EP4623727A1

EP4623727A1 - An article for use with an aerosol provision device

Info

Publication number: EP4623727A1
Application number: EP24167687.3A
Authority: EP
Inventors: Marcus Hartley
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2024-03-28
Filing date: 2024-03-28
Publication date: 2025-10-01
Also published as: WO2025202339A1

Abstract

An article (3) for use with an aerosol provision device (2) is disclosed. The article includes aerosol generating material (12), a first panel (13) comprising a first join portion (22) and a second panel (14) comprising a second join portion (23). The first join portion and the second join portion define a joint. At least one of the first join portion and second join portion comprises a deformation; and the deformation of the at least one of the first join portion and the second join portion forms the joint as a consequence of that deformation.

Description

Technical Field

The present invention relates to articles for use in connection with aerosol provision devices and as part of an aerosol provision system, a method of providing an aerosol and an aerosol provision means.

Background

Aerosol provision systems which generate an aerosol for a user to inhale are known in the art. Such systems are generally battery powered and contain an aerosol provision device comprising the battery and an aerosol generator, and an article which includes aerosol generating material. Such an article is sometimes known as a consumable. The aerosol can be generated in a variety of ways. For example, the aerosol may be generated by heating a substrate that includes or is formed from an aerosol generating material to form a vapour which subsequently condenses in passing air so to form a condensation aerosol. Alternatively, the aerosol might be generated by mechanical means, vibration etc., so that the substrate becomes dispersed in passing air so as to form an aerosol.

Summary

According to a first aspect of the present disclosure there is provide an article for use with an aerosol provision device, the article comprising:

aerosol generating material;
a first panel comprising a first join portion; and
a second panel comprising a second join portion;
wherein the first join portion and the second join portion define a joint;
wherein at least one of the first join portion and second join portion comprises a deformation; and
wherein the deformation of the at least one of the first join portion and the second join portion forms the joint as a consequence of that deformation.

In accordance with a second aspect of the present disclosure there is provided an aerosol provision system. In which the aerosol provision system includes an aerosol provision device and an article according to the first aspect of the present disclosure.
In accordance with a third aspect of the present disclosure there is provided a method of manufacture of an article comprising aerosol generating material for use in an aerosol provision device. In which the method includes

providing a first panel comprising a first join portion; and
providing a second panel comprising a second join portion;
wherein the first join portion and the second join portion define a joint;
deforming at least one of the first join portion and second join portion to form a joint between the first join portion and the second join portion.

Further features and advantages of the present disclosure will become apparent from the following description of embodiments of the disclosure given by way of example and with reference to the accompanying drawings.

Drawings

Figure 1 shows a schematic view of an embodiment of an aerosol provision system which includes an article according to the present disclosure;
Figure 2 shows a schematic view of an embodiment of an article according to the present disclosure for use in the system of Figure 1;
Figure 3 shows a schematic partial sectional view of a first embodiment of the article of Figure 2 along the section line A-A';
Figure 4 shows a schematic partial sectional view of a second embodiment of the article of Figure 2 along the section line A-A';
Figure 5 shows a schematic partial sectional view of a third embodiment of the article of Figure 2 along the section line A-A';
Figure 6 shows a schematic partial view of a fourth embodiment of an article according to the present disclosure for use in the system of Figure 1;
Figure 7 shows a schematic partial sectional view of a first embodiment of the article of Figure 6 along the section line B-B';
Figure 8 shows a schematic partial view of a fifth embodiment of an article according to the present disclosure for use in the system of Figure 1; and
Figure 9 shows a schematic partial sectional view of a second embodiment of the article of Figure 8 along the section line B-B'.

