EP4355132A1 - A component for use in a non-combustible aerosol provision system - Google Patents

A component for use in a non-combustible aerosol provision system

Info

Publication number
EP4355132A1
EP4355132A1 EP22738711.5A EP22738711A EP4355132A1 EP 4355132 A1 EP4355132 A1 EP 4355132A1 EP 22738711 A EP22738711 A EP 22738711A EP 4355132 A1 EP4355132 A1 EP 4355132A1
Authority
EP
European Patent Office
Prior art keywords
aerosol
component
helically
strip
generating material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP22738711.5A
Other languages
German (de)
English (en)
French (fr)
Inventor
Benjamin Taylor
Matthew Hodgson
Barry DIMMICK
Richard Hepworth
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nicoventures Trading Ltd
Original Assignee
Nicoventures Trading Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nicoventures Trading Ltd filed Critical Nicoventures Trading Ltd
Publication of EP4355132A1 publication Critical patent/EP4355132A1/en
Pending legal-status Critical Current

Links

Classifications

    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D1/00—Cigars; Cigarettes
    • A24D1/20—Cigarettes specially adapted for simulated smoking devices
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
    • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
    • A24B15/10—Chemical features of tobacco products or tobacco substitutes
    • A24B15/16—Chemical features of tobacco products or tobacco substitutes of tobacco substitutes
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24C—MACHINES FOR MAKING CIGARS OR CIGARETTES
    • A24C5/00—Making cigarettes; Making tipping materials for, or attaching filters or mouthpieces to, cigars or cigarettes
    • A24C5/14—Machines of the continuous-rod type
    • A24C5/24—Pasting the seam
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D1/00—Cigars; Cigarettes
    • A24D1/02—Cigars; Cigarettes with special covers
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D1/00—Cigars; Cigarettes
    • A24D1/22—Cigarettes with integrated combustible heat sources, e.g. with carbonaceous heat sources

Definitions

  • the present invention relates to a component for use in a non-combustible aerosol provision system, an article for use in a non-combustible aerosol provision system, an aerosol provision system and a method of forming a component for use in a non combustible aerosol provision system.
  • tobacco industry products produce an aerosol during use, which is inhaled by a user.
  • tobacco heating devices heat an aerosol generating substrate such as tobacco to form an aerosol by heating, but not burning, the substrate.
  • tobacco industry products commonly include mouthpieces through which the aerosol passes to reach the user’s mouth.
  • a component for use in a non-combustible aerosol provision system comprising at least one helically-wound strip comprising aerosol-generating material.
  • a component for use in a non-combustible aerosol provision system comprising a plurality of braided or helically- wound strips, at least one of the plurality of braided and/or helically- wound strips comprising aerosol-generating material, the component further comprising a cavity extending from a first end of the component.
  • an article for use with a non-combustible aerosol provision device comprising a component according to the first or second aspect above.
  • a non-combustible aerosol provision system comprising an article according to the third aspect and an aerosol provision device for forming an aerosol from the aerosol- generating material.
  • a method of forming a component according to the first or second aspects above comprising the steps of: providing a source of strip material comprising aerosol-generating material; feeding said strip material towards a mandrel; and winding the strip material around the mandrel to form a helically-wound strip comprising aerosol-generating material.
  • Figure la is a side-on cross sectional view of an article for use in a non-combustible aerosol provision system, the article including a component having at least one helically-wound strip comprising aerosol-generating material.
  • An aerosol provision device is also illustrated, the article and device forming a system;
  • Figure lb is a side-on view of the component of Figure la;
  • Figure 2a is a side-on cross sectional view of an article for use in a non-combustible aerosol provision system, the article including a component having multiple helically- wound or braided strips.
  • An aerosol provision device is also illustrated, the article and device forming a system;
  • Figure 2b is a side-on view of the component of Figure 2a;
  • Figures 3a and 3b illustrate respective machinery arrangements for forming the components of Figures lb and 2b respectively;
  • Figure 4 is a flow diagram illustrating a method of forming a component as described herein.
  • the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials; and aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not
  • a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.
  • the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.
  • the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.
  • END electronic nicotine delivery system
  • the non-combustible aerosol provision system is an aerosol generating material heating system, also known as a heat-not-burn system.
  • a heat-not-burn system is a tobacco heating system.
  • the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated.
  • Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine.
  • the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material.
  • the solid aerosol-generating material may comprise a plant-based material, for example, tobacco or a non-tobacco product.
  • the non-combustible aerosol provision system may comprise a non- combustible aerosol provision device and a consumable for use with the non combustible aerosol provision device.
  • the disclosure relates to consumables comprising aerosol generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.
  • upstream and downstream used herein are relative terms defined in relation to the direction of mainstream aerosol drawn through an article or device in use.
  • the non-combustible aerosol provision system such as a non combustible aerosol provision device thereof, may comprise a power source and a controller.
  • the power source may, for example, be an electric power source or an exothermic power source.
  • the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.
  • the non-combustible aerosol provision system comprises an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/ or an aerosol-modifying agent.
  • the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/ or an aerosol-modifying agent.
  • 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 aerosolised. As appropriate, either material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.
  • the substance to be delivered comprises an active substance.
  • the active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response.
  • the active substance may for example be selected from nutraceuticals, nootropics, psychoactives.
  • the active substance may be naturally occurring or synthetically obtained.
  • the active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or Bi2 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof.
  • the active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.
  • the active substance comprises nicotine.
  • the active substance comprises caffeine, melatonin or vitamin B12.
  • the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof.
  • botanical includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like.
  • the material may comprise an active compound naturally existing in a botanical, obtained synthetically.
  • the material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like.
  • Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon
  • the mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.
  • the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.
  • the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.
  • the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.
  • the substance to be delivered comprises a flavour.
  • flavour and “flavourant” refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch,
  • the flavour comprises menthol, spearmint and/or peppermint.
  • the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry.
  • the flavour comprises eugenol.
  • the flavour comprises flavour components extracted from tobacco.
  • the flavour comprises flavour components extracted from cannabis.
  • the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect.
  • a suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.
  • An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way.
  • An aerosol-generating material may be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants.
  • the aerosol-generating material maybe incorporated into an article for use in the aerosol-generating system.
  • tobacco material refers to any material comprising tobacco or derivatives or substitutes thereof.
  • the tobacco material may be in any suitable form.
  • tobacco material may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes.
  • the tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and/or tobacco extract.
  • a consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user.
  • a consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/ or an aerosol-modifying agent.
  • a consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use.
  • the heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.
  • a susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field.
  • the susceptor maybe an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material.
  • the heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material.
  • the susceptor maybe both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms.
  • the device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.
  • An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol.
  • the aerosol modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent.
  • the aerosol-modifying agent may, for example, be an additive or a sorbent.
  • the aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent.
  • the aerosol-modifying agent may, for example, be a solid, a liquid, or a gel.
  • the aerosol-modifying agent maybe in powder, thread or granule form.
  • the aerosol-modifying agent may be free from filtration material.
  • An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material.
  • the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol.
  • the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating.
  • the aerosol generator maybe configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.
  • the filamentary tow material described herein can comprise cellulose acetate fibre tow.
  • the filamentary tow can also be formed using other materials used to form fibres, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(i-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT), starch based materials, cotton, aliphatic polyester materials and polysaccharide polymers or a combination thereof.
  • PVOH polyvinyl alcohol
  • PLA polylactic acid
  • PCL polycaprolactone
  • PBS poly(i-4 butanediol succinate)
  • PBAT poly(butylene adipate-co-terephthalate)
  • starch based materials cotton, aliphatic polyester materials and polysaccharide polymers or a combination thereof.
  • the filamentary tow may be plasticised with a suitable plasticiser for the tow, such as triacetin where the material is cellulose acetate tow, or the tow may be non
  • the tow can have any suitable specification, such as fibres having a ⁇ ’ shaped or other cross section such as ‘X’ shaped, filamentary denier values between 2.5 and 15 denier per filament, for example between 8.0 and 11.0 denier per filament and total denier values of 5,000 to 50,000, for example between 10,000 and 40,000.
  • suitable specification such as fibres having a ⁇ ’ shaped or other cross section such as ‘X’ shaped, filamentary denier values between 2.5 and 15 denier per filament, for example between 8.0 and 11.0 denier per filament and total denier values of 5,000 to 50,000, for example between 10,000 and 40,000.
  • Figure la is a side-on cross sectional view of an article la for use in a non-combustible aerosol provision system, the article la including a component 3 having at least one helically-wound strip 3c comprising aerosol-generating material.
  • Figure la also schematically illustrates an aerosol provision device 100.
  • the article la includes a mouthpiece 2, and a component 3, also referred to as an aerosol-generating section 3, connected to the mouthpiece 2.
  • the aerosol generating section 3 includes a recess or cavity 3a extending into the component 3.
  • the recess or cavity 3a forms a channel extending through the full length of the component 3.
