CN118765166A

CN118765166A - Article for use in an aerosol supply system and method of manufacturing an article

Info

Publication number: CN118765166A
Application number: CN202280084410.1A
Authority: CN
Inventors: 巴里·迪米克; 科特尼·R·杰克逊
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2021-12-20
Filing date: 2022-12-20
Publication date: 2024-10-11
Also published as: CA3241447A1; WO2023118845A1; KR20240100466A; IL313256A; EP4451934A1; MX2024007492A; AU2022418379A1

Abstract

The present disclosure relates to an article (1) for use in an aerosol provision system (200). The article (1) comprises an aerosol-generating material (3), a receiving member (2) and a blocking member (4). The receiving member (2) comprises an end wall (8), an open end (7) and a peripheral wall (5) surrounding a storage area (6) containing the aerosol-generating material (3). The blocking member (4) comprises a body of material (12) arranged to prevent the aerosol-generating material (3) from moving out of the storage region (6) through the open end (7) of the receiving member (2). The present disclosure also relates to a method (100) of manufacturing an article (1) for use in an aerosol provision system (200). The disclosure also relates to an aerosol provision system (200) comprising an article (1) and a package of an article. The disclosure also relates to a sheet (9) for forming a receiving member (2) of an aerosol supply system article (1), a receiving member (2) for an aerosol supply device system (200), and a method of manufacturing a sheet (9).

Description

Article for use in an aerosol supply system and method of manufacturing an article

Technical Field

The present disclosure relates to an article for use in an aerosol supply system and a method of manufacturing an article for use in an aerosol supply system. The present disclosure also relates to an aerosol provision system comprising an article and a package of an article. The present disclosure also relates to a sheet for forming a receiving member for an aerosol supply system article, a receiving member for an aerosol supply device system, and a method of manufacturing a sheet.

Background

The aerosol provision system generates an inhalable aerosol or vapour during use by releasing a compound from the aerosol generating material. For example, these may be referred to as non-combustible smoking articles, aerosol-generating components or aerosol-supplying devices.

Disclosure of Invention

According to some embodiments described herein, there is provided an article for use in an aerosol provision system, the article comprising: an aerosol-generating material; a receiving member comprising an end wall, an open end and a peripheral wall surrounding a storage region containing an aerosol-generating material; and a blocking member comprising a body of material arranged to prevent the aerosol-generating material from moving out of the storage region through the open end of the receiving member.

In some embodiments, the receiving member comprises a sheet.

In some embodiments, the sheet comprises paper and/or foil.

In some embodiments, the sheet is folded to form an end wall.

In some embodiments, the sheet includes a plurality of ends that extend radially inward to form end walls, and preferably each end includes a flap of the sheet.

In some embodiments, the ends are secured together by an adhesive.

In some embodiments, the end wall is gas permeable.

In some embodiments, the end wall includes one or more apertures.

In some embodiments, the receiving member is generally cup-shaped.

In some embodiments, the article further comprises a wrapper that secures the barrier member relative to the receiving member, and preferably wherein the wrapper surrounds the receiving member and the barrier member.

In some embodiments, the wrapper is adhered to the receiving member and the blocking member.

In some embodiments, the blocking member is generally cylindrical.

In some embodiments, the blocking member comprises an end of a rod of aerosol generating material, and preferably the end of the rod has a higher density than another portion of the rod.

In some embodiments, the density of the end of the rod is at least 10% higher than the other portion of the rod, preferably at least 20% higher than the other portion of the rod.

In some embodiments, the rod is a tobacco rod.

In some embodiments, the body of material comprises a plug of material.

In some embodiments, the body of material is disposed adjacent to the open end of the receiving member.

In some embodiments, at least a portion of the body of material is received within the open end of the receiving member.

The axial length of the article 1 may be at least 10mm, preferably at least 12mm, 14mm, 16mm, 18mm, 20mm, 22mm or 23mm.

The axial length of the article 1 may be at most 36mm, and preferably at most 34mm, 32mm, 30mm, 28mm, 26mm, 24mm, or 23mm.

The axial length of the article 1 may be in the range of 10mm to 36mm, and preferably in the range of 14mm to 32mm, in the range of 20mm to 26mm, or in the range of 22mm to 24 mm.

In some embodiments, the axial length of the body of material is in the range of 3mm to 20mm, preferably in the range of 4mm to 15mm, 5mm to 12mm or 7mm to 10 mm.

In some embodiments, the body of material has an axial length of at least 3mm, and preferably has an axial length of at least 4mm, 5mm, 6mm, or 7 mm.

In some embodiments, the body of material has an axial length of at most 20mm, and preferably an axial length of at most 15mm, 12mm, 10mm or 8 mm.

In some embodiments, the body of material comprises an aerosol generating material.

In some embodiments, the material body comprises an aerosol former material.

In some embodiments, the barrier member comprises an aerosol-generating material comprising: about 10wt% to about 50wt% of an aerosol former material; about 15wt% to about 60wt% of a gelling agent; optionally a filler; wherein the wt% value is calculated on a dry weight basis.

In some embodiments, the aerosol-generating material of the barrier member comprises a flavour.

In some embodiments, the aerosol-generating material in the storage region is a first aerosol-generating material and the aerosol-generating material of the barrier member is a second aerosol-generating material.

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

In some embodiments, one of the first aerosol-generating material and the second aerosol-generating material has a density of from about 0.4g/cm ³ to about 2g/cm ³.

In some embodiments, the density of the other of the first aerosol-generating material and the second aerosol-generating material is from about 0.1g/cm ³ to about 1g/cm ³.

In some embodiments, the heating of the article provides a relatively constant release of the volatile compound into the inhalable medium.

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

In some embodiments, the first aerosol-generating material comprises beads.

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

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

In some embodiments, the first aerosol-generating material and the second aerosol-generating material have the same level of volatile compounds. In some embodiments, the volatile compound is nicotine.

In some embodiments, the volatile compounds are released from the first and second aerosol-generating materials at the same rate when the materials reach a given temperature.

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

In some embodiments, the barrier member comprises tobacco material.

In some embodiments, the barrier member comprises paper.

In some embodiments, the body of material comprises a sheet arranged to form the body of material, and preferably the sheet is gathered to form the body of material.

In some embodiments, the sheet is curled.

In some embodiments, the sheet of material body comprises one or more of aerosol generating material and/or paper. The sheet material may comprise tobacco.

In some embodiments, the blocking member comprises an end portion in contact with the aerosol-generating material.

In some embodiments, the aerosol-generating material is a bulk material.

In some embodiments, the aerosol-generating material comprises, consists of, or consists essentially of a tobacco material.

In some embodiments, the article further comprises a cooling section, and preferably wherein the cooling section is arranged such that, when the article with the aerosol supply device is in use, the cooling section is downstream of the receiving member.

In some embodiments, the cooling section comprises aerosol-generating material, and preferably comprises aerosol-generating material in the form of a plug.

In some embodiments, the cooling section includes a flavoring agent.

In some embodiments, the blocking member is located upstream of the storage region. In other embodiments, the blocking member is located downstream of the storage region.

In some embodiments, the end wall is located upstream of the storage region. In other embodiments, the end wall is downstream of the storage region.

In some embodiments, the article further comprises providing a plug of material to the storage area on the other side of the end wall.

In accordance with the present disclosure, there is also provided an aerosol provision system comprising the article disclosed herein and an aerosol provision device.

In accordance with the present disclosure, there is also provided a package comprising a plurality of articles as disclosed herein. Preferably, the plurality of articles are hermetically sealed.

There is also provided in accordance with the present disclosure, a method of manufacturing an article for use in an aerosol provision system, the method comprising: providing a receiving member comprising an end wall, an open end and a peripheral wall surrounding a storage region containing an aerosol-generating material; and providing a blocking member comprising a body of material arranged to prevent the aerosol-generating material from moving out of the storage region through the open end of the receiving member.

In some embodiments, providing the receiving member comprises forming the receiving member and then providing the aerosol-generating material in the storage region.

In some embodiments, providing the receiving member comprises forming the receiving member around the aerosol-generating material.

In some embodiments, the receiving member comprises a sheet, and preferably wherein the sheet comprises paper and/or foil.

In some embodiments, providing the receiving member includes arranging the sheet material to form the peripheral wall such that the peripheral wall is generally cylindrical, and preferably includes rolling the sheet material to form the peripheral wall.

In some embodiments, providing the receiving member includes folding the sheet material to form an end wall of the receiving member.

In some embodiments, the method includes forming a plurality of ends in the sheet, and preferably, forming the ends includes providing one or more cuts in the sheet.

In some embodiments, the method includes adhering the ends together using an adhesive.

In some embodiments, the method includes forming one or more apertures in a portion of the sheet including the end wall.

In some embodiments, the or each aperture is formed in the sheet prior to the sheet being formed into the receiving member. In some embodiments, the or each aperture is formed in the sheet after the sheet is formed into the receiving member.

In some embodiments, the receiving member is generally cup-shaped.

In some embodiments, the method includes securing the barrier member with respect to the receiving member using a wrapping material, and preferably wherein securing the barrier member with respect to the receiving member using the wrapping material includes surrounding the barrier member and the receiving member with the wrapping material.

In some embodiments, the blocking member is generally cylindrical.

In some embodiments, the blocking member comprises an end of a rod of aerosol-generating material, and preferably the end of the rod has a higher density than another portion of the rod, and preferably the rod is a tobacco rod.

In some embodiments, the blocking member comprises a plug of material.

In some embodiments, the material body comprises an aerosol former material.

In some embodiments, the barrier member comprises an aerosol generating material.

In some embodiments, the barrier member comprises tobacco material.

In some embodiments, the barrier member comprises a sheet, and preferably wherein the method comprises arranging the sheet to form the body of material, and preferably comprises gathering the sheet to form the body of material.

In some embodiments, the sheet is curled, and preferably the method comprises curling the sheet.

In some embodiments, the aerosol-generating material in the storage region is a bulk material.

In some embodiments, the aerosol-generating material in the storage region comprises, consists of, or consists essentially of tobacco material.

In some embodiments, the tobacco material comprises tobacco beads, and preferably, wherein the tobacco material further comprises another tobacco material in addition to the tobacco beads.

In some embodiments, the method includes providing a cooling section and incorporating the cooling section into the article, and preferably wherein the cooling section is disposed such that the cooling section is downstream of the receiving member when the article is in use.

In some embodiments, the cooling section includes a flavoring agent.

In some embodiments, the method includes providing a plug of material to the storage area on the other side of the end wall.

In accordance with the present disclosure, there is also provided a sheet for forming a receiving member of an aerosol provision system article, wherein the sheet comprises one or more regions of discontinuous strength configured to facilitate folding of the sheet in a predetermined manner to form an end wall of the receiving member.

In some embodiments, the one or more areas of weakness are arranged such that the sheet can be folded along the one or more areas of weakness to form the end walls.

In some embodiments, the one or more intensity discontinuity areas comprise one or more of: embossing; incisions (including incisions that extend partially through the thickness of the sheet or through the entire thickness of the sheet); a pin hole; crease lines; a score line; and/or areas of reduced thickness of the sheet.

In some embodiments, the one or more areas of discontinuous intensity are areas of weakness.

In some embodiments, the one or more lines of intensity discontinuity include areas of increased intensity.

In some embodiments, the intensity discontinuity areas are continuous. In other embodiments, the intensity discontinuity areas are discontinuous.

In some embodiments, the one or more intensity discontinuity areas are intensity discontinuity lines.

In some embodiments, the sheet has a first edge and a second edge, and wherein at least one of the lines of intensity discontinuity extends substantially perpendicular to the first edge and the second edge.

In some embodiments, the first edge and the second edge are configured to overlap when the sheet is formed into the receiving member.

In some embodiments, the basis weight of the sheet is at least 35GSM, and preferably at least 100GSM, 150GSM, or 200GSM.

In some embodiments, the basis weight of the sheet is at most 300GSM, and preferably at most 250GSM, 200GSM or 150GSM.

In some embodiments, the sheet includes one or more flaps configured to be folded to form the end walls.

In some embodiments, one or more of the flaps are generally triangular.

In some embodiments, at least one of the strength discontinuity areas is arranged to facilitate folding of one or more flaps to form an end wall.

In some embodiments, the sheet comprises paper and/or foil.

According to the present disclosure there is also provided a receiving member for an aerosol provision system article, wherein the receiving member comprises an end wall, an open end and a peripheral wall surrounding a storage area for containing an aerosol generating material, wherein the receiving member comprises a sheet as disclosed herein, wherein the sheet is arranged to form the peripheral wall and the end wall.

There is also provided in accordance with the present disclosure, an article for an aerosol provision system, comprising: a receiving member as disclosed herein; an aerosol-generating material disposed in the storage region of the receiving member; and a blocking member comprising a body of material arranged to prevent the aerosol-generating material from moving out of the storage region through the open end of the receiving member.

In some embodiments, the article has one or more features of the articles disclosed herein.

In accordance with the present disclosure, there is also provided a method of manufacturing a sheet for an article in an aerosol supply system, the method comprising providing a sheet and forming one or more areas of weakness in the sheet, the sheet being arranged such that the areas of weakness promote folding of the sheet in a predetermined manner to form end walls of a receiving member.

In some embodiments, the sheet has any of the features of the sheet disclosed herein.

