WO2024094781A1

WO2024094781A1 - Aerosol-generating beads, processes for preparing said beads, and compositions and articles comprising said beads

Info

Publication number: WO2024094781A1
Application number: PCT/EP2023/080521
Authority: WO
Inventors: Katherine CONNER; Cortney JACKSON; Thaddeus JACKSON; John Mua; Timothy Williams
Original assignee: Nicoventures Trading Limited
Priority date: 2022-11-03
Filing date: 2023-11-02
Publication date: 2024-05-10

Abstract

This invention relates to process for preparing beads for use as an aerosol-generating material in an aerosol provision system comprising extruding a mixture to form an extrudate, cutting the extrudate to form beads; and drying the beads at a temperature no higher than 45°C to reduce their moisture content to no less than about 10% by weight. This invention also relates to the aerosol-generating material comprising at least one said bead, as well as to articles comprising the aerosol-generating material.

Description

Aerosol-generating beads, processes for preparing said beads, and compositions and articles comprising said beads

Field This invention relates to processes for preparing beads for use as an aerosol-generating material in an aerosol provision system, and aerosol-generating materials comprising at least one extruded and dried bead, and articles for use in an aerosol provision system, the article comprising the aerosol-generating material. Background

Tobacco material or a tobacco extract may be used in combustible and non-combustible aerosol-generating devices, including hybrid devices and tobacco heating products, to provide the user with an aerosol with an authentic tobacco taste and texture. One issue encountered with such materials is that the processes used to produce them can negatively impact the flavour. For example, volatile compounds may evaporate and marmorisation of the material may occur in the drying process. An additional problem may be the moisture content of such materials may have a negative effect on the flavour and the flavour profile over time of the material whilst in use. There is therefore a need to improve the flavour of the aerosol-generating material.

Summary

According to a first aspect of the invention there is provided a process for preparing beads for use as an aerosol-generating material in an aerosol provision system, the process comprising: extruding a mixture to form an extrudate, the mixture comprising: plant particles, an aerosol former material and water; cutting the extrudate to form beads; and drying the beads by heating them to a temperature no higher than about 45°C to reduce their moisture content to no less than about 10% by weight.

In some embodiments, the beads are dried to reduce their moisture content to no less than about 13% by weight.

In some embodiments, the beads are dried to reduce their moisture content to no greater than about 20% by weight. In some embodiments, the beads are heated to a temperature no higher than about 35°C. In some embodiments, the beads are dried using heated air dryer or a fluid bed processor.

In some embodiments, the beads are dried using forced heated air flow which moves the beads.

In some embodiments, the beads are exposed to air flow heated to a temperature of from about 3O°C to about 45°C.

In some embodiments, the beads are dried for up to about to hours, and optionally for up to about 2 hours.

In some embodiments, the cut extrudate is spheronised.

In some embodiments, the mixture further comprises one or more of: a binder, a filler and a flavour.

According to a second aspect of the invention, there is provided an aerosol-generating material comprising at least one extruded and dried bead comprising plant particles and an aerosol former material and having a moisture content of no less than about 10% by weight.

In some embodiments, the bead has a diameter of from about 0.5 to about 5 mm.

In some embodiments, the bead has a moisture content of no less than about 13% by weight.

In some embodiments, the bead has a moisture content of no greater than about 20% by weight. In some embodiments, the bead comprises the plant particles in an amount of from about 10 to about 80% by weight, optionally from about 25% to about 80% by weight. In some embodiments, the plant particles have a diameter of no greater than about 0.5 mm, optionally wherein the plant particles have a diameter of no greater than about 0.1 mm or no greater than about 0.06 mm.

In some embodiments, the bead comprises the aerosol former material in an amount of from about 1% to about 50% by weight, optionally from about 10 to about 30% or from about 15 to about 20% by weight. In some embodiments, the aerosol former material is selected from the group consisting of: glycerine, 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 bead comprises a binder in an amount of from about 0.01% to about 5% by weight, optionally from about 0.5 to about 1.5% by weight. In some embodiments, the binder is selected from the group consisting of: thermoreversible gelling agents such as gelatin, starches, polysaccharides, pectins, alginates, wood pulp, celluloses, and cellulose derivatives such as carboxymethylcellulose. In some embodiments, the bead further comprises a filler in an amount of from about 0.01% to about 40% by weight, optionally from about 10 to about 35% by weight or from about 15 to about 30% by weight.

In some mebodiments, the filler is selected from the group consisting of: calcium carbonate, microcrystalline cellulose, wood fibres, carboxymethylcellulose, titanium dioxide, sodium carbonate, clay, limestone, talc, and gypsum.

In some embodiments, the bead further comprises a flavour, optionally in an amount from about 0.01% to about 5% by weight, optionally from about 2 to about 4% by weight. In some embodiments, the aerosol-generating material further comprises a different form of plant material in addition to the beads.

According to a third aspect of the present invention, there is provided an article for use in an aerosol provision system, the article comprising an aerosol-generating material according to the second aspect.

In some embodiments, the article comprises a section comprising the aerosolgenerating material comprising the beads, and further comprising one or more sections of reconstituted plant material.

In some embodiments, the article further comprises a filter at or near a mouth end of the article. In some embodiments, the article further comprises a cooling segment positioned between the section of aerosol-generating material and a mouth end of the article.

In some embodiments, the article has a rod shape and the section of aerosol-generating material is cylindrical.

In some embodiments, the article comprises a chamber holding the aerosol-generating material comprising the beads.

In some embodiments, the article comprises a removable cartridge with a housing that defines an inner chamber in which the beads are retained.

According to a fourth aspect of the invention, there is provided an aerosol provision system comprising an aerosol provision device and an article according to the third aspect, and wherein the device comprises a heating system configured to heat the aerosolgenerating material to generate an aerosol.

Brief Description of the Drawings

Embodiments of the invention will now be described, by way of example only, with reference to accompanying drawings, in which: Figure i shows a section view of an example of a consumable comprising an aerosolgenerating material as described herein.

Figure 2 shows a perspective view of the consumable of Figure i.

Figure 3 is an exemplary rod of aerosol-generating material comprising sections of different aerosol-generating materials.