  • the article la is generally rod shaped and has a longitudinal axis shown as the dotted line X - X’.
  • the recess or cavity 3a is formed by a hollow tube 3b.
  • the hollow tube 3b is formed by a plurality of layers of paper which are parallel wound, with butted seams.
  • the helically-wound strip 3c is wrapper around the hollow tube 3b and, in the present example, is adhered to the tube 3b.
  • the hollow tube can be formed in other ways such as using spirally or helically wound layers of paper (such as those described herein), cardboard tubes, tubes formed using a moulded pulp or moulded fibre type process, moulded or extruded plastic tubes or similar.
  • the hollow tube 3b is manufactured to have a rigidity that is sufficient to withstand the axial compressive forces and bending moments that might arise during manufacture and whilst the article la is in use.
  • the manufacturing tolerance in a diameter of the cavity can be below that usually associated with aerosol-generating materials, for instance less than 0.5 mm, or less than 0.4 mm, or less than 0.3 mm.
  • the aerosol-generating material forming the helically-wound strip 3c in the present example is a strip formed from a reconstituted tobacco sheet material.
  • the helically-wound strip 3c can be formed from other materials such as a tobacco-free sheet material, amorphous solid sheet material, a gelled sheet material, or a paper material with a material deposited thereon.
  • the helically-wound strip 3c can be formed from a sheet material including an aerosol-modifying agent, such as a flavourant, as defined herein.
  • the aerosol-generating material can, for instance, be laminated on a support material, such as a support material formed from metal foil such as aluminium foil, paper, polylactide (PLA) material, starch-based sheet materials and the like.
  • the helically- wound strip can have a tensile strength of at least 4N/i5mm. This can ensure that the strip has sufficient tensile strength during the winding process used to wind the strip 3c around the tube 3b.
  • the recess or cavity 3a in the present example extends all of the way through the component 3. However, in other examples the recess or cavity 3a can extend only partially through the component 3.
  • the length of the recess or cavity 3a in the direction of the longitudinal axis can be less than the length of the component 3 along the longitudinal axis.
  • the device too includes a housing 101 and a region 102 for receiving the article la.
  • the region 102 includes an aerosol-generating element 103, in the present case a heatable element, which generates an aerosol from the aerosol-generating material of the article la.
  • the recess or cavity 3a is arranged to receive at least a part of the aerosol generating element 103.
  • the article la is pushed onto the aerosol-generating element 103 such that the aerosol-generating element 103 of the aerosol provision device too enters the recess or cavity 3a.
  • the article la is consumed by drawing mainstream aerosol through the downstream portion 2, in the present case the mouthpiece 2, of the article la.
  • the aerosol-generating element 103 is removed from the aerosol-generating material 3.
  • the component 3 has a circumference of about 22.7 mm. In alternative embodiments, the component 3 may have any suitable circumference, for example between about 20 mm and about 26 mm.
  • the component 3 has a length, for instance, of between about 5mm and about 20mm, or between about 8mm and about 15mm.
  • the recess or cavity 3a extends through at least 25%, 50% or 75% of the length of the component 3. For instance, for a component 3 having a length of 12mm, the recess 3a can extend 9mm or more into the body.
  • the maximum diameter of the recess or cavity 3a can be greater than 10%, or greater than 15%, or greater than 20% of the diameter of the component 3.
  • the maximum diameter of the recess 3a can be less than 60%, or less than 50%, or less than 40% of the diameter of the component 3, for instance from 10% to 40% of the diameter of the component 3 or from 15% to 30% of the diameter of the component 3.
  • the aerosol-generating material in any of the embodiments described herein can comprise aerosol-generating material in sheet form or in an extruded form or in a moulded form.
  • the aerosol-generating material can, for instance, comprise plant based material which is extruded and/or moulded to form the strips 3c.
  • Extruded or moulded tobacco can be produced by a process such as that described in international patent publication no. WO2020148538, the contents of which are incorporated herein by reference.
  • the recess or cavity 3a in the component 3 can be at least partially filled with a second aerosol-generating material, which could be the same or different from the aerosol- generating material forming the strip 3c, in this case referred to as the first aerosol generating material.
  • the helically-wound strip 3c is wound around the hollow tube 3b such that a gap 3d is provided between the edges of the strip 3c.
  • This gap 3d creates a path through the component 3, maximising airflow over the surface of the strip 3c for a given length of strip, and therefore exposure of air to the aerosol-generating material included in the strip.
  • the helically- would strip 3c can be a first of two strips and a second helically-wound strip (not shown) can be wound around the first helically- wound strip 3c, also with a gap between the edges of the second strip.
  • the second helically-wound strip can at least partially overlie the first helically-wound strip 3c, and may overlie the full width of the gap. This can allow airflow in the gap formed by the edges of the first strip 3c and the inner surface of the second strip.
  • the gap can range in size from about 0.5mm to about 10mm, or from about imm to about 5mm between the edges of the first and/ or second strip 3c.
  • the helically- wound strip 3c can be tightly wound such that there is no gap 3d, increasing the amount of strip material which is provided for a given length of component.
  • the helically- would strip 3c in this case can also be a first of two strips and a second helically-wound strip (not shown) can be wound around the first helically-wound strip 3c, either tightly wound such that there is no gap or wound with a gap as described above.
  • the component 3 has a longitudinal axis Z-Z’, and when viewed side-on to the longitudinal axis, as shown in Figure lb, a long edge of the helically-wound strip forms two angles with the longitudinal axis of the component when projected onto said axis. One of said angles is greater than 90 degrees, and the other is less than 90 degrees. In some examples, the angle between the long edge of the helically-wound strip and the longitudinal axis which is less than 90 degrees is less than about 70 degrees, for example less than about 60 degrees, or less than about 50 degrees.
  • Figure 3a illustrates a machinery arrangement for forming the component 3 of Figure lb.
  • a section of hollow tube 3b is fed/pulled along a mandrel 16 in the direction of arrow ‘X’ while being turned.
  • the hollow tube 3b can, for instance, be formed of helically or spirally wound paper which forms a core, and this can be pre-formed, or formed immediately prior to wrapping the core with strip material 14.
  • a source of a first strip material 14 is provided, in the present example comprising aerosol generating material.
  • the first strip material 14 is wound around the tube 3b as the tube 3b is turned and moved forwards.
  • the first strip material 14 forms first helically- wound strips 3c around the tube 3b.
  • An optional second strip material 15 is provided, in the present case used to adhere the first strip material 14 to the tube 3b.
  • the second strip material 15 can be a paper material which is dipped in a reservoir of adhesive before it reaches the hollow tube 3b and is then adhered to the tube 3b and used to adhere the first strip material 14 to the tube 3b.
  • the second strip material 15 forms second helically-wound strips 3c around the tube 3b.
  • the strip material 14 has a width which is at least twice the diameter of the mandrel 16.
  • the helically-wound strip of the component 3 preferably has a width which is at least 1.5 times the diameter of the recess or cavity 3a.
  • the width of the helically-wound strip may be 2 times, 2.5 times, or 3 times the diameter of the recess.
  • a continuous rod is formed using the machinery arrangement and a cutting arrangement 17 is provided to cut the continuously formed rod into individual components 3 or groups of components 3.
  • the cutting arrangement includes a plurality of blades, for instance spinning circular blades, longitudinally spaced along the transfer path of the rod.
  • the cutting arrangement can be arranged to reciprocate along a path parallel to the transfer path of the rod, and to cut the rod while moving in the same direction as the rod.
  • the cutting arrangement can be arranged to move alongside the rod at the same speed as the rod, and to cut the rod into segments while moving at the same speed as the rod. This can assist with providing a clean cut through the rod, at an angle perpendicular to the transfer path of the rod.
  • the mouthpiece 2 includes a cooling section 8, also referred to as a cooling element, positioned immediately downstream of and adjacent to the source of aerosol - generating material 3.
  • the cooling section 8 is in an abutting relationship with the source of aerosol-generating material.
  • the mouthpiece 2 also includes, in the present example, a body of material 6 downstream of the cooling section 8, and a hollow tubular element 4 downstream of the body of material 6, at the mouth end of the article 1.
  • the cooling section 8 comprises a hollow channel, having an internal diameter of between about 1 mm and about 4 mm, for example between about 2 mm and about 4 mm. In the present example, the hollow channel has an internal diameter of about 3 mm.
  • the hollow channel extends along the full length of the cooling section 8.
  • the cooling section 8 comprises a single hollow channel. In alternative embodiments, the cooling section can comprise multiple channels, for example, 2, 3 or 4 channels.
  • the single hollow channel is substantially cylindrical, although in alternative embodiments, other channel geometries/cross- sections may be used.
  • the channel can be, for instance, a circular cylinder, an elliptical cylinder, a hyperbolic cylinder or a parabolic cylinder.
  • the hollow channel can provide a space into which aerosol drawn into the cooling section 8 can expand and cool down.
  • the cooling section 8 may have a wall thickness in a radial direction, which can be measured, for example, using a calliper.