Drawings

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

FIG. 1 is a side cross-sectional view of an embodiment of an article for use with an aerosol supply device;

FIG. 2 is an end view of the receiving member of the article of FIG. 1;

FIG. 3 is a perspective view of a receiving member of the article of FIG. 1;

FIG. 4 is a top view of a sheet of material used to form the receiving member of the article of FIG. 1, wherein the sheet of material is laid flat prior to forming the receiving member;

FIG. 5 is a side cross-sectional view of a sheet rolled into a tube;

FIG. 6 is a side cross-sectional view of a sheet rolled into a tube with ends folded to form end walls;

FIG. 7 is a perspective view of a blocking member of the article of FIG. 1;

FIG. 8 is a block diagram depicting a method of manufacturing an article for use with an aerosol provision device;

FIG. 9 is an alternative embodiment of a sheet for forming a receiving member of an article for use with an aerosol supply device, wherein the sheet is laid flat prior to forming the receiving member;

FIG. 10 is another alternative embodiment of a sheet for forming a receiving member of an article for use with an aerosol supply device, wherein the sheet is laid flat prior to forming the receiving member;

FIG. 11 is a side cross-sectional view of an alternative blocking member;

FIG. 12 is a side cross-sectional view of another alternative blocking member;

FIG. 13 is a cross-sectional view of an embodiment of a non-combustible sol supply device;

fig. 14 is a simplified schematic view of components within the aerosol provision device housing of fig. 13;

FIG. 15 is a cross-sectional view of the non-combustible sol supply device of FIG. 13 with the article of FIG. 1 inserted into the device; and

Fig. 16 is a side cross-sectional view of another embodiment of an article for use with an aerosol supply device.

Detailed Description

As used herein, the term "delivery system" is intended to include a system that delivers at least one substance to a user, and includes: combustible sol supply systems such as cigarettes, cigarillos, cigars and pipe tobacco, tobacco for manual rolling or self-made cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable materials); non-combustible aerosol provision systems such as electronic cigarettes, tobacco heating products, and hybrid systems that use a combination of aerosol-generating materials to generate an aerosol that release a compound from the aerosol-generating material without burning the aerosol-generating material; and aerosol-free delivery systems that deliver at least one substance orally, nasally, transdermally, or in another manner to a user without forming aerosols, including but not limited to lozenges, gums, patches, inhalable powder-containing products, and oral products such as oral tobacco that include snuff or wet snuff, wherein at least one substance may or may not include nicotine.

According to the present disclosure, a "non-combustible" aerosol supply system is a system in which the constitutive aerosol-generating material of the aerosol supply system (or components thereof) is not combusted or ignited in order to deliver at least one substance to a user.

In some embodiments, the delivery system is a non-combustible sol supply system, such as a powered non-combustible sol supply system.

In some embodiments, the non-combustible aerosol supply system is an electronic cigarette, also referred to as an electronic cigarette device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol generating material is not necessary.

In some embodiments, the non-combustible sol supply system is an aerosol generating material heating system, also referred to as a heated non-combustion system. One example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol supply system is a hybrid system that uses a combination of aerosol-generating materials to generate an aerosol, one or more of which may be heated. Each aerosol-generating material may be in the form of a solid, liquid or gel, for example, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise a plant-based material, such as tobacco or a non-tobacco product.

Typically, the non-combustible sol supply system may include a non-combustible sol supply device and a consumable for use with the non-combustible sol supply device.

In some embodiments, the present disclosure relates to a consumable comprising an aerosol-generating material and configured for use with a non-combustible aerosol supply device. Throughout this disclosure, these consumables are sometimes referred to as articles of manufacture.

The terms "upstream" and "downstream" as used herein are relative terms defined with respect to the direction of mainstream aerosol drawn through the article or device in use. Reference to "distal" refers to the upstream end of the device, and "proximal" refers to the downstream end of the device.

In some embodiments, a non-combustible sol supply system, such as a non-combustible sol supply thereof, may include a power source and a controller. For example, the power source may be an electric power source or an exothermic source. In some embodiments, the heat-generating source comprises a carbon matrix that can be energized to distribute power in the form of heat to the aerosol-generating material or the heat transfer material in the vicinity of the heat-generating source.

In some embodiments, the non-combustible aerosol provision system comprises a region for receiving a consumable, an aerosol generator, an aerosol generating region, a housing, a mouthpiece, a filter, and/or an aerosol modifier.

In some embodiments, a consumable for use with a non-combustible aerosol supply device may include an aerosol generating material, an aerosol generating material storage region, an aerosol generating material delivery component, an aerosol generator, an aerosol generating region, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol modifier.

The consumable comprises the substance to be delivered. The substance to be delivered is an aerosol generating material. Where appropriate, the material may include one or more active ingredients, one or more flavourings, 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. As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. For example, the active substance may be selected from nutraceuticals, nootropic agents and psychoactive substances. The active substance may be naturally occurring or synthetically obtained. The active may include, for example, nicotine, caffeine, taurine, caffeine, vitamins (e.g., B6 or B12 or C), melatonin, or components, derivatives, or combinations thereof. The active substance may comprise one or more ingredients, derivatives or extracts of tobacco or another botanical preparation. In some embodiments, the active comprises nicotine. In some embodiments, the active comprises caffeine, melatonin, or vitamin B12.

As noted herein, the active substance may comprise or be derived from one or more plant materials or components, derivatives or extracts thereof. As used herein, the term "plant material" includes any material derived from a plant, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, bark, hulls, and the like. Alternatively, the material may comprise an active compound naturally present in a synthetically obtained plant preparation. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, pellets, granules, chips, ribbons, sheets, and the like. Exemplary botanical preparations are tobacco, eucalyptus, star anise, cocoa, fennel, lemon grass, peppermint, spearmint, loyi Bai Si, chamomile, flax, ginger, ginkgo leaf, hazelnut, hibiscus, bay, licorice (licorice root), green tea, yerba mate, orange peel, papaya, rose, sage, green tea or black tea, thyme, clove, cinnamon, coffee, fennel seed (fennel), basil, bay leaf, cardamon, caraway, cumin, nutmeg, oregano, capsicum, rosemary, saffron, lavender, lemon peel, peppermint, juniper, elder, vanilla, wintergreen, perilla, turmeric, sandalwood, coriander, bergamot, orange flower, myrtle, blackcurrant, valerian, multi-fragrant fruit, nutmeg dried skin, idan (damien), marjoram, olive, melissa leaf, lemon basil, licorice, caraway, whip, tarragon, geranium, ginseng, gin, tea, matrine, tea, macadamia, combinations of any of them. The peppermint can be selected from the following peppermint varieties: peppermint (MENTHA ARVENTIS), peppermint cultivar (Mentha c.v.), egyptian mint (MENTHA NILIACA), peppermint (MENTHA PIPERITA), bergamot cultivar (MENTHA PIPERITA CITRATA c.v.), peppermint cultivar (MENTHA PIPERITA c.v.), morocco mint (MENTHA SPICATA CRISPA), peppermint (Mentha cordifolia), spearmint (Mentha longifolia), macleaya She Fengli mint (Mentha suaveolens variegata), mentha pulegium (Mentha pulegium), spearmint cultivar (MENTHA SPICATA c.v.), and apple mint (Mentha suaveolens).

In some embodiments, the active substance comprises or is derived from one or more botanical agents or ingredients, derivatives or extracts thereof, and the botanical agent is tobacco.

In some embodiments, the active substance comprises or is derived from one or more botanical agents or ingredients, derivatives or extracts thereof, and the botanical agents are selected from eucalyptus, star anise and cocoa.

In some embodiments, the active substance comprises or is derived from one or more botanical agents or ingredients, derivatives or extracts thereof, and the botanical agents are selected from loyi Bai Si and fennel.

In some embodiments, the substance to be delivered comprises a flavoring agent.

As used herein, the terms "flavoring" and "flavoring" refer to materials that can be used to create a desired taste, aroma, or other somatosensory in a product for an adult consumer, as permitted by local regulations. They may include natural flavoring materials, botanical preparations, botanical preparation extracts, synthetic materials or combinations thereof (e.g., tobacco, licorice (licorice root), hydrangea, eugenol, japanese white magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, japanese mint, fennel seed (fennel), cinnamon bark, turmeric, indian spice, asian spice, herbal, holly, cherry, berry, red berry, cranberry, peach, apple, orange, mango, small citrus claiming, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruit, du Linbiao wine, bourbon whiskey, scotch whiskey, juniper, tequila, rum, spearmint, peppermint, lavender, aloe, cardamom, celery, kauri, nutmeg, sandalwood, bergamot geranium, arabian tea leaves, naswales, betel nuts, shikake, pine, honey essences, rose oil, vanilla, lemon oil, orange flowers, cherry flowers, cassia, caraway, cognac, jasmine flowers, ylang-ylang, sage, fennel, horseradish, peppermint, ginger, coriander, coffee, peppermint oil of any mint species, eucalyptus, star anise, cocoa, lemon grass, red leaf tea, flax, ginkgo, hazel tree, hibiscus, bay, wintergreen tea, orange peel, rose, tea (e.g., green tea or black tea), thyme, juniper, elder, basil, bay leaves, cumin, oregano, capsicum, rosemary, saffron, lemon peel, peppermint, steak, turmeric, coriander leaves, myrtle, black currant, valerian, spanish, red pepper, nutmeg skin, damiana, marjoram, olives, lemon balm, lemon basil, chives, carvacrol, verbena, tarragon, limonene, thymol, camphene), odorants, bitter taste receptor site blockers or stimulants, sugar and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanical preparations, or breath fresheners. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example liquid such as oil, solid such as powder or gas.

In some embodiments, the flavoring agent comprises menthol, spearmint, and/or peppermint. In some embodiments, the flavoring includes a flavoring component of cucumber, blueberry, citrus fruit, and/or raspberry. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring includes a flavoring component extracted from tobacco.

In some embodiments, the flavoring agents may include sensates intended to achieve a body feel that is chemically induced and perceived, typically by stimulating the fifth cranial nerve (trigeminal nerve), in addition to or in lieu of aromatic or gustatory nerves, and these may include agents that provide heating, cooling, stinging, numbing effects. Suitable thermal effectors may be, but are not limited to, vanillyl diethyl ether and suitable coolants may be, but are not limited to, eucalyptol, 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, the film being an amorphous solid. The amorphous solid may be a "monolithic solid". The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a xerogel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, therein. In some embodiments, the amorphous solids may, for example, comprise from about 50wt%, 60wt%, or 70wt% amorphous solids to about 90wt%, 95wt%, or 100wt% amorphous solids. The aerosol-generating material may also be referred to as an aerosolizable material.

An aerosol-generating material is a material that is capable of generating an aerosol, for example, when heated, irradiated, or otherwise energized in any other manner. The 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 flavour. The aerosol-generating material is incorporated into an article for use in an 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 include one or more of tobacco dust, tobacco fibers, cut filler, extruded tobacco, tobacco stalks, tobacco leaves, reconstituted tobacco, and/or tobacco extracts.

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

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 materials.

The aerosolizable material may be present on a substrate. For example, the substrate may be or include paper, cardboard, paperboard, cardboard, reconstituted aerosols, plastics, ceramics, composites, glass, metal or metal alloys.

The aerosol former material may comprise one or more components capable of forming an aerosol. In some embodiments, the aerosol former material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, endocrythritol, ethyl vanillic acid, ethyl laurate, diethyl suberate, triethyl citrate, glyceryl triacetate, glyceryl diacetate mixtures, benzyl benzoate, benzyl phenyl acetate, glyceryl tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

The one or more other functional materials may include one or more of pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and/or antioxidants.

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

A susceptor is a material that is heated by penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material such that penetration thereof by a varying magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material such that penetration thereof by a varying magnetic field causes hysteresis heating of the heating material. The susceptor may be either electrically conductive or magnetic such that the susceptor may be heated by two heating mechanisms. The device configured to generate the varying magnetic field is referred to herein as a magnetic field generator.

An aerosol-modifying agent is a substance typically located downstream of the aerosol-generating region that is configured to modify the aerosol generated, for example by altering the taste, flavor, acidity or another characteristic of the aerosol. The aerosol modifier may be disposed in an aerosol modifier release assembly operable to selectively release the aerosol modifier.

For example, the aerosol modifier may be an additive or an adsorbent. For example, the aerosol modifiers may include one or more of flavors, colorants, water, and carbon adsorbents. For example, the aerosol modifier may be a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, wire or pellet. The aerosol modifier may be free of filter material.

An aerosol generator is a device configured to cause an aerosol to be generated from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy, thereby releasing one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

The filamentary tow material described herein may comprise cellulose acetate tow. The filament tows may also be formed using other materials for forming fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly (1-4 butylene succinate) (PBS), poly (butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. The filaments may be plasticized with a suitable plasticizer for the filaments, such as glyceryl triacetate, wherein the material is cellulose acetate filaments, or the filaments may be non-plasticized. The tow may have any suitable gauge, such as fibers having a "Y" shape or other cross-section (e.g., an "X" shape), a denier per filament of 2.5 to 15 denier, such as a denier per filament of 8.0 to 11.0 denier, and a total denier of 5,000 to 50,000, such as 10,000 to 40,000.

In the drawings described herein, the same reference numerals are used to illustrate equivalent features, articles, or components.

Fig. 1 is a side cross-sectional view of an article 1 for use in an aerosol delivery system that includes an aerosol delivery device 200 (see fig. 13-15).

