EP4451933A2

EP4451933A2 - Apparatus for manufacturing a rod of aerosol generating material, methods of manufacturing a rod of aerosol generating material and methods of manufacturing an article for an aerosol provision system

Info

Publication number: EP4451933A2
Application number: EP22838936.7A
Authority: EP
Inventors: Barry DIMMICK; John Richardson
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2021-12-20
Filing date: 2022-12-20
Publication date: 2024-10-30
Also published as: JP2024546861A; US20250049102A1; MX2024007367A; WO2023118857A3; CA3241346A1; IL313277A; WO2023118857A2; AU2022421019A1; CN118555914A; KR20240100458A

Abstract

The present disclosure relates to an apparatus for manufacturing a rod of aerosol generating material. The apparatus comprises a suction belt for conveying aerosol generating material, the suction belt comprising suction holes to retain aerosol generating material on the suction belt, and wherein the apparatus is arranged such that the suction belt receives a first aerosol generating material at a first supply zone. The apparatus further comprises a blocking member configured to block some of the suction holes in the suction belt at the first supply zone such that the first aerosol generating material is arranged in a profile comprising a plurality of first regions of the first aerosol generating material, with no or a reduced amount of first aerosol generating material provided between the first regions. The apparatus further comprises a first feeding device configured to supply at least one of beads, pellets or granules of a second aerosol generating material between said first regions. The present disclosure also relates to methods of manufacturing a rod of aerosol generating material, and to methods of manufacturing an article for an aerosol provision system. The present disclosure also relates to an article for use in an aerosol provision system.

Description

Apparatus for Manufacturing a Rod of Aerosol Generating Material, Methods of Manufacturing a Rod of Aerosol Generating Material and Methods of Manufacturing an Article for an Aerosol Provision System. Field

The present disclosure relates to apparatus for manufacturing a rod of aerosol generating material, to methods of manufacturing a rod of aerosol generating material, and to methods of manufacturing an article for an aerosol provision system. The present disclosure also relates to an article for use in an aerosol provision system.

Background

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

Summary

According to the present invention, there is provided an apparatus for manufacturing a rod of aerosol generating material, the apparatus comprising: a suction belt for conveying aerosol generating material, the suction belt comprising suction holes to retain aerosol generating material on the suction belt, and wherein the apparatus is arranged such that the suction belt receives a first aerosol generating material at a first supply zone; and, a blocking member configured to block some of the suction holes in the suction belt at the first supply zone such that the first aerosol generating material is arranged in a profile comprising a plurality of first regions of the first aerosol generating material, with no or a reduced amount of first aerosol generating material provided between the first regions; and, a first feeding device configured to supply at least one of beads, pellets or granules of a second aerosol generating material between said first regions.

In some embodiments, the first feeding device is disposed downstream of the first supply zone.

In some embodiments, the profile is arranged such that substantially no first aerosol generating material is disposed between the first regions such that the first regions are discrete and spaced apart from each other. In some embodiments, the profile is arranged such that a connection region is provided between each first region, wherein each connection region comprises a reduced amount of the first aerosol generating material than the first region.

In some embodiments, the first feeding device comprises a drum comprising a plurality of receiving spaces configured to receive the beads, pellets and/ or granules and transfer the beads, pellets and/or granules between said first regions. In some embodiments, the first feeding device is configured such that the beads, pellets and/or granules are blown and/or sucked from the receiving spaces. The first feeding device may comprise a flow generator configured to blow and/or suck the beads, pellets and/or granules from the receiving spaces. In some embodiments, the drum comprises a plurality of mesh sections that define the receiving spaces.

In some embodiments, the feeding device is configured to supply the beads, pellets and/ or granules to the suction belt.

In some embodiments, the feeding device is configured to supply the beads, pellets and/ or granules downstream of the suction belt.

In some embodiments, the apparatus further comprises wrapping device. In some embodiments, the wrapping device is adapted to wrap a ribbon of paper about the first aerosol generating material and the beads, pellets and/ or granules to form a continuous rod of aerosol generating material

In some embodiments, the feeding device is configured to supply the beads, pellets and/ or granules to the wrapping device.

The wrapping device may comprise a garniture arranged to receive the profile of first aerosol generating material from the suction belt. In some embodiments, the feeding device is configured to supply the beads, pellets and/ or granules to the profile on the garniture. In some embodiments, the garniture is adapted to wrap a ribbon of paper about the first aerosol generating material and the beads, pellets and/ or granules to form a continuous rod of aerosol generating material.

In some embodiments, the apparatus further comprises a cutter adapted to cut the continuous rod of aerosol generating material.

In some embodiments, the first feeding device is configured to supply at least one of extruded beads, pellets or granules and, preferably, at least one of beads, pellets or granules that have been extruded and subject to spheronisation.

In some embodiments, first feeding device is configured to supply beads, pellets and/ or granules having a density from at least about 0.4 g/cm3 and, preferably, from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3. The beads, pellets and/or granules may have a density of no more than about 2 g/cm3 and, optionally no more than about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6 or 0.5 g/cm3, in some embodiments, the density of the beads, pellets and/or granules is from about 0.4 to 1.99 g/cm3.

In some embodiments, the first aerosol generating material has a density of from at least about 0.1 g/cm3 and optionally from at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8 or 0.9 g/cm3. The first aerosol generating material 4 may have a density of no more than about 1 g/cm3 and, optionally no more than about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3 or 0.2 g/ cm3. In some embodiments, the density of the first aerosol-generating material 4 is from about 0.1 to 0.9 g/cm3.

In some embodiments, the density of one of the first aerosol-generating material and the second aerosol generating material (e.g. the beads, pellets and/or granuules) is at least about 25% higher than the density of the other one of the first and second aerosol generating materials. However, in other embodiments, the density of the first and second aerosol generating materials is the same.

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

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

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

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

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

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

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

In some embodiments, the first feeding device is configured to supply beads, pellets and/or granules having a particle size in the range of 0.5 to 3 mm and, preferably, in the range of 1 to 2 mm. In some embodiments, the first and/or second aerosol generating materials comprise, consist of, or essentially consist of tobacco material.

In some embodiments, the first aerosol generating material comprises, consists of, or essentially consists of cut rag tobacco.

In some embodiments, the suction belt is arranged to retain the first aerosol generating material on an underside of the suction belt. In some embodiments, the apparatus further comprises a second feeding device arranged to feed the first aerosol generating material onto the suction belt in the first supply zone and, preferably, the second feeding device is disposed below the suction belt. In some embodiments, the first feeding device is disposed below the suction belt.

In some embodiments, the blocking member comprises a profile belt. The profile belt may be arranged to overlap the suction belt in the first region, the profile belt being configured to block some of the suction holes in the suction belt such that the first aerosol generating material is retained on the suction belt in the profile.

In some embodiments, the apparatus further comprises rollers, and wherein the suction belt is arranged to run on the rollers such that the suction belt has an upper run and a lower run and, preferably, wherein the profile belt is disposed between the upper run and the lower run of the suction belt.

In some embodiments, the apparatus further comprises first, second and third rollers, the third roller being disposed between the first roller and the second roller, and wherein the suction belt is arranged to run on the first roller and the second roller, and wherein the profile belt is arranged to run on the first roller and the third roller such that the profile belt overlaps the suction belt between the first roller and the third roller.

In some embodiments, the apparatus further comprises first, second, third and fourth rollers, wherein the third and fourth rollers are disposed between the first and second rollers, and wherein the suction belt is arranged to run on the first and second rollers and wherein the profile belt is arranged to run on the third and fourth rollers.

In some embodiments, profile belt comprises a plurality of suction regions and a plurality of blocking regions arranged along the length of the profile belt.

In some embodiments, each suction region comprises a plurality of suction holes.

In some embodiments, each suction region comprises a single aperture.

In some embodiments, the profile belt further comprises connecting suction regions disposed between the suction regions, each of the connecting suction regions being smaller than the suction regions such that less aerosol generating material is retained on the suction belt in each connecting suction region than in each suction region.

In some embodiments, wherein each connecting suction region comprises a plurality of suction holes.

In some embodiments, each connecting suction region comprises a single aperture.

In some embodiments, the profile belt has a higher porosity in the suction regions than in the blocking regions.

In some embodiments, the material of the profile belt has a higher porosity in the suction regions than in the blocking regions.

In some embodiments, the suction belt has a first width and the profile belt has a second width, and wherein the second width is less than the first width. In some embodiments, the apparatus further comprises a trimmer arranged to trim the first and/or second aerosol generating material on the suction belt, the trimmer being disposed between the first supply zone and a second supply zone (the beads, pellets and/ or granules of second aerosol generating material being supplied at the second supply zone). In some embodiments, the apparatus further comprises a second trimmer arranged to trim the aerosol generating material on the suction belt downstream of the second supply zone. In some embodiments, the trimmer and/or the second trimmer comprises an ecreteur.