  • the wall thickness of the cooling section 8, for a given outer diameter of cooling section, defines the internal diameter for the cavity surrounded by the walls of the cooling section 8.
  • the cooling section 8 can have a wall thickness of at least about 1.5 mm and up to about 2 mm. In the present example, the cooling section 8 has a wall thickness of about 2 mm.
  • Providing a cooling section 8 having a wall thickness within this range improves the retention of the source of aerosol-generating material in the aerosol generating section, in use, by reducing the longitudinal displacement of strands and/or strips of aerosol-generating material when the aerosol generator is inserted into the article.
  • the cooling section 8 is formed from filamentary tow. Other constructions can be used, such as a plurality of layers of paper which are parallel wound, with butted seams, to form the cooling section 8; or spirally wound layers of paper, cardboard tubes, tubes formed using a papier-mache type process, moulded or extruded plastic tubes or similar.
  • the cooling section 8 is manufactured to have a rigidity that is sufficient to withstand the axial compressive forces and bending moments that might arise during manufacture and whilst the article 1 is in use.
  • the wall material of the cooling section 8 can 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 instance, at least 92% or at least 95% of the aerosol generated by the aerosol generating material 3 can pass longitudinally through the one or more hollow channels.
  • the density of the material forming the cooling section 8 is at least about 0.20 grams per cubic centimetre (g/cc), at least about 0.25 g/cc. , the density of the material forming the cooling section 8 is less than about 0.80 grams per cubic centimetre (g/cc), more preferably less than 0.6 g/cc. In some embodiments, the density of the material forming the cooling section 8 is between 0.20 and 0.8 g/cc, more preferably between 0.3 and 0.6 g/cc, or between 0.4 g/cc and 0.6 g/cc or about 0.5 g/cc.
  • the "density" of the material forming the cooling section 8 refers to the density of any filamentary tow forming the element with any plasticiser incorporated. 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 can be calculated using appropriate measurements of the material forming the cooling section 8 taken, for example, using callipers. Where necessary, the appropriate dimensions maybe measured using a microscope.
  • the length of the cooling section 8 is less than about 30 mm. More preferably, the length of the cooling section 8 is less than about 25 mm. Still more preferably, the length of the cooling section 8 is less than about 20 mm. In addition, or as an alternative, the length of the cooling section 8 is preferably at least about 10 mm. Preferably, the length of the cooling section 8 is at least about 15 mm. In some preferred embodiments, the length of the cooling section 8 is from about 15 mm to about 20 mm, more preferably from about 16 mm to about 19 mm. In the present example, the length of the cooling section 8 is 19 mm.
  • the cooling section 8 is located around and defines an air gap within the mouthpiece 2 which acts as a cooling section.
  • the air gap provides a chamber through which heated volatilised components generated by the rod of aerosol-generating material 3 flow.
  • the cooling section 8 is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article 1 is in use.
  • the cooling section 8 provides a physical displacement between the aerosol-generating material 3 and the body of material 6. The physical displacement provided by the cooling section 8 can provide a thermal gradient across the length of the cooling section 8.
  • the mouthpiece 2 comprises a cavity having an internal volume greater than 110 mm3. Providing a cavity of at least this volume has been found to enable the formation of an improved aerosol. More preferably, the mouthpiece 2 comprises a cavity, for instance formed within the cooling section 8, having an internal volume greater than 120 mm 3 , and still more preferably greater than 130 mm 3 , allowing further improvement of the aerosol. In some examples, the internal cavity comprises a volume of between about 130 mm 3 and about 230 mm 3 , for instance about 134 mm 3 or 227 mm 3 .
  • the cooling section 8 can be configured to provide a temperature differential of at least 40 degrees Celsius between a heated volatilised component entering a first, upstream end of the cooling section 8 and a heated volatilised component exiting a second, downstream end of the cooling section 8.
  • the cooling section 8 is preferably configured to provide a temperature differential of at least 60 degrees Celsius, preferably at least 80 degrees Celsius and more preferably at least too degrees Celsius between a heated volatilised component entering a first, upstream end of the cooling section 8 and a heated volatilised component exiting a second, downstream end of the cooling section 8. This temperature differential across the length of the cooling section 8 protects the temperature sensitive body of material 6 from the high temperatures of the aerosol generating material 3 when it is heated.
  • the aerosol-generating section When in use, the aerosol-generating section may exhibit a pressure drop of from about 15 to about 40 mm H 2 0. In some embodiments, the aerosol-generating section exhibits a pressure drop across the aerosol-generating section of from about 15 to about 30 mm H O.
  • the aerosol-generating material may have a packing density of between about 400 mg/ cm3 and about 900 mg/ cm3 within the aerosol-generating section.
  • a moisture impermeable wrapper 10 circumscribes the rod of aerosol-generating material and comprises aluminium foil.
  • the wrapper 10 comprises a paper wrapper, optionally comprising a barrier coating to make the material of the wrapper substantially moisture impermeable.
  • Aluminium foil has been found to be particularly effective at enhancing the formation of aerosol within the aerosol-generating material 3.
  • the aluminium foil has a metal layer having a thickness of about 6 pm.
  • the aluminium foil has a paper backing.
  • the aluminium foil can be other thicknesses, for instance between 4 pm and 16 pm in thickness.
  • the aluminium foil also need not have a paper backing, but could have a backing formed from other materials, for instance to help provide an appropriate tensile strength to the foil, or it could have no backing material.
  • Metallic layers or foils other than aluminium can also be used.
  • the total thickness of the wrapper is preferably between 20 pm and 60 pm, more preferably between 30 pm and 50 pm, which can provide a wrapper having appropriate structural integrity and heat transfer characteristics.
  • the moisture impermeable wrapper to is also substantially impermeable to air.
  • the wrapper to preferably has a permeability of less than too Coresta Units, more preferably less than 60 Coresta Units.
  • low permeability wrappers for instance having a permeability of less than too Coresta Units, more preferably less than 60 Coresta Units, result in an improvement in the aerosol formation in the aerosol-generating material 3.
  • the permeability of the wrapper 10 can be measured in accordance with ISO 2965:2009 concerning the determination of air permeability for materials used as cigarette papers, filter plug wrap and filter joining paper.
  • the body of material 6 and hollow tubular element 4 each define a substantially cylindrical overall outer shape and share a common longitudinal axis.
  • the body of material 6 is wrapped in a first plug wrap 7.
  • the first plug wrap 7 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm.
  • the first plug wrap 7 has a thickness of between 30 pm and 60 pm, more preferably between 35 pm and 45 pm.
  • the first plug wrap 7 is a non-porous plug wrap, for instance having a permeability of less than too Coresta units, for instance less than 50 Coresta units.
  • the first plug wrap 7 can be a porous plug wrap, for instance having a permeability of greater than 200 Coresta Units.
  • the length of the body of material 6 is less than about 15 mm. More preferably, the length of the body of material 6 is less than about 12 mm. In addition, or as an alternative, the length of the body of material 6 is at least about 5 mm.
  • the length of the body of material 6 is at least about 8 mm.
  • the length of the body of material 6 is from about 5 mm to about 15 mm, more preferably from about 6 mm to about 12 mm, even more preferably from about 6 mm to about 12 mm, most preferably about 6 mm, 7 mm, 8 mm, 9 mm or 10 mm.
  • the length of the body of material 6 is 10 mm.
  • the body of material 6 is formed from filamentary tow.
  • the tow used in the body of material 6 has a denier per filament (d.p.f.) of 5 and a total denier of 25,000.
  • the tow comprises plasticised cellulose acetate tow.
  • the plasticiser used in the tow comprises about 9% by weight of the tow.
  • the plasticiser is triacetin.
  • different materials can be used to form the body of material 6.
  • the body 6 can be formed from paper, for instance in a similar way to paper filters known for use in cigarettes.
  • the paper, or other cellulose- based material can be provided as one or more portions of sheet material which is folded and/or crimped to form body 6.
  • the sheet material can have a basis weight of from I5gsm to 6ogsm, for instance between 20 and 50 gsm.
  • the sheet material can, for instance, have a basis weight in any of the ranges between 15 and 25 gsm, between 25 and 30 gsm, between 30 and 40 gsm, between 40 and 45 gsm and between 45 and 50 gsm.
  • the sheet material can have a width of between 50mm and 200mm, for instance between 60mm and 150mm, or between 80mm and 150mm.
  • the sheet material can have a basis weight of between 20 and 50 gsm and a width between 80mm and 150mm. This can, for instance, enable the cellulose-based bodies to have appropriate pressure drops for an article having dimensions as described herein.
  • the body 6 can be formed from tows other than cellulose acetate, for instance polylactic acid (PLA), other materials described herein for filamentary tow 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.
  • the tow has a denier per filament of no more than 12 d.p.f., preferably no more than 11 d.p.f. and still more preferably no more than 10 d.p.f.