The article 1 has an upstream or distal end "D" and a downstream or proximal end "P". In some embodiments, in use, the proximal end P is positioned relatively closer to the mouthpiece 207 of the aerosol delivery device 200 than the distal end D. In another embodiment (not shown), the proximal end P of the article 1 comprises a mouthpiece.

The article 1 comprises a receiving member 2, an aerosol-generating material 3 and a blocking member 4.

The receiving member 2 comprises a peripheral wall 5 surrounding a space 6 containing the aerosol-generating material 3. The space 6 forms a storage area 6 for the aerosol-generating material 3.

The receiving member 2 has a first open end 7. The receiving member 2 comprises an end wall 8 at a second end of the receiving member 2 opposite the first open end 7.

In some embodiments, the peripheral wall 5 and the end wall 8 of the receiving member 2 are integrally formed.

In this example, the receiving member 2 comprises a sheet 9. In some embodiments, the sheet 9 comprises paper and/or foil, for example a metal foil, such as an aluminum foil. The sheet 9 may optionally comprise a plurality of material layers, for example a paper layer with a foil layer. In some embodiments, the sheet 9 does not comprise any foil.

The sheet 9 is rolled into a tube shape to form the outer peripheral wall 5 of the receiving member 2 (as shown in fig. 5). In some embodiments, an adhesive is applied to the sheet 9 to hold the sheet 9 as a tube. In other embodiments (not shown), the sheet 9 is alternatively or additionally held in a tubular shape by a wrapping material surrounding the sheet 9.

One end of the sheet 9 is folded radially inwardly to form an end wall 8 (as shown in figure 6). Thus, the end wall 8 is located at the end of the peripheral wall 5. The end wall 8 at least partially forms the boundary of the space 6. The end wall 8 may close or at least partially close the end of the receiving member 2.

In this example, the sheet 9 comprises a plurality of ends 10, which are each folded radially inwards once the peripheral wall 5 has been formed such that the ends 10 form the end walls 8. Alternatively, each end 10 is folded and then the sheet 9 is wound/wrapped to form the peripheral wall 5, wherein this winding of the sheet 9 causes the ends 10 to bunch together, or towards each other, to form the end wall 8.

In some embodiments, each end 10 comprises a flap 10 of sheet 9. Each flap 10 may be generally triangular. However, one skilled in the art will recognize that other shapes of flaps 10 are possible, such as semi-circular or rectangular flaps.

The end 10 may be held in a folded position forming the end wall 8 using an adhesive. In alternative embodiments, the end 10 may be held in place by the stiffness and/or ductility of the sheet 9 or by another component (e.g. a plug of material as now shown) provided on the opposite side of the end 10 to the aerosol-generating material 3, and for example, the other component may abut the end 10.

In this example, the receiving member 2 is generally cup-shaped, having a generally cylindrical peripheral wall 5 closed or at least partially closed at one end by an end wall 8, and having an open end 7 at the end of the receiving member 2 opposite the end wall 8.

The end wall 8 helps to retain the aerosol-generating material 3 in the space 6, which may optionally be a loose material, such that the aerosol-generating material 3 is prevented from falling out of the end of the space 6 by the end wall 8.

The end wall 8 is configured to be gas permeable. Thus, in embodiments in which the open end 7 is upstream of the end wall 8 during use of the article 1 in the device 200, gas may enter the open end 7 of the receiving member 2, pass through the aerosol-generating material 3, and pass through the end wall 8 to exit the receiving member 2 for inhalation by a user. Alternatively, in embodiments in which the end wall 8 is upstream of the open end 7, gas may pass through the end wall 8 to enter the space 6, wherein the gas passes through the aerosol-generating material 3 and then out of the open end 7 of the receiving member 2 for inhalation by the user.

In some embodiments, the end wall 8 includes one or more apertures 11 to allow gas to flow through the end wall 8. The or each aperture 11 may be a hole or slit through the sheet 9. For example, one or more holes and/or slits may be provided in one or more of the ends 10. In another embodiment (not shown), the or each aperture 11 may comprise one or more gaps between adjacent ends 10 of the end walls 8. In another embodiment (not shown), the ends 10 may be sized such that they do not meet at the axial center of the article 1 when folded to form the end wall 8, thereby providing an aperture for gas to flow therethrough.

The or each orifice 11 may be of sufficient size to allow gas to flow through the end wall 8, whilst being small enough to prevent aerosol-generating material 3 from flowing out of the end wall 8 via the orifice 11. In some embodiments, the diameter of the or each orifice 11 is in the range 0.1mm to 1mm, and preferably in the range 0.2mm to 0.8 mm.

In some embodiments, each orifice 11 has a diameter of at least 0.1mm, and preferably at least 0.2 mm.

In some embodiments, each orifice 11 has a diameter of at most 1mm, and preferably at most 0.8 mm.

In another embodiment, the sheet 9 at the end wall 8 comprises a gas permeable material to allow gas to flow through the end wall 8. The permeable material may be, for example, paper, and may have a porosity of at least 100Coresta units, and preferably a porosity of at least 200, 300, 400, 500, 1000, 2000, 3000, 5000, 7000, 10000 or 20000Corestta units. In some embodiments, the entire sheet 9 is made of the breathable material. In other embodiments, only the sheet 9 in the region of the end 10 is made of this breathable material. In some embodiments, the permeability of the sheet 9 is selected based on the desired stretch resistance of the article 1 (having a higher permeability results in a lower stretch resistance).

The blocking member 4 comprises a body of material 12 arranged to prevent the aerosol-generating material 3 from falling out of the open end 7 of the receiving member 2.

In this example, the material body 12 of the blocking member 4 is generally cylindrical. However, it should be appreciated that the body of material 12 may have a different shape.

The article 1 further comprises a wrapper 13 securing the barrier member 4 relative to the receiving member 2. In this example, the wrapping material 13 surrounds both the receiving member 2 and the blocking member 4. The wrapping material 13 may wrap around the entire axial length of the receiving member 2 and/or the blocking member 4. In other embodiments, the wrapping material 13 may wrap around only a portion of the axial length of the receiving member 2 and/or the blocking member 4, and may be provided, for example, as a strip of material that overlaps the junction between the receiving member 2 and the blocking member 4 without extending to the other end of the receiving member 2 and/or the blocking member 4.

In some embodiments, the wrapping material 13 is adhered to the receiving member 2 and/or the blocking member 4. However, those skilled in the art will recognize that in other embodiments, the wrapping material 13 may not adhere to the receiving member 2 and/or the blocking member 4, and may be held in place, for example, by friction.

In the present embodiment, the material body 12 is a material plug. In this embodiment, the material plug comprises an aerosol generating material 14. For example, the aerosol-generating material 14 may comprise, consist of, or consist essentially of tobacco material. As previously noted, 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 include one or more of tobacco dust, tobacco fibers, cut filler, extruded tobacco, tobacco stems, tobacco flakes, reconstituted tobacco, and/or tobacco extracts.

In some embodiments, the material body 12 additionally or alternatively includes one or more aerosol former materials. For example, the body of material 12 may additionally or alternatively include one or more components capable of forming an aerosol. The aerosol former material comprises one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, endocrythritol, ethyl vanillic acid, ethyl laurate, diethyl suberate, triethyl citrate, glyceryl triacetate, glyceryl diacetate mixture, benzyl benzoate, benzyl phenylacetate, glyceryl tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol former material may be glycerol or propylene glycol.

In some embodiments, the axial length of the material body 12 is in the range of 3mm to 20mm, preferably in the range of 4mm to 15mm, 5mm to 12mm, or 7mm to 10 mm.

In some embodiments, the axial length of the receiving member 2 is in the range of 5mm to 25mm, and preferably in the range of 11mm to 18mm, or 13mm to 16 mm.

In some embodiments, the total weight of the aerosol-generating material 3, 14 in the article 1 is in the range of 150mg to 350mg, and preferably in the range of 200mg to 300mg, 220mg to 280mg, or 230mg to 260 mg.

In some embodiments, the barrier member 4 comprises an aerosol-generating material in the range of 7mg to 13mg per millimetre of length of the barrier member 4, and preferably 8mg to 12mg, 9mg to 11.5mg, 9mg to 11mg or 9.5mg to 10.5mg of aerosol-generating material per millimetre of length of the barrier member 4.

In some embodiments, the space 6 contains aerosol-generating material in the range of 7mg to 13mg per millimetre of length of the space 6, and preferably 8mg to 12mg, 9mg to 11.5mg, 9mg to 11mg or 9.5mg to 10.5mg of aerosol-generating material per millimetre of length of the space 6.

In some embodiments, the article 1 contains aerosol-generating material in the range of 7mg to 13mg per millimeter length of the article 1, and preferably 8mg to 12mg, 9mg to 11.5mg, 9mg to 11mg, or 9.5mg to 10.5mg of aerosol-generating material per millimeter length of the article 1.

The blocking member 4 is disposed near the open end 7 of the receiving member 2. The blocking member 4 may be disposed adjacent the open end 7 of the receiving member 2 and optionally may abut the open end 7 of the receiving member 2. Alternatively, at least a portion of the blocking member 4 may be received within the open end 7 of the receiving member 2 such that the peripheral wall 5 of the receiving member 2 surrounds the blocking member 4.

In some embodiments, the material body 12 comprises an end portion that is in contact with the aerosol-generating material 3 contained in the space 6 of the receiving member 2.

In some embodiments, the body of material 12 is wrapped in a forming paper 15. The forming paper 15 may comprise paper or another sheet, for example a foil, including a metal foil such as aluminum foil.

The aerosol-generating material 3 may be provided in the space 6 of the receiving member 2 as a loose material which is held in the space 6 by the end walls 8 of the receiving member 2 and by the blocking member 4. The aerosol-generating material 3 may for example be discrete strands or particles of the aerosol-generating material 3. Another example of a loose aerosol-generating material 3 is beads/pellets of aerosol-generating material 3, including aerosol-generating material that has been extruded and subsequently cut into beads/pellets. Yet another example of an aerosol-generating material 3 is a sheet of aerosol-generating material that has been cut into individual pieces, e.g. into individual strips of aerosol-generating material 3. The sheet of aerosol-generating material may be a reconstituted tobacco sheet.

In some embodiments, the aerosol-generating material 3 in the space 6 of the receiving member 2 is the first aerosol-generating material 3. In embodiments in which the material body 12 of the barrier member 4 comprises an aerosol-generating material 14, this is the second aerosol-generating material 14. Thus, the article 1 may comprise a first region 3A and a second region 14A of aerosol-generating material 3, 14. The first region 3A and the second region 14A may be separate regions.

In some embodiments, the first aerosol-generating material 3 has at least one different characteristic than the second aerosol-generating material 14. The different characteristics may be one or more of the form, size, moisture content, amount (by weight), one or more materials or material proportions constituting each aerosol-generating material 3, 14 (including the formulation of the aerosol-generating material when each aerosol-generating material 3, 14 is made from more than one material). In other embodiments, the first aerosol-generating material 3 and the second aerosol-generating material 14 do not have different characteristics, but are the same.

In some embodiments, the first aerosol-generating material 3 and the second aerosol-generating material 14 may comprise the same material having different characteristics, such as tobacco. In one such embodiment, the first aerosol-generating material 3 and the second aerosol-generating material 14 may be in different forms. For example, the first aerosol-generating material 3 may be in the form of beads or pellets of aerosol-generating material (e.g. tobacco or another material), and the second aerosol-generating material 14 may be, for example: a strand or ribbon of aerosol-generating material (e.g., tobacco or another material); aggregating into plugs or cut strips of aerosol-generating material; bulk material (e.g., shredded tobacco); a dense end of an aerosol-generating material (e.g., tobacco) rod; or have been formed into the form of a plug of tobacco sheet and/or stem material. However, it will be appreciated that the first aerosol-generating material 3 and the second aerosol-generating material 14 may alternatively be of the same form (e.g. both are cut tobacco) and have some other different characteristics (e.g. different material densities).

In some embodiments, the first aerosol-generating material 3 and the second aerosol-generating material 14 may release one or more volatile compounds at different rates when heated. This allows for a more consistent delivery of the compound during consumption of the article 1. For example, the second aerosol-generating material 14 may reach a given temperature more rapidly than the first aerosol-generating material 3 when heated by a heater of a particular power. This may result in the second aerosol-generating material initially releasing volatile compounds at a greater rate than the first aerosol-generating material 3. In one such embodiment, the second aerosol-generating material 14 may provide release of the volatile compound during a first period of the consumption process, and the first aerosol-generating material 3 may provide release of the volatile compound during a later second period of the consumption process. In one such embodiment, the second aerosol-generating material 14 is heated during a first period of time and the first aerosol-generating material 3 is heated during a second period of time of the consumption process.

In some embodiments, the first aerosol-generating material 3 initially releases one or more volatile compounds at a faster rate than the second aerosol-generating material 14 when subjected to a given heating power. In other embodiments, the first aerosol-generating material 3 releases one or more volatile compounds at a slower rate than the second aerosol-generating material 14 when subjected to a given heating power.

In some embodiments, one of the first aerosol-generating material 3 and the second aerosol-generating material 14 is denser than the other of the first aerosol-generating material 3 and the second aerosol-generating material 14. Thus, a denser material may have a greater thermal mass so that it heats more slowly (and thus releases volatile compounds initially more slowly) when subjected to a given heating power.