According to the present disclosure, there is also provided a method of manufacturing a rod of aerosol generating material, the method comprising: applying suction to a suction belt having suction holes to retain a first aerosol generating material on the suction belt in a first supply zone; blocking some suction holes of the suction belt in the first region such that the first aerosol generating material is retained on the suction belt in a profile comprising a plurality of first regions of the first aerosol generating material, with no or a reduced amount of first aerosol generating material provided between the first regions; and, supplying at least one of beads, pellets or granules of a second aerosol generating material between said first regions.

In some embodiments, the beads, pellets and/or granules are supplied to the suction belt. In some embodiments, the beads, pellets and/or granulesare supplied downstream of the suction belt.

In some embodiments, the method further comprises transferring the first aerosol generating material to a garniture.

In some embodiments, the beads, pellets and/or granules are supplied to the garniture.

In some embodiments, the method further comprises wrapping the aerosol generating material in a ribbon of paper to form a continuous rod of aerosol generating material.

In some embodiments, further comprises cutting the continuous rod of aerosol generating material.

In some embodiments, the first feeding device is configured to supply extruded beads, pellets and/ or granules and, preferably, beads, pellets and/ or granules that have been extruded and subject to spheronisation. In some embodiments, the first feeding device is configured to supply beads, pellets and/or granules having a density from at least about 0.4 g/cm3 and, preferably, from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3. The beads, pellets and/ or granules may have a density of no more than about 2 g/ cm3 _and, optionally no more than about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6 or 0.5 g/cm3, in some embodiments, the density of the beads, pellets and/or granules is from about 0.4 to 1.99 g/cm3. In some embodiments, the first aerosol generating material has a density of from at least about 0.1 g/cm3 and optionally from at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8 or 0.9 g/cm3. The first aerosol generating material 4 may have a density of no more than about 1 g/cm3 and, optionally no more than about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3 or 0.2 g/cm3. In some embodiments, the density of the first aerosol-generating material 4 is from about 0.1 to 0.9 g/cm3.

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

In some embodiments, the beads, pellets or granules has a density of from about 0.4 g/cm3 to about 2 g/cm3.

In some embodiments, the second aerosol-generating material comprises extruded tobacco. In some embodiments, the second aerosol-generating material comprises beads. In some embodiments, the first aerosol-generating material comprises one or more tobacco material selected from the group consisting of lamina and reconstituted tobacco material. In some embodiments, the first and/or second aerosol-generating material comprises a combination of lamina and reconstituted tobacco material. In some embodiments, the lamina and reconstituted tobacco material are present in the aerosol-generating material in a ratio of from 1:4 to 4:1, by weight. In some embodiments, the first and second aerosol-generating materials have the same levels of a volatile compound. In some embodiments, the volatile compound is nicotine.

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

In some embodiments, the first feeding device is configured to supply beads, pellets and/or granules having a particle size in the range of 0.5 to 3 mm and, preferably, in the range of 1 to 2 mm. In some embodiments, the first aerosol generating material and/ or the beads, pellets and/or granules comprise, consist of, or essentially consist of tobacco material.

According to the present disclosure, there is also provided a method of manufacturing an article for an aerosol provision system, the method comprising manufacturing a rod of aerosol generating material according to the method disclosed herein, wherein first and second ends of the rod of aerosol generating material comprises first and second ends of the article. According to the present disclosure, there is also provided a method of manufacturing rods of aerosol generating material, the method comprising: providing at least one of beads, pellets or granules of tobacco material; entraining the beads, pellets and/or granules in a continuous pressurised fluid stream; and feeding the stream into a first aerosol generating material.

In some embodiments, entraining the beads, pellets and/or granules in a continuous pressurised fluid stream comprises using a venturi device to entrain the beads, pellets and/or granules.

In some embodiments, entraining the beads, pellets and/or granules in a continuous pressurised fluid stream comprises propelling the beads, pellets and/or granules in a high pressure jet. In some embodiments, entraining the beads, pellets and/ or granules in a continuous pressurised fluid stream comprises using a vacuum pump to propel the beads, pellets and/or granules.

In some embodiments, feeding the stream into a first aerosol generating material comprising feeding the stream into a body or rod of first aerosol generating material.

In some embodiments, feeding the stream comprises positioning the stream substantially parallel to a longitudinal axis of the body or rod. In some embodiments, providing the beads, pellets and/ or granules of tobacco material comprises storing beads, pellets and/or granules of tobacco material in a storage unit and receiving the beads, pellets and/or granules from the storage unit.

In some embodiments, storing the beads, pellets and/or granules comprises storing the beads, pellets and/or granules in a conical hopper.

In some embodiments, the beads, pellets and/or granules are extruded and, preferably, beads, pellets and/or granules have been extruded and subject to spheronisation. In some embodiments, the beads, pellets and/or granules have a density from at least about 0.4 g/cm3 and, preferably, from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3. The beads, pellets and/ or granules may have a density of no more than about 2 g/ cm3 and, optionally no more than about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6 or 0.5 g/cm3, in some embodiments, the density of the beads, pellets and/or granules is from about 0.4 to 1.99 g/cm3. In some embodiments, the first aerosol generating material has a density of from at least about 0.1 g/cm3 and optionally from at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8 or 0.9 g/cm3. The first aerosol generating material 4 may have a density of no more than about 1 g/cm3 and, optionally no more than about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3 or 0.2 g/cm3. In some embodiments, the density of the first aerosol-generating material 4 is from about 0.1 to 0.9 g/cm3.

In some embodiments, the beads, pellets and/or granules have a particle size in the range of 0.5 to 3 mm and, preferably, in the range of about 1 to 2 mm.

In some embodiments, the first aerosol generating material comprise, consist of, or essentially consist of tobacco material.

In some embodiments, the first aerosol generating material comprises, consists of, or essentially consists of cut rag tobacco. According to the present disclosure, there is also provided a method of manufacturing an article for an aerosol provision system, the method comprising manufacturing a rod of aerosol generating material according to a method described herein, wherein first and second ends of the rod of material comprises first and second ends of the article. According to the present disclosure, there is also provided a pack comprising a plurality of articles manufactured according to a method described herein. According to the present disclosure, there is also provided an article manufactured from a rod of aerosol generating material manufactured according to a method described herein.

According to the present disclosure, there is also provided an article for an aerosol provision system comprising a rod of aerosol generating material, wherein the rod of aerosol generating material comprises a first region of a first aerosol generating material and a second region of a second aerosol generating material comprising at least one of beads, pellets and/ or granules.

In some embodiments, the beads, pellets or granules are inserted into the first aerosol generating material. In some embodiments, the article is manufactured by an apparatus as described herein or according to a method as described herein.

In some embodiments, the first and second ends of the rod of aerosol generating material comprise first and second ends of the article.

In some embodiments, the beads, pellets and/or granules have a density from at least about 0.4 g/cm3 and, preferably, from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3. The beads, pellets and/ or granules may have a density of no more than about 2 g/ cm3 and, optionally no more than about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6 or 0.5 g/cm3, in some embodiments, the density of the beads, pellets and/or granules is from about 0.4 to 1.99 g/cm3. In some embodiments, the first aerosol generating material has a density of from at least about 0.1 g/cm3 and optionally from at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8 or 0.9 g/cm3. The first aerosol generating material may have a density of no more than about 1 g/cm3 and, optionally no more than about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3 or 0.2 g/cm3. In some embodiments, the density of the first aerosol-generating material is from about 0.1 to 0.9 g/cm3. In some embodiments, the density of one of the beads, pellets and/ or granules is at least about 25% higher than the first aerosol generating material. However, in other embodiments, the density of the first and second aerosol generating materials is the same.

In some embodiments, the beads, pellets or granules has a density of from about 0.4 g/ cm3 to about 2 g/ cm3.

In some embodiments, the heating of the article provides a relatively constant release of volatile compounds into an inhalable medium. In some embodiments, the second aerosol-generating material comprises extruded tobacco.

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

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

In some embodiments, the release of a volatile compound from the first and second aerosol-generating material is at the same rate when the materials reach a given temperature. In some embodiments, the first and second aerosol-generating materials are present in the article in a ratio of from 1:10 to 10:1, by weight.

In some embodiments, the first aerosol generating material comprise, consist of, or essentially consist of tobacco material. In some embodiments, the first aerosol generating material comprises, consists of, or essentially consists of cut rag tobacco.

Brief Description of the Drawings

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

Figures 1A to 1D show examples of articles for an aerosol provision system that include two different types of aerosol generating material;

Figures 2A and 2B show examples of wrapped aerosol generating material rods having two different types of aerosol generating material, the wrapped aerosol generating material rods being formed during the manufacture of the consumables for an aerosol provision system of Figures lAto 1D;

Figure 3A shows a part of apparatus for manufacturing the example wrapped aerosol generating material rods of Figures 2A and 2B; Figure 3B shows a part of an alternative apparatus for manufacturing the example wrapped aerosol generating material rods of Figures 2A and 2B;

Figure 4A shows a part of an alternative apparatus for manufacturing the example wrapped aerosol generating material rods of Figures 2A and 2B;

Figure 4B shows a part of an alternative apparatus for manufacturing the example wrapped aerosol generating material rods of Figures 2A and 2B;

Figures 5A to 5D show different examples of the blocking member of the apparatus of Figure 3 or Figure 4;

Figure 6 shows the suction belt of the apparatus of Figure 3 or Figure 4.