  • the total denier of the tow forming the body of material 6 is preferably at most 30,000, more preferably at most 28,000 and still more preferably at most 25,000. These values of total denier provide a tow which takes up a reduced proportion of the cross sectional area of the mouthpiece 2 which results in a lower pressure drop across the mouthpiece 2 than tows having higher total denier values.
  • the tow preferably has a total denier of at least 8,000 and more preferably at least 10,000.
  • the denier per filament is between 5 and 12 while the total denier is between 10,000 and 25,000.
  • the cross-sectional shape of the filaments of tow are ⁇ shaped, although in other embodiments other shapes such as ‘X’ shaped filaments can be used, with the same d.p.f. and total denier values as provided herein.
  • the pressure drop across body 6 can, for instance, be between 0.3 and smmWG per mm of length of the body 6, for instance between o.smmWG and 2mmWG per mm of length of the body 6.
  • the pressure drop can, for instance, be between 0.5 and immWG/mm of length, between 1 and i.5mmWG/mm of length or between 1.5 and 2mmWG/mm of length.
  • the total pressure drop across body 6 can, for instance, be between 3mmWG and 8mWG, or between 4mmWG and 7mmWG.
  • the total pressure drop across body 6 can be about 5, 6 or 7mmWG.
  • the mouthpiece 2 of the article la comprises an upstream end 2a adjacent to the rod of aerosol-generating material 3 and a downstream end 2b distal from the rod of aerosol-generating material 3.
  • the mouthpiece 2 has a hollow tubular element 4 formed from filamentary tow. This has advantageously been found to significantly reduce the temperature of the outer surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece which comes into contact with a consumer’s mouth when the article 1 is in use.
  • tubular element 4 has also been found to significantly reduce 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 hypothesised that this is due to the tubular element 4 channelling aerosol closer to the centre of the mouthpiece 2, and therefore reducing the transfer of heat 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 a radial direction. This may be measured, for example, using a calliper.
  • the wall thickness is advantageously greater than 0.9 mm, and more preferably 1.0mm or greater.
  • the wall thickness is substantially constant around the entire wall of the hollow tubular element 4.
  • the wall thickness is preferably greater than 0.9 mm at any point around the hollow tubular element 4, more preferably 1.0mm or greater.
  • the wall thickness of the hollow tubular element 4 is about 1.3 mm.
  • the length of the hollow tubular element 4 is less than about 20 mm. More preferably, the length of the hollow tubular element 4 is less than about 15 mm. Still more preferably, the length of the hollow tubular element 4 is less than about 10 mm.
  • the length of the hollow tubular element 4 is at least about 5 mm.
  • the length of the hollow tubular element 4 is at least about 6 mm.
  • the length of the hollow tubular element 4 is from about 5 mm to about 20 mm, more preferably from about 6 mm to about 10 mm, even more preferably from about 6 mm to about 8 mm, most preferably about 6 mm, 7 mm or about 8 mm.
  • the length of the hollow tubular element 4 is 7 mm.
  • the density of the hollow tubular element 4 is at least about 0.25 grams per cubic centimetre (g/cc), more preferably at least about 0.3 g/cc.
  • the density of the hollow tubular element 4 is less than about 0.75 grams per cubic centimetre (g/cc), more preferably less than 0.6 g/cc.
  • the density of the hollow tubular element 4 is between 0.25 and 0.75 g/cc, more preferably between 0.3 and 0.6 g/cc, and more preferably between 0.4 g/cc and 0.6 g/cc or about 0.5 g/cc.
  • the "density" of the hollow tubular element 4 refers to the density of the filamentary tow forming the element with any plasticiser 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 can be calculated using appropriate measurements of the hollow tubular element 4 taken, for example, using callipers. Where necessary, the appropriate dimensions may be measured using a microscope.
  • the filamentary tow forming the hollow tubular element 4 preferably has 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 a tubular element 4 which is not too dense.
  • the total denier is at least 20,000, more preferably at least 25,000.
  • the filamentary tow forming the hollow tubular element 4 has a total denier between 25,000 and 45,000, more preferably between 35,000 and 45,000.
  • the cross-sectional shape of the filaments of tow are ⁇ ’ shaped, although in other embodiments other shapes such as ‘X’ shaped filaments can be used.
  • the filamentary tow forming the hollow tubular element 4 preferably has a denier per filament of greater than 3. This denier per filament has been found to allow the formation of a tubular element 4 which is not too dense.
  • the denier per filament is at least 4, more preferably at least 5.
  • the filamentary tow forming the hollow tubular element 4 has a denier per filament between 4 and 10, more preferably between 4 and 9.
  • the filamentary tow forming the hollow tubular element 4 has an 7 ⁇ 3U3 ⁇ ,000 tow formed from cellulose acetate and comprising 18% plasticiser, for instance triacetin.
  • the hollow tubular element 4 preferably has an internal diameter of greater than 3.0mm. Smaller diameters than this can result in increasing the velocity of aerosol passing though the mouthpiece 2 to the consumers mouth more than is desirable, such that the aerosol becomes too warm, for instance reaching temperatures greater than 40°C or greater than 45°C. More preferably, the hollow tubular element 4 has an internal diameter of greater than 3.1mm, and still more preferably greater than 3.5mm or 3.6mm. In one embodiment, the internal diameter of the hollow tubular element 4 is about 4.7 mm.
  • the hollow tubular element 4 preferably comprises from 15% to 22% by weight of plasticiser.
  • the plasticiser is preferably triacetin, although other plasticisers such as polyethelyne glycol (PEG) can be used. More preferably, the hollow tubular element 4 comprises from 16% to 20% by weight of plasticiser, for instance about 17%, about 18% or about 19% plasticiser.
  • the first hollow tubular element 4, body of material 6 and cooling section 8 are combined using a second plug wrap 9 which is wrapped around all three sections.
  • the second plug wrap 9 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 45 gsm.
  • the second plug wrap 9 has a thickness of between 30 pm and 60 pm, more preferably between 35 pm and 45 pm.
  • the second plug wrap 9 is preferably a non-porous plug wrap having a permeability of less than too Coresta Units, for instance less than 50 Coresta Units.
  • the second plug wrap 9 can be a porous plug wrap, for instance having a permeability of greater than 200 Coresta Units.
  • a tipping paper 5 is wrapped around the full length of the mouthpiece 2 and in the present example over the full length of the rod of aerosol-generating material 3 and has an adhesive on its inner surface to connect the mouthpiece 2 and rod 3.
  • the rod of aerosol-generating material 3 is wrapped in wrapper 10, which forms a first wrapping material
  • the tipping paper 5 forms an outer wrapping material which extends at least partially over the rod of aerosol-generating material 3 to connect the mouthpiece 2 and rod 3.
  • the tipping paper can extend only partially over the rod of aerosol-generating material.
  • the tipping paper 5 can extend 5 mm over the rod of aerosol-generating material 3 or it can alternatively extend between 3 mm and 10 mm over the rod 3, or more preferably between 4 mm and 6 mm, to provide a secure attachment between the mouthpiece 2 and rod 3.
  • the tipping paper can have a basis weight greater than 20 gsm, for instance greater than 25 gsm, or preferably greater than 30 gsm, for example 37 gsm.
  • the article has a ventilation level of about 10% of the aerosol drawn through the article. In alternative embodiments, the article can have a ventilation level of between 1% and 20% of aerosol drawn through the article, for instance between 1% and 12%.
  • Ventilation at these levels helps to increase the consistency of the aerosol inhaled by the user at the mouth end 2b, while assisting the aerosol cooling process.
  • the ventilation is provided directly into the mouthpiece 2 of the article 1.
  • the ventilation is provided into the cooling section 8, which has been found to be particularly beneficial in assisting with the aerosol generation process.
  • the ventilation is provided via perforations 12, in the present case formed as a single row of laser perforations, positioned 13 mm from the downstream, mouth-end 2b of the mouthpiece 2.
  • two or more rows of ventilation perforations may be provided. These perforations pass though the tipping paper 5, second plug wrap 9 and cooling section 8.
  • the ventilation can be provided into the mouthpiece at other locations, for instance into the body of material 6 or first tubular element 4.
  • the article is configured such that the perforations are provided about 28mm or less from the upstream end of the article 1, preferably between 20mm and 28mm from the upstream end of the article 1.
  • the apertures are provided about 25mm from the upstream end of the article.
  • Figure 2a is a side-on cross sectional view of a further article lb for use in a non- combustible aerosol provision system, the further article lb including a component 3’ having multiple helically-wound or braided strips 3c, 3e.
  • An aerosol provision device too is also illustrated, the article and device forming a system.
  • Figure 2b is a side-on view of the component 3’ of Figure 2a.
  • the component 3’ includes a plurality of braided or helically- wound strips 3c, 3e, at least one of the plurality of braided and/ or helically- wound strips comprising aerosol-generating material.
  • the component 3’ includes a cavity extending from a first end of the component 3’, and, in the present example, also extending through the full length of the component 3’.
