WO2023118832A2

WO2023118832A2 - Aerosol provision systems and articles for use therein

Info

Publication number: WO2023118832A2
Application number: PCT/GB2022/053292
Authority: WO
Inventors: Barry DIMMICK
Original assignee: Nicoventures Trading Limited
Priority date: 2021-12-20
Filing date: 2022-12-19
Publication date: 2023-06-29
Also published as: WO2023118832A3

Abstract

The invention relates to aerosol provision systems configured to heat an article, wherein the article comprises a first region comprising a first aerosol-generating material and a second region comprising a second aerosol-generating material. The invention also relates to articles for an aerosol provision system, the articles comprising a first aerosol-generating material and a second aerosol-generating material. The invention also relates to uses of the systems and articles.

Description

Aerosol provision systems and articles for use therein

Technical Field

Background

Articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Attempts have been made to provide alternatives to these articles by creating products that release compounds without combusting. Examples of such products are so-called “heat not burn” products, also known as tobacco heating products or tobacco heating apparatus, which release compounds by heating, but not burning, aerosol generating material.

The aerosol generating material maybe, for example, tobacco or other non-tobacco products, or a combination, such as a blended mix, which may or may not contain nicotine.

Some known tobacco heating devices include more than one heater, with each heater configured to heat different parts of the aerosol generating material in use. This then allows the different parts of the aerosol generating material to be heated at different times so as to provide longevity of aerosol formation over the use lifetime.

Summary

According to a first aspect of the invention, there is provided an aerosol provision system comprising an aerosol provision device and an article, wherein the article comprises a first region comprising a first aerosol-generating material and a second region comprising a second aerosol-generating material, wherein the second aerosolgenerating material has a greater density than the first aerosol-generating material, and wherein the device comprises a heating system configured to heat the first region to a first peak temperature and to heat the second region to a second peak temperature, wherein the second region reaches the second peak temperature later than the first region reaches the first peak temperature.

In some embodiments, the density of the second aerosol-generating material is at least about 25% higher than the density of the first aerosol generating material.

In some embodiments, the first aerosol generating material has a density of from about 0.1 g/cm3 to about 1 g/cm3. In some embodiments, the second aerosol generating material has a density of from about 0.4 g/cm3 to about 2 g/cm3.

In some embodiments, heating of the second region to the second peak temperature occurs later than the heating of the first region to the first peak temperature.

In some embodiments, the second region is heated for a longer time period than the first region.

In some embodiments, there is no overlap between the timing of the heating of the first and second regions.

In some embodiments, the first peak temperature is from about iso°C to about 35O°C.

In some embodiments, the first region is heated to the first peak temperature for a period of from about 10 seconds to about 300 seconds.

In some embodiments, the second peak temperature is from about 15O°C to about 35O°C. In some embodiments, the second region is heated to the second peak temperature for a period of from about 10 seconds to about 300 seconds.

In some embodiments, the second peak temperature is from about 10 to about ioo°C higher than the first peak temperature. In some embodiments, the heating of the article provides a relatively constant release of volatile compounds into an inhalable medium.

In some embodiments, the second region is heated to the second peak temperature after the first region has been heated to the first peak temperature.

In some embodiments, the second region is heated to the second peak temperature after heating of the first region has ceased. In some embodiments, the second aerosol-generating material comprises extruded tobacco.

In some embodiments, the second aerosol-generating material comprises beads. In some embodiments, the first aerosol-generating material comprises one or more tobacco material selected from the group consisting of lamina and reconstituted tobacco material.

In some embodiments, at least one of the first and second aerosol-generating material comprises a combination of lamina and reconstituted tobacco material. In some embodiments, the lamina and reconstituted tobacco material are present in the aerosolgenerating material in a ratio of from 1:4 to 4:1, by weight.

In some embodiments, the first and second aerosol-generating materials have the same levels of a volatile compound. In some embodiments, the volatile compound is nicotine.

In some embodiments, the release of a volatile compound from the first and second aerosol-generating material is at the same rate when the materials reach a given temperature.

In some embodiments, the second region is configured to be downstream of the first region. In some embodiments, the first and second aerosol-generating materials are in distinct regions. In some embodiments, the first and second aerosol-generating materials are present in the article in a ratio of from 1:10 to 10:1, by weight. According to a second aspect of the invention, there is provided an article for an aerosol provision system, the article comprising a first aerosol-generating material and a second aerosol-generating material, wherein the second aerosol-generating material is in the form of discrete particles, or in the form of an agglomerated body of particles, wherein the second aerosol-generating material has a greater density than the second aerosol-generating material.

In some embodiments, the second aerosol-generating material comprises beads or pellets of aerosol-generating material. In some embodiments, the second aerosol-generating material is a compressed, extruded or moulded body of aerosol-generating material.

In some embodiments, the article is for use in an aerosol provision system according to the first aspect.

In some embodiments, the first aerosol-generating material and the second aerosolgenerating material have the same nicotine content.

In some embodiments, the first aerosol-generating material and second aerosol- generating material release nicotine at the same rate once heated to a given temperature.

In some embodiments, the first aerosol-generating material is in the form of discrete particles, or in the form of an agglomerated body of particles. In some embodiments, the first aerosol-generating material comprises beads or pellets of aerosol-generating material, or is a compressed, extruded or moulded body of aerosol-generating material.

In some embodiments, the article comprises a first region comprising the first aerosolgenerating material and a second region comprising the second aerosol-generating material. In some embodiments, the second region is configured to be downstream of the first region. According to a third aspect of the invention, there is provided use of an aerosol provision system according to the first aspect to provide a consistent delivery of volatile components in an aerosol produced by the system over a period of use producing multiple puffs.

According to a fourth aspect of the invention, there is provided use of an article according to the second aspect to provide a consistent delivery of volatile components in an aerosol produced by heating the article over a period of use producing multiple puffs.

According to a fifth aspect of the invention, there is provided a method of generating an aerosol using the system according to the first aspect or the article according to the second aspect, wherein the method comprises heating the first region to a first peak temperature and heating the second region to a second peak temperature, wherein the second region reaches the second peak temperature later than the first region reaches the first peak temperature.

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

Figure i is a graph showing the per-puff percentage of nicotine released by different aerosol-generating material samples upon heating.