Figure 7 is a three dimensional perspective view of a rod making machine and bead insert unit attached thereto;

Figure 8 is a cross sectional view of the bead insert unit shown in Figure 7; Figure 9 is an exploded cross sectional view of the bead insert unit shown in Figure 8; Figure 10 is a cross sectional plan view showing the operation of the venturi device of Figure 9;

Figure 11 is side-on cross sectional view of an alternative embodiment of the present disclosure;

Figure 12 is a cross sectional view of a rod of aerosol generating material;

Figure 13 is a cross sectional view of an alternative rod of aerosol generating material; Figure 14 is a cross sectional view of an aerosol provision system comprising a rod of aerosol generating material; Figure 15 is a side view of a bead insert unit according to an alternative embodiment; and

Figure 16 is a three dimensional view of a hopper according to an embodiment.

Figure 17 is a cross sectional view of an embodiment of a non-combustible aerosol provision device; Figure 18 is a simplified schematic of the components within the housing of the aerosol provision device shown in Figure 17;

Figure 19 is a cross sectional view of the non-combustible aerosol provision device shown in Figure 17 with the article shown in Figures 1A to 1D and Figures 12 to 14 inserted into the device.

Detailed Description

Figure 1A to 1D show different examples of articles 1, such as consumables, for an aerosol provision system. One example of an aerosol provision system 200 is shown and described with reference to Figures 17 to 19. The articles 1 comprise a rod of aerosol generating material 3 that, during use, generates an aerosol for delivery to a user.

As illustrated, in these examples the rods of aerosol generating material 3 include a first aerosol generating material 4 and a second aerosol generating material 5. The first and second aerosol generating materials 4, 5 are different. In particular, the second aerosol generating material 5 is provided in the form of beads, pellets and/ or granules 5. The beads of second aerosol generating material 5 are hereafter referred to as “beads” for brevity. The first aerosol generating material 4 and the beads 5 are arranged in distinct areas of the rod of aerosol generating material 3, such that a boundary is formed between the first aerosol generating material 4 and the beads 5 in the rod of aerosol generating material 3, as illustrated in Figures 1A to 1D. In the example of Figure 1A, the first aerosol generating material 4 extends from a first end 2 of the rod of aerosol generating material 3. The first aerosol generating material 4 extends alongside the beads 5 to the second end 6 of the rod of aerosol generating material 3. In this example, the first aerosol generating material 4 extends from the first end 2 to the second end 6 of the rod of aerosol generating material 3, and overlaps the beads 5 along a part of the length of the rod of aerosol generating material 3. In this example, the beads 5 are disposed closer to the first end 2 than the second end 6. The boundary between the first aerosol generating material 4 and the beads 5 is angled with respect to the axial direction of the article 1 so that at any given point along the article 1, there are areas that contain varying amounts of the first aerosol generating material 4 and the beads 5.

The example of Figure 1B is similar to that of Figure 1A, although the first aerosol generating material 4 and the second aerosol generating material 5 are oppositely arranged with respect to the first end 2 and the second end 6 of the rod of aerosol generating material 3. The beads 5 are disposed closer to the second end 6 of the rod of aerosol generating material 3 than the first end 2.

The example of Figure 1C is similar to those of Figure 1A and 1B, but a first area of the first aerosol generating material 4 extends from the first end 2 of the aerosol generating material rod 3. A second area of the first aerosol generating material 4 extends from the second end 6 of the rod of aerosol generating material 3. A region of beads 5 is disposed between the first and second areas of first aerosol generating material 4 disposed at either end 2, 6 of the aerosol generating material rod 3.

The example of Figure 1D is similar to those of Figure 1A, 1B and 1C, but the beads 5 are located abutting the first end 2 of the rod of aerosol generating material 3, and the first aerosol generating material 4 extends to the second end 6 of the rod of aerosol generating material 3. In this example, the article 1 includes a filter plug 24 and a tube 42, at the first end 2 of the rod of aerosol generating material 3. The filter 24 and tube

24 may comprise a filtering material, for example but not limited to cellulose acetate, and a wrapper. The article 1 may comprise a wrapper of, for example but not limited to, paper or foil. For clarity, these details are omitted from Figures 1A to 1D, which schematically illustrate the arrangement of first and second aerosol generating tobacco materials 4, 5 in the tobacco rod 3. It can be appreciated that any of the articles i shown and described may comprise a filter 24 and/or a tube 42, or any other further component of a known article 1. Alternatively, the first and second ends 2, 6 of the rod of aerosol generating material 3 comprise the first and second ends of the article 1. Where the first and second ends 2, 6 of the rod of aerosol generating material 3 comprise the first and second ends of the article 1, no further components are added to the ends 2, 6 of the rod of aerosol generating material 3, before it is used as an article 1 for an aerosol provision system.

In other examples, the boundary between the first aerosol generating material 4 and beads 5 may be a line that is perpendicular to the longitudinal direction of the article 1, at a location along the length of the rod of aerosol generating material 3.

Preferably the first aerosol generating material 4 is arranged within the rod of aerosol generating material 3, to prevent the beads 5 from falling out of the ends 2, 6 of the rod of aerosol generating material 3. It can be appreciated that a number of configurations of first aerosol generating material 4 and beads 5 based on Figures 1A to 1D can be envisaged, not only those shown in the Figures.

During manufacture of the article 1, a continuous wrapped rod of aerosol generating material 7 is formed by wrapping a wrapper about a stream of aerosol generating material 4, 5. The stream of aerosol generating material is formed of the first aerosol generating material 4 and the beads 5, arranged in the appropriate manner for forming the rods of aerosol generating material 3. The continuous wrapped rod of aerosol generating material 7 is subsequently cut into rods of aerosol generating material 3 for the individual articles 1 shown in Figures 1A to 1D.

Figure 2A shows an example continuous wrapped rod of aerosol generating material, for example a continuous rod of aerosol generating material 7. The continuous rod of aerosol generating material 7 is formed during the manufacture of the article 1 of Figure 1C.

Figure 2B shows an example continuous wrapped rod of aerosol generating material, for example a continuous rod of aerosol generating material 7. The continuous rod of aerosol generating material 7 is formed during the manufacture of the articles 1 of Figure 1A, 1B and 1D, although the cut lines 8 are located in alternative positions from what is shown in Figure 2B for each of the articles 1 shown in Figure 1A, 1B and 1D. Figure 2A and 2B are schematic drawings showing the arrangement of the first aerosol generating material 4 and the beads 5 along the length of the continuous rods of aerosol generating material 7, and the lengths and widths illustrated are not dimensionally representative of the actual continuous rod of aerosol generating material 7. In particular, the length dimension is compressed and the width dimension is exaggerated to provide a clear illustration of the arrangement of the first aerosol generating material 4 and the beads 5 along the continuous rod of aerosol generating material 7. As shown, the first aerosol generating material 4 and the beads 5 are arranged in an alternating pattern along the continuous rods of aerosol generating material 7. In particular, the first aerosol generating material 4 and the beads 5 are arranged such that the continuous rods of aerosol generating material 7 can be cut at regular intervals to form the rods of aerosol generating material 3 for the articles 1 of Figures 1A to 1D. The first aerosol generating material 4 and the beads 5 are arranged such that after the continuous rod of aerosol generating material 7 is cut at lines 8 the individual rods of aerosol generating material 3 are arranged in an opposing back-to-back manner (i.e. they are mirror-images of each other about the cut line). The individual rods of aerosol generating material 3 can then be sent for further processing if required, for example, known assembly apparatus can then attach any required filter plugs 24 and/ or tubes 42 in the manner shown in Figure 1D.

Apparatus 9 for manufacturing the articles 1, in particular the rods of aerosol generating material 3, is described hereinafter. However, it will be appreciated that the apparatus 9 may be used to manufacture articles 1 that include a material in addition to an aerosol generating material.

Figures 3, 4A and 4B are schematic views of example apparatuses 9 for manufacturing a continuous rod of aerosol generating material, for example the continuous rod of aerosol generating material 7 of Figure 2A and 2B.

As shown in Figures 3A, 3B, 4A and 4B, the apparatus 9 includes a suction conveyor 10 that includes a suction belt 11. The suction belt 11 is arranged to run on rollers 12, 13 such that it has an upper run 14 and a lower run 15, the lower run 15 moving to the left as illustrated in Figures 3A, 3B, 4A and 4B. Referring to Figure 3 in particular, the lower run 15 of the suction belt 11 receives the first aerosol generating material 4 and the beads 5 and conveys the first aerosol generating material 4 and the beads 5.