  • a first braided and/or helically- wound strip 3c includes a first aerosol-generating material as described herein
  • a second braided and/ or helically- wound strip 3e includes a second aerosol-generating material as described herein.
  • the second aerosol-generating material can be different to the first aerosol-generating material.
  • the second braided and/or helically-wound strip 3e can be paper strip which is used to adhere the first braided and/ or helically-wound strip 3c to the tube 3b.
  • at least one of the braided and/or helically-wound strips can have a glued surface, for instance where the glued surface connects other braided and/ or helically-wound strips in the component 3’.
  • the braided and/ or helically- wound strip 3c comprising a first aerosol-generating material is arranged in greater proximity to the cavity 3a than the at least one braided and/or helically-wound strip comprising a second aerosol-generating material.
  • a first gap 3d is provided between the edges of the first braided and/or helically- wound strip 3c and a second gap 3f is provided between the edges of the second braided and/ or helically- wound strip 3e. These first and second gaps 3d, 3f provide helical airflow paths through the component 3’.
  • At least one of the braided and/or helically- wound strips 3c, 3e can include a spacer material, for instance where the spacer material has a ridged and/or corrugated structure.
  • This spacer material can allow the formation of air gaps in the component 3’ and can, for instance, be provided as a layer between inner and outer strips which each contain an aerosol-generating material.
  • a long edge of at least one of the braided and/or helically- wound strips forms two angles with the longitudinal axis of the component when projected onto said axis.
  • One of said angles is greater than 90 degrees, and the other is less than 90 degrees.
  • the angle between the long edge of at least one of the braided and/or helically-wound strips and the longitudinal axis which is less than 90 degrees is less than about 70 degrees, for example less than about 60 degrees, or less than about 50 degrees.
  • Figure 3b illustrates a machinery arrangement for forming the component 3’ of Figure 2b.
  • a mandrel 16 is provided, along which the material forming the component 3’ is fed/pulled in the direction of arrow ‘X’.
  • the mandrel 16 can, for instance, be static.
  • a source of a first strip material 14 is provided, in the present example comprising aerosol-generating material.
  • the source of first strip material 14, for instance a bobbin of the material is wound around the mandrel 16 as the mandrel is moved forwards, by moving the bobbin around the mandrel 16.
  • the first strip material 14 forms a first helically-wound strip 3c around the mandrel.
  • a second strip material 15 is provided, again on a bobbin, in the present case used to bond to and provide rigidity to the first strip material 14.
  • the second strip material 15 can be a paper material which is dipped in a reservoir of adhesive such that adhesive is present on its outer surface before it reaches the mandrel and is then adhered to the first strip material 14.
  • the bobbin of second strip material 15 is moved around the mandrel such that the second strip material 15 forms second helically-wound strips 3c around the tube 3b.
  • the respective bobbins of the first and second strip materials 14, 15 are, in the present example, arranged to turn about the mandrel 16 in opposite directions.
  • at least one of the braided and/ or helically- wound strips is arranged in a left handed helical pattern and at least one of the plurality of braided strips is arranged in a right handed helical pattern.
  • a cutting arrangement 17 is provided, which is the same as that described with reference to Figure 3a.
  • FIG. 4 is a flow diagram illustrating a method of forming a component 3, 3’ as described herein.
  • a source of strip material comprising aerosol generating material is provided. This can, for instance, be provided on a bobbin.
  • the strip material is fed towards a mandrel.
  • the strip material is wound around the mandrel to form a helically-wound strip comprising aerosol generating material. As described above, this can be achieved by turning a mandrel (with optional hollow tube) or by moving the bobbins of material around the mandrel.
  • the aerosol-generating material 3 can be provided in the form of a sheet or cut sheet which comprises a first surface and a second surface opposite the first surface.
  • the dimensions of the first and second surfaces are congruent.
  • the first and second surfaces of the sheet or cut sheet may have any shape.
  • the first and second surfaces may be square, rectangular, oblong or circular. Irregular shapes are also envisaged.
  • the first and/or second surfaces of the sheet or cut sheet may be relatively uniform (e.g. they may be relatively smooth) or they may be uneven or irregular.
  • the first and/or second surfaces of the sheet maybe textured or patterned to define a relatively coarse surface.
  • the first and/or second surfaces are relatively rough.
  • the smoothness of the first and second surfaces may be influenced by a number of factors, such as the area density of the sheet or cut sheet, the nature of the components that make up the aerosol generating material or whether the surfaces of the material have been manipulated, for example embossed, scored or otherwise altered to confer them with a pattern or texture.
  • the width, or cut width, of the strands or strips of material 14, 15 can be between 1 mm and 15 mm.
  • the width can be between 5mm and 12mm.
  • the width of the strands or strips of material 14, 15 is greater than 1.5 times the diameter of the cavity 3a.
  • the width of the strands or strips of material 14, 15 can be greater than 2, 2.5, 3 or 4 times the diameter of the cavity. Such a ratio of strip widths to cavity diameter can result in a more resilient structure of the component 3’.
  • the strips of material 14, 15 can be formed from a sheet of aerosol-generating material.
  • the sheet of aerosol-generating material has a thickness of at least about too pm.
  • the sheet may have a thickness of at least about 120 pm, 140 pm, 160 pm, 180 pm or 200 pm.
  • the sheet has a thickness of from about 150 pm to about 300 pm, from about 151 pm to about 299 pm, from about 152 pm to about 298 pm, from about 153 pm to about 297 pm, from about 154 pm to about 296 pm, from about 155 pm to about 295 pm, from about 156 pm to about 294 pm, from about 157 pm to about 293 pm, from about 158 pm to about 292 pm, from about 159 pm to about 291 pm or from about 160 pm to about 290 pm.
  • the sheet has a thickness of from about 170 pm to about 280 pm, from about 180 to about 270 pm, from about 190 to about 260 pm, from about 200 pm to about 250 pm or from about 210 pm to about 240 pm.
  • the thickness of the sheet may vary between the first and second surfaces.
  • an individual strip or piece of the aerosol-generating material has a minimum thickness over its area of about too pm.
  • an individual strip or piece of the aerosol-generating material has a minimum thickness over its area of about 0.05 mm or about 0.1 mm.
  • an individual strip of the aerosol-generating material has a maximum thickness over its area of about 1.0mm.
  • an individual strip or piece of the aerosol-generating material has a maximum thickness over its area of about 0.5 mm or about 0.3 mm.
  • the thickness of the sheet can be determined using ISO 534:2011 “Paper and Board-
  • the sheet of aerosol-generating material is too thick, then heating efficiency can be compromised. This can adversely affect power consumption in use, for instance the power consumption for release of flavour from the aerosol-generating material.
  • the aerosol-generating material is too thin, it can be difficult to manufacture and handle; a very thin material can be harder to cast and may be fragile, compromising aerosol formation in use. It is postulated that if the sheet of aerosol-generating material is too thin (e.g. less than 100 pm), then it may be necessary to increase the cut width of the sheet to achieve sufficient tensile strength.
  • a sheet having a thickness of at least about 100 pm, along with an area density of from about 100 g/m 2 to about 250 g/ m 2 is less liable to tear, split or become otherwise deformed during its manufacture.
  • a thickness of at least about too pm may have a positive effect on the overall structural integrity and strength of sheet or shredded sheet. For example, it may have a good tensile strength and thus be relatively easy to process.
  • the thickness of the sheet is also thought to have a bearing on its area density. That is to say, increasing the thickness of the sheet may increase the area density of the sheet.
  • area density this refers to an average area density calculated for a given strip, strand, piece or sheet of the aerosol-generating material, the area density calculated by measuring the surface area and weight of the given strip, strand, piece or sheet of aerosol-generating material.
  • the sheet of aerosol-generating material has an area density of from about too g/ m 2 to about 250 g/m 2 .
  • the sheet may have an area density of from about 110 g/m 2 to about 240 g/m 2 , from about 120 g/m 2 to about 230 g/m 2 , from about 130 g/m 2 to about 220 g/m 2 or from about 140 g/m 2 to about 210 g/m 2 .
  • the sheet has an area density of from about 130 g/m 2 to about 190 g/m 2 , from about 140 g/m 2 to about 180 g/m 2 , from about 150 g/m 2 to about 170 g/m 2 .
  • the sheet has an area density of about 160 g/m 2 .
  • the area density of about too g/m 2 to about 250 g/m 2 is thought to contribute to the strength and flexibility of sheet.
  • the flexibility of the sheet is considered be dependent, at least in part, upon the thickness and area density of the sheet. A thicker sheet may be less flexible than a thinner sheet. Also, the greater the area density of the sheet, the less flexible the sheet is. It is thought that the combined thickness and area density of the aerosol-generating material described herein provides a sheet that is relatively flexible. When the aerosol- generating material is incorporated into an article for use in a non-combustible aerosol- provision device, this flexibility, may give rise to various advantages.
  • the strands or strips are able to readily deform and flex when an aerosol generator is inserted into the aerosol generating material, thus facilitating insertion of an aerosol generator (e.g. a heater) into the material and also improving retention of the aerosol generator by the aerosol-generating material.