Figure 2 is a graph showing the per-puff percentage of glycerol released by different aerosol-generating material samples upon heating.

Figure 3 is a longitudinal cross-sectional view of a rod having a first configuration of two regions of aerosol-generating material with different densities.

Figure 4 is a longitudinal cross-sectional view of a rod having an alternative configuration of two regions of aerosol-generating material with different densities. Figure 5a is longitudinal cross-sectional view of a rod with a yet further configuration of two regions of aerosol-generating material with different densities.

Figure 5b is an alternative cross-sectional view of the rod shown in Figure 5a.

Figure 6 is a longitudinal cross-sectional view of an article for use in an aerosol provision system, comprising two regions of aerosol-generating material and a mouth end section. Figure 7 is a longitudinal cross-sectional view of an article for use in an aerosol provision system, comprising two regions of aerosol-generating material and a mouth end assembly comprising a spacer section, as cooling section and a mouth end section. Figure 8 is a longitudinal cross-sectional view of an article for use in an aerosol provision system, comprising two regions of aerosol-generating material and a mouth end assembly comprising a spacer section, as cooling section and a tubular mouth end section.

Detailed Description The invention relates generally to an aerosol provision system configured to heat an article, wherein the article comprises a first region comprising a first aerosol-generating material and a second region comprising a second aerosol-generating material, and wherein the second aerosol-generating material has a greater density than the first aerosol-generating material.

Whilst it is known to heat first and second tobacco materials separately, using first and second heaters, it has not been suggested that the second material has a greater density than the first material. This greater density will mean that the second aerosol generating material will take longer to heat up. This allows the timing of the release of the volatiles from the first and second aerosol-generating materials to be controlled to provide a desired delivery profile. For instance, in some embodiments, the delivery of at least one volatile may be relatively consistent from puff to puff over the period of use of the article. The volatile component may, for example, be nicotine and/or one or more flavour components.

In the systems of the invention, the aerosol provision device comprises a heating system configured to heat the first region to a first peak temperature and to heat the second region to a second peak temperature. As a result of the greater density of the second aerosol-generating material, the second region and/or the second aerosol- generating material therein reaches the second peak temperature later than the first region and/or the first aerosol-generating material therein reaches the first peak temperature. In some embodiments, this facilitates a more consistent release of volatile components, such as nicotine, throughout the session of use of the system. According to the present disclosure, an 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. Specifically, the aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system.

It comprises an aerosol provision device which comprises a heating system configured to heat the aerosol-generating material.

In some embodiments, the system is a powered aerosol provision system.

In some embodiments, the 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 aerosolgenerating material and a solid aerosol-generating material. The solid aerosol- generating material may comprise, for example, tobacco or a non-tobacco product.

Typically, the aerosol provision system may comprise an aerosol provision device and a consumable or article for use with the aerosol provision device. In some embodiments, the disclosure relates to articles (also referred to herein as consumables) comprising aerosol-generating material and configured to be used with aerosol provision devices.

In some embodiments, the articles disclosed herein comprise a first region comprising a first aerosol-generating material and a second region comprising a second aerosol-generating material. The articles may, in some embodiments, comprise further, such as, third, fourth or fifth regions and/or further aerosolgenerating materials. The first and second aerosol-generating materials of the article have different densities. Otherwise, the aerosol-generating materials in the article may be the same or different.

It has been found that providing regions comprising a second aerosol-generating material with a greater density than the first aerosol-generating material, the different densities cause the second aerosol generating material to heat up slower than the first aerosol generating material when exposed to the same heating and will release its volatile compounds (e.g. nicotine) at a slower rate than the first aerosol-generating material. Thus, combining the aerosol-generating materials with different densities with separate heating of these materials at optionally different times and/or different temperatures allows the provision of a more tailored release of the volatile compound(s) over the period of consumption of the article, for example providing a more consistent and longer-lasting release of volatile compound(s). Alternatively, it may be desirable to have a more rapid or greater release of volatiles towards the beginning of the consumption of the article, to provide the user with a greater initial impact from use. The capacity to control the aerosol generation and volatile compound release may be particularly advantageous because the article can be made relatively small whilst still achieving a particular desired release of volatile compound(s) over the period of consumption.

In some embodiments, the second aerosol generating material has a density that is at least about 25% higher than the density of the first aerosol generating material and, optionally, at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70% or 75% higher than the density of the first aerosol-generating material. The second aerosol generating material may have a density that is no more than about 200% higher than the density of the first aerosol generating material and, optionally, no more than about 150%, 125%, 100% or 75% higher than the density of the first aerosol-generating material. In some embodiments, the second aerosol generating material has a density that is from about 25% to about 75% higher than the density of the first aerosol generating material. In some embodiments, the first aerosol generating material has a density of from at least about 0.1 g/cm3 and optionally from at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8 or 0.9 g/cm3. The first aerosol generating material may have a density of no more than about 1 g/cm3 and, optionally no more than about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3 or 0.2 g/cm³. in some embodiments, the density of the first aerosol-generating material is from about 0.1 to 0.9 g/cm³.

In some embodiments, the second aerosol generating material has a density of from at least about 0.4 g/cm3 and optionally from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3. The second aerosol generating material may have a density of no more than about 2 g/ cm3 and, optionally no more than about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6 or 0.5 g/cm3, in some embodiments, the density of the first aerosol-generating material is from about 0.4 to 1.99 g/cm3.

Aerosol-generating material 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 gel which may or may not contain an active substance and/or flavourants. In some embodiments, the aerosolgenerating material may comprise an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). In some embodiments, the amorphous solid maybe a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosolgenerating material may for example comprise from about 50 wt%, 60 wt% or 70 wt% of amorphous solid, to about 90 wt%, 95 wt% or 100 wt% of amorphous solid.

The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material. The aerosol-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 glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

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 and 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 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 or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cardifolia, Mentha 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 substance to be delivered by the aerosol-generating material 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 maybe, 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 first and second aerosol-generating materials comprise the same components. Upon heating, they will therefore release very similar aerosols, potentially having the same content of active substance and/ or flavour, etc. Their different densities allow the aerosol to be generated from the two materials at different speeds and/or different times during heating.