Figure 4 is a further exemplary rod of aerosol-generating material with an alternative configuration of sections of different aerosol-generating materials.

Detailed Description In a first aspect of the invention, there is provided a process for preparing beads for use as an aerosol-generating material in an aerosol provision system. These beads comprise plant material. In some embodiments, the beads comprise tobacco and/or other plant material. The plant material may comprise an active and/or flavour component that is to be present in the aerosol generated by heating the beads.

An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. The aerosol-generating material may be used in aerosol provision systems, which may be non-combustible. The present invention addresses some of the most significant shortcomings of conventional tobacco heating products and aerosol provision systems, namely the provision of an aerosol that provides an authentic tobacco taste.

It is known to produce tobacco beads by extruding tobacco material with a subsequent drying step. However, the conventional processing of such known beads can lead to a significant loss of desirable tobacco components that contribute to the organoleptic properties of the aerosol generated when such beads are heated. Specifically, the drying step conventionally used involves heating the beads to temperatures of 5O°C or higher to drive off the excess moisture. At the same time, heating to these temperatures will also drive off volatile and semi-volatile components, such as flavour and aroma components and nicotine from the tobacco starting material, that are present in the bead before the drying step.

The present invention provides plant-based beads that provide an improved and enduring taste to the user. In particular, the improved processes used to prepare the beads ensure that the desirable components are retained in the beads, so that they can contribute to the improved aerosol generated therefrom. Specifically, according to the present invention, the beads are prepared using lower drying temperatures and less moisture is extracted from the beads as a result of the drying step. The gentler process results in beads having a higher moisture content than is conventionally seen and a higher content of volatile and semi-volatile plant components that contribute positively to the properties of the aerosol generated when the beads are heated, for example, in an aerosol provision system.

The invention described herein enjoys the advantage that the beads, and aerosol - generating material including such beads, may contain more flavour components than conventionally produced tobacco beads.

Compared to tobacco beads generated by conventional processes, the beads prepared by the inventive process described herein may provide a more consistent and more gradual release of the volatile and semi-volatile plant components. The aerosolgenerating material comprising the beads of the invention may also deliver an improved taste to the user over a longer period of time. In some embodiments, the beads have a specific release profile, wherein the active and / or flavour notes may be released gradually and consistently over time and delivered to the user.

The flavour may be that of the plant material, such as tobacco, included in the bead and/or that of any additional flavours or components. The inventors have found that the lower drying temperature and the higher moisture content of the dried beads together provide this particularly well delivered flavour which affords the aforementioned release profile and flavour advantages.

Another benefit of the present invention is that in some embodiments, the beads, and aerosol-generating material comprising such beads, may deliver more than one flavour, added flavour, sensation or active substance to the user. In some embodiments, a mix of flavours, sensations or active substances is delivered to the user. In some embodiments, the profile of flavours, sensations or active substances delivered to the user may change over time.

In some embodiments, an aerosol-generating material comprises more than one bead, wherein the beads comprise different flavours, plant material or added substances, for example added flavours, sensates or active substances, as described herein. In some embodiments, the aerosol-generating material comprises beads with different added substances, which may be mixed together to provide a mix of flavours, sensations or active substances to the user. The added flavour is an additional favour component that is delivered to the user in addition to that of the flavour of the plant material in the bead.

The processes for preparing tobacco beads disclosed herein involve extruding a mixture to form an extrudate. The mixture to be extruded comprises plant particles, an aerosol former material, a binder and water.

In some embodiments, the mixture and beads comprise the same components. In some embodiments, the mixture, beads and the aerosol-generating material comprising at least one bead comprise the same components. The mixture to be extruded may be in the form of a slurry, a suspension, a gel, a liquid or a solid.

In some embodiments, the mixture and/or beads comprise plant particles, an aerosol former material, a binder and water.

In one of the embodiments that maybe preferred, the plant particles used to form the beads are derived from tobacco. Whilst much of the following discussion refers specifically to tobacco particles and to tobacco beads, it is intended that this disclosure is also relevant to material from other plants. In particular, this invention is relevant to plant material that comprises at least one of an active substance and/or flavour.

The plant particles used in the processes and products discussed herein may comprise any form of suitable plant material. In some embodiments, the plant particles comprise milled plant material. In some embodiments, the plant particles consist of plant tobacco. The plant particles may be in the form of a powder or a free-flowing powder.

In some embodiments, the plant particles are formed from tobacco. For example, the tobacco particles are milled tobacco material. In other embodiments, alternative botanical materials can also be used in conjunction with or instead of tobacco. The tobacco material may be from or may be any type of tobacco and any part of the tobacco plant, including tobacco 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 may be expanded, such as dry-ice expanded tobacco (DIET), or processed by any other means. In some embodiments, the tobacco material may be reconstituted tobacco material. The tobacco may be 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 maybe fermented, cured, uncured, toasted, or otherwise pre-treated. The tobacco material maybe provided in the form of cut rag tobacco. The cut rag tobacco can have a cut width of at least 15 cuts per inch (about 5.9 cuts per cm, equivalent to a cut width of about 1.7 mm) for example. The cut rag tobacco can be formed from a mixture of forms of tobacco material, for instance a mixture of one or more of paper reconstituted tobacco, leaf tobacco, extruded tobacco and bandcast tobacco.

In some embodiments, the plant particles have a diameter no greater than about 5 mm, no greater than about 4 mm, no greater than about 3 mm, no greater than about 2 mm, no greater than about 1 mm, no greater than about 0.5 mm, no greater than about 0.1 mm, no greater than about 0.08 mm, no greater than about 0.06 mm, or no greater than about 0.03 mm. In some embodiments, the plant particles have a diameter no greater than about 0.06 mm. In some embodiments, the plant particles have a diameter of at least about 0.2 mm, at least about 0.5 mm, at least about 1 mm, or at least about 2 mm.

The size of the plant particles is advantageously small enough to form a mixture that is suitable to be extruded. The plant particle size may be measured by sieving or by observing the size of the particles by SEM. If necessary, the plant particles or the mixture may be processed to ensure that they do not include particles with a size greater than desired when measured by sieving.

