EP4734776A1

EP4734776A1 - Aerosol generating composition

Info

Publication number: EP4734776A1
Application number: EP24740059.1A
Authority: EP
Inventors: Alina-Mariana CRAINIC; Benjamin Jenkins
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2023-06-30
Filing date: 2024-06-28
Publication date: 2026-05-06
Also published as: CN121865974A; TW202512960A; GB202310020D0; WO2025003425A1

Abstract

The present disclosure relates to an aerosol-generating composition comprising one or more extruded strands of aerosol-generating material, the one or more extruded strands of aerosol-generating material comprising a length, a width and a height and wherein the width and height are substantially the same and the length is greater than the height or width. A method for manufacturing the aerosol-generating composition and articles comprising the aerosol-generating composition are also disclosed.

Description

Aerosol generating composition

Technical field

The present disclosure relates to an aerosol-generating composition, a method for manufacturing an aerosol-generating material and articles comprising aerosol generating material.

Background Aerosol provision products produce an aerosol during use, which is inhaled by a user. For example, tobacco heating devices heat an aerosol generating material such as tobacco to form an aerosol by heating, but not burning, the substrate. Such an aerosol provision product commonly includes an aerosol-generating section or region, which generate an aerosol in use, and a mouthpiece through which the aerosol passes to reach the user’s mouth.

There is a need however to improve such aerosol generating materials, both in terms of, for example, their flavour delivery, ease of manufacture and their format in the delivery device.

Summary

According to a first aspect of the invention, there is provided an aerosol generating composition comprising one or more extruded strands of aerosol-generating material, the one or more extruded strands of aerosol-generating material comprising a length, a width and a height and wherein the width and height are substantially the same and the length is greater than the height or width.

In some embodiments, the one or more extruded strands has a cross-section with the shape selected from a group consisting of: circular, semi-circular, crescent, Y-shaped and star.

In some embodiments, the one or more extruded strands has a cross-section which is substantially non-rectangular, non-square or non-cuboidal. In some embodiments, each of the one or more extruded strands is in the form of a continuous strand.

In some embodiments, the aerosol generating composition comprises two or more extruded strands and at least two of the two or more extruded strands are substantially the same length.

In some embodiments, each of the one or more extruded strands has substantially the same width across its length, and optionally substantially the same cross section along its length.

In some embodiments, the one or more extruded strands has a tensile strength of at least 4 N/15 mm. In some embodiments, one or more of the extruded strands can stretch to at least about 104% of its length before breaking.

In some embodiments, the aerosol-generating material comprises water. In some embodiments, the aerosol-generating material comprises a water content of up to about 40% by weight.

In some embodiments, the aerosol generating material comprises botanical material. In some embodiments, the aerosol generating material comprises a botanical material content of about 50 to about 80% by weight.

In some embodiments, the aerosol-generating material has a density of about from about 0.5 g/cm3 to about 1 g/cm3.

In some embodiments, the aerosol generating composition comprises botanical material in the form of particles.

In some embodiments, the particles have a D90 of about 70 to about 600 pm. According to a second aspect of the invention, there is provided an article for use with a non-combustible aerosol-provision system comprising the aerosol generating composition. In some embodiments, the one or more extruded strands are aligned lengthways with a longitudinal axis of the article. The extruded strands maybe in parallel alignment with a longitudinal axis of the article.

In some embodiments, the method comprises: forming a mixture; extruding the mixture through a die to form an extruded aerosol-generating material; and cutting the aerosol-generating material to form the one or more extruded strands.

In some embodiments, the method does not comprise shredding the aerosol generating composition.

In some embodiments, the extruded aerosol-generating material is dried at a temperature not exceeding too °C.

According to a fourth aspect of the invention, there is provided an aerosol generating composition produced by the process. According to a fifth aspect of the invention, there is provided a non-combustible aerosol-provision system comprising the article.

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

Figure 1 is a perspective view of an exemplary embodiment of a strand of aerosolgenerating material; Figure 2 is a side-on cross-sectional view of an article comprising an aerosol-generating composition comprising a plurality of strands of the aerosol-generating material; Figure 3 depicts example steps of a process used to manufacture an example aerosolgenerating composition;

Figure 4 is a perspective view of an article for use with a non-combustible aerosol provision device and comprising an aerosol-generating composition; and Figure 5 is a side-on cross-sectional view of the article shown in Figure 4.

Detailed description

As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials; and aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine. 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 aerosolgenerating 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 an article for use with the non-combustible aerosol provision device.

In some embodiments, the disclosure relates to articles comprising the aerosolgenerating composition and configured to be used with non-combustible aerosol provision devices. These articles are sometimes referred to as consumables throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, such as a non- combustible aerosol provision device THP 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 non-combustible aerosol provision system may comprise an area for receiving the article, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent. In some embodiments, the article for use with the non-combustible aerosol provision device may comprise the aerosol-generating composition, 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. In some embodiments, the substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolised. As appropriate, either material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials. In a first aspect of the invention, an aerosol generating composition comprising one or more extruded strands of aerosol-generating material is provided, the one or more extruded strands of aerosol-generating material comprising a length, a width and a height and wherein the width and height are substantially the same and the length is greater than the height or width.

The strands of aerosol-generating material have a longitudinal dimension. Figure 1 depicts a particular embodiment wherein the strand has a circular cross section. The dimensions as described herein are marked thereon. As used herein, the term 'length' denotes the longest dimension in the direction of a longitudinal dimension of the strands. In embodiments in which the strands are not straight, wavy or irregular in directionality, the length denotes dimension in the direction of a longitudinal axis of the strands when the strands are in a straightened form. In Figure 1, the length of an exemplary embodiment of a strand is denoted as “L”, and the strand is in said straightened form.

