EP4734777A1

EP4734777A1 - Article for use with a non-combustible aerosol provision device

Info

Publication number: EP4734777A1
Application number: EP24740060.9A
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: GB202310023D0; WO2025003427A1; CN121969251A; TW202519135A

Abstract

The present disclosure relates to an article (1) for use with a non-combustible aerosol provision device (100), the article (1) comprising a first end (2b) comprising a mouthpiece (2) and a second end (2a) distal from the first end (2b), the second end (2a) comprising an extruded plug (4) comprising a first aerosol-generating material. A non-combustible aerosol provision system comprising the article (1), a method of producing an extruded plug (4) for use with the article (1) and an extruded plug (4) produced by the process is also disclosed.

Description

Article for use with a non-combustible aerosol provision device

Technical Field An article for use with a non-combustible aerosol provision device, the article comprising an 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, for example, in terms of their flavour delivery, ease of manufacture and also their format in the delivery device.

Summary

In a first aspect of the invention, an article for use with a non-combustible aerosol provision device is provided, the article comprising a first end comprising a mouthpiece and a second end distal from the first end, the second end comprising an extruded plug comprising a first aerosol-generating material.

In some embodiments, the article comprises a second aerosol generating material between the plug and the first end.

In some embodiments, the second aerosol generating material is in the form of a rod.

In some embodiments, wherein the extruded plug is configured to receive an aerosol generator of the non-combustible aerosol provision device. In some embodiments, the extruded plug comprises a receiving portion configured to receive the aerosol generator.

In some embodiments, the plug is configured such that when the aerosol generator is received by the plug, the aerosol generator extends into the plug and into the second aerosol generating material.

In some embodiments, the aerosol generator is a pin. In some embodiments, the first aerosol-generating material and/ or the second aerosolgenerating material comprises botanical material.

In some embodiments, the plug comprises a botanical material content of about 5 to about 75% by weight.

In some embodiments, the plug comprises channels or indentations.

In some embodiments, the channels are aligned with a longitudinal axis of the article. In some embodiments, the channels are configured to allow a fluid to pass through the plug.

In some embodiments, the channels are located on the surface of the plug. In some embodiments, the indentations or channels have a depth of about 5 to about 300 pm.

In some embodiments, the plug has a length of less than 6 mm and/or the width of the plug is from about 15 to about 35 mm.

In some embodiments, the plug substantially consists of the first aerosol generating material.

In some embodiments, the plug comprises water. In some embodiments, the plug comprises a water content of about o to about 15% by weight.

In a third aspect, a method of producing the article is provided. The method may comprise extruding the plug and incorporating the plug into the article.

In a fourth aspect, a non-combustible aerosol provision system comprising the article and a non-combustible aerosol provision device is provided. In a fifth aspect, a method of producing an extruded plug for use with the article is provided.

In some embodiments, wherein the process comprises extrusion. In a fifth aspect, an extruded plug produced by the process is provided.

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 article for use with a non-combustible aerosol provision device; Figure 2 is a side-on cross-sectional view of the article shown in Figure 1;

Figure 3 is a perspective view of an article for use with a non-combustible aerosol provision device;

Figure 4 is a schematic cross-sectional view of an aerosol-generating section of an article for use with a non-combustible aerosol provision device; Figure 5 depicts example steps of a process used to manufacture an example aerosolgenerating composition;

Figure 6 is a perspective illustration of a non-combustible aerosol provision system for generating aerosol from the article of Figure 1; and

Figure 7 is a side-on cross-sectional schematic view of a plug as described herein.

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 noncombustible aerosol provision device and an article for use with the non-combustible aerosol provision device.

In some embodiments, the disclosure relates to articles comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These articles are sometimes referred to as articles throughout the disclosure. 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. The terms ‘upstream’ and ‘downstream’ used herein are relative terms defined in relation to the direction of mainstream aerosol drawn through an article or device in use.

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 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. According to a first aspect of the invention, an article for use with a non-combustible aerosol provision device is provided, the article comprising a first end comprising a mouthpiece and a second end distal from the first end, the second end comprising an extruded plug comprising a first aerosol-generating material. In the figures described herein, like reference numerals are used to illustrate equivalent features, articles or components.

Referring to Figure 1, the article 1 comprises a first end 2b which is downstream and a second end 2a which is upstream and distal from the downstream end 2b.

Referring to Figure 2, the first end 2b of the article 1 comprises a first end 2a comprising a mouthpiece 2 and a second end 2b distal from the first end. The second end 2a may comprise an extruded plug 4 comprising a first aerosol-generating material. The article further comprises an optional second aerosol-generating material 3.

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 a substance to be delivered, such as an active substance and/or flavourant.

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 some embodiments, the substance to be delivered comprises an active substance. In some embodiments, the first and or second aerosol generating material comprises at least one 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. As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

The active substance may be CBD or a derivative thereof. In some embodiments, the substance to be delivered comprises a flavour.

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. As noted, the plug 4 comprises a first aerosol generating material. This provides the advantage that the plug may provide an aerosol to the user when the plug is heated. The aerosol may comprise flavourants and/or actives that enhance the sensory (for example, organoleptic) properties of the aerosol. In addition, the enhanced sensory characteristics of the aerosol that is produced when the plug is heated may help to mask or reduce the perception of “off-notes” or flavours that exhibit a negative sensory attribute. Overall, the aerosol generating material can provide an aerosol to the user with an improved taste.

In some embodiments and the present example, the plug 4 is located adjacent to a second aerosol generating material 3. The second aerosol generating material 3 maybe between the plug 4 and the first end 2a. The plug may therefore provide the advantage of preventing the movement of the second aerosol-generating material 3, which may otherwise move during use or storage. For example, the plug prevents the second aerosol-generating material 3, or other components of the article, from falling out of the end 2a.

The incorporation of the plug 4 comprising the aerosol-generating material also allows for greater flexibility in the design and manufacture of articles. A variety of plugs can be manufactured comprising different aerosol-generating materials and, as a consequence, the flavour profile of the aerosol produced by the plug 4 can be tailored.