The suction belt 11 comprises suction holes 16 (shown in Figure 6) that draw the first aerosol generating material 4 and the beads 5 onto the suction belt 11 and retain the first aerosol generating material 4 and the beads 5 on the suction belt 11 for conveyance. Guides (not shown) may be provided to guide the first aerosol generating material 4 and the beads 5 along the suction conveyor 10 as the suction belt 11 moves. The suction belt 11 is illustrated in Figure 6. As shown, the suction holes 16 are arranged in a continuous pattern along the suction belt 11. As explained below, suction is applied through the suction holes 16 in the suction belt 11 to retain the first aerosol generating material 4, and optionally the beads 5, on the suction belt 11 during use. The suction holes 16 are sized such that the first aerosol generating material 4 and optionally, the beads 5 are retained on an underside of a lower run 15 of the suction belt 11 by the suction applied through the suction holes 16.

As illustrated in Figure 3, the suction belt 11 receives the first aerosol generating material 4 in a first supply zone 17, and the beads 5 in a second supply zone 18. The second supply zone 18 is downstream of the first supply zone 17. That is, the lower run 15 of the suction belt 11 passes through the second supply zone 18 after having passed through the first supply zone 17. In this way, the suction belt 11 is provided with a combined supply of the first aerosol generating material 4 and the beads 5. In various examples, described below, the first aerosol generating material 4 is formed into a profile on the suction belt 11 before the beads 5 are added to the first aerosol generating material 4 such that the combined supply of the first aerosol generating material 4 and the beads 5 are arranged in a profile for manufacturing a continuous rod of aerosol generating material, for example the continuous rod of aerosol generating material 7 illustrated in Figure 2A or 2B.

A blocking member 19 is arranged to overlap and/or block a part of the suction belt 11.

The blocking member 19 is disposed between upper and lower runs 14, 15 of the suction belt 11, and has a blocking surface 20 that is in contact with, or proximate to, a part of the lower run 15 of the suction belt 11. Specifically, the blocking member 19 is configured to block some of the suction holes 16 in the suction belt 11 at the first supply zone 17 such that the first aerosol generating material 4 is arranged in a profile comprising a plurality of first regions of the first aerosol generating material 4, with no or a reduced amount of first aerosol generating material 4 provided between the first regions.

In the example of Figure 3A, the blocking member 19 is a profile belt which runs on roller 12 and roller 21. Both the suction belt 11 and the blocking member 19 run on roller 12 (with the suction belt 11 outermost), and roller 21 is located between the upper and lower runs 14, 15 of the suction belt 11.

In the example of Figure 3B, the blocking member 19 is a profile belt which runs on roller 12 and roller 13. Both the suction belt 11 and the blocking member 19 run on roller 12 and 13 (with the suction belt 11 outermost). The blocking member 19 is directed away or lifted from the suction belt 11 in a location proximate the second supply zone 18 so that suction holes 16 are not blocked by the blocking member 19 in the second supply zone 18. The blocking member 19 is lifted by rollers 21A and 21B located between the upper and lower runs 14, 15 of the suction belt 11, and between rollers 12 and 13. The blocking member 19 travels over roller 21A, between the lower run 15 of the suction belt 11 and roller 21A proximate to a start of the second supply zone 18. The blocking member 19 subsequently travels over roller 21B, between roller

21B and the upper run 14 of the suction belt 11, as the lower run 15 of the suction belt 11 travels through the second supply zone 18.

The example of Figure 3B may also include a further roller 21C (not shown) located between the upper and lower runs 14, 15 of the suction belt 11, and between rollers 12 and 13. After the blocking member 19 has travelled over rollers 21A and 21B the blocking member 19 subsequently travels over roller 21C, between roller 21C and the upper run 14 of the suction belt 11, as the lower run 15 of the suction belt 11 travels through the second supply zone 18. It can be appreciated that the blocking member 19 may travel over further rollers 21 until the blocking member 19 is directed back towards the suction belt 11 to travel over roller 13.

In the example of Figure 4A, the blocking member 19 is a profile belt which runs on roller 36 and roller 37, which are separate to rollers 12 and 13. Rollers 36, 37 are disposed between the upper and lower runs 14, 15 of the suction belt 11. Rollers 36 and

37 are substantially smaller in diameter than rollers 12 and 13, such that the blocking member 19 is spaced further from the upper run 14 of the suction belt 11 than the lower run 15 of the suction belt 11.

In the example of Figure 4B, the blocking member 19 is a substantially planar element, such as a profiled plate, which is disposed between the upper and lower runs 14, 15 of the suction belt 11. The planar element 19 moves with the lower run 15 of the suction belt 11 proximate to the first supply zone 17. It can be envisaged that there is more than one planar element (not shown) so as one planar element moves with the lower run 15 of the suction belt 11 in a direction towards the second supply zone 18, a further planar element is disposed in place of the first planar element in the region of the first supply zone 17.

In the examples of Figure 3A, 3B, 4A and 4B, the blocking member 19 is disposed such that the blocking surface 20 substantially faces the lower run 15 of the suction belt 11, and contacts, or is proximate to, the lower run 15 of the suction belt 11 and overlaps the suction belt 11 in the first supply zone 17.

The blocking member 19 has suction regions 22 arranged in a profile along the blocking member 19. Blocking regions 47 are disposed between the suction regions 22. Different examples of the blocking member 19 are illustrated in Figure 5A to 5D. As explained further below, the suction regions 22 and blocking regions 47 are arranged to limit the suction provided to the suction holes 16 on the suction belt 11. In particular, the blocking regions 47 of the blocking member 19 blocks at least some of the suction holes 16 to prevent the first aerosol generating material 4 being retained by those suction holes 16, and the suction regions 22 do not block other suction holes 16 such that first aerosol generating material 4 is retained by those suction holes 16. In this way, a profile of first aerosol generating material 4, i.e. a plurality first regions, is provided on the suction belt 11 according to the profile of suction regions 22 and blocking regions 47 in the blocking member 19.

In the example of Figure 5A, a plurality of suction regions 22 are spaced along the length of the blocking member 19. Each suction region 22 comprises a plurality of suction holes 23. Suction holes 16 on the suction belt 11 that are aligned with, or at least partially aligned with, the spaced suction regions 22 on the blocking member 19 will be provided with suction in the first supply zone 17 during use, while the suction holes 16 on the suction belt 11 that are aligned with the blocking regions 47 during use will be blocked, preventing suction from acting through these suction holes 16. In this way, the first aerosol generating material 4 is only retained on the suction belt 11 in the profile of the suction regions 22 on the blocking member 19. The profile of this example comprises a plurality of first regions of the first aerosol generating material 4 with no, or a reduced amount of, first aerosol generating material 4 provided between the first regions. Preferably, the first regions are discrete and spaced apart from each other.

In the example of Figure 5B, the blocking member 19 includes a plurality of suction regions 22 spaced along the length of the blocking member 19, as per Figure 5A. Each suction region 22 comprises a plurality of suction holes 23. In this example, the blocking member 19 includes connecting suction regions 25 formed of one or more suction holes 26 disposed between the suction regions 22, in the blocking regions 47. In this way, a lesser amount of first aerosol generating material 4 is retained on the suction belt 11 in the areas corresponding to the connecting suction regions 25 than in the areas corresponding to the suction regions 22 formed by the spaced groups of suction holes 23 in the blocking member 19. The profile of this example comprises a plurality of first regions of the first aerosol generating material 4 with a reduced amount of first aerosol generating material 4 provided between the first regions. Preferably, the profile is arranged such that a connection region is provided between each first region, wherein each connection region comprises a reduced amount of the first aerosol generating material 4 than the first region.

The example blocking members 19 of Figure 5C and 5D are similar to those of Figure

5A and 5B, respectively, but each suction region 22 is formed of a single aperture 27 in the blocking member 19, rather than as a group of suction holes 23 as per Figure 5A and 5B. In the example of Figure 5D the connecting suction regions 28, between each suction region 22, are formed of a single aperture in the blocking member 19, which are smaller than the apertures 27 forming the suction regions 22. In an alternative example, the blocking member 19 may have a width that is less than the width of the suction belt 11. In this example, the blocking member 19 may not include any suction regions, or it may have suction regions like those described with reference to Figure 5A to 5D. In this way, in the first supply zone 17 the blocking member 19 only blocks some of the suction holes 16 in the suction belt 11, allowing the non-blocked suction holes 16 to retain the first aerosol generating material 4. In an alternative example, the blocking member 19 has areas of higher porosity and areas of lower porosity. For example, the blocking member 19 may have suction regions corresponding to the suction regions 22 of Figure 5A to 5D formed by providing the blocking member 19 with a higher porosity in the suction regions 22 compared to a lower porosity in regions corresponding to the blocking regions 47. The variations in porosity of the blocking member 19 can be achieved by using different materials in different regions of the blocking member 19, or by changing the material of the blocking member 19, for example a thinner material or a looser weave of a woven material will provide a higher porosity. Alternatively or additionally, the blocking member 19 is formed of a laminate, and one of the layers of the laminate has varying porosity, varying thickness, or holes formed in it such that the porosity of the blocking member 19 is higher in the suction regions 22 than in the blocking regions 47.