In some embodiments, the mixture and/or beads comprise at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, at least about 30 wt%, at least about 35 wt%, or at least about 40 wt% plant particles (calculated on a wet weight basis). Additionally or alternatively, the mixture or beads comprise up to about 80 wt%, up to about 70 wt%, up to about 60 wt%, up to about 55 wt%, up to about 50 wt%, up to about 45 wt%, or up to about 40 wt% plant particles (calculated on a wet weight basis). In some embodiments, the mixture or beads comprise from about 20 wt% to about 40 wt% plant particles (calculated on a wet weight basis). In some embodiments, these plant particles are tobacco particles. In some embodiments, the mixture and/or beads comprise the aerosol former material in an amount of from about 1% to about 50%. In some embodiments, the mixture and/or beads comprises the aerosol former material in an amount of from about 5% to about 40%, from about 10% to about 30% or from about 15% to about 20%. 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, , 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 mixture and/or beads comprises the binder in an amount of from about 0.1% to about 5%. In some embodiments, the mixture and/or beads comprises the binder in an amount of from about 0.1% to about 5%, from about 0.5% to about 4.5%, from about 0.5% to about 3%, or from about 0.5% to about 1.5%. The binder may be selected from the group consisting of: thermo reversible gelling agents such as gelatin, starches, polysaccharides, pectins, alginates, wood pulp, celluloses, and cellulose derivatives such as carboxymethylcellulose, or a combination thereof.

Extrusion

The mixture is extruded to produce an extrudate.

Extrusion may be performed using one of the main classes of extruders: screw, sieve and basket, roll, ram and pin barrel extruders. This has the advantage that this processing combines mixing, conditioning, homogenizing and moulding of the components of the mixture. An additional advantage is that extrusion provides an even distribution of the components through the extrudate. In embodiment wherein a flavour is added to the mixture, the extrusion process helps to further structurally integrate the flavour into the extrudate and modify the release profile from the ultimate bead. The extrudate may be in any suitable format. In some embodiments, the extrudate is in the form of strands or rods. In some embodiments, the extruded strands are about 0.5 to about 3 mm in width. In some embodiments, the strands are about 1 to about 2 mm in width. The width of the strand maybe selected to improve the speed of extrusion, and/or to provide beads of the desired size. The extrudate may be cut to form pieces of extrudate. In some embodiments, the extrudate is cut as or very shortly after the extrudate exits the die of the extruder. In other embodiments, the strands of extrudate maybe cut in a separate processing step, optionally in a location removed from the extruder. In some embodiments, the extruded strands are cut to pieces having a length of about 0.5 to about 3 mm. In some embodiments, the cut pieces of extrudate have a length of about 1 to about 2 mm. The length of the pieces to which the extruded strand are cut maybe selected to provide beads of the desired size. In some embodiments, the cut pieces of extruded strands have a length that is roughly the same as their width.

Spheronisation

In some embodiments, the cut pieces of extrudate may undergo additional processing to adjust their size and/or shape, for example to render them more uniform and/or more spherical. In some embodiments, the process for preparing the beads includes a spheronisation step (also referred to as marmorisation or pelletisation).

Spheronisation is the process of making substantially uniformly sized spherical particles commonly referred to as spheres, spheroids or pellets The advantage of spheronisation is that the resultant beads are of a substantially consistent size and/or shape. This makes handling, packing and processing the beads and/or aerosolgenerating material comprising the beads easier. In addition, this allows for more accurate quantities of the beads to be measured and included in an article, which in turn provides an accurate and predictable amount of flavour or other components in the article. Advantageously, the particles are in a sphere or spheroid shape. This can be advantageous for packing in an article and providing a favourable air-flow through the article and the aerosol-generating device. Drying

The drying step comprises lowering the moisture content of the beads and the purpose of drying is to remove moisture from the bead that has been formed. This is achieved using any suitable equipment, which may include ovens, heaters, hot air or other apparatus. Different types of drying apparatus are known and these are usually selected based upon the desired moisture content of the resultant dried beads, and upon the chemical and physical properties of the beads to be dried. In some embodiments of the invention, the drying apparatus uses the flow of heated air to move beads up and down. In some embodiments, the drying apparatus is a fluid bed processor, for example a Flo Coater Granulator and/ or a Granulator VFC 6oM. A fluid bed processor provides the advantage that the apparatus can be configured to provide suitable drying conditions.

Preferred drying steps or processes are those that do not result in any significant change to the morphology, density and size of the bead. This means that the extrusion, cutting and optional spheronisation may be carried out to make dried beads of known and desired morphology, density and size.

In some embodiments, the drying step heats the beads to a temperature that is no greater than 45°C. In some embodiments, the temperature of the beads is heated during the drying step to no greater than 4O°C, 35°C, 3O°C, or 25°C. In some embodiments, the temperature of the mixture or the beads does not exceed 45°C at any point during the process of preparing the beads. The drying step may involve exposing the beads to heated air flow. In some embodiments, the beads are exposed to air flow heated to a temperature of from about 3O°C to about 45°C.

In some embodiments, the drying time may be up to about 10 hours. The drying time will be selected depending on the drying temperature. This is because the intention is to dry the beads to a target moisture content using a lower drying temperature. The batch size and components of the bead can also affect the time required to dry the bead to a target moisture content. In some embodiments, the drying time may be up to about 8 hours, up to about 6 hours, up to about 4 hours, up to about 2 hours, or up to about 1 hours. In some embodiments, the drying time is at least about 30 minutes, at least about 60 minutes, at least about 90 minutes, at least about 120 minutes, at least about i8o minutes, at least about 240 minutes, or at least about 300 minutes. For example, in some embodiments, the beads may be dried for 1 hour at 45°C to reach a moisture content of 13%. In another example, the beads maybe dried for 2 hours at 35°C to reach a moisture content of 13%. In some embodiments, the beads maybe dried until they have a moisture content in the range of from about 5% to about 30%.

According to the processes described herein, the beads are heated for longer at a lower temperature than in conventional processes, retaining more components of the starting material and thereby providing a particularly intense and consistent taste to the end user when the beads are used to generate an aerosol. The gentler drying process may leave the beads with a more even distribution of the flavour, which is then delivered to the user whilst in use.