The second aerosol-generating material 3 can also be tailored. Furthermore, in the present embodiment, as the plug 4 is a discrete component that abuts the second aerosol-generating material 3, there is no mixing of the plug 4 and the second aerosolgenerating material 3. Thus, it is possible to carefully control (or “tune”) the sensory characteristics of an aerosol produced by the first and second aerosol-generating materials through the selection of the first aerosol-generating material and the second aerosol-generating material.

Referring again to Figure 2, the extruded plug 4 is adjacent the second aerosol- generating material 3. In the present example, the aerosol-generating section 3a (between points 2a and 2c in Figure 2) comprises a cylindrical rod of the second aerosol-generating material 3 and the plug 4.

The mouthpiece 2 includes a cooling section 6, also referred to as a cooling element, positioned immediately downstream of and adjacent to the second aerosol-generating material 3. In the present example, the cooling section 6 is in an abutting relationship with the second aerosol-generating material 3. The aerosol-generating section 3a comprises plug 4 and the second aerosol generation material 3. 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 the present example, the extruded plug 4 is in the form of a cylindrical rod. In some embodiments the plug may be in any suitable shape. For example, the plug may be in a ball, triangular, wedge or “T-shape”, wherein a first section of the plug has a smaller diameter than a second section of the plug.

The plug 4 comprises an upstream end 4a, a downstream end 4b and a longitudinal axis that is parallel to and/or aligned with the longitudinal axis, X-X’ of the article 1. In a cross-section transverse or perpendicular to the longitudinal axis X-X’ of the article 1, the plug 4 may have any suitable cross-sectional shape. The cross section of the plug 4 may be a round, oval, circular, square or rectangular shape, or any other suitable shape. This provides the advantage that the cross-section of the plug may be tailored to match the cross-section of the mouthpiece, which maybe shaped to be ergonomic to handle or use.

The plug comprises a length and a width. The length of the plug is the distance between the upstream end 4a of the plug and the downstream end 4b of the plug 4. The width is the dimension of the plug 4 that is transverse to the length. The width of the plug may be from about 15 to about 35 mm. In some embodiments, the width of the plug is from about 15 to about 35 mm, from about 18 to about 30 mm, from about 20 to about 25 mm or from about 22 to 23 mm. The width of the plug may be selected or configured to fit the article suitably. The plug 4 may have a width that is substantially the same as a width of the aerosol-generating section 3a.

The length of the plug may be up to about 6 mm, up to about 5 mm, up to about 3 mm or up to about 2 mm.

The incorporation of a plug into an article can help to retain another (for example, a second) aerosol-generating material within the aerosol-generating section of the article, for example. However, plugs typically take up room within the aerosol-generating section that could otherwise be occupied by other aerosol-generating materials.

The process of extrusion enables the plug that have a relatively short length to be made. The extruded plug may also require less material to manufacture. In addition, a shorter plug can leave more space in the article for a second aerosol generating material but still provide the benefits of incorporating a plug into the article, as described herein.

Where the extruded plug has a relatively short length, it may provide a more subtle flavour profile due to having a lower mass of material and a lower surface area to volume ratio. This may be beneficial for certain flavours and flavour profiles.

In some embodiments and in the present example, the article comprises a second aerosol generating material 3. The second aerosol generating material 3 is between plug 4 and the mouthpiece 2. In some embodiments, the second aerosol generating material 3 may be in the form of a rod. The form of a rod is desirable because this provides a suitable shape for the aerosol delivery system, which may be an ergonomic shape to be held by the user.

Advantageously, the second aerosol generating material may have a different composition and/or be manufactured in a different way than the first aerosol generating compositions. This provides a different properties to the materials. For example, the flavours in the materials may be different. This can deliver combinations of flavours to the user, and the aerosol generated may have a complex and desirable flavour profile. For example, the first aerosol generating material may be manufactured by extrusion, yielding an extruded plug having the advantages described herein. The second aerosol generating material may be manufactured by a bandcasting method, or be formed by forming a slurry, which is then dried to form a solid. In some embodiments, the plug 4 and/or the second aerosol-generating material 3 is circumscribed by a wrapper 5. In the present example, the wrapper 5 is a moisture impermeable wrapper. In some embodiments, the wrapper 5 also circumscribes the plug 4- In some embodiments, at least about 70% of a volume of the aerosol-generating section 3a is filled with the second aerosol-generating material 3. In some embodiments, from about 75% to about 85% of the volume of the cavity is filled with the second aerosolgenerating material 3.

The packing density and fill volume of the aerosol-generating section 3a maybe selected to provide a suitable pressure drop across the section. This is to provide suitable delivery of the aerosol or vapour to the user, whilst providing a preferred pressure drop.

When in use, the aerosol-generating section may exhibit a pressure drop of from about 15 to about 90 mm H₂0. In some embodiments, the aerosol-generating section exhibits a pressure drop across the aerosol-generating section of from about 15 to about 90, from about 15 to about 40, from about 30 to about 90, or from about 60 to about 90 mm H₂0. The first and/or second aerosol-generating material may have a packing density of between about 400 mg/ cm3 and about 900 mg/ cm3, A packing density higher than this may increase the pressure drop.

The first second aerosol-generating material and/or second aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosolformer materials, and optionally one or more other functional material.

In some embodiments, the first aerosol generating material and/ or the second aerosol generating material comprise a botanical material. In some embodiments, the botanical material comprises or consist of one or more botanicals or constituents, derivatives or extracts thereof. In some embodiments, the second aerosol generating material may a botanical material. 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.

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. 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.

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 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 first aerosol generating material and/or the second aerosol generating material 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 first aerosol generating material and/ or the second aerosol generating material comprises at least about to wt% of the botanical(s) or constituent(s), derivative(s) or extract(s) thereof. In some embodiments, the first aerosol generating material and/ or the second aerosol generating material comprises at least to wt%, at least about 25 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 first aerosol generating material and/or the second aerosol generating material substantially consists 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 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 least most 25 wt%, at most about 50 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 first and/or second aerosol generating material substantially consists of the botanical(s) or constituent(s), derivative(s) or extract(s) thereof.

