CN117897060A

CN117897060A - Article for use in a non-combustible sol supply system

Info

Publication number: CN117897060A
Application number: CN202280043141.4A
Authority: CN
Inventors: 杰里米·坎贝尔
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2021-06-18
Filing date: 2022-06-17
Publication date: 2024-04-16
Also published as: JP2024523255A; BR112023026099A2; KR20240013235A; WO2022263842A1; US20240284962A1; EP4355134A1; GB202108822D0

Abstract

An article (1) for use with a non-combustible sol supply device (100) comprises a body of aerosol generating material (3) having at least one of: a recess (3 a) extending from the distal end (1 a) of the article (1) and a cavity within the body of aerosol-generating material (3). The cross-sectional area of the recess (3 a) or cavity decreases along the longitudinal axis (X-X1) of the article. An article is also described comprising a body (17) of aerosol-generating material having a longitudinal axis, the article having a first portion having a first cross-sectional area of the aerosol-generating material perpendicular to the longitudinal axis and a second portion having a second cross-sectional area of the aerosol-generating material perpendicular to the longitudinal axis, the second cross-sectional area being at least 5% greater than the first cross-sectional area. A body of aerosol-generating material is also described, the body comprising a heatable element (13) in the shape of a cone, a truncated cone, a pyramid or a truncated pyramid. Systems and methods of manufacture including the articles are also described.

Description

Article for use in a non-combustible sol supply system

Technical Field

The present invention relates to an article for use in a non-combustible aerosol provision system, a body of aerosol generating material, an aerosol provision system and a method of forming a body of aerosol generating material.

Background

Some tobacco industry products produce aerosols that are inhaled by the user during use. For example, a tobacco heating device heats an aerosol-generating substrate (such as tobacco) to form an aerosol by heating, rather than burning, the substrate. Such tobacco industry products typically include a mouthpiece through which the aerosol passes into the mouth of the user.

Disclosure of Invention

According to embodiments described herein, in a first aspect there is provided an article for use with a non-combustible sol supply device, the article comprising a body of aerosol generating material, the body comprising at least one of:

a recess (recess) extending from a distal end of the article; and

A cavity within the body of aerosol-generating material,

Wherein the cross-sectional area of the groove or cavity decreases along the longitudinal axis of the article.

According to embodiments described herein, in a second aspect, there is provided an article for use with a non-combustible aerosol-supplying device, the article comprising a body of aerosol-generating material having a longitudinal axis, the article comprising a first portion and a second portion, the first portion having a first cross-sectional area of the aerosol-generating material perpendicular to the longitudinal axis, and the second portion having a second cross-sectional area of the aerosol-generating material perpendicular to the longitudinal axis, the second cross-sectional area being at least 5% greater than the first cross-sectional area.

According to embodiments described herein, in a third aspect, there is provided a body of aerosol-generating material comprising a heatable element in the shape of a cone, a truncated cone, a pyramid, or a truncated pyramid.

According to embodiments described herein, in a fourth aspect, there is provided a body of aerosol-generating material comprising at least one of:

a recess extending from an end of the body of aerosol-generating material; and

A cavity within the body of aerosol-generating material,

According to an embodiment described herein, in a fifth aspect, there is provided a body of aerosol-generating material having a longitudinal axis, the body comprising a first portion and a second portion, the first portion having a first cross-sectional area of the aerosol-generating material perpendicular to the longitudinal axis, and the second portion having a second cross-sectional area of the aerosol-generating material perpendicular to the longitudinal axis, the second cross-sectional area being at least 5% greater than the first cross-sectional area.

According to embodiments described herein, in a sixth aspect there is provided an article for use with a non-combustible sol supply device, the article comprising a body of aerosol generating material according to the third, fourth or fifth aspect described above.

According to an embodiment described herein, in a seventh aspect, there is provided an aerosol provision system comprising an article according to the first, second or sixth aspect described above and an aerosol provision device.

According to embodiments described herein, in a seventh aspect, there is provided an aerosol provision system comprising:

An article comprising a body of aerosol-generating material, the body comprising an aerosol-generating material surface; and

An aerosol provision device comprising a heatable element, wherein the heatable element comprises a heating surface, wherein the aerosol generating material surface and the heating surface are arranged to combine together in use to provide a heat transfer region of at least about 60mm ², at least about 70mm ², at least about 80mm ², or at least about 90mm ² between the aerosol generating material and the heatable element.

According to an eighth aspect of embodiments described herein, there is provided a method of forming a body of aerosol-generating material, the method comprising:

forming a body of aerosol-generating material; and

A groove is provided extending from an end of the body of aerosol-generating material, wherein the cross-sectional area of the groove decreases along the longitudinal axis of the article.

According to an embodiment described herein, in a ninth aspect, there is provided a method of forming a body of aerosol-generating material, the method comprising:

generating a stream of aerosol-generating material;

a heatable element is inserted into the flow of aerosol-generating material, wherein the heatable element is in the shape of a cone, a truncated cone, a pyramid, or a truncated pyramid.

Drawings

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

FIG. 1a is a side cross-sectional view (side-on cross sectional view) of an article for use with a non-combustible aerosol supply device, the article including a recess;

FIG. 1b is a side cross-sectional view of another article for use with a non-combustible sol supply, in this example, the article including a recess having a layer of material on a surface thereof;

FIG. 2a is a side cross-sectional view of another article for use with a non-combustible sol supply device, in this example, the article including a heatable element;

FIGS. 2 b-2 e are side cross-sectional views of a heatable element used in the article of FIG. 2 a;

FIG. 3 is a side cross-sectional view of another article for use with a non-combustible sol supply device, in this example, the article including a heatable element having a layer of material on a surface thereof;

FIG. 4 is a simplified schematic diagram of components of an aerosol supply device;

fig. 5 is a cross-sectional view of the aerosol provision device of fig. 4 with the article of fig. 2a inserted therein;

FIG. 6 is a side cross-sectional view of a body of aerosol-generating material (in the form of a square-based pyramid) and an aerosol-supplying device for use with a non-combustible aerosol-supplying device; and

Fig. 7 and 8 are flowcharts illustrating respective methods of forming a body of aerosol-generating material.

Detailed Description

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

combustible sol supply systems such as cigarettes, cigarillos, cigars, tobacco for pipes or self-wrapping or self-making cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable materials);

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

An aerosol-free delivery system for delivering at least one substance orally, nasally, transdermally or otherwise to a user without forming an aerosol, including but not limited to lozenges, chewing gums, patches, inhalable powder-containing articles, and oral products (e.g., oral tobacco) comprising snuff or wet snuff, wherein the at least one substance may or may not comprise nicotine.

According to the present disclosure, a "non-combustible" aerosol provision system is a system in which the constituent aerosol-generating materials of the aerosol provision system (or components thereof) are non-combustible or burn to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible sol supply system, such as an electric (powered) non-combustible sol supply system.

In some embodiments, the non-combustible aerosol supply system is an electronic cigarette, also referred to as an electronic cigarette device (VAPING DEVICE) or electronic nicotine delivery system (END), but note that the presence of nicotine in the aerosol generating material is not required.

In some embodiments, the non-combustible sol supply system is an aerosol generating material heating system, also referred to as a heated non-combustion system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol supply system is a hybrid system for generating aerosols using a combination of aerosol generating materials, wherein one or more of the aerosol generating materials may be heated. Each aerosol-generating material may be, for example, in the form of a solid, liquid or gel, and may or may not contain 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, the non-combustible sol supply system may include a non-combustible sol supply device and a consumable for use with the non-combustible sol supply device.

In some embodiments, the present disclosure relates to a consumable comprising an aerosol generating material and configured for use with a non-combustible aerosol supply device. Throughout this disclosure, these consumables are sometimes referred to as articles of manufacture.

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

In some embodiments, a non-combustible sol supply system (such as a non-combustible sol supply thereof) may include a power source and a controller. The power source may be, for example, an electrical power source or an 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 the heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol supply system includes 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 supply device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material delivery assembly, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol modifier.

In some embodiments, the consumable comprises a substance to be delivered. The substance to be delivered may be an aerosol generating material or a material that is not intended to be aerosolized. Any material may comprise one or more active components, one or more flavours, one or more aerosol former materials and/or one or more other functional materials, where appropriate.

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 nutritional substances, 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 material.

In some embodiments, the active comprises nicotine. In some embodiments, the active comprises caffeine, melatonin, or vitamin B ₁₂.

As noted herein, the active substance may comprise or be derived from one or more plant materials or components, derivatives or extracts thereof. As used herein, the term "plant material" 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 a synthetically derived active compound naturally occurring in plant material. The material may be in the form of a liquid, gas, solid, powder, dust (dust), crushed particles, granules, pellets, chips, ribbons, sheets, or the like. Exemplary plants are tobacco, eucalyptus, star anise, cocoa, fennel, lemon grass, peppermint, spearmint, loyi Bai Si, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay, licorice (licorice), green tea, mate tea (mate), orange peel, papaya, rose, sage, tea (e.g., green tea or black tea), thyme, clove, cinnamon, coffee, fennel seed (pimpinella), basil, bay leaf, cardamom, coriander, fennel seed (cumin), nutmeg, oregano, red pepper powder, rosemary, saffron, lavender, lemon peel, peppermint juniper (juniper), elder flower, vanilla, holly, perilla, turmeric root powder, sandalwood, coriander leaf, bergamot, orange flower, myrtle, blackcurrant liqueur (cassis), valerian, spanish sweet pepper (pimento), nutmeg seed coating, damiana (damien), marjoram, olive, lemon mint, lemon basil, leek, caraway (carvi), verbena, tarragon, geranium, mulberry, ginseng, theanine, matrine, maca, south african kava, damiana (damiana), guarana (guarana), chlorophyll, monkey tree, or any combination thereof. Peppermint may be selected from the following mint varieties: peppermint (MENTHA ARVENTIS), mint cultivars (Mentha c.v.), egyptian mint (MENTHA NILIACA), peppermint (MENTHA PIPERITA), lemon-peppermint cultivars (MENTHA PIPERITA CITRATA c.v.), peppermint cultivars (MENTHA PIPERITA c.v.), spearmint (MENTHA SPICATA CRISPA), madder mint (Mentha cordifolia), peppermint (Mentha longifolia), macleaya She Fengli mint (Mentha suaveolens variegata), spearmint (Mentha pulegium), spearmint cultivars (MENTHA SPICATA c.v.), and apple mint (Mentha suaveolens).