As used herein, the term ‘width’ denotes a dimension in a direction or plane transverse to the longitudinal dimension according to the invention. In some embodiments, the width may denote a dimension in a direction or plane orthogonal to the longitudinal dimension. In Figure 1, the width of an exemplary embodiment of a strand is denoted as “W”.

As used herein, the term ‘height’ denotes a dimension in a dimension transverse to the length and width dimensions. In some embodiments, the width may denote a dimension in a direction or plane orthogonal to the longitudinal dimension. In Figure 1, the height of an exemplary embodiment of a strand is denoted as “H”. In some embodiments, the height of the one or more stands is about o.i to about 5 mm. In some embodiments, the height of the one or more stands is about 0.3 to about 4 mm, about 0.5 to about 2 mm, or about 0.8 to about 1.5 mm. In some embodiments, the height of the one or more stands is about 0.8 to about 1.2 mm. In some embodiments, the height of the one or more stands is about 1 mm. In some embodiments, the height of the one or more stands is about 0.2 to about 0.4 mm. In some embodiments, the height of the one or more stands is about 200 to about 300 |um. In some embodiments, the width of the one or more stands is about 0.1 to about 5 mm. In some embodiments, the width of the one or more stands is about 0.5 to about 4 mm, about 0.8 to about 2 mm, or about 0.9 to about 1.5 mm. In some embodiments, the width of the one or more stands is about 0.8 to about 1.2 mm. In some embodiments, the width of the one or more stands is about 1 mm. In some embodiments, the width of the one or more stands is about 200 to about 400 |um, or about 245 to about 250 |um. In some embodiments, the width of the one or more stands is about 200 to about 300 |um.

Advantageously, the strands may have a smaller width or height compared to other aerosol generating materials. Without wishing to be bound by a particular theory, it is thought that because the strands are formed via a die, the die may be made to be small or large, producing strands with particularly small or large widths and/or heights.

Other aerosol generating materials may be formed as a sheet and sliced, which prevents small widths and/or heights from being formed. The height and the width may be selected to provide a suitable surface-area to volume ratio to provide a flavour to the user. The height and the width may also be selected in order to provide a malleable strand which may be manipulated and placed in the article. The height and width may further be selected to provide suitable packing in the article.

The height and the width also determine the thickness of the strand. Relatively thick strands may be more difficult to manufacture. However, if the strands are too thin, then they may tear easily during the manufacture process and post-manufacturing. The height and the width are substantially the same. For example, the ratio of the height to the width maybe from about 1:0.5 to about 1:5. In some embodiments, the ratio of the height to the width may be from about 1:0.8 to about 1:1.5, or about 1:0.9 to about 1.2. In some embodiments, the ratio of the height to the width maybe about 1:1. As described herein, the feature of the strands having a height and width that is substantially the same may be a result of the shape of the cross section of the strands, and the extrusion process.

In some embodiments, the length of the one or more stands is about 6 to about 34 mm.

In some embodiments, the length of the one or more stands is at least about 6, at least about 12, at least about 20 mm. In some embodiments, the length of the one or more stands is at most about 14, at most about 20, at most about 34 mm, at most about 72 mm. In some embodiments, the length of the one or more stands is about 12 to about 34 mm. The length may be selected to fit the article or aerosol-generating section suitably. For example, the length of the strands maybe similar or smaller than that of the article or aerosol-generating section. This means that the strands may be aligned with one another whilst in the article or aerosol-generating section. In another example, the strands are longer than that of the article or aerosol-generating section, in which case they may be otherwise manipulated, for example folded, to fit the article or aerosol-generating section. The length is greater than the height or width of the strands. In some embodiments, the ratio of the length to the height may be between about 1:1000 and about 1:5. In some embodiments, the ratio of the length to the height maybe between about 1:100 and about 1:10. This creates the overall shape of the strand. The larger the length: height ratio, the more elongated the strand.

In some embodiments, the one or more strands are substantially the same length. In such embodiments, the strands may be easier to manufacture, as the strands may be cut at a regular interval. In some embodiments, the one or more strands are different lengths. This may make packing into the article easier.

In some embodiments, the one or more strands may be of different lengths, heights or widths. For example, the aerosol generating composition may comprise a portion of strands with a first size or range of sizes, and one or more other portion(s) of strands with a second, different size or range of sizes. In some embodiments, the aerosol generating composition may comprise one or more extruded strands which are substantially the same length. In some embodiments, the one or more extruded strands is the form of a continuous strand. Thus, the aerosol generating composition comprises one or more extruded strands in the form of a continuous strand. In such embodiments, the strand may be extruded continuously to form the continuous strand form. In some embodiments, in which the one or more extruded strands is the form of a continuous strand, the strand may be folded over in the article. Alternatively, the strand may be cut up into shorter, non-continuous strands. Extruded stands may be of any suitable shape and have any suitable cross sections. In some embodiments, the one or more extruded stands have an elongated shape, formed from the extrusion process.

In some embodiments, cross section of the one or more extruded strands is selected from a group including circular, semi-circular, crescent. Y-shaped and star. This provides the advantage that there maybe gaps between the strands in the article and air or vapour more freely travel through the article. This results in an improved pressure drop whilst in use and can increase the strength and longevity of the flavours that are produced from the strands. The cross section of the strands may be selected to increase the volume to surface-area ratio, thereby further improving the strength and longevity of the flavours that are produced from the strands. A Y-shaped cross-sectional shape is believed to be particularly beneficial because it may provide an optimal surface-area to volume ratio. In some embodiments, the strands have a cross sectional shape which enables the strands to “interlock” with other strands. For example, a first strand may be configured to interlock with one or more other strands. In such embodiments, the strands may at least partially fit together. This may increase the packing density of the aerosol generating composition and enables more strands to be packed in a given volume of space.