In some embodiments, the botanical material is tobacco. Thus, in some embodiments, the first and/or the second aerosol-generating material comprises tobacco. In alternative embodiments, the botanical material is not tobacco. Thus, in some embodiments, the first and/or the second aerosol-generating material does not comprise tobacco.

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. As used herein, the term “tobacco material” refers to a material derived from a plant of the Nicotiana species. The selection of the plant of the Nicotiana species is not limited, and the types of tobacco or tobaccos used may vary. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, leaf tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract. As used herein, “leaf tobacco” means cut lamina tobacco. In some embodiments, the tobacco material is selected from flue-cured or Virginia, Burley, sun-cured, Maryland, dark-fired, dark air cured, light air cured, Indian air cured, Red Russian and Rustica tobaccos, and mixtures thereof, as well as various other rare or specialty tobaccos, green or cured. Tobacco material produced via any other type of tobacco treatment which could modify the tobacco taste, such as fermented tobacco or genetic modification or crossbreeding techniques, is also within the scope of the present disclosure. For example, it is envisaged that tobacco plants maybe genetically engineered or crossbred to increase or decrease production of components, characteristics or attributes. In some embodiments, the tobacco material is sun-cured tobacco, selected from Indian Kurnool and Oriental tobaccos, including Izmir, Basma, Samsun, Katerini, Prelip, Komotini, Xanthi and Yambol tobaccos. In some embodiments, the tobacco material is dark air cured tobacco, selected from Passanda, Cubano, Jatin and Besuki tobaccos. In some embodiments, the tobacco material is light air cured tobacco, selected from North Wisconsin and Galpao tobaccos.

In some embodiments, the tobacco material is selected from Brazilian tobaccos, including Mata Fina and Bahia tobaccos. In some embodiments, the tobacco material is selected from criollo, Piloto Cubano, Olor, Green River, Isabela DAC, White Pata, Eluru, Jatim, Madura, Kasturi, Connecticut Seed, Broad Leaf, Connecticut, Pennsylvanian, Italian dry air cured, Paraguayan dry air cured and One Sucker tobaccos.

The tobacco material may comprise or consist of reconstituted tobacco, tobacco lamina, paper reconstituted tobacco, extruded tobacco, bandcast reconstituted tobacco, or a combination of reconstituted tobacco and another form of tobacco, such as tobacco lamina or granules.

In some embodiments, the first and/or second aerosol generating material comprises a botanical material content of from about 5 to about 75 wt%, from about 10 to about 30 wt% , from about 30 to about 50 wt% , from about 50 to about 70 wt% , or from about 70 to about 75 wt% tobacco. The botanical material content may be selected to provide a positive flavour to the user and to provide a suitable texture in the aerosol generating material. The botanical content affects the elasticity and the tensile strength in the plug, the first and/or second aerosol generating material

The botanical material maybe a particulate or granular material. In some embodiments, the botanical material is a powder or may be 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 botanical material. In some embodiments, the botanical material consists of particles or granules of botanical material. 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 tobacco 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 tobacco, or particle surface. The maximum dimension of a particle of particulate tobacco 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. A population of particles of the botanical material may have a particle size distribution (D90) of at least about 70 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, at least about 200 pm, of at least about 250, of at least about 300 pm, or of at least about 320 pm. In some embodiments, a population of particles of the botanical material has a particle size distribution (D90) of at most about 500 pm, of at most about 450 pm, of at most about 400 pm, of at most about 350 pm, at most about 720 pm, of at most about 740 pm, of at most about 760 pm, of at most about 780 pm, of at most about 800 pm, of at most about 820 pm, of at most about 840 pm, 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, the particles have a D90 of about 320 to about 350 pm. A particle size and shape analyser, such as a Camsizer may be used to measure the particle size distribution, and sieve analysis may be 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 (D90) is associated with a higher tensile strength and higher density of the aerosol generating material or the plug. A lower density is desirable as this reduces the amount of material required to produce the plug and the plug is lighter which is advantageous for transportation. The plug may be optimised to balance these properties.

The inventors have found that the particle size distribution (D90) may be controlled to achieve the desired area density of the aerosol-generating material, and the sheet, shredded sheet or product produced therefrom. 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 aerosolgenerating material is incorporated into an article for use in a non-combustible 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 a density of about 400 g/cm3, in some embodiments, the aerosol generating material has a density of at least about 400 g/cm3, _at least about 450 g/cm3, _at least about 500 g/cm3, _at least about 550 g/cm3, or at least about 600 g/cm3. i_n some embodiments, the aerosol generating material has a density of at most about 700 g/cm3, _at most about 750 g/cm3, _at most about 800 g/cm3, _at most about 820 g/cm3, _Or at most about 850 g/cm3.

These densities have been found to provide a good balance between improved firmness afforded by denser material and minimising the overall weight of the article. The density may be determined by dividing the total weight of the plug by the total volume of the plug, wherein the total volume can be calculated using appropriate measurements of the material forming the cooling section 6 taken, for example, using callipers. Where necessary, the appropriate dimensions maybe measured using a microscope.

The articles described herein are suitable for use with a non-combustible aerosol provision device. In some embodiments, the non-combustible aerosol provision device comprises an aerosol generator. An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator maybe configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy. The aerosol generator can be configured for insertion into the aerosol-generating section of an article for use with a non-combustible aerosol provision device. In some embodiments, the aerosol generator may be a blade or a pin.

In some embodiments, the aerosol generator may abut the plug, which provides the advantage that the plug or aerosol generator may be easily moved and changed. In some embodiments, the aerosol generator is configured to extend into the plug. In some embodiments, the extruded plug is configured to receive an aerosol generator of the non-combustible aerosol provision device. In such embodiments, the plug may comprise a receiving portion. For example, the receiving portion can be a cavity that is configured to receive the aerosol generator of the non-combustible aerosol provision device. When the aerosol generator is received in the receiving portion of the plug, it is in direct contact with the plug. This facilitates heat transfer from the aerosol generator to the plug.

Referring to Figure 7, exemplary plug 4 has a receiving portion 15 configured to receive an aerosol generator of a non-combustible aerosol provision device, which is in the form of a pin 16. In this embodiment, the extruded plug does not have indentations or channels.

