WO2023118848A1

WO2023118848A1 - An article for use in an aerosol provision system and a method of manufacturing an article for use in an aerosol provision system

Info

Publication number: WO2023118848A1
Application number: PCT/GB2022/053320
Authority: WO
Inventors: Fahim ASHRAF; Barry DIMMICK
Original assignee: Nicoventures Trading Limited
Priority date: 2021-12-20
Filing date: 2022-12-20
Publication date: 2023-06-29

Abstract

The present disclosure relates to an article for use in an aerosol provision system. The article comprises a sheet material comprising a first aerosol generating material, wherein the sheet material is gathered to form a body. The article further comprises a second aerosol generating material that is engaged by the sheet material such that the second aerosol generating material is held within the body by the sheet material. The present disclosure also relates to a method of manufacturing an article for an aerosol provision device, a kit of parts comprising an article and an aerosol provision device, and to a package of articles.

Description

An article for use in an aerosol provision system and a method of manufacturing an article for use in an aerosol provision system

Technical field The present disclosure relates to an article for an aerosol provision device. The present disclosure also relates to a method of manufacturing an article for an aerosol provision device, a kit of parts comprising an article and an aerosol provision device, and to a package of articles. Background

Aerosol-provision systems generate an inhalable aerosol or vapour during use by releasing compounds from an aerosol-generating-material. These may be referred to as non-combustible smoking articles, aerosol generating assemblies, or aerosol provision devices, for example.

Summary

In accordance with some embodiments described herein, there is provided an article for use in an aerosol provision system, the article comprising: a sheet material comprising a first aerosol generating material, wherein the sheet material is gathered to form a body; and, a second aerosol generating material that is engaged by the sheet material such that the second aerosol generating material is held within the body by the sheet material.

In some embodiments, the second aerosol generating material is held within the body by friction.

In some embodiments, the second aerosol generating material is held between portions of the sheet material and, preferably, wherein the body comprises a plurality of layers of the sheet material and the second aerosol generating material is held between the layers of the sheet material.

In some embodiments, said portions of the sheet material are strips or strands of the sheet material. In other embodiments, said portions are folds of the sheet material. In some embodiments, the sheet material is formed into strips or strands, wherein the second aerosol generating material is held between the strips or strands.

In some embodiments, the sheet material is shredded and/ or cut. In some embodiments, the sheet material is cut into strips.

In some embodiments, the sheet material is formed into strips that have a width in the range of 0.5 mm to 3 mm and, preferably, in the range of 0.5 to 1.5 mm. In some embodiments, the sheet material is formed into strips with a width of at least 0.5 mm and, preferably, at least about 0.6, 0.7, 0.8, or 0.9 1 mm.

In some embodiments, the sheet material is formed into strips with a width of at most about 3 mm and, preferably, at most about 2.5, 2, 1.8, 1.6, 1.4, 1.2 or 1.1 mm.

In some embodiments, the sheet material is formed into strips that have a length that is the same as the length of the article.

In some embodiments, the strips or strands extend in a direction from a first end towards a second end of the article.

In some embodiments, the strips or strands extend generally parallel to a central axis of the article. In other embodiments, the strips or strands may not be orientated in a particular direction and, for example, may be randomly orientated.

In some embodiments, the sheet material is crimped.

In some embodiments, the article does not comprise additive or binder to retain the second aerosol generating material within the body.

In some embodiments, the body of material extends from a first end of the article to a second end of the article.

In some embodiments, the body of material extends over a portion of the length of the article. In some embodiments, the body of material extends over the entire length of the article. In some embodiments, the first and second aerosol generating materials form a collation of aerosol generating material that extends at least 90% of the length of the article and, preferably, at least 92%, 94%, 96%, 98% or 99% of the length of the article and, preferably, extends the entire length of the article.

In some embodiments, the body comprises a single sheet material that is gathered to form the body. In other embodiments, the body may comprise a plurality of sheets of material that are gathered to form the body.

In some embodiments, the first and/or second aerosol generating material comprises, consists of, or essentially consists of, tobacco material.

In some embodiments, the aerosol generating material extends at least 90% of the length of the article and, preferably, at least 92%, 94%, 96%, 98% or 99% of the length of the article and, preferably, extends the entire length of the article.

In some embodiments, the first aerosol generating material comprises reconstituted tobacco.

In some embodiments, the first aerosol generating material comprises tobacco lamina.

In some embodiments, the first aerosol generating material is substantially tobacco free. In some embodiments, the first aerosol generating material does not comprise tobacco.

In some embodiments, the first aerosol generating material comprises a filler.

In some embodiments, the filler is a non-tobacco fibre.

In some embodiments, the filler is wood fibre or pulp or wheat fibre.

In some embodiments, the filler comprises cellulose. In some embodiments, the filler is a non-tobacco cast material or a non-tobacco extruded material. In some embodiments, the article comprises an aerosol-former material.

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

In some embodiments, the aerosol-former material comprises one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3- butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

In some embodiments, the second aerosol generating material comprises extruded and/or compressed aerosol generating material and, preferably, comprises extruded and/ or compressed tobacco.

In some embodiments, the tobacco material of the first and/or second aerosol generating material is derived only from tobacco lamina and no other types of tobacco material.

In some embodiments, the first and/or second aerosol generating material comprises tobacco lamina and reconstituted tobacco.

In some embodiments, the first and second aerosol generating material together have an average nicotine level in the range of 0.5% to 2.5% by weight of the aerosol generating material and, preferably, in the range of 1% to 2.1%.

In some embodiments, the first and/or second aerosol generating material is a solid material.

In some embodiments, the article does not comprise plastic.

In some embodiments, the article does not comprise cellulose acetate. In some embodiments, the first and second aerosol generating materials are manufactured from the same aerosol generating starter materials that are processed to have different forms. In some embodiments, the second aerosol generating material comprises beads of aerosol generating material.

In some embodiments, the beads are generally cylindrical. In some embodiment, the beads are extruded beads and, preferably, are extruded tobacco beads.

In some embodiments, the beads have a particle size in the range of about 0.5 mm to about 3 mm .

In some embodiments, first and second aerosol generating materials have different densities and, preferably, the density of the second aerosol-generating material is at least 25% higher than the density of the first aerosol-generating material. In some embodiments, the second aerosol-generating material has a density in the range of about 0.4 g/cm3 to about 2 g/cm3.

In some embodiments, the first aerosol-generating material with a density in the range of about 0.1 g/cm3 to about 1 g/cm3.

In some embodiments, the second aerosol generating material comprises fibres of aerosol generating material.

In some embodiments, the second aerosol generating material is distributed throughout the body of material.

In some embodiments, the second aerosol generating material is discretely distributed within the body of material to form a plurality of discrete regions of the second aerosol generating material. In some embodiments, the sheet material comprises aerosol-generating material comprising: from about 10 to about 50 wt% aerosol-former material; from about 15 to about 60 wt% gelling agent; and optionally filler; wherein the wt% values are calculated on a dry weight basis.

In some embodiments, the aerosol-generating material of the sheet comprises a flavourant.

In some embodiments, the sheet material is resiliently deformable.

In some embodiments, first and second aerosol-generating materials are present in the article in a ratio of from 1:10 to 10:1, by weight.

In some embodiments, the density of one of the first and second aerosol-generating materials is at least about 25% higher than the density of the other one of the first and second aerosol generating materials. However, in other embodiments, the density of the first and second aerosol generating materials is the same.

In some embodiments, one of the first and second aerosol generating materials has a density of from about 0.1 g/cm3 to about 1 g/cm3.

In some embodiments, the other one of the first and second aerosol generating materials has a density of from about 0.4 g/cm3 to about 2 g/cm3. 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 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 article comprises from about 20 to about 330 mg of the first aerosol generating material and, preferably, from about 50 to about 300 mg, or from about 40 to about 125 mg of the first aerosol generating material.

In some embodiments, the article comprises from about 20 to about 330 mg of the second aerosol generating material and, preferably, from about 50 to about 300 mg, or from about 40 to about 125 mg of the second aerosol generating material.

In some embodiments, the body of material is circumscribed by a wrapper.

In some embodiments, the wrapper forms an exterior surface of the article.