An example of this embodiment is illustrated in Figure 2. Figure 2 is a cross-section view of an article 1 comprising the aerosol-generating section 3 in which strands 13 are packed. The cross section of strands 13 has a crescent shape. The article 1 may further comprise wrapper 5, which may circumscribe said aerosol-generating section 3 and the strands therein. Due to the shape of the strands, the strands can interlock thereby allowing more strands to fit into the aerosol generating section. This may also prevent the movement of the strands in the aerosol generating section when during transport, storage or use. The packing density has an effect on the flavour delivery. As more strands are packed into the article or aerosol generating section, a stronger flavour may be delivered to the user. In addition, in embodiments which the aerosol generating composition comprises a plurality of aerosol generating materials with different compositions, a more complex flavour maybe delivered to the user. On the other hand, a higher packing density reduces the air flow, and increase the pressure drop and resistance to draw for the user. In some embodiments, the number of strands per article may be 150 to 340.

The aerosol-generating composition may have a packing density of from about 2 cm3/g to about 9 cm3/g. Such packing densities may provide an optimal pressure drop and thus enhance the sensory characteristics.

The cross section of the strands may also be selected to prevent interlocking of the aerosol generating material. Such embodiments enjoy the advantage of increasing the fill value of the strands in the article, making the article lighter and requiring fewer strands to fill the volume. Some of these embodiments also have the advantage that the strands have reduced movement in the article, and secure each other in place.

The “fill value” (also known as “filling value”) is a measure of the ability of a material to occupy a specific volume at a given moisture content. The fill value is measured using a densimeter, wherein the volume occupied by unit weight of the material or composition is measured. A high fill value indicates that a lower weight of material is required to produce a rod at acceptable hardness/firmness levels of a given circumference, volume and length than is required with a material of lower fill value.

In some embodiments, the aerosol-generating material may have a fill value of from about 3 to about 8 cc/g, about 4 to about 8 g/cc, or about 4.5 to about 5.5 cc/g.

The cross section of the strands is a result of the process of manufacturing them, wherein the dye is shaped to provide the strands with a selected cross section. The cross-sectional shape of the strands may be formed by changing the shape of the die in the extrusion process as described herein. This can also change the density of the of strand.

In some embodiments, the strands may have, or substantially have, a non-rectangular, non-square or non-cuboidal cross section. That is to say that they may not have sharp, 90° corners.

Alternatively, in some embodiments, the cross section of the strand may be cuboidal or square. This may be a result of the strand being further cut in its manufacturing process.

In some embodiments, the one or more extruded strands has substantially the same width across its length. In such embodiments, the one or more extruded strands has substantially the same cross section along its length. This provides the advantage of improved consistency of flavour to the user. It is thought that the provision of substantially the same cross section along the length of the strand(s) provides a consistent surface area to volume ratio, thereby providing a consistent generation of aerosol and a consistent flavour delivery. The invention enjoys the advantage that the extrusion process controls the size and shape of the strands. This means that the strands may be uniform, consequently improving their flavour consistency. The strands are more consistent in shape and weight, which is advantageous for packing and logistics of preparing the material in the consumable or article. Without wishing to be bound by a singular theory, it is thought that the process of extrusion provides the consistent width and cross section along the length because pressure and/ or speed through which the material may be forced through the die can be tightly controlled and may therefore be very consistent. This has the consequence of a consistent width and cross section of the resultant strand(s).

In other manufacturing processes, for example “bandcast”, the final product may vary in thickness and this can have an unpredictable and variable effect on the properties of the article (e.g. the pressure drop). The present invention therefore provides the advantage over such methods as the extruded strands have a more uniform and predictable shape. The aerosol generating composition comprising one or more extruded strands are formed from an aerosol generating material which is extruded. Optionally, the one or more extruded strands may be dried, shredded, cut or further processed. In some embodiments, the aerosol generating material is produced by forming a mixture; extruding the mixture through a die to form an extruded aerosol-generating material; and cutting the aerosol-generating material to form the one or more extruded strands. The method may include some or all of these steps. The mixture may be formed in any suitable means. The mixture may be stored prior to extrusion, or extruded immediately. The aerosol generating material and/or aerosol generating composition may comprise the same components as the mixture. In some embodiments the aerosol generating material and/or aerosol generating composition may comprise additional components to the mixture. The components of the aerosol generating material, aerosol generating composition and/or mixture are described herein.

In some embodiments, the method of forming the aerosol generating material comprises forming a first composition, forming a second composition, and combining the first composition and the second composition to form a mixture of the first composition and the second composition, and extruding the mixture of the first composition and the second composition to form the aerosol generating material.

In some embodiments, the first composition, also known as the “wet mixture”, comprises an aerosol former or humectant and a binder. The first composition may also comprise other liquids or suspensions disclosed herein. The first composition maybe in a liquid phase.

In some embodiments, the second composition, also known as the “dry mixture”, comprises a botanical material, a filler and optionally a second binder. The second composition may also comprise other solids or gels disclosed herein. The second composition may be in the solid phase. In some embodiments, the second composition does not comprise a binder. The mixture, once formed and mixed, may be extruded using any extrusion technique or apparatus known in the art to from the aerosol-generating material. The mixture enjoys the advantage that said mixture has suitable consistency for extrusion, and furthermore requires a minimal water content to achieve this. This has the advantageous result that less water is then required to be removed after the extrusion process and thus less drying is required. This has the advantages described herein, included reduced loss of flavour and use of less energy during the drying process.