The receiving portion of the plug can be made during the extrusion process. Using extrusion to form the plug and the cavity means that the dimensions of the receiving portion can be made to relatively tight tolerances and the dimensions of the receiving portion can be relatively consistent between different plugs. As a consequence, a greater surface area of the aerosol generator can be in direct contact with the plug when the aerosol generator is received by the receiving portion of the plug. Furthermore, as the aerosol generator may be in direct contact with the plug when it is received by the receiving portion of the plug, a certain amount of force is necessary to insert the aerosol generator into the receiving portion. As the extrusion process consistently produces a plug having precise dimensions, the force required to insert the aerosol generator into the plug and remove the aerosol generator from the plug can be consistent between different plugs, thereby improving the ease of use of the article.

In some embodiments, the receiving portion may be 100% of the length of the plug, such that the whole length of the plug may receive the aerosol generator. In some embodiments, the receiving portion maybe up to about 10%, up to about 25%, up to about 50%, up to about 75%, up to about 80%, up to about 90%, or up to about 99% of the length of the plug.

The receiving portion provides the advantage that the aerosol generator may heat the plug directly, and be located closer to the plug in order to more efficiently heat it. A greater surface area of the aerosol generator may be in contact with the plug, therefore improving heating efficiency. As described herein, the plug comprises aerosol- generating material, which would also be heated and thus generate the aerosol. This provides an improved flavour to the user.

Said receiving portion may be in the form of a cavity in the plug, into which the aerosol generator can extend. The cavity may have a cylindrical shape or be shaped to fit the aerosol generator. An exemplary embodiment of said cavity is illustrated in Figure 3.

Figure 3 depicts a perspective view of an article 1. In this embodiment, second aerosol generating material 13 abuts the plug 4. Plug 4 comprises cavity 14 and channels 15, described herein.

In this embodiment, the cavity 14 has a diameter of about 2 mm. The aerosol generator may have the shape of a pin with a diameter of about 2 mm. The cavity therefore receives the aerosol generator and provides improved contact and reduced distance between said aerosol generator and plug. This provides the advantage of improved (e.g. faster) heating, which improves the release rate of flavours to the user.

In some embodiments, the receiving portion is in the form of a cavity in the plug and said cavity has a diameter of at most about 1, at most about 2, at most about 3 or at most about 5 mm.

In some embodiments, the aerosol generator extends into the plug and into the second aerosol generating material. In such embodiments, the receiving portion of the plug extends through the entire length of the plug from the first end to the second end of the plug. This provides the advantage that the aerosol generator may heat the second aerosol generating material directly, and be located closer to the plug in order to more efficiently heat it. In some embodiments, the aerosol generator extends into the second aerosol generating material. The aerosol generator may extend into up to about too, about 80, about 50, about 20, about 10% of the length of the second aerosol generating material. The aerosol generator may extend into up to about 2 or up to about 3mm of the length of the plug.

The receiving portion may be manufactured during the extrusion process in which the plug is formed. An advantage of the extruded plug is that is it malleable after extrusion so that a receiving portion may be formed into the plug in one piece. The plug with the receiving portion may then be dried and the rigidity increased. This provides the advantage that the shape of the plug and the optional indentations or channels is not affected or distorted by the introduction of a receiving portion. This means that the plug is a consistent shape and more suitable to fit into the article. When a plug is produced by a different method, the receiving portion maybe introduced using drilling or other methods which can alter the rest of the shape of the plug.

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

The flavour content maybe adjusted to accommodate for a flavouring in both the first and second aerosol generating material for example.

In some embodiments, the first aerosol generating material and/ or second aerosol generating material comprises an aerosol-former material.

The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material 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 some embodiments, the first aerosol generating material and/ or second aerosol generating material comprises an aerosol former content of about 5 to about 50% by weight. In some embodiments, the first aerosol generating material and/ or second aerosol generating material comprises an aerosol former content of about 10 to about 30%, or about 15 to about 25% by weight.

The aerosol former material may act as a plasticiser. In some cases, the aerosol former material comprises one or more compound selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases, the aerosol former material comprises, consists essentially of, or consists of glycerol. The aerosol former may enhance the mouthfeel, as well as the organoleptic properties in general, of the aerosol produced by the aerosol-generating material when heated and inhaled by a user, particularly where the aerosol-generating material comprises relatively high quantities (e.g. >40 wt%) of aerosol former. The capability of aerosolgenerating materials to retain high quantities of aerosol former may reduce the need for other components of the aerosol-generating material, such as the expanded botanical material, to be loaded with high quantities of aerosol former. This may improve manufacturing efficiency.

In some embodiments, the first aerosol generating material and/ or second aerosol generating material 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 first aerosol generating material and/or second aerosol generating material. The first aerosol generating material and/or second aerosol generating material 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 first aerosol generating material and/ or second aerosol generating material may comprise a binder content of about 5 to about 40% by weight. In some embodiments, the first aerosol generating material and/ or second aerosol generating material may comprise 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 first aerosol generating material and/ or second aerosol generating material 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 theory, it is believed that including fibrous filler may increase the tensile strength of the aerosol-generating 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 plug or aerosol-generating material.

The filler may also contribute to the texture of the plug or 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 plug or aerosol-generating 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 first aerosol generating material and/ or second aerosol generating material 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. The plug comprises an outer surface, that is a surface on the exterior of the plug. In some embodiments, this surface may comprise indentations. Indentations are depressions in the surface of the plug. Such indentations maybe formed using the extrusion process in which the plug is made. Alternatively, the indentations may be formed may be machined after the extrusion process. For example, the indentations maybe formed by impressing, drilling, cutting or otherwise forming the depressions into the surface of the plug.

Said indentations maybe of any suitable size or shape, and may form a pattern on the surface. For example, the sections may form a “stripe” pattern on the surface of the plug, wherein there is a section comprising indentations adjacent to a section which does not comprise such indentations. This provides the advantage that pattern of the indentations can be controlled, which may have an effect on air flow, pressure drop and flavour delivery to the user as described herein.