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

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

In some embodiments, the active comprises or is derived from one or more plant materials or components, derivatives or extracts thereof, and the plant materials are selected from the group consisting of loyi Bai Si and fennel.

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

As used herein, the terms "flavor" and "flavoring" refer to materials that can be used to produce a desired taste, aroma, or other somatosensory sensation in an adult consumer product, as permitted by local regulations. They may include naturally occurring flavor materials, plant material extracts, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice (licorice), hydrangea, eugenol, white-bark magnolia leaf, chamomile, fenugreek, clove, maple, green tea, menthol, japanese mint, fennel seed (pimpinella), cinnamon, turmeric root powder, indian flavor, asian flavor, herbal, holly, cherry, berry, red berry, cranberry, peach, apple, orange, mango, citrus, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruit, scotch whiskey (Drambuie), bourbon whiskey (bourbon), scotch whiskey, juniper, tequila rum, spearmint, peppermint, lavender, aloe, cardamom, celery, casserole (cascarilla), nutmeg, sandalwood oil, bergamot, geranium, arabian tea (khat), nasval (naswar), betel nut leaf, hookah (shisha), pine, honey essence, rose oil, vanilla, lemon oil, orange flower, cherry blossom, cassia oil, caraway seed, colpitis, jasmine, ylang-ylang (ylang-ylang), sage, fennel, wasabi, multi-spice fruit (piment), ginger, coriander, coffee, peppermint oil of any mint genus, eucalyptus, star anise, cocoa, lemon grass, loyi Bai Si, flax, hazelnut, hibiscus, bay, mate tea (mate), orange peel, rose, tea (e.g., green tea or black tea), thyme, juniper, elderberry, basil, bay leaf, fennel seed, oregano, red pepper powder, rosemary, saffron powder, lemon peel, peppermint, perilla, turmeric, coriander leaf, myrtle, black currant liqueur, valerian, spanish sweet pepper, nutmeg seed coating, damiana, marjoram, olive, lemon mint, lemon basil, leek, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, 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, plant material, or breath fresheners. They may be imitation, synthetic or natural ingredients or mixtures thereof. They may be in any suitable form, for example liquid (such as oil), solid (such as powder) or gas.

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

In some embodiments, the flavoring agents may include sensates in addition to or in lieu of the aroma or gustatory nerves, which are intended to achieve somatosensory sensations that are chemically induced and perceived, typically by stimulating the fifth cranial nerve (trigeminal nerve), and these may include agents that provide heating, cooling, stinging, numbing effects. Suitable thermal effectors may be, but are not limited to, vanillyl diethyl 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 energized in any other manner. 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 flavours. The aerosol-generating material may be incorporated into an article for use in an aerosol-generating system.

As used herein, the term "tobacco material" refers to any material comprising 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 tobacco (cut tobacco), extruded tobacco, tobacco stems, tobacco flakes, 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 wrapper, a mouthpiece, a filter, and/or an aerosol modifier. The consumable may also include an aerosol generator (such as a heater) which, in use, emits heat to cause the aerosol generating material to generate an aerosol. The heater may for example comprise a combustible material (a material heatable by conduction) or a susceptor.

A susceptor is a material that can be heated by penetrating it with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material such that its penetration with a varying magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material such that its penetration with a varying magnetic field causes hysteresis heating of the heating material. The susceptor may be electrically conductive and magnetic such that the susceptor may 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 modifier is a substance typically located downstream of an 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 assembly operable to selectively release the aerosol modifier.

The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifiers may, for example, include one or more of flavors, 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 generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

The filamentary tow material described herein may comprise cellulose acetate tow. The filament tows may also be formed using other materials for forming fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly (1-4 butylene succinate) (PBS), poly (butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. The filament bundles may be plasticized with a suitable plasticizer (such as triacetin) where the material is a cellulose acetate bundle, or the bundles may be non-plasticized. The filament bundles may have any suitable gauge, such as fibers having a "Y" shape or other cross-section (such as an "X" shape), a filament denier of 2.5 to 15 denier per filament (DENIER PER FILAMENT), e.g., 8.0 to 11.0 denier per filament, and a total denier of 5,000 to 50,000, e.g., 10,000 to 40,000.

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

Fig. 1a is a side cross-sectional view of an article 1 for use with a non-combustible sol supply device 100.

The article 1 comprises a mouthpiece 2 and an aerosol-generating section connected to the mouthpiece 2. In this example, the aerosol-generating section comprises a body of aerosol-generating material 3 in the form of a cylindrical rod of aerosol-generating material. The body of aerosol-generating material 3 comprises a recess 3a extending from the distal end 1a of the article 1. The article 1 is generally rod-shaped and has a longitudinal axis as indicated by the dashed line X-X'. In this example, the cross-sectional area of the groove 3a decreases along the longitudinal axis of the article 1. The first portion of the aerosol-generating material at a location towards the broken line Y-Y' of the distal end 1a of the article has a first cross-sectional area of the aerosol-generating material perpendicular to the longitudinal axis. The second portion of aerosol-generating material at a location spaced from the distal end 1a of the article 1 by the dashed line Z-Z' has a second cross-sectional area of aerosol-generating material perpendicular to the longitudinal axis. The second cross-sectional area is at least 5% greater than the first cross-sectional area. For example, the second cross-sectional area may be at least 20%, at least 50%, or at least 100% greater than the first cross-sectional area.

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 from about 20mm to about 26mm.

In this example, the recess 3a has a substantially cone-shaped boundary. In alternative embodiments, the grooves may have other shapes, such as boundaries defining a shape that is substantially a truncated cone, pyramid, or truncated pyramid.

The article 1 is configured for use in a non-combustible sol supply device 100 comprising a heatable element 103 for insertion into a recess 3 a. In the present example, the article 1 is configured for receiving the heatable element 103 in a recess 3a of a rod of aerosol-generating material 3. In this example, the heatable element 103 has a surface defining a shape that substantially corresponds to the shape of the boundary of the recess 3a to provide a relatively large contact area between the heatable element 103 and the aerosol-generating material 3. In this example, at least a portion of the outer surface of the heatable element 103 is substantially defined as cone-shaped. In alternative embodiments, at least a portion of the outer surface of the heatable element 103 may have other shapes, such as a surface that is substantially frustoconical, pyramidal, or truncated pyramidal in shape. The contact area between the heatable element 103 and the aerosol-generating material 3 may be, for example, greater than 60mm ²70mm²80mm², or 90mm ². For example, for a groove 3a defining a cone-shaped inner boundary having a radius of 3.5mm and a depth of 8mm, the inclined height of the cone will be 8.73mm, and the inner surface area of the groove 3a is calculated as:

Inclined height xpir=8.73pi3.5=96 mm.

Advantageously, the variation of the cross-sectional area of the aerosol-generating material results in a variation of the thermal mass of the aerosol-generating material 3 at different longitudinal positions through the aerosol-generating material 3. Thus, the portion of the aerosol-generating material 3 closest to the distal end 1a of the article 1 reaches the aerosol-forming temperature faster than the portion of the aerosol-generating material 3 further from the distal end 1 a.

The body of aerosol-generating material 3 has a length of, for example, about 5mm to about 20mm, or about 8mm to about 15 mm. The grooves extend through at least 25%, 50% or 75% of the length of the body of aerosol-generating material 3. For example, for a body of aerosol-generating material 3 having a length of 12mm, the recess 3a may extend to 9mm or more of the body.

The maximum diameter of the recess 3a may be greater than 50%, or greater than 60%, or greater than 70% of the diameter of the body of aerosol-generating material 3.

The maximum diameter of the recess 3a may be less than 90%, or less than 80%, or less than 70% of the diameter of the body of aerosol-generating material 3, for example 50% to 90% of the diameter of the body of aerosol-generating material 3, or 60% to 90% of the diameter of the aerosol-generating material 3.

The minimum diameter of the groove 3a may be less than 20% of the maximum diameter of the groove 3a, or less than 10% of the maximum diameter of the groove 3 a.

In any of the embodiments described herein, the aerosol-generating material 3 may comprise an aerosol-generating material in sheet form, in extruded form, or in molded form. The aerosol-generating material 3 may for example comprise a plant-based material that is extruded and/or molded to form a body of aerosol-generating material. In one example, the aerosol-generating material 3 is formed from reconstituted tobacco material that is extruded into a rod shape and then shaped using a mandrel to include the grooves 3a described herein. In other examples, the aerosol-generating material 3 is formed from a reconstituted plant-based material that is extruded into a rod shape and then shaped using a mandrel to include the grooves 3a described herein. In other examples, the aerosol-generating material 3 is formed from a reconstituted plant or tobacco-based material that is formed in a mold to a desired shape, for example, including the grooves 3a described herein. Extrudable or moldable tobacco may be produced by a process such as that described in International patent publication No. WO2020148538, the disclosure of which is incorporated herein by reference.

The mouthpiece 2 comprises a cooling section 8 (also referred to as a cooling element) positioned directly 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 8 is in an abutting relationship with the source of aerosol generating material. In the present example, the mouthpiece 2 further comprises a body 6 of material downstream of the cooling section 8, and a hollow tubular element 4 downstream of the body 6 of material, at the mouth end of the article 1.