In one embodiment, the first aerosol-generating material 3 or the second aerosol-generating material 14 may comprise beads/pellets of aerosol-generating material which have been found to release volatile compounds at a relatively slow rate. In some such embodiments, the other of the first aerosol-generating material 3 and the second aerosol-generating material 14 comprises tobacco sheets; one or more of tobacco stems or reconstituted tobacco. In one such embodiment, the other of the first aerosol-generating material 3 and the second aerosol-generating material 14 comprises a mixture of tobacco flakes and reconstituted tobacco.

In other embodiments, the first aerosol-generating material 3 and the second aerosol-generating material 14 are the same.

Advantageously, the material body 12 is arranged to prevent the aerosol-generating material 3 from falling out of the open end 7 of the receiving member 2. This reduces the size and weight of the article 1 and the amount of material required to manufacture the article 1, as the article 1 does not require additional components to retain the aerosol-generating material 3 in the receiving member 2. For example, arranging the body of material 12 to retain the aerosol-generating material 3 in the receiving member 2 means that the receiving member 2 may have an open end 7 instead of comprising a second end wall (on the opposite side of the space 6 from the end wall 8) to enclose the space 6 and thus require less material.

Furthermore, the material body 12 may perform another function of the article 1 in addition to retaining the aerosol-generating material 3 in the space 6. In this example, the material body 12 comprises an aerosol-generating material 14, so that the material body 12 performs the function of retaining the aerosol-generating material 3 in the space 6 and of releasing one or more volatile compounds upon heating. Similarly, the material body 12 may alternatively or additionally comprise an aerosol former material and thus also perform the function of forming an aerosol. In other embodiments, the material body 12 may include a filter (e.g., paper gathered into a plug) that also performs the function of filtering the air flow as it passes through the article 1.

The first aerosol-generating material 3 and/or the second aerosol-generating material 14 may comprise a plurality of strands or ribbons of aerosol-generating material. For example, the first aerosol-generating material 3 and/or the second aerosol-generating material 14 may comprise a plurality of strands or ribbons of aerosolizable material and/or a plurality of strands or ribbons of amorphous solid.

The first aerosol-generating material 3 and/or the second aerosol-generating material 14 may comprise a plant-based material, such as a tobacco material. The first aerosol-generating material 3 and/or the second aerosol-generating material 14 may be a sheet or cut piece of an aerosolizable 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 additionally, the plant-based material may comprise strips, strands or fibres of tobacco. For example, where a tobacco material is provided, the tobacco material may include particles, granules, fibers, ribbons, and/or strands of tobacco. In some embodiments, the tobacco material consists of microparticles or particles of the tobacco material.

The tobacco material may include tobacco obtained from any portion of a tobacco plant. In some embodiments, the tobacco material comprises tobacco leaf.

The flakes or cut pieces may comprise from 5wt% to about 90wt% tobacco leaves. In some embodiments, both the first aerosol-generating material 3 and the second aerosol-generating material 14 comprise, consist of, or consist essentially of tobacco material.

The first aerosol-generating material 3 and/or the second aerosol-generating material 14 may comprise an aerosol-former material. The aerosol former material comprises one or more components capable of forming an aerosol. The aerosol former material comprises one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, endocrythritol, ethyl vanillic acid, ethyl laurate, diethyl suberate, triethyl citrate, glyceryl triacetate, glyceryl diacetate mixture, benzyl benzoate, benzyl phenylacetate, glyceryl tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol former material may be glycerol or propylene glycol.

In some embodiments, the first aerosol-generating material 3 and/or the second aerosol-generating material 14 comprise sheets or shreds of aerosolizable material, including aerosol-former material. Optionally, the aerosol former material is provided in an amount of up to about 50wt% based on the dry weight of the sheet or shredded sheet. In some embodiments, the aerosol former material is provided in an amount of about 5wt% to about 40wt%, based on the dry weight of the tablet or chopped tablet, about 10wt% to about 30wt%, based on the dry weight of the tablet or chopped tablet, or about 10wt% to about 20wt%, based on the dry weight of the tablet or chopped tablet.

The first aerosol-generating material 3 and/or the second aerosol-generating material 14 may comprise a filler. In some embodiments, the flakes or shreds comprise a filler. Fillers are generally non-tobacco components, i.e., components that do not include tobacco-derived ingredients. The filler may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may be non-tobacco fibres, such as wood fibres or pulp or wheat fibres. The filler may be a material comprising cellulose or a material comprising cellulose derivatives. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material.

The first aerosol-generating material 3 and/or the second aerosol-generating material 14 herein may comprise an aerosol-modifying agent, such as any of the flavourings described herein. In one embodiment, the first aerosol-generating material 3 and/or the second aerosol-generating material 14 comprises menthol. When the first aerosol-generating material 3 and/or the second aerosol-generating material 14 are incorporated into an article for use in an aerosol-supply system, the article may be referred to as a menthol-containing article 1. The first aerosol-generating material 3 and/or the second aerosol-generating material 14 may comprise from 0.5mg to 20mg of menthol, from 0.7mg to 20mg of menthol, from 1mg to 18mg or from 8mg to 16mg of menthol.

In some embodiments, the article 1 comprises an aerosol-generating composition comprising an aerosol-generating material. The aerosol-generating material may comprise the first aerosol-generating material 3 and/or the second aerosol-generating material 14.

An aerosol-generating material is a material capable of generating an aerosol, for example, when heated, irradiated or in any other way energized. The aerosol-generating material (e.g. the first aerosol-generating material 3 and/or the second aerosol-generating material 14) may be in the form of, for example, a solid, liquid or semi-solid (e.g. a gel), which may or may not contain an active substance and/or a flavour.

The aerosol-generating material (e.g. the first aerosol-generating material 3 and/or the second aerosol-generating material 14) may comprise a binder and an aerosol-former. Optionally, active substances and/or fillers 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 be soluble or insoluble in the solvent. In some embodiments, the aerosol-generating material (e.g., the first aerosol-generating material 3 and/or the second aerosol-generating material 14) is substantially free of plant formulation material. In particular, in some embodiments, the aerosol-generating material (e.g., the first aerosol-generating material 3 and/or the second aerosol-generating material 14) is substantially free of tobacco.

The aerosol-generating material (e.g. the first aerosol-generating material 3 and/or the second aerosol-generating material 14) may comprise or be an "amorphous solid". The amorphous solid may be a "monolithic solid". In some embodiments, the amorphous solid may be a xerogel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, therein. In some embodiments, the aerosol-generating material may, for example, comprise from about 50wt%, 60wt%, or 70wt% amorphous solids to about 90wt%, 95wt%, or 100wt% amorphous solids. The amorphous solid may be substantially non-fibrous.

The aerosol-generating material (e.g. the first aerosol-generating material 3 and/or the second aerosol-generating material 14) may comprise or be an aerosol-generating film. Formation of an aerosol-generating film may be accomplished by combining a binder (e.g., a gelling agent) with a solvent (e.g., water), an aerosol-forming agent, and one or more other components (e.g., an active substance) to form a slurry, and then heating the slurry to volatilize at least some of the solvent. The slurry may be heated to remove at least about 60wt%, 70wt%, 80wt%, 85wt%, or 90wt% of the solvent. The aerosol-generating film may be a continuous film or a discontinuous film, such as an arrangement of discrete portions of film on a support. The aerosol-generating film may be substantially free of tobacco.

The aerosol-generating film may comprise or be a sheet, which may optionally be chopped to form chopped sheets.

The aerosol-generating material (e.g., the first aerosol-generating material 3 and/or the second aerosol-generating material 14) may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional materials.

In each of the embodiments of the article 1 described herein, the article may comprise such a first aerosol-generating material 3 and/or a second aerosol-generating material 14, and may comprise such an aerosol-generating composition.

The first aerosol-generating material 3 and/or the second aerosol-generating material 14 may comprise paper reconstituted tobacco material. Alternatively or additionally, the composition may comprise tobacco in any of the forms described herein. The first aerosol-generating material 3 and/or the second aerosol-generating material 14 may comprise a sheet or cut-up sheet comprising tobacco material comprising from 10wt% to 90wt% tobacco leaf, wherein the aerosol-former material is provided in an amount up to about 20wt% of the sheet or cut-up sheet and the remainder of the tobacco material comprises paper reconstituted tobacco.

In case the first aerosol-generating material 3 and/or the second aerosol-generating material 14 comprises an amorphous solid material, the amorphous solid material may be a xerogel comprising menthol.

In some embodiments, the first aerosol-generating material 3 and/or the second aerosol-generating material 14 comprises an extruded aerosol-generating material, which is then cut into pellets of beads.

In the above-described embodiments, the material body 12 of the barrier member 4 comprises a plug of aerosol-generating material 14, for example a plug of tobacco fibres, or a reconstituted tobacco strip, or a reconstituted tobacco sheet gathered into a plug. In one embodiment, the body of material 12 is formed from a curled sheet of aerosol-generating material (e.g., reconstituted tobacco). Apparatus and methods for manufacturing a crimped web for an aerosol-generating article 1 are known in the art and generally involve feeding a web or sheet between a pair of staggered rolls that apply a plurality of parallel, equidistant longitudinally extending crimping corrugations to the web or sheet. Once crimped, the sheet or web is gathered to form a continuous rod.

In some embodiments, the material body 12 of the barrier member 4 is formed from a sheet of material with aerosol-generating material added during casting of the sheet. For example, the sheet may be cast from a slurry, wherein aerosol-generating material (e.g., fibers, pellets, pills, beads, or dust, including tobacco fibers, pills, beads, or dust, and/or other plant material) is added to the slurry during casting. In other embodiments, the aerosol-generating material is added to the sheet once the sheet has been formed. For example, an aerosol-generating material (e.g., fibers, pellets, pills, beads or dust, including tobacco fibers, pills, pellets, beads or dust, and/or other plant material) is adhered to the sheet using an adhesive, or applied to the sheet and then held within the sheet as the sheet is gathered into a plug. In some embodiments, the sheet comprises a paper or gel sheet and the aerosol-generating material is incorporated within or applied to the sheet.

It should be appreciated that in other embodiments, the body of material 12 does not include an aerosol generating material. For example, in one alternative embodiment, the body of material 12 comprises a plug-forming paper (e.g., rolled or cut into strips and formed into plugs) without any aerosol-generating material applied to or incorporated within the plug sheet.

An example of the blocking member 4 including a sheet is shown in fig. 11. In this embodiment, the material body 12 of the barrier member 4 comprises a sheet 14B that has been gathered to form the material body 12. The blocking member 4 may have any of the features previously described. For example, the sheet may include aerosol generating material and/or aerosol former material (formed with the sheet during manufacture of the sheet or subsequently applied to the sheet). In one embodiment, the sheet comprises tobacco material and/or gel. In one embodiment, the sheet comprises paper. The sheet may be rolled and gathered to form a plug. In other embodiments, the sheet may be rolled (e.g., in a spiral) to form a body of material. In yet further embodiments, the sheet may be cut into ribbons and/or strands, which are then formed into a body of material. In some embodiments, the barrier member 4 further comprises a forming paper 15 surrounding the body of material 12.

Another example of a blocking member 4 is shown in fig. 12. The blocking member 4 comprises an end 17 of a body of material 12 in the form of a rod 16 of aerosol-generating material 14. Optionally, this end 17 of the rod 16 has a higher density than the other part 18 of the rod. For example, the end 17 may be at least 10% denser than the other portion 18 of the rod 16, and preferably at least 20% (and the other portion 18 may be adjacent to the end 17).

In some embodiments, the rod 16 is a tobacco rod. In some embodiments, the other portion 18 of the rod 16 is the remaining length of the rod 16. The end 17 may extend along the length of the rod 16a first region, while the other portion 18 may extend along the length of the rod 16a second region, which may be the remaining axial length of the rod 16.

In some embodiments, the stem 16 includes a plug wrap 15 surrounding the material body 12 of the stem 16.

The increased density of the ends 17 of the rods 16 helps to prevent the aerosol-generating material 3 from falling out of the space 6 in the receiving member 2. Furthermore, the end 17 of the increased density rod 16 helps to prevent the material of the end 17 from falling out of the end 17 and mixing with the aerosol-generating material 3 in the space 6 of the receiving member 2.

In some embodiments, the end 17 of the rod 16 includes a greater amount of material per unit axial length (e.g., per millimeter) of the rod 16 than the other portion 18. For example, the end 17 includes a greater amount of aerosol-generating material 14, aerosol-former material, filler material, and/or other materials. Thus, when the aerosol-generating material 14 is formed into the stem 16 (e.g., using stem forming equipment known to those skilled in the art), an increase in the amount of material at the end 17 results in the stem 16 having an increased density at the end 17 as compared to the other portion 18 of the stem 16. In some embodiments, the rod 16 per millimeter of length of the end 17 of the rod 16 comprises at least 10% (by weight) and preferably at least 20% (by weight) of material as compared to the other portion 18 of the rod 16.

Referring now to fig. 8, a block diagram depicting an embodiment of a method 100 for manufacturing an article 1 of an aerosol provision device is shown.

The method 100 comprises the step of providing a receiving member 2 comprising a peripheral wall 5 surrounding a space 6 containing an aerosol-generating material 3, an end wall 8 and an open end 7 (S1). The method 100 further comprises the step of providing a blocking member 4 (S2) comprising a body of material 12 arranged to prevent the aerosol-generating material 3 from falling out of the open end 7 of the receiving member 2.