In other embodiments, the first and second aerosol-generating materials comprise different components. Upon heating, they will therefore release different aerosols, potentially having different make-up of active substance and/or flavour, etc. Their different densities allow the different aerosols to be generated from the two materials at different speeds and/or different times during heating, potentially providing an aerosol that changes over the period of use. In some embodiments, the first aerosol-generating material and the second aerosolgenerating material each comprise tobacco. The tobacco will contain volatile components including nicotine, aromas and flavours. The tobacco maybe any type of tobacco and any part of the tobacco plant, including tobacco leaf, lamina, stem, stalk, ribs, scraps and shorts or mixtures of two or more thereof. Suitable tobacco materials include the following types: Virginia or flue-cured tobacco, Burley tobacco, Oriental tobacco, or blends of tobacco materials, optionally including those listed here. The tobacco maybe expanded, such as dry-ice expanded tobacco (DIET), or processed by any other means. In some embodiments, the tobacco material maybe reconstituted tobacco material. The tobacco may be pre-processed or unprocessed, and may be, for instance, solid stems (SS); shredded dried stems (SDS); steam treated stems (STS); or any combination thereof. The tobacco material may be fermented, cured, uncured, toasted, or otherwise pre-treated.

The first and second aerosol-generating materials may comprise different tobacco. Alternatively, the tobacco may be the same, but is provided in a different form, so that the second aerosol-generating material has a greater density than the first aerosolgenerating material.

In some embodiments, the first aerosol-generating material has at least one further different characteristic to the second aerosol generating material. The different characteristic may be one or more of form, size, , water content, amount (by weight), material or materials, or proportion of materials that make the first and second aerosolgenerating materials (including the recipe of the aerosol generating materials when each is manufactured from more than one material). In some embodiments, the first and second aerosol-generating materials do not have a different characteristic, other than their different densities.

In some embodiments, the first aerosol-generating material comprises one or more tobacco in the form of cut rag. This tobacco material may lamina or reconstituted tobacco material. In some embodiments, the first aerosol-generating material is a blend comprising both lamina and reconstituted tobacco. For example, the ratio of lamina and reconstituted tobacco may from about 1:4 to about 4:1.

The second aerosol-generating material has a greater density than the first aerosolgenerating material. In some embodiments, this more dense, second aerosol- generating material comprises particles or may be in the form of beads or one or more sheets. Each bead or sheet maybe formed from smaller particles that have been agglomerated.

As used herein, the term “beads” is meant to include beads, pellets, or other discrete small units that have been shaped, moulded, compressed or otherwise fashioned into a desired shape. The beads may have smooth, regular outer shapes (e.g., spheres, cylinders, ovoids, etc.) and/or they may have irregular outer shapes.

In some embodiments, the beads have a diameter (for example, as measured by sieving) of at least about 0.5 mm and, optionally at least about 1, 1.5, 2. 2.5 or 3 mm. The beads may have a diameter (for example, as measured by sieving) of no more than about 5 mm and, optionally no more than about 4.5, 4, 3.5, 3, 2.5, 2 or 1.5 mm. In some embodiments, the diameter of each bead may range from about 0.5 mm to about 3 mm, or from about 1 mm to about 2 mm. The size of the beads may refer to their average size, such as the number or volume mean size.

Agglomeration

In some embodiments, the desired density of the aerosol-generating material is achieved or controlled through the formulation of the material and/or the method(s) by which the material is processed. Processes involving agglomeration, and especially agglomeration with the application of some of compressive forces will tend to increase the density of the material.

Thus, in some embodiments, the aerosol-generating material comprises particles of material that are agglomerated.

In the case of a sheet material, the sheet maybe formed from particles of material that are bound and optionally compressed to form a sheet with the desired dimensions and density.

In some embodiments, beads or pellets can be formed using a so called marumarising process.

In some embodiments, the agglomeration is by pelletisation. Pelletisation is an agglomeration process that converts fine particles of material, optionally together with excipient, into free-flowing units, referred to as pellets. Depending on the type of equipment and processes selected, pellet formation and growth may occur in a number of ways. These pellets maybe formed by agitation and as the particles are rolled and tumbled in the presence of appropriate quantities of a liquid, agglomerates are formed. Balling may involve the use of apparatus such as pans, discs, drums or mixers to produce pellets. Compaction pelletisation is a form of pressure agglomeration, in which the particles are forced together by a mechanical force, optionally with formulation aids. The compressive forces mean that the pellets formed have increased density compared to the starting material. In some embodiments, the agglomeration is by extrusion. In some embodiments, pellets formed by pelletisation may be extruded to form higher density extrudates.

The particles to be extruded may have a size selected to produce a more dense aerosolgenerating material, which will have an impact on the heat transfer within the material and the release of the volatile components.

Extrusion involves feeding a composition (also referred to as a precursor composition) through a die to produce an extruded product. The process applies pressure to the composition combined with shear forces.

Extrusion maybe performed using one of the main classes of extruders: screw, sieve and basket, roll, ram and pin barrel extruders. A single screw or twin screw extruder may be used. Forming the tobacco beads by extrusion has the advantage that this processing combines compression, mixing, conditioning, homogenizing and moulding of the composition.

In some embodiments, during extrusion the free-flowing composition comprising particles, such as tobacco particles, is exposed to elevated pressure and temperature and is forced though an orifice, such as a shaping nozzle or die, to form an extrudate. In some embodiments, the extrudate has a rod-like form and it may be cut into segments of a desired length.

In some embodiments, the composition is exposed to temperatures from about 4O°C to about 15O°C, or from about 8o°C to about 13O°C, or from about 6o°C to about 95°C within the extruder. In some embodiments, including those using double extrusion, the precursor composition is exposed to temperatures from about 7O°C to about 95°C within the extruder. In some embodiments, including those using single extrusion, the precursor composition is exposed to temperatures from about 6o°C to about 8o°C within the extruder. The composition may be exposed to pressures (immediately before the die or nozzle) ranging from about 2 bar to about 100 bar, or from about 5 bar to about 60 bar, depending on the design of the die or nozzle being used. The higher the pressure, the greater the density of the extrudate is likely to be. Thus, the extrusion process may be adjusted to provide extruded aerosol-generating material with the desired density.

In some embodiments where tobacco particles are extruded, due to the relatively high density of the extrudate and the relatively open surface of the tobacco particles within it, the tobacco beads formed from the extrudate exhibit good heat transfer and mass transfer, which has a positive impact on the release of tobacco constituents, such as flavours and nicotine.