The cooling section 8 comprises a hollow channel having an inner diameter of about 1mm to about 4mm, for example about 2mm to about 4mm. 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 8. In this example, the cooling section 8 comprises a single hollow channel. In alternative embodiments, the cooling section may include multiple channels, such as 2,3, or 4 channels. In this example, the single hollow channel is substantially cylindrical, but in alternative embodiments other channel geometries/cross-sections may be used. The hollow channel may provide a space into which the aerosol sucked into the cooling section 8 may expand and cool.

The cooling section 8 may have a wall thickness in the radial direction, which may be measured, for example, using calipers. For a given outer diameter of the cooling section, the wall thickness of the cooling section 8 defines the inner diameter of the cavity surrounded by the wall of the cooling section 8. The cooling section 8 may have a wall thickness of at least about 1.5mm and at most about 2 mm. In this example, the cooling section 8 has a wall thickness of about 2 mm. In use, providing the cooling section 8 with a wall thickness in this range improves the retention of the source of aerosol-generating material in the aerosol-generating section by reducing longitudinal displacement of the strands and/or strips of aerosol-generating material when the aerosol generator is inserted into the article.

The cooling section 8 is formed from a filiform filament bundle. Other configurations may be used, such as parallel wound multi-ply paper with butt seams for forming the cooling section 8; or a helically wound paper layer, cardboard tube, tube formed using the paper (papier-macch) process, molded or extruded plastic tube, or the like. The cooling section 8 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 used.

The wall material of the cooling section 8 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 8. 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 material forming the cooling section 8 has a density of at least about 0.20 grams per cubic centimeter (g/cc), and preferably at least about 0.25g/cc. Preferably, the material forming the cooling section 8 has a density of less than about 0.80 grams per cubic centimeter (g/cc), more preferably less than 0.6g/cc. In some embodiments, the material forming the cooling section 8 has a density of 0.20 to 0.8g/cc, more preferably 0.3 to 0.6g/cc, or 0.4g/cc to 0.6g/cc, or about 0.5g/cc. These densities have been found to provide a good balance between the improved hardness provided by the denser material and minimizing the total weight of the article. For the purposes of the present invention, the "density" of the material forming the cooling section 8 refers to the density of any filament strand forming the element with the incorporation of any plasticizer. The density may be determined by dividing the total weight of the material forming the cooling section 8 by the total volume of the material forming the cooling section 8, wherein the total volume may be calculated using suitable measurements made (e.g., using calipers) of the material forming the cooling section 8. If necessary, a microscope may be used to measure the appropriate dimensions.

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

The cooling section 8 is located around the mouthpiece 2 and defines an air gap (air gap) within the mouthpiece 2, which acts as a cooling section. The air gap provides a chamber through which the heated volatile components generated by the rod of aerosol-generating material 3 flow. The cooling section 8 is hollow to provide a chamber for aerosol accumulation, but is sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacture and when the article 1 is used. The cooling section 8 provides a physical displacement between the aerosol-generating material 3 and the body 6 of material. The physical displacement provided by the cooling section 8 may provide a thermal gradient over the length of the cooling section 8.

Preferably, the mouthpiece 2 comprises a cavity having an internal volume of greater than 110mm ³. It has been found that providing at least this volume of cavity enables the formation of an improved aerosol. More preferably, the mouthpiece 2 comprises a cavity, for example formed within the cooling section 8, having an internal volume of more than 120mm ³, and still more preferably more than 130mm ³, allowing further improvements of the aerosol. In some examples, the internal cavity has a volume of about 130mm ³ to about 230mm ³, e.g., about 134mm ³ or 227mm ³.

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

When used, the aerosol-generating segment may exhibit a pressure drop of about 15 to about 40mm H ₂ O. In some embodiments, the aerosol-generating section exhibits a pressure drop of about 15 to about 30mm H ₂ O over the aerosol-generating section.

The aerosol-generating material may have a packing density (PACKING DENSITY) within the aerosol-generating section of from about 400mg/cm ³ to about 900mg/cm ³.

In this embodiment, the moisture impermeable wrapper 10 surrounds the rod of aerosol generating material and comprises aluminium foil. In other embodiments, the wrapper 10 comprises a paper wrapper, optionally including a barrier coating (barrier coating), such that the material of the wrapper is 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 with a thickness of about 6 m. In this example, the aluminum foil has a paper backing. However, in alternative arrangements, the aluminium foil may have other thicknesses, for example a thickness of 4 m to 16 m. 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 proper 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 package is preferably 20 m to 60 m, more preferably 30 m to 50 m. This may provide a package with suitable structural integrity and heat transfer characteristics.

In this example, the moisture impermeable wrapper 10 is also substantially impermeable to air. In alternative embodiments, the wrapper 10 preferably has a permeability of less than 100Coresta units, more preferably less than 60Coresta units. It has been found that a low permeability package, for example having a permeability of less than 100Coresta units, more preferably less than 60Coresta units, results in an improvement in aerosol formation in the aerosol generating material 3. The permeability of the wrapper 10 may be measured according to ISO 2965:2009, which relates to the determination of air permeability of the materials used as cigarette paper, filter plug wrap (filter plug wrap) and filter connecting paper (filter joining paper).

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

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

In this example, the body 6 of material is formed from a filamentary tow. In this example, the filament bundle used in the body 6 of the material had a denier per filament (d.p.f.) of 5 and a total denier of 25,000. In this example, the tow comprises plasticized cellulose acetate tow. The plasticizer used in the tow was about 9% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, a different material may be used to form the body 6 of material. For example, the body 6 may be formed of paper instead of tow, for example in a similar manner to paper filters known for use in cigarettes. For example, paper or other cellulose-based material may be provided as one or more portions of sheet material that is folded and/or rolled to form the body 6. The sheet may have a basis weight of 15gsm to 60gsm, for example 20 to 50 gsm. For example, the sheet may have a basis weight in any of the ranges 15 to 25gsm, 25 to 30gsm, 30 to 40gsm, 40 to 45gsm, and 45 to 50 gsm. Additionally or alternatively, the sheet material may have a width of 50mm to 200mm, for example 60mm to 150mm, or 80mm to 150 mm. For example, the sheet material may have a basis weight of 20 to 50gsm and a width of 80mm to 150 mm. For example, this may provide a cellulose-based body with an appropriate pressure drop for an article having the dimensions as described herein.

Alternatively, the body 6 may be formed of tows of other materials than cellulose acetate, such as polylactic acid (PLA), for use with filiform tows described herein, or similar materials. The tow is preferably formed from cellulose acetate. The tow (whether formed from cellulose acetate or other materials) preferably has a d.p.f. of at least 5. Preferably, in order to obtain a body 6 of sufficiently homogeneous material, the filament denier of the filament bundle does not exceed 12d.p.f., preferably does not exceed 11d.p.f., and still more preferably does not exceed 10d.p.f.

The total denier of the tows forming the body 6 of material is preferably at most 30,000, more preferably at most 28,000, and still more preferably at most 25,000. These total denier values provide a reduced proportion of tows in the cross-sectional area of the mouthpiece 2, which results in a lower pressure drop across the mouthpiece 2 than tows with higher total denier values. The tows preferably have a total denier of at least 8,000, more preferably at least 10,000 for proper stiffness of the body 6 of material. Preferably, the denier per filament is from 5 to 12 and the total denier is from 10,000 to 25,000. Preferably, the cross-sectional shape of the filaments of the tow is "Y" shaped, but other shapes, such as "X" shaped filaments, may be used in other embodiments with the same d.p.f. and total denier values as provided herein.

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

As shown in fig. 1a, the mouthpiece 2 of the article 1 comprises an upstream end 2a adjacent to the rod of aerosol-generating material 3 and a downstream end 2b remote from the rod of aerosol-generating material 3. At the downstream end 2b, the mouthpiece 2 has a hollow tubular element 4 formed of a filiform tow. Advantageously, it has been found that this significantly reduces the temperature of the outer surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece that is in contact with the consumer's mouth when the article 1 is in use. Furthermore, it has been found that the use of the tubular element 4 significantly reduces the temperature of the outer surface of the mouthpiece 2, even upstream of the tubular element 4. Without wishing to be bound by theory, it is assumed that this is due to the tubular element 4 guiding the aerosol closer to the centre of the mouthpiece 2, thus reducing the heat transfer from the aerosol to the outer surface of the mouthpiece 2.

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

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

Preferably, the hollow tubular element 4 has a density of at least about 0.25 grams per cubic centimeter (g/cc), more preferably at least about 0.3g/cc. Preferably, the hollow tubular element 4 has a density of less than about 0.75 grams per cubic centimeter (g/cc), more preferably less than 0.6g/cc. In some embodiments, the hollow tubular element 4 has a density of 0.25 to 0.75g/cc, more preferably 0.3 to 0.6g/cc, and more preferably 0.4g/cc to 0.6g/cc, or about 0.5g/cc. These densities have been found to provide a good balance between the improved hardness provided by denser materials and the lower heat transfer properties of lower density materials. For the purposes of the present invention, the "density" of the hollow tubular element 4 refers to the density of the filiform strands forming the element in the presence of any plasticizer incorporated. The density may be determined by dividing the total weight of the hollow tubular element 4 by the total volume of the hollow tubular element 4, wherein the total volume may be calculated using suitable measurements of the hollow tubular element 4 (e.g. using calipers). If necessary, the appropriate dimensions can be measured using a microscope.

The filament bundles forming the hollow tubular member 4 preferably have a total denier of less than 45,000, more preferably less than 42,000. This total denier has been found to allow the formation of less dense tubular elements 4. Preferably, the total denier is at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filiform filament bundles forming the hollow tubular element 4 have a total denier of 25,000 to 45,000, more preferably 35,000 to 45,000. Preferably, the cross-sectional shape of the tow filament is a "Y" shape, but other shapes, such as an "X" shaped filament, may be used in other embodiments.