Extrusion involves the feeding of the mixture through an orifice or dye to produce an extruded agglomerate. The process, which applies pressure to the precursor composition combined with shear forces, results in agglomerated structures, which may be in the form of any shape described herein.

Extrusion may be performed using one of the main classes of extruders: screw, sieve and basket, roll, ram and pin barrel extruders.

Forming the strands by extrusion has the advantage that this processing combines mixing, conditioning, homogenizing and moulding of the mixture of the first composition and the second composition.

In embodiments in which the strands comprise tobacco, the process of extrusion increased tobacco likeness, as the strands produced may have a similar texture and favour notes to tobacco. Other materials or additives may also be added during the extrusion process, such as a base, diluent, solid aerosol forming agents, solid flavour modifiers, expansion agents and other additives known in the art. This has the advantage that the additive is evenly distributed throughout the structures formed. The structures formed may be agglomerated due to the extrusion process.

In some embodiments, the resultant extruded strands are dried using any suitable drying technique known in the art. For example, microwave, infrared, air and oven drying are suitable techniques to dry the aerosol-generating material. The water may be removed by allowing the water to evaporate from the extruded mixture at ambient temperature and pressure (for example, 25 °C and 101 kPa.) Alternatively, the water may be removed by applying heat to the strands (for example, by heating it to above about 25 °C) and/or reducing the atmospheric pressure surrounding the strands (for example, to less than 101 kPa).

The temperature of the drying step may be below ioo°C, and is below 9O°C in some embodiments of the invention. The drying temperature employed may be at most about 25°C, about 3O°C, about 4O°C, about 5O°C, about 6o°C, about 7O°C, about 8o°C, about 9O°C, or about ioo°C. The drying temperature maybe above ambient temperature.

For example, the drying temperature maybe above 15°C, 20°C or 25 °C. A low drying temperature is advantageous as it reduces loss of volatile components, such as nicotine, glycerol and flavours, that contribute to the flavour, taste and mouthfeel of the final product. The strands are also dried to provide a suitable texture and strength. For example, strands that have been dried too much may be frangible and lack malleability. On the other hand, if the stands are too wet, then they may be sticky and difficult to use in an article.

The length of time of the drying step may be at most about 5, at most about 10, at most about 30, at most about 45, at most about 60, at most about 90, at most about 120, or at most about 360 minutes.

An advantage of the extrusion process is that less time is required to adequately dry the strands because the strands have a relatively high surface area to volume ratio. This uses less energy, saves energy costs, and a faster manufacturing process. Without wishing to be bound by any particular theory, the material can be extruded using less water, and so the mixture requires less water. This results in shorter drying times and lower drying temperatures to achieve a suitable water content.

The overall moisture content (OV) of the strands also has an effect on the physical properties of the strand. For example, if the OV is too low, then the strand may not be supple enough to withstand the processing conditions. For example, it may crumble or disintegrate during processing. In order to assist with processing, the aerosolgenerating material may be conditioned prior to the formation of the plurality of elongate strips of aerosol-generating material. In some embodiments, the mixture comprises water in an amount of between about 0% and about 15%, between about 5% and about 40%, between about 30% and about 40%, between about 28% and about 34%, or between about 30% and about 34%, by weight of the mixture.

In some embodiments, the mixture comprises oven volatiles in an amount of between about 0% and about 15% or between about 5% and about 40% by weight of the mixture. In some embodiments, the mixture comprises oven volatiles in an amount of between about 30% and about 40% by weight of the mixture.

In some embodiments, the one or more strands or aerosol generating material comprise water in an amount of between about 0% and about 15%, between about 5% and about 40%, between about 5% and about 15%, between about 6% and about 10%, or between about 6% and about 8%, by weight of the one or more strands or aerosol generating material. The water content of the strands or aerosol generating material affects the flavour delivery and the “hot puff’ effect that may be noted by consumers. Thus, a lower water content reduces the negatively perceived “hot puff’. On the other hand, if the water content is too low, then the strands may have a brittle texture and be too dry.

In some embodiments, the one or more strands or aerosol generating material comprise oven volatiles in an amount of between about 0% and about 15%, between about 5% and about 20%, between about 10% and about 20%, or between about 5% and about 15% by weight of the one or more strands or aerosol generating material. In some embodiments, the one or more strands or aerosol generating material comprises oven volatiles in an amount of between about 5% and about 15% by weight of the one or more strands or aerosol generating material.

In some embodiments, in which the strands or aerosol generating material comprise nicotine, the one or more strands or aerosol generating material comprise nicotine in an amount of between about 0% and about 5% or between about 1% and about 3% by weight of the one or more strands or aerosol generating material. In some embodiments, the one or more strands comprise about 2% nicotine by weight of the one or more strands or aerosol generating material.

In some embodiments, in which the strands or aerosol generating material comprise glycerol, the one or more strands comprise glycerol in an amount of between about 10% and about 20% or between about 15% and about 18% by weight of the one or more strands or aerosol generating material.

The water content of the aerosol-generating material described herein may vary according to, for example, the temperature, pressure and humidity conditions at which the compositions are maintained. The water content can be determined by Karl-Fisher analysis, as known to those skilled in the art.