The indentations may be of any suitable volume, but may be selected to provide the advantages described herein. In some embodiments, the indentations have a length and a width. The length may be measured as the longest distance across an indentation. In some embodiments, the length and the width have a ratio of about 1:0.25 to about 1:10, of about 1:0.5 to about 1:5, of about 1:0.75 to about 1:2, or of about 1:1.

The indentations may be in the form of a channel, such that the channel is provided on the outer surface of the plug. In some embodiments, the plug comprises a plurality of indentations in the form of channels on the outer surface.

Alternatively, the indentations may be in a shape which is not a channel, for example, the shape of circular, semi-circular, rectangular, triangular, or star-shaped.

In some embodiments, the length of the indentations is from about 0.01 to about 6 mm, from about 0.1 to about 1 mm, or from about 0.5 to about 0.8 mm.

In embodiments in which the indentations are channels or embodiments in which the channels extend through the plug, and said channels are aligned with the axis of the article, the length of the indentations maybe from about 5% to about 100% of the length of the plug, may be from about 5% to about 100% of the length of the plug, may be from about 50% to about 100% of the length of the plug, may be from about 75% to about 100% of the length of the plug or may be from about 90% to about 100% of the length of the plug.

In some embodiments, the indentations or channels cover up to about 60%, about 50%, about 20%, about 10% or about 5% of the total surface area of the plug.

The indentations may be of any suitable depth, but may be selected to provide the advantages described herein. As used herein, the term depth refers to the distance from the surface of the plug to the bottom and lowest point of the indentation. In some embodiments, the indentations have a depth of about 5 to about 300 pm, about 10 to about 100 pm, or about 50 to about 80 pm. In some embodiments, the indentations have a depth of about 5 to about 300 pm, about 10 to about 100 pm, or about 50 to about 80 pm. The lowest point of the indentation may be measured using SEM or by measuring the apparatus used to impress the indentions into the plug.

The larger the volume of the indentation or channel, the higher the air flow and pressure drop across the plug. This provides a more pleasant user experience when the aerosol generating material is used in an article in a delivery system. Thus, the dimensions of the indentations may be selected to provide a suitable airflow and pressure drop across the plug.

In addition, the larger the volume of the indentation or channel, the higher the surface area to volume ratio is, and the greater the flavour imparted onto the aerosol from the first aerosol generating material.

In some embodiments, the plug comprises channels that extend through the plug. This embodiment can provide greater flow through of the fluid. The channels may be positioned in the plug to optimise such fluid movement. The channels may extend through the full length of the plug.

In embodiments in which the channels that extend through the plug, the channels may have a diameter of at most about 5 pm, at most about 10 pm, at most about 25 pm, at most about 500 pm, at most about 1 mm, at most about 2 mm. The indentations or channels that extend through the plug may be formed during extrusion of the plug. This has the advantage that the indentations or channels that extend through the plug are formed simultaneously with the plug, which is fast and does not require further processing steps. The use of extrusion to form the channels also maintains the structure of the plug. Other methods may distort the structure or shape of the plug.

Advantageously, the plug is malleable after the extrusion step, and may be manipulated to add the indentations or channels. The plug may then increase in rigidity in the drying step after the formation of the indentations or channels. Alternatively, the indentations or channels may be formed in another process, for example drilling or cutting.

The indentations or channels may be aligned with the axis of the article, for example such that their longitudinal dimension is in parallel alignment with a longitudinal axis, X-X’ of the article 1. The channels may be aligned with 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. This provides the advantage of allowing the movement of fluid through the article and therefore the provision of a suitable pressure drop. This provides a positive experience to the user because there is a suitable resistance to draw when in use. This also provides an improved delivery of the aerosol and its flavours to the user.

In some embodiments, the pressure drop across the plug is about too to about 500 mmWg. In some embodiments, the pressure drop across the aerosol-generating section is about too to about 200 mmWg about 200 to about 400 mmWg, or about 300 to about 350 mmWg.

In some embodiments, the pressure drop across the article is about 20 to about 120 mmWg, about 50 to about too mmWg, about 60 to about 90 mmWg.

The pressure drop however may be greater when the plug comprises indentations and/or channels. The indentations and/or channels provides the advantage that the plug provides an improved pressure drop across the article. When in use, the article may exhibit a pressure drop of from about 15 to about 40 mm H₂0. In some embodiments, the article exhibits a pressure drop across the aerosolgenerating section of from about 15 to about 30 mm H₂0. An exemplary embodiment of the invention is shown in Figure 3, which illustrates a perspective view of the article 1 wherein the plug 4 comprises a plurality of channels 15 on the outer surface of the plug 4. Said channels are in parallel alignment with the longitudinal axis, X-X’ of the article 1. In this embodiment, the channels extend across the full length of the plug. The length of the plug 4 may be defined as the distance of the plug 4 aligned to the longitudinal axis, X-X’ of the article.

Another exemplary embodiment of the invention is shown in Figure 4, which illustrates a cross section (that is perpendicular to the longitudinal axis, X-X’ of the article) wherein the plug 4 comprises a plurality of channels 16 extending through the plug. The plug is otherwise monolithic. In this embodiment, channels 16 are in parallel alignment with a longitudinal axis, X-X’ of the article. In some embodiments, the channels are in parallel alignment with one another.

In some embodiments, the plug comprises channels extending through the plug. In some embodiments, the indentations or channels are configured to allow a fluid to pass through a body of the plug.

The fluid can be a liquid, a gas or a gas/liquid mixture. In some embodiments, the fluid is air or a mixture of air and an aerosol, which may be generated by the aerosol- generating material as it is heated by the aerosol generator. In some embodiments, the fluid may move through the article 1 between the upstream end 2a and the downstream end 2b, according to figure 1. The fluid may be directed to move along the axis of the article via the channels. This distributes the fluid to desired locations in the article. This provides the advantage that the fluid may then take up the flavours and active substances in the plug, first aerosol generating material and/or second aerosol generating material. This provides improves delivery to the user of such flavours and substances.