  • an aerosol generator e.g. a heater
  • the area density of the sheet of aerosol-generating material influences the roughness of the first and second surfaces of the sheet or shredded sheet. By changing the area density, the roughness of the first and/ or second surfaces can be tailored.
  • the average volume density of the sheet of aerosol-generating material may be calculated from the thickness of the sheet and the area density of the sheet.
  • the average volume density maybe greater than about 0.2 g/cm 3 , about 0.3 g/cm 3 or about 0.4 g/cm 3 .
  • the average volume density is from about 0.2 g/cm 3 to about 1 g/ cm 3 , from about 0.3 g/ cm 3 to about 0.9 g/ cm 3 , from about 0.4 g/ cm 3 to about 0.9 g/cm3, from about 0.5 g/ cm 3 to about 0.9 g/cms or from about 0.6 g/cms to about 0.9 g/cm3.
  • an aerosol-generating material comprising a sheet of aerosol-generating material comprising tobacco material, an aerosol-former material and a binder, wherein the sheet has a density of greater than about 0.4 g/cms.
  • the density is from about 0.4 g/cm3 to about 2.9 g/cm?-, from about 0.4 g/cm-Ao about 1 g/ cm?-, from about 0.6 cm3 to about 1.6 cm3 0 r from about 1.6 cm3 to about 2.9 cm3.
  • the sheet may have a tensile strength of at least 4 N/15 mm. Where the sheet has a tensile strength below 4 N/15 mm, the sheet is likely to tear, break or otherwise deform during its manufacture and/ or subsequent incorporation into an article for use in a non-combustible aerosol provision system. Tensile strength maybe measured using ISO 1924:2008.
  • the aerosol-generating material comprises tobacco material.
  • the sheet of aerosol generating material comprises tobacco material.
  • the tobacco material may be a particulate or granular material.
  • the tobacco material is a powder.
  • the tobacco material may comprise may comprise strips, strands or fibres of tobacco.
  • the tobacco material may comprise particles, granules, fibres, strips and/or strands of tobacco.
  • the tobacco material consists of particles or granules of tobacco material.
  • the density of the tobacco material has an impact on the speed at which heat conducts through the material, with lower densities, for instance those below 900 mg/ cc, conducting heat more slowly through the material, and therefore enabling a more sustained release of aerosol.
  • the tobacco material can comprise reconstituted tobacco material having a density of less than about 900 mg/cc, for instance paper reconstituted tobacco material.
  • the aerosol-generating material comprises reconstituted tobacco material having a density of less than about 800 mg/ cc.
  • the aerosol-generating material can comprise reconstituted tobacco material having a density of at least 350 mg/cc.
  • the reconstituted tobacco material can be provided in the form of a shredded sheet.
  • the sheet of reconstituted tobacco material may have any suitable thickness.
  • the reconstituted tobacco material may have a thickness of at least about 0.145 mm, for instance at least about 0.15 mm, or at least about 0.16 mm.
  • the reconstituted tobacco material may have a maximum thickness of about 0.30 mm or 0.25 mm, for instance the thickness of the reconstituted tobacco material maybe less than about 0.22 mm, or less than about 0.2 mm.
  • the reconstituted tobacco material may have an average thickness in the range 0.175 mm to 0.195 mm.
  • the tobacco is a particulate tobacco material.
  • Each particle of the particulate tobacco material may have a maximum dimension.
  • maximum dimension refers to the longest straight line distance from any point on the surface of a particle of tobacco, or on a particle surface, to any other surface point on the same particle of tobacco, or particle surface.
  • the maximum dimension of a particle of particulate tobacco material may be measured using scanning electron microscopy (SEM).
  • the maximum dimension of each particle of tobacco material can be up to about 200 pm. In some embodiments, the maximum dimension of each particle of tobacco material is up to about 150 pm.
  • a population of particles of the tobacco material may have a particle size distribution
  • a population of particles of the tobacco material has a particle size distribution (D90) of about 110 pm, at least about 120 pm, at least about 130 pm, at least about 140 pm or at least about pm. In an embodiment, a population of particles of the tobacco material has a particle size distribution (D90) of about 150 pm. Sieve analysis can also be used to determine the particle size distribution of the particles of tobacco material.
  • a particle size distribution (D90) of at least about too pm is thought to contribute to the tensile strength of the sheet of aerosol-generating material.
  • a particle size distribution (D90) of less than 100 pm can provide a sheet of aerosol generating material having good tensile strength.
  • the inclusion of such fine particles of tobacco material in the sheet can increase its density.
  • this higher density may decrease the fill-value of the tobacco material.
  • a balance between a satisfactory tensile strength and suitable density (and thus fill -value) maybe achieved where the particle size distribution (D90) is at least about 100 pm.
  • the particle size of the particulate tobacco material can also influence the roughness of the sheet of aerosol generating material. It is postulated that forming the sheet of aerosol-generating material by incorporating relatively large particles of tobacco material decreases the density of the sheet of aerosol generating material.
  • the tobacco material may comprise tobacco obtained from any part of the tobacco plant.
  • the tobacco material comprises tobacco leaf.
  • the sheet can comprise from 5% to about 90% by weight tobacco leaf.
  • the tobacco material may comprise lamina tobacco and/or tobacco stem, such as midrib stem.
  • the lamina tobacco can be present in an amount of from 0% to about 100%, from about 20% to about 100%, from about 40% to about 100%, from about
  • tobacco material consists or consists essentially of lamina tobacco material.
  • the tobacco material may comprise tobacco stem in an amount of from 0% to about 100%, from about 0% to about 50%, from about o to about 25%, from about o to about 20%, from about 5 to about 15% by weight of the sheet or shredded sheet.
  • the tobacco material comprises a combination of lamina and tobacco stem.
  • the tobacco material can comprise lamina in an amount of from about 40% to about 95% and stem in an amount of from about 5% to about 60%, or lamina in an amount of from about 60% to about 95% and stem in an amount of from about 5% to about 40%, or lamina in an amount of from about 80% to about 95% and stem in an amount of from about 5% to about 20% by weight of the sheet of aerosol-generating material.
  • the incorporation of stem may decrease the tackiness of the aerosol-generating material.
  • Incorporating tobacco material comprising stem tobacco into the aerosol generating material may increase its burst strength.
  • the sheet or the shredded sheet of aerosol-generating material may have a burst strength of at least about 75 g, at least about too g or at least about 200 g.
  • the sheet may be relatively brittle.
  • breakages in the sheet may occur during the process of manufacturing the aerosol generating material. For example, when the sheet is shredded to form a shredded sheet by a cutting process, the sheet may shatter or break into pieces or shards when cut.
  • the tobacco material described herein contains nicotine.
  • the nicotine content is from 0.1 to 3% by weight of the tobacco material, and may be, for example, from 0.5 to 2.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material contains between 10% and 90% by weight tobacco leaf having a nicotine content of greater than about 1% or about 1.5% by weight of the tobacco leaf.
  • the tobacco leaf, for instance cut rag tobacco can, for instance, have a nicotine content of between 1% and 5% by weight of the tobacco leaf.
  • the sheet of aerosol-generating material may comprise nicotine in an amount of between 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 material described herein.
  • Paper reconstituted tobacco refers to tobacco material formed by a process in which tobacco feedstock is extracted with a solvent to afford an extract of solubles and a residue comprising fibrous material, and then the extract (usually after concentration, and optionally after further processing) is recombined with fibrous material from the residue (usually after refining of the fibrous material, and optionally with the addition of a portion of non-tobacco fibres) by deposition of the extract onto the fibrous material.
  • the process of recombination resembles the process for making paper.
  • the paper reconstituted tobacco may be any type of paper reconstituted tobacco that is known in the art.
  • the paper reconstituted tobacco is made from a feedstock comprising one or more of tobacco strips, tobacco stems, and whole leaf tobacco.
  • the paper reconstituted tobacco is made from a feedstock consisting of tobacco strips and/or whole leaf tobacco, and tobacco stems.
  • scraps, fines and winnowings can alternatively or additionally be employed in the feedstock.
  • the paper reconstituted tobacco for use in the tobacco material described herein may be prepared by methods which are known to those skilled in the art for preparing paper reconstituted tobacco.
  • the paper reconstituted tobacco is present in an amount of from 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 constituents capable of forming an aerosol.
  • the aerosol-former material comprises one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
  • the aerosol-former material is glycerol or propylene glycol.
  • the sheet of aerosol-generating material comprises an aerosol-former material.
  • the aerosol-former material is provided in an amount of up to about 50% on a dry weight base by weight of the sheet or shredded sheet.
  • the aerosol former material is provided in an amount of from about 5% to about 40% on a dry weight base by weight of the sheet or shredded sheet, from about 10% to about 30% on a dry weight base by weight of the sheet or from about 10% to about 20% on a dry weight base by weight of the sheet or shredded sheet.
  • the sheet may also comprise water.