In some embodiments, the step S1 of providing the receiving member 2 comprises forming the receiving member 2 and then providing the aerosol-generating material 3 in the space 6. For example, the aerosol-generating material 3 may be poured into the open end 7 of the receiving member 2. In one such embodiment, the receiving member 2 is oriented such that the central axis of the receiving member 2 is substantially vertical, the open end 7 facing upwards, and then the space 6 of the receiving member 2 is filled or at least partially filled with the aerosol-generating material 3. In some embodiments, the plurality of receiving members 2 move along a conveying path to pass through a filling machine (not shown), wherein the filling machine is configured to deposit the aerosol-generating material 3 in each receiving member 2 as it passes through the filling machine. Optionally, a filling machine may deposit a metered amount of aerosol-generating material 3 in each receiving member 2. For example, the filling machine may comprise a dose wheel configured to deposit the aerosol-generating material 3 in the receiving member 2. Alternatively, the filling machine may supply a continuous flow of aerosol-generating material 3 (e.g. using one or more hoppers), and the aerosol-generating material 3 that does not enter the space 6 of one of the receiving members 2 is collected, processed or recycled.

In other embodiments, the step S1 of providing the receiving member 2 comprises forming the receiving member 2 around the aerosol-generating material 3. For example, the aerosol-generating material 3 may be deposited on the sheet 9, and the sheet 9 is then wrapped around the aerosol-generating material 3 and formed into the receiving member 2. In some embodiments, a metered amount of aerosol-generating material 3 may be deposited on the sheet 9, for example using a dose wheel (not shown) or any other suitable device.

In embodiments in which the receiving member 2 is formed from sheet 9, the sheet 9 may have the features previously discussed, including, for example, paper and/or foil. Optionally, the sheet 9 may have one or all of the features of any of the sheets described herein, including those shown in fig. 4, 9, and/or 10.

In some embodiments, step S1 of providing the receiving member 2 includes rolling/wrapping the sheet 9 to form the peripheral wall 5 of the receiving member 2. An example of rolling of sheet 9 is depicted in fig. 5. In some embodiments, sheet 9 is rolled to form an open-ended tube.

In some embodiments (not shown), the web of sheet 9 is formed as a continuous tube, the ends of which are folded to form the end walls 8, and then a portion of sheet 9 comprising end walls 8 and peripheral wall 5 is cut from the remainder of the continuous tube, thereby forming the receiving member 2. This process may then be repeated for the remainder of the coiled tubing to form additional receiving members 2. That is, a new end of the continuous tube is folded to form the end wall 8, then a portion of the sheet 9 including the end wall 8 and the outer peripheral wall 5 is cut from the remaining portion of the continuous tube, thereby forming the additional receiving member 2, and the process may be repeated again to form the additional receiving member 2.

In some embodiments, step S1 of providing receiving member 2 includes folding sheet 9 to form end wall 8 of receiving member 2. The folding of the sheet 9 to form the end wall 8 of the receiving member 2 may be performed before or after this rolling of the sheet 9.

An example of folding the sheet 9 to form the end wall 8 is shown in fig. 6. The end of the sheet 9 is folded along a fold line (indicated by a broken line "X-X" in fig. 6) in a radially inward direction (in the direction of arrow "Y" in fig. 6) to form an end wall 8 of the receiving member 2. In some embodiments, the ends 10 of the sheet 9 partially overlap when folded to form the end walls 8. In other embodiments, the ends 10 do not overlap, and in some embodiments one or more gaps (not shown) may be formed between the ends 10 to form apertures that allow gas to flow through the end walls 8.

In some embodiments, step S1 of providing receiving member 2 includes forming a plurality of ends 10 in sheet 9, and folding ends 10 to form end walls 8 of receiving member 2. Preferably, forming the end 10 includes providing one or more cuts in the sheet 9. In one such example, to form the end 10, a generally zigzag-shaped arrangement of cuts is provided in the sheet 9, which forms a cut edge 10A.

In some embodiments, the sheet 9 includes a first edge 9A and a second edge 9B. In some embodiments, edges 9A, 9B overlap when sheet 9 is formed into receiving member 2.

In some embodiments, the first plurality of notched edges 10A extend at an angle to the first edge 9A and the second edge 9B in the first direction. In some embodiments, the second plurality of kerf edges 10A extend at an angle to the first edge 9A and the second edge 9B in the second direction. The first and second plurality of slit edges 10A may be alternately arranged between the first edge 9A and the second edge 9B.

In some embodiments, step S1 of providing receiving member 2 includes securing ends 10 together using an adhesive. An adhesive may be provided on one or more of the ends 10 prior to folding the ends 10. Alternatively, adhesive may be provided on one or more of the ends 10 after folding the ends 10. In other examples, the ends 10 may be welded together or held in place by one or more securing members (e.g., staples, decals, or labels).

In some embodiments, step S1 of providing receiving member 2 includes forming one or more apertures 11 in a portion of sheet 9 including end wall 8.

In some embodiments, the or each aperture 11 is formed in the sheet 9 before the sheet 9 is formed into the receiving member 2. In other embodiments, the or each aperture 11 is formed in the sheet 9 after the sheet 9 is formed into the receiving member 2.

In some embodiments, the or each aperture 11 is formed in one or more ends 10 of the sheet 9.

In some embodiments, the or each aperture 11 is formed by cutting, tearing, stamping or burning the sheet and/or by forming a gap between the ends 10 of the sheet 9. The or each aperture 11 may be formed, for example, by cutting using a knife or laser. In some embodiments, the or each aperture 11 comprises a hole in the sheet 9, for example a circular hole. In other embodiments, the or each aperture 11 comprises a slit in the sheet 9.

In some embodiments, the method further includes forming one or more areas of weakness of the sheet 9, the areas being arranged such that the sheet 9 can be folded along the one or more areas of weakness to form the end wall 8, as described in more detail with reference to fig. 9 and 10. However, in other embodiments, the method does not include forming such areas of intensity discontinuity.

In some embodiments, the sheet 9 is provided from a continuous web of sheet material that is cut into pieces to form the sheet 9 of each receiving member 2.

In some embodiments, the receiving member 2 is generally cup-shaped.

In some embodiments, the step S2 of providing the blocking member 4 comprises fixing the blocking member 4 relative to the receiving member 2 using a wrapping material 13. In one such embodiment, securing the barrier member 4 relative to the receiving member 2 using the wrapping material 13 includes surrounding the barrier member 4 and the receiving member 2 with the wrapping material 13.

In some embodiments, the wrapping material 13 is adhered to the receiving member 2 and/or the blocking member 4. However, in other embodiments, the wrapping material 13 may utilize friction to hold the receiving member 2 and/or the blocking member 4 in place.

In some embodiments, the blocking member 4 is generally cylindrical. In some embodiments, the body of material 12 is generally cylindrical.

In some embodiments, the peripheral wall 5 of the receiving member 2 is generally cylindrical.

In some embodiments, the blocking member 4 comprises an end 17 of the rod 16 of aerosol-generating material 14, and preferably this end 17 of the rod 16 has a higher density than the other portion 18 of the rod 16, as described above. In some embodiments, the rod 16 is a tobacco rod.

In one such embodiment, the step S2 of providing the blocking member 4 comprises forming the stem 16 of the aerosol-generating material 14 such that the end 17 of the stem 16 has a higher density than the other portion 18 of the stem 16. In one such example, step S2 includes providing the aerosol-generating material 14 and forming the aerosol-generating material into the rod 16, wherein an amount of material (e.g., aerosol-generating material, aerosol-former material, filler material, or other material) provided at the end 17 of the rod 16 is greater than an amount provided at the other portion 18 of the rod 16 such that when the rod 16 is formed, the end 17 has a higher material density than the other portion 18 of the rod 16.

The material density of the rod 16 per millimetre of axial length of the end 17 of the rod 16 may be higher than that of the further portion 18.

In some embodiments, the mass of material of the rod 16 per millimeter of axial length of the end 17 of the rod 16 may be higher than the other portion 18.

In some embodiments, the blocking member 4 comprises a plug of material. In some embodiments, the body of material 12 is formed as a plug of material.

In some embodiments, the step S2 of providing the blocking member 4 comprises arranging the body of material 12 such that the body 12 is disposed adjacent to the open end 7 of the receiving member 2.

In some embodiments, at least a portion of the body of material 12 is received within the open end 7 of the receiving member 2. In other embodiments, the body of material 12 is not received within the open end 7 of the receiving member 2.

As previously described, the material body 12 may include the aerosol-generating material 14 and/or may include an aerosol-former material.

In some embodiments, the barrier member 4 comprises an aerosol-generating material 14 comprising: about 10wt% to about 50wt% of an aerosol former material; about 15wt% to about 60wt% of a gelling agent; optionally a filler; wherein the wt% value is calculated on a dry weight basis.

In some embodiments, the aerosol-generating material 14 of the barrier member 4 comprises a flavouring.

In some embodiments, the barrier member 4 comprises an amorphous solid, and preferably, the amorphous solid is a gel.

In some embodiments, the barrier member 4 comprises tobacco material.

In some embodiments, the barrier member 4 comprises a sheet material, and preferably wherein the method comprises gathering the sheet material into a body of material. The sheet may comprise paper.

In some embodiments, the sheet of barrier member 4 is curled. The step S2 of providing the barrier member 4 may comprise crimping the sheet. For example, step S2 may include passing the sheet for forming the blocking member 4 through a pair of crimping rollers.

In some embodiments, the sheet of barrier member 4 comprises one or more of an aerosol-generating material and/or paper. The sheet 4 may comprise tobacco material. The sheet 4 may comprise a gel.

In some embodiments, the sheet 9 of receiving member 2 comprises one or more of an aerosol-generating material, foil, and/or paper. The sheet 9 may comprise tobacco material. The sheet 9 may comprise a gel.

In some embodiments, the blocking member 4 comprises an end face 4A in contact with the aerosol-generating material 3.

In some embodiments, the aerosol-generating material 3 provided in the space 6 is provided as a loose material, such as loose tobacco material. The loose material may be poured into the space 6 of the receiving member 2 or deposited on a sheet 9, which is then wrapped around the aerosol-generating material 3 to form the receiving member 2. The aerosol-generating material 3 may be provided as discrete particles.

In some embodiments, the aerosol-generating material 3 in the space 6 of the receiving member 2 comprises, consists of, or consists essentially of tobacco material. In some embodiments, the tobacco material comprises beads/pellets of tobacco material, as previously described. In some embodiments, the tobacco material further comprises another tobacco material in addition to the tobacco beads/pellets.

In some embodiments, the method 100 further comprises providing and incorporating a cooling section into the article, and preferably wherein the cooling section is disposed such that the cooling section is downstream of the receiving member when the article 1 is in use. In some embodiments, the cooling section comprises an aerosol-generating material, and preferably comprises a plug of aerosol-generating material. In some embodiments, the cooling section includes a flavor, for example, the aerosol-generating material of the cooling section may include a flavor. The cooling section may comprise a gel, such as a gel plug.

In some embodiments, the blocking member 4 is upstream of the space 6 when the article 1 is used in the aerosol provision device 200. In other embodiments, the blocking member 4 is downstream of the space 6.

In some embodiments, the end wall 8 of the receiving member 2 is upstream of the space 6 when the article 1 is used in the aerosol provision device 200. In other embodiments, the end wall 8 is downstream of the space 6.

In some embodiments, the method 100 further comprises providing another plug of material (not shown) to the space 6 on the other side of the end wall 8. The further material plug may comprise, for example, a filtration material section or a cooling section and/or a flavour section.

Referring now to fig. 9, an alternative embodiment of a sheet 9 for forming the receiving member 2 of the article 1 is shown. The sheet 9 may have any of the features of the sheet 9 of the article 1 described herein, including any of the features of the sheet 9 described above with reference to fig. 1-8. Except that the sheet 9 also comprises one or more areas of discontinuous intensity 20.

The one or more areas of weakness 20 are arranged such that the sheet 9 can be folded along the one or more areas of weakness 20 to form the end walls 8 of the receiving member 2.

In some embodiments, the discontinuous region(s) 20 of strength comprise weakened areas of the sheet 9. Thus, when the sheet 9 is folded, the sheet 9 is folded along the weakened region(s). For example, the weakened region may include one or more of the following: a cut partially or completely through the thickness of the sheet 9; embossing; a pinhole; preformed crease lines; a score line; and/or areas of reduced thickness of the sheet 9. In one embodiment (not shown), the area of reduced strength is achieved by reinforcing at least a portion of the remainder of the sheet 9, for example, by applying a reinforcing coating (e.g., varnish) to the sheet 9 in the area around the weakened area(s) of the sheet 9 or throughout the remainder.

In some embodiments, the intensity discontinuous region(s) 20 comprise regions of increased intensity of the sheet 9. Therefore, when the sheet 9 is folded, the sheet 9 is folded in the vicinity of the region of increased strength. For example, the region(s) of increased strength may include embossing, coating (e.g., varnish or other coating) or region of increased thickness of the sheet.

In some embodiments, the one or more areas of weakness 20 include embossments.

In some embodiments, one or more of the intensity discontinuous lines 20 are continuous. In other embodiments, one or more of the intensity discontinuity lines 20 are discontinuous.