Detailed Description

According to a first aspect of the present disclosure there is provided an article for use with an aerosol provision device. The article includes aerosol generating material; a first panel comprising a first join portion; and a second panel comprising a second join portion. The first join portion and the second join portion define a joint. At least one of the first join portion and second join portion comprises a deformation, and the deformation of the at least one of the first join portion and the second join portion forms the joint as a consequence of that deformation.
The joint defined by the first and second join portions is a connection between the first and second join portions. That connection may be alternatively described as an engagement between the first and second join portions, an attachment of the first join portion to the second join portion, or a binding between the first and second join portions.
In an embodiment of the above embodiment, at least one of the first join portion and second join portion comprises a plurality of deformations, and the deformations of the at least one of the first join portion and the second join portion collectively form the joint as a consequence of those deformations.
In an embodiment of any of the above embodiments, the first join portion extends at least one of across and into a plane of the second join portion.
In an embodiment of any of the above embodiments, the first join portion and second join portion are both substantially planar and the first join portion extends in a plane parallel to or approximately parallel to the plane of the second join portion.
In an embodiment of any of the above embodiments, the first join portion and second join portion are both substantially planar and the first join portion extends in a plane that intersects the plane of the second join portion.
In an embodiment of any of the above embodiments, the first join portion includes one of a curved surface and a flat surface, the second join portion includes one of a curved surface and a flat surface, and the first join portion surface extends at least one of across and into the second join portion surface.
In an embodiment of any of the above embodiments, the article is rod shaped or tubular.
In an embodiment of the above embodiment the rod shaped or tubular article has a longitudinal axis and the cross section of the tubular article perpendicular to the longitudinal axis is one of circular or rectangular.
In an embodiment of any of the above embodiments, the second join portion interlocks with the first join portion. In such an embodiment the interlocking of the first join portion and second join portion is caused by the deformation of the at least one of the first join portion and the second join portion and the joint is formed as a consequence of that interlocking / deformation.
In an embodiment of any of the above embodiments, the joint is free from a joining material.
In an embodiment of any of the above embodiments, the joint is formed only from the first and second join portions. In such an embodiment there is no part of the joint that is not part of the first or the second join portions
In an embodiment of any of the above embodiments, the joint is free from an adhesive to bind the first join portion and the second join portion to each other.
An advantage of the formation of the joint without the use of any external or additional joining material is that there is no concern that any undesirable flavours, compounds or off-notes are generated when the aerosol provision device and article are in use.
The above advantage is achieved because there is no joining material used in the formation of the joint. This has the result that a possible source for such undesirable flavours, compounds or off-notes is absent because there is no joining material.
A further advantage is that joining materials, such as adhesives, may typically include a solvent that allows the joining material set and adhere to the material that forms the joint. The absence of the joining material results in none of that solvent being caused to be emitted from the joining material when the article is in use. This is likely to be beneficial to both the user of the article and the environment as a whole.
In an embodiment of any of the above embodiments, each of the first join portion and the second join portion comprise deformation.
In an embodiment of any of the above embodiments, each of the first join portion and the second join portion comprise at least one deformation.
In an embodiment of any of the above embodiments, the deformation comprises a deformed element.
In an embodiment of any of the above embodiments, at least one deformation comprises a deformed element.
In an embodiment of any of the above embodiments, the deformation comprises a cut.
In an embodiment of any of the above embodiments, at least one deformation comprises a cut.
In an embodiment of any of the above embodiments, the cut is made in the material of the panel that includes the join portion that includes the deformation.
In some embodiments of the above embodiments, the or at least one cut extends through the material of that panel.
In some embodiments of the above embodiments, the or at least one cut does not extend through the material of that panel.
In an embodiment of any of the above embodiments, the deformation comprises a fold.
In an embodiment of any of the above embodiments, at least one deformation comprises a fold.
In an embodiment of any of the above embodiments, the deformation comprises a compression.
In an embodiment of any of the above embodiments, at least one deformation comprises a compression.
In an embodiment of the above embodiments, the compression is the result of the exertion of an external force on at least a part of the join portion that includes the deformation, the result of that force being a change in one or more of shape and density of the part of the join portion that includes the deformation.
In an embodiment of the above embodiments, the compression is of the first join portion and the second join portion against each other.
In an embodiment of the above embodiments, the compression is the result of the exertion of an external force on the first join portion and second join portion, and the result of that force is that the material of the compressed parts of the first join portion and second join portion integrate with each other.
In an embodiment of any of the above embodiments, the deformation comprises an embossment.
In an embodiment of any of the above embodiments, at least one deformation comprises an embossment
In an embodiment of any of the above embodiments, the deformation comprises a ridge in at least one of the first join portion and second join portion.
In an embodiment of any of the above embodiments, the deformation comprises a fold in at least one of the first join portion and second join portion.
In an embodiment of any of the above embodiments, the deformation comprises a cut in at least one of the first join portion and second join portion.
In an embodiment of any of the above embodiments, the deformation comprises a compression in at least one of the first join portion and second join portion.
In some embodiments of the above embodiments, the deformation comprises an embossment.
In some embodiments of the above embodiments, the deformation comprises the removal of material from at least one of the first join portion and second join portion.
In some embodiments of the above embodiments, the deformation comprises ultrasonic welding. The ultrasonic welding may be performed using known techniques appropriate to the nature of the material of the first join portion and / or the second join portion.
In an embodiment of any of the above embodiments, the deformation comprises stitching the first join portion to the second join portion.
In an embodiment of any of the above embodiments, the article includes a sheet of material, and the sheet of material includes the first panel.
In an embodiment of the above embodiment, the sheet of material includes the second panel.
In an alternative embodiment of the above embodiment, the sheet of material is a first sheet of material, and the article includes a second sheet of material. The second sheet of material includes the second panel.
In an embodiment of any of the above embodiments, the first and second panels are discrete panels.
In an embodiment of any of the above embodiments, the second panel is integrally formed with the first panel.
In an embodiment of any of the above embodiments, the aerosol generating material is located on at least one of the sheet of material, the first panel and the second panel.
In an embodiment of any of the above embodiments, the aerosol generating material is a layer of aerosol generating material.
In an embodiment of any of the above embodiments, the aerosol generating material is a solid material.
In an embodiment of any of the above embodiments, the solid material is or includes shredded botanical material, for example and without limitation, one or more of tobacco, rooibos, and reconstituted tobacco.
In an embodiment where the article is rod shaped or tubular. The article may be hollow and a layer or film of aerosol generating material located on the inner face of the rod or tube. The inner face of the rod or tube is the face that faces toward another part of the inner face of the rod or tube.
In an embodiment where the article is rod shaped or tubular. The article may be hollow and the hollow space defined by the inner face of the rod or tube packed with a solid aerosol generating material. In some embodiments the solid material is or includes shredded botanical material, for example and without limitation, one or more of tobacco, rooibos, and reconstituted tobacco.
In an embodiment where the article is rod shaped or tubular and the hollow space defined by the inner face of the rod or tube is packed with a solid aerosol generating material the joint resultant from the deformation is sufficiently robust that the joint resists any outwardly directed force exerted by the aerosol generating material when the article is in use. As a result the article does not split.
In an embodiment of any of the above embodiments, the aerosol generating material is a gel.
In an embodiment of any of the above embodiments, at least one of the sheet of material, the first panel and the second panel comprises a support.
In an embodiment of the above embodiment, the support comprises a support layer.
In an embodiment of any of the above embodiments, at least one of the sheet of material, the first panel and the second panel comprises a heating material.
In an embodiment of the above embodiment, the heating material is heatable by penetration with a varying magnetic field.
In an embodiment of any of the above embodiments, at least one of the sheet of material, the first panel and the second panel comprises a heating layer.
In an embodiment of the above embodiment, the heating layer comprises a or the heating material.
In an embodiment of the above embodiment, the heating layer is located on the support layer.
In an embodiment of the above embodiment, the aerosol generating material is on the heating layer.
In an embodiment of the above embodiment, the heating layer comprises a resistive heating element.
In an embodiment of the above embodiment, the heating layer comprises a susceptor.
In an embodiment of the above embodiment, the heating layer is a foil.
In an embodiment of the above embodiment, the heating layer comprises aluminium.
In an embodiment of the above embodiment, the support layer and the heating layer form a laminate.
In an embodiment of the above embodiment, the laminate comprises the aerosol generating material layer.
In some embodiments of the above embodiments, the article comprises a plurality of first join portions and second join portions, at least two of the first join portions and second join portions include a deformation; and
wherein the deformations of the at least two of the first join portion and the second join portion form the joint as a consequence of those deformations.
In an embodiment of any of the above embodiments, the first and second panels are planar panels.
In an embodiment of any of the above embodiments, the article includes a susceptor layer.
In an embodiment of the above embodiment, the susceptor layer includes aluminium.
In an embodiment of the above embodiment, the heating material is heatable by penetration with a varying magnetic field.
In an embodiment of any of the above embodiments, the article is configured to be receivable in an aerosol provision device.
In accordance with some embodiments described herein, there is provided an aerosol provision device comprising: a chamber configured to at least partially receive the article of any of the above embodiments, the chamber being configured to be a heating chamber for heating the article.
In accordance with a second aspect of the present disclosure there is provided an aerosol provision system. In which the aerosol provision system includes an aerosol provision device and an article of the first aspect of the present disclosure.
In accordance with a third aspect of the present disclosure there is provided a method of manufacture of an article comprising aerosol generating material for use in an aerosol provision device. In which the method includes