It is known that the higher the drying temperatures, the more volatile compounds are released during processing. Unexpectedly, the inventors have found that when drying the beads using a temperature that is no greater than 45°C, the beads have a particularly satisfactory flavour and flavour retention. This effect is even more pronounced when drying the beads using a temperature that is no greater than 35°C. Without wishing to be bound by any particular theory, it is thought that when a higher drying temperature is used, the volatile compounds located toward the outside of the bead may be released and lost during the drying step, whilst those located toward the centre of the bead are retained. In contrast, when the beads are dried at a lower drying temperature as employed in the present invention, these volatile compounds are retained and are therefore present throughout the bead. This provides the user with sustained delivery of taste over time when the beads are heated to form an aerosol.

The determination of moisture content is important in the tobacco industry because moisture has a great influence on tobacco materials, their processing properties and on the finished product itself. The terms “moisture” or “moisture content” are used to refer to water content of a material. The water content can be determined by Karl-Fisher analysis or by gas chromatography-thermal conductivity detector (GC-TCD), as known to those skilled in the art. Karl Fischer titration is a classic method of chemical analysis for reliably determining the amount of water in a sample, and even just trace amounts. The method can be readily carried out using an automated Karl Fischer titrator.

Similarly, the use of GC-TCD is also a well-established method for reliably determining the water content in a sample. Unless stated otherwise, references to moisture content herein are references to the moisture content as measured by Karl Fischer.

The processes disclosed herein include drying the beads to a moisture content of from about o% to about 30% by weight. In some embodiments, the moisture content is reduced to no less than about 20%, to no less than about 15% by weight, to no less than about 13% by weight, to no less than about 6% by weight or to about 0% by weight.

In some embodiments, the beads are dried to a moisture content of no greater than about 20% by weight, no greater than about 18%, or no greater than 15% by weight.

Also, the dried beads disclosed herein, and optionally prepared using the processes disclosed herein, have a moisture content of no less than about 10% by weight. In some embodiments, the bead has a moisture content of no less than about 13%, or no less that about 15% by weight.

In some embodiments, the bead has a moisture content of no greater than about 20% by weight, no greater than about 18%, or no greater than about 15% by weight. It is important to dry the beads to a suitable moisture content. If the moisture content is too low, for example 9% or less, the bead loses its flavour. If the moisture content is 6% or less, flavour components and nicotine may be lost, for example through evaporation or flash evaporation. In addition, the texture of the bead changes. If the moisture content is too high, then this may have a negative effect on the shelflife of the beads, for example due to the increased microbial growth or increased amounts of Tobacco-Specific Nitrosamines (TSNAs) developing over time. In addition, if the moisture content is too high, this can have a negative impact on the flavour profile of the beads. A high moisture content, such as above 20%, may increase the sensorial aerosol warmth or “hot puff’ as described herein. Finally, beads with higher moisture content may also be less suitable for machine processing.

Without wishing to be bound by any particular theory, it is thought that the lower drying temperature and the higher moisture content of the beads changes the chemical make-up of the beads, such that chemical make-up is different and this locks in flavours. Unexpectedly, the inventors have found that despite the higher moisture content of the beads, the beads are still resistant to microbial growth. This provides the further advantage of contributing to the long shelflife of the beads. Without wishing to be bound by any particular theory, it is thought that a combination of the nicotine content and the moisture content of less than 20% inhibits bacteria and/or mould growth.

In another unexpected finding, the inventors have found that despite the higher moisture content of the beads, users have not noted “hot puff’ when using the beads in an aerosol-generating device. “Hot puff’ is the sensation of evaporated moisture that is commonly associated in aerosol-generating materials with higher moisture contents and is commonly considered negatively by users. Without wishing to be bound by any particular theory, it is thought that the increase in the surface area and the depth or density of the bead matrix results in a more gradual release of moisture, and thereby reduces the chance of experiencing a “hot puff’.

This means that the beads may have a higher moisture content without the disadvantages usually associated with aerosol-generating materials that have higher moisture contents. (Tobacco) beads

The beads may be substantially spherical or spheroid in shape. In some embodiments, the beads have an uneven shape. In some embodiments, the size of the tobacco beads ranges from about 1 mm to about 2 mm in one dimension. In some embodiments, the size of the beads ranges from about 1.2 mm to about 1.8 mm, or from about 1.4 mm to about 1.6 mm. The size of the beads may be selected to provide the optimal surface-area to volume ratio to control the aerosol generation and release of volatile components, thereby providing the user with a desired strength of taste, and producing a sustained generation of flavour over the period of use. In addition, the particle size maybe selected to be suitable to be incorporated in the aerosol-generating material in an article.

In some embodiments, the beads have a shelflife of at least 6 months, at least 8 months, at least 1 year. The term shelflife means that the flavour is stable for this period of time, and the bead provides the same taste delivery profile after this period of time. The beads enj oy the benefit of being easy to store and transport. An additional advantage of the beads and aerosol-generating material comprising at least one such bead, is that the beads are free flowing. This makes them easy to add into a consumable and remove, or to combine with other material to form an aerosolgenerating material.

In some embodiments, the mixture and the beads comprise plant particles formed from different plants or different parts of the plant, which provide different tastes and/or different active substances to the user. In some embodiments, the mixture and the beads comprise tobacco particles formed from different tobacco materials, which provide different tastes to the user.

Aerosol-generating material

In another aspect of the invention, aerosol-generating material is provided that comprises at least one extruded and dried bead comprising plant particles, a binder and an aerosol former material, and having a moisture content of no less than about 10% by weight.

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

The aerosol-generating material may additionally comprise one or more active substances and/or added flavours, one or more aerosol-former materials, and optionally one or more other functional material, as described herein.

In some embodiments, the aerosol-generating material may comprise a binder or a gel.

This has the advantage that the beads maybe bounds together and form a mass. This alters the surface area to volume ratio of the aerosol-generating material and therefore effects its taste profile. Another advantage of this is that the aerosol-generating materials may not mix together if more than one aerosol-generating material is incorporated into an article.