In some embodiments, the extrusion may be a generally dry process, with the composition including aerosol generating particles that are dry or substantially dry. The composition may optionally include other particulate materials including, for example, base, diluent, solid aerosol forming agents, solid flavour modifiers, etc.

In some embodiments, liquids may be added to the composition prior to or during the extrusion process. For example, water maybe added, for example as a processing aid to assist dissolution or solubilisation of components of the composition, or to aid binding or agglomeration. Alternatively or additionally, a wetting agent maybe added to the composition.

In some embodiments, the liquid may be an aerosol former material such as glycerol or others discussed herein. When liquid is added to the composition in this manner, the liquid is applied not only on the surface, but, as a result of the extruder pressure combined with the intensive mixing by high shear forces, the extrudate becomes impregnated with the liquid. Where the liquid is an aerosol former material, this can result in a high availability of the aerosol former material in the resultant beads to enhance evaporation of volatile components.

In some embodiments, the amount of aerosol former material incorporated into the extruded beads may be up to about 30% by weight and even up to about 40% by weight. Ordinarily, such high amounts of aerosol former material could render the composition difficult to handle. However, this is less of an issue where extrusion results in the particles being impregnated with the aerosol former material. It maybe desirable to include an aerosol former material in an amount such as at least about 10% or at least about 20% by weight where the beads are to generate an aerosol in addition to releasing the volatile components. Smaller amounts of aerosol former material, such as up to about 5% by weight, maybe sufficient where the beads’ primary function is to release volatile constituents carried by the beads into an existing aerosol or air flow.

In some embodiments, the agglomerates do not include a binder or binding additive. For example, extruded beads may not require a binder to maintain their structural integrity. In other embodiments, the agglomerates comprise a binder or binding additive. The binding additive may be selected to assist in the formation of an agglomerated structure by helping to adhere the particles to each other and to other components in the composition. Suitable binding additives include, for example, thermoreversible gelling agents such as gelatin, starches, polysaccharides, pectins, alginates, wood pulp, celluloses, and cellulose derivatives such as carboxymethylcellulose.

In some embodiments, processing by extrusion is sufficient to provide the desired higher density of the second aerosol-generating material. However, in other embodiments, the extrudate may be further treated to increase the density of aerosol- generating material.

For example, in some embodiments, the extruded aerosol-generating material undergoes spheronisation. In spheronisation, the extruded, cylindrically shaped particles are broken into uniform lengths and are gradually transformed into spherical shapes due to plastic deformation. Where the extrudate is first broken into uniform lengths, spheres with a uniform diameter will be produced by the spheronisation step.

According to one specific example of the embodiments discussed herein, samples of the second aerosol-generating material were produced as follows.

Three sample formulations with and without binders are shown in Table 1, with the amounts indicated as percent wet weight basis (WWB). Table 1

The tobacco was ground to produce a fine powder, taking care not to overheat the tobacco. The ground tobacco particles were sieved to select those with a desired size, for example a particle size of less than 250 pm, of less than 100 pm or less than 60 pm.

Next, all of the dry (non-liquid) components of the formulation were combined and mixed or blended in a mixer. In this particular instance, the mixture was mixed for 1 minute at a speed to 75 RPM. This was to ensure that the dry components are homogenously distributed within the mixture.

Next, half of the glycerol and half of the water were added to the dry mixture and mixed. Specifically, the mixture was mixed for a further minute at 75 RPM. The remaining glycerol and water was then added and mixed, again for 1 minute at 75 RPM. Then, to ensure that a homogenous mixture was achieved, mixing was continued until the mixture had a crumbly consistency that could be squeezed into a mass. In this specific instance, the additional mixing lasted 3 minutes.

The mixture was then extruded using a Caleva Multilab. The extruder was operated at approximately 1500 rpm to produce lengths of extrudate resembling spaghetti.

The extrudate was broken into pieces of varying length as it came out of the extruder.

These pieces were then spheronised. Spheronisation was carried out until spherical beads were formed. In this instance, the extrudate was initially spheronised in a Caleva Multilab operating at 2,500 RPM for 1 minute and then the beads were checked for any defects. Then, spheronisation continued for a further 1 to 2 minutes. This spheronisation step broke the extruded tobacco into the individual pieces and formed the dense, spherical beads.

In a final step, the spheronised beads were dried in an oven at 6s°C for 30 minute periods. After each drying period, the beads were weighed and drying was halted when the desired moisture weight loss was achieved. Generally, such drying will take about 1 hour.

In some embodiments, the first aerosol-generating material is in the form of discrete particles, or in the form of an agglomerated body of particles. These particles may share various characteristics with the second aerosol-generating material, such as particle size, but will have a lower density than the second aerosol-generating material. As described above, there are various ways to adjust the density of the aerosolgenerating material, such as the formulation and/or the processing of the material into particles, beads or pellets.

In some embodiments, the first aerosol-generating material comprises a combination of 60% reconstituted tobacco and 40% lamina tobacco, with the density of this material being in the range of from about 0.1 to about 0.9 g/cm³. The second aerosol- generating material comprises from about 30 to about 90% tobacco, with a density in the range of from about 0.4 to about 1.99 g/cm³. The amount of aerosol forming material included in the second aerosol-generating material may be from about 8 to about 15%. The second aerosol-generating material may comprise largely spherical beads with a particle size between about 0.5 and about 3 mm. In some embodiments, the aerosol generating material in an article comprises approximately 50% of the first aerosol-generating material and about 50% of the second aerosol-generating material, by weight. Thus, for example, an article comprising 260 mg of aerosol-generating material may comprise 130 mg of the first aerosol-generating material and 130 mg of the second aerosol-generating material.

In some embodiments were the aerosol-generating material comprises tobacco, the tobacco is present in an amount of between about 10% and about 90% by weight of the aerosol generating material. In some embodiments, the tobacco may be present in an amount of at least about 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, or at last about 35% tobacco based on the weight of the aerosol generating material.

In some embodiments, the tobacco maybe present in an amount of no more than about 90%, 89%, 88%, 87%, 86%, 85%, 84%, 83%, 82%, 81%, 80%, 75%, 70%, 65%, 60%,

55%, 50%, 45%, or no more than about 40% tobacco based on the weight of the aerosol generating material.