The joint formed between the first join portion and and second join portion is a connection between the first join portion and second join portion. That connection may be alternatively described as an engagement between the first join portion and second join portion, an attachment of the first join portion to the second join portion, or a binding between the first join portion and second join portion.
In an embodiment of the above embodiment, at least one of the first join portion and second join portion comprises a plurality of deformations, and the deformations of the at least one of the first join portion and the second join portion collectively form the joint as a consequence of those deformations.
In an embodiment of any of the above embodiments, the method includes orientating the first join portion to extend at least one of across and into a plane of the second join portion.
In an embodiment of any of the above embodiments, the first join portion and second join portion are both substantially planar and the first join portion is orientated to extend in a plane parallel to or approximately parallel to the plane of the second join portion.
In an embodiment of any of the above embodiments, the first join portion and second join portion are both substantially planar and the first join portion is orientated to extend in a plane that intersects the plane of the second join portion.
In an embodiment of any of the above embodiments, the first join portion includes one of a curved surface and a flat surface, the second join portion includes one of a curved surface and a flat surface, and the first join portion surface is orientated to extend at least one of across and into the second join portion surface.
In an embodiment of any of the above embodiments, the second join portion interlocks with the first join portion. In such an embodiment the interlocking of the first join portion and second join portion is caused by the deformation of the at least one of the first join portion and the second join portion and the joint is formed as a consequence of that interlocking / deformation.
In an embodiment of any of the above embodiments, the joint is free from a joining material.
In an embodiment of any of the above embodiments, the forming of the joint does not include use of any joining materials that were not part of the first or second panels before the deformation occurred.
In an embodiment of any of the above embodiments, the joint is formed only from the first and second join portions. In such an embodiment there is no part of the joint that is not part of the first or the second join portions
In an embodiment of any of the above embodiments, the joint is free from an adhesive to bind the first join portion and the second join portion to each other.
In an embodiment of any of the above embodiments, the forming of the joint does not include use of adhesive.
In an embodiment of any of the above embodiments, each of the first join portion and the second join portion are deformed.
In an embodiment of any of the above embodiments, each of the first join portion and the second join portion are deformed at least once.
In an embodiment of any of the above embodiments, the deformation comprises a deformed element.
In an embodiment of any of the above embodiments, at least one deformation comprises at least one deformed element.
In an embodiment of any of the above embodiments, the deformation of at least one of the first join portion and second join portion is the creation of a cut in at least one of the first join portion and second join portion.
In an embodiment of any of the above embodiments, the deformation of at least one of the first join portion and second join portion is the creation of at least one cut in at least one of the first join portion and second join portion.
In an embodiment of any of the above embodiments, the cut is made in the material of the panel that includes the join portion that includes the deformation.
In some embodiments of the above embodiments, the or at least one cut extends through the material of that panel.
In some embodiments of the above embodiments, the or at least one cut does not extend through the material of that panel.
In an embodiment of any of the above embodiments, the deformation of at least one of the first join portion and second join portion is formed by folding one of the first join portion and second join portion.
In an embodiment of any of the above embodiments, the deformation of at least one of the first join portion and second join portion is formed by folding at least one of the first join portion and second join portion at least once.
In an embodiment of any of the above embodiments, the deformation is formed by application of a compressive force to at least part of at least one of the first join portion and second join portion.
In an embodiment of the above embodiment the result of the compression is a change in one or more of the shape and density of the part of the join portion that includes the deformation.
In an embodiment of the above embodiments, the compression is compression of the first join portion and the second join portion against each other.
In an embodiment of the above embodiments, the compression is compression of the first join portion and second join portion against each other, and the result of that compression is that the material of the compressed parts of the first join portion and second join portion integrate with each other.
In an embodiment of any of the above embodiments, the method of creating the or each deformation is the use of an embossing technique.
In an embodiment of any of the above embodiments, the forming of one or more deformations includes forming one or more ridges in at least one of the first join portion and second join portion.
In an embodiment of any of the above embodiments, the forming of one or more deformations includes forming one or more folds in at least one of the first join portion and second join portion.
In an embodiment of any of the above embodiments, the forming of the deformation includes forming one or more cuts in at least one of the first join portion and second join portion.
In an embodiment of any of the above embodiments the forming of the deformation includes applying one or more compressions to at least one of the first join portion and second join portion.
In some embodiments of the above embodiments, the forming of the deformation includes application of at least one embossing technique to at least one of the first join portion and second join portion.
In an embodiment of any of the above embodiments, the forming of the deformation includes removing material from at least one of the first join portion and second join portion.
In some embodiments of the above embodiments, the forming of the deformation includes the use of ultrasonic welding. The ultrasonic welding may be performed using known techniques appropriate to the nature of the material of the first join portion and second join portion.
In an embodiment of any of the above embodiments, the forming of the deformation includes stitching the first join portion to the second join portion.
In an embodiment of any of the above embodiments, the method includes providing a sheet of material and the sheet of material includes the first panel of the article.
In an embodiment of the above embodiment, the sheet of material includes the second panel.
In an alternative embodiment of the above embodiment, the method includes providing a first and a second sheet of material, and the first sheet of material includes the first panel of the article and the second sheet of material includes the second panel of the article.
In an embodiment of any of the above embodiments, the method includes application of the aerosol generating material to at least one of the sheet of material, the first panel and the second panel.
In an embodiment of any of the above embodiments, the method includes application of the aerosol generating material as a layer of aerosol generating material.
In an embodiment of any of the above embodiments, the aerosol generating material applied is a solid material.
In an embodiment of any of the above embodiments, the solid material is or includes shredded botanical material, for example and without limitation, one or more of tobacco, rooibos, and reconstituted tobacco.
In an embodiment where the article is rod shaped or tubular. The article may be hollow and a layer or film of aerosol generating material located on the inner face of the rod or tube. The inner face of the rod or tube is the face that faces toward another part of the inner face of the rod or tube.
In an embodiment where the article is rod shaped or tubular. The article may be hollow and the hollow space defined by the inner face of the rod or tube packed with a solid aerosol generating material. In some embodiments the solid material is or includes shredded botanical material, for example and without limitation, one or more of tobacco, rooibos, and reconstituted tobacco.
In an embodiment where the article is rod shaped or tubular and the hollow space defined by the inner face of the rod or tube is packed with a solid aerosol generating material the joint resultant from the deformation is sufficiently robust that the joint resists any outwardly directed force exerted by the aerosol generating material when the article is in use. As a result the article does not split.
In an embodiment of any of the above embodiments, the aerosol generating material is applied as a gel.
In an embodiment of any of the above embodiments, at least one of the sheet of material, the first panel and the second panel comprises a support.
In an embodiment of the above embodiment, the support comprises a support layer.
In an embodiment of any of the above embodiments, at least one of the sheet of material, the first panel and the second panel comprises a heating material.
In an embodiment of the above embodiment, the heating material is heatable by penetration with a varying magnetic field.
In an embodiment of any of the above embodiments, at least one of the sheet of material, the first panel and the second panel comprises a heating layer.
In an embodiment of the above embodiment, the heating layer comprises a or the heating material.
In an embodiment of the above embodiment, the heating layer is located on the support layer.
In an embodiment of the above embodiment, the aerosol generating material is on the heating layer.
In an embodiment of the above embodiment, the heating layer comprises a resistive heating element.
In an embodiment of the above embodiment, the heating layer comprises a susceptor.
In an embodiment of the above embodiment, the heating layer is a foil.
In an embodiment of the above embodiment, the heating layer comprises aluminium.
In an embodiment of the above embodiment, the support layer and the heating layer form a laminate.
In an embodiment of the above embodiment, the laminate comprises the aerosol generating material layer.
In some embodiments of the above embodiments, the article comprises a plurality of first join portions and second join portions, at least two of the first join portions and second join portions are deformed; and
wherein the deformation of the at least two of the first join portion and the second join portion form the joint.
In an embodiment of any of the above embodiments, the first and second panels are planar panels.
In an embodiment of any of the above embodiments, the article includes a susceptor layer.
In an embodiment of the above embodiment, the susceptor layer includes aluminium.
In an embodiment of the above embodiment, the heating material is heatable by penetration with a varying magnetic field.
In an embodiment of any of the above embodiments, the article is configured to be receivable in an aerosol provision device.##
In some embodiments, the article comprises aerosol-generating material. The article may comprise an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, an aerosol-modifying agent, one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.
