a longitudinal direction to receive the heating element.

2. The article of claim 1, comprising a mouth end opposite the distal end, the mouth end configured to be placed between the lips of a user when the distal end is inserted into a non-combustible sol providing device.

3. An article according to claim 2, wherein a cooling segment is located between the aerosol-generating material and the mouth end portion.

4. The article of claim 3, wherein a filter segment is located between the cooling segment and the mouth end portion.

5. An article according to any preceding claim, wherein the cavity extends the entire length of the aerosol-generating material.

6. An article according to any preceding claim, wherein the cavity is coaxial with a longitudinal axis of the article.

7. An article according to claim 6, wherein the aerosol-generating material comprises a tube.

8. The article of claim 7, wherein the tube comprises an inner surface and a profile extending in a longitudinal direction is formed in the surface.

9. The article of claim 8, wherein the profile comprises a spiral groove or recess.

10. The article of claim 8, wherein the profile comprises a linear groove or recess.

11. An article according to any preceding claim, wherein a plurality of cavities extend from the distal end into the aerosol-generating material.

12. The article of claim 11, wherein one or more of the cavities are disposed about the longitudinal axis.

13. An article according to claim 11 or claim 12, wherein one of the cavities is coaxial with the longitudinal axis of the aerosol-generating material.

14. An article according to any preceding claim, wherein the or each cavity has a non-circular cross-section.

15. An article according to any preceding claim, wherein the or each cavity has a non-uniform cross-section in the longitudinal direction.

16. An article according to claim 15, wherein the or each cavity tapers in a longitudinal direction.

17. An article according to claim 16, wherein the or each cavity tapers to narrow in a direction away from the distal end.

18. The article of any preceding claim, comprising a filter rod at the distal end.

19. An article according to claim 18, wherein the filter rod abuts the aerosol generating material.

20. An article according to claim 18 or claim 19, comprising a passageway in the filter rod, the passageway being positioned to correspond to the cavity extending in the aerosol-generating material.

21. The article of claim 20, wherein the passageway is a slit or groove in the filter rod.

22. The article of any one of claims 18 to 21, wherein the filter rod is formed from gathered paper, and optionally curled paper.

23. An article according to any preceding claim, comprising a layer of material on the inner wall of the cavity.

24. The article of claim 23, wherein the layer of material is a gel, an amorphous solid, or a layer of sheet material such as paper.

25. An article according to claim 24, wherein the layer of material is another layer of aerosol-generating material different from the aerosol-generating material 3.

26. The article of claim 23, wherein the layer of material comprises a thermally conductive material.

27. The article of claim 26, wherein the layer of material comprises a metal or metal alloy, a polymer ceramic, or graphite.

28. A system comprising a non-combustible sol providing device having a heating element; and an article comprising a rod of aerosol-generating material having a distal end for insertion into a non-combustible aerosol-providing device such that the heating element of the device extends into the aerosol-generating material through the distal end, wherein a cavity extends into the rod of aerosol-generating material in a longitudinal direction from the distal end to receive the heating element.

29. The system of claim 28, wherein the heating element and the cavity each have the same cross-sectional shape.

30. The system of claim 28 or claim 29, wherein the heating element fits or is interference fit in the cavity.

31. A system according to claim 28, wherein the heating element and the cavity each have a different cross-sectional shape such that a passageway 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 with a cross-section complementary to the cross-section of the heating element such that the heating element is received within the portion, the cavity further comprising at least one lobe extending from the portion to form the passageway.

33. A system according to any one of claims 28 to 32, wherein the aerosol-generating material has a longitudinal axis and the cavity to receive the heating element is a central cavity extending along the longitudinal axis.

34. A system according to claim 33, comprising a plurality of additional cavities extending into the aerosol-generating material from the distal end, wherein the additional cavities surround the central cavity and form an open passageway through the aerosol-generating material when the heating element is received in the central cavity.

35. A method of manufacturing an article comprising a rod of aerosol-generating material having a distal end for insertion into a non-combustible sol providing device, the method comprising extruding the aerosol-generating material through a die head and over a mandrel to form a cavity extending through the aerosol-generating material.

36. A method according to claim 34, wherein the mandrel is shaped to provide a correspondingly shaped cavity in the aerosol generating material.

37. A method of manufacturing an article comprising an aerosol-generating material, the article having a distal end for insertion into a non-combustible aerosol-providing device, the method comprising moulding the aerosol-generating material around a precursor.

38. A method according to claim 36, wherein the precursor is shaped to provide a correspondingly shaped cavity in the aerosol-generating material.