  • the sheet of aerosol-generating material may comprise water in an amount of less than about 15%, less than about 10% or less than about 5% by weight of the aerosol-generating material.
  • the aerosol-generating material comprises water in an amount of between about 0% and about 15% or between about 5% and about 15% by weight of the aerosol-generating material.
  • the sheet of aerosol-generating material may comprise water and an aerosol-former material, in a total amount, of less than about 30% by weight of the sheet of aerosol generating material or less than about 25% by weight of the sheet of aerosol-generating material. It is thought that incorporating water and aerosol-former material in the sheet of aerosol-generating material in an amount of less than about 30% by weight of the sheet of aerosol-generating material may advantageously reduce the tackiness of the sheet. This may improve the ease by which the aerosol-generating material can be handled during processing. For example, it maybe easier to roll a sheet of aerosol generating material to form a bobbin of material and then unroll the bobbin without the layers of sheet sticking together. Reducing the tackiness may also decrease the propensity for strands or strips of shredded material to clump or stick together, thus further improving processing efficiency and the quality of the final product.
  • the sheet comprises a binder.
  • the binder is arranged to bind the components of the aerosol-generating material to form the sheet or shredded sheet.
  • the binder may at least partially coat the surface of the tobacco material. Where the tobacco material is in a particulate form, the binder may at least partially coat the surface of the particles of tobacco and bind them together.
  • the binder may be selected from one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof.
  • the binder comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol.
  • the binder comprises alginate and/ or pectin or carrageenan.
  • the binder comprises guar gum.
  • the binder may be present in an amount of from about 1 to about 20% by weight of the sheet or shredded sheet, or in an amount of from 1 to about 10% by weight of the sheet of aerosol-generating material.
  • the binder may be present in an amount of about i%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9% or 10% by weight of the sheet of aerosol generating material.
  • the aerosol-generating material may comprise a filler.
  • the sheet comprises the filler.
  • the filler is generally a non-tobacco component, that is, a component that does not include ingredients originating from tobacco.
  • the filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves.
  • the filler may be a non-tobacco fibre such as wood fibre or pulp or wheat fibre.
  • the filler can be a material comprising cellulose or a material comprises a derivate of cellulose.
  • the filler component may also be a non-tobacco cast material or a non tobacco extruded material.
  • the filler is fibrous.
  • the filler may be a fibrous organic filler material such as wood, wood pulp, hemp fibre, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that including fibrous filler may increase the tensile strength of the material.
  • the filler may also contribute to the texture of the sheet of the aerosol-generating material.
  • a fibrous filler, such as wood or wood pulp may provide a sheet of aerosol-generating material having relatively rough first and second surfaces.
  • a non-fibrous, particulate filler such as powdered chalk, may provide a sheet of aerosol-generating material having relatively smooth first and second surfaces.
  • the aerosol-generating material comprises a combination of different filler materials.
  • the filler component maybe present in an amount of o to 20% by weight of the sheet or shredded sheet, or in an amount of from 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 properties of the aerosol generating material, such as its tensile strength and burst strength.
  • this refers to a dry weight basis, unless specifically indicated to the contrary.
  • any water that may be present in the aerosol-generating material, or in any component thereof, is entirely disregarded for the purposes of the determination of the weight %.
  • the water content of the aerosol-generating material described herein may vary and may be, for example, from 5 to 15% by weight.
  • the water content of the aerosol-generating material described herein may vary according to, for example, the temperature, pressure and humidity conditions at which the compositions are maintained.
  • the water content can be determined by Karl-Fisher analysis, as known to those skilled in the art.
  • the aerosol-former material is a component that is in liquid phase, such as glycerol or propylene glycol, any component other than water is included in the weight of the aerosol-generating material.
  • 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" in the weight % as defined herein. All other ingredients present in the tobacco component are included in the weight of the tobacco component, even if of non-tobacco origin (for example non-tobacco fibres in the case of paper reconstituted tobacco).
  • the aerosol-generating material herein can comprise an aerosol-modifying agent, such as any of the flavours described herein.
  • the aerosol-generating material comprises menthol.
  • the article may be referred to as a mentholated article.
  • the aerosol-generating material can comprise from o.5mg to 20mg of menthol, from 0.7 mg to 20 mg of menthol, between lmg and i8mg or between 8mg and i6mg of menthol.
  • the aerosol-generating material comprises i6mg of menthol.
  • the aerosol-generating material can comprise between 1% and 8% by weight of menthol, preferably between 3% and 7% by weight of menthol and more preferably between 4% and 5.5% by weight of menthol. In one embodiment, the aerosol-generating material comprises 4.7% by weight of menthol.
  • Such high levels of menthol loading can be achieved using a high percentage of reconstituted tobacco material, for instance greater than 50% of the tobacco material by weight.
  • the use of a high volume of, for instance tobacco material can increase the level of menthol loading that can be achieved, for instance where greater than about 500 mm3 0 r suitably more than about 1000 mm3 0 f aerosol generating material, such as tobacco material, are used.
  • the composition comprises an aerosol-forming “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous).
  • the amorphous solid may comprise a dried gel.
  • the amorphous solid is a solid material that may retain some fluid, such as liquid, within it.
  • the amorphous solid comprises: - 1-60 wt% of a gelling agent
  • the amorphous solid comprises:
  • the amorphous solid material may be provided in sheet or in shredded sheet form.
  • the amorphous solid material may take the same form as the sheet of aerosol-generating material described previously.
  • the amorphous solid may comprise from about iwt%, 5wt%, iowt%, I5wt%, 20wt% or 25wt% to about 6owt%, 50wt%, 45wt%, 40wt% or 35wt% of a gelling agent (all calculated on a dry weight basis).
  • the amorphous solid may comprise i-50wt%, 5 45wt%, io-40wt% or 20-35wt% of a gelling agent.
  • the gelling agent comprises a hydrocolloid.
  • the gelling agent comprises one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof.
  • the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol.
  • the gelling agent comprises alginate and/or pectin, and maybe combined with a setting agent (such as a calcium source) during formation of the amorphous solid.
  • the amorphous solid may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.
  • the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of from io-30wt% of the amorphous solid (calculated on a dry weight basis).
  • alginate is the only gelling agent present in the amorphous solid.
  • the gelling agent comprises alginate and at least one further gelling agent, such as pectin.
  • the amorphous solid may include gelling agent comprising carrageenan.
  • the amorphous solid may comprise from about o.iwt%, o.5wt%, iwt%, 3wt%, 5wt%, 7wt% or 10% to about 50wt%, 45wt%, 40wt%, 35wt%, 30wt% or 25wt% of an aerosol-former material (all calculated on a dry weight basis).
  • the aerosol-former material may act as a plasticiser.
  • the amorphous solid may comprise 0.5- 40wt%, 3 35wt% or io-25wt% of an aerosol-former material.
  • the aerosol-former material comprises one or more compound selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol.
  • the aerosol- former material comprises, consists essentially of or consists of glycerol.
  • the amorphous solid comprises a flavour.
  • the amorphous solid may comprise up to about 8owt%, 70wt%, 6owt%, 55wt%, 50wt% or 45wt% of a flavour.
  • the amorphous solid may comprise at least about o.iwt%, iwt%, iowt%, 20wt%, 30wt%, 35wt% or 40wt% of a flavour (all calculated on a dry weight basis).
  • the amorphous solid may comprise i-8owt%, io-8owt%, 20-70wt%, 30- 6owt%, 35 55wt% or 30-45wt% of a flavour.
  • the flavour comprises, consists essentially of or consists of menthol.
  • the amorphous solid may additionally comprise an emulsifying agent, which emulsified molten flavour during manufacture.
  • the amorphous solid may comprise from about 5wt% to about I5wt% of an emulsifying agent (calculated on a dry weight basis), suitably about iowt%.
  • the emulsifying agent may comprise acacia gum.
  • the amorphous solid is a hydrogel and comprises less than about 20 wt% of water calculated on a wet weight basis. In some cases, the hydrogel may comprise less than about i5wt%, 12 wt% or 10 wt% of water calculated on a wet weight basis. In some cases, the hydrogel may comprise at least about iwt%, 2wt% or at least about 5wt% of water (WWB). In some embodiments, the amorphous solid additionally comprises an active substance. For example, in some cases, the amorphous solid additionally comprises a tobacco material and/or nicotine.
  • the amorphous solid may comprise 5- 6owt% (calculated on a dry weight basis) of a tobacco material and/or nicotine. In some cases, the amorphous solid may comprise from about iwt%, 5wt%, iowt%, I5wt%, 20wt% or 25wt% to about 70wt%, 6owt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt%
  • the amorphous solid may comprise from about iwt%, 5wt%, iowt%, I5wt%, 20wt% or 25wt% to about 70wt%, 6owt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of a tobacco material.
  • the amorphous solid may comprise 10- 50wt%, i5-40wt% or 20-35wt% of a tobacco material.