The apparatus for heating the aerosol-generating material with which the article is to be used is a part of a non-combustible aerosol provision system. Non-combustible aerosol provision systems 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.
According to the present disclosure, 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.
In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.
In some embodiments, 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.
In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.
In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate 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. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.
Typically, 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.
In some embodiments, 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.
In some embodiments, 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. In some embodiments, 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.
In some embodiments, the article 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.
Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants.
The aerosol-generating material 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 may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.
The aerosol-generating material may comprise or be in the form of an aerosol-generating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.
The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.
The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film.
The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.
The aerosol-generating material may comprise or be an "amorphous solid". In some embodiments, the aerosol-generating material comprises an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid". The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.
The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free.
A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the susceptor by resistive heating as a result of electric eddy currents. The susceptor may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the susceptor. The susceptor may be 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.
The susceptor may comprise a ferromagnetic metal such as iron or an iron alloy such as steel or an iron nickel alloy. Some example ferromagnetic metals are a 400 series stainless steel such as grade 410 stainless steel, or grade 420 stainless steel, or grade 430 stainless steel, or stainless steel of similar grades. Alternatively, the susceptor may comprise a suitable non-magnetic, in particular paramagnetic, conductive material, such as aluminium. In a paramagnetic conductive material inductive heating occurs solely by resistive heating due to eddy currents. Alternatively, the susceptor may comprise a non-conductive ferrimagnetic material, such as a non-conductive ferrimagnetic ceramic. In that case, heat is only generated by hysteresis losses. The susceptor may comprise a commercial alloy like Phytherm 230 (with a composition (in % by weight = wt %) with 50 wt % Ni, 10 wt % Cr and the rest Fe) or Phytherm 260 (with a composition with 50 wt % Ni, 9 wt % Cr and the rest Fe).
In an embodiment of any of the above embodiments the aerosol-generating material 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, terpenes of non-cannabinoid origin, theine, vitamins such as B6 or B12 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 may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.
In some embodiments, the active substance comprises nicotine. In some embodiments, 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. As used herein, the term "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. Alternatively, 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 balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. 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
In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.
In some embodiments, 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.
In some embodiments, 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.
In some embodiments, the aerosol-generating material comprises a flavour or flavourant.
As used herein, the terms "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, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.
In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.
In some embodiments, 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.
The aerosol generating material comprises an aerosol generating agent. In some embodiments the aerosol generating agent may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol generating agent may comprise one or more of 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. In particular examples, the aerosol generating agent comprises glycerol.
In some embodiments, the aerosol generating agent comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1 ,3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and/or aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.
In some embodiments, the aerosol generating material may comprise from about 0.1wt%, 0.5wt%, 1wt%, 3wt%, 5wt%, 7wt% or 10% to about 50wt%, 45wt%, 40wt%, 35wt%, 30wt% or 25wt% of an aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticiser. For example, the aerosol generating material may comprise 0.5-40wt%, 3-35wt% or 10-25wt% of an aerosol generating agent.
In some embodiments, the aerosol generating material may comprise from about 5wt%, 10wt%, 20wt%, 25wt%, 27wt% or 30wt% to about 60wt%, 55wt%, 50wt%, 45wt%, 40wt%, or 35wt% of an aerosol generating agent (DWB). For example, the aerosol generating material may comprise 10-60wt%, 20-50wt%, 25-40wt% or 30-35wt% of an aerosol generating agent.
In some embodiments, the aerosol generating material may comprise up to about 80wt%, such as about 40 to 80wt%, 40 to 75wt%, 50 to 70wt%, or 55 to 65wt% of an aerosol generating agent (DWB).
The aerosol generating material may also comprise a gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, 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. In some cases, the gelling agent comprises alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during formation of the aerosol generating material. In some cases, the aerosol generating material may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.
In some embodiments, the gelling agent comprises one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum and mixtures thereof.
In some embodiments, the cellulosic gelling agent is selected from the group consisting of: hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP) and combinations thereof.
In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose, guar gum, or acacia gum.
In some embodiments, the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum Arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In preferred embodiments, the non-cellulose based gelling agent is alginate or agar.
In some embodiments, the gelling agent comprises alginate, and the alginate is present in the aerosol generating material in an amount of from 10-30wt% of the aerosol generating material (calculated on a dry weight basis). In some embodiments, alginate is the only gelling agent present in the aerosol generating material. In other embodiments, the gelling agent comprises alginate and at least one further gelling agent, such as pectin.
In some embodiments, the aerosol generating material comprises from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt% or 35wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 1-50wt%, 5-45wt%, 10-40wt% or 20-35wt% of a gelling agent.
In some embodiments, the aerosol generating material comprises from about 20wt% 22wt%, 24wt% or 25wt% to about 30wt%, 32wt% or 35wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 20-35wt% or 25-30wt% of a gelling agent.
In some cases, the aerosol generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt% or 20wt% to about 60wt%, 50wt%, 40wt%, 30wt% or 25wt% of a gelling agent (DWB). For example, the aerosol generating material may comprise 10-40wt%, 15-30wt% or 20-25wt% of a gelling agent (DWB).
In examples, the aerosol generating material comprises gelling agent and filler, taken together, in an amount of from about 10wt%, 20wt%, 25wt%, 30wt%, or 35wt% to about 60wt%, 55wt%, 50wt%, or 45wt% of the aerosol generating material. In examples, the aerosol generating material comprises gelling agent and filler, taken together, in an amount of from about 20 to 60wt%, 25 to 55wt%, 30 to 50wt%, or 35 to 45wt% of the aerosol generating material.
In examples, the aerosol generating material comprises gelling agent (i.e. without taking into account the amount of filler) in an amount of from about 5wt%, 10wt%, 15wt%, 20wt%, 25wt%, 30wt%, or 35wt% to about 60wt%, 55wt%, 50wt%, or 45wt% of the aerosol generating material. In examples, the aerosol generating material comprises gelling agent (i.e. without taking into account the amount of filler) in an amount of from about 5 to 60wt%, 20 to 60wt%, 25 to 55wt%, 30 to 50wt%, or 35 to 45wt% of the aerosol generating material.
In some examples, alginate is comprised in the gelling agent in an amount of from about 5 to 40wt% of the aerosol generating material, or 15 to 40wt%. That is, the aerosol generating material comprises alginate in an amount of about 5 to 40wt% by dry weight of the aerosol generating material, or 15 to 40wt%. In some examples, the aerosol generating material comprises alginate in an amount of from about 20 to 40wt%, or about 15wt% to 35wt% of the aerosol generating material.
In some examples, pectin is comprised in the gelling agent in an amount of from about 3 to 15wt% of the aerosol generating material. That is, the aerosol generating material comprises pectin in an amount of from about 3 to 15wt% by dry weight of the aerosol generating material. In some examples, the aerosol generating material comprises pectin in an amount of from about 5 to 10wt% of the aerosol generating material.
In some examples, guar gum is comprised in the gelling agent in an amount of from about 3 to 40wt% of the aerosol generating material. That is, the aerosol generating material comprises guar gum in an amount of from about 3 to 40wt% by dry weight of the aerosol generating material. In some examples, the aerosol generating material comprises guar gum in an amount of from about 5 to 10wt% of the aerosol generating material. In some examples, the aerosol generating material comprises guar gum in an amount of from about 15 to 40wt% of the aerosol generating material, or from about 20 to 40wt%, or from about 15 to 35wt%.
In examples, the alginate is present in an amount of at least about 50wt% of the gelling agent. In examples, the aerosol generating material comprises alginate and pectin, and the ratio of the alginate to the pectin is from 1:1 to 10:1. The ratio of the alginate to the pectin is typically >1:1, i.e. the alginate is present in an amount greater than the amount of pectin. In examples, the ratio of alginate to pectin is from about 2:1 to 8:1, or about 3:1 to 6:1, or is approximately 4:1.
The aerosol generating material may be formed by (a) forming a slurry comprising components of the aerosol generating material or precursors thereof, (b) forming a layer of the slurry, (c) setting the slurry to form a gel, and (d) drying to form an aerosol generating material.
The (b) forming a layer of the slurry typically comprises spraying, casting or extruding the slurry. In examples, the slurry layer is formed by electrospraying the slurry. In examples, the slurry layer is formed by casting the slurry.
In some examples, (b) and/or (c) and/or (d), at least partially, occur simultaneously (for example, during electrospraying). In some examples, (b), (c) and (d) occur sequentially.
In some examples, the slurry is applied to a support. The layer may be formed on a support.
In examples, the slurry comprises gelling agent, aerosol-former material and active substance. The slurry may comprise these components in any of the proportions given herein in relation to the composition of the aerosol generating material. For example, the slurry may comprise (on a dry weight basis):