In some embodiments, the wrapper has a permeability of less than too Coresta Units and, preferably, less than 90, 80, 70, 60 or 50 Coresta Units.

In some embodiments, the wrapper has a thickness in the range of 20 to too microns.

In some embodiments, the wrapper has a basis weight in the range of 20 to 50 gsm.

In some embodiments, the article comprises a cooling element immediately downstream of the body.

In some embodiments, the cooling element comprises a hollow channel. In some embodiments, the article comprises a further body of material downstream of the cooling element. In some embodiments, the further body of material comprises flavouring and/or filtering material.

In some embodiments, the article comprises a segment upstream of the body. According to the present disclosure, there is also provided a method of manufacturing an article for use in an aerosol provision system, the method comprising: providing a sheet material comprising a first aerosol generating material; providing a second aerosol generating material; and, gathering the sheet material to form a body such that the second aerosol generating material is engaged by the sheet material such that the second aerosol generating material is held within the body by the sheet material.

In some embodiments, the method comprises combining the sheet material and the second aerosol generating material and then gathering the sheet material to form the body.

In some embodiments, the method comprises combining the sheet material and the second aerosol generating material whilst gathering the sheet material to form the body. In some embodiments, the method comprises forming the sheet material into strips or stands.

In some embodiments, the method comprises shredding and/or cutting the sheet material.

In some embodiments the sheet may be cut into strips using a stripcut maker.

In some embodiments, the method comprises crimping the sheet material. In some embodiments, the sheet material is formed into strips or strands, wherein the second aerosol generating material is held between the strips or strands. In some embodiments, the second aerosol generating material is held within the body by friction.

In some embodiments, gathering the sheet material comprises gathering the sheet material such that the second aerosol generating material is held between portions of the sheet material and, preferably, such that the body comprises a plurality of layers of the sheet material and the second aerosol generating material is held between the layers of the sheet material.

In some embodiments, the method does not comprise using additive or binder to hold the second aerosol generating material within the body.

In some embodiments, the body of material extends from a first end of the article to a second end of the article. In some embodiments, the body of material extends over a portion of the length of the article. In some embodiments, the body of material extends over the entire length of the article.

In some embodiments, the first aerosol generating material extends at least 90% of the length of the article and, preferably, at least 92%, 94%, 96%, 98% or 99% of the length of the article and, preferably, extends the entire length of the article.

In some embodiments, the body comprises a single sheet material that is gathered to form the body. In some embodiments, the first and/or second aerosol generating material comprises, consists of, or essentially consists of, tobacco material. In some embodiments, the first aerosol generating material comprises reconstituted tobacco. In some embodiments, the first aerosol generating material comprises tobacco lamina.

In some embodiments, the first aerosol generating material comprises a filler.

In some embodiments, the filler is a non-tobacco fibre. In some embodiments, the filler is wood fibre or pulp or wheat fibre.

In some embodiments, the filler comprises cellulose.

In some embodiments, the filler is a non-tobacco cast material or a non-tobacco extruded material.

In some embodiments, the article comprises an aerosol-former material.

In some embodiments, the second aerosol generating material comprises extruded and/or compressed aerosol generating material and, preferably, comprises extruded and/ or compressed tobacco. In some embodiments, the tobacco material of the first and/or second aerosol generating material is derived only from tobacco lamina and no other types of tobacco material. In some embodiments, the first and/or second aerosol generating material comprises tobacco lamina and reconstituted tobacco.

In some embodiment, the first and second aerosol generating material together have an average nicotine level in the range of 0.5% to 2.5% by weight of the first and second aerosol generating material and, preferably, in the range of 1% to 2.1%.

In some embodiments, the first and/or second aerosol generating material is a solid material. In some embodiments, the article does not comprise plastic.

In some embodiment, the article does not comprise cellulose acetate.

In some embodiments, the first and second aerosol generating materials are manufactured from the same aerosol generating starter materials that are processed to have different forms.

In some embodiments, the second aerosol generating material comprises beads of aerosol generating material.

In some embodiments, providing the second aerosol generating material comprises extruding the second aerosol generating material.

In some embodiments, the beads are generally cylindrical

In some embodiments, the beads are extruded beads and, preferably, are extruded tobacco beads.

In some embodiments, the beads have a particle size in the range of 0.5 to 3 mm. In some embodiments, the second aerosol generating material comprises fibres of aerosol generating material.

In some embodiments, the second aerosol generating material is discretely distributed within the body of material to form a plurality of discrete regions of the second aerosol generating material.

In some embodiments, the first and second aerosol generating materials have different densities and, preferably, the density of the second aerosol generating material is at least 25% higher than the density of the first aerosol generating material. In some embodiments, the density of one of the first and second aerosol-generating materials is at least about 25% higher than the density of the other one of the first and second aerosol generating materials. However, in other embodiments, the density of the first and second aerosol generating materials is the same. In some embodiments, one of the first and second aerosol generating materials has a density of from about 0.1 g/cm3 to about 1 g/cm3.

In some embodiments, the other one of the first and second aerosol generating materials has a density of from about 0.4 g/cm3 to about 2 g/cm3.

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 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 aerosol- generating 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 first and second aerosol-generating materials are present in the article in a ratio of from 1:10 to 10:1, by weight.

In some embodiments, the article comprises in the range of 7 mg per mm to 13 mg of the first and second aerosol generating material combined per mm length of the article and, preferably, in the range of 8 to 12, 9 to 11.5, 9 to 11, or 9.5 to 10.5 mg of aerosol generating material per mm length of the article.

In some embodiments, the sheet material comprises aerosol-generating material comprising: from about 10 to about 50 wt% aerosol-former material; from about 15 to about 60 wt% gelling agent; and optionally filler; wherein the wt% values are calculated on a dry weight basis.

In some embodiments, the aerosol generating material of the sheet material comprises a flavourant.

In some embodiments, the sheet material is resiliently deformable and wherein gathering the sheet material causes the second aerosol generating material to be held between regions of the sheet material such that the sheet material is resiliently deformed. In some embodiments, the article comprises a cooling element immediately downstream of the body. The method may comprise providing the cooling element and locating the cooking element immediately downstream of the body. In some embodiments, the cooling element comprises a hollow channel.

In some embodiments, the article comprises a further body of material downstream of the cooling element. The method may comprise providing the further body of material and locating the further body of material downstream of the cooling element.

In some embodiments, the further body of material comprises flavouring and/or filtering material.

In some embodiments, the article comprises a segment upstream of the body. The method may comprise providing the segment and providing the segment upstream of the body.

In some embodiments, the article comprises in the range of 7 mg per mm to 13 mg of aerosol generating material (including the first and second aerosol generating material) per mm length of the article and, preferably, in the range of 8 to 12, 9 to 11.5, 9 to 11, or 9.5 to 10.5 mg of aerosol generating material per mm length of the article.

In some embodiments, the wrapper has a basis weight in the range of 20 to 50 gsm. According to the present disclosure, there is also provided an article manufactured according to the method described herein. According to the present disclosure, there is also provided a package comprising a plurality of articles as described herein. In some embodiment, the package is hermetically sealed.

According to the present disclosure, there is also provided a kit of parts comprising: an article as described herein; and, an aerosol provision device.

In some embodiments, the aerosol provision device comprises a heating zone for receiving the article to heat the first and second aerosol generating materials. Brief Description of the Drawings

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

Fig. 1 is cross-sectional side view of an embodiment of an article for use in an aerosol provision system; Fig. 2 is a cross-sectional front view of the article of Fig. 1, along the line Z-Z of Fig. 1; Fig. 3 is a top view of a sheet material of the article of Fig. 1, wherein the sheet material is laid flat;

Fig. 4 is a top view of a strip of the sheet material of the article of Fig. 1, wherein the strip is laid flat; Fig. 5 is a perspective view of a bead of aerosol-generating material of the article of Fig. 1;

Fig. 6 is cross-sectional side view of another embodiment of an article for use in an aerosol provision system;

Fig. 7 is a cross-sectional front view of the article of Fig. 6, along the line Z-Z of Fig. 6; Fig. 8 is cross-sectional side view of another embodiment of an article for use in an aerosol provision system;

Fig. 9 is a cross sectional view of an embodiment of a non-combustible aerosol provision device;

Fig. 10 is a simplified schematic of the components within the housing of the aerosol provision device shown in Fig. 9; Fig. n is a cross sectional view of the non-combustible aerosol provision device shown in Fig. 9 with the article shown in Fig. 1 inserted into the device; and,

Fig. 12 is a block diagram illustrating a method of manufacturing an article for use in an aerosol provision system.