In some embodiments, the one or more intensity discontinuity areas 20 are intensity discontinuity lines 20. The intensity discontinuity areas 20 may extend substantially linearly.

In some embodiments, the sheet 9 has a first axis A-A extending parallel to the first and second ends 9A, 9B of the sheet 9, wherein the at least one line of intensity discontinuity 20 extends substantially perpendicular to the first axis A-A. In some embodiments, the first axis A-A extends from the end 10 to an opposite end of the sheet 9. It will be appreciated that in other embodiments (not shown) the or each intensity discontinuity areas 20 extends at an angle to the first axis A-A.

In some embodiments, the basis weight of the sheet 9 is at least 35GSM, and preferably at least 100GSM, 150GSM or 200GSM.

In some embodiments, the basis weight of the sheet 9 is at most 300GSM, and preferably at most 250GSM, 200GSM or 150GSM.

In this example, the sheet 9 comprises a plurality of ends 10, which are each folded radially inwards once the peripheral wall 5 has been formed such that the ends 10 form the end walls 8. Alternatively, each end 10 is folded and then sheet 9 is wound to form peripheral wall 5, wherein this winding of sheet 9 brings ends 10 together to form end wall 8.

In some embodiments, each end 10 comprises a flap 10 of sheet 9. Each flap 10 may be generally triangular. That is, the plurality of triangular cutouts may be formed as a sheet. However, one skilled in the art will recognize that other shapes of flaps 10 are possible, such as semi-circular or rectangular flaps.

In this example, the sheet 9 comprises a plurality of intensity discontinuity areas 20, which are discrete and spaced apart from each other. In this example, this region comprises a line of weakness 20 formed by embossing the sheet 9. Each intensity discontinuity area 20 is provided at the edge of the respective end portion 10, where this end portion 10 is connected to the remainder of the sheet 9. Thus, each region 20 facilitates folding of the respective end 10 to form the end wall 8 of the receiving member 2.

Referring now to fig. 10, there is shown yet another embodiment of a sheet 9 for forming the receiving member 2 of the article 1. The sheet 9 may have any of the features of the sheet 9 of the article 1 described above with reference to fig. 1-8 or 9. Except that the sheet 9 comprises a single area of intensity discontinuity 20 extending over the entire width of the sheet 9. Furthermore, the end portion 10 is rectangular and is formed by a cut 10A substantially parallel to the first end 9A and the second end 9B of the sheet 9.

Referring now to fig. 13-15, one embodiment of an aerosol provision device 200 is shown.

The article 1 is configured for an aerosol provision device 200 (see fig. 13) comprising an aerosol generator in the form of a heating element 203 for heating the article 1. In this example, the heating element 203 at least partially surrounds the heating region 202, e.g., the heating chamber 202. The heating element 203 may be resistance heated and/or induction heated.

In other embodiments (not shown), the heating element 203 instead comprises a blade or pin for insertion into the article 1, e.g. the blade or pin may be inserted into the aerosol-generating material 3 in the space 6 and/or into the material body 12 of the blocking member 4. In other embodiments (not shown), the article 1 may comprise a heating element, which may for example be embedded in the aerosol-generating material 3 and/or the barrier member 4.

In fig. 13, the components of one embodiment of an aerosol provision device 200 are shown in a simplified manner. In particular, in fig. 13, the elements of the aerosol provision device 200 are not drawn to scale. Elements irrelevant to understanding the present embodiment are omitted for simplifying fig. 13.

In the example of fig. 13, the aerosol provision device 200 is a non-combustible aerosol provision device 200. The non-combustible sol supply means 200 comprises a housing 201 comprising a region 202 for receiving the article 1.

When the article 1 is received into the heating zone 202, at least a portion of the article 1 is in thermal proximity to the heater 203. Thus, at least a portion of the aerosol-generating material 3 and/or the aerosol-generating material 14 of the material body 12 in the space 6 is in thermal proximity to the heater 203. In some embodiments, the heater 203 is spaced apart from the article 1, e.g., surrounding the article 1 but having a larger diameter and spaced apart from the article. In other embodiments, the heater 203 is in direct contact with the article 1, e.g., contacts the outer surface of the wrapper 13 of the article 1. In another embodiment, the heater 203 comprises a blade or pin in contact with the interior of the article 1, e.g. in contact with the aerosol-generating material 3 and/or the material body 12 of the barrier member 4 in the space 6.

When the article 1 is heated, the aerosol-generating material 3 in the space 6 and/or the aerosol-generating material 14 of the barrier member 4 will release one or more volatile compounds and may release a range of volatile compounds at different temperatures. By controlling the maximum operating temperature of the electrically heated aerosol-generating system 200, the selective release of undesired compounds may be controlled by preventing the release of selected volatile compounds.

As shown in fig. 14, within the housing 201 is an electrical energy supply 204, such as a rechargeable lithium ion battery. The controller 205 is connected to the heater 203, the power supply 204 and a user interface 206, such as a button or a display. The controller 205 controls the power supplied to the heater 203 to adjust the temperature thereof. Typically, the aerosol-forming substrate is heated to a temperature of from 250 degrees celsius to 450 degrees celsius.

Fig. 15 is a schematic cross-sectional view of a non-combustible sol supply device 200 of the type shown in fig. 13, wherein the article 1 is received in a heating zone 202 of the device 200 for heating by a heater 203. The non-combustible aerosol provision device 200 is illustrated receiving an aerosol-generating article 1 for consumption of the aerosol-generating article 1 by a user.

The housing 201 of the non-combustible sol supply device 200 defines a region 202 in the form of a cavity that is open at a proximal (or mouth) end for receiving the aerosol-generating article 1 for consumption by a user.

In this example, the aerosol provision device 200 includes a mouthpiece 207 that is detachable from the remainder of the device 200 to allow access to the region 202 so that the article 1 can be inserted into the region 202 and removed from the region 202. Once the article 1 has been provided in the region 202, the mouthpiece 207 may 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 the user draws on the mouthpiece 207, air is drawn into the article 1 and the volatile material condenses to form an inhalable aerosol. The aerosol passes through the mouthpiece 207 of the device 200 and into the user's mouth.

It should be appreciated that in other embodiments, the mouthpiece 207 of the device 200 may be omitted. In some embodiments, the article 1 may form a mouthpiece and may be in contact with the user's mouth.

In the above-described embodiments, the end wall 8 of the receiving member 2 forms a first end (i.e., the proximal end P or the distal end D) of the article 1, and the blocking member 4 forms a second end (i.e., the other of the proximal end P or the distal end D) of the article 1. However, it should be appreciated that in alternative embodiments (not shown), the article 1 may comprise one or more further segments, for example on the side of the end wall 8 opposite the space 6 and/or on the side of the barrier member 4 opposite the space 6.

For example, an alternative embodiment of the article 1 is shown in fig. 16, which further comprises a cooling section 25, also referred to as cooling element, positioned immediately downstream of the receiving member 2. In this example, the cooling element 25 is immediately downstream of and adjacent to the end wall 8 of the receiving member 2. In some such embodiments, the cooling element 25 is in abutting relationship with the end wall 8. The article 1 may additionally or alternatively comprise a further body 26 of material downstream of the cooling element 25. The further material body 26 may comprise flavourant and/or filter material and/or may be arranged to block the view of the cooling element 25.

The cooling element 25 comprises a hollow channel having an inner diameter of about 1mm to about 4mm, for example about 2mm to about 4mm. The inner diameter of the hollow channel may be about 3mm. The hollow channel extends along the entire length of the cooling element 25. The cooling element 25 may comprise a single hollow channel. In alternative embodiments, the cooling element 25 may comprise a plurality of 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 may provide a space into which the aerosol sucked into the cooling element 25 may expand and cool. The cooling element 25 may be configured to limit the cross-sectional area of the hollow passage in use to limit the displacement of tobacco into the cooling element 25.

The cooling element 25 may have a wall thickness in the radial direction. For a given outer diameter of the cooling element 25, the wall thickness of the cooling element 25 defines the inner diameter of the chamber enclosed by the cooling element 25 wall. The cooling element 25 may have a wall thickness of at least about 1.5mm and at most about 2 mm. In this example, the cooling element 25 has a wall thickness of about 2 mm.

The cooling element 25 may be formed from a filiform filament bundle. Other configurations may be used, such as multiple paper layers wound in parallel with butt seams to form cooling element 25; or a helically wound paper layer, cardboard tube, tube formed using a coagulated paper process, molded or extruded plastic tube, or the like. The cooling element 25 is made with a stiffness sufficient to withstand axial compression forces and bending moments that may occur during manufacture and when the article 1 is in use.

The wall material of the cooling element 25 may be relatively non-porous such that at least 90% of the aerosol generated by the aerosol-generating material 3 passes longitudinally through the one or more hollow channels instead of through the wall material of the cooling element 25. For example, at least 92% or at least 95% of the aerosol generated by the aerosol-generating material 3 may pass longitudinally through the one or more hollow channels.

The cooling element 25 may be configured to provide a temperature difference of at least 40 degrees celsius between the heated volatile components entering the first upstream end of the cooling element 25 and the heated volatile components exiting the second downstream end of the cooling element 25. The cooling element 25 may be configured to provide a temperature difference of at least 60 degrees celsius, or at least 80 degrees celsius, or at least 100 degrees celsius, between the heated volatile component entering the first upstream end of the cooling element 25 and the heated volatile component exiting the second downstream end of the cooling element 25. The temperature difference over the entire length of the cooling element 25 protects the body 26 of temperature sensitive material from the higher temperature of the aerosol generating material 3 when the aerosol generating material 3 is heated.

The body of material 26 defines a generally cylindrical overall shape and is wrapped in a forming paper 28. The forming paper 28 may have a basis weight of less than 50gsm, or between about 20gsm and 40 gsm. The forming paper 28 may have a thickness of 30 μm to 60 μm, or 35 μm to 45 μm. The forming paper 28 may be, for example, a nonporous forming paper having a permeability of less than 100Coresta units, such as less than 50Coresta units. However, in other embodiments, the forming paper 28 may be a porous forming paper, for example having a permeability of at least 100Coresta units or at least 200Coresta units.

The cooling element 25 and/or the body of material 26 may form a mouthpiece of the article 1 configured to be received within the mouth of a user. In some embodiments, the mouthpiece 207 of the device 200 may be omitted.

In some embodiments, the tipping paper 29 is wrapped around the cooling element 25 and the material body 26, and also surrounds the wrapper 13 surrounding the receiving element 2, and may be attached to these components by adhesive. Thus, the tipping paper 29 connects the cooling element 25 and the material body 26 to the receiving member 2 and the blocking member 4. In some embodiments, the wrapper 13 is omitted.

In the above example, the receiving member 2 is formed of the sheet 9. However, in other embodiments, the receiving member 2 may be formed as a molded part or using an additive manufacturing process (e.g., 3D printing), for example.

In each of the examples of articles described above (including each of the articles shown in fig. 1 to 16), the first aerosol-generating material 3 and the second aerosol-generating material 14 may have different densities. Otherwise, the aerosol-generating materials of the article may be the same or different. In other embodiments, the densities of the first aerosol-generating material 3 and the second aerosol-generating material 14 may be the same.

It has been found that providing a first aerosol-generating material 3 and a second aerosol-generating material 14 of different densities means that when both materials are exposed to the same heating, the higher density material heats up more slowly and therefore 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 first aerosol-generating material 3 has a greater density than the second aerosol-generating material 14, such that when exposed to the same heating, the first aerosol-generating material 3 heats up slower than the second aerosol-generating material 14 and will release its volatile compounds (e.g. nicotine) at a slower rate than the second aerosol-generating material 14 (however, in other embodiments the opposite may be true, such that the second aerosol-generating material 14 has a higher density than the first aerosol-generating material 3). Thus, combining aerosol-generating materials having different densities may provide a more consistent and sustained release of the volatile compound(s). In some embodiments, different densities of aerosol-generating materials are combined with separate heating of these materials at optionally different times and/or different temperatures, allowing for more tailored release of the volatile compound(s) during consumption of the article, e.g., alternatively, it may be desirable to have a faster or greater release of volatiles at the beginning of the article consumption to provide a greater initial impact of use from use to the user. The ability to control aerosol generation and volatile compound release may be particularly advantageous because the article can be made relatively small while still achieving a particular desired release of the volatile compound(s) during consumption.

In some embodiments, the density of one of the first aerosol-generating material 3 and the second aerosol-generating material 14 is at least about 25% higher than the density of the other of the first aerosol-generating material 3 and the second aerosol-generating material 14, and optionally at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70% or 75% higher. The density of the one of the first aerosol-generating material 3 and the second aerosol-generating material 14 may be no more than about 200% higher than the density of the other of the first aerosol-generating material 3 and the second aerosol-generating material 14, and optionally no more than about 150%, 125%, 100% or 75% higher. In some embodiments, the density of one of the first aerosol-generating material 3 and the second aerosol-generating material 14 is about 25% to about 75% higher than the density of the other of the first aerosol-generating material 3 and the second aerosol-generating material 14.