As illustrated in Figures 3A, 3B, 4A and 4B, a first feeding device 30 is arranged to feed the beads 5 onto the suction belt 11 or the garniture 44 in the second supply zone 18 and a second feeding device 49, such as a vertical feeder 29, is arranged to feed the first aerosol generating material 4 onto the suction belt 11 in the first supply zone 17. The first feeding device 30 is disposed downstream of the first supply zone 17 and configured to supply the beads 5 between the first regions of the profile of first aerosol generating material 4.

The vertical feeder 29, comprises a vertical chimney 31 that receives the first aerosol generating material 4. The aerosol generating material 4, is fed into the bottom of the vertical chimney 31 and is urged upwards towards the suction conveyor 10. The vertical feeder 29 is disposed beneath the lower run 15 of the suction belt 11 in the first supply zone 17. Optionally, air flow is induced within the vertical chimney 31 to urge the aerosol generating material 4 vertically upwards towards the suction belt 11.

As illustrated in Figures 3A and 4A, the first feeding device 30 comprises a drum or roller in the form of a pocket wheel, comprising a plurality of pockets forming receiving spaces 48 configured to receive the beads 5 and transfer the beads 5 between said first regions of the first aerosol generating material 4. Figure 4A shows a first feeding device 30 with six receiving spaces 48. However, the first feeding device 30 may comprise more or less than six receiving spaces. Furthermore, each receiving space 48 can be split further into smaller sub-receiving spaces. Optionally, the first feeding device 30 comprises a plurality of mesh sections to define the receiving spaces 48. The mesh sections allow for the flow of air through the receiving spaces 48, this facilitates the beads 5 being blown and/or sucked out of the receiving spaces 48.

In Figures 3A and 4A, the drum 30 is disposed beneath the lower run 15 of the suction belt 11 in the second supply zone 18, downstream of the first supply zone 17.

As illustrated in Figure 3B, the first feeding device 30 comprises a modified carding drum. The carding drum 30 is configured to pick up the beads 5 in the second supply zone 18 and convey them to the suction belt 11. The drum 30 is disposed beneath the lower run 15 of the suction belt 11 in the second supply zone 18, downstream of the first supply zone 17.

In the examples illustrated in Figure 3A, 3B and 4A the first feeding device 30 is configured to supply the beads 5 to the suction belt 11. However, as illustrated in Figure 4B, the first feeding device 30 can be configured to supply the beads 5 downstream of the suction belt 11.

As illustrated in Figure 4B, at the end of the suction conveyor 10 the profile of the first aerosol generating material 4 is transferred to a garniture 44, which is described in more detail below. In this example, the garniture 44 is arranged to receive the profile of the first aerosol generating material 4 from the suction belt 11.

As illustrated in Figure 4B, the first feeding device 30 is disposed above the garniture 44, disposed downstream of the suction belt 11, and downstream of the first supply zone 17. The first feeding device 30 is configured to supply beads 5 to the profile of first aerosol generating material 4 on the garniture 44, before the first aerosol generating material 4 and the beads 5 are formed into the rod of aerosol generating material 3. The first feeding device 30 of this example can comprise a hopper as shown, a metered drum for example a pocket wheel as previously described, a modified carding drum, a belt conveyor and/ or beads 5 can be supplied pneumatically from above, or can be gravity fed. The first feeding device 30 may also comprise more than one of the above listed examples, for example the first feeding device 30 may comprise a hopper and a pocket wheel. As illustrated in Figure 4B, the apparatus 9 may further comprise a second feeding device 49 arranged to feed the first aerosol generating material 4 onto the suction belt 11 in the first supply zone 17. Preferably, the second feeding device 49 is disposed below the suction belt 11. The second feeding device 49 is similar to the first feeding device 30 and therefore for brevity the description will not be repeated. The first feeding device 30 of any of the above described examples may be, but is not limited to, a metered drum for example a pocket wheel wherein the pockets may or may not comprise mesh, a modified carding drum, a belt conveyor, a pneumatically powered system or a belt conveyor. The beads 5 are denser than the first aerosol generating material 4 and therefore, the first feeding device 30 is configured to be able to effectively transfer the more dense beads 5.

The second feeding device 49 of any of the above described examples may be, but is not limited to, a metered drum for example a pocket wheel wherein the pockets may or may not comprise mesh, a modified carding drum, a belt conveyor, a pneumatically powered system or a belt conveyor.

The configuration and type of the first feeding device 30 of any of the above described examples may be combined with the configuration and type of the second feeding device 49 of any of the above described examples.

In the examples comprising the first feeding device 30 and/or the second feeding device 49, the first aerosol generating material 4 and/ or the beads 5 can be blown and/ or sucked from the first feeding device 30 and/ or the second feeding device 49 to assist in transferring the beads 5 and/or the first aerosol generating material 4 to the suction belt 11 or garniture 44.

As illustrated in Figure 3A, 3B, 4A and 4B, suction is provided to the suction belt 11 by at least one suction chamber 32, which is connected to a vacuum pump via an outlet 33. The suction chamber 32 is located between the upper and lower runs 14, 15 of the suction belt 11.

As illustrated in Figure 3A and 4A, in some examples a second suction chamber 34 may be provided proximate the blocking member 19, to provide suction to the suction belt 11 in the first supply zone 17. The second suction chamber 34 may be connected to a vacuum pump via a second outlet 35. However, it will be appreciated that a single suction chamber maybe arranged to provide suction to the full length of the suction belt 11, including the first supply zone 17.

In the first supply zone 17, suction acts through the suction holes 16 in the suction belt 11 and the suction regions 22 in the blocking member 19 to draw the first aerosol generating material 4 onto the underside of the lower run 15 of the suction belt 11 as the suction belt 11 passes over the vertical feeder 29. Subsequently, in some examples such as shown in Figure 3A, 3B and 4A, as the suction belt 11 passes over the first feeding device 30 suction acts through the suction holes 16 in the suction belt 11 to draw the beads 5 onto the underside of the lower run 15 of the suction belt 11.

As briefly described above, the profile of suction regions 22 and blocking regions 47 in the blocking member 19 is adapted to block some of the suction holes 16 in the suction belt 11 in the first supply zone 17. In this way, the first aerosol generating material 4 is retained on the suction belt 11 only where the suction holes 16 are not blocked by the blocking member 19. Therefore, the profile of suction regions 22 on the blocking member 19 determines the profile of first aerosol generating material 4 retained on the suction belt 11, i.e. the plurality of first regions. As the lower run 15 of the suction belt 11 moves out of the first supply zone 17, all of the suction holes 16 in the suction belt 11 are uncovered. As the suction belt 11 moves over the first feeding device 30, the beads 5 are drawn onto, and retained on, the suction belt 11. The beads 5 are retained on the suction belt 11 in areas where there is no, or less, first aerosol generating material 4. In this way, a combined stream of first aerosol generating material 4 and beads 5 is formed on the suction belt 11.

The first aerosol generating material 4 on the suction belt 11 may be trimmed by a first trimmer unit 38. The first trimmer 38 can include an ecreteur having a pair of counterrotating blades 39 that are spaced from the suction belt 11 so that they trim the first aerosol generating material 4 to an appropriate thickness and/ or shape. Alternatively or additionally, the first trimmer 38 can include a paddle wheel that rotates and knocks first aerosol generating material 4 off of the suction belt 11.

The first trimmer 38 is disposed between the first supply zone 17 and the second supply zone 18, i.e. downstream of the first supply zone 17 and upstream of the second supply zone 18, so that the first aerosol generating material 4 is trimmed to the appropriate thickness before the beads 5 are supplied between the first regions of first aerosol generating material 4. A recycling device 40 may be arranged to collect first aerosol generating material 4 that is trimmed by the first trimmer 38 and recycle it to the vertical feeder 29.

In further examples, the combined profile of the first aerosol generating material 4 and the beads 5 may be trimmed by a second trimmer 41. The second trimmer 41 is disposed downstream of the first feeding device 30. The second trimmer 41 can include a paddle wheel that rotates and knocks aerosol generating material 4, 5 off of the profile. Depending on the arrangement of the profile of the first aerosol generating material 4 and the beads 5, one or both of the first aerosol generating material 4 and the beads 5 may be trimmed by the second trimmer 41.

The second trimmer 41 may include a recycling device 43 arranged to collect aerosol generating material 4, 5 that is trimmed by the second trimmer 41. If only one the first aerosol generating material 4 and the beads 5 is trimmed from the profile, then that trimmed aerosol generating material 4, 5 can be recycled as appropriate. If the trimmed aerosol generating material is a mix of the first aerosol generating material 4 and the beads 5 then the trimmed aerosol generating material can be recycled for alternative uses, for example in different articles or separated and then recycled separately.