gelling agent and, optionally, filler, wherein the amount of gelling agent and filler taken together is about 10 to 60wt% of the slurry;
aerosol-former material in an amount of about 40 to 80wt% of the slurry; and
optionally, active substance in an amount of up to about 20wt% of the slurry.

The setting the gel (c) may comprise supplying a setting agent to the slurry. For example, the slurry may comprise sodium, potassium or ammonium alginate as a gel-precursor, and a setting agent comprising a calcium source (such as calcium chloride), may be added to the slurry to form a calcium alginate gel.
In examples, the setting agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the setting agent comprises or consists of calcium formate and/or calcium lactate. In particular examples, the setting agent comprises or consists of calcium formate. It has been identified that, typically, employing calcium formate as a setting agent results in an aerosol generating material having a greater tensile strength and greater resistance to elongation.
The total amount of the setting agent, such as a calcium source, may be 0.5-5wt% (calculated on a dry weight basis). Suitably, the total amount may be from about 1wt%, 2.5wt% or 4wt% to about 4.8wt% or 4.5wt%. It has been found that the addition of too little setting agent may result in an aerosol generating material which does not stabilise the aerosol generating material components and results in these components dropping out of the aerosol generating material. It has been found that the addition of too much setting agent results in an aerosol generating material that is very tacky and consequently has poor handleability.
When the aerosol generating material does not contain tobacco, a higher amount of setting agent may need to be applied. In some cases the total amount of setting agent may therefore be from 0.5-12wt% such as 5-10wt%, calculated on a dry weight basis. Suitably, the total amount may be from about 5wt%, 6wt% or 7wt% to about 12wt% or 10wt%. In this case the aerosol generating material will not generally contain any tobacco.
In examples, supplying the setting agent to the slurry comprises spraying the setting agent on the slurry, such as a top surface of the slurry.
Alginate salts are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic (M) and α-L-guluronic acid (G) units (blocks) linked together with (1 ,4)-glycosidic bonds to form a polysaccharide. On addition of calcium cations, the alginate crosslinks to form a gel. It has been found that alginate salts with a high G monomer content more readily form a gel on addition of the calcium source. In some cases therefore, the gel-precursor may comprise an alginate salt in which at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginate copolymer are α-L-guluronic acid (G) units.
In examples, the drying (d) removes from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% to about 80wt%, 90wt% or 95wt% (WWB) of water in the slurry.
In examples, the drying (d) reduces the cast material thickness by at least 80%, suitably 85% or 87%. For instance, the slurry is cast at a thickness of 2mm, and the resulting dried aerosol generating material has a thickness of 0.2mm.
In some examples, the slurry solvent consists essentially of or consists of water. In some examples, the slurry comprises from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% of solvent (WWB).
In examples where the solvent consists of water, the dry weight content of the slurry may match the dry weight content of the aerosol generating material. Thus, the discussion herein relating to the solid composition is explicitly disclosed in combination with the slurry aspect of the invention.
The aerosol generating material may comprises a flavour. Suitably, the aerosol generating material may comprise up to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt% or 45wt% of a flavour. In some cases, the aerosol generating material may comprise at least about 0.1wt%, 1wt%, 10wt%, 20wt%, 30wt%, 35wt% or 40wt% of a flavour (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 1-80wt%, 10-80wt%, 20-70wt%, 30-60wt%, 35-55wt% or 30-45wt% of a flavour. In some cases, the flavour comprises, consists essentially of or consists of menthol.
The aerosol generating material may comprise a filler.
In some embodiments, the aerosol generating material comprises less than 60wt% of a filler, such as from 1wt% to 60wt%, or 5wt% to 50wt%, or 5wt% to 30wt%, or 10wt% to 20wt%.
In other embodiments, the aerosol generating material comprises less than 20wt%, suitably less than 10wt% or less than 5wt% of a filler. In some cases, the aerosol generating material comprises less than 1wt% of a filler, and in some cases, comprises no filler.
In some such cases the aerosol generating material comprises at least 1 wt% of the filler, for example, at least 5 wt%, at least 10wt%, at least 20wt% at least 30wt%, at least 40wt%, or at least 50wt% of the filler. In some embodiments, the aerosol generating material comprises 5-25wt% of the filler.
The filler, if present, may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium 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 (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)). In particular cases, the aerosol generating material comprises no calcium carbonate such as chalk.
In particular embodiments which include filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)).
Without wishing to be bound by theory, it is believed that including fibrous filler in an aerosol generating material may increase the tensile strength of the material. This may be particularly advantageous in examples wherein the aerosol generating material is provided as a sheet, such as when an aerosol generating material sheet circumscribes a rod of aerosolisable material.
In some embodiments, the aerosol generating material does not comprise tobacco fibres. In particular embodiments, the aerosol generating material does not comprise fibrous material.
The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.
In some embodiments, the aerosol generating material additionally comprises an active substance. For example, in some cases, the aerosol generating material additionally comprises a tobacco material and/or nicotine. In some embodiments, the aerosol generating material comprises powdered tobacco and/or nicotine and/or a tobacco extract.
In some cases, the aerosol generating material may comprise 5-60wt% (calculated on a dry weight basis) of a tobacco material and/or nicotine. In some cases, the aerosol generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of an active substance. In some cases, the aerosol generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of a tobacco material. For example, the aerosol generating material may comprise 10-50wt%, 15-40wt% or 20-35wt% of a tobacco material. In some cases, the aerosol generating material may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) of nicotine. For example, the aerosol generating material may comprise 1-20wt%, 2-18wt% or 3-12wt% of nicotine.
In some cases, the aerosol generating material comprises an active substance such as tobacco extract. In some cases, the aerosol generating material may comprise 5-60wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the aerosol generating material may comprise from about 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) tobacco extract. For example, the aerosol generating material may comprise 10-50wt%, 15-40wt% or 20-35wt% of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the aerosol generating material comprises 1wt% 1.5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%, 4.5wt% or 4wt% (calculated on a dry weight basis) of nicotine. In some cases, there may be no nicotine in the aerosol generating material other than that which results from the tobacco extract.
In some embodiments the aerosol generating material comprises no tobacco material but does comprise nicotine. In some such cases, the aerosol generating material may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) of nicotine. For example, the aerosol generating material may comprise 1-20wt%, 2-18wt% or 3-12wt% of nicotine.
In some cases, the total content of active substance and/or flavour may be at least about 0.1wt%, 1wt%, 5wt%, 10vnt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of active substance and/or flavour may be less than about 90wt%, 80wt%, 70wt%, 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis). In some cases, the total content of tobacco material, nicotine and flavour may be at least about 0.1wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of active substance and/or flavour may be less than about 90wt%, 80wt%, 70wt%, 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis).
The aerosol-generating composition may comprise one or more active substances. In examples, the aerosol generating material comprises one or more active substances, e.g. up to about 20wt% of the aerosol generating material. In examples, the aerosol generating material comprises active substance in an amount of from about 1wt%, 5wt%, 10vnt%, or 15wt% to about 20wt%, 15wt%, 15wt% or 5wt% of the aerosol generating material.
The active substance may comprise a physiologically and/or olfactory active substance which is included in the aerosol-generating composition in order to achieve a physiological and/or olfactory response.
Tobacco material may be present in the aerosol-generating composition in an amount of from about 50 to 95wt%, or about 60 to 90wt%, or about 70 to 90wt%, or about 75 to 85wt%.
The tobacco material may be present in any format, but is typically fine-cut (e.g. cut into narrow shreds). Fine-cut tobacco material may advantageously be blended with the aerosol generating material to provide an aerosol-generating composition which has an even dispersion of tobacco material and aerosol generating material throughout the aerosol-generating composition.
In examples, the tobacco material comprises one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract. Surprisingly it has been identified that it is possible to use a relatively large amount of lamina tobacco in the aerosol-generating composition and still provide an acceptable aerosol when heated by a non-combustible aerosol provision system. Lamina tobacco typically provides superior sensory characteristics. In examples, the tobacco material comprises lamina tobacco in an amount of at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt%, or 95wt% of the tobacco material. In particular examples, the tobacco material comprises cut tobacco in an amount of at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt%, or 95wt% of the tobacco material.
The tobacco used to produce tobacco material may be any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental.
In some embodiments the one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.
In some cases, the aerosol generating material may additionally comprise an emulsifying agent, which emulsified molten flavour during manufacture. For example, the aerosol generating material may comprise from about 5wt% to about 15wt% of an emulsifying agent (calculated on a dry weight basis), suitably about 10wt%. The emulsifying agent may comprise acacia gum.
In some embodiments, the aerosol generating material 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 15wt%, 12 wt% or 10 wt% of water calculated on a wet weight basis. In some cases, the hydrogel may comprise at least about 1wt%, 2wt% or at least about 5wt% of water (WWB).
The aerosol generating material may have any suitable water content, such as from 1wt % to 15wt%. Suitably, the water content of the aerosol generating material is from about 5wt%, 7wt% or 9wt% to about 15wt%, 13wt% or 11wt% (WWB), most suitably about 10wt%.. The water content of the aerosol generating material may, for example, be determined by Karl-Fischer-titration or Gas Chromatography with Thermal Conductivity Detector (GC-TCD).
In some cases, the aerosol generating material may consist essentially of, or consist of a gelling agent, water, an aerosol generating agent, a flavour, and optionally an active substance.
In some cases, the aerosol generating material may consist essentially of, or consist of a gelling agent, water, an aerosol generating agent, a flavour, and optionally a tobacco material and/or a nicotine source.
In examples, the aerosol generating material consists essentially of, or consists of a gelling agent, aerosol generating agent, active substance, and water. In examples, the aerosol generating material consists essentially of, or consists of a gelling agent, aerosol generating agent, and water.
In examples, the aerosol generating material does not comprise a flavourant; in particular examples, the aerosol generating material does not comprise an active substance.
In some embodiments the aerosol generating material comprises an aerosol generating material, the aerosol generating material comprising:

1-60 wt% of a gelling agent;
0.1-50 wt% of an aerosol generating agent; and
0.1-80 wt% of a flavour;

In some embodiments, the aerosol generating material comprising:

1-50 wt% of a gelling agent;
0.1-50 wt% of an aerosol generating agent; and
30-60 wt% of a flavour;

In alternative embodiments of the aerosol generating material, the aerosol generating material comprises an aerosol generating material, the aerosol generating material comprising:

1-60 wt% of a gelling agent;
5-60 wt% of an aerosol generating agent; and
10-60 wt% of a tobacco extract;

In some embodiments, the aerosol generating material comprises:

1-60 wt% of a gelling agent;
20-60 wt% of an aerosol generating agent; and
10-60 wt% of a tobacco extract;

In some embodiments, the aerosol generating material comprises 20 - 35 wt % of the gelling agent; 10 - 25 wt % of the aerosol-former material; 5 - 25 wt % of the filler comprising fibres; and 35 - 50 wt % of the flavourant and/or active substance. In some cases, the aerosol generating material may consist essentially of, or consist of a gelling agent, an aerosol generating agent a tobacco extract, water, and optionally a flavour. In some cases, the aerosol generating material may consist essentially of, or consist of glycerol, alginates and/or pectins, a tobacco extract and water.
In some embodiments, the aerosol generating material may have the following composition (DWB): gelling agent (preferably comprising alginate) in an amount of from about 5wt% to about 40wt%, or about 10wt% to 30wt%, or about 15wt% to about 25wt%; tobacco extract in an amount of from about 30wt% to about 60wt%, or from about 40wt% to 55wt%, or from about 45wt% to about 50wt%; aerosol generating agent (preferably comprising glycerol) in an amount of from about 10wt% to about 50wt%, or from about 20wt% to about 40wt%, or from about 25wt% to about 35wt% (DWB).
In one embodiment, the aerosol generating material comprises about 20wt% alginate gelling agent, about 48wt% Virginia tobacco extract and about 32wt% glycerol (DWB).
The "thickness" of the aerosol generating material describes the shortest distance between a first surface and a second surface. In embodiments where the aerosol generating material is in the form of a sheet, the thickness of the aerosol generating material is the shortest distance between a first planar surface of the sheet and a second planar surface of the sheet which opposes the first planar surface of the sheet.
In some cases, the aerosol-forming aerosol generating material layer has a thickness of about 0.015mm to about 1.5mm, suitably about 0.05mm to about 1.5mm or 0.05mm to about 1.0mm. Suitably, the thickness may be in the range of from about 0.1 mm or 0.15mm to about 1.0mm, 0.5mm or 0.3mm.
In some cases, the aerosol generating material may have a thickness of about 0.015mm to about 1.0mm. Suitably, the thickness may be in the range of about 0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3mm.
A material having a thickness of 0.1 mm is particularly suitable. The aerosol generating material may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.
It has been found that if the aerosol-generating material is too thick, then heating efficiency is compromised. This adversely affects the power consumption in use. Conversely, if the aerosol-generating material is too thin, it is difficult to manufacture and handle; a very thin material is harder to cast and may be fragile, compromising aerosol formation in use.
The thickness stipulated herein is a mean thickness for the material. In some cases, the aerosol generating material thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%.
In some examples, the aerosol generating material in sheet form, and absent may have a tensile strength of from around 200 N/m to around 900 N/m. In some examples, such as where the aerosol generating material does not comprise a filler, the aerosol generating material 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 aerosol generating material is formed as a sheet and then shredded and incorporated into an aerosol generating article. In some examples, such as where the aerosol generating material comprises a filler, the aerosol generating material may have a tensile strength of from 600 N/m to 900 N/m, or from 700 N/m to 900 N/m, or around 800 N/m.
In some examples, the aerosol generating material in sheet form may have a tensile strength of from around 200 N/m to around 2600 N/m. In some examples, the aerosol generating material may have a tensile strength of from 600 N/m to 2000 N/m, or from 700 N/m to 1500 N/m, or around 1000 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosol-generating material comprising the aerosol generating material is formed and incorporated into an aerosol-generating consumable as a sheet.
The aerosol generating material comprising the aerosol generating material may have any suitable area density, such as from 30 g/m² to 350 g/m². In some cases, the sheet may have a mass per unit area of 50-250 g/m², or from about 70 to 210 g/m², or from about 90 to 190 g/m², or suitably about 100 g/m² (so that it has a similar density to cut rag tobacco and a mixture of these substances will not readily separate). In some cases, the sheet may have a mass per unit area of about 30 to 70 g/m², 40 to 60 g/m², or 25-60 g/m² and may be used to wrap an aerosolisable material such as tobacco.
All percentages by weight described herein (denoted wt%) are calculated on a dry weight basis, unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis. A weight quoted on a dry weight basis refers to the whole of the extract or slurry or material, other than the water, and may include components which by themselves are liquid at room temperature and pressure, such as glycerol. Conversely, a weight percentage quoted on a wet weight basis refers to all components, including water.
As used herein, the term "sheet" denotes an element having a width and length substantially greater than a thickness thereof. A major surface of the sheet is a surface which extends in both width and length dimensions when the sheet is flat. The sheet may be a strip, for example.
The aerosol generating material may comprise a colourant. The addition of a colourant may alter the visual appearance of the aerosol generating material. The presence of colourant in the aerosol generating material may enhance the visual appearance of the aerosol generating material and the aerosol-generating material. By adding a colourant to the aerosol generating material, the aerosol generating material may be colour-matched to other components of the aerosol-generating material or to other components of an article comprising the aerosol generating material.
A variety of colourants may be used depending on the desired colour of the aerosol generating material. The colour of aerosol generating material may be, for example, white, green, red, purple, blue, brown or black. Other colours are also envisaged. Natural or synthetic colourants, such as natural or synthetic dyes, food-grade colourants and pharmaceutical-grade colourants may be used. In certain embodiments, the colourant is caramel, which may confer the aerosol generating material with a brown appearance. In such embodiments, the colour of the aerosol generating material may be similar to the colour of other components (such as tobacco material). In some embodiments, the addition of a colourant to the aerosol generating material renders it visually indistinguishable from other components in the aerosol-generating material.
The colourant may be incorporated during the formation of the aerosol generating material (e.g. when forming a slurry comprising the materials that form the aerosol generating material) or it may be applied to the aerosol generating material after its formation (e.g. by spraying it onto the aerosol generating material).
In some embodiments of any of the above embodiments, talcum powder, calcium carbonate powder or other powder is applied to the exposed surface of at least one discrete portion of aerosol-generating material. This may reduce the level of tackiness or adhesion of the aerosol-generating material.
In the following discussions of the accompanying drawings, where the same element is present in a more than one embodiment the same reference numeral is used for that element throughout, where there are similar elements similar reference numerals (the same numeral plus a multiple of 100) are used.
With reference to Figure 1, an aerosol provision system 1 comprises an aerosol provision device 2 and an article 3.
The aerosol provision device 2 comprises a casing 4 which encloses a receptacle 5, an aerosol generator 6, a power supply 7 and a controller 8.
The aerosol generator 6 is, in the illustrated embodiment, a resistive heater powered by the power supply 7. In other embodiments the aerosol generator 6 is a magnetic field generator powered by the power supply 7 and one of a part of the receptacle 5 or the article 3 includes a susceptor which may be inductively heated.
The power supply 7 is a rechargeable battery. In other embodiments the power supply 7 may be an alternative suitable means for storing the power needed to power the aerosol generator 6.
The aerosol provision device 2 also includes a passage or fluid flow path 9 which extends from an inlet mouth 10 to an outlet mouth 11. The passage 9 includes the receptacle 5 and fluid flow from the inlet mouth 10 to the outlet mouth 11 passes through the receptacle 5.
With reference to Figures 1 and 2, the article 3 includes a first panel 13, a second panel 14, a third panel 15, a fourth panel 16, and a fifth panel 17. The first to fifth panels 13, 14, 15, 16, 17 are integral with each other and formed from a sheet material, for example and without limitation formed from card.
The first panel 13 is connected to the third panel 15 at a first fold line 18. The third panel 15 is also connected to the fourth panel 14 at a second fold line 19. The fourth panel 14 is also connected to the fifth panel 17 at a third fold line 20. The fifth panel 17 is also connected to the second panel 14 at a fourth fold line 21.
The first panel 13 overlies and is parallel or approximately parallel to the second panel 14.