Unless otherwise stated, as used herein, the phrases “volatile components”, “volatiles”, “total volatile”, “volatile content” and “total volatiles” are used to refer to volatile compounds, including water. The volatile content of a material maybe measured as the reduction in mass when a sample is dried in a forced draft oven at a temperature regulated to no°C ± 1°C for three hours ± 0.5 minutes. After drying, the sample is cooled in a desiccator to room temperature for approximately 30 minutes, to allow the sample to cool.

In some embodiments, the strands are cut or sliced after drying. In some embodiments the strands are not shredded. In some embodiments strands are shredded. Extrusion of the mixture to form strands provides the advantage that the strands are immediately formed into the width and height desired, and so further shredding is not required.

This is faster and cost saving because a step is missed from a typical aerosol-generating material manufacturing process. The strands may be cut or sliced horizontally (across the width as opposed along the length) in order to make strands of a known length. The strands may be sliced directly after extrusion, after drying or after further processing steps.

An advantage of the present invention is that the extrusion process provides more elasticity, allowing shaping of the aerosol generating composition. The aerosol generating material is also less brittle, so that it can be bent to fit the article.

In some embodiments, the tensile strength of the aerosol generating material at least about 3, 4, 6, 8, 10, 12 or 14 N/15 mm. In some embodiments, the tensile strength of the aerosol generating material at least about 5 N/15 mm. In some embodiments, the tensile strength of the aerosol generating material at most about 15 N/15 mm. In some embodiments, the tensile strength of the aerosol generating material at least about 3, 4,

6, 8, 10, 12 or 14 N/15 mm. A suitable tensile strength provides the advantage of withstanding processing, manufacturing, storage and use without significant degradation. The extruded strands may have a particularly high tensile strength.

The elasticity of the aerosol generating material may also be measured by measuring the amount that the strand may stretch before breaking when pulled in the direction of the length of the strand. In some embodiments, the strand stretches to at least about 110% of its length before breaking. In some embodiments, the strand stretches to at least about 104%, at least about 105%, at least about 108%, or at least about 110% of its length before breaking. In some embodiments, the strand is able to expand by about 4 to about 10%, or about 5 to about 9%. This may be measured % of strand elongation compared to the initial size when break occurs.

Extensibility measures how much the material extends compared to its original dimensions before it breaks. Extensibility maybe measured along the length of the strand(s) and may be measured using a ruler or mircometer. Extensibility is related to elasticity. For example, the higher the elasticity, the higher the extensibility. In this case, some embodiments, the strand may extend up to about 1 mm, up to about 2 mm, or up to about 4 mm before it breaks. The elasticity or extensibility provides the advantage that the strands may be manipulated in the article and during manufacture. As a result, the strands are more robust, and are easier to handle during manufacture and storage. Without wishing to be bound by reason, it is thought that the extrusion process contributes to the improved elasticity or extensibility, as this enables the aerosol generating material to be in a shape and form conducive to increased elasticity or extensibility.

In some embodiments, the aerosol generating material and/ or aerosol generating composition comprises a botanical material. As noted herein, the botanical material 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. As noted herein, the botanical material may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

The botanical material may be CBD or a derivative thereof.

In some embodiments, the botanical material is plant derived material or plant material that has been cut into smaller pieces, for example the plant derived material or plant material may be milled, pulverised, dices, slices, or otherwise partitioned to reduce the size of the pieces. In some embodiments, the botanical material is plant derived material or plant material in the form of particles, as described herein.

Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material maybe 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 botanical material comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.

In some embodiments, the aerosol generating composition does not comprise tobacco.

In embodiments, the aerosol generating composition may comprise a botanical material that does not comprise or consist of tobacco. In such embodiments, the botanical material may be selected to be non-tobacco to be desirable to the consumer or for regulatory reasons. The botanical material maybe selected to provide a pleasant or desirable flavour to the consumer.

In some embodiments, the botanical material 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 botanical is selected from rooibos and fennel. Rooibos and tobacco may be preferred botanical materials. In some embodiments the mixture, aerosol generating material and/or aerosol generating composition may comprise different botanical(s) or constituent(s), derivative(s) or extract(s) thereof. This provides the advantage that the consumer tastes different botanical materials. In some embodiments, the different flavours are delivered to the user at different times, due to the proximity of the plug to the mouth end.

In some embodiments, the mixture, aerosol generating material and/or aerosol generating composition comprises at least about 10 wt% of the botanical(s) or constituent(s), derivative(s) or extract(s) thereof. In some embodiments, the mixture, aerosol generating material and/ or aerosol generating composition comprises at least 10 wt%, at least about 25 wt%, at least about 30 wt%, at least about 50 wt%, at least about 75 wt%, at least about 95 wt%, at least about 99 wt% of the botanical(s) or constituent(s), derivative(s) or extract(s) thereof. In some embodiments, the mixture, aerosol generating material and/ or aerosol generating composition substantially consists of the botanical(s) or constituent(s), derivative(s) or extract(s) thereof.

In some embodiments, the mixture, aerosol generating material and/or aerosol generating composition comprises at most about 10 wt% of the botanical(s) or constituent(s), derivative(s) or extract(s) thereof. In some embodiments, the first and/or second aerosol generating material comprises at most 10 wt%, at most about 25 wt%, at most about 50 wt%, at most 70 wt%, at most about 75 wt%, at most about 95 wt%, at most about 99 wt% of the botanical(s) or constituent(s), derivative(s) or extract(s) thereof. In some embodiments, the mixture, aerosol generating material and/or aerosol generating composition substantially consists of the botanical(s) or constituent(s), derivative(s) or extract(s) thereof. The botanical material maybe present in an amount of from about 50 to about 80% by weight of the aerosol generating material.