In some embodiments, the aerosol-generating material has a substantially cylindrical shape or substantially circular cross-section. In some embodiments, the aerosolgenerating material has a cylindrical shape or a circular cross-section. In some embodiments, the section(s) of the aerosol-generating material has a substantially cylindrical shape or substantially circular cross-section. This has the advantage of being an easy shape to handle and use.

In some embodiments, the aerosol-generating material comprises more than one bead, at least some of the beads comprising different compositions. For example, the aerosolgenerating material may comprise at least one first bead comprising a first added flavour or plant material and at least one second bead comprising a second added flavour or plant material. This embodiment enjoys the advantage that the beads with different added flavours can be combined in different proportions to provide a distinct or unique flavour profile to the user.

Alternatively or in addition, the beads may include different aerosol former material or binders, or different amounts of these components. Alternatively or in addition, the beads may have different densities, different shapes and/or different sizes. The composition of the aerosol-generating material may therefore be selected to provide particular flavour to the users. In some embodiments, the aerosol-generating material comprising beads may deliver flavours at different rates. This embodiment enjoys the advantage of providing the different flavours to the user over time, and provide a complex flavour profile.

Added flavours

In some embodiments, the mixture, beads and/or aerosol-generating material additionally comprise at least one added flavour as described herein. In some embodiments, the substance to be delivered comprises an additional flavour, in addition to the flavour and taste provided by the plant material or other components in the bead. As discussed herein, the beads produced by the inventive process provide a particularly enhanced and sustained flavour profile of the added flavour. In some embodiments, the mixture, beads and/or aerosol-generating material does not have an additional flavour. As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers.

In some embodiments, the added flavour may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They maybe imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas. In some embodiments, the flavour comprises menthol, spearmint and/ or peppermint.

In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.

In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

In some embodiments, the beads may comprise one flavour. In some embodiments, the beads may comprise more than one flavour, for example to deliver more than one flavour or a combination of flavours. This embodiment enjoys the advantage that the flavour is homogenously distributed through the bead. The bead retains the flavour during use and provides a sustained flavour profile. Additional components

In some embodiments, the mixture and/or beads and/or aerosol-generating material comprises additional components.

In some embodiments, the mixture and/or beads and/or aerosol-generating material comprises one or more other functional materials, which may comprise one or more of pH regulators, colouring agents, preservatives, fillers, stabilizers, and/or antioxidants.

In some embodiments, the mixture and/or beads and/or aerosol-generating material contains a filler component. The filler component is generally a non-tobacco component, that is, a component that does not include ingredients originating from tobacco. In some embodiments, the precursor material comprises less than 60 wt% of a filler, such as from 1 wt% to 60 wt%, or 5 wt% to 50 wt%, or 5 wt% to 30 wt%, or 10 wt% to 20 wt% on a wet weight basis. The filler provides the advantage of providing a bead with the desired density and size for use. The filler, if present, may comprise one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp, hemp fibre, cellulose and cellulose derivatives. In some embodiments, the filler is selected from the group consisting of: calcium carbonate, carboxymethylcellulose, titanium dioxide, sodium carbonate, clay, limestone, talc, and gypsum. In some embodiments, the mixture and/ or beads and/ or aerosol-generating material comprises one or more active substance. This may be derived from the extract or it may be added. In some embodiments, the extract from a flavour- or active-substance containing plant material comprises an active substance. The active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics and psychoactives. The active substance may 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 additional nicotine. In some embodiments, the mixture and/or beads and/or aerosol-generating material does not comprise additional nicotine.

In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12. In some embodiments, the mixture and/ or beads and/ or aerosol-generating material may comprise an extract from other botanical source(s) along with or instead of the tobacco extract.

As noted herein, the extract 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. The extract may comprise or be derived from botanicals 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, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens In some embodiments, the extract comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the extract comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof selected from rooibos and fennel.

In some embodiments, the mixture and/or beads and/or aerosol-generating material comprises one or more cannabinoid compounds selected from the group consisting of: cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM) and cannabielsoin (CBE), cannabicitran (CBT). 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.

Article In another aspect of the invention, an article for use in an aerosol provision system comprising the inventive aerosol-generating material is provided.

An article comprises or consists of at least one aerosol-generating material, part or all of which is intended to be consumed during use by a user. An article may comprise one or more other components, such as an 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. An article may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

In some cases, the article has a rod shape. In some embodiments, the article may further comprise a wrapper that circumscribes the rod. As used herein, the term “rod” generally refers to an elongate body which may be any suitable shape for use in an aerosol-generating assembly. In some cases, the rod is substantially cylindrical.

Articles comprising the aerosol-generating material enjoy the advantage that they may be biodegradable or comprise biodegradable components. In such embodiments, the article may also comprise a biodegradable wrapper.

In some embodiments, the article may be packed with the aerosol-generating material, wherein the aerosol-generating material fills the capacity of the article and the beads cannot significantly move or roll around. This embodiment has the advantage that the article is easy to handle. In some embodiments, the article comprises more than one aerosol-generating material. For example, one section of the article may comprise a first aerosolgenerating material (for example, comprising beads with a first added flavour), and a different section of the article may comprise a second (different) aerosol-generating material (for example, comprising beads with a second added flavour).

In some embodiments, the article comprises at least one aerosol-generating material comprising at least one extruded and dried bead as described herein, and at least one other form of aerosol-generating material, such as plant material in a different form. In some embodiments, the article may comprise reconstituted plant material in addition to aerosol-generating material comprising at least one extruded and dried bead.

In some embodiments, the article comprises at least one aerosol-generating material comprising at least one extruded and dried tobacco bead as described herein, and at least one other form of aerosol-generating material, such as tobacco in a different form.