In some embodiments, the density of the one of the first aerosol-generating material 3 and the second aerosol-generating material 14 is at least about 0.4g/cm ³, and optionally at least about 0.5g/cm³、0.6g/cm³、0.7g/cm³、0.8g/cm³、0.9g/cm³、1g/cm³、1.1g/cm³、1.2g/cm³、1.3g/cm³、1.4g/cm³、1.5g/cm³、1.6g/cm³、1.7g/cm³、1.8g/cm³、1.9g/cm³ or 2g/cm ³. The density of the one of the first aerosol-generating material 3 and the second aerosol-generating material 14 may be no greater than about 2g/cm ³, and optionally no greater than about 1.9g/cm³、1.8g/cm³、1.7g/cm³、1.6g/cm³、1.5g/cm³、1.4g/cm³、1.3g/cm³、1.2g/cm³、1.1g/cm³、1g/cm³、0.9g/cm³、0.8g/cm³、0.7g/cm³、0.6g/cm³ or 0.5g/cm ³. In some embodiments, the density of the one of the first aerosol-generating material 3 and the second aerosol-generating material 14 is from about 0.4g/cm ³ to 1.99g/cm ³.

In some embodiments, the other of the first aerosol-generating material 3 and the second aerosol-generating material 14 has a density of at least about 0.1g/cm ³, and optionally at least about 0.2g/cm³、0.3g/cm³、0.4g/cm³、0.5g/cm³、0.6g/cm³、0.7g/cm³、0.8g/cm³ or 0.9g/cm ³. The density of the other of the first aerosol-generating material 3 and the second aerosol-generating material 14 may be no greater than about 1g/cm ³, and optionally no greater than about 0.9g/cm³、0.8g/cm³、0.7g/cm³、0.6g/cm³、0.5g/cm³、0.4g/cm³、0.3g/cm³ or 0.2g/cm ³. In some embodiments, the density of the other of the first aerosol-generating material 3 and the second aerosol-generating material 14 is from about 0.1g/cm ³ to 0.9g/cm ³.

In some embodiments, the first aerosol-generating material 3 and the second aerosol-generating material 14 comprise the same composition. Thus, upon heating, they will release very similar aerosols, possibly with the same content of active substances and/or flavourings etc. Their different densities allow aerosols to be generated from the two materials at different rates and/or for different times during the heating process.

In other embodiments, the first aerosol-generating material 3 and the second aerosol-generating material 14 comprise different components (and may have the same or different densities). Thus, upon heating, they will release different aerosols, possibly with different active compositions and/or flavourings etc. Their different densities allow different aerosols to be generated from the two materials during heating at different rates and/or for different times, potentially providing aerosols that vary with age.

In some embodiments, the first aerosol-generating material 3 and the second aerosol-generating material 14 each comprise tobacco. Tobacco will contain volatile components including nicotine, flavoring and flavoring agents. The tobacco may be any type of tobacco and any portion of a tobacco plant, including tobacco leaves, flakes, stems, stalks, ribs, scraps and fines (shorts) or a mixture of two or more thereof. Suitable tobacco materials include the following types: virginia or flue-cured tobacco, burley tobacco, flavoring tobacco, or blends of tobacco materials, optionally including those listed herein. The tobacco may be puffed, such as dry ice puffed 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 may be, for example, solid Stems (SS); a dry stem filament (SDS); steam Treating Stems (STS); or any combination thereof. The tobacco material may be fermented, smoked, unvulcanized, baked or otherwise pre-treated.

The first aerosol-generating material 3 and the second aerosol-generating material 14 may comprise different tobacco. Alternatively, the tobacco may be the same but provided in a different form such that one of the first aerosol-generating material 3 and the second aerosol-generating material 14 has a greater density than the other of the first aerosol-generating material 3 and the second aerosol-generating material 14.

In some embodiments, the first aerosol-generating material 3 has at least one (further) different property than the second aerosol-generating material 14. The different characteristics may be one or more of the form, size, moisture content, amount (by weight), one or more materials or material proportions constituting the first aerosol-generating material 3 and the second aerosol-generating material 14, including the formulation of the aerosol-generating material when each aerosol-generating material is made from more than one material. In some embodiments, the first aerosol-generating material 3 and the second aerosol-generating material 14 do not have different characteristics other than having different densities. In other embodiments, the densities of the first aerosol-generating material and the second aerosol-generating material are the same.

In some embodiments, the second aerosol-generating material 14 comprises tobacco in the form of one or more cut filler. Such tobacco material may be sheet tobacco material or reconstituted tobacco material. In some embodiments, the second aerosol-generating material 14 is a blend comprising both sheet tobacco and reconstituted tobacco. For example, the ratio of sheet tobacco to reconstituted tobacco may be about 1:4 to about 4:1.

In some embodiments, the first aerosol-generating material 3 has a greater density than the second aerosol-generating material 14. In some embodiments, such denser first aerosol-generating material 3 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 aggregated. However, it should be appreciated that in other embodiments the second aerosol-generating material 14 may be denser than the first aerosol-generating material 3 and may be in the form of beads or one or more sheets, for example. In some embodiments, both the first aerosol-generating material 3 and the second aerosol-generating material 14 may be in the form of beads or one or more sheets, and optionally may be treated such that one of the first aerosol-generating material 3 and the second aerosol-generating material 14 has a higher density than the other of the first aerosol-generating material 3 and the second aerosol-generating material 14.

As used herein, the term "bead" refers to a bead, pellet, or other discrete small unit that has been formed, molded, compressed, or otherwise manufactured into a desired shape. The beads may have a smooth, regular shape (e.g., spherical, cylindrical, oval, etc.) and/or they may have an irregular shape.

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

In some embodiments, the desired density of the aerosol-generating material 3, 14 is achieved or controlled by the formulation of the material and/or the method(s) of treating the material. The process involving agglomeration, particularly agglomeration with some application of compressive forces, will tend to increase the density of the material.

Thus, in some embodiments, the first aerosol-generating material 3 and/or the second aerosol-generating material 14 comprises agglomerated material particles.

In the case of sheets, the sheets may be formed from particles of material that are combined and optionally compressed to form sheets of the desired size and density.

In some embodiments, the beads or pellets may be formed using a so-called pelletization (marumarising) process.

In some embodiments, agglomeration is by granulation. Granulation is an agglomeration process that converts fine particles of a material (optionally together with excipients) into free-flowing units, called pellets. Pellet formation and growth may occur in a variety of ways depending on the type of equipment and process selected. These pellets may be formed by agitation and agglomerates are formed when the particles are rolled and tumbled in the presence of a suitable amount of liquid. Spheroidization may involve the use of equipment such as pans, discs, drums, or mixers to produce pellets. Compaction granulation is a form of pressure agglomeration in which the particles are forced together by mechanical forces (optionally with formulation aids). The compressive force means that the pellets formed have an increased density compared to the starting material.

In some embodiments, agglomeration is by extrusion. In some embodiments, pellets formed by granulation may be extruded to form higher density extrudates.

The size of the particles to be extruded may be selected to produce a denser aerosol-generating material (e.g. a denser first aerosol-generating material 3 or second aerosol-generating material 14), which will have an effect on heat transfer and release of volatile components within the material.

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

Extrusion can be performed using one main extruder category: screw, screen and basket, roller, ram and pin barrel extruders. Single screw or twin screw extruders may be used. The advantage of forming the tobacco beads by extrusion is that this treatment combines compression, mixing, conditioning, homogenization and shaping of the composition.

In some embodiments, during extrusion, a free-flowing composition comprising particles (e.g., tobacco particles) is exposed to elevated pressure and temperature and forced through an orifice (e.g., 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 a temperature of about 40 ℃ to about 150 ℃, or about 80 ℃ to about 130 ℃, or about 60 ℃ to about 95 ℃ within the extruder. In some embodiments, including those employing dual extrusion, the precursor composition is exposed to a temperature of about 70 ℃ to about 95 ℃ within the extruder. In some embodiments, including those using a single extrusion, the precursor composition is exposed to a temperature of from about 60 ℃ to about 80 ℃ within the extruder.

Depending on the design of the mold or nozzle used, the composition may be exposed to a pressure of about 2 bar to about 100 bar, or about 5 bar to about 60 bar (immediately prior to the mold or nozzle). The higher the pressure, the more dense the extrudate may be. Thus, the extrusion process may be adjusted to provide an extruded aerosol-generating material having a desired density.

In some embodiments in which tobacco particles are extruded, the tobacco beads formed from the extrudate exhibit good heat and mass transfer due to the relatively high density of the extrudate and the relatively open surfaces in which the tobacco particles are present, which has a positive impact on the release of tobacco components (e.g., flavoring and nicotine).

In some embodiments, extrusion may be a general drying process in which the composition includes dry or substantially dry aerosol-generating particles. The composition may optionally include other particulate materials including, for example, bases, diluents, solid aerosol formers, solid flavor modifiers, and the like.

In some embodiments, the liquid 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 aid in the dissolution or solubilization of the components of the composition, or to aid in the bonding 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 glycerin or other materials discussed herein. When liquid is added to the composition in this way, the liquid is not only applied on the surface, but the extrudate is impregnated with liquid due to the combination of extruder pressure and intense mixing with high shear forces. Where the liquid is an aerosol former material, this may lead to high availability of the aerosol former material in the resulting 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 30wt%, even up to about 40wt%. In general, such large amounts of aerosol former material may make the composition difficult to handle. However, this is not a problem in case the extrusion results in particles being impregnated with aerosol former material. It may be desirable to include an amount of aerosol former material, such as at least about 10wt% or at least about 20wt%, wherein the beads generate an aerosol in addition to releasing volatile components. Where the primary function of the beads is to release the volatile components carried by the beads into an existing aerosol or gas stream, a relatively small amount of aerosol former material, such as up to about 5wt%, may be sufficient.

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

In some embodiments, it is sufficient to provide a higher density of the first aerosol-generating material 3 or the second aerosol-generating material 14 by an extrusion process, if desired. However, in other embodiments, the extrudate may be further processed to increase the density of the first aerosol-generating material 3 or the second aerosol-generating material 14.

For example, in some embodiments, the extruded aerosol-generating material undergoes spheronization. During the spheronization process, the extruded cylindrical pellets are broken into uniform lengths and gradually transformed into spheres due to plastic deformation. In the case where the extrudate is first broken into uniform lengths, a sphere with a uniform diameter will be produced by the spheronization step.

According to one specific example of the embodiments discussed herein, the sample of the first aerosol-generating material 3 is produced as follows (but note that in some embodiments, the sample may be produced according to the following, which is used instead for the second aerosol-generating material).

Three sample formulations with and without binder are shown in table 1, the amounts of which are expressed as percentage of Wet Weight Basis (WWB).

TABLE 1

The tobacco is ground to a fine powder, taking care not to overheat the tobacco. The ground tobacco particles are screened to select particles having a desired size, such as particles less than 250 μm, less than 100 μm, or less than 60 μm.

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

Next, half of the glycerin and half of the water were added to the dry mixture and mixed. Specifically, the mixture was mixed for one more minute at 75 RPM. The remaining glycerin and water were then added and mixed again at 75RPM for 1 minute. Then, to ensure that a homogeneous mixture is obtained, mixing is continued until the mixture has a friable consistency that can be extruded into a block. In this particular example, the additional mixing was continued for 3 minutes.

The mixture was then extruded using Caleva Multilab. The extruder was operated at about 1500rpm to produce a spaghetti-like extrudate length.

The extrudate exits the extruder and is broken into pieces of varying lengths. The blocks are then rounded. Spheronization is carried out until spherical beads are formed. In this case, the extrudate was first spheronized for 1 minute in Caleva Multilab operating at 2,500RPM, and then the beads were inspected for any defects. Then, the rounding was continued for 1 to 2 minutes again. This spheronization step breaks the extruded tobacco into individual pieces and forms dense spherical beads.

In the final step, the spheronized beads were dried in an oven at 65 ℃ for 30 minutes. After each drying period, the beads were weighed and drying was stopped when the desired moisture weight loss was reached. Typically, such drying will take about 1 hour.

In some embodiments, the other of the first aerosol-generating material 3 and/or the second aerosol-generating material 14 is in the form of discrete particles, or in the form of agglomerates of particles. These particles may share various characteristics, such as particle size, with the (denser) first aerosol-generating material 3 and the second aerosol-generating material 14, but will have a lower density. As mentioned above, there are various methods to adjust the density of the aerosol-generating material 3, 14, such as formulating and/or processing the material into particles, beads or pellets.

In some embodiments, the one of the first aerosol-generating material 3 and the second aerosol-generating material 14 comprises a combination of 60% reconstituted tobacco and 40% sheet tobacco, the density of the material being in the range of about 0.1g/cm ³ to about 0.9g/cm ³. The other of the first aerosol-generating material 3 and the second aerosol-generating material 14 comprises from about 30% to about 90% tobacco and has a density in the range of from about 0.4g/cm ³ to about 1.99g/cm ³. The amount of aerosol-forming material included in the one of the first aerosol-generating material 3 and the second aerosol-generating material 14 may be from about 8% to about 15%. The one of the first aerosol-generating material 3 and the second aerosol-generating material 14 may comprise predominantly spherical beads having a particle size of from about 0.5mm to about 3 mm. In some embodiments, the aerosol-generating material in the article comprises about 50% by weight of the first aerosol-generating material 3 and about 50% by weight of the second aerosol-generating material 14. Thus, for example, an article comprising 260mg of aerosol-generating material may comprise 130mg of the first aerosol-generating material 3 and 130mg of the second aerosol-generating material 14.

In some embodiments, if the aerosol-generating material comprises tobacco, the tobacco is present in an amount of about 10wt% to about 90wt% of the aerosol-generating material.