The filament bundles forming the hollow tubular member 4 preferably have a denier per filament of greater than 3. This denier per filament has been found to allow the formation of a less dense tubular element 4. Preferably, the denier per filament is at least 4, more preferably at least 5. In a preferred embodiment, the filament bundles forming the hollow tubular member 4 have a denier per filament of from 4 to 10, more preferably from 4 to 9. In one example, the filiform tows forming the hollow tubular element 4 have 7.3Y36,000 tows formed from cellulose acetate and containing 18% of a plasticizer, such as triacetin.

The hollow tubular element 4 preferably has an inner diameter greater than 3.0 mm. Smaller diameters less than this may result in an increase in the velocity of the aerosol through the mouthpiece 2 to the mouth of the consumer beyond the desired velocity, causing the aerosol to become overheated, for example to a temperature greater than 40 or greater than 45 . More preferably, the hollow tubular element 4 has an inner diameter of more than 3.1mm, and still more preferably more than 3.5mm or 3.6 mm. In one embodiment, the inner diameter of the hollow tubular unit 4 is about 4.7mm.

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

In the present example, a second forming paper 9 is used to combine the first hollow tubular element 4, the body 6 of material and the cooling section 8, the second forming paper 9 being wrapped around all three sections. Preferably, the second forming paper 9 has a basis weight of less than 50gsm, more preferably about 20gsm to 45 gsm. Preferably, the second forming paper 9 has a thickness of 30 m to 60 m, more preferably 35 m to 45 m. The second forming paper 9 is preferably a non-porous forming paper having a permeability of less than 100Coresta units, for example less than 50Coresta units. However, in alternative embodiments, the second forming paper 9 may be a porous forming paper, for example having a permeability of more than 200Coresta units.

The tipping paper 5 is wrapped around the entire length of the mouthpiece 2 and over a portion of the stem of the aerosol-generating material 3 and has adhesive on its inner surface to connect the mouthpiece 2 and stem 3. In this example, the rod of aerosol-generating material 3 is wrapped in a wrapper 10, which forms a first wrapper and the tipping paper 5 forms an outer wrapper which extends 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 may extend only partially over the stem of the aerosol-generating material.

In this example, the tipping paper 5 extends 5mm over the rod of aerosol-generating material 3, but alternatively it may extend 3mm to 10mm, or more preferably 4mm to 6mm, over the rod 3 to provide a secure attachment between the mouthpiece 2 and the rod 3. The tipping paper may have a basis weight of greater than 20gsm (e.g., greater than 25 gsm) or preferably greater than 30gsm (e.g., 37 gsm).

The article has a ventilation level of about 10% of the aerosol inhaled through the article. In alternative embodiments, the article may have a ventilation level of 1% to 20%, for example 1% to 12%, of the aerosol inhaled through the article. Ventilation at these levels helps to increase the consistency of the aerosol inhaled by the user at the mouth end 2b, while at the same time 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 8, which has been found to be particularly beneficial in assisting the aerosol generation process. Ventilation is provided by perforations 12, in this example perforations 12 are formed as a single row of laser perforations positioned 13mm from downstream mouth end 2b of mouthpiece 2. In alternative embodiments, two or more rows of vent perforations may be provided. These perforations pass through the tipping paper 5, the second forming paper 9 and the cooling section 8. In alternative embodiments, ventilation may be provided into the mouthpiece at other locations, for example to the body 6 of material or the first tubular element 4. Preferably, the article is configured such that the perforations are disposed about 28mm or less from the upstream end of the article 1, preferably 20mm to 28mm from the upstream end of the article. In this example, the aperture is disposed about 25mm from the upstream end of the article.

Fig. 1b is a side cross-sectional view of another article 1' for use with a non-combustible sol supply device, in this example an article comprising a recess 3a having a layer of material 14 on its surface. The body of aerosol-generating material 3 is thus separated from the recess 3a by the layer of material 14. In this example, the material layer 14 is formed from a sheet material that includes an aerosol modifier. The aerosol modifier may be sprayed onto the sheet material, which may be formed in a shape corresponding to the inner surface of the groove 3a and adhered to the outer surface of the groove 3a. The sheet material 14 may be formed of paper, amorphous solid material, or other material that may form a sheet material, such as woven (or nonwoven) material, polylactic acid (PLA), or the like. The material layer 14 may seal or partially seal the end of the rod of aerosol generating material 3 and may additionally or alternatively provide a source of aerosol modifier, such as those described herein. The material layer 14 may alternatively or additionally comprise an aerosol former as described herein, such as glycerol and/or propylene glycol.

Fig. 2a is a side cross-sectional view of another article 1 "for use with a non-combustible sol supply device, in this example the article 1" comprising a heatable element 13.

In this example, the heatable element 13 is cone-shaped. In other examples, the heatable element 13 may have the general shape of a truncated cone, pyramid, or truncated pyramid, or another shape having a base at a first end and decreasing in size in one or two dimensions as it extends toward a smaller second end. The heatable element 13 may be a susceptor as defined herein for use with a device capable of generating an electromagnetic field for heating the susceptor, as described in more detail below. The heatable element 13 may have the same shape and dimensions as the inner surface of the recess 3a described herein. The heatable element 13 may be formed of a heating material capable of generating heat when exposed to a varying electromagnetic field. In some embodiments, the heating material may be a metal (such as aluminum, gold, or silver), for example, in the form of a sheet, optionally with a backing layer of paper or other material. In some embodiments, the heating material may be a ferromagnetic material. Examples of ferromagnetic materials include metals (such as iron, nickel, and cobalt) and metal alloys (such as certain types of stainless steel, e.g., grade 430 stainless steel). In some embodiments, the heating material may be ferromagnetic stainless steel, for example in the form of a sheet or foil.

Fig. 2 b-2 e are side cross-sectional views of a heatable element for use in the article of fig. 2a, which may be formed from the heating material described above in connection with heatable element 13 of fig. 2 a. Fig. 2b shows the first heatable element 13 of fig. 2a, defining the general shape of a cone. Fig. 2c shows a second heatable element 13', which in this case contains a second aerosol-generating material 16 in a recess formed by the cone of the heatable element 13'. The second aerosol-generating material 16 may be any aerosol-generating material described herein, such as a tobacco material, an amorphous solid material, a gel, or other material capable of generating an aerosol. Alternatively or additionally, the second aerosol-generating material 16 may be composed of, or comprise, an aerosol-modifying agent.

Fig. 2d shows a third heatable element 13", which in this case comprises a solid cone of heating material.

Fig. 2e shows a fourth heatable element 13' ", in this case similar to the first heatable element 13 of fig. 2a and 2b, except that there is an aperture at the apex of the cone which allows the aerosol to pass through the aperture in use. This may be used to reduce the inhalation resistance of the section of the article providing the aerosol-generating material and enhance the release of the aerosol from within the recess formed by the cone.

Another article 1 "of fig. 2a comprises a mouthpiece 2' comprising a capsule. An aerosol modifier is provided within the body 6 of material, in this example in the form of a capsule 11, and an oil resistant (oil resistance) first forming paper 7' surrounds the body 6 of material. In other examples, the aerosol modifier may be provided in other forms, such as a material injected into the body 6 of material or a material provided on a wire (e.g., a wire carrying a flavor or other aerosol modifying agent), which may also be disposed within the body 6 of material.

The capsule 11 may comprise a rupturable capsule, such as a capsule having a solid frangible outer shell surrounding a liquid payload (payload). In this example, a single capsule 11 is used. The capsule 11 is completely embedded in the body 6 of material. In other words, the capsule 11 is completely surrounded by the material forming the body 6. In other examples, a plurality of rupturable capsules, for example 2, 3 or more rupturable capsules, may be disposed within the body of material 6. The length of the body 6 of material may be increased to accommodate the number of capsules required, for example a body of length 15mm to 20mm for accommodating two capsules. In the instance where multiple capsules are used, the individual capsules may be identical to each other or may differ from each other in size and/or capsule payload. In other examples, multiple bodies 6 of material may be provided, wherein each body contains one or more capsules.

The capsule 11 has a core-shell structure. In other words, the capsule 11 includes a housing that encapsulates a liquid agent (e.g., a flavor or other agent), which may be any of the flavor or aerosol modifiers described herein. The outer shell of the capsule may be ruptured by a user to release flavouring or other agents into the body 6 of material. The first plug wrap 7' may include a barrier coating to render the plug wrap material substantially impermeable to the liquid payload of the capsule 11. Alternatively or in addition, the second forming paper 9 and/or tipping paper 5 may include a barrier coating to render the material of the forming paper and/or tipping paper substantially impermeable to the liquid payload of the capsule 11.

In this example, the capsule 11 is spherical and has a diameter of about 3 mm. In other examples, other shapes (i.e., non-spherical) and other sizes of capsules may be used. For example, the capsule may have a diameter of less than 4mm, or less than 3.5mm, or less than 3.25 mm. In alternative embodiments, the capsule may have a diameter greater than about 3.25mm, such as greater than 3.5mm or greater than 4 mm. The total weight of the capsule 11 may be in the range of about 10mg to about 50 mg.

Fig. 3 is a side cross-sectional view of another article 1' "for use with a non-combustible sol supply device, in this example, the article including a heatable element 13" ", having a layer of material 14 on a surface thereof. The material layer 14 may be the same as the material layer 14 described with reference to the article 1' of fig. 1b, except that it may coat or cover one or both of the upstream and downstream surfaces of the heatable element 13 ".

Fig. 4 is a simplified schematic diagram of an aerosol provision device 200 for use with the articles 1 "and 1'" of fig. 2a and 3 comprising a heatable element. The device 200 comprises a magnetic field generator 203, which magnetic field generator 203 comprises in this example a coil mounted in a housing 201 of the device 200 and surrounding an area 202 of the device 200 for receiving an article. As shown in fig. 5, the article 1 "of fig. 2a is inserted into the region 202 of the device 200 such that the heatable element 13 of the article 1' may be exposed to the magnetic field generated by the magnetic field generator 203.

Fig. 5 is a side cross-sectional view of a body 17 of aerosol-generating material for use with a non-combustible aerosol-supplying device 300, the body being in the form of a positive quadrangular pyramid.