In another aspect of the invention, a method of producing an article is provided. In some embodiments, a method of producing the first aerosol generating material, the second aerosol generating material, and/ or the plug is provided. In some embodiments, the first aerosol generating material is produced by forming a mixture; said mixture through a die to form an extruded aerosol-generating material; and optionally cutting the aerosol-generating material to form the plug. The method may include some or all of these steps.

In some embodiments, the first aerosol generating material is produced by forming a mixture; extruding the mixture through a die to form an extruded aerosol-generating material; tooling the extruded aerosol-generating material; drying the extruded aerosol-generating material; and cutting the aerosol-generating material. The method may include some or all of these steps.

In some embodiments, the method to make the extruded plug includes the steps of

In some embodiments, wherein the plug consists of the first aerosol generating material, the plug is produced by forming a mixture; extruding the mixture through a die to form an extruded aerosol-generating material; tooling the extruded aerosolgenerating material; drying the extruded aerosol-generating material; and cutting the aerosol-generating material. The method may include some or all of these steps.

The invention enjoys the advantage that the extrusion process controls the size and shape of the first aerosol generating material and/ or plug. Without wishing to be bound by a singular reason, it has been noted that the extrusion process applies a consistent pressure on the material being extruded. This means there is consistent and precise control over the shape of the extruded aerosol generating material. This means that the material and/or plug maybe uniform, consequently improving its flavour consistency.

The material and/ or plug is more consistent in shape and weight, which is advantageous for packing and logistics of preparing the material in the consumable or article. The plug may be consistently and precisely manufactured to make a plug of the same size and shape each time. This enables the components of the article to be manufactured to precisely fit the plug, and the plug to fit securely into the noncombustible aerosol provision system. For example, in embodiments wherein the article comprises an aerosol generator, plug may be manufactured to improve the contact between the surface of the plug and the aerosol generator. A further advantage is that indentations or channels, when present, may be formed from the extrusion process. This reduces the steps required to form the plug, which makes it faster and cheaper to produce. The plug prepared in this method enjoys the advantage of improved elasticity, and in particular has specific elasticity properties that make the material particularly suitable for retention of indentations or channels. For example, such plugs retain the indentations for a longer period of time. The plug is also more malleable and so can be compatible more other features of the device. For example, the plug maybe compatible with an aerosol generator as described herein.

The mixture maybe formed in any suitable means. The mixture maybe stored prior to extrusion, or extruded immediately. The aerosol generating material may comprise the same components as the mixture. In some embodiments the aerosol generating material may comprise additional components to the mixture. The components of the aerosol generating material 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 processing the mixture of the first composition and the second composition to form the aerosol generating material. This process is illustrated in Figure 6. In some embodiments, the method of forming the aerosol generating material comprises forming a mixture, and processing 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 tobacco 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.

Extrusion involves the feeding of a precursor composition, in this case 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. Extrusion of the mixture to form the plug and/ or the first aerosol generating material provides the advantage that the first aerosol generating material or the plug are immediately formed into the width and height desired, and so further shaping is not required. This is faster and cost saving compared to the manufacture of other plugs. Forming the aerosol generating material by extrusion has the advantage that this processing combines mixing, conditioning, homogenizing and moulding of the mixture.

In particular, the process of extrusion can produce the first aerosol generating material in a suitable shape. For example, the shape of the plug may be formed from the die during extrusion. This enables specific shapes to be formed. For example, the cross sectional shape and the width of the plug or first aerosol generating material may be manufactured to fit the shape and size of the article. The die may provide the aerosolgenerating material with a relatively smooth surface. A smooth surface may not be achieved using other processes, such as band casting.

Other materials 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 agglomerated structures formed during the extrusion process. In some embodiments, the extruded material may undergo a tooling process. In such a tooling process, the receiving portion, indentations, channels and/ or other features maybe added to the material. Advantageously, the material after extrusion is malleable, and maybe manipulated to add these features. This makes the tooling process faster and reduces the energy required to form the features. In addition, this reduces the impact of the tooling process on the shape of the remainder of the extruded material. For example, the shape of the plug is affected less when the tooling process is performed on an extruded plug compared to a plug formed by another means. The tooling process may include machining, impressing, drilling, cutting or otherwise forming the features into or onto the plug.

In some embodiments, the resultant extruded material is 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 plug (for example, by heating it to above about 25 °C) and/or reducing the atmospheric pressure surrounding the plug (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.

A low drying temperature employed is advantageous as this reduces loss of volatile components, such as nicotine, glycerol and flavours, that contribute to the flavour, taste and mouth-feel of the final product. The material is also dried to provide a suitable texture and strength. For example, materials that have been dried too much may be frangible and lack malleability. On the other hand, if the material is 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 plug. 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 plug also has an effect on the physical properties of the plug. For Example, if the OV is too low, then the plug 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 sheet of 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 o% and about 40% or between about 25% and about 35% by weight of the mixture.

In some embodiments, the mixture comprises oven volatiles in an amount of between about 0% and about 40% or between about 25% and about 35% by weight of the mixture.

In some embodiments, the first aerosol generating material comprises water in an amount of between about 0% and about 15% or between about 5% and about 40% by weight of the aerosol generating material. In some embodiments, the first aerosol generating material comprises water in an amount of between about 5% and about 15% by weight of the aerosol generating material.

In some embodiments, the first aerosol generating material comprises oven volatiles in an amount of between about 0% and about 15% or between about 5% and about 15% by weight of the plug. In some embodiments, the first aerosol generating material comprises oven volatiles in an amount of between about 5% and about 15% by weight of the plug.

In some embodiments, the plug comprises a water content of about o to about 15%, about 5 to about 10 or about 6.5 to about 9.5 % by weight. The water content of the aerosol-generating material described herein may vary according to, for example, the temperature, pressure and humidity conditions at which the compositions are maintained. The water content can be determined by Karl-Fisher analysis, as known to those skilled in the art.

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 extruded aerosol generating material is cut or sliced. The cutting or slicing may take place after any one of the extrusion, tooling or drying steps.