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 a plant based material, for example, tobacco or a non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise a non- combustible aerosol provision device, and a consumable for use with the non- combustible aerosol provision device.

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

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. Reference to the ‘distal end’ refers to an upstream end of the device, whereas ‘proximal end’ refers to the downstream end of the device.

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 comprises an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/ or an aerosol-modifying agent. In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/ or an aerosol-modifying agent.

The consumable comprises a substance to be delivered. The substance to be delivered is an aerosol-generating material. As appropriate, the 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.

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 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 maybe 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 substance to be delivered comprises a flavour.

As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, maybe 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. The aerosol-generating material may comprise or be an “amorphous solid”. In some embodiments, the aerosol-generating material comprises an aerosol-generating film that is an amorphous solid. The amorphous solid maybe a “monolithic solid”. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 6owt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid. An aerosol-generating material may also be referred to as an aerosolisable material.

An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. An aerosol-generating material may be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants. The aerosol-generating material is incorporated into an article for use in the aerosol-generating system.

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

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

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 aerosolisable material may be present on a substrate. The substrate may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted aerosolisable material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy.

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.

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

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor maybe both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein. An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol- modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent.

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent maybe in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material. An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. 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 filamentary tow material described herein can comprise cellulose acetate fibre tow.

The filamentary tow can also be formed using other materials used to form fibres, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(i-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT), starch based materials, cotton, aliphatic polyester materials and polysaccharide polymers or a combination thereof. The filamentary tow may be plasticised with a suitable plasticiser for the tow, such as triacetin where the material is cellulose acetate tow, or the tow may be non-plasticised. The tow can have any suitable specification, such as fibres having a

‘Y’ shaped or other cross section such as ‘X’ shaped, filamentary denier values between

2.5 and 15 denier per filament, for example between 8.0 and 11.0 denier per filament and total denier values of 5,000 to 50,000, for example between 10,000 and 40,000. In the figures described herein, like reference numerals are used to illustrate equivalent features, articles or components. Fig. 1 is a cross-sectional side view of an article 1 for use in an aerosol delivery system that includes an aerosol delivery device 200 (see Figs. 9 to 11). The article 1 comprises a sheet material 2 that is arranged to form a body 3. The sheet material 2 comprises a first aerosol generating material 4.

The body 3 is circumscribed by a wrapper 6. In the present example, the wrapper 7 comprises paper.

The article 1 further comprises a second aerosol generating material 5. In the present example, the second aerosol generating material 5 comprises beads 5 of aerosol generating material. However, it should be recognised that in other embodiments the second aerosol generating material 5 may take a different form. The second aerosol generating material 5 may be in the form of discrete particles of aerosol generating material.

The second aerosol generating material 5 is engaged by the sheet material 2 such that the second aerosol generating material 5 is held within the body 3 by the sheet material 2. In the present example, the second aerosol generating material 5 is held within the body 3 by friction. That is, the friction between the second aerosol generating material 5 and the sheet material 2 retains the second aerosol generating material 5 in position within the body 3. The second aerosol generating material 5 being held in place within the body 3 by the sheet material 2 has the advantage of preventing the second aerosol generating material 5 from falling out of the body 3 during transport and use of the article 1. This also provides the advantage that no binder or additive is required to hold the second aerosol generating material 5 within the body 3 (for example, the second aerosol generating material 5 does not need to be adhered to the sheet material 2), which makes manufacture of the article easier, less expensive and more environmentally friendly.

In the present example, the sheet material 2 is formed into strips 7, for example, but cutting or shredding the sheet material 2 into the strips 7. The second aerosol generating material 5 is then combined with the strips 7 and then the strips 7 are gathered together to form the body 3. The strips 7 may be aligned in a predetermined manner (for example, extending substantially parallel to the central axis of the article 1) or may be orientated in a random manner.

Additionally, or alternatively, the sheet material 2 may be crimped, for example, before or after cutting or shredding the sheet material 2.

The second aerosol generating material 5 is held between the strips 7 when the strips 7 are gathered to form the body 3. The second aerosol generating material 5 is held between portions of the sheet material 2 to retain the second aerosol generating material 5 within the body 3. In the present example, said portions of the sheet material 2 are adjacent strips 7. However, in other embodiments, the sheet material 2 of the body 3 may be a continuous sheet that is gathered to form the body 3, wherein the second aerosol generating material 5 is held between portions of the same continuous piece of sheet material 2, for example, held between folds of the sheet material 2. In some embodiments, the body 3 comprises a plurality of layers of the sheet material 2 and the second aerosol generating material 5 is held between the layers of the sheet material 2.

In the present example, the strips 7 of the body 2 extend in a direction from a first end P towards a second end D of the article 1. In some embodiments, the strips or strands 7 extend generally parallel to a central axis of the article 1, and may extend longitudinally. The strips or strands 7 may extend from a first end P to a second end D of the article 1, and may extend the entire, or substantially the entire, axial length (shown by arrow ‘X’ in Fig. 1) of the article 1. In other embodiments, the strips or strands 7 may extend at an angle to the central axis of the article 1 and, for example, may be perpendicular to the central axis. In some embodiments, the strips or strands 7 may be orientated randomly.

In the present example, the body of material 3 extends from a first end P of the article 1 to a second end D of the article 1.

In the present example, the body of material 3 extends over the entire length X of the article 1. This increases the amount of aerosol that can be generated for an article 1 of a given axial length. In the present example, the first and second aerosol generating materials 4, 5 form a collation of aerosol generating material that extends at least 90% of the length X of the article 1 and, preferably, at least 92%, 94%, 96%, 98% or 99% of the length X of the article and, preferably, extends the entire length X of the article 1. In other embodiments, the body of material 3 extends over a portion of the length X of the article 1. In some embodiments, the first and/or second aerosol generating material 4, 5 comprises, consists of, or essentially consists of, tobacco material.

In the present example, the first aerosol generating material 4 comprises reconstituted tobacco.

In some embodiments, the first aerosol generating material 4 comprises tobacco lamina.

In some embodiments, the second aerosol generating material 5 comprises beads 5 of second aerosol generating material 5, for example, tobacco beads.

In some embodiments, the beads 5 are generally cylindrical.

In some embodiments, the beads 5 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 5 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 5 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 5may refer to their average size, such as the number or volume mean size.

In some embodiments, the second aerosol generating material 5 comprises extruded and/or compressed aerosol generating material and, preferably, comprises extruded and/or compressed tobacco.

In some embodiments, the tobacco material of the first and/or second aerosol generating material 4, 5 is derived only from tobacco lamina and no other types of tobacco material. In some embodiments, the first and/or second aerosol generating material 4, 5 comprises tobacco lamina and reconstituted tobacco. In some embodiment, the first and second aerosol generating material 4, 5 together have an average nicotine level in the range of 0.5% to 2.5% by weight of the first and second aerosol generating material and, preferably, in the range of 1% to 2.1%.

In some embodiments, the first and/or second aerosol generating material 4, 5 is a solid material.

In some embodiments, the article 1 does not comprise plastic. This makes the article 1 more environmentally friendly.

In some embodiments, the article 1 does not comprise cellulose acetate.

In some embodiments, the first and second aerosol generating materials 4, 5 are manufactured from the same aerosol generating starter materials that are processed to have different forms.

In some embodiments, the second aerosol generating material 5 comprises fibres of aerosol generating material.

In some embodiments, the second aerosol generating material 5 is distributed throughout the body 3. In some embodiments, the second aerosol generating material 5 is discretely distributed within the body 3 to form a plurality of discrete regions of the second aerosol generating material 5.