The tobacco described herein may contain nicotine. In some embodiments, the nicotine content is from 0.5 to 2% by weight of the tobacco, and may be, for example, from 0.5 to 1.75% by weight of the tobacco, from 0.8 to 1.2% by weight of the tobacco or from about 0.8 to about 1.75% by weight of the tobacco. In some embodiments, the nicotine content may be from 0.8 to 1% by weight of the tobacco. In some embodiments, the first and second aerosol-generating materials have the same nicotine content.

In some embodiments, the first and second aerosol-generating materials comprise one or more volatile components. In some embodiments, the first and second aerosol- generating materials have the same volatile component content.

Release of volatile components

The aerosol-generating materials are heated, irradiated or energized to generate an aerosol. The aerosol will include different components released from the different constituents of the aerosol-generating material. For example, the aerosol former material will form an aerosol upon heating. Additionally, the aerosol will also include volatile components such as active substances and flavours that are released upon heating. Where the aerosol-generating material comprises tobacco material, upon heating, volatile tobacco components including nicotine and flavours and aromas will be released and will be included in the aerosol formed from the aerosol former material.

Release of volatile components is generally temperature-dependent and so will occur when the aerosol-generating material and the components within it reach a certain threshold temperature. Heat will generally spread or transfer through the material so that different parts or regions of the aerosol-generating material may be at different temperatures at a particular time. The spread or transfer of the heat through the aerosol-generating material will depend upon various factors, including the density of the material. One aim of the present invention is to provide two regions of first and second aerosolgenerating materials of different densities to allow the timing of the release of the volatiles from the first and second aerosol-generating materials to be controlled to provide a desired delivery profile. Specifically, the aim is to combine a first aerosolgenerating material that will release volatile components during an initial phase of the use of a delivery system, whilst the second aerosol-generating material releases volatile components during a later phase of the use. Appropriate coordination of these phases allows the delivery system to deliver at least one volatile relatively consistently from puff to puff over the period of use. The inventors have demonstrated that the density of the aerosol-generating material influences the release of volatile components including nicotine and glycerol as the aerosol-generating material is heated to a target temperature for a period of use. This is shown in the graphs of Figures 1 and 2. Samples i and 2 are lower density aerosol-generating materials, comprising a blend comprising lamina and reconstituted tobacco. Samples 3 and 4 include both the lower density blend of lamina and reconstituted tobacco, and higher density aerosolgenerating material in the form of beads formed from a blend comprising lamina and reconstituted tobacco. A method that may be used to form the higher density beads is set out in the Example below.

Samples 1 and 2 show a rapid increase in the per-puff release of these volatile components from the start of heating, which peaks at the third puff. In the third puff, both Samples 1 and 2 released over 30% of the total nicotine delivered over the nine puffs, and significantly more than in any of the other puffs. The glycerol delivery also peaks at this point for these samples. After the third puff, the release of the volatile components rapidly drops off, with only low levels of release per puff after the fourth puff. The inclusion of this low density aerosol-generating material thus has the benefit of providing a good release profile over the first few puffs, but produces an unsatisfactory aerosol during the latter stages of use. In contrast, the release of volatile components from Samples 3 and 4 is slower from the start of heating, but is also more consistent over the period of heating. Whilst the rate of release rapidly increases to a peak at the third or fourth puff, the peak level or rate of release of nicotine and glycerol is lower than that seen with just the lower density aerosol-generating material of Samples 1 and 2. What is more, the release of the volatile components is maintained at a reasonable level for longer (i.e. for a greater number of puffs) following the peak, rather than dropping almost immediately to very low levels. Thus, the combination of the two or more aerosol-generating materials with different densities improves the level of volatile components in the later puffs, especially from puffs five to nine in a session of use.

Although not shown in the graphs, this effect is further improved where the higher density aerosol-generating material is heated to its peak temperature separately and after heating the lower density aerosol-generating material to its peak temperature. By staggering the heating of the different aerosol-generating materials, an aerosol provision system can deliver a consistently high level of volatile components throughout the period of use of the system, providing a much improved consistency of delivery over a session of use providing nine or more puffs. This improved delivery is achieved without the need to use greater amounts of aerosol-generating material.

Consumable

A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/ or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

In some embodiments, the consumable or article has a rod shape, such as a cylinder. In some cases, the first, second and any other regions comprising aerosol-generating material may be cylindrical and arranged coaxially along the rod. Such an arrangement is shown in Figure 3, which is a longitudinal cross-sectional view of an aerosol-generating rod. The rod includes a first region 1 comprising a first aerosol-generating material 3, and second region 2 comprising a second aerosol- generating material. In this embodiment, the regions are abutting cylindrical plugs of aerosol generating material.

An alternative configuration is shown in Figure 4 which is also a longitudinal cross- sectional view of a rod. Here, the first and second regions 1,2 of aerosol-generating material 3,4 are arranged so that they overlap.

A yet further arrangement of the regions 1,2 of aerosol generating material 3,4 is shown in Figures 3a and 3b. Each region has a hemicylindrical shape, with the flat surfaces of the two regions facing one another.

The rods illustrated in Figures 1 to 3 may be included in an article or consumable for use in an aerosol provision system. In some embodiment, such rods are the article, optionally circumscribed with a wrapper, such as a paper wrapper which may serve to protect the aerosol-generating material and/or to hold the different regions of aerosol- generating material together in the rod.

Figure 6 is a longitudinal cross-sectional view of an article 11 for use in an aerosol provision system, comprising two regions 1,2 of aerosol-generating material 3,4 and an additional mouth end section 5. The mouth end section 5 may, for example, be a plug of a filter material such as tow or sheet material, optionally comprising cellulose acetate, paper, or other known materials.

Figure 7 is a longitudinal cross-sectional view of an article 11 for use in an aerosol provision system, comprising two regions 1,2 of aerosol-generating material 3,4 and a mouth end assembly. The mouth end assembly comprises a series of adjacent sections, namely a spacer section 6, cooling section 7 and a mouth end section 5. The sections of the article maybe present in any order, and not just the order shown. The spacer section is tubular, with a wall 7 and a central lumen 8. The wall 7 of the tubular spacer may comprise a material such as cellulose acetate, polylactide or paper. The cooling section 6 may be any section with a shape and/ or material that assists the cooling of the vapour or aerosol generated with the aerosol-generating material 3,4 is heated. The mouth end section 5 may once again be a plug of a filter material such as tow or sheet material, optionally comprising cellulose acetate, paper, or other known materials.