The body 17 has a longitudinal axis as indicated by the dashed line X-X'. In this example, the cross-sectional area of the body 17 increases along the longitudinal axis of the body 17. The first portion of aerosol-generating material at a location towards the apex of the body 17, indicated by the dashed line Y-Y', has a first cross-sectional area of aerosol-generating material perpendicular to the longitudinal axis. The second portion of aerosol-generating material at a location spaced from the apex of the body 17 by the dashed line Z-Z' has a second cross-sectional area of aerosol-generating material perpendicular to the longitudinal axis. The second cross-sectional area is at least 5% greater than the first cross-sectional area. For example, the second cross-sectional area may be at least 20%, at least 50%, or at least 100% greater than the first cross-sectional area.

In this example, the body 17 has a maximum circumference of about 30 mm. In alternative embodiments, the body 17 may have any suitable maximum circumference, such as about 20mm to about 40mm.

In this example, the body 17 is substantially pyramid-shaped. In alternative embodiments, the body 17 may have other shapes, such as defining boundaries that are substantially in the form of cones, truncated cones, pyramids, or truncated pyramids, wherein the pyramids may have triangular, square, pentagonal, or hexagonal bases.

In this example, the body 17 includes a hollow passage 17a extending therethrough. In this example, the hollow passage passes through the longitudinal axis. The body 17 may be formed of a permeable aerosol generating material and in this case, a hollow passage may not be required and may be omitted. The channel 17a may have a diameter of, for example, about 0.5mm to about 5mm, for example, about 1mm to about 4mm. In some examples, the diameter of the channel 17a is about 2mm, about 3mm, or about 4mm.

The body 17 is configured for use in a non-combustible sol supply device 300 comprising a heatable element 303 for contact with a heatable outer surface 17b of the body 17. In this example, the device includes a recess or receptacle 302 for receiving the body 17. In this example, the heatable element 303 has a surface defining a shape that substantially corresponds to the shape of the heatable outer surface 17b of the body 17 to provide a relatively large contact area between the heatable element 303a and the aerosol-generating material of the body 17. The contact area between the heatable element 303 and the aerosol generating material of the body 17 may be, for example, greater than 60mm ²70mm²80mm² or 90mm ². For example, for a body 17 defining a cone shape with a radius of 3.5mm and a depth of 8mm, the inclined height of the cone would be 8.73mm, and the heatable outer surface 17b would be calculated as:

Inclined height xpir=8.73pi3.5=96 mm.

Fig. 7 is a flow chart illustrating a method of forming a body of aerosol-generating material 3 as shown in fig. 1 b. In step S301, a body of aerosol generating material is formed, for example using an extrusion or molding process as described herein. In step S302, a recess extending from an end of the body of aerosol-generating material is formed, for example using a mandrel. The cross-sectional area of the groove decreases along the longitudinal axis of the article.

Fig. 8 is a flow chart illustrating a method of forming a body of aerosol-generating material 3 comprising a heatable element 13 as shown in fig. 2 a. In step S401, a stream of aerosol generating material is generated. In step S402, a heatable element is inserted into the flow of aerosol-generating material, wherein the heatable element is in the shape of a cone, a truncated cone, a pyramid or a truncated pyramid.

The aerosol-generating material 3 may be provided in the form of a sheet or shredded sheet comprising a first surface and a second surface opposite the first surface. The dimensions of the first surface and the second surface are uniform. The first and second surfaces of the sheet or shredded sheet may have any shape. For example, the first and second surfaces may be square, rectangular, oval (oblong), or circular. Irregular shapes are also contemplated.

The first and/or second surfaces of the sheet or shredded sheet may be relatively uniform (e.g., they may be relatively smooth), or they may be non-uniform or irregular. For example, the first surface and/or the second surface of the sheet may be textured or patterned to define a relatively rough surface. In some embodiments, the first surface and/or the second surface is relatively rough.

The smoothness of the first and second surfaces may be affected by a number of factors, such as the area density of the sheet or shredded sheet, the nature of the components comprising the aerosol-generating material, or whether the surfaces of the material have been treated, e.g. embossed, scored or otherwise altered, to impart a pattern or texture thereto.

The areas of the first and second surfaces are each defined by a first dimension (e.g., width) and a second dimension (e.g., length). The measurement of the first and second dimensions may have a ratio of 1:1 or greater than 1:1, so the sheet or shredded sheet may have an "aspect ratio" of 1:1 or greater than 1:1. As used herein, the term "aspect ratio" is the ratio of a measurement of a first dimension of a first surface or a second surface to a measurement of a second dimension of the first surface or the second surface. By "aspect ratio of 1:1" is meant that the measurement of the first dimension (e.g., width) and the measurement of the second dimension (e.g., length) are the same. By "aspect ratio greater than 1:1" is meant that the measurement of the first dimension (e.g., width) and the measurement of the second dimension (e.g., length) are different. In some embodiments, the first and second surfaces of the sheet or shredded sheet have an aspect ratio of greater than 1:1, such as 1:2, 1:3, 1:4, 1:5, 1:6, 1:7, or greater.

The shredded sheet material may include one or more strands (or one or more strips) of aerosol-generating material. In some embodiments, the shredded sheet material includes a plurality of strands or strips (e.g., two or more) of aerosol-generating material. The strands or strips of aerosol-generating material may have an aspect ratio of 1:1. In one embodiment, the strands or strips of aerosol-generating material have an aspect ratio of greater than 1:1. In some embodiments, the strands or strips of aerosol-generating material have an aspect ratio of from about 1:5 to about 1:16, or about 1:5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:11, or 1:12. In the case where the aspect ratio of the strand or strand is greater than 1:1, the strand or strand includes a longitudinal dimension or length extending between a first end of the strand or strand and a second end of the strand or strand.

Where the shredded sheet material includes multiple strands or strips of material, the size of each strand or strip may vary from strand to strand or strip to strip. For example, the shredded sheet material may include a population of first strands or strips and a population of second strands or strips, wherein the strands or strips of the first population are of a different size than the strands or strips of the second population. In other words, the multiple strands or strips may include a first population of strands or strips having a first aspect ratio and a second population of strands or strips having a second aspect ratio different from the first aspect ratio.

The first dimension or cut width of the strands or strips of aerosol-generating material is from 0.9mm to 1.5mm. When strands or strips of aerosol-generating material having a cut width of less than 0.9mm are incorporated into an article for use in a non-combustible sol supply system, the pressure drop across the article may increase to a level that makes the article unsuitable for use in a non-combustible sol supply device. However, if the cut width of the strands or strips exceeds 2mm (e.g., greater than 2 mm), it can be challenging to insert the strands or strips of aerosol-generating material into the article during manufacture of the article. In a preferred embodiment, the cut width of the strands or strips of aerosol-generating material is from about 1mm to 1.5mm.

The strands or strips of material are formed by shredding sheets of aerosol generating material. For example, in a cross-cut shredding process, a sheet of aerosol generating material may be cut in the same direction as the width to define the cut length of strands or strips of aerosol generating material in addition to the cut width. The cut length of the shredded aerosol-generating material is preferably at least 5mm, for example at least 10mm, or at least 20mm. The cut length of the shredded aerosol-generating material may be less than 60mm, less than 50mm, or less than 40mm.

In some embodiments, a plurality of strands or strips of aerosol-generating material are provided, and at least one of the plurality of strands or strips of aerosol-generating material has a length of greater than about 10 mm. Alternatively or in addition, at least one of the plurality of strands or strips of aerosol-generating material may have a length of from about 10mm to about 60mm, or from about 20mm to about 50 mm. Each of the plurality or plurality of strands of aerosol-generating material may have a length of from about 10mm to about 60mm, or from about 20mm to about 50 mm.

The sheet or shredded sheet of aerosol-generating material has a thickness of at least about 100 m. The sheet or shredded sheet may have a thickness of at least about 120 m, 140 m, 160 m, 180 m, or 200 m. In some embodiments, the sheet or shredded sheet has a thickness of about 150 m to about 300 m, about 151 m to about 299 m, about 152 m to about 298 m, about 153 m to about 297 m, about 154 m to about 296 m, about 155 m to about 295 m, about 156 m to about 294 m, about 157 m to about 293 m, about 158 m to about 292 m, about 159 m to about 291 m, or about 160 m to about 290 m. In some embodiments, the sheet or shredded sheet has a thickness of about 170 m to about 280 m, about 180 to about 270 m, about 190 to about 260 m, about 200 m to about 250 m, or 210 m to about 240 m.

The thickness of the sheet or shredded sheet may vary between the first surface and the second surface. In some embodiments, a single strip or segment of aerosol-generating material has a minimum thickness of about 100 m over its area. In some cases, individual strips or segments of aerosol-generating material have a minimum thickness of about 0.05mm or about 0.1mm over its area. In some cases, individual strips, strands or segments of aerosol-generating material have a maximum thickness of about 1.0mm over its area. In some cases, a single strip or sheet of aerosol-generating material has a maximum thickness of about 0.5mm or about 0.3mm over its area.

The thickness of the sheet may be determined using ISO 534:2011 "determination of paper and board thickness".

If the sheet or shredded sheet of aerosol-generating material is too thick, the heating efficiency may be compromised. This may have an adverse effect on power consumption in use (e.g. power consumption for releasing flavour from aerosol generating material). Conversely, if the aerosol-generating material is too thin, it may be difficult to manufacture and handle; very thin materials can be more difficult to cast and can be brittle, thereby compromising aerosol formation in use.

It is hypothesized that if the sheet or shredded sheet of aerosol-generating material is too thin (e.g. less than 100 m), it may be necessary to increase the cut width of the shredded sheet to achieve adequate packaging of the aerosol-generating material when incorporated into the article. As previously mentioned, increasing the cut width of the shredded sheet increases the pressure drop, which is undesirable.