The second aerosol generating material 5 maybe provided as a loose material. For instance, the second aerosol generating material 5 may be a loose material that is held in place in the body 3 by engagement with the sheet material 2. The second aerosol generating material 5 may, for example, be loose strands or particles of aerosol generating material. Another example of loose aerosol generating material is beads/pellets of aerosol generating material, including aerosol generating material that has been extruded and then cut into beads/pellets. Yet another example of aerosol generating material is a sheet of aerosol generating material that has been cut into individual pieces, for example, cut into individual strips of aerosol generating material. The sheet of aerosol generating material maybe a sheet of reconstituted tobacco.

In some embodiments, the first and second aerosol generating materials 4, 5 have different densities.

In some embodiments, the sheet material 2 is resiliently deformable. This may allow the sheet material 2 to deform about the second aerosol generating material 5 and thus help to retain the second aerosol generating material 5 in position within the body 3.

In some embodiments, the aerosol generating material in an article 1 comprises approximately 50% of the first aerosol-generating material 4 and about 50% of the second aerosol-generating material 5, by weight. Thus, for example, an article comprising 260 mg of aerosol-generating material may comprise 130 mg of the first aerosol-generating material 4 and 130 mg of the second aerosol-generating material 5.

In some embodiments, the body 3 is circumscribed by a wrapper 6.

In some embodiments, the wrapper 6 forms an exterior surface 1A of the article 1.

In some embodiments, the wrapper 6 has a permeability of less than too Coresta Units and, preferably, less than 90, 80, 70, 60 or 50 Coresta Units.

In some embodiments, the wrapper 6 has a thickness in the range of 20 to too microns.

In some embodiments, the wrapper 6 has a basis weight in the range of 20 to 50 gsm.

In some embodiments, the first and/or second aerosol-generating material 4, 5 may comprise, consist of, or essentially consist of, tobacco material. The term “tobacco material” refers to any material comprising tobacco or derivatives or substitutes thereof. The tobacco material may be in any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and/ or tobacco extract. In some embodiments, the first and/or second aerosol generating material 4, 5 or another material (not shown) of the article 1, for example, another material of the body 3, may comprise one or more aerosol-former materials. For example, the first and/or second aerosol generating material 4, 5 or said another material may comprise one or more constituents capable of forming an aerosol. The aerosol-former material comprises one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol-former material can be glycerol or propylene glycol.

In the present example, the second aerosol generating material 5 comprises extruded and/or compressed tobacco. In such embodiments, the second aerosol generating material 5 may comprise a single body of aerosol generating material 5. However, in the present example, the second aerosol generating material 5 comprises a plurality of bodies of aerosol generating material.

In the present example, the second aerosol generating material 5 comprises beads/pellets/granules of aerosol generating material (hereinafter referred to as ‘beads’ of aerosol generating material). The beads 5 maybe extruded and/or compressed beads 5, and may be subject to a spheronisation process.

Optionally, the second aerosol generating material 5 has a higher density than the first aerosol generating material 4. It has been found that this causes the second aerosol generating material 5 to heat up slower than the first aerosol generating material 4 when the heater of the device 200 is operated to heat the article 1. This means that the first aerosol generating material 4 will initially release one or more volatile compounds (e.g. nicotine) at a higher rate than the second aerosol generating material 5. This also means that the first aerosol generating material 4 will become relatively depleted of said volatile compound(s) more quickly than the second aerosol generating material 5. However, as the first aerosol generating material 4 starts to become relatively depleted of said volatile compound(s), the second aerosol generating material 5 will begin to reach a temperature wherein it begins to release volatile compound(s) at a higher rate. The effect of this is a more consistent release of the volatile compound(s) over the period of consumption of the article 1, with the first aerosol generating material 4 releasing a greater proportion of volatile compound(s) towards the beginning of the consumption of the article i and the second aerosol generating material 5 releasing a greater proportion of volatile compound(s) towards the end of the consumption of the article 1. This is particularly advantageous because the article 1 can be made relatively small whilst still achieving a relatively consistent and/ or sufficient release of volatile compound(s) over the period of consumption.

In some embodiments, said one or more volatile compound(s) released by the first aerosol generating material 4 are the same as the volatile compound(s) released by the second aerosol generating material 5.

In some embodiments, the second aerosol generating material 5 comprises aerosol generating material that has been compressed or extruded (without subsequent expansion or with a relatively low/ minimal expansion) such that the density of the second aerosol generating material 5 is higher than the density of the first aerosol generating material 4.

In some embodiments, the first aerosol generating material 4 comprises one or more of: tobacco lamina; tobacco stems or reconstituted tobacco. In one such embodiment, the first aerosol generating material 4 comprises a mixture of tobacco lamina and reconstituted tobacco. The first aerosol generating material 4 is formed into a sheet.

In some embodiments, the first and second aerosol-generating material 4, 5 may comprise the same material, for example, tobacco, but are processed to have different densities. In one such embodiment, the first and second aerosol generating materials 4,

5 may be in different forms. For example, the first aerosol generating material 5 is formed into a sheet material 2, whereas the second aerosol generating material 5 may be compressed or extruded (without or with minimal expansion) such that the second aerosol generating material 5 has a higher density than the first aerosol generating material 4.

It should be recognised that in alternative embodiments, the density of the second aerosol generating material 5 is lower than the density of the first aerosol generating material 4. In yet another embodiment, the densities of the first and second aerosol generating materials 4, 5 are the same. In some embodiments, the first aerosol-generating material 4 has at least one further different characteristic to the second aerosol generating material 5. 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 aerosol- generating materials 4, 5 (including the recipe of the aerosol generating materials 4, 5 when each is manufactured more than one material). In some embodiments, the first and second aerosol-generating materials 4, 5 do not have a different characteristic, other than being in a different form. The first aerosol-generating material 4 may comprise a plurality of strands or strips of aerosol-generating material. For example, the first aerosol-generating material 4 may comprise a plurality of strands or strips of an aerosolisable material and/or a plurality of strands or strips of an amorphous solid. The first and/or second aerosol-generating material 4, 5 may comprise a plant based material, such as a tobacco material. The first and/or second aerosol-generating material 4, 5 maybe a sheet or shredded sheet of aerosolisable material comprising a plant based material, such as a tobacco material. The plant based material may be a particulate or granular material. In some embodiments, the plant based material is a powder. Alternatively, or in addition, the plant based material may comprise may comprise strips, strands or fibres of tobacco. For example, where tobacco material is provided, the tobacco material may comprise particles, granules, fibres, strips and/or strands of tobacco. In some embodiments, the tobacco material consists of particles or granules of tobacco material.

The tobacco material of the first and/ or second aerosol-generating material 4, 5 may comprise tobacco obtained from any part of the tobacco plant. In some embodiments, the tobacco material comprises tobacco leaf.

The sheet or shredded sheet can comprise from 5% to about 90% by weight tobacco leaf.

In some embodiments, both of the first and/or second aerosol-generating material 4, 5 comprise, consist of, or essentially consist of tobacco material. In some embodiments, the first aerosol-generating material 4 comprises a sheet or shredded sheet of aerosolisable material that comprises an aerosol-former material. In some embodiments, the aerosol-former material is provided in an amount of up to about 50% on a dry weight base by weight of the sheet or shredded sheet. In some embodiments, the aerosol-former material is provided in an amount of from about 5% to about 40% on a dry weight base by weight of the sheet or shredded sheet, from about 10% to about 30% on a dry weight base by weight of the sheet or shredded sheet or from about 10% to about 20% on a dry weight base by weight of the sheet or shredded sheet.

The first and/or second aerosol-generating material 4, 5 may comprise a filler. The filler is generally a non-tobacco component, that is, a component that does not include ingredients originating from tobacco. The filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may be a non-tobacco fibre such as wood fibre or pulp or wheat fibre. The filler can be a material comprising cellulose or a material comprises a derivate of cellulose. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material. In some embodiments, first and/or second aerosol generating materials 4, 5 are in the form of a sheet or shredded sheet that comprises the filler.