Figure 8 shows an article 11 similar to that of Figure 7, but with a tubular mouth end section with a wall 9 and a central lumen 10.

The illustrated embodiments show the two regions in the form of a single rod.

However, the regions could be provided separately, such as in separate plugs or cartridges that are to be inserted into a device and heated to their respective peak temperatures by heaters.

The illustrated embodiments also show the first and second regions abutting one another. In other embodiments, there may be a gap or a further section between these regions. This may be to prevent the heating of one region leading to the unintentional heating of the other region. Thus, some form of thermal insulation may be provided between the regions of aerosol-generating material.

In some embodiments, the first and second regions may each have the same dimensions. In other embodiments, the first and second regions may have different dimensions. In some embodiments, the cylindrical regions may have a cross-sectional diameter of at least about 5 mm, about 5.5 mm, about 6 mm, about 6.5 mm, about 7 mm or at least about 7 mm to no more than about 9 mm, about 8.5 mm, or no more than about 8 mm. In some embodiments the article comprises two sections, each having a length of at least about 15 mm, about 16 mm, about 17 mm or about 18 mm, and no greater than about 27 mm, about 26 mm, about 25 mm or about 24 mm. In some embodiment, the first and second regions each have a length of from about 17 to about 24 mm. In some cases, the rod may comprise two sections, each having a length of about 15-20 mm, suitably about 18 mm. In some cases, the rod may comprise two sections, each having a length of about 22-27 ^mm, suitably about 24 mm.

In other cases, the sections of the aerosol generating material may be in the form of prismatic sections that are arranged to together form a rod such as a cylinder. For example, in the case where there are two sections, they may be hemicylindrical and arranged with their respective planar faces in contact.

The consumables or articles are for use in an aerosol provision assembly that comprises an aerosol provision device and an article.

In some embodiments, the aerosol provision device 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 maybe 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 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 assembly is configured to provide a different heat profile to each of the regions of the article comprising the different aerosol-generating materials. This allows the flavour profile of the inhaled aerosol to be tuned. In some cases, the assembly maybe configured to supply an aerosol in which the aerosol composition changes over the period of use. In other cases, the assembly may be configured to supply an aerosol in which the aerosol composition is substantially uniform over the period of use.

In some embodiments, the assembly may be configured such that at least a portion of the aerosol-generating material is exposed to a temperature of at least i8o°C or 200°C for at least 50% of the heating period. In some examples, the aerosol-generating material may be exposed to a heat profile as described in WO 2018/019855, the contents of which are incorporated herein in their entirety.

In some embodiments, an assembly is provided which is configured to heat the at least two regions of aerosol-generating material separately. By controlling the temperature of the first and second regions over time such that the temperature profiles of the sections are different, it is possible to control the puff profile of the aerosol during use. The heat provided to the two regions of the aerosol-generating material maybe provided at different times or rates; staggering the heating in this way may allow for both fast aerosol production and longevity of use.

The assembly device comprises a heating system configured to heat the first region comprising the first aerosol-generating material to a first peak temperature and to heat the second region comprising the second aerosol-generating material to a second peak temperature, wherein the second region reaches the second peak temperature after the first region reaches the first peak temperature. In some embodiments, the heating of the second region to the second peak temperature occurs later than the heating of the first region to the first peak temperature.

In some embodiments, the heating system may be configured such that on initiation of use, the first region of the article comprising the first aerosol-generating material is immediately heated to the first peak temperature and this region of the article is maintained at the first peak temperature for a first time period.

In some embodiments, the heating system may be configured such that on initiation of use, the second region of the article comprising the second aerosol-generating material is immediately heated to the second peak temperature and this region of the article is maintained at the second peak temperature for a second time period.

In other embodiments, the heating of the second region commences later than the heating of the first region. For example, the heating of the second region may commence only once the heating of the first region has finished. In some embodiments, there is no overlap between the heating of the first and second regions.

In some embodiments, the first peak temperature is at least about 150, 160, 170, 180, 190, 200, 210, 220, 230, 240 or about 25O°C. In some embodiments, the first peak temperature is no more than about 350, 340, 330, 320, 310, 300, 290, 280, 270, 260 or about 25O°C.

In some embodiments, the second peak temperature is at least about 150, 160, 170, 180, 190, 200, 210, 220, 230, 240 or about 25O°C. In some embodiments, the second peak temperature is no more than about 350, 340, 330, 320, 310, 300, 290, 280, 270, 260 or about 25O°C. In some embodiments, the second peak temperature is higher than the first peak temperature. In some embodiments, the second peak temperature is from about 10 to about ioo°C higher than the first peak temperature, or from about 10 to 5O°C, from about 10 to 4O°C, from about 10 to 3O°C or from about 10 to 20°C higher that the first peak temperature.

The peak temperature of a region may be defined as the highest temperature that the region is heated to. In some embodiments, the temperature of the region is measured as the temperature of the aerosol-generating material in the region. This may be measured as the temperature in the heating zone of the region using thermocouples. In alternative embodiments, the temperature of the region is considered to be the temperature of the heater used to heat the region. In some embodiments, the first region is heated to and maintained at the first peak temperature for a period of from about 10 seconds to about 300 seconds. In some embodiments, the first region is heated for a period of at least about 10 seconds, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, or 290 seconds. In some embodiments, the first region is heated for a period of no more than about 300 seconds, 290, 280, 270, 260, 250, 240, 230, 220, 210, 200, 190, 180, 170, 160, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, or 30 seconds. In some embodiments, the first region is maintained at the first peak temperatures for a period of from about 30 to about 120 seconds. In some embodiments, the second region is heated to and maintained at the second peak temperature for a period of from about 10 seconds to about 300 seconds. In some embodiments, the second region is heated for a period of at least about 10 seconds, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, or 290 seconds. In some embodiments, the second region is heated for a period of no more than about 300 seconds, 290, 280, 270, 260, 250, 240, 230, 220, 210, 200, 190, 180, 170, 160, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, or 30 seconds. In some embodiments, the second region is maintained at the second peak temperatures for a period of from about 45 to about 240 seconds. In some embodiments, the second region reaches the second peak temperature after a period of from about 10 to 240 seconds after the first region reaches the first peak temperature. In some embodiments, the second region is heated to the second peak temperatures from about 30 to about 120 seconds after the first region reaches the first peak temperature. In some embodiments, the second region is heated to the second peak temperature at least about 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115 or 120 seconds after the first region reaches the first peak temperature. In some embodiments, the second region is heated to the second peak temperature no more than about 120, 115, 110, 105, 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35 or 30 seconds after the first region reaches the first peak temperature. In some embodiments, the heating of the two or more regions of the article is coordinated so that it provides a relatively constant release of volatile compounds into an inhalable medium over the period of use of the aerosol provision system. In some embodiments, the period of use maybe up to about 300 seconds or up to about 250 seconds. In some embodiments, the period of release of volatiles may be up to about 300 seconds or up to about 250 seconds.