In some embodiments, the botanical material comprises a tobacco material. In some embodiments, the botanical material is not a tobacco material. In some embodiments, the aerosol generating composition, or the article does not comprise a tobacco material.

As used herein, the term “tobacco material” refers to any material comprising tobacco or derivatives or substitutes thereof. The tobacco material may be in any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, paper reconstituted tobacco, or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and/or tobacco extract.

In some embodiments, the strands comprise tobacco. This provides the advantage that the strands delivery flavour of tobacco to the user with improved organoleptic properties, but without the use of a combustible device. The tobacco-likeness is particularly improved because the extruded strands have a texture and flavour profile that is similar to tobacco. The botanical material may be a particulate or granular material. In some embodiments, the botanical material is a powder or maybe ground. Alternatively or in addition, the botanical material may comprise strips, strands or fibres of botanical material. For example, the botanical material may comprise particles, granules, fibres, strips and/or strands of plant or botanical material. In some embodiments, the botanical material consists of particles or granules of botanical material. The botanical material particles provide the benefit that the particle size distribution and the resulting characteristics as described herein may be more easily controlled. In embodiments in which the botanical material is a particulate botanical material, each particle of the particulate botanical material may have a maximum dimension. As used herein, the term “maximum dimension” refers to the longest straight line distance from any point on the surface of a particle of botanical material, or on a particle surface, to any other surface point on the same particle of botanical material, or particle surface. The maximum dimension of a particle of particulate botanical material may be measured using scanning electron microscopy (SEM). In some embodiments, the maximum dimension of each particle of botanical material is up to about 800 pm. In some embodiments, the maximum dimension of each particle of botanical material is up to about 2000 pm, up to about 1000 pm, up to about 500 pm, up to about 350 pm, up to about 320 pm, or up to about 300 pm. In some embodiments, the maximum dimension of each particle of botanical material is about 200 pm to about 800 pm.

In some embodiments, a population of particles of the botanical material has a particle size distribution (D90) of at least about 50 pm, of at least about 60, of at least about 70 pm, of at least about 80 pm, of at least about 90, of at least about too pm, of at least about 110 pm, of at least about 120 pm, of at least about 130 pm. In some embodiments, a population of particles of the botanical material has a particle size distribution (D90) of at most about 360, of at most about 400 pm, of at most about 500 pm, of at most about 600 pm, of at most about 700 pm, of at most about 800 pm, or of at most about

860 pm. In some embodiments, a population of particles of the botanical material has a particle size distribution (D90) of about 600 pm. In some embodiments, a population of particles of the botanical material has a particle size distribution (D90) of about 70 pm. In some embodiments, a population of particles of the botanical material has a particle size distribution (D90) of about 70 pm to about 600 pm, or about 70 to about 360 pm. A particle size and shape analyser, such as a Camsizer may be used to measure the particle size distribution, and sieve analysis maybe used to determine the particle size distribution of the particles of botanical material. The inventors have found that the botanical material particle size affects the tensile strength. A small particle size distribution is associated with a higher tensile strength and higher and density of the aerosol generating material. The aerosol generating composition may be optimised for this, wherein the particle size is selected to provide a suitable tensile strength.

The inventors have found that the particle size distribution (D90) may be controlled to achieve the desired area density of the aerosol-generating material. The area density of the material maybe measured in GSM (grams per square metre or g/m²). For example, lower particle size distributions (D90) are associated with higher area densities. When the aerosol-generating material is incorporated into an article for use in a noncombustible aerosol provision system, this higher area density may decrease the fill- value of the botanical material. A particular example of this is that a particle size distribution (D90) of 300 is predicted to provide an area density of 246.6 g/m².

In some embodiments, the aerosol-generating material has an area density of from about too g/m² to about 300 g/ m², from about 110 g/ m² to about 280 g/ m², from about 120 g/m² to about 260 g/m², f from about 150 to about 210 g/m², from about 180 to about 205 g/m² or from about 185 to about 195 g/m². In some embodiments, the aerosol-generating material has an area density of about 180 to about 200 g/m². The average volume density or grammage of the aerosol-generating material may be calculated from the thickness of the aerosol-generating material and the area density of the aerosol-generating material. In some embodiments, average volume density or grammage maybe from about 0.5 g/cm3 to about 1 g/cm3. j_n some embodiments, the average volume density is from about 0.6 g/cm3 to about 0.9 g/cm3, from about 0.7 g/ cm3 to about 0.86 g/ cm3. j_n some embodiments, the average volume density is about

0.8 g/cm3.

The aerosol generating material has a lower density compared to other aerosol generating materials. As a result of this lower density, the rod is lighter, and therefore easier to handle and stored.

A lower density is desirable as this reduces the amount of material required to produce the strands. The mixture, aerosol generating material and/ or aerosol generating composition may further contain additional substances. In some embodiments, mixture, aerosol generating material and/or aerosol generating composition may comprise an active substance. The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or 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.

In one embodiment the active substance is a legally permissible recreational drug

In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

In some embodiments, the mixture, aerosol generating material and/or aerosol generating composition may comprise a flavour.

In some embodiments, the mixture, aerosol generating material and/or aerosol generating composition may comprises a flavour content of about o to about 20% by weight. In some embodiments, the mixture, aerosol generating material and/or aerosol generating composition may comprises a flavour content of from about o to about 20 %, about 5 to about 20 %, about 5 to about 15 %, about 8 to about 12% by weight.