The first and/or second aerosol generating materials 4, 5 can comprise an aerosol modifying agent, such as any of the flavours described herein. In one embodiment, the first and/or second aerosol generating materials 4, 5comp rises menthol. When the first and/ or second aerosol generating materials 4, 5 is incorporated into an article 1 for use in an aerosol-provision system, the article may be referred to as a mentholated consumable or article 1. The first and/or second aerosol generating materials 4, 5 can comprise from o.5mg to 20mg of menthol, from 0.7 mg to 20 mg of menthol, between img and i8mg or between 8mg and i6mg of menthol.

In some embodiments, the article 1 comprises an aerosol-generating composition comprising aerosol-generating material. The aerosol-generating material may comprise the first and/or second aerosol-generating materials 4, 5. An 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 (for example, the first and/or second aerosol generating material 4, 5) may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/ or flavourants.

The aerosol-generating material (for example, the first and/or second aerosol generating material 4, 5) may comprise a binder and an aerosol former. Optionally, an active and/ or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material (for example, the first and/or second aerosol generating material 4, 5) is substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material (for example, the first and/ or second aerosol generating material 4, 5) is substantially tobacco free.

The aerosol-generating material (for example, the first and/or second aerosol generating material 4, 5) may comprise or be an “amorphous solid”. The amorphous solid maybe a “monolithic solid”. 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 aerosol-generating material may, for example, comprise from about 50wt%, 6owt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid. The amorphous solid may be substantially non-fibrous.

The aerosol-generating material (for example, the first and/or second aerosol generating material 4, 5) may comprise or be an aerosol-generating film. The aerosolgenerating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as active substances, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film. The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent. The aerosolgenerating film may be a continuous film or a discontinuous film, such an arrangement of discrete portions of film on a support. The aerosol-generating film maybe substantially tobacco free. The aerosol-generating film may comprise or be a sheet, which may optionally be shredded to form a shredded sheet.

The aerosol-generating material (for example, the first and/or second aerosol generating material 4, 5) may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

In each of the embodiments of article 1 described herein, the article may comprise such a first and/or second aerosol generating material 4, 5, and may comprise such an aerosol-generating composition.

The first and/or second aerosol generating materials 4, 5 can comprise a paper reconstituted tobacco material. The composition can alternatively or additionally comprise any of the forms of tobacco described herein. The first and/or second aerosol generating materials 4, 5 can comprise a sheet or shredded sheet comprising tobacco material comprising between 10% and 90% by weight tobacco leaf, wherein an aerosolformer material is provided in an amount of up to about 20% by weight of the sheet or shredded sheet, and the remainder of the tobacco material comprises paper reconstituted tobacco.

Where the first and/or second aerosol generating material 4, 5 comprises an amorphous solid material, the amorphous solid material may be a dried gel comprising menthol.

In some embodiments, the second aerosol generating material 5 comprises an extruded aerosol generating material that is then cut into beads of pellets..

Referring now to Figs. 6 and 7, an alternative embodiment of an article 1 for an aerosol provision device 200 is shown. The article 1 has similar features to the article 1 described above in relation to Figs. 1 to 5, with like features retaining the same reference numerals, and may have any of the variations of features described herein. A difference is that, the sheet material 2 is not cut into strips 7. Instead, the continuous sheet material 2 is gathered to form the body 3 such that the second aerosol generating material 5 is held in the folds between the sheet material 2. That is, the second aerosol generating material 5 is held between portions of the same continuous piece of sheet material 2, for example, held between folds of the sheet material 2. In some embodiments, the body 3 comprises a plurality of layers of the sheet material 2 and the second aerosol generating material 5 is held between the layers of the sheet material 2. The sheet material 2 may be gathered in a similar manner to the gathering of a paper sheet during the manufacture of a ‘crepe filter’, as will be known to a person skilled in the art.

In the above described embodiments, the body 3 extends between the ends P, D of the article 1. However, it should be recognised that in alternative embodiments (not shown), the article 1 may comprise one or more further segments, for example, a further segment upstream or downstream of the body 3.

For example, an alternative embodiment of an article 1 is shown in Fig. 8 which further comprises a cooling section 25, also referred to as a cooling element, positioned immediately downstream of the body 3. In the present example, the cooling element 25 is immediately downstream of and adjacent to the body 3. In some such embodiments, the cooling element 25 is in an abutting relationship with the body 3. The article 1 may additionally or alternatively include a further body of material 26 downstream of the cooling element 25. The further body of material 26 may comprise flavouring and/or filtering material and/ or may be provided to obscure the view of the cooling element

25-

The cooling element 25 comprises a hollow channel, having an internal diameter of between about 1 mm and about 4 mm, for example between about 2 mm and about 4 mm. The hollow channel may have an internal diameter of about 3 mm. The hollow channel extends along the full length of the cooling element 25. The cooling element 25 may comprise a single hollow channel. In alternative embodiments, the cooling element 25 can comprise multiple channels, for example, 2, 3 or 4 channels. The single hollow channel may be substantially cylindrical, although in alternative embodiments, other channel geometries/cross-sections may be used. The hollow channel can provide a space into which aerosol drawn into the cooling element 25 can expand and cool down. The cooling element 25 may be configured to limit the cross-sectional area of the hollow channel/s, to limit tobacco displacement into the cooling element 25, in use. The cooling element 25 may have a wall thickness in a radial direction. The wall thickness of the cooling element 25, for a given outer diameter of cooling element 25, defines the internal diameter for the chamber surrounded by the walls of the cooling element 25. The cooling element 25 can have a wall thickness of at least about 1.5 mm and up to about 2 mm. In the present example, the cooling element 25 has a wall thickness of about 2 mm.

The cooling element 25 may be formed from filamentary tow. Other constructions can be used, such as a plurality of layers of paper which are parallel wound, with butted seams, to form the cooling element 25; or spirally wound layers of paper, cardboard tubes, tubes formed using a papier-mache type process, moulded or extruded plastic tubes or similar. The cooling element 25 is manufactured to have a rigidity that is sufficient to withstand the axial compressive forces and bending moments that might arise during manufacture and whilst the article 1 is in use.

The wall material of the cooling element 25 can be relatively non-porous, such that at least 90% of the aerosol generated by the aerosol generating material 4, 5 passes longitudinally through the one or more hollow channels rather than through the wall material of the cooling element 25. For instance, at least 92% or at least 95% of the aerosol generated by the first and/ or second aerosol generating material 4, 5 can pass longitudinally through the one or more hollow channels.

The cooling element 25 can be configured to provide a temperature differential of at least 40 degrees Celsius between a heated volatilised component entering a first, upstream end of the cooling element 25 and a heated volatilised component exiting a second, downstream end of the cooling element 25. The cooling element 25 can be configured to provide a temperature differential of at least 60 degrees Celsius, or at least 80 degrees Celsius, or at least too degrees Celsius between a heated volatilised component entering a first, upstream end of the cooling element 25 and a heated volatilised component exiting a second, downstream end of the cooling element 25. This temperature differential across the length of the cooling element 25 protects the temperature sensitive body of material 26 from the higher temperatures of the aerosolgenerating material 4, 5 when it is heated.

The body of material 26 defines a substantially cylindrical overall outer shape and is wrapped in a plug wrap 28. The plug wrap 28 can have a basis weight of less than 50 gsm, or between about 20 gsm and 40 gsm. The plug wrap 28 can have a thickness of between 30 pm and 60 pm, or between 35 pm and 45 pm. The plug wrap 28 may be a non-porous plug wrap, for instance having a permeability of less than 100 Coresta units, for instance less than 50 Coresta units. However, in other embodiments, the plug wrap 28 can be a porous plug wrap, for instance having a permeability of at least 100 Coresta Units or at least 200 Coresta Units.

The cooling element 25 and/ or body of material 26 may form a mouthpiece of the article 1 that is configured to be received within the mouth of the user. In some embodiments, the mouthpiece 207 of the device 200 may be omitted. In some embodiments, a tipping paper (not shown) is wrapped around the cooling element 25 and body of material 26 and also circumscribes the wrapper 6 that circumscribes the body 3, and may be connected to these components by adhesive. Thus, the tipping paper connects the cooling element 25 and body of material 26 to the body 3. In other embodiments, the tipping paper is omitted and instead the wrapper 6 extends to circumscribe the cooling element 25 and body of material 26 to connect these components to the body 3.