In some embodiments, the article may comprise reconstituted tobacco and the aerosolgenerating material comprising at least one extruded and dried tobacco bead. The aerosol-generating material and the reconstituted tobacco maybe in any proportions. In embodiments wherein the article comprises more than one aerosol-generating material, the aerosol-generating materials may be mixed homogenously. Alternatively, in some embodiments, the article may comprise the different aerosol-generating materials in different sections. A section refers to a portion of the article comprising an aerosol-generating material. The sections may have different lengths or sizes, or alternatively have the same size or length

The articles described herein therefore enjoy the advantage of being adaptable and it is envisioned that there are many different arrangements and configurations. These may be selected to provide the user with the best taste profile. In addition, the user may be able to configure the article to comprise the desired proportion of aerosol-generating materials and other forms of plant material, such as tobacco. The user may also adapt the composition, proportion and flavours of the sections and provide a personalised taste profile. In some embodiments, the article may comprise at least two flavours. The flavours may be “layered” and delivered to the user over a period of time. In some embodiments, beads comprising different flavours maybe arranged in layers in the article. For example, an inner layer of beads comprising a first flavour maybe surrounded by an outer layer of beads comprising a second flavour. This provides the advantages that that the differences in exposure to heat result in a dynamic flavour transition between the layers.

Embodiments in which the article comprises at least one other form of plant material in addition to the beads have the advantage of restricting the movement of the beads. This also provides the further advantage of making handling the article easier. For example, the plant material may form a plug at least one end of the article, which advantageously prevents movement or loss of the beads.

In some embodiments, the article further comprises a filter at or near a mouth end of the article. This provides the advantage of filtering the aerosol generated and may also act as a plug preventing the movement or loss of the beads .

In some embodiments, the article further comprises a cooling segment positioned between the section of aerosol-generating material and a mouth end of the article. In some embodiments, the article further comprises a plug. The plug at least partially closes at least one end of the article and prevents loss of the aerosol-generating material from said end(s). The plug may comprise a gel, a metal (such as aluminium) or tobacco, for example. In some embodiments, the article comprises a cartridge in which a housing defines an inner chamber in which the beads may be retained. The housing has an opening through which the beads may be introduced into the inner chamber. The housing of this embodiment may further comprise a cover or lid to close the opening, which prevents the loss of the contents of the inner chamber via the opening. In some embodiments, the article may further comprise means for facilitating the transfer of the beads into the inner chamber. Such means may, for example, be a narrow sleeve, a pop-top, slide opening or funnel integrated into the housing to assist filling the article.

Embodiments wherein the article comprises a cartridge including a housing to retain the beads enjoy the advantage that the article is refillable and therefore need not be disposed of following a single use. This, in turn, has environmental advantages, which may be further enhanced if the beads and/ or the housing are biodegradable.

An additional advantage of the refillable cartridge is that the user can control their own experience, for example, by adding beads comprising particular types of tobacco or flavours (for example comprising at least one added flavour) to provide a customised product and aerosol. This embodiment enjoys the advantage that it provides a personalised flavour to the user. Furthermore, said delivered favour may be multilayered and complex in taste and sensation.

Referring to Figures i and 2, there are shown a partially cut-away section view and a perspective view of an example of article or consumable 101. The article 101 is adapted for use with a device having a power source and a heater. The article 101 of this embodiment is particularly suitable for use with the device 1 shown in Figure 5, described below. In use, the article 101 may be removably inserted into the device shown in Figure 5 at an insertion point 20 of the device 1.

The article 101 of one example is in the form of a substantially cylindrical rod that includes a body of aerosol-generating composition 103 and a filter assembly 105 in the form of a rod. The aerosol-generating composition comprises aerosol-generating material described herein.

The filter assembly 105 of the illustrated embodiment includes three segments, a cooling segment 107, a filter segment 109 and a mouth end segment 111. The article 101 has a first end 113, also known as a mouth end or a proximal end and a second end 115, also known as a distal end. The body of aerosol-generating composition 103 is located towards the distal end 115 of the article 101. In one example, the cooling segment 107 is located adjacent the body of aerosol-generating composition 103 between the body of aerosol-generating composition 103 and the filter segment 109, such that the cooling segment 107 is in an abutting relationship with the aerosol-generating composition 103 and the filter segment 103. In other examples, there may be a separation between the body of aerosol-generating composition 103 and the cooling segment 107 and between the body of aerosol-generating composition 103 and the filter segment 109. The filter segment 109 is located in between the cooling segment 107 and the mouth end segment 111. The mouth end segment 111 is located towards the proximal end 113 of the article

101, adjacent the filter segment 109. In one example, the filter segment 109 is in an abutting relationship with the mouth end segment ill. In one embodiment, the total length of the filter assembly 105 is between 37 mm and 45 mm, more preferably, the total length of the filter assembly 105 is 41 mm. In one example, the rod of aerosol-generating composition 103 is between 34 mm and 50 mm in length, suitably between 38 mm and 46 mm in length, suitably 42 mm in length.

In one example, the total length of the article 101 is between 71 mm and 95 mm, suitably between 79 mm and 87 mm, suitably 83 mm.

An axial end of the body of aerosol-generating composition 103 is visible at the distal end 115 of the article 101. However, in other embodiments, the distal end 115 of the article 101 may comprise an end member (not shown) covering the axial end of the body of aerosol-generating composition 103.

The body of aerosol-generating composition 103 is joined to the filter assembly 105 by annular tipping paper (not shown), which is located substantially around the circumference of the filter assembly 105 to surround the filter assembly 105 and extends partially along the length of the body of aerosol-generating composition 103. In one example, the tipping paper is made of 58 GSM standard tipping base paper. In one example the tipping paper has a length of between 42 mm and 50 mm, suitably of 46 mm. In one example, the cooling segment 107 is an annular tube and is located around and defines an air gap within the cooling segment. The air gap provides a chamber for heated volatilised components generated from the body of aerosol-generating composition 103 to flow. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article 101 is in use during insertion into the device 51. In one example, the thickness of the wall of the cooling segment 107 is approximately 0.29 mm.