In some embodiments, 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 least 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 greater than about 90%, 89%, 88%, 87%, 86%, 85%, 84%, 83%, 82%, 81%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, or no greater 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 0.5wt% to 2.5wt% or from 0.5wt% to 2wt% of the tobacco, and may be, for example, from 0.5wt% to 1.75wt% of the tobacco, from 0.8wt% to 1.2wt% of the tobacco, or from about 0.8wt% to about 1.75wt% of the tobacco. In some embodiments, the nicotine content may be 0.8wt% to 1wt% of the tobacco.

In some embodiments, the first aerosol-generating material 3 and the second aerosol-generating material 14 have the same nicotine content.

In some embodiments, the first aerosol-generating material 3 and the second aerosol-generating material 14 comprise one or more volatile components. In some embodiments, the first aerosol-generating material 3 and the second aerosol-generating material 14 have the same volatile component content.

In some embodiments, the first aerosol-generating material 3 and/or the second aerosol-generating material 14 comprises tobacco. For example, the first aerosol-generating material 3 and/or the second aerosol-generating material 14 may comprise from about 80mg to about 350mg of tobacco. In some embodiments, the weight of the aerosol-generating material in the article or consumable is 260mg, including 130mg of the combination of the second aerosol-generating material 14 (e.g., including a blend of sheet tobacco and reconstituted tobacco) and 130mg of the first aerosol-generating material 3 (e.g., including higher density tobacco beads).

In some embodiments, the article comprises regions of aerosol-generating material, wherein each region comprises an equal amount of tobacco containing aerosol-generating material. In alternative embodiments, the regions may contain different amounts of tobacco. In the case of a total amount of tobacco of about 80mg to about 350mg, one region of the aerosol-generating material comprises about 20mg to about 330mg, or about 50mg to about 300mg, or about 40mg to about 125mg of tobacco, and another region of the aerosol-generating material comprises about 20mg to about 330mg, or about 30mg to about 300mg, or about 40mg to about 125mg of tobacco.

In accordance with the present disclosure, there is also provided a kit of parts comprising an article according to any of the examples described herein and an aerosol supply device.

In accordance with 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 include a container including a body and a lid, wherein a space is provided within the container body to receive a plurality of articles. For example, the cover may be a hinged cover, a snap-fit cover, or a cover that is threaded.

The various embodiments described herein are only used to aid in understanding and teaching the claimed features. These embodiments are provided as representative examples of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that the advantages, embodiments, examples, functions, features, structures and/or other aspects described herein are not to be taken as limiting the scope of the invention as defined by the claims or the equivalents of the claims, and that other embodiments may be used 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 the appropriate combination of the disclosed elements, assemblies, features, components, steps, means, etc. other than those specifically described herein. Furthermore, the present disclosure may include other inventions not presently claimed but which may be claimed in the future.

Claims

1. An article for use in an aerosol provision system, the article comprising:

An aerosol-generating material;

a receiving member comprising an end wall, an open end and a peripheral wall surrounding a storage area containing the aerosol-generating material; and

A blocking member comprising a body of material arranged to prevent movement of the aerosol-generating material out of the storage region through the open end of the receiving member.

2. The article of claim 1, wherein the receiving member comprises a sheet.

3. The article of claim 2, wherein the sheet comprises paper and/or foil.

4. An article according to claim 2 or claim 3 wherein the sheet is folded to form the end wall.

5. The article of any one of claims 2 to 4, wherein the sheet comprises a plurality of ends extending radially inward to form end walls, and preferably each end comprises a flap of the sheet.

6. The article of claim 5, wherein the ends are secured together by an adhesive.

7. The article of any one of the preceding claims, wherein the end wall is breathable.

8. The article of claim 7, wherein the end wall comprises one or more apertures.

9. The article of any one of the preceding claims, wherein the receiving member is generally cup-shaped.

10. The article of any of the preceding claims, further comprising a wrapping material that secures the barrier member relative to the receiving member, and preferably wherein the wrapping material surrounds the receiving member and the barrier member.

11. The article of any of the preceding claims, wherein the barrier member is generally cylindrical.

12. An article according to any preceding claim, wherein the blocking member comprises an end of a rod of aerosol generating material, and preferably the end of the rod has a higher density than another portion of the rod, and preferably the rod is a tobacco rod.

13. The article of any one of the preceding claims, wherein the body of material comprises a plug of material.

14. The article of any one of the preceding claims, wherein the body of material is disposed near the open end of the receiving member.

15. The article according to any of the preceding claims, wherein the axial length of the material body is in the range of 3mm to 20mm, preferably in the range of 4mm to 15mm, 5mm to 12mm or 7mm to 10mm.

16. An article according to any preceding claim, wherein the body of material comprises an aerosol generating material and/or an aerosol former material.

17. An article according to any preceding claim, wherein the density of the aerosol-generating material in the storage region is in the range of from about 0.4g/cm ³ to about 2g/cm ³.

18. An article according to any preceding claim, wherein the body of material comprises an aerosol-generating material having a density in the range of from about 0.1g/cm ³ to about 1g/cm ³.

19. An article according to any preceding claim, wherein the density of the aerosol-generating material in the storage region is at least 25% higher than the density of the material body.

20. An article according to any preceding claim, wherein the barrier member comprises an aerosol-generating material comprising: about 10wt% to about 50wt% of an aerosol former material; about 15wt% to about 60wt% of a gelling agent; optionally a filler; wherein the wt% value is calculated on a dry weight basis, and preferably wherein the aerosol-generating material of the barrier member comprises a flavour.

21. The article of any one of the preceding claims, wherein the barrier member comprises a tobacco material.

22. The article of any of the preceding claims, wherein the barrier member comprises paper.

23. The article of any one of the preceding claims, wherein the body of material comprises a sheet arranged to form the body of material, and preferably the sheet is gathered to form the body of material.

24. The article of claim 23, wherein the sheet is curled.

25. An article according to any preceding claim, wherein the barrier member comprises an end portion in contact with the aerosol-generating material.

26. An article according to any preceding claim, wherein the aerosol-generating material is a bulk material.

27. An article according to any preceding claim, wherein the aerosol-generating material comprises, consists of, or consists essentially of a tobacco material.

28. The article of any preceding claim, further comprising a cooling section, and preferably wherein the cooling section is arranged such that, when the article with an aerosol supply device is in use, the cooling section is downstream of the receiving member.

29. An article according to claim 28, wherein the cooling section comprises an aerosol-generating material, and preferably comprises an aerosol-generating material in the form of a plug.

30. The article of claim 29, wherein the cooling section comprises a flavor.

31. The article of any one of the preceding claims, further comprising providing a plug of material to the storage area on the other side of the end wall.

32. An aerosol provision system comprising an article according to any preceding claim and an aerosol provision device.

33. A package comprising a plurality of articles according to any one of claims 1 to 31, and preferably wherein a plurality of said articles are hermetically sealed.

34. A method of manufacturing an article for use in an aerosol provision system, the method comprising:

Providing a receiving member comprising an end wall, an open end and a peripheral wall surrounding a storage area containing the aerosol-generating material; and

A blocking member is provided, the blocking member comprising a body of material arranged to prevent the aerosol-generating material from moving out of the storage region through the open end of the receiving member.

35. A method according to claim 34, wherein providing the receiving member comprises forming the receiving member and then providing the aerosol-generating material in the storage region.

36. A method according to claim 34, wherein providing the receiving means comprises forming the receiving member around the aerosol-generating material.

37. A method according to any one of claims 34 to 36, wherein the receiving member comprises a sheet, and preferably wherein the sheet comprises paper and/or foil.

38. The method of claim 37, wherein providing the receiving member comprises arranging the sheet to form the peripheral wall such that the peripheral wall is generally cylindrical, and preferably comprises rolling the sheet to form the peripheral wall.

39. The method of claim 37 or claim 38, wherein providing the receiving member comprises folding the sheet to form an end wall of the receiving member.

40. The method of any one of claims 37 to 39, comprising forming a plurality of ends in the sheet, and preferably forming the ends comprises providing one or more cuts in the sheet.

41. The method of claim 40, comprising bonding the ends together using an adhesive.

42. A method according to any one of claims 37 to 41, comprising forming one or more apertures in a portion of the sheet comprising the end wall.

43. The method of any one of claims 34 to 42, wherein the receiving member is generally cup-shaped.

44. The method of any of claims 34 to 43, further comprising securing the blocking member relative to the receiving member using a wrapping material, and preferably wherein securing the blocking member relative to the receiving member using the wrapping material comprises surrounding the blocking member and the receiving member with the wrapping material.

45. The method of any one of claims 34 to 44, wherein the blocking member is generally cylindrical.

46. A method according to any one of claims 34 to 45, wherein the blocking member comprises an end of a rod of aerosol generating material, and preferably the end of the rod has a higher density than another portion of the rod, and preferably the rod is a tobacco rod.

47. The method of any one of claims 34 to 46, wherein the blocking member comprises a plug of material.

48. The method of any one of claims 34 to 47, wherein the body of material is disposed near the open end of the receiving member.

49. The method according to any one of claims 34 to 48, wherein the axial length of the material body is in the range 3mm to 20mm, preferably in the range 4mm to 15mm, 5mm to 12mm or 7mm to 10 mm.

50. A method according to any one of claims 34 to 49, wherein the body of material comprises an aerosol generating material.

51. A method according to any one of claims 34 to 50, wherein the body of material comprises an aerosol former material.

52. A method according to any one of claims 34 to 51, wherein the barrier member comprises an aerosol generating material.

53. A method according to any one of claims 34 to 52, wherein the barrier member comprises tobacco material.

54. A method according to any one of claims 34 to 53, wherein the barrier member comprises a sheet material, and preferably wherein the method comprises arranging the sheet material to form the body of material, and preferably comprises gathering the sheet material to form the body of material.

55. The method of claim 54, wherein the sheet is curled, and preferably the method comprises curling the sheet.

56. A method according to any one of claims 34 to 55, wherein the blocking member comprises an end portion in contact with the aerosol-generating material.

57. A method according to any one of claims 34 to 56, wherein the aerosol-generating material in the storage region is a bulk material.

58. A method according to any one of claims 34 to 57, wherein the aerosol-generating material in the storage region comprises, consists of or consists essentially of tobacco material.

59. The method of claim 58, wherein the tobacco material comprises tobacco beads, and preferably wherein the tobacco material further comprises another tobacco material other than tobacco beads.

60. The method of any of claims 34 to 59, further comprising providing a cooling section and incorporating the cooling section into the article, and preferably wherein the cooling section is disposed such that the cooling section is downstream of the receiving member when the article is in use.

61. A method according to claim 60, wherein the cooling section comprises aerosol generating material, and preferably comprises aerosol generating material in the form of a plug.

62. The method of claim 61, wherein the cooling section comprises a flavoring.

63. The method of any one of claims 34 to 62, further comprising providing a plug of material on the other side of the end wall to the storage region.

64. A sheet for forming a receiving member of an aerosol supply system article, wherein the sheet comprises one or more regions of discontinuous intensity configured to facilitate folding of the sheet in a predetermined manner to form an end wall of the receiving member.

65. The sheet of claim 64, wherein the one or more areas of intensity discontinuity comprise one or more of: embossing; a cut partially through the thickness of the sheet; a cut through the entire thickness of the sheet; a pin hole; crease lines; a score line; and/or a region of reduced thickness of the sheet.

66. The sheet of claim 64 or claim 65, wherein the one or more areas of discontinuous strength are areas of weakness.

67. The sheet of any one of claims 64-66, wherein the one or more regions of intensity discontinuity are lines of intensity discontinuity.

68. The sheet of claim 67, wherein the sheet has a first edge and a second edge, and wherein at least one line of intensity discontinuity extends substantially perpendicular to the first edge and the second edge.

69. The sheet of any one of claims 64 to 68, wherein the basis weight of the sheet is at least 35GSM, and preferably at least 100GSM, 150GSM or 200GSM.

70. The sheet according to any one of claims 64 to 69, wherein the basis weight of the sheet is at most 300GSM, and preferably at most 250GSM, 200GSM or 150GSM.

71. The sheet of any one of claims 64-70, wherein sheet comprises one or more flaps configured to fold to form the end walls.

72. The sheet of claim 71 wherein the one or more flaps are generally triangular.

73. The sheet of claim 71 or claim 72, wherein at least one of the strength discontinuity areas is arranged to facilitate folding of the one or more flaps to form the end wall.

74. The sheet of any one of claims 64 to 73, wherein the sheet comprises paper and/or foil.

75. A receiving member for an aerosol provision system article, wherein the receiving member comprises an end wall, an open end and a peripheral wall surrounding a storage area for containing an aerosol-generating material, wherein the receiving member comprises a sheet according to any one of claims 64 to 74, the sheet being arranged to form the peripheral wall and the end wall.

76. An article for use in an aerosol provision system, the article comprising:

the receiving member of claim 75;

an aerosol-generating material disposed in the storage region of the receiving member; and

77. The article of claim 76, wherein the article has one or more features of the article of any one of claims 1 to 31.

78. A method of manufacturing a sheet for an article in an aerosol supply system, the method comprising providing a sheet and forming one or more areas of strength discontinuity in the sheet, the sheet being arranged such that the areas of strength discontinuity promote folding of the sheet in a predetermined manner to form end walls of a receiving member.

79. The method of claim 78, wherein the sheet has the features of any one of claims 64 to 74.