Embodiments wherein the aerosol generating material extends over the entire axial length X of the article 1 (or the entire axial length of the body 3) provide the advantage of increasing the amount of aerosol generating material in the article 1 and thus the amount of aerosol that can be generated for a given axial length X of the article 1.

Embodiments wherein the aerosol generating material over only a portion of the entire axial length X of the article 1 provide the advantage that the aerosol generating material is not visible from the ends P, D of the article 1 and also helps to reduce the possibility of the aerosol generating material from falling out of the ends P, D of the article 1.

Referring now to Figs. 9 to 11, an embodiment of an aerosol provision device 200 is shown.

The article 1 is configured for use in an aerosol provision device 200 (see Fig. 9) comprising an aerosol generator in the form of a heating element 203 for heating the article 1. In the present example, the heating element 203 at least partially surrounds a heating area 202, for example, a heating chamber 202. The heating element 203 may be resistively and/ or inductively heated. In other embodiments (not shown), the heating element 203 instead comprises a blade or pin, for insertion into the article 1, for example, the blade or pin may be inserted through the body of material 3. In other embodiments (not shown), the consumable 1 may comprise the heating element which, for example, maybe embedded in the body of material 3.

In Fig. 9, the components of an embodiment of an aerosol provision device 200 are shown in a simplified manner. Particularly, the elements of the aerosol provision device 200 are not drawn to scale in Fig. 9. Elements that are not relevant for the understanding of this embodiment have been omitted to simplify Fig. 9.

In the example of Fig. 9, the aerosol provision device 200 is a non-combustible aerosol provision device 200. The non-combustible aerosol provision device 200 comprises a housing 201 comprising an area 202 for receiving an article 1.

When the article 1 is received into the heating area 202, at least a portion of the article 1 comes into thermal proximity with the heater 203. Thus, at least a portion of the aerosol generating material 4, 5 is in thermal proximity with the heater 203. In some embodiments, the heater 203 is spaced from the article 1, for example, circumscribing the article 1 but having a larger diameter and being spaced therefrom. In other embodiments, the heater 203 is in direct contact with the article 1, for example, contacting an outer surface of the first sheet material 6 of the article . In another embodiment, the heater 203 comprises a blade or pin that contacts the inside of the article 1, for example, contacting the body of material 3 and/or the substrate 2.

When the article 1 is heated, the first and/or second aerosol generating material 4, 5 will release one or more volatile compounds and may release a range of volatile compounds at different temperatures. By controlling the maximum operation temperature of the electrically heated aerosol generating system 200, the selective release of undesirable compounds may be controlled by preventing the release of select volatile compounds.

As shown in Fig. 10, within the housing 201 there is an electrical energy supply 204, for example a rechargeable lithium ion battery. A controller 205 is connected to the heater 203, the electrical energy supply 204, and a user interface 206, for example a button or display. The controller 205 controls the power supplied to the heater 203 in order to regulate its temperature. Typically, the aerosol-forming substrate is heated to a temperature of between 250 and 450 degrees centigrade.

Fig. 11 is a schematic cross-section of a non-combustible aerosol-provision device 200 of the type shown in Fig. 9, with the article 1 received in the heating area 202 of the device 200 for heating by the heater 203. The non-combustible aerosol provision device 200 is illustrated receiving the aerosol-generating article 1 for consumption of the aerosol-generating article 1 by a user. The housing 201 of non-combustible aerosol provision device 200 defines an area 202 in the form of a cavity, open at the proximal end (or mouth end), for receiving an aerosol-generating article 1 for consumption by a user.

In the present example, the aerosol-provision device 200 comprises a mouthpiece 207 that is detachable from the remainder of the device 200 to allow access to the area 202 such that an article 1 can be interested into and removed from the area 202. Once an article 1 has been provided in the area 202, the mouthpiece 207 can be reattached. In some embodiments, the mouthpiece 207 is removably attached to the housing 201 of the device 200, for example, by a screw thread or bayonet connection.

As a user draws on the mouthpiece 207, air is drawn into the article 1 and the volatile substances condense to form an inhalable aerosol. This aerosol passes through the mouthpiece 207 of the device 200 and into the user's mouth. It should be recognised that in other embodiments the mouthpiece 207 of the device 200 maybe omitted. In some embodiments, the article 1 may form a mouthpiece and may come into contact with a user’s mouth.

Referring now to Fig. 12, a block diagram depicting an exemplary embodiment of a method too of manufacturing an article 1 for an aerosol provision device is shown.

The method too comprises the step (Si) of providing a sheet material 2 comprising a first aerosol generating material 4 (for example, a tobacco sheet). The method 100 also comprises the step (S2) of providing a second aerosol generating material 5. The method 100 also comprises the step (S3) of gathering the sheet material 2 to form a body 3 such that the second aerosol generating material 5 is engaged by the sheet material 2 such that the second aerosol generating material 5 is held within the body 3 by the sheet material 2.

In some embodiments, the method 100 comprises combining the sheet material 2 and the second aerosol generating material 5 and then gathering the sheet material 2 to form the body 3.

In some embodiments, the method 100 comprises combining the sheet material 2 and the second aerosol generating material 5 whilst gathering the sheet material 2 to form the body 2. For example, whilst the sheet material 2 is being fed through a garniture.

In some embodiments, the method 100 comprises forming the sheet material 2 into strips or strands 7. In some embodiments, the method 100 comprises shredding and/or cutting the sheet material 2.

In some embodiments, the strips or strands 7 extend in a direction from a first end P towards a second end D of the article 1. In other embodiments, the strips or stands 7 may be randomly orientated.

In some embodiments, the method 100 comprises crimping the sheet material 2.

In some embodiments, the sheet material 2 is formed into strips or strands 7, wherein the second aerosol generating material 5 is held between the strips or strands 7.

In some embodiments, the second aerosol generating material 5 is held within the body 3 by friction. In some embodiments, the step (S3) of gathering the sheet material 2 comprises gathering the sheet material 2 such that the second aerosol generating material 5 is held between portions of the sheet material 2.

In some embodiments, the step (S3) of gathering the sheet material 2 comprises gathering the sheet material 2 such that the body 2 comprises a plurality of layers of the sheet material 2 and the second aerosol generating material 5 that is held between the layers of the sheet material 2.

In some embodiment, no additive or binder is applied to the sheet material 2 or second aerosol generating material 5 to hold the second aerosol generating material 5 within the body 3.

In all of the above examples, the second aerosol generating material 5 may comprise, consist of, or essentially consist of extruded or compressed bodies of tobacco material and, preferably, the extruded or compressed bodies of tobacco material comprise beads of tobacco material.

In each of the above examples, the first and/or second aerosol generating material 4, 5 may comprise, consist of, or essentially consist of reconstituted tobacco and, preferably, comprises a shredded sheet of reconstituted tobacco.

In all of the above examples, the first and/or second aerosol generating material 4, 5 may comprise, consist of, or essentially consist of lamina tobacco. In all of the above examples, the first and/or second aerosol generating material 4, 5 may comprise, consist of, or essentially consist of reconstituted tobacco and lamina tobacco and, preferably, the reconstituted tobacco and lamina tobacco are mixed together. In all of the above examples, the first and/or second aerosol generating material 4, 5 may comprise, consist of, or essentially consist of a sheet of aerosol generating material that is cut into strips. In some embodiments, the sheet is a sheet of reconstituted tobacco. For example, the first aerosol generating material 4 may be cut into strips that are then arranged to form the body 3.

In all of the above examples, the first and/or second aerosol generating material 4, 5 may comprise tobacco material, and wherein the tobacco material is manufactured only from tobacco lamina and no other types of tobacco material. In all of the above examples, the first and second aerosol generating materials 4, 5 are manufactured from the same aerosol generating starter materials that are processed to have different forms. According to the present disclosure, there is also provided a kit of parts comprising a article 1 according to any of the examples described herein and an aerosol provision device 200.

According to the present disclosure, there is also provided a package (not shown) comprising a plurality of articles according to any of the examples described herein. In some embodiments, the package is hermetically sealed. The package may comprise a container comprising a body and a lid, wherein a space is provided within the container body to receive the plurality of articles. The lid may, for example, be a hinged lid, a snap-fit lid or lid that is connected by a screw thread.