In some embodiments, the flavour is added to the first or second composition. This embodiment enjoys the advantage of the liquid flavour being added to the liquid composition prior to mixing the first and the second composition, and that the flavour will be distributed evenly throughout at least the first composition. This embodiment has the disadvantage that the flavour may be lost during the drying operation.

In some embodiments, the flavour maybe added after extrusion. For example, a flavour nozzle may be provided on the machinery to deposit the flavour onto the surface of the strands of the aerosol generating material.

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 maybe 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. In some embodiments, the mixture, aerosol generating material and/or aerosol generating composition may contain one or more functional materials. The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

The binder is arranged to bind the components of the mixture, aerosol generating material and/or aerosol generating composition. The mixture, aerosol generating material and/or aerosol generating composition can comprise more than one binder. In such embodiments, the binders can be the same or different.

In some embodiments, the binder comprises or is a gelling agent. The binder may be selected from one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, the binder comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the binder comprises alginate and/or pectin or carrageenan. In some embodiments, the binder comprises CMC.

In some embodiments, the mixture, aerosol generating material and/or aerosol generating composition may comprises a binder content of about 5 to about 40% by weight. In some embodiments, the mixture, aerosol generating material and/or aerosol generating composition may comprises a binder content of about 5 to about 30%, about 5 to about 20%, about 5 to about 15%, or about 5 to about 10% by weight.

In some embodiments, the mixture, aerosol generating material and/or aerosol generating composition may comprises an aerosol former. The aerosol former comprises one or more constituents capable of forming an aerosol. The aerosol former comprises one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some embodiments, the aerosol former is glycerine, glycerol or propylene glycol. In some embodiments, the mixture, aerosol generating material and/or aerosol generating composition may comprise an aerosol former content of about 5 to about 50% by weight. In some embodiments, the mixture, aerosol generating material and/or aerosol generating composition may comprises an aerosol former content of about 10 to about 30%, or about 15 to about 25% by weight.

In some embodiments, the mixture, aerosol generating material and/or aerosol generating composition comprises a filler. The filler is generally a non-tobacco component, that is, a component that does not include ingredients or components originating from tobacco. The filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may be a non-tobacco fibre such as wood fibre or pulp or wheat fibre. The filler can be a material comprising cellulose or a material comprises a derivate of cellulose. The filler component may also be a non- tobacco cast material or a non-tobacco extruded material. In some embodiments, the filler is cellulosic material, cellulose or CMC. In some embodiments, the filler is essentially composed or consists of cellulose. In particular embodiments which include filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood, wood pulp, hemp fibre, cellulose or cellulose derivatives. Without wishing to be bound by a singular theory, it is believed that including fibrous filler may increase the tensile strength of the aerosolgenerating material that is formed. The use of cellulose as a filler has been found to have a particularly favourable impact on the burst strength of the aerosol-generating material.

The filler may also contribute to the texture of the aerosol-generating material. For example, a fibrous filler, such as cellulose, may provide an aerosol-generating material having relatively rough first and second surfaces. Conversely, a non-fibrous, particulate filler, such as powdered chalk, may provide an aerosol-generating material having relatively smooth first and second surfaces. In some embodiments, the aerosolgenerating material comprises a combination of different filler materials. The filler may help to improve the general structural properties of the aerosol-generating material, such as its tensile strength and burst strength. In some embodiments, the mixture, aerosol generating material and/or aerosol generating composition may comprises a filler content of about o to about 20% by weight. In some embodiments, the mixture, aerosol generating material and/or aerosol generating composition may comprises a filler content of about 1 to about 15%, about 3 to about 10%, or about 4 to about 6% by weight.

In some embodiments of the invention, an article for use with a non-combustible aerosol-provision system comprises the aerosol generating composition. An article or consumable is an article comprising or consisting of the aerosolgenerating material, part or all of which is intended to be consumed during use by a user. An article may comprise one or more other components, such as an aerosolgenerating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying agent. An article may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor. In some embodiments, the aerosol generating composition comprises different aerosol generating materials, wherein the aerosol generating compositions comprise different or different amounts of flavour, botanical material, binder, water, and/or filler. Advantageously, stands comprising different aerosol generating materials may be mixed together in the aerosol generating composition. The mixed proportions may be easily controlled, either by differing numbers of strands, or changing the size/shape of the strands. This means that the flavours of the aerosol generated may be finely tuned and controlled. In addition, this improved consistency is beneficial for manufacturing because the strands are reproducible. In an exemplary embodiment, Figure 4 is a perspective view of an article 1 for use in an aerosol delivery system. Figure 5 is a side-on cross sectional view of the article 1.

The article 1 comprises a mouthpiece 2, and an aerosol-generating section 3, connected to the mouthpiece 2. In the present example, the aerosol-generating section 3 comprises the aerosol-generating composition, comprising a plurality of strands. The article i comprises a downstream end 2b and an upstream end 2a distal from the downstream end 2b.

In the present example, the aerosol-generating material is circumscribed by a wrapper 5. In the present example, the wrapper 5 is a moisture impermeable wrapper. In some embodiments, the wrapper is paper, but may be made of alternative materials, such as aluminium.

The mouthpiece 2 includes a cooling section 6, also referred to as a cooling element, positioned immediately downstream of and adjacent to the source of aerosolgenerating composition 3. In the present example, the cooling section 6 is in an abutting relationship with the source of aerosol-generating material. The mouthpiece 2 also includes, in the present example, a body of material 7 downstream of the cooling section 6, and a hollow tubular element 8 downstream of the body of material 7, at the mouth end of the article 1.