It is known that the release of volatiles from aerosol-generating material maybe rapid during the early phase of heating, with a substantial proportion of the volatiles being released once the material reaches a peak temperature. This leads to a spike in the release of the volatiles, followed by a rapid drop off of release thereafter, as the aerosolgenerating material is effectively depleted of the volatile components. In the articles and systems of the present invention, two regions of aerosol-generating material are provided and are heated consecutively, to allow the second aerosol-generating material to release volatiles as the release of volatiles from the first aerosol generating material drops off.

In addition to the temporal coordination of the heating, the articles and systems provide a further measure of control of the release of the volatiles by using a second aerosol-generating material that has a higher density than the first aerosol-generating material. The higher density affects the heating of the second aerosol-generating material. The heat is transferred more slowly through the denser material, leading to a slower and steadier heating profile and slower and steadier released of volatile components. In some known assemblies, more than one heater is used and these heaters are arranged to heat different parts of the aerosol generating material, with the intention that parts of the aerosol generating material are not heated initially, thereby saving the volatiles in those parts for consumption later in the product use lifetime. However, bleeding of heat between different heating zones in such assemblies causes depletion of volatiles in zones where direct heating has not yet been initiated. This increases the delivery of such volatiles early in the consumption period, and reduces the levels of such volatiles available for consumption later. Thus, the delivery of such volatile components generally reduces puff-by-puff. However, the effect of such bleeding of heat can be reduced by including a second aerosol-generating material that has a great density than the first aerosol-generating material. The denser material is slower to heat and the heat spread less through it.

In some embodiments, the heating system comprises one or more separate heaters configured to heat the first region of the article, and one or more heaters configured to heat the second region of the article. These heaters are controlled by a controller of the heating system.

The heaters are configured to heat the regions to their respective peak temperatures.

They may also be configured to maintain the regions at the peak temperature.

Alternatively or in addition, the heaters may also be configured to maintain the regions at a lower temperature before and/ or after the peak temperature has been reached.

In some embodiments, the first and/or second aerosol-generating materials comprise tobacco. For example, the first and/or second aerosol-generating materials may comprise from about 8o to about 350 mg of tobacco. In some specific embodiments, the aerosol-generating material in an article or consumable has a weight of 260 mg, comprising a combination of 130 mg of a first aerosol-generating material, for example comprising a blend of lamina and reconstituted tobacco, and 130 mg of a second aerosol-generating material, for example comprising higher density tobacco beads. In some embodiments, each of the regions comprising aerosol-generating material contain an equal amount of tobacco. In alternative embodiments, the regions may contain different amounts of tobacco. Where the total amount of tobacco is from about 80 to about 350 mg, , one region of aerosol-generating material comprises from about 20 to about 330 mg, or from about 50 to about 300 mg, or from about 40 to about 125 mg of tobacco and the other region of aerosol-generating material comprises from about 20 to about 330 mg, or from about 30 to about 300 mg or from about 40 to about 125 mg of tobacco.

In some particular embodiments, the aerosol-generating material has a rod shape and is formed from two cylindrical sections arranged coaxially along the rod of aerosolgenerating material. In some examples, the cylindrical sections each comprise from about 20 to about 330 mg, or from about 50 to about 300 mg or from about 40 to about 125 mg of tobacco and have a length of from about 15 to about 20 mm, or about 18 mm. In some other examples, the cylindrical sections each comprise from about 100 to about 250 mg, or from about 115 to about 235 mg of tobacco and have a length of from about

22 to about 27 mm, or about 24 mm.

In some embodiments, the aerosol generating article may comprise the aerosol generating material and additionally a cooling element and/ or a filter. The cooling element, if present, may act or function to cool gaseous or aerosol components. In some cases, it may act to cool gaseous components such that they condense to form an aerosol. It may also act to space the very hot parts of the apparatus from the user. The filter, if present, may comprise any suitable filter known in the art such as a cellulose acetate plug.

The aerosol generating article may be circumscribed by a wrapping material such as paper. The aerosol generating article may additionally comprise ventilation apertures. These may be provided in the sidewall of the article. In some cases, the ventilation apertures may be provided in the filter and/or cooling element. These apertures may allow cool air to be drawn into the article during use, which can mix with the heated volatilised components thereby cooling the aerosol.

The ventilation enhances the generation of visible heated volatilised components from the article when it is heated in use. The heated volatilised components are made visible by the process of cooling the heated volatilised components such that supersaturation of the heated volatilised components occurs. The heated volatilised components then undergo droplet formation, otherwise known as nucleation, and eventually the size of the aerosol particles of the heated volatilised components increases by further condensation of the heated volatilised components and by coagulation of newly formed droplets from the heated volatilised components. In some cases, the ratio of the cool air to the sum of the heated volatilised components and the cool air, known as the ventilation ratio, is at least 15%. A ventilation ratio of 15% enables the heated volatilised components to be made visible by the method described above. The visibility of the heated volatilised components enables the user to identify that the volatilised components have been generated and adds to the sensory experience of the smoking experience.

In another example, the ventilation ratio is between 50% and 85% to provide additional cooling to the heated volatilised components. In some cases, the ventilation ratio may be at least 60% or 65%.

As used herein, an aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent

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

An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. 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.

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 maybe utilised and modifications maybe 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 mayinclude other inventions not presently claimed, but which maybe claimed in future.