The cooling segment 107 provides a physical displacement between the aerosol- generating composition 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 will provide a thermal gradient across the length of the cooling segment 107. In one example the cooling segment 107 is configured to provide a temperature differential of at least 4O°C between a heated volatilised component entering a first end of the cooling segment 107 and a heated volatilised component exiting a second end of the cooling segment 107. In one example the cooling segment 107 is configured to provide a temperature differential of at least 60 °C between a heated volatilised component entering a first end of the cooling segment 107 and a heated volatilised component exiting a second end of the cooling segment 107. This temperature differential across the length of the cooling element 107 protects the temperature sensitive filter segment 109 from the high temperatures of the aerosol- generating composition 103 when it is heated by the device 51. If the physical displacement was not provided between the filter segment 109 and the body of aerosolgenerating composition 103 and the heating elements of the device 51, then the temperature sensitive filter segment may 109 become damaged in use, so it would not perform its required functions as effectively.

In one example, the length of the cooling segment 107 is at least 15 mm. In one example, the length of the cooling segment 107 is between 20 mm and 30 mm, more particularly 23 mm to 27 mm, more particularly 25 mm to 27 mm, suitably 25 mm. The cooling segment 107 is made of paper, which means that it is comprised of a material that does not generate compounds of concern, for example, toxic compounds when in use adjacent to the heater of the device 51. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube which provides a hollow internal chamber yet maintains mechanical rigidity. Spirally wound paper tubes are able to meet the tight dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness and straightness.

In another example, the cooling segment 107 is a recess created from stiff plug wrap or tipping paper. The stiff plug wrap or tipping paper 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 101 is in use during insertion into the device 51. The filter segment 109 may be formed of any filter material sufficient to remove one or more volatilised compounds from heated volatilised components from the aerosol- generating material. In one example the filter segment 109 is made of a mono-acetate material, such as cellulose acetate. The filter segment 109 provides cooling and irritation-reduction from the heated volatilised components without depleting the quantity of the heated volatilised components to an unsatisfactory level for a user.

In some embodiments, a capsule (not illustrated) maybe provided in filter segment 109. It may be disposed substantially centrally in the filter segment 109, both across the filter segment 109 diameter and along the filter segment 109 length. In other cases, it may be offset in one or more dimension. The capsule may in some cases, where present, contain a volatile component such as a flavour or aerosol-former composition.

The density of the cellulose acetate tow material of the filter segment 109 controls the pressure drop across the filter segment 109, which in turn controls the draw resistance of the article 101. Therefore the selection of the material of the filter segment 109 is important in controlling the resistance to draw of the article 101. In addition, the filter segment performs a filtration function in the article 101.

In one example, the filter segment 109 is made of an 8Y15 grade of filter tow material, which provides a filtration effect on the heated volatilised material, whilst also reducing the size of condensed aerosol droplets which result from the heated volatilised material.

The presence of the filter segment 109 provides an insulating effect by providing further cooling to the heated volatilised components that exit the cooling segment 107. This further cooling effect reduces the contact temperature of the user’s lips on the surface of the filter segment 109.

In one example, the filter segment 109 is between 6 mm to 10 mm in length, suitably 8 mm. The mouth end segment 111 is an annular tube and is located around and defines an air gap within the mouth end segment 111. The air gap provides a chamber for heated volatilised components that flow from the filter segment 109. The mouth end segment 111 is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article is in use during insertion into the device 51. In one example, the thickness of the wall of the mouth end segment 111 is approximately 0.29 mm. In one example, the length of the mouth end segment m is between 6 mm to 10 mm, suitably 8 mm.

The mouth end segment 111 may be manufactured from a spirally wound paper tube which provides a hollow internal chamber yet maintains critical mechanical rigidity. Spirally wound paper tubes are able to meet the tight dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness and straightness. The mouth end segment in provides the function of preventing any liquid condensate that accumulates at the exit of the filter segment 109 from coming into direct contact with a user.

It should be appreciated that, in one example, the mouth end segment 111 and the cooling segment 107 may be formed of a single tube and the filter segment 109 is located within that tube separating the mouth end segment 111 and the cooling segment 107.

Referring to Figures 3 and 4, there are shown a schematic representation of exemplary bodies of aerosol-generating composition that may be included in articles, such as the article illustrated in Figure 1.

Figure 3 illustrates an exemplary body of aerosol-generating composition 203 comprising three distinct sections. Plugs, segments or sections comprising reconstituted tobacco 201 are positioned at either end of the illustrated body 203. A plug, segment or section comprising an aerosol-generating material comprising the extruded and dried tobacco beads made according to the inventive process 202 is positioned between the sections of reconstituted tobacco 201. In this embodiment, the sections comprising reconstituted material 201 prevent excessive movement of the aerosol-generating material 202 and keep it within the article.

Figure 4 illustrates an exemplary body of aerosol-generating composition 203 comprising five sections of aerosol-generating material. Plugs, segments or sections comprising reconstituted tobacco 201 are alternated with plugs, segments or sections comprising an aerosol-generating material comprising the extruded and dried tobacco beads made according to the inventive process 202. Sections comprising reconstituted tobacco 201 are positioned at either end of the illustrated body 203 and prevent the aerosol-generating material comprising the extruded and dried tobacco beads from falling out of the body of aerosol-generating composition 203. Sections 202 may comprise beads comprising one or more flavour. For example, the beads in both sections 202 may comprise the same flavour or alternatively comprise different flavours.

Aerosol provision system

In another aspect of the invention, an aerosol provision system may comprise the aerosol provision device and the article. In such embodiments, the device comprises a heating system configured to heat the aerosol-generating material to generate an aerosol.

In some embodiments, the aerosol provision system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

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 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. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product. Typically, the non-combustible aerosol provision system may comprise a noncombustible aerosol provision device and an article or consumable for use with the non-combustible aerosol provision device.

In some embodiments, the disclosure relates to articles comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These articles are sometimes referred to as consumables throughout the disclosure. In some embodiments, the non-combustible aerosol provision system, such as a non- combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system may comprise 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.

Examples

In Table 1 below there are detailed some examples of the articles according to the present invention, each comprising at least one section comprising tobacco beads as described herein.

Table 1

In some embodiments of these examples, the amount of the beads or reconstituted tobacco in the mouth end section may be about 25 mg ± 2.5 mg. In some embodiments of these examples, the amount of the beads or reconstituted tobacco in the distal end section maybe about 25 mg ± 2.5 mg.