As mentioned above, at the end of the suction conveyor 10 the combined profile of the first aerosol generating material 4 and the beads 5 is transferred to a garniture 44. The suction conveyor 10 is angled at a downwards slope towards the garniture 44. The skilled person will be aware of suitable existing garnitures, but a brief description of the garniture 44 is provided below.

The garniture 44 comprises a continuous garniture belt 45 that drives a ribbon of paper 46 through the garniture 44. The garniture belt 45 is disposed below the ribbon of paper 46, and the combined stream or profile of first and second aerosol generating materials 4, 5 is transferred from the suction conveyor 10 onto the ribbon of paper 46. In this way, the first aerosol generating material 4 and the beads 5 are arranged on the ribbon of paper 46, which is moved through the garniture 44 by the garniture belt 45. At the end of the lower run 15 of the suction belt 11, where the garniture 44 is located, no suction is provided to the suction belt 11 such that the aerosol generating material(s) are released from the suction belt 11 for transfer to the garniture 44. An adhesive applicator (not illustrated) applies adhesive to the top of the ribbon of paper 46 along one side. The garniture 44 includes a wrapping unit (not illustrated) through which the ribbon of paper 46 with the combined stream of the first aerosol generating material 4 and the beads 5 is conveyed. The wrapping unit wraps the ribbon of paper 46 about the first aerosol generating material 4 and the beads 5 and the adhesive glues the ribbon of paper 46 in place to form a continuous rod of aerosol generating material, for example a continuous rod aerosol generating material 7 as illustrated in one of Figure 2A and 2B.

The apparatus 9 further comprises a cutter (not shown) adapted to cut the continuous rod of aerosol generating material 7. The continuous rod of aerosol generating material 7 is then cut to the appropriate length for forming consumables, for example the articles 1 shown in Figure 1A to 1D. In various examples, the continuous rod of aerosol generating material 7 is cut on the aerosol generating material rod making machine and/or on subsequent assembly apparatus. In various examples, the continuous rod of aerosol generating material 7 can be cut into double-length rods, quadruple-length rods, and so on, and transferred to an assembly machine for further cutting and combining with a filter to produce complete consumables. In examples, this can be referred to as a ‘two-up’ or ‘four-up’ manufacturing process.

Advantageously, the suction conveyor 10, second feeding device 49 such as the vertical feeder 29 and the first feeding device 30 can be produced by modification of conventional apparatuses already used in the tobacco product industry. For example, the Hauni Protos cigarette making machine includes a vertical feeder and suction conveyor arrangement, commonly known as a ‘V.E’. This machine can be modified to be used as the apparatus described with reference to the examples. For example, modification might include replacement of the suction belts, modification of the suction chambers, and/or addition of trimmers, and the provision of a feeding device for feeding the denser beads.

A further embodiment relating to a rod of aerosol generating material 3 is described with reference to Figures 7 to 16. In the following description reference will be made to the insertion of objects in the form of beads 5 such as the beads, pellets and/or granules of the second aerosol generating material 5 previously described, and specifically tobacco beads 5, into a first aerosol generating material 4. Referring now to Figure 7, beads 5 may be inserted or fed into the first aerosol generating material 4. Figure 7 shows part of a rod making machine 101 comprising a bead insert unit 102. During operation of the machine 101, the first aerosol generating material 4, is drawn through a set of conveying rollers (not shown), and is compressed through a stuffer jet (not shown) and through the tongue 104 of a garniture 44, where it is wrapped with a wrapping 106 and subsequently cut into segments by a cutter (not shown) to form rods of aerosol generating material 3. Figure 8 shows a cross section of the bead insert unit 102 in engagement with the tongue 104 of the rod making machine 101 shown in Figure 7. The bead insert unit 102 comprises a bead feed funnel or hopper 107, a venturi insert device 108 and an insert tube 109. The insert tube 109 may be bent so that it can be aligned longitudinally with the direction in which the first aerosol generating material 4 is conveyed. The position of the insert tube 109 may be adjusted using the insert tube adjustment wheel 109A shown in Figure 7. This allows the stream of beads 5 to be positioned along the longitudinal axis of the first aerosol generating material 4 or alternatively off-centre but parallel to the longitudinal axis. The bead insert unit 102 also comprises air jet inlets toa-c shown in Figure 7.

Referring again to Figure 8, the feed funnel or hopper 107 is configured to accept beads 5 for insertion or feeding into the first aerosol generating material 4. The hopper 107 is preferably conical in shape to allow beads 5 to be transferred to the hopper 7 manually or alternatively using mechanical or electromechanical delivery means such as a feed conveyor, fluted feed drum or screw feeder (not shown).

Figure 9 is an enlarged cross sectional view of the venturi device 108 shown in Figure 8. The venturi device 108 comprises a generally conical block 111 with an axial bore 112 with an inlet 113 that receives a supply of beads 5 from the hopper 107 and an outlet 115 that supplies the beads 5 into the insert tube 109.

The conical block 111 is received within a generally cylindrical housing 116 with a conical end spaced from the block 111 to define a converging air passageway 117 which opens into the insert tube 109 in the region of the outlet 115 of the bore 112. The air supply passageway 117 is fed with compressed air from the three air jet inlets toa-c, one of which 110a is shown in Figure 9. The air jet inlets noa-c are coupled to a compressed air or other gas source (not shown) and feed into respective longitudinal bores 118 that connect into the converging air supply passageway 117.

Although the jet inlets noa-c are fed with air, other fluids could be employed, for example helium or nitrogen.

Beads 5 are received from the hopper 107 and are directed into the axial bore 112.

Compressed air from the inlet 110a is directed along the longitudinal bore 118 towards the region 115 where the axial bore 112 and the longitudinal bore 118 converge.

During operation of the venturi device 108 the Venturi effect is exploited to propel the beads 5 towards the first aerosol generating material 4 as it is formed into rods of aerosol generating material 3. Figure 10 shows a schematic view of the air flow in the venturi device 108 during operation of the bead insert unit 102. As air is propelled from two of the jet sources 110a, 110b through the longitudinal bores 118a, 118b and into the insert tube 109, an area of low pressure is created in the region 115 and insert tube 109.

The beads 5 initially occupy an area of high pressure relative to this low pressure region 115. A pressure gradient force is created that acts on the beads 5 and propels them into the insert tube 109 with a velocity greater than if they were to be acted upon by the force due to gravity alone. This allows a high density of beads 5 to be inserted into the first aerosol generating material 4.

The insert tube 109 feeds into the tongue 104 of the rod making machine 101. The position of the insert tube 109 may be adjusted relative to the longitudinal axis of the rod of aerosol generating material 7 under manufacture. In Figure 8 the insert tube 109 is bent, however in other embodiments the insert tube 109 may be straight. The beads 5 may be centred along the longitudinal axis of the rod of aerosol generating material 7 or substantially parallel to, but offset from, the longitudinal axis using the insert tube adjustment wheel 109A shown in Figure 7.

Figure 11 shows an alternative embodiment. Prior to insertion into the first aerosol generating material 4, the beads 5 (i.e. the second aerosol generating material 5) are stored in a bead storage unit 119. The storage unit 119 comprises a pressurised air source 120 that is operable to inject an air jet 121 into a chamber 122. The direction of the air jet 121 is represented by the arrows in Figure 11. The pressurised air jet 121 urges a stream of the beads 5 into an exit tube 123. The beads 5 that are urged into the exit tube 123 are entrained in the highly pressurised air jet 121 and are directed towards the insert tube 109 of an alternative embodiment of the bead insert unit 2. The highly pressurised air jet 121 maybe a continuous pressurised fluid stream. The beads 5 entrained in the continuous pressurised fluid stream are then fed into the first aerosol generating material 4. The insert tube 109 may operate in much the same way as hereinbefore described with reference to Figures 7-10.

Figure 12 is a cross sectional view of a rod of aerosol generating material 7 manufactured using the machine 101. A region 125 comprising beads 5 may extend substantially along the longitudinal axis of the rod of aerosol generating material 7.

The diameter of the region 125 may be determined in large part by the diameter of the insert tube 109 of the bead insert unit 102. Alternatively, the region 125 comprising beads 5 may extend parallel to but offset from the longitudinal axis. This flexibility allows the position of the region 125 to be controlled. The rod of aerosol generating material 124 may then be wrapped in a suitable wrapper and cut into separate rods of aerosol generating material 3, in a manner well known in the art for forming articles 1 for aerosol provision systems.

In the embodiments hereinbefore described with reference to Figures 7-11 the region 125 may be formed from a single continuous stream of beads 5 inserted into the first aerosol generating material 4. In addition to this configuration it may be desirable to provide a series of regions 125 formed of continuous streams of beads 5, the regions 125 separated by gaps 126. A rod of aerosol generating material 7 compatible with such a configuration is shown in Figure 13. The rod of aerosol generating material 7 may then be cut, in a manner well known in the art, along the dashed lines i28a-c to produce individual rods of aerosol generating material 3.