The first aerosol generating or plug material may be cut or sliced horizontally (across the width as opposed along the length) in order to make the first aerosol generating material or plug of a known length as described herein. The extruded aerosol generating material may be sliced at frequent intervals to provide plugs of the selected length.

This is advantageous because the length of the plug can be manufactured to be shorter than plugs manufactured in different methods. In particular, the plug may be sliced directly after extrusion, and so the plug may be cut to have a length of less than 6 mm. This is hard to achieve using other methods and provides the advantage of reducing the amount of the plug in the article.

The plug or first aerosol generating material may be sliced directly after extrusion, after drying or after further processing steps.

In some embodiments, the tensile strength of the aerosol generating material at least about 3, 4, 5, 6, 8, 10, 12 or 14 N/15 mm. In some embodiments, the tensile strength of the plug is at most about 15 N/15 mm. In some embodiments, the tensile strength of the aerosol generating material at most about 6, 8, 10, 12 or 14 N/15 mm. In some embodiments, the tensile strength of the plug is at least about 3 N/15 mm. In some embodiments, the second aerosol generating material is made produced by forming a mixture; extruding the mixture through a die to form an extruded aerosolgenerating material; and cutting the aerosol-generating material. The method may include some or all of these steps. In some embodiments, the second aerosol generating material is manufactured in the same process as the first generating material. In some embodiments, the first and second aerosol generating material may be produced together as one material, and divided into the first and second aerosol generating material in a cutting or slicing process. Referring again to Figure 2, the cooling section 6 comprises a hollow channel, having an internal diameter of between about i mm and about 4 mm, for example between about 2 mm and about 4 mm. In the present example, the hollow channel has an internal diameter of about 3 mm. The hollow channel extends along the full length of the cooling section 6. In the present example, the cooling section 6 comprises a single hollow channel. In alternative embodiments, the cooling section can comprise multiple channels, for example, 2, 3 or 4 channels. In the present example, the single hollow channel is substantially cylindrical, although in alternative embodiments, other channel geometries/cross-sections maybe used. The hollow channel can provide a space into which aerosol drawn into the cooling section 6 can expand and cool down. In some embodiments, the cooling section is configured to limit the cross-sectional area of the hollow channel/s, to limit tobacco displacement into the cooling section, in use.

The filamentary tow forming the cooling section 6 preferably has a total denier of less than 45,000, more preferably less than 42,000. This total denier has been found to allow the formation of a cooling section 6 which is not too dense. Preferably, the total denier is at least 20,000, more preferably at least 25,000. In preferred embodiments, the filamentary tow forming the cooling section 6 has a total denier between 25,000 and 45,000, more preferably between 35,000 and 45,000. Preferably the cross- sectional shape of the filaments of tow are ‘Y’ shaped, although in other embodiments other shapes such as ‘X’ shaped filaments can be used.

The cooling section 6 is located around and defines an air gap within the mouthpiece 2 which acts as a cooling section. The air gap provides a chamber through which heated volatilised components generated by the rod of aerosol-generating material 3 flow. The cooling section 6 is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article 1 is in use. The cooling section 6 provides a physical displacement between the aerosol-generating material 3 and the body of material 7. The physical displacement provided by the cooling section 6 can provide a thermal gradient across the length of the cooling section 6.

In some embodiments, the mouthpiece 2 comprises a cavity having an internal volume greater than 110 mm3. Providing a cavity of at least this volume has been found to enable the formation of an improved aerosol. In some embodiments, the mouthpiece 2 comprises a cavity, for instance formed within the cooling section 6, having an internal volume greater than 110 mm3, or greater than 130 mm3, allowing further improvement of the aerosol. In some examples, the internal cavity comprises a volume of between about 130 mm3 and about 230 mm3, for instance about 134 mm3 _or 227 mm3.

The cooling section 6 can be configured to provide a temperature differential of at least about 40 °C between a heated volatilised component entering a first, upstream end of the cooling section 6 and a heated volatilised component exiting a second, downstream end of the cooling section 6. The cooling section 6 is configured to provide a temperature differential of at least about 60 °C, at least about 80 °C or at least about too °C between a heated volatilised component entering a first, upstream end of the cooling section 6 and a heated volatilised component exiting a second, downstream end of the cooling section 6. This temperature differential 7 the length of the cooling section 6 protects the temperature sensitive body of material 7 from the high temperatures of the aerosol-generating material 3 when it is heated. The body of material 7 and hollow tubular element 8 each define a substantially cylindrical overall outer shape and share a common longitudinal axis. The body of material 7 is wrapped in a first plug wrap 9. Preferably, the first plug wrap 9 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. Preferably, the first plug wrap 9 has a thickness of between 30 pm and 60 pm, more preferably between 35 pm and 45 pm. Preferably, the first plug wrap 9 is a non-porous plug wrap, for instance having a permeability of less than too Coresta units, for instance less than 50 Coresta units. However, in other embodiments, the first plug wrap 9 can be a porous plug wrap, for instance having a permeability of greater than 200 Coresta Units. The article may have a ventilation level of about 10% of the aerosol drawn through the article. In alternative embodiments, the article can have a ventilation level of between 1% and 20% of aerosol drawn through the article, for instance between 1% and 12%. Ventilation at these levels helps to increase the consistency of the aerosol inhaled by the user at the mouth end 2b, while assisting the aerosol cooling process. The ventilation is provided directly into the mouthpiece 2 of the article 1. In the present example, the ventilation is provided into the cooling section 6, which has been found to be particularly beneficial in assisting with the aerosol generation process. The ventilation is provided via perforations 12, in the present case formed as a single row of laser perforations, positioned 13 mm from the downstream, mouth-end 2b of the mouthpiece 2. In alternative embodiments, two or more rows of ventilation perforations maybe provided. These perforations pass though the tipping paper 11, second plug wrap 10 and cooling section 6. In alternative embodiments, the ventilation can be provided into the mouthpiece at other locations, for instance into the body of material 7 or first tubular element 8. Preferably, the article is configured such that the perforations are provided about 28mm or less from the upstream end of the article 1, preferably between 20mm and 28mm from the upstream end of the article 1. In the present example, the apertures are provided about 25mm from the upstream end of the article. The plug may comprise susceptor material, which is a material capable of being inductively heated by penetration with a varying magnetic field. In some embodiments the susceptor material is the first aerosol generating material. That is to say that the first aerosol generating material is capable of being inductively heated by penetration with a varying magnetic field.