It is assumed that a sheet or shredded sheet having a thickness of at least about 100 m and an areal density of from about 100g/m ² to about 250g/m ² is not prone to tearing, splitting or otherwise deforming during its manufacture. A thickness of at least about 100 m may have a positive effect on the overall structural integrity and strength of the sheet or shredded sheet. For example, it may have good tensile strength and thus be relatively easy to process.

The thickness of the sheet or shredded sheet is also believed to have an effect on its areal density. That is, increasing the thickness of the sheet or shredded sheet may increase the areal density of the sheet or shredded sheet.

Conversely, reducing the thickness of the sheet or shredded sheet may reduce the areal density of the sheet or shredded sheet. For the avoidance of doubt, where reference is made herein to an area density, that area density is an average area density calculated for a given strip, strand, segment or sheet of aerosol-generating material, that area density is calculated by measuring the surface area and weight of the given strip, strand, segment or sheet of aerosol-generating material.

The sheet or shredded sheet of aerosol-generating material has an areal density of from about 100g/m ² to about 250g/m ². The sheet or shredded sheet may have an areal density of about 110g/m ² to about 240g/m ², about 120g/m ² to about 230g/m ², about 130g/m ² to about 220g/m ², or about 140g/m ² to about 210g/m ². In some embodiments, the sheet or shredded sheet has an areal density of about 130g/m ² to about 190g/m ², about 140g/m ² to about 180g/m ², about 150g/m ² to about 170g/m ². In a preferred embodiment, the sheet or shredded sheet has an areal density of about 160g/m ².

An areal density of about 100g/m ² to about 250g/m ² is believed to contribute to the strength and flexibility of the sheet or shredded sheet. A rod comprising a shredded sheet of aerosol-generating material having an areal density of about 180gsm and a minimum thickness of 220-230 m may be packaged such that the aerosol-generating material remains in place within the rod while maintaining a desired weight of tobacco material (e.g., about 300 mg) within the rod and delivering acceptable organoleptic properties (e.g., taste and smell) when heated in a non-combustible aerosol supply device.

The flexibility of a sheet or shredded sheet is believed to depend at least in part on the thickness and areal density of the sheet or shredded sheet. Thicker or shredded sheets may be less flexible than thinner or shredded sheets. Also, the greater the areal density of the sheet, the less flexible the sheet or shredded sheet. It is believed that the combination of thickness and areal density of the aerosol-generating materials described herein provides a relatively flexible sheet or shredded sheet. Such flexibility may yield various advantages when the aerosol generating material is incorporated into an article for use in a non-combustible aerosol delivery device. For example, the strands or strips can be easily deformed and bent when the aerosol generator is inserted into the aerosol-generating material, thereby facilitating insertion of the aerosol generator (e.g., heater) into the material, and also improving retention of the aerosol generator by the aerosol-generating material.

The areal density of the sheet or shredded sheet of aerosol-generating material affects the roughness of the first and second surfaces of the sheet or shredded sheet. By varying the area density, the roughness of the first surface and/or the second surface may be adjusted.

The average bulk density of a sheet or shredded sheet of aerosol-generating material may be calculated from the thickness of the sheet and the areal density of the sheet. The average bulk density may be greater than about 0.2g/cm ³, about 0.3g/cm ³, or about 0.4g/cm ³. In some embodiments, the average bulk density is from about 0.2g/cm ³ to about 1g/cm ³, from about 0.3g/cm ³ to about 0.9g/cm ³, from about 0.4g/cm ³ to about 0.9g/cm ³, from about 0.5g/cm ³ to about 0.9g/cm ³, or from about 0.6g/cm ³ to about 0.9g/cm ³.

According to one aspect of the present disclosure, there is provided an aerosol-generating material comprising a sheet or shredded sheet of aerosol-generating material comprising tobacco material, an aerosol-former material, and a binder, wherein the sheet or shredded sheet has a density of greater than about 0.4g/cm ³. In some embodiments, the density is from about 0.4g/cm ³ to about 2.9g/cm ³, from about 0.4g/cm ³ to about 1g/cm ³, from about 0.6cm ³ to about 1.6cm ³, or from about 1.6cm ³ to about 2.9cm ³.

The sheet or shredded sheet may have a tensile strength of at least 4N/15 mm.

When the sheet or shredded sheet has a tensile strength of less than 4N/15mm, the sheet or shredded sheet may tear, break or otherwise deform during its manufacture and/or subsequent incorporation into articles for use in a non-combustible sol supply system. Tensile strength can be measured using ISO 1924:2008.

Aerosol-generating materials include plant-based materials, such as tobacco materials. The sheet or shredded sheet of aerosol-generating material comprises a plant-based material, such as a tobacco material.

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

The density of the tobacco material has an effect on the rate of heat transfer through the material, and at lower densities (e.g. less than 900 mg/cc) the heat transfer through the material is slower and therefore enables a more sustained release of aerosol.

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

The reconstituted tobacco material may be provided in the form of cut sheets. The sheet of reconstituted tobacco material may have any suitable thickness. The reconstituted tobacco material may have a thickness of at least about 0.145mm, such as at least about 0.15mm, or at least about 0.16 mm. The reconstituted tobacco material may have a maximum thickness of about 0.30mm or 0.25mm, for example the reconstituted tobacco material may have a thickness of less than about 0.22mm, or less than about 0.2mm. In some embodiments, the reconstituted tobacco material may have an average thickness in the range of 0.175mm to 0.195 mm.

In some embodiments, the tobacco is a particulate tobacco material. Each particle of particulate tobacco material may have a maximum size. As used herein, the term "maximum dimension" refers to the longest straight line distance from any point on the surface of a tobacco particle or particle surface to any other surface point on the same tobacco particle or particle surface. The maximum size of the particles of particulate tobacco material can be measured using a Scanning Electron Microscope (SEM).

The largest dimension of each particle of tobacco material can be up to about 200 m. In some embodiments, each particle of tobacco material may have a maximum dimension of at most about 150 m.

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

A particle size distribution (D90) of at least about 100 m is believed to contribute to the tensile strength of the sheet or shredded sheet of aerosol-generating material.

Particle size distribution (D90) of less than 100 m can provide sheets or chopped sheets of aerosol-generating material having good tensile strength. However, including such fine particles of tobacco material in the sheet or shredded sheet may increase its density. Such higher densities may reduce the filling value of the tobacco material when the sheet or shredded sheet is incorporated into an article for use in a non-combustible sol supply system. Advantageously, a satisfactory balance between tensile strength and suitable density (and thus filling value) can be achieved with a particle size distribution (D90) of at least about 100 m.

The particle size of the particulate tobacco material may also affect the roughness of the sheet or shredded sheet of aerosol-generating material. It is hypothesized that forming the sheet or shredded sheet of aerosol-generating material by incorporating relatively large particles of tobacco material reduces the density of the sheet or shredded sheet of aerosol-generating material.

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

The tobacco material may include tobacco flakes (lamina tabacco) and/or tobacco stems, such as midrib stems. The tobacco sheet may be present in an amount of 0 wt.% to about 100 wt.%, about 20 wt.% to about 100 wt.%, about 40 wt.% to about 95 wt.%, about 45 wt.% to about 90 wt.%, about 50 wt.% to about 85 wt.%, or about 55 wt.% to about 80 wt.% of the sheet or shredded sheet and/or tobacco material. In some embodiments, the tobacco material consists of or consists essentially of tobacco sheet material.

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

In some embodiments, the tobacco material comprises a combination of a sheet and a tobacco stem. In some embodiments, the tobacco material may comprise flakes in an amount of about 40% to about 95% by weight of the sheet of aerosol-generating material or shredded sheet and stems in an amount of about 5% to about 60% by weight of the sheet of aerosol-generating material or shredded sheet, or flakes in an amount of about 60% to about 95% by weight of the sheet of aerosol-generating material or shredded sheet and stems in an amount of about 5% to about 40% by weight of the sheet of aerosol-generating material or shredded sheet, or flakes in an amount of about 80% to about 95% by weight of the sheet of aerosol-generating material or shredded sheet, and stems in an amount of about 5% to about 20% by weight of the sheet of aerosol-generating material or shredded sheet.

The incorporation of stems can reduce the viscosity of the aerosol-generating material. Incorporating tobacco material including tobacco stems into aerosol-generating materials may increase their burst strength.

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

If the burst strength is too low, the sheet or shredded sheet may be relatively brittle. Thus, during the process of manufacturing the aerosol-generating material, the sheet or shredded sheet may break. For example, when the sheet is shredded through a cutting process to form shredded sheet, the sheet may break or fracture into pieces or fragments when cut.

The tobacco materials described herein contain nicotine. The nicotine content is 0.1 to 3% by weight of the tobacco material and may for example be 0.5 to 2.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material contains 10 to 90 wt% tobacco leaf having a nicotine content greater than about 1wt% or about 1.5 wt% of the tobacco leaf. Tobacco leaves (e.g., cut tobacco) may, for example, have a nicotine content of 1% to 5% by weight of the tobacco leaves.

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

Paper reconstituted tobacco may also be present in the aerosol-generating materials described herein. Paper reconstituted tobacco refers to tobacco material formed by the process of: the tobacco material is extracted with a solvent to provide an extract of solubles and a residue comprising fibrous material, and then the extract (typically after concentration and optionally after further processing) is recombined with fibrous material from the residue (typically after refining of the fibrous material and optionally adding a portion of non-tobacco fibers) by depositing the extract onto the fibrous material. The process of recombination is similar to that of paper making.

The paper reconstituted tobacco may be any type of paper reconstituted tobacco known in the art. In a particular embodiment, the paper reconstituted tobacco is made from a raw material comprising one or more of tobacco rod, tobacco stem and whole leaf tobacco. In another embodiment, the paper reconstituted tobacco is made from a stock consisting of tobacco rod and/or whole leaf tobacco and tobacco stems. However, in other embodiments, crushed aggregates (scrap), fines (fine) and wind sizing (winnowing) may alternatively or additionally be used in the feedstock.