In some embodiments, the one or more extruded strands are aligned with a longitudinal axis of the article. The one or more extruded strands may be aligned within the aerosol-generating section such that their longitudinal dimension is in parallel alignment with a longitudinal axis, X-X’ of the article 1. Alternatively, the strands may generally be arranged such that their longitudinal dimension aligned is transverse to the longitudinal axis of the article. In some embodiments, at least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or 95% of the strands maybe arranged such that their longitudinal dimension is in parallel alignment with the longitudinal axis of the article. A majority of the strands may be arranged such that their longitudinal dimensions are in parallel alignment with the longitudinal axis of the article. In some embodiments, about 95% to about 100% of the strands are arranged such that their longitudinal dimension is in parallel alignment with the longitudinal axis of the article. In some embodiments, substantially all of the strands are arranged in the aerosolgenerating section such that their longitudinal dimension is in parallel alignment with the longitudinal axis of the aerosol-generating section of the article.

This enable more strands to be packed into the article because the strands are aligned and can pack together. This is advantageous as it provides a stronger flavour to the user in a smaller amount of space or size of article. The directionality of the strands may also affect the pressure drop across the article, requiring less resistance in the air flow through the article. In some embodiments, the extruded strands are not aligned. For example, the strands may be not straight, non-linear, wavy or irregular in directionality. This increases the space the strands take up, reducing the amount in the article and the weight of the article. This may also increase air flow and provide a more suitable pressure drop. In some embodiments, the pressure drop across the article is about 20 to about 120 mmWg, about 30 to about 80 mmWg, or about 30 to about 60 mmWg. The pressure drop may be measured between an upstream end and a downstream end of the article. In some embodiments, a non-combustible aerosol-provision system comprising the article is provided. The non-combustible aerosol-provision system may be as described herein.

As used herein, the term ‘air permeability’ refers to the time required for a known volume of air, aerosol or a mixture of air and aerosol, to pass through a known volume of the aerosol generating material. Thus, a lower air permeability is associated with a lower permeability of the aerosol generating material. In some embodiments, the air permeability of the aerosol generating material is between about 5 and about 40 s/100 cm3’ between about 5 and about 20 s/100 cm3, or between about 5 and about 15 s/ too cm³. Air permeability may be measured using a Gurley Precision Instruments Densometer and/or a Gurley Precision Instruments Porosity Test Plate.

The aerosol generating material enjoys the benefit of a lower air permeability. A lower air permeability has a positive impact on aerosol generation, as more air or aerosol passes though the material in a given time. This enables more of the aerosol to be generated and to pass to the user.

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

Claims

1. An aerosol generating composition comprising one or more extruded strands of aerosol-generating material, the one or more extruded strands of aerosol-generating material comprising a length, a width and a height and wherein the width and height are substantially the same and the length is greater than the height or width.

2. The aerosol generating composition according to claim 1, wherein the one or more extruded strands has a cross-section with the shape selected from a group consisting of: circular, semi-circular, crescent, Y-shaped and star.

3. The aerosol generating composition according to any preceding claim, wherein the one or more extruded strands has a cross-section which is substantially non- rectangular, non-square or non-cuboidal.

4. The aerosol generating composition according to any preceding claim, wherein each of the one or more extruded strands is in the form of a continuous strand.

5. The aerosol generating composition according to any preceding claim, wherein the aerosol generating composition comprises two or more extruded strands and wherein at least two of the two or more extruded strands are substantially the same length.

6. The aerosol generating composition according to any preceding claim, wherein each of the one or more extruded strands has substantially the same width across its length, and optionally substantially the same cross section along its length.

7. The aerosol generating composition according to any preceding claim, wherein the one or more extruded strands has a tensile strength of at least 4 N/15 mm.

8. The aerosol generating composition according to any preceding claim, wherein one or more of the extruded strands can stretch to at least about 104% of its length before breaking. . The aerosol generating composition according to any preceding claim, wherein the aerosol-generating material comprises water. 10. The aerosol generating composition according to claim 9, wherein the aerosolgenerating material comprises a water content of up to about 40% by weight. 11. The aerosol generating composition according to any preceding claim, wherein the aerosol generating material comprises botanical material.

12. The aerosol generating composition according to claim 11, wherein the aerosol generating material comprises a botanical material content of about 50 to about 80% by weight.

13. The aerosol generating composition according to any preceding claim, wherein the aerosol-generating material has a density of about from about 0.5 g/cm3 to about

1 g/cm3.

14. The aerosol generating composition according to any preceding claim, comprising botanical material in the form of particles.

15. The aerosol generating composition material according to claim 14, wherein the particles have a D90 of about 70 to about 600 pm.

16. An article for use with a non-combustible aerosol-provision system comprising the aerosol generating composition according to any one of claims 1 to 15. 17. The article according to claim 15 or 16, wherein the one or more extruded strands are aligned lengthways with a longitudinal axis of the article.

18. A method of forming the aerosol generating composition according to any one of claims 1 to 15, wherein the method comprises: forming a mixture; extruding the mixture through a die to form an extruded aerosol-generating material; and cutting the aerosol-generating material to form the one or more extruded strands. 19- The method of forming the aerosol generating material according to claim 18, wherein the method does not comprise shredding the aerosol generating composition.

20. The method of forming the aerosol generating material according to either of claim 18 or claim 19, wherein the extruded aerosol-generating material is dried at a temperature not exceeding 100 °C.

21. An aerosol generating composition produced by the process as claimed in any one of claims 18 to 20.

22. A non-combustible aerosol-provision system comprising the article as claimed in either claim 16 or claim 17.