In the illustrated embodiment the first to fifth panels 13, 14, 15, 16, 17 are flat and the first to fourth fold lines 18, 19, 20, 21 are approximately parallel to each other. As a result, the article 3 forms a longitudinally extending tube (that extends in the direction that each of the first to fourth fold lines 18, 19, 20, 21 extend) with an approximately rectangular cross section in a plane perpendicular to the direction in which the first to fourth fold lines 18, 19, 20, 21 extend.
The article 3 and the receptacle 5 of the aerosol provision device 2 are so shaped and dimensioned that when the article 3 is positioned in the receptacle 5 fluid flow along the passage 9 passes along / through the longitudinally extending tube of article 3.
The surface of the fifth panel 17 that faces the third panel 15 supports a plurality of portions of aerosol generating material 12.
With reference to Figures 2 and 3, the first panel 13 includes a plurality of first join portions 22. Each of the first join portions 22 are, in the illustrated embodiment, the same as each other and the illustrated second join portion 22 in Figure 3 is thus representative of each of the first join portions 22.
The second panel 14 includes a plurality of second join portions 23 (for visual clarity the second join portions 23 are not illustrated in Figure 2). Each of the second join portions 23 are, in the illustrated embodiment, the same as each other and the illustrated second join portion 23 in Figure 3 is thus representative of each of the second join portions 23.
The first and second join portions 22, 23 are so located on the respective first and second panels 13, 14 that the first and second join portions 22, 23 are adjacent to each other when the first panel 13 overlies the second panel 14 as shown in Figures 2 and 3.
The first join portion 22 and the second join portion 23 collectively define a joint. The joint is a connection between the material of the first and second panels 13, 14 in the first and second join portions 22, 23.
At least one of the first join portion 22 and second join portion 23 includes a deformation (not shown). The deformation of at least one of the first join portion 22 and the second join portion 23 forms the joint as a consequence of that deformation.
In the first embodiment of the article 3 shown in Figure 3 the card from which the first and second panels 13, 14 are formed is a card that includes fibrous elements, and the deformation to the first and second join portions 22, 23 is the compression of the first and second join portions 22, 23 against each other. The result of the compression is that the fibrous elements of the card in the first and second join portions 22, 23 in the interface region 24 are caused to interlink with each other. This causes the material of the first and second join portions 22, 23 to attach to each other and cause the formation of the joint.
The formation of the joint between the first and second join portions 22, 23 and thus the first and second panels 13, 14 has the result that the article 3 is held in the shape or configuration shown in Figure 2 without the use of any external or additional joining material, for example adhesive.
An advantage of the formation of the joint without the use of any external or additional joining material is that there is no concern that any undesirable flavours, compounds or off-notes are introduced into the fluid flow along the passage 9 and the longitudinally extending tube of article 3 when the aerosol provision device 2 and article 3 are in use.
The above advantage is achieved because there is no joining material used in the formation of the joint. This has the effect that a possible source for such undesirable flavours, compounds or off-notes is absent because there is no joining material.
A further advantage is that joining materials such as adhesives typically include a solvent that allows the joining material set and adhere to the material that forms the joint. The absence of the joining material results in none of that solvent being caused to be emitted from the joining material when the article is in use which is likely to be beneficial to both the user of the article and the environment as a whole.
In alternative non-illustrated embodiments of the first embodiment of the article 3, the first to fifth panels 13, 14, 15, 16, 17 are formed from a material that when the first and second join portions 22, 23 are compressed against each other, at a sufficiently high compression, the material in the first and second join portions 22, 23 will flow and integrate with each other.
With reference to Figure 4, a portion of a second embodiment of an article 103 is shown. The article 103 is the same as article 3 described above but with the following differences.
The first to fifth panels 113, 114, 115, 116, 117 are formed from a suitable plastics material, for example but without limitation polyether ether ketone (PEEK) and the deformation of the first and second join portions 122, 123 is the melting and subsequent resetting / hardening of the material in the interface zone 125.
The melting of the material in the first and second join portions 122, 123 may be achieved using ultrasonic welding techniques.
The formation of the joint in the article 103 has the same advantages as set out for the article 3 and discussed above.
With reference to Figure 5, a portion of a third embodiment of an article 203 is shown. The article 203 is the same as article 3 as described above but with the following differences.
The deformation of the first and second join portions 222, 223 is the stitching together of first and second join portions 222, 223 by a thread 226.
The thread 226 is formed form a material that is stable, that is non-combustible and structurally undamaged, at the temperatures to which the article 203 is expected to be exposed when the aerosol provision device is in use.
The material of the thread 226 may be a metal or a metal alloy thread.
The formation of the joint in the article 203 has the same advantages as set out for the article 3 and as discussed above.
With reference to Figures 6 and 7, a portion of a fourth embodiment of an article 303 is shown. The article 303 is the same as article 3 described above but with the following differences.
The first to fifth panels 313, 314, 315, 316, 317 are formed from card or paper.
The deformation of the second join portion 323 has the form of a cut 331 which extends through the second panel 314.
The deformations of the first join portion 322 have the forms of a first cut 327, a second cut 328 and a plurality of folds. The first and second cuts 327, 328 both extend through the first panel 313, and the first cut 327 is positioned so that it overlies the cut 331 in the second join portion 323.
The second cut 328 on the first join portion 322 is shaped so that it forms a tab 329 of the material of the first panel 313. The tab 329 is deformed by being folded relative to the rest of the first panel 313 at a fold 332, and the free end of the tab 329 is passed through the first cut 327 in the first panel and the cut 331 in the second panel as schematically illustrated in Figure 7. This will cause further folds 333, 334 to be formed in the tab 329. Otherwise expressed, the deformation that the tab 329 experiences causes part of the tab 329 to extend parallel to or across part of the second join portion 323 of the second panel 314, and part of the tab 329 to extend into plane of the second join portion 323 of the second panel 314.
The extension of the tab 329 through the first and second join portions 322, 323 causes the second join portion 323 to interlock with the first join portion 322 and a joint to be formed therebetween.
The formation of the joint in the article 303 has the same advantages as set out for the article 3 and as discussed above.
With reference to Figures 8 and 9, a portion of a fifth embodiment of an article 403 is shown. The article 403 is the same as article 3 described above but with the following differences.
The first to fifth panels 413, 414, 415, 416, 417 are formed from card or paper.
The deformations of the second join portion 423 have the forms of a first cut 331, a second cut 435 and a plurality of folds. The first and second cuts 331, 435 both extend through the second panel 414.
The second cut 435 on the second join portion 423 is shaped so that it forms a tab 436 of the material of the second panel 414.
The deformations of the first join portion 422 have the forms of a first cut 327, a second cut 328 and a plurality of folds. The first and second cuts 327, 328 both extend through the first panel 413, and the first cut 327 is positioned so that it overlies the first cut 331 in the second join portion 423.
The second cut 328 on the first join portion 422 is shaped so that it forms a tab 329 of the material of the first panel 413.
The tabs 329, 436 are deformed by being folded relative to the rest of the first and second panels 413, 414 at folds 332, 437 respectively. The free ends of the tabs 329, 436 are passed through the first cut 327 in the first panel and the first cut 331 in the second panel 414 as schematically illustrated in Figure 9. This will cause further folds 333, 334 in the tab 329 and folds 438, 439 in the tab 436.
The extension of the tabs 329, 436 through the first and second join portions 422, 423 causes the second join portion 423 to interlock with the first join portion 422 and a joint to be formed therebetween.
The formation of the joint in the article 303 has the same advantages as set out for the article 3 and as discussed above.
The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without departing from the scope of the disclosure disclosed. Still other modifications which fall within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure.
Various aspects of the aerosol provision devices and systems disclosed in the various embodiments may be used alone, in combination, or in a variety of arrangements not specifically discussed in the embodiments described above. This disclosure is therefore not limited in its application to the details and arrangement of components set forth in the foregoing description or illustrated in the drawings. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments. Although particular embodiments have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from this disclosure in its broader aspects. The scope of the following claims should not be limited by the embodiments set forth in the examples, but should be given the broadest reasonable interpretation consistent with the description as a whole.