Figure 14 shows an article 1 that has been manufactured according to the above description with reference to Figure 7. The filter 24 may be attached to the rod of aerosol generating material 3 in a manner well known in the art such as through the use of tipping paper (not shown). The region 125 of the rod of aerosol generating material 3 containing beads 5 may be in contact with the first end 2 of the article 1. The region 126 that does not contain any beads 5 may be located at the second end 6 of the rod of aerosol generating material 3. Alternatively, the first and second ends 2, 6 of the rod of aerosol generating material 3 comprise the first and second ends of the article 1. Where the first and second ends 2, 6 of the rod of aerosol generating material 3 comprise the first and second ends of the article 1, no further components are added to the ends 2, 6 of the rod of aerosol generating material 3, before it is used as an article 1 for an aerosol provision system. Figure 15 shows a granule insert unit 102 according to a further embodiment. The insert unit 102 shown in Figure 15 is similar to the insert unit 102 shown in Figure 8. However, the insert unit 102 shown in Figure 15 comprises a high flow vacuum pump 132 instead of the venturi insert device 108 shown in Figure 8. The bead insert unit 102 also comprises a bead feed hopper 107 and an exit tube 109.

The hopper 107 shown in Figure 15 is a funnel formed from a frustoconical section 135 and a tubular section 136 which are connected to each other. The flow of beads 5 from the hopper 107 to the vacuum pump 132 may be facilitated by passing air through the bottom of the hopper 107 thereby fluidising the beads 5 stored therein.

The high flow vacuum pump 132 may be of a type known in the art for material transfer such as KVPDF High Flow Vacuum Pumps. Compressed air enters the vacuum pump 132 through an air inlet 133 and flows cyclonically through a central tube 134 of the pump 132. The cyclonic flow of compressed air produces a vacuum which can draw beads 5 from the hopper 107, through the central tube 134 and into the exit tube 109 to converge with the tongue 104 of the garniture 44 shown in Figure 7.

It is intended that, when used to insert beads 5 into a stream of first aerosol generating material 4, the insert unit 102 may be attached to a rod manufacturing device of a type that is well known in the art. The insert unit 102 may insert beads 5 into a stream of first aerosol generating material 4 as the stream of first aerosol generating material 4 is being conveyed towards a garniture 44 along a device known as a suction chamber rail or conveyor that is known in the art. Modifications may be made to the insert unit 102 such as using a plough (not shown) to form a furrow in the stream of first aerosol generating material 4 to further facilitate bead 5 insertion. However, it is intended that the embodiments described in the foregoing description be compatible with insertion of beads 5 into a stream of first aerosol generating material 4 without substantial alterations made thereto. This insertion technique allows beads 5 to be accurately inserted in specific amounts, minimising the amount of beads 5 lost during rod manufacture. An alternative hopper 107 is shown in Figure 16. The hopper 107 comprises a frustoconical section 135 and a tubular section 136. The tubular section 136 is connected to a hopper exit tube 137. The hopper exit tube 137 maybe connected to the venturi device 108 hereinbefore described with reference to Figures 7-9 or, alternatively, to the vacuum pump 132 hereinbefore described with reference to Figure 15-

In use, beads 5 are placed in the hopper 107 shown in Figure 16 and drop, under gravity, into the hopper exit tube 137. From the hopper exit tube 137 the beads 5 are entrained by the venturi device 108 or the vacuum pump 132 and fed or inserted into the first aerosol generating material 4 as described in the foregoing description.

Alternatively, beads 5 may drop, under gravity, from the hopper 107 into a stream of first aerosol generating material 4 that is being conveyed by a suction chamber rail or conveyor that is known in the art.

Articles 1 manufactured according to the foregoing description have the advantage that they can contain large quantities of beads 5 inserted into a small volume of first aerosol generating material 4. Articles manufactured according to the foregoing description also have the advantage that they comprise two different types of aerosol generating material without the requirement of further components to hold the beads 5 in place. As no further components are required to retain the beads 5 in the articles other than the first aerosol generating material, the articles 1 can be smaller for the same delivery of aerosol generating material to a user.

The articles described in the foregoing description preferably do not comprise the beads 5 at the end of the articles 1 as they may fall out. Preferably, there are discrete pockets of beads 5 provided within the first aerosol generating material 4.

Referring now to Figures 17 to 19, an embodiment of an aerosol provision device 200 is shown.

The articles 1 described in the foregoing description are configured for use in an aerosol provision device 200 comprising an aerosol generator in the form of a heating element

203 for heating the article 1. In the present example, the heating element 203 at least partially surrounds a heating area 202, for example, a heating chamber 202. The heating element 203 may be resistively and/ or inductively heated.

In other embodiments (not shown), the heating element 203 instead comprises a blade or pin, for insertion into the article 1. In other embodiments (not shown), the article 1 may comprise the heating element which, for example, maybe embedded in the rod of aerosol generating material 3.

In Figure 17, the components of an embodiment of an aerosol provision device 200 are shown in a simplified manner. Particularly, the elements of the aerosol provision device 200 are not drawn to scale in Figure 17. Elements that are not relevant for the understanding of this embodiment have been omitted to simplify Figure 17.

In the example of Figure 17, the aerosol provision device 200 is a non-combustible aerosol provision device 200. The non-combustible aerosol provision device 200 comprises a housing 201 comprising an area 202 for receiving an article 1.

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

When the article 1 is heated, the first aerosol generating material 4 and/or the beads 5 will release one or more volatile compounds and may release a range of volatile compounds at different temperatures. Preferably, the beads 5 heat up more slowly than the first aerosol generating material 4. By controlling the maximum operation temperature of the electrically heated aerosol generating system 200, the selective release of undesirable compounds maybe controlled by preventing the release of select volatile compounds. As shown in Figure 18, within the housing 201 there is an electrical energy supply 204, for example a rechargeable lithium ion battery. A controller 205 is connected to the heater 203, the electrical energy supply 204, and a user interface 206, for example a button or display. The controller 205 controls the power supplied to the heater 203 in order to regulate its temperature. Typically, the aerosol-forming substrate is heated to a temperature of between 250 and 450 degrees centigrade.

Figure 19 is a schematic cross-section of a non-combustible aerosol-provision device 200 of the type shown in Figure 17, with the article 1 received in the heating area 202 of the device 200 for heating by the heater 203. The non-combustible aerosol provision device 200 is illustrated receiving the aerosol-generating article 1 for consumption of the aerosol-generating article 1 by a user.

The housing 201 of non-combustible aerosol provision device 200 defines an area 202 in the form of a cavity, open at the proximal end (or mouth end), for receiving an aerosol-generating article 1 for consumption by a user.

In the present example, the aerosol-provision device 200 comprises a mouthpiece 207 that is detachable from the remainder of the device 200 to allow access to the area 202 such that an article 1 can be interested into and removed from the area 202. Once an article 1 has been provided in the area 202, the mouthpiece 207 can be reattached. In some embodiments, the mouthpiece 207 is removably attached to the housing 201 of the device 200, for example, by a screw thread or bayonet connection. As a user draws on the mouthpiece 207, air is drawn into the article 1 and the volatile substances condense to form an inhalable aerosol. This aerosol passes through the mouthpiece 207 of the device 200 and into the user's mouth.

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

As used herein, the term ‘aerosol generating material’ includes materials that provide volatilised components upon heating, typically in the form of vapour or an aerosol. In some examples, as described above, the aerosol generating material includes a tobacco material. In other examples, the aerosol generating material consists of a tobacco material, or a blend of different tobacco materials. In other examples, the aerosol generating material is free from tobacco material. The apparatus described herein may be used to manufacture a rod of any aerosol generating material. The first aerosol generating material 4 and the beads 5 are different materials. The first aerosol generating material 4 and/ or the beads 5 may comprise, consist of, or essentially consist of tobacco material. For example, the first aerosol generating material 4, may have different types of tobacco leaf (e.g. burley, oriental, Virginia), or different blends of these different types of tobacco leaf. Alternatively or additionally, the first aerosol generating material 4, may have tobacco that is dried, cured or treated differently (e.g. flue-cured, air-cured etc.). The first aerosol generating material may comprise, consist of, or essentially consist of cut rag tobacco. Alternatively or additionally, the first aerosol generating material 4, may have different additives. Additives may include, for example flavourants (e.g. menthol) in the form of granules or liquid additives, burn rate modifiers, smoke modifiers etc. Alternatively or additionally, the first aerosol generating material 4, may include tobacco substitutes, for example reconstituted tobacco materials, or blends of tobacco substitutes with tobacco materials. The second aerosol generating material 5 is provided in the form of beads. The first feeding device 30 is configured to supply extruded beads 5 and, optionally, beads 5 that have been extruded and subject to spheronisation. In some embodiments, the first feeding device 30 is configured to supply beads 5 having a density of at least about 0.4 g/cm3 _and, preferably, at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3, in some embodiments, the first feeding device 30 is configured to supply beads 5 having a particle size in the range of 0.5 to 3 mm and, preferably, in the range of 1 to 2 mm.