Inductive heating is a process of heating an electrically conducting object (such as a susceptor) by electromagnetic induction. A magnetic field generator may comprise an inductive element, for example, one or more inductor coils, and a device for passing a varying electric current, such as an alternating electric current, through the inductive element. The varying electric current in the inductive element produces a varying magnetic field. The varying magnetic field penetrates a susceptor suitably positioned with respect to the inductive element, and generates eddy currents inside the susceptor material. The susceptor has electrical resistance to the eddy currents, and hence the flow of the eddy currents against this resistance causes the susceptor to be heated by Joule heating. In cases where the susceptor material comprises ferromagnetic material such as iron, nickel or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor material, i.e. by the varying orientation of magnetic dipoles in the magnetic material as a result of their alignment with the varying magnetic field. In inductive heating, as compared to heating by conduction for example, heat is generated inside the susceptor, allowing for rapid heating. Further, there need not be any physical contact between the inductive heater and the susceptor, allowing for enhanced freedom in construction and application.

In some embodiments, the article for use with the non-combustible aerosol provision device may comprise a second 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.

Figure 6 shows an example of a non-combustible aerosol provision device too for generating aerosol from an article 110, as described herein. In a broad outline, the device too may be used to heat a replaceable article 110, for instance an article 1 as illustrated in Figure 1 or as described elsewhere herein, to generate an aerosol or other inhalable medium which is inhaled by a user of the device too. The device too and replaceable article 110 together form a system.

The device too comprises a housing 102 (in the form of an outer cover) which surrounds and houses various components of the device too. The device too has an opening 104 in one end, through which the article 110 may be inserted for heating by a heating assembly. In use, the article 110 may be fully or partially inserted into the heating assembly where it may be heated by one or more components of the heater assembly.

The device too may comprise a pin or blade (not shown) for insertion into the receiving portion of the plug.

In another aspect of the invention, a non-combustible aerosol provision system comprising the article and a non-combustible aerosol provision device is provided.

The non-combustible aerosol provision system may further comprise another aerosol generating material. This aerosol generating material may be in addition to the first aerosol generating material or the optional second aerosol generating material, as described herein.

In some embodiments, the system may comprise an aerosol-modifying agent. An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol.

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent maybe in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent. In some embodiments, the non-combustible aerosol provision system comprises an aerosolmodifying agent release component such as a capsule, thread, or bead.

In some embodiments, the non-combustible aerosol provision system further comprises a capsule. In embodiments wherein the aerosol-modifying agent release component is a capsule, said capsule maybe frangible. The capsule can comprise a breakable capsule, for instance a capsule which has a solid, frangible shell surrounding a liquid payload. The capsule can comprise a flavour, an active substance or other substance, for example an aerosol modifying agent. This provides the advantage that the user cand break the capsule to release an additional substance(s) into the non- combustible aerosol provision system and further alter the aerosol generated. In a fifth aspect, a method of producing an extruded plug for use with the article is provided. The method may also be referred to as a process, and may be as described herein. In some embodiments, wherein the process comprises extrusion.

In a fifth aspect, an extruded plug produced by the process is provided. The process of extrusion provides the plug with attributes as described herein. For example, the density and uniformity of the plug is affected by the process of extrusion. In addition, extrusion affects the surface of the plug, which may be particularly smooth or consistent. Without wishing to be bound by a singular reason, the material is forced through a die and this provides a particular texture to plug. The die maybe smooth and so the plug may have a smooth surface texture.

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 article for use with a non-combustible aerosol provision device, the article comprising a first end comprising a mouthpiece and a second end distal from the first end, the second end comprising an extruded plug comprising a first aerosol-generating material.

2. The article according to claim i, wherein the article comprises a second aerosol generating material between the plug and the first end.

3. The article according to claim 2, wherein the second aerosol generating material is in the form of a rod.

4. The article according to any preceding claim, wherein the extruded plug is configured to receive an aerosol generator of the non-combustible aerosol provision device.

5. The article according to claim 4, wherein the extruded plug comprises a receiving portion configured to receive the aerosol generator.

6. The article according to claim 4 or 5, wherein the plug is configured such that when the aerosol generator is received by the plug, the aerosol generator extends into the plug and into the second aerosol generating material.

7. The article according to anyone of claims 4 to 6, wherein the aerosol generator is a pin.

8. The article according to any preceding claim, wherein the first aerosolgenerating material and/ or the second aerosol-generating material comprises botanical material.

9. The article according to claim 8, wherein the plug comprises a botanical material content of about 5% to about 75% by weight.

10. The article according to any preceding claim, wherein the plug comprises channels or indentations.

11. The article according to claim 10, wherein the channels or indentations are aligned with a longitudinal axis of the article.

12. The article according to either one of claim io or claim 11, wherein the channels are configured to allow a fluid to pass through the plug.

13. The article according to any one of claims 10 to 12, wherein the channels or indentations are located on the surface of the plug.

14. The article according to any one of claims 10 to 13, wherein the indentations or channels have a depth of about 5 to about 300 pm.

15. The article according to any preceding claim, wherein the plug has a length of less than 6 mm and/or the width of the plug is from about 15 to about 35 mm.

16. The article according to any preceding claim, wherein the plug substantially consists of the first aerosol generating material.

17. The article according to any preceding claim, wherein the plug comprises water.

18. The article according to claim 17, wherein the plug comprises a water content of up to about 15% by weight.

19. A method of producing the article according to any one of the preceding claims.

20. A method according to claim 19, wherein the method comprises extruding the plug and incorporating the plug into the article.

21. A non-combustible aerosol provision system comprising the article according to any one of the preceding claims and a non-combustible aerosol provision device.

22. A method of producing an extruded plug for use with the article as claimed in any one of claims 1 to 18.

23. A method according to claim 22, wherein the process comprises extrusion.

24. An extruded plug produced by the process according to claim 22.