  • the amorphous solid may comprise from about iwt%, 2wt%, 3wt% or 4wt% to about 20wt%, i8wt%, I5wt% or I2wt% (calculated on a dry weight basis) of nicotine.
  • the amorphous solid may comprise i-20wt%, 2-i8wt% or 3-i2wt% of nicotine.
  • the amorphous solid comprises an active substance such as tobacco extract.
  • the amorphous solid may comprise 5-6owt% (calculated on a dry weight basis) of tobacco extract.
  • the amorphous solid may comprise from about 5wt%, iowt%, I5wt%, 20wt% or 25wt% to about 6owt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) tobacco extract.
  • the amorphous solid may comprise io-50wt%, i5-40wt% or 20-35wt% of tobacco extract.
  • the tobacco extract may contain nicotine at a concentration such that the amorphous solid comprises iwt% i.5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%, 4-5wt% or 4wt% (calculated on a dry weight basis) of nicotine.
  • the amorphous solid comprises no tobacco material but does comprise nicotine.
  • the amorphous solid may comprise from about iwt%, 2wt%, 3wt% or 4wt% to about 20wt%, i8wt%, i5wt% or i2wt% (calculated on a dry weight basis) of nicotine.
  • the amorphous solid may comprise l- 20wt%, 2-i8wt% or 3-i2wt% of nicotine.
  • the total content of active substance and/ or flavour may be at least about o.iwt%, iwt%, 5wt%, iowt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of active substance and/ or flavour may be less than about 90wt%, 8owt%, 70wt%,
  • the total content of tobacco material, nicotine and flavour may be at least about o.iwt%, iwt%, 5wt%, iowt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of active substance and/ or flavour may be less than about 90wt%, 8owt%, 70wt%, 6owt%, 50wt% or 40wt% (all calculated on a dry weight basis).
  • the amorphous solid may be made from a gel, and this gel may additionally comprise a solvent, included at o.i-50wt%.
  • a solvent in which the flavour is soluble may reduce the gel stability and the flavour may crystallise out of the gel.
  • the gel does not include a solvent in which the flavour is soluble.
  • the amorphous solid comprises less than 6owt% of a filler, such as from iwt% to 6owt%, or 5wt% to 50wt%, or 5wt% to 30wt%, or iowt% to 20wt%.
  • the amorphous solid comprises less than 20wt%, suitably less than iowt% or less than 5wt% of a filler. In some cases, the amorphous solid comprises less than iwt% of a filler, and in some cases, comprises no filler.
  • the filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves.
  • the filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives.
  • the amorphous solid comprises no calcium carbonate such as chalk.
  • the filler is fibrous.
  • the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that including fibrous filler in an amorphous solid may increase the tensile strength of the material.
  • the amorphous solid does not comprise tobacco fibres.
  • the amorphous solid in sheet form may have a tensile strength of from around 200 N/m to around 1500 N/m.
  • the amorphous solid may have a tensile strength of from 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m.
  • Such tensile strengths may be particularly suitable for embodiments wherein the amorphous solid material is formed as a sheet and then shredded and incorporated into an aerosol-generating article.
  • the amorphous solid may have a tensile strength of from 600 N/m to 1500 N/m, or from 700 N/m to 900 N/m, or around 800 N/m.
  • tensile strengths may be particularly suitable for embodiments wherein the amorphous solid material is included in an aerosol-generating article as a rolled sheet, suitably in the form of a tube.
  • the amorphous solid may consist essentially of, or consist of a gelling agent, water, an aerosol-former material, a flavour, and optionally an active substance.
  • the amorphous solid may consist essentially of, or consist of a gelling agent, water, an aerosol-former material, a flavour, 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 material.
  • the aerosol-generating material can comprise a paper reconstituted tobacco material.
  • the composition can alternatively or additionally comprise any of the forms of tobacco described herein.
  • the aerosol generating material can comprise a sheet comprising tobacco material comprising between 10% and 90% by weight tobacco leaf, wherein an 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.
  • the aerosol-generating material comprises an amorphous solid material
  • the amorphous solid material maybe a dried gel comprising menthol.
  • the amorphous solid may have any composition as described herein.
  • An improved article maybe produced comprising aerosol-generating material comprising a first component comprising a sheet of aerosol-generating material and a second component comprising amorphous solid, wherein the material properties (e.g. density) and specification (e.g. thickness, length, and cut width) fall within the ranges set out herein.
  • material properties e.g. density
  • specification e.g. thickness, length, and cut width
  • the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm.
  • the thickness maybe in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.
  • a material having a thickness of about 0.09 mm can be used.
  • the amorphous solid may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.
  • the thickness of the amorphous solid material maybe measured using a calliper or a microscope such as a scanning electron microscope (SEM), as known to those skilled in the art, or any other suitable technique known to those skilled in the art.
  • SEM scanning electron microscope
  • an individual strip or piece of the amorphous solid has a minimum thickness over its area of about 0.015. In some cases, an individual strip or piece of the amorphous solid has a minimum thickness over its area of about 0.05 mm or about 0.1 mm. In some cases, an individual strip or piece of the amorphous solid has a maximum thickness over its area of about 1.0mm. In some cases, an individual strip or piece of the amorphous solid has a maximum thickness over its area of about 0.5 mm or about 0.3 mm.
  • the amorphous solid thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1% across its area.
  • the area density of the amorphous solid material may be between 50% and 150% of the area density of the aerosol-generating material.
  • the area density of the amorphous solid material may be between 60% and 140% of the density of the aerosol-generating material, or between 70% and 110% of the area density of the aerosol-generating material, or between 80% and 120% of the area density of the aerosol-generating material.
  • 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 with an aerosol- generating material, such as the sheet of aerosol-generating material described herein.
  • the amorphous solid sheet may additionally be incorporated as a planar sheet, as a gathered or bunched sheet, as a crimped sheet, or as a rolled sheet (i.e. in the form of a tube).
  • the amorphous solid of these embodiments may be included in an aerosol-generating article as a sheet, such as a sheet circumscribing a rod comprising aerosol-generating material.
  • the amorphous solid sheet maybe formed on a wrapping paper which circumscribes an aerosol-generating material such as tobacco.
  • the amorphous solid in sheet form may have any suitable area density, such as from about 30 g/ m 2 to about 150 g/ m 2 .
  • the sheet may have a mass per unit area of about 55 g/m 2 to about 135 g/m 2 , or about 80 to about 120 g/m 2 , or from about 70 to about 110 g/ m 2 , or particularly from about 90 to about 110 g/ m 2 , or suitably about too g/ m 2 .
  • These ranges can provide a density which is similar to the density of cut rag tobacco and as a result a mixture of these substances can be provided which will not readily separate.
  • Such area densities may be particularly suitable where the amorphous solid material is included in an aerosol-generating article as a shredded sheet (described further hereinbelow).
  • the sheet may have a mass per unit area of about 30 to 70 g/ m 2 , 40 to 60 g/ m 2 , or 25 to 60 g/ m 2 and may be used to wrap an aerosol-generating material, such as the aerosol-generating material described herein.
  • the aerosol-generating material may comprise a blend of the aerosol-generating material and the amorphous solid material as described herein.
  • Such aerosol generating material can provide an aerosol, in use, with a desirable flavour profile, since additional flavour may be introduced to the aerosol-generating material by inclusion in the amorphous solid material component.
  • Flavour provided in the amorphous solid material maybe more stably retained within the amorphous solid material compared to flavour added directly to the tobacco material, resulting in a more consistent flavour profile between articles produced according to this disclosure.
  • tobacco material having a density of at least 350 mg/cc and less than about 900 mg/cc, preferably between about 600 mg/cc and about 900 mg/cc, has been advantageously found to result in a more sustained release of aerosol.
  • the amorphous solid material component of the aerosol-generating material should be evenly distributed throughout the rod.
  • the aerosol-generating material comprises a plurality of strips of amorphous solid material.
  • the aerosol generating section comprises a plurality of strands and/or strips of the sheet of aerosol-generating material and a plurality of strips of amorphous solid material
  • the material properties and/or dimensions of the at least two components may be suitably selected in other ways, to ensure a relatively uniform mix of the components is possible, and to reduce separation or un-mixing of the components during or after manufacture of the rod of aerosol generating material.
  • the longitudinal dimension of the plurality of strands or strips may be substantially the same as a length of the aerosol generating section.
  • the plurality of strands and/ or strips may have a length of at least about 5 mm.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Cigarettes, Filters, And Manufacturing Of Filters (AREA)
  • Fireproofing Substances (AREA)
EP22738711.5A 2021-06-18 2022-06-17 A component for use in a non-combustible aerosol provision system Pending EP4355132A1 (en)

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GBGB2108825.7A GB202108825D0 (en) 2021-06-18 2021-06-18 A component for use in a non-combustible aerosol provision system
PCT/GB2022/051560 WO2022263865A1 (en) 2021-06-18 2022-06-17 A component for use in a non-combustible aerosol provision system

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EP (1) EP4355132A1 (pt)
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