Claims

An article for use with an aerosol provision device, the article comprising:
aerosol generating material;

a first panel comprising a first join portion; and

a second panel comprising a second join portion;

wherein the first join portion and the second join portion define a joint;

wherein at least one of the first join portion and second join portion comprises a deformation; and

wherein the deformation of the at least one of the first join portion and the second join portion forms the joint as a consequence of that deformation.
The article of claim 1, wherein the first join portion extends at least one of across and into a plane of the second join portion.
The article of claim 1 or 2, wherein the second join portion interlocks with the first join portion.
The article of any of claims 1 to 3, wherein the joint is free from a joining material.
The article of claim 4, wherein the joint is free from an adhesive to bind the first join portion and the second join portion to each other.
The article of any of claims 1 to 5, wherein each of the first join portion and the second join portion comprise deformation.
The article of any of claims 1 to 6, wherein the deformation comprises a ridge in at least one of the first join portion and second join portion.
The article of any of claims 1 to 7, wherein the deformation comprises a fold in at least one of the first join portion and second join portion.
The article of any of claims 1 to 8, wherein the deformation comprises a cut in at least one of the first join portion and second join portion.
The article of any of claims 1 to 9, wherein the deformation comprises a compression in at least one of the first join portion and second join portion.
The article of any of claims 1 to 10, wherein the deformation comprises an embossment.
The article of any of claims 1 to 11, wherein the deformation comprises the removal of material from at least one of the first join portion and second join portion.
The article of any of claims 1 to 12, wherein the deformation comprises stitching of the first join portion to the second join portion.
An aerosol provision system comprising an aerosol provision device and an article of any of claims 1 to 13.
A method of manufacture of an article for use in an aerosol provision device comprising aerosol generating material, the method comprising:
providing a first panel comprising a first join portion; and

providing a second panel comprising a second join portion;

wherein the first join portion and the second join portion define a joint;

deforming at least one of the first join portion and second join portion to form a joint between the first join portion and the second join portion.