The paper reconstituted tobacco used in the tobacco materials described herein may be prepared by methods known to those skilled in the art for preparing paper reconstituted tobacco.

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

The aerosol generating material comprises an aerosol former material. The aerosol former material comprises one or more components capable of forming an aerosol. The aerosol former material comprises one or more of the following: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, m-erythritol, ethyl vanillic acid, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyl essence, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some examples, the aerosol former material is glycerol or propylene glycol.

The sheet or shredded sheet of aerosol-generating material comprises aerosol former material. The aerosol former material is provided in an amount of up to about 50% by weight of the dry weight-based sheet or shredded sheet. In some embodiments, the aerosol former material is provided in an amount of about 5% to about 40% by weight of the dry weight-based sheet or shredded sheet, in an amount of about 10% to about 30% by weight of the dry weight-based sheet or shredded sheet, in an amount of about 10% to about 20% by weight of the dry weight-based sheet or shredded sheet.

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

The sheet or shredded sheet of aerosol-generating material may comprise a total amount of water and aerosol-former material of less than about 30% by weight of the sheet or shredded sheet of aerosol-generating material or less than about 25% by weight of the sheet or shredded sheet of aerosol-generating material. It is believed that incorporating water and aerosol-former material into the sheet or shredded sheet of aerosol-generating material in an amount of less than about 30% by weight of the sheet or shredded sheet of aerosol-generating material may advantageously reduce the tackiness of the sheet. This may improve the ease of handling the aerosol generating material during processing. For example, a sheet of aerosol-generating material may be more easily rolled up to form a bobbin (bobbin) of material, and then the bobbin is unrolled without the layers of sheet sticking together. Reducing tackiness may also reduce the tendency of strands or strips of shredded material to agglomerate or stick together, thereby further improving processing efficiency and quality of the final product.

The sheet or shredded sheet comprises an adhesive. The adhesive is arranged to adhere components of the aerosol-generating material to form a sheet or shredded sheet. The binder may at least partially coat the surface of the tobacco material. In the case of a tobacco material in particulate form, the binder may at least partially cover the surfaces of the tobacco particles and bind them together.

The binder may be selected from one or more compounds selected from the group comprising: alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the adhesive includes one or more of the following: alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the binder includes alginate and/or pectin or carrageenan. In one embodiment, the binder comprises guar gum.

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

The aerosol generating material may comprise a filler. In some embodiments, the sheet or shredded sheet comprises a filler. Fillers are generally 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 absorbents 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 (non-tobacco CAST MATERIAL) or a non-tobacco extruded material.

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

The filler may also contribute to the texture of the sheet or shredded sheet of aerosol-generating material. For example, a fibrous filler (such as wood or wood pulp) may provide a sheet or chopped sheet of aerosol-generating material having relatively rough first and second surfaces. Conversely, a non-fibrous particulate filler (such as powdered chalk) may provide a sheet or shredded sheet of aerosol-generating material having relatively smooth first and second surfaces. In some embodiments, the aerosol-generating material comprises a combination of different filler materials.

The filler component may be present in an amount of 0 to 20% by weight of the sheet or shredded sheet or in an amount of 1 to 10% by weight of the sheet or shredded sheet. In some embodiments, the filler component is absent.

The filler may help to improve the general structural characteristics of the aerosol-generating material, such as its tensile strength and burst strength.

In the compositions described herein, where amounts are given in weight percent, for the avoidance of doubt, this refers to dry basis weight unless specifically indicated to the contrary. Thus, any water that may be present in the aerosol-generating material or any component thereof may be omitted entirely for the purpose of determining the weight percent. The water content of the aerosol-generating material described herein may vary and may be, for example, 5 to 15% by weight. The water content of the aerosol-generating materials described herein may vary depending on, for example, the temperature, pressure, and humidity conditions under which the composition is maintained. The water content may be determined by Karl-Fisher analysis known to those skilled in the art. On the other hand, for the avoidance of doubt, even when the aerosol-former material is a component in the liquid phase (such as glycerol or propylene glycol), any component other than water is included in the weight of the aerosol-generating material. However, when the aerosol-former material is provided in the tobacco component of the aerosol-generating material, or in the filler component of the aerosol-generating material (if present), instead of being added to the aerosol-generating material alone or in addition to being added to the aerosol-generating material alone, the aerosol-former material is not included in the weight of the tobacco component or filler component, but is included in the weight of the "aerosol-former material" as defined herein in weight%. All other ingredients present in the tobacco component are included in the weight of the tobacco component, even in the case of non-tobacco sources (e.g., non-tobacco fibers in the case of paper reconstituted tobacco).

The aerosol-generating material herein may comprise an aerosol-modifying agent, such as any of the flavors described herein. In one embodiment, the aerosol-generating material comprises menthol. When the aerosol generating material is incorporated into an article for use in an aerosol provision system, the article may be referred to as a menthol-containing article. The aerosol generating material may comprise from 0.5mg to 20mg of menthol, from 0.7mg to 20mg of menthol, from 1mg to 18mg, or from 8mg to 16mg of menthol. In this example, the aerosol generating material comprises 16mg menthol. The aerosol-generating material may comprise from 1 to 8% by weight menthol, preferably from 3 to 7% by weight menthol, and more preferably from 4 to 5.5% by weight menthol. In one embodiment, the aerosol-generating material comprises 4.7% menthol by weight. Such high levels of menthol loading may be achieved using a high percentage (e.g., greater than 50% by weight of the tobacco material) of reconstituted tobacco material. Alternatively or additionally, using a high volume of, for example, tobacco material may increase the menthol loading level that may be achieved, for example, where an aerosol generating material (e.g., tobacco material) of greater than about 500mm ³ or, suitably, greater than about 1000mm ³ is used.

In some embodiments, the composition includes an aerosol-forming "amorphous solid," which may alternatively be referred to as a "monolithic solid (monolithic solid)" (i.e., non-fibrous). In some embodiments, the amorphous solid may comprise a dried gel. An amorphous solid is a solid material in which some fluid (such as a liquid) may be retained.

In some examples, the amorphous solid comprises:

-1-60 wt% of a gelling agent;

-0.1-50 wt% aerosol former material; and

-0.1-80 Wt% of a flavour;

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% aerosol former material; and

-30-60 Wt% of a flavour;

wherein these weights are calculated on a dry weight basis.

The amorphous solid material may be provided in sheet or shredded sheet form. The amorphous solid material may take the same form as the sheet or chopped sheet of aerosol-generating material described previously.

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

In some embodiments, the gelling agent comprises an alginate, and the alginate is present in the amorphous solid in an amount of 10-30 wt% (based on dry weight) of the amorphous solid. In some embodiments, the alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises an alginate and at least one additional gelling agent, such as pectin.

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

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

The amorphous solid contains a flavoring agent. Suitably, the amorphous solid may comprise up to about 80, 70, 60, 55, 50 or 45 wt% flavour.

In some cases, the amorphous solid may comprise at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% flavoring (all on a dry weight basis).

For example, the amorphous solid may contain 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% of a flavoring agent. In some cases, the flavoring agent comprises, consists essentially of, or consists of menthol.

In some cases, the amorphous solid may additionally contain an emulsifier that emulsifies the melted flavor during manufacture. For example, the amorphous solid may comprise from about 5% to about 15% by weight of the emulsifier (calculated on a dry weight basis), suitably about 10% by weight. The emulsifying agent may include acacia.

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

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

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

In some cases, there may be no nicotine in the amorphous solid other than that produced by the tobacco extract.

In some embodiments, the amorphous solid does not comprise tobacco material, but does comprise nicotine. In some such cases, the amorphous solid may comprise about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% (based on dry weight) of nicotine. For example, the amorphous solid may comprise 1-20 wt%, 2-18 wt%, or 3-12 wt% nicotine.

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

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

The amorphous solid may be made of a gel, and the gel may additionally contain a solvent in an amount of 0.1 to 50% by weight. However, inclusion of a solvent in which the flavoring agent is soluble may reduce gel stability and the flavoring agent may crystallize out of the gel. Thus, in some cases, the gel does not include a solvent in which the flavoring agent is soluble.

In some embodiments, the amorphous solid comprises less than 60 wt% filler, such as 1 wt% to 60 wt%, or 5 wt% to 50 wt%, or 5 wt% to 30 wt%, or 10 wt% to 20 wt%.

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

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

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

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

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

In some examples, such as where the amorphous solid includes a filler, the amorphous solid may have a tensile strength of 600N/m to 1500N/m, or 700N/m to 900N/m, or about 800N/m. Such tensile strength may be particularly suitable for embodiments in which the amorphous solid material is included in the aerosol-generating article as a rolled sheet (suitably in the form of a tube).

In some cases, the amorphous solid may consist essentially of, or consist of, the gelling agent, water, aerosol former material, flavor, and optional active.

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

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

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

In the case where the aerosol-generating material comprises an amorphous solid material, the amorphous solid material may be a dry gel comprising menthol. In alternative embodiments, the amorphous solid may have any of the compositions described herein.

Improved articles may be produced that comprise an aerosol-generating material comprising a first component comprising a sheet or shredded sheet of aerosol-generating material and a second component comprising an amorphous solid, wherein material properties (e.g., density) and specifications (e.g., thickness, length, and cut width) fall within the ranges described herein.

In some cases, the amorphous solid may have a thickness of about 0.015mm to about 1.0 mm. Suitably, the thickness may be in the range of about 0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3 mm. A material having a thickness of about 0.09mm may be used. The amorphous solid may include more than one layer, and the thicknesses described herein refer to the aggregate thickness of those layers.

The thickness of the amorphous solid material may be measured using calipers or microscopes known to those skilled in the art, such as Scanning Electron Microscopes (SEM), or any other suitable technique known to those skilled in the art.