In each of the examples of article described above (including each of the articles shown in Figs. 1 to 8), the first and second aerosol-generating materials 4, 5 may have different densities. Otherwise, the aerosol-generating materials of the article maybe the same or different. In other embodiments, the densities of the first and second aerosol-generating materials 4, 5 may be the same.

It has been found that providing different densities of first and second aerosol generating materials 4, 5 means that the higher density material heats up slower when both materials are exposed to the same heating and thus the higher density material will release its volatile compounds (e.g. nicotine) at a slower rate than the lower density material. In some embodiments, the second aerosol-generating material 5 has a greater density than the first aerosol-generating material 4 so that the second aerosol generating material 5 heats up slower than the first aerosol generating material 4 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 4 (however, in other embodiments the reverse may be true such that the first aerosol generating material 4 has a higher density than the second aerosol generating material 5). Thus, combining aerosol-generating materials with different densities provides a more consistent and longer-lasting release of volatile compound(s). In some embodiments, the aerosol- generating materials of different densities are combined with separate heating of these materials at optionally different times and/or different temperatures, thereby allowing the provision of a more tailored release of the volatile compound(s) over the period of consumption of the article, for example 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, one of the first and second aerosol generating materials 4, 5 has a density that is at least about 25% higher than the density of the other one of the first and second aerosol generating materials 4, 5 and, optionally, at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70% or 75% higher. The said one of the first and second aerosol generating materials 4, 5 may have a density that is no more than about 200% higher than the density of the other one of the first and second aerosol generating materials 4, 5 and, optionally, no more than about 150%, 125%, 100% or 75% higher. In some embodiments, the one of the first and second aerosol generating materials 4, 5 has a density that is from about 25% to about 75% higher than the density of the other one of the first and second aerosol generating materials 4, 5. In some embodiments, said one of the first and second aerosol generating materials 4, 5 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 said one of the first and second aerosol generating materials 4, 5 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 said one of the first and second aerosol generating materials 4, 5 is from about 0.4 to 1.99 g/cm3.

In some embodiments, the said other one of the first and second aerosol generating materials 4, 5 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 said other one of the first and second aerosol generating materials 4, 5 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 said other one of the first and second aerosolgenerating materials 4, 5 is from about 0.1 to 0.9 g/cm3. In some embodiments, the first and second aerosol-generating materials 4, 5 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 4, 5 comprise different components (and may have the same or different densities). 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 4 and the second aerosolgenerating material 5 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 maybe pre-processed or unprocessed, and maybe, 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 4, 5 may comprise different tobacco. Alternatively, the tobacco may be the same, but is provided in a different form, so that one of the first and second aerosol-generating materials 4, 5 has a greater density than the other one of the first and second aerosol-generating materials 4, 5.

In some embodiments, the first aerosol-generating material 4 has at least one (further) different characteristic to the second aerosol generating material 5. 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 4, 5 (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 4, 5 do not have a different characteristic, other than their different densities. In other embodiments, the densities of the first and second aerosol generating materials 4, 5 is the same.

In some embodiments, sheet 2 of the first aerosol-generating material 4 may be formed from cut rag. This tobacco material may lamina or reconstituted tobacco material. In some embodiments, the second aerosol-generating material 5 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.

In some embodiments, the second aerosol-generating material 5 has a greater density than the first aerosol-generating material 4. In some embodiments, this more dense, second aerosol-generating material 5 comprises particles or may be in the form of beads or one or more sheets. Each bead or sheet may be formed from smaller particles that have been agglomerated. However, it should be recognised that in other embodiments, the first aerosol-generating material 4 may be denser than the second aerosol generating material 5 or the materials may have the same density. In some embodiments, the both of the first and second aerosol generating materials 4, 5 may be in the form of one or more sheets and, optionally, maybe processed such that one of the first and second aerosol generating materials 4, 5 has a higher density than the other one of the first and second aerosol generating materials 4, 5, wherein the second aerosol generating material 5 is cut into discrete portions that are then held between the sheet 2 of first aerosol generating material 4 within the body 3.

The second aerosol generating material 5 maybe in the form of beads 5. Optionally, the first aerosol generating material 4 may comprise beads that are incorporated into the sheet 2.

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.

In some embodiments, the desired density of the aerosol-generating material 4, 5 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 first and/ or second aerosol-generating material 4, 5 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 aerosol- generating material (e.g. a more dense first or second aerosol generating material 4, 5), 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 may be 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 too 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 may be 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 may be 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 higher density of the first or second aerosol-generating material 4, 5, where desired. However, in other embodiments, the extrudate may be further treated to increase the density of the first or second aerosol-generating material 4, 5.

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 beads of the second aerosol-generating material 5 were produced as follows (but note that in some embodiments samples may be produced according to the below, which are instead used for the first aerosol generating material 4, for example, being incorporated into the sheet 2 such as being cast in a slurry to form the sheet 2).

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

Table i

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 65°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 other one of the first and/or second aerosol-generating material 4, 5 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 (denser) one of the first and second aerosol-generating material 4, 5, such as particle size, but will have a lower density. As described above, there are various ways to adjust the density of the aerosol-generating material 4, 5, such as the formulation and/or the processing of the material into particles, beads or pellets. In some embodiments, said one of the first and second aerosol-generating materials 4, 5 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 other one of the first and second aerosol-generating materials 4, 5 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 said one of the first and second aerosol-generating materials 4, 5 may be from about 8 to about 15%. The said one of the first and second aerosol-generating materials 4, 5 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 4 and about 50% of the second aerosolgenerating material 5, by weight. Thus, for example, an article comprising 260 mg of aerosol-generating material may comprise 130 mg of the first aerosol-generating material 4 and 130 mg of the second aerosol-generating material 5. In some embodiments where 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 may be 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 4, 5 have the same nicotine content.

In some embodiments, the first and second aerosol-generating materials 4, 5 comprise one or more volatile components. In some embodiments, the first and second aerosol- generating materials 4, 5 have the same volatile component content.

In some embodiments, the first and/or second aerosol-generating materials 4, 5 comprise tobacco. For example, the first and/or second aerosol-generating materials 4, 5 may comprise from about 80 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 4, for example comprising a blend of lamina and reconstituted tobacco in sheet form, and 130 mg of a second aerosol-generating material 5, for example comprising higher density tobacco beads.

In some embodiments, the article comprises regions of aerosol-generating material, wherein each region comprises 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.

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

- 54 -

Claims

1. An article for use in an aerosol provision system, the article comprising: a sheet material comprising a first aerosol generating material, wherein the sheet material is gathered to form a body; and, a second aerosol generating material that is engaged by the sheet material such that the second aerosol generating material is held within the body by the sheet material. 2. An article according to claim 1, wherein the second aerosol generating material is held within the body by friction.

3. An article according to claim 1 or claim 2, wherein the second aerosol generating material is held between portions of the sheet material and, preferably, wherein the body comprises a plurality of layers of the sheet material and the second aerosol generating material is held between the layers of the sheet material.

4. An article according to any one of the preceding claims, wherein the sheet material is formed into strips or strands, wherein the second aerosol generating material is held between the strips or strands.

5. An article according to claim 4, wherein the strips or strands extend in a direction from a first end towards a second end of the article. 6. An article according to any one of the preceding claims, wherein the sheet material is crimped.

7. An article according to any one of the preceding claims, wherein the article does not comprise additive or binder to retain the second aerosol generating material within the body.

8. An article according to any one of the preceding claims, wherein the body of material extends from a first end of the article to a second end of the article. . An article according to any one of the preceding claims, wherein the first and second aerosol generating materials form a collation of aerosol generating material that - 55 - extends at least 90% of the length of the article and, preferably, at least 92%, 94%, 96%, 98% or 99% of the length of the article and, preferably, extends the entire length of the article. 10. An article according to any one of the preceding claims, wherein the first and/ or second aerosol generating material comprises, consists of, or essentially consists of, tobacco material.

11. An article according to claim 10, wherein the first aerosol generating material comprises reconstituted tobacco.

12. An article according to claim 10 or claim 11, wherein the first aerosol generating material comprises tobacco lamina. 13. An article according to any one of claims 1 to 9, wherein the first aerosol generating material is substantially tobacco free.