In some embodiments of these examples, the amount of the beads in the middle section may be about 500 mg ± 50 mg. In other embodiments of these examples, the amount of the beads in the middle section may be about 250 mg ± 25 mg. In other embodiments of these examples, the amount of the reconstituted tobacco in the middle section may be about 20 mg ± 5 mg.

These embodiments may be combined to configure a suitable article.

Table 2 lists the composition of mixtures to be extruded to form the beads according to illustrative examples. The amounts of the ingredients are provided on a wet weight basis. Table 2

Specific examples of the different components listed in Table 2 include: - the milled plant material comprising or consisting of milled tobacco, or any one or more of the other plant materials disclosed herein;

- the filler material comprising or consisting of calcium carbonate;

- the aerosol-former material comprising or consisting of glycerol, or any one or more of the aerosol-former materials disclosed herein;

- the flavour comprising or consisting of menthol, or any one or more of the flavours disclosed herein; and

- the binder comprising or consisting of carboxymethyl cellulose (CMC), or any one or more of the binders disclosed herein.

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

Claims

1. A process for preparing beads for use as an aerosol-generating material in an aerosol provision system, the process comprising: extruding a mixture to form an extrudate, the mixture comprising: plant particles, an aerosol former material and water; cutting the extrudate to form beads; and drying the beads by heating them to a temperature no higher than about 45°C to reduce their moisture content to no less than about 10% by weight.

2. A process as claimed in claim i, wherein the beads are dried to reduce their moisture content to no less than about 13% by weight.

3. A process as claimed in claim 1 or claim 2, wherein the beads are dried to reduce their moisture content to no greater than about 20% by weight.

4. A process as claimed in any one of claims 1 to 3, wherein the beads are heated to a temperature no higher than about 35°C. 5. A process as claimed in any one of claims 1 to 4, wherein the beads are dried using heated air dryer or a fluid bed processor.

6. A process as claimed in any one of claims 1 to 5, wherein the beads are dried using forced heated air flow which moves the beads. . A process as claimed in any one of claims 1 to 6, wherein the beads are exposed to air flow heated to a temperature of from about 3O°C to about 45°C.

8. A process as claimed in any one of claims 1 to 7, wherein the beads are dried for up to about 10 hours, and optionally for up to about 2 hours.

9. A process as claimed in any one of claims 1 to 7, wherein the cut extrudate is spheronised. 10. A process as claimed in any one of claims 1 to 9, wherein the mixture further comprises one or more of: a binder, a filler and a flavour.

11. An aerosol-generating material comprising at least one extruded and dried bead comprising plant particles and an aerosol former material and having a moisture content of no less than about 10% by weight.

12. An aerosol-generating material as claimed in claim n, wherein the bead has a diameter of from about 0.5 to about 5 mm.

13. An aerosol-generating material as claimed in claim 11 or 12, wherein the bead has a moisture content of no less than about 13% by weight.

14. An aerosol-generating material as claimed in any one of claims 11 to 13, wherein the bead has a moisture content of no greater than about 20% by weight. 15. An aerosol-generating material as claimed in any one of claims 11 to 14, wherein the bead comprises the plant particles in an amount of from about 10 to about 80% by weight, optionally from about 25% to about 80% by weight.

16. An aerosol-generating material as claimed in any one of claims 11 to 15, wherein the plant particles have a diameter of no greater than about 0.5 mm, optionally wherein the plant particles have a diameter of no greater than about 0.1 mm or no greater than about 0.06 mm.

17. An aerosol-generating material as claimed in any one of claims 11 to 16, wherein the bead comprises the aerosol former material in an amount of from about 1% to about

50% by weight, optionally from about 10 to about 30% or from about 15 to about 20% by weight.

18. An aerosol-generating material as claimed in any one of claims 11 to 17, wherein the aerosol former material is selected from the group consisting of: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. 19- An aerosol-generating material as claimed in any one of claims 11 to 18, wherein the bead comprises a binder in an amount of from about 0.01% to about 5% by weight, optionally from about 0.5 to about 1.5% by weight. 20. An aerosol-generating material as claimed in claim 19, wherein the binder is selected from the group consisting of: thermoreversible gelling agents such as gelatin, starches, polysaccharides, pectins, alginates, wood pulp, celluloses, and cellulose derivatives such as carboxymethylcellulose. 21. An aerosol-generating material as claimed in any one of claims 11 to 20, wherein the bead further comprises a filler in an amount of from about 0.01% to about 40% by weight, optionally from about 10 to about 35% by weight or from about 15 to about 30% by weight. 22. An aerosol-generating material as claimed in claim 21, wherein the filler is selected from the group consisting of: calcium carbonate, microcrystalline cellulose, wood fibres, carboxymethylcellulose, titanium dioxide, sodium carbonate, clay, limestone, talc, and gypsum. 23. An aerosol-generating material as claimed in any one of claims 11 to 22, wherein the bead further comprises a flavour, optionally in an amount from about 0.01% to about 5% by weight, optionally from about 2 to about 4% by weight.

24. An aerosol-generating material as claimed in any one of claims 11 to 23, further comprising a different form of plant material in addition to the beads.

25. An article for use in an aerosol provision system, the article comprising an aerosol-generating material as claimed in any one of claims 11 to 24. 26. An article as claimed in claim 25, wherein the article comprises a section comprising the aerosol-generating material comprising the beads, and further comprising one or more sections of reconstituted plant material.

27. An article as claimed in claim 25 or 26, wherein the article further comprises a filter at or near a mouth end of the article.

28. An article as claimed in any one of claims 25 to 27, wherein the article further comprises a cooling segment positioned between the section of aerosol-generating material and a mouth end of the article. 29. An article as claimed in any one of claims 25 to 28, wherein the article has a rod shape and the section of aerosol-generating material is cylindrical.

30. An article as claimed in any one of claims 25 to 29, comprising a chamber holding the aerosol-generating material comprising the beads.

31. An article as claimed in claim 30, wherein the article comprises a removable cartridge with a housing that defines an inner chamber in which the beads are retained.

32. An aerosol provision system comprising an aerosol provision device and an article as claimed in any one of claims 25 to 31, and wherein the device comprises a heating system configured to heat the aerosolgenerating material to generate an aerosol.