If the amorphous solid is too thick, the heating efficiency may be impaired. This can have an adverse effect on the power consumption in use (e.g., the power consumption of releasing the flavoring agent from the amorphous solid). Conversely, if the amorphous solid formed from the aerosol is too thin, it may be difficult to manufacture and handle; very thin materials can be more difficult to cast and can be brittle, which can cause damage to aerosol formation when in use. In some cases, individual strips or fragments of amorphous solid have a minimum thickness of about 0.015 over its area. In some cases, individual strips or fragments of amorphous solid have a minimum thickness of about 0.05mm or about 0.1mm over its area. In some cases, individual strips or fragments of amorphous solid have a maximum thickness of about 1.0mm over its area. In some cases, individual strips or fragments of amorphous solid have a maximum thickness of about 0.5mm or about 0.3mm over its area.

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

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

In embodiments described herein, the amorphous solid material may be incorporated into the article in sheet form. The amorphous solid material in sheet form may be shredded and then incorporated into the article, suitably mixed into an aerosol-generating material (such as the sheets of aerosol-generating material or shredded sheets described herein).

In further embodiments, the amorphous solid sheet may be additionally incorporated as a planar sheet, as an aggregate or bundle sheet, as a coiled sheet, or as a rolled sheet (i.e., in the form of a tube). In some such cases, the amorphous solids of these embodiments may be included in an aerosol-generating article as a sheet (such as a sheet surrounding a rod comprising an aerosol-generating material). For example, an amorphous solid sheet may be formed on a wrapper that surrounds an aerosol-generating material, such as tobacco.

The amorphous solid in sheet form may have any suitable areal density, such as from about 30g/m ² to about 150g/m ². In some cases, the sheet may have a mass per unit area of about 55g/m ² to about 135g/m ², or about 80 to about 120g/m ², or about 70 to about 110g/m ², or specifically about 90 to about 110g/m ², or suitably about 100g/m ². These ranges can provide a density similar to that of shredded tobacco, and thus can provide a mixture of these materials that will not readily separate. Such area densities may be particularly suitable when the amorphous solid material is included in the aerosol-generating article as a shredded sheet material (described further below). In some cases, the sheet may have a mass per unit area of about 30 to 70g/m ², 40 to 60g/m ², or 25 to 60g/m ², and may be used to encapsulate an aerosol-generating material, such as the aerosol-generating materials described herein.

The aerosol-generating material may comprise a blend of an aerosol-generating material described herein and an amorphous solid material. Such an aerosol-generating material may provide an aerosol having the desired flavour profile in use, as additional flavour may be incorporated into the aerosol-generating material by inclusion in the amorphous solid material component. The flavoring provided in the amorphous solid material may be more stably retained in the amorphous solid material than the flavoring added directly to the tobacco material, thereby producing more consistent flavor profiles between articles produced according to the present disclosure.

As noted above, it has been advantageously found that tobacco materials having a density of at least 350mg/cc and less than about 900mg/cc, preferably from about 600mg/cc to about 900mg/cc, result in a more sustained release of the aerosol. In order to provide an aerosol with consistent flavor profile, the amorphous solid material component of the aerosol-generating material should be uniformly distributed throughout the rod. This can be achieved by: the amorphous solid material is cast to have a thickness as described herein to provide an amorphous solid material having an area density similar to that of the tobacco material, and is processed as described below to ensure uniform distribution throughout the aerosol-generating material.

As described above, optionally, the aerosol-generating material comprises a plurality of strands of amorphous solid material. Where the aerosol-generating section comprises a plurality of strands and/or sheets of aerosol-generating material and a plurality of amorphous solid materials, the material properties and/or dimensions of the at least two components may be otherwise suitably selected to ensure that relatively uniform mixing of the components is possible and to reduce separation or unmixement of the components during or after manufacture of the rod of aerosol-generating material.

The longitudinal dimension of the multi-strand or multi-strand may be substantially the same as the length of the aerosol-generating section. The multiple strands or strands may have a length of at least about 5 mm.

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 is to be understood that the advantages, embodiments, examples, functions, features, structures and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be used and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably include, consist of, or consist essentially of, in addition to those specifically described herein: suitable combinations of the disclosed elements, components, features, parts, steps, means, etc. Furthermore, the present disclosure may include other inventions not presently claimed but which may be claimed in the future.

Claims

1. An article for use with a non-combustible aerosol provision device, the article comprising a body of aerosol generating material comprising at least one of:

a recess extending from a distal end of the article; and

A cavity within the body of aerosol-generating material,

2. An article for use with a non-combustible aerosol provision device, the article comprising a body of aerosol-generating material having a longitudinal axis, the article comprising a first portion having a first cross-sectional area of the aerosol-generating material perpendicular to the longitudinal axis and a second portion having a second cross-sectional area of the aerosol-generating material perpendicular to the longitudinal axis, the second cross-sectional area being at least 5% greater than the first cross-sectional area.

3. The article of claim 2, wherein the body of aerosol-generating material comprises at least one of:

A recess extending from a distal end of the article to the aerosol-generating material; and

A cavity within the body of aerosol-generating material,

Wherein the first portion is closer to the distal end of the article than the second portion.

4. The article of claim 1 or 3, wherein the cross-sectional area of the groove or cavity continuously decreases along the longitudinal axis of the article.

5. The article of claim 1, 3, or 4, wherein the cross-sectional area of the groove or cavity decreases at a substantially continuous rate along the longitudinal axis of the article.

6. An article according to any one of claims 1 or 3 to 5, wherein the body of aerosol-generating material is separated from the recess or cavity by a layer of material.

7. The article of claim 6, wherein the material layer comprises a sheet material and/or an amorphous solid material.

8. The article of claim 6 or 7, wherein the material layer comprises an aerosol modifier.

9. An article according to any one of claims 1 or 3 to 8, wherein the body of aerosol-generating material has a length and the recess or cavity extends through at least 25%, 50% or 75% of the length of the body of aerosol-generating material.

10. The article of any one of claims 1 or 3 to 9, wherein the maximum diameter of the groove or cavity is greater than 50%, or greater than 60%, or greater than 70% of the diameter of the body of aerosol-generating material.

11. An article according to any one of claims 1 or 3 to 10, wherein the maximum diameter of the groove or cavity is less than 90%, or less than 80%, or less than 70% of the diameter of the body of aerosol-generating material, for example from 50% to 90%, or from 60% to 90% of the diameter of the body of aerosol-generating material.

12. The article of any one of claims 1 or 3-11, wherein the minimum diameter of the groove or cavity is less than 20% of the maximum diameter of the groove, or less than 10% of the maximum diameter of the groove.

13. The article of any one of claims 1 or 3-12, wherein the boundaries of the grooves or cavities are formed as cones or truncated cones, and/or wherein the boundaries of the grooves or cavities have a surface area of at least about 60mm ², at least about 70mm ², at least about 80mm ², or at least about 90mm ².

14. An article according to any one of claims 1 to 13, wherein the body of aerosol-generating material comprises a plant-based material and/or an aerosol-forming material.

15. The article of any one of claims 1 to 14, wherein the body of aerosol-generating material comprises an extruded and/or molded material.

16. The article of any one of claims 1-15, wherein the article is configured to receive a heater having a cone profile.

17. An article according to any one of claims 1 to 16, wherein the body of aerosol-generating material comprises a first aerosol-generating material and a second aerosol-generating material, wherein the first aerosol-generating material and the second aerosol-generating material are disposed at different positions along a longitudinal axis of the article.

18. A body of aerosol-generating material, the body comprising a heatable element in the shape of a cone, a truncated cone, a pyramid or a truncated pyramid.

19. A body of aerosol-generating material, the body of aerosol-generating material comprising at least one of:

a recess extending from an end of the body of aerosol-generating material; and

A cavity within the body of aerosol-generating material,

20. A body of aerosol-generating material having a longitudinal axis, the body comprising a first portion having a first cross-sectional area of the aerosol-generating material perpendicular to the longitudinal axis and a second portion having a second cross-sectional area of the aerosol-generating material perpendicular to the longitudinal axis, the second cross-sectional area being at least 5% greater than the first cross-sectional area.

21. The body of claim 20, wherein the body is substantially cone, frustoconical, pyramid or truncated pyramid shaped.

22. The body of claim 21 or 22, wherein the body comprises a hollow passage extending through the body, optionally wherein the hollow passage passes through the longitudinal axis.

23. A body as claimed in claim 21 or 22, wherein the body comprises an outer surface region arranged to contact a heatable element of an aerosol provision device in use to provide a heat transfer region between the aerosol generating material and the heatable element, wherein the outer surface region is at least about 60mm ², at least about 70mm ², at least about 80mm ² or at least about 90mm ².

24. An article for use with a non-combustible sol supply device, the article comprising a body of aerosol generating material according to any of claims 18 to 23.

25. An aerosol provision system comprising:

The article of any one of claims 1 to 17 or 24; and

Aerosol supply means.

26. An aerosol provision system according to claim 25, wherein the device comprises a heatable element in the shape of a cone, truncated cone, pyramid or truncated pyramid.

27. An aerosol provision system comprising:

An article comprising a body of aerosol-generating material, the body of aerosol-generating material comprising an aerosol-generating material surface; and

An aerosol provision device comprising a heatable element, wherein the heatable element comprises a heating surface, wherein the aerosol generating material surface and the heating surface are arranged to combine together in use to provide a heat transfer area between the aerosol generating material and the heatable element of at least about 60mm ², at least about 70mm ², at least about 80mm ² or at least about 90mm ².

28. A method of forming a body of aerosol-generating material, the method comprising:

forming a body of aerosol-generating material; and

A groove is provided extending from an end of the body of aerosol-generating material, wherein a cross-sectional area of the groove decreases along a longitudinal axis of the article.

29. A method of forming a body of aerosol-generating material, the method comprising:

generating a stream of aerosol-generating material;

A heatable element is inserted into the flow of aerosol-generating material, wherein the heatable element is cone, frustoconical, pyramid or truncated pyramid shaped.