Claims

- 33 - Claims

1. An aerosol provision system comprising an aerosol provision device and an article, wherein the article comprises a first region comprising a first aerosol-generating material and a second region comprising a second aerosol-generating material, wherein the second aerosol-generating material has a greater density than the first aerosol-generating material, and wherein the device comprises a heating system configured to heat the first region to a first peak temperature and to heat the second region to a second peak temperature, wherein the second region reaches the second peak temperature later than the first region reaches the first peak temperature.

2. An aerosol provision system as claimed in claim 1, wherein the density of the second aerosol-generating material is at least about 25% higher than the density of the first aerosol generating material.

3. An aerosol provision system as claimed in claim 1 or claim 2, wherein the first aerosol generating material has a density of from about 0.1 g/cm3 to about 1 g/cm3.

4. An aerosol provision system as claimed in any one of claims 1 to 3, wherein the second aerosol generating material has a density of from about 0.4 g/cm3 to about 2 g/cm3.

5. An aerosol provision system as claimed in any one of claims 1 to 4, wherein heating of the second region to the second peak temperature occurs later than the heating of the first region to the first peak temperature.

6. An aerosol provision system as claimed in any one of claims ito 5, wherein the second region is heated for a longer time period than the first region.

7. An aerosol provision system as claimed in any one of claims 1 to 6, wherein there is no overlap between the timing of the heating of the first and second regions.

8. An aerosol provision system as claimed in any one of claims 1 to 7, wherein the first peak temperature is from about 15O°C to about 35O°C. - 34 -

9. An aerosol provision system as claimed in any one of claims 1 to 8, wherein the first region is heated to the first peak temperature for a period of from about 10 seconds to about 300 seconds.

10. An aerosol provision system as claimed in any one of claims 1 to 9, wherein the second peak temperature is from about 15O°C to about 35O°C.

11. An aerosol provision system as claimed in any one of claims 1 to 10, wherein the second region is heated to the second peak temperature for a period of from about 10 seconds to about 300 seconds.

12. An aerosol provision system as claimed in any one of claims 1 to 11, wherein the second peak temperature is from about 10 to about ioo°C higher than the first peak temperature.

13. An aerosol provision system as claimed in any one of claims 1 to 12, wherein the heating of the article provides a relatively constant release of volatile compounds into an inhalable medium.

14. An aerosol provision system as claimed in any one of claims 1 to 13, wherein the second region is heated to the second peak temperature after the first region has been heated to the first peak temperature.

15. An aerosol provision system as claimed in any one of claims 1 to 14, wherein the second region is heated to the second peak temperature after heating of the first region has ceased.

16. An aerosol provision system as claimed in any one of claims 1 to 15, wherein the second aerosol-generating material comprises extruded tobacco.

17. An aerosol provision system as claimed in any one of claims 1 to 16, wherein the second aerosol-generating material comprises beads.

18. An aerosol provision system as claimed in any one of claims 1 to 17, wherein the first aerosol-generating material comprises one or more tobacco material selected from the group consisting of lamina and reconstituted tobacco material.

19. An aerosol provision system as claimed in any one of claims 1 to 18, wherein at least one of the first and second aerosol-generating material comprises a combination of lamina and reconstituted tobacco material.

20. An aerosol provision system as claimed in claim 19, wherein the lamina and reconstituted tobacco material are present in the aerosol-generating material in a ratio of from 1:4 to 4:1, by weight.

21. An aerosol provision system as claimed in any one of claims 1 to 20, wherein the first and second aerosol-generating materials have the same levels of a volatile compound.

22. An aerosol provision system as claimed in claim 21, wherein the volatile compound is nicotine.

23. An aerosol provision system as claimed in any one of claims 1 to 22, wherein the release of a volatile compound from the first and second aerosol-generating material is at the same rate when the materials reach a given temperature.

24. An aerosol provision system as claimed in any one of claims 1 to 23, wherein the second region is configured to be downstream of the first region.

25. An aerosol provision system as claimed in any one of claims 1 to 24, wherein the first and second aerosol-generating materials are in distinct regions.

26. An aerosol provision system as claimed in any one of claims 1 to 25, wherein the first and second aerosol-generating materials are present in the article in a ratio of from 1:10 to 10:1, by weight.

27. An article for an aerosol provision system, the article comprising a first aerosol- generating material and a second aerosol-generating material, wherein the second aerosol-generating material is in the form of discrete particles, or in the form of an agglomerated body of particles, wherein the second aerosol-generating material has a greater density than the second aerosol-generating material.

28. An article as claimed in claim 27, wherein the second aerosol-generating material comprises beads or pellets of aerosol-generating material.

29. An article as claimed in claim 27 or claim 28, wherein the second aerosol- generating material is a compressed, extruded or moulded body of aerosol-generating material.

30. An article as claimed in any one of claims 27 to 29, for use in an aerosol provision system as claimed in any one of claims 1 to 26.

31. An article as claimed in any one of claims 27 to 30, wherein the first aerosolgenerating material and the second aerosol-generating material have the same nicotine content.

32. An article as claimed in any one of claims 27 to 31, wherein the first aerosolgenerating material and second aerosol-generating material release nicotine at the same rate once heated to a given temperature.

33. An article as claimed in any one of claims 27 to 32, wherein the first aerosol- generating material is in the form of discrete particles, or in the form of an agglomerated body of particles.

34. An article as claimed in claim 33, wherein the first aerosol-generating material comprises beads or pellets of aerosol-generating material, or is a compressed, extruded or moulded body of aerosol-generating material.

35. An article as claimed in any one of claims 27 to 34, the article comprising a first region comprising the first aerosol-generating material and a second region comprising the second aerosol-generating material. - 37 -

36. An article as claimed in claim 35, wherein the second region is configured to be downstream of the first region.

37. Use of an aerosol provision system as claimed in any one of claims 1 to 26 to provide a consistent delivery of volatile components in an aerosol produced by the system over a period of use producing multiple puffs.

38. Use of an article as claimed in any one of claims 27 to 36 to provide a consistent delivery of volatile components in an aerosol produced by heating the article over a period of use producing multiple puffs.

39. A method of generating an aerosol using the system of any one of claims 1 to 26 or the article of any one of claims 27 to 36, wherein the method comprises heating the first region to a first peak temperature and heating the second region to a second peak temperature, wherein the second region reaches the second peak temperature later than the first region reaches the first peak temperature.