14. An article according to any one of the preceding claims, wherein the first aerosol generating material comprises a filler.

15. An article according to claim 14, wherein the filler is a non-tobacco fibre.

16. An article according to claim 14 or claim 15, wherein the filler is wood fibre or pulp or wheat fibre.

17. An article according to any one of claims 14 to 16, wherein the filler comprises cellulose.

18. An article according to any one of claims 14 to 17, wherein the filler is a non- tobacco cast material or a non-tobacco extruded material.

19. An article according to any one of the preceding claims, wherein the article comprises an aerosol-former material. 20. An article according to claim 19, wherein the first and/ or second aerosol generating material comprises the aerosol-former material. - 56 -

21. An article according to claim 19 or claim 20, wherein the aerosol-former material comprises one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso- Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. 22. An article according to any one of the preceding claims, wherein the second aerosol generating material comprises extruded and/or compressed aerosol generating material and, preferably, comprises extruded and/or compressed tobacco.

23. An article according to any one of the preceding claims, wherein the second aerosol generating material comprises beads of aerosol generating material.

24. An article according to claim 22, wherein the beads have a particle size in the range of about 0.5 mm to about 3 mm . 25. An article according to any one of the preceding claims, wherein first and second aerosol generating materials have different densities and, preferably, the density of the second aerosol-generating material is at least 25% higher than the density of the first aerosol-generating material. 26. An article according to any one of the preceding claims, wherein the second aerosol-generating material has a density in the range of about 0.4 g/cm3 to about 2 g/cm3.

27. An article according to any one of the preceding claims, wherein the first aerosol-generating material with a density in the range of about 0.1 g/ cm3 to about 1 g/cm3.

28. An article according to any one of the preceding claims, wherein the second aerosol generating material comprises fibres of aerosol generating material. - 57 -

29. An article according to any one of the preceding claims, wherein the sheet material comprises aerosol-generating material comprising: from about 10 to about 50 wt% aerosol-former material; from about 15 to about 60 wt% gelling agent; and optionally filler; wherein the wt% values are calculated on a dry weight basis.

30. An article according to any one of the preceding claims, wherein the aerosolgenerating material of the sheet comprises a flavourant.

31. An article according to any one of the preceding claims, wherein the sheet material is resiliency deformable.

32. An article according to any one of the preceding claims, the first and second aerosol-generating materials are present in the article in a ratio of from 1:10 to 10:1, by weight.

33. An article according to any one of the preceding claims, wherein the article comprises from about 20 to about 330 mg of the first aerosol generating material and, preferably, from about 50 to about 300 mg, or from about 40 to about 125 mg of the first aerosol generating material.

34. An article according to any one of the preceding claims, wherein the article comprises from about 20 to about 330 mg of the second aerosol generating material and, preferably, from about 50 to about 300 mg, or from about 40 to about 125 mg of the second aerosol generating material.

35. An article according to any one of the preceding claims, comprising a cooling element immediately downstream of the body.

36. An article according to claim 35, wherein the cooling element comprises a hollow channel.

37. An article according to claim 35 or claim 36, comprising a further body of material downstream of the cooling element. 38. An article according to claim 37, wherein the further body of material comprises flavouring and/or filtering material. 39. An article according to any one of the preceding claims, comprising a segment upstream of the body. 40. A method of manufacturing an article for use in an aerosol provision system, the method comprising: providing a sheet material comprising a first aerosol generating material; providing a second aerosol generating material; and, gathering the sheet material to form a body such that the second aerosol generating material is engaged by the sheet material such that the second aerosol generating material is held within the body by the sheet material.

41. A method according to claim 40, comprising combining the sheet material and the second aerosol generating material and then gathering the sheet material to form the body.

42. A method according to claim 40, comprising combining the sheet material and the second aerosol generating material whilst gathering the sheet material to form the body.

43. A method according to any one of claims 40 to 42, comprising forming the sheet material into strips or stands.

44. A method according to claim 43, comprising shredding and/or cutting the sheet material.

45. A method according to claim 43 or claim 44, wherein the strips or strands extend in a direction from a first end towards a second end of the article. 46. A method according to any one of claims 40 to 45, comprising crimping the sheet material.

47. A method according to any one of claims 40 to 46, wherein gathering the sheet material comprises gathering the sheet material such that the second aerosol generating material is held between portions of the sheet material and, preferably, such that the body comprises a plurality of layers of the sheet material and the second aerosol generating material is held between the layers of the sheet material.

48. A method according to any one of claims 40 to 47, wherein the method does not comprise using additive or binder to hold the second aerosol generating material within the body.

49. A method according to any one of claims 40 to 48, wherein the first and/ or second aerosol generating material comprises, consists of, or essentially consists of, tobacco material.

50. A method according to claim 49, wherein the first aerosol generating material comprises reconstituted tobacco. 51. A method according to claim 49 or claim 50, wherein the first aerosol generating material comprises tobacco lamina.

52. A method according to any one of claims 40 to 51, wherein the first aerosol generating material is substantially tobacco free.

53. A method according to any one of claims 40 to 52, wherein the first aerosol generating material comprises a filler.

54. A method according to claim 53, wherein the filler is a non-tobacco fibre.

55. A method according to claim 53 or claim 54, wherein the filler is wood fibre or pulp or wheat fibre.

56. A method according to any one of claims 53 to 55, wherein the filler comprises cellulose.

57. A method according to any one of claims 53 to 56, wherein the filler is a nontobacco cast material or a non-tobacco extruded material. 58. A method according to any one of claims 40 to 57, wherein the article comprises an aerosol-former material. 59. A method according to claim 58, wherein the first and/ or second aerosol generating material comprises the aerosol-former material. 60. A method according to claim 58 or claim 59, wherein the aerosol-former material comprises one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso- Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

61. A method according to any one of claims 40 to 60, wherein the second aerosol generating material comprises extruded and/or compressed aerosol generating material and, preferably, comprises extruded and/or compressed tobacco.

62. A method according to any one of claims 40 to 61, wherein the second aerosol generating material comprises beads of aerosol generating material.

63. A method according to any one of claims 40 to 3962 wherein the second aerosol generating material comprises fibres of aerosol generating material.

64. A method according to any one of claims 40 to 63, wherein the first and second aerosol generating materials have different densities and, preferably, the density of the second aerosol generating material is at least 25% higher than the density of the first aerosol generating material.

65. A method according to any one of claims 40 to 64, wherein the sheet material comprises aerosol-generating material comprising: from about 10 to about 50 wt% aerosol-former material; from about 15 to about 60 wt% gelling agent; and optionally filler; wherein the wt% values are calculated on a dry weight basis.

66. A method according to claim 65, wherein the aerosol generating material of the sheet material comprises a flavourant. 67. A method according to any one of claims 40 to 66, wherein the sheet material is resiliently deformable and wherein gathering the sheet material causes the second - 61 - aerosol generating material to be held between regions of the sheet material such that the sheet material is resiliently deformed.

68. A method according to any one of claims 40 to 67, comprising a cooling element immediately downstream of the body.

69. A method according to claim 68, wherein the cooling element comprises a hollow channel. 70. A method according to claim 68 or claim 69, comprising a further body of material downstream of the cooling element.

71. A method according to claim 70, wherein the further body of material comprises flavouring and/or filtering material.

72. A method according to any one claims 40 to 71, comprising a segment upstream of the body.

73. A method according to any one of claims 40 to 72, wherein the article comprises from about 20 to about 330 mg of the second aerosol generating material and, preferably, from about 50 to about 300 mg, or from about 40 to about 125 mg of the second aerosol generating material.

74. An article manufactured according to the method of any one of claims 40 to 73.

75. A package comprising a plurality of articles according to any one of claims 1 to 39 or claim 74 and, preferably, wherein the package is hermetically sealed.

76. A kit of parts comprising an article according to any one of claims 1 to 39 or claim 74 and an aerosol provision device.

77. A kit of parts according to claim 76, wherein the aerosol provision device comprises a heating zone for receiving the article to heat the first and second aerosol generating materials.