As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials; and aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

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

In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.

In some embodiments, the non-combustible aerosol provision system is an aerosolgenerating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise a plant based material, for example, tobacco or a non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise a non- combustible aerosol provision device, and a consumable for use with the non- combustible aerosol provision device. In some embodiments, the disclosure relates to consumables comprising aerosolgenerating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

The terms ‘upstream’ and ‘downstream’ used herein are relative terms defined in relation to the direction of mainstream aerosol drawn through an article or device in use. Reference to the ‘distal end’ refers to an upstream end of the device, whereas ‘proximal end’ refers to the downstream end of the device.

In some embodiments, the non-combustible aerosol provision system, such as a noncombustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source. In some embodiments, the non-combustible aerosol provision system comprises an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/ or an aerosol-modifying agent.

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/ or an aerosol-modifying agent. The consumable comprises a substance to be delivered. The substance to be delivered is an aerosol-generating material. As appropriate, the material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials. In some embodiments, the substance to be delivered comprises an active substance.

The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical. In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

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

Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.

In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco. In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp. In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

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

As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, maybe used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice

(liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits,

Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang- ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They maybe imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

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

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

The aerosol-generating material may comprise or be an “amorphous solid”. In some embodiments, the aerosol-generating material comprises an aerosol-generating film that is an amorphous solid. The amorphous solid maybe a “monolithic solid”. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 6owt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid. An aerosol-generating material may also be referred to as an aerosolisable material.

An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. An aerosol-generating material may be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants. The aerosol-generating material is incorporated into an article for use in the aerosol-generating system. As used herein, the term “tobacco material” refers to any material comprising tobacco or derivatives or substitutes thereof. The tobacco material may be in any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and/or tobacco extract. A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/ or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, in particular a heating element, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, comprise, a material heatable by electrical conduction, or a susceptor.

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

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

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

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

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor maybe an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor maybe both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosolmodifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent. The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent maybe in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol.

In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator maybe configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy. The filamentary tow material described herein can comprise cellulose acetate fibre tow. The filamentary tow can also be formed using other materials used to form fibres, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(i-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT), starch based materials, cotton, aliphatic polyester materials and polysaccharide polymers or a combination thereof. The filamentary tow may be plasticised with a suitable plasticiser for the tow, such as triacetin where the material is cellulose acetate tow, or the tow may be non-plasticised. The tow can have any suitable specification, such as fibres having a ‘Y’ shaped or other cross section such as ‘X’ shaped, filamentary denier values between 2.5 and 15 denier per filament, for example between 8.0 and 11.0 denier per filament and total denier values of 5,000 to 50,000, for example between 10,000 and 40,000.

In the figures described herein, like reference numerals are used to illustrate equivalent features, articles or components. In some embodiments, the article 1 comprises an aerosol-generating composition comprising aerosol-generating material. The aerosol-generating material may comprise the first and/or second aerosol-generating material 4, 5.

An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material (for example, the first and/or second aerosol generating material 4, 5) may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants. The aerosol-generating material (for example, the first and/or second aerosol generating material 4, 5) may comprise a binder and an aerosol former. Optionally, an active and/ or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material (for example, the first and/or second aerosol generating material 4, 5) is substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material (for example, the first and/ or second aerosol generating material 4, 5) is substantially tobacco free.

The aerosol-generating material (for example, the first and/or second aerosol generating material 4, 5) may comprise or be an “amorphous solid”. The amorphous solid maybe a “monolithic solid”. In some embodiments, the amorphous solid maybe a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating material may, for example, comprise from about 50wt%, 6owt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid. The amorphous solid may be substantially non-fibrous.

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

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

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

In each of the embodiments of article 1 described herein, the article may comprise such a first and/or second aerosol generating material 4, 5, and may comprise such an aerosol-generating composition. The first aerosol-generating material 4 can comprise a paper reconstituted tobacco material. The composition can alternatively or additionally comprise any of the forms of tobacco described herein. The first aerosol-generating material 4 can comprise a sheet or shredded sheet comprising tobacco material comprising between 10% and 90% by weight tobacco leaf, wherein an aerosol-former material is provided in an amount of up to about 20% by weight of the sheet or shredded sheet, and the remainder of the tobacco material comprises paper reconstituted tobacco.

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

In some embodiments, the first and/or second aerosol-generating material 4, 5 comprises an extruded aerosol generating material that is then cut into beads of pellets.

In each of the examples of apparatus, method and article described above (including the apparatus of each of Figs. 3A to 11, 15 and 16 and the articles of each of 1A to 1D, 12 to 14, and 19) a first aerosol generating material 4 is provided (which in some embodiments is a tobacco material) and beads, granules and/or pellets of a second aerosol generating material 5 is provided (which in some embodiments is a tobacco material). In some embodiments, the second aerosol generating material 5 has a greater density than the first aerosol generating material 4. Otherwise, the aerosolgenerating materials 4, 5 of the article may be the same or different. It has been found that the second aerosol generating material 5 having a higher density than the first aerosol generating material 4 means that the higher density material heats up slower when both materials are exposed to the same heating and thus the higher density material will release its volatile compounds (e.g. nicotine) at a slower rate than the lower density material. Thus, the second aerosol-generating material 5 has a greater density than the first aerosol-generating material 4 so that the second aerosol generating material 5 heats up slower than the first aerosol generating material 4 when exposed to the same heating and will release its volatile compounds (e.g. nicotine) at a slower rate than the first aerosol-generating material 4. Thus, combining aerosol-generating materials with different densities provides a more consistent and longer-lasting release of volatile compound(s). In some embodiments, the aerosolgenerating materials of different densities are combined with separate heating of these materials at optionally different times and/or different temperatures, thereby allowing the provision of a more tailored release of the volatile compound(s) over the period of consumption of the article, for example. Alternatively, it may be desirable to have a more rapid or greater release of volatiles towards the beginning of the consumption of the article, to provide the user with a greater initial impact from use. The capacity to control the aerosol generation and volatile compound release maybe particularly advantageous because the article can be made relatively small whilst still achieving a particular desired release of volatile compound(s) over the period of consumption. In some embodiments, the second aerosol generating material 5 has a density that is at least about 25% higher than the density of the first aerosol generating material 4 and, optionally, at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70% or 75% higher. The second aerosol generating material 5 may have a density that is no more than about 200% higher than the density of the first and second aerosol generating material 4 and, optionally, no more than about 150%, 125%, 100% or 75% higher. In some embodiments, the second aerosol generating material 5 has a density that is from about 25% to about 75% higher than the density of the first aerosol generating material 4- In some embodiments, the second aerosol generating material 5 has a density of from at least about 0.4 g/cm3 and optionally from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3. The second aerosol generating material 5 may have a density of no more than about 2 g/cm3 and, optionally no more than about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6 or 0.5 g/cm3. In some embodiments, the density of the second aerosol generating material 5 is from about 0.4 to 1.99 g/cm3.

In some embodiments, the first aerosol generating material 4 has a density of from at least about 0.1 g/cm3 and optionally from at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8 or 0.9 g/cm3. The first aerosol generating material 4 may have a density of no more than about 1 g/cm3 and, optionally no more than about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3 or 0.2 g/cm3. In some embodiments, the density of the first aerosol-generating material 4 is from about 0.1 to 0.9 g/cm3. In some embodiments, the first and second aerosol-generating materials 4, 5 comprise the same components. Upon heating, they will therefore release very similar aerosols, potentially having the same content of active substance and/ or flavour, etc. Their different densities allow the aerosol to be generated from the two materials at different speeds and/or different times during heating. In other embodiments, the first and second aerosol-generating materials 4, 5 comprise different components (and may have the same or different densities). Upon heating, they will therefore release different aerosols, potentially having different make-up of active substance and/or flavour, etc. Their different densities allow the different aerosols to be generated from the two materials at different speeds and/ or different times during heating, potentially providing an aerosol that changes over the period of use.

In some embodiments, the first aerosol-generating material 4 and the second aerosolgenerating material 5 each comprise tobacco. The tobacco will contain volatile components including nicotine, aromas and flavours. The tobacco may be any type of tobacco and any part of the tobacco plant, including tobacco leaf, lamina, stem, stalk, ribs, scraps and shorts or mixtures of two or more thereof. Suitable tobacco materials include the following types: Virginia or flue-cured tobacco, Burley tobacco, Oriental tobacco, or blends of tobacco materials, optionally including those listed here. The tobacco may be expanded, such as dry-ice expanded tobacco (DIET), or processed by any other means. In some embodiments, the tobacco material maybe reconstituted tobacco material. The tobacco maybe pre-processed or unprocessed, and maybe, for instance, solid stems (SS); shredded dried stems (SDS); steam treated stems (STS); or any combination thereof. The tobacco material may be fermented, cured, uncured, toasted, or otherwise pre-treated.

The first and second aerosol-generating materials 4, 5 may comprise different tobacco. Alternatively, the tobacco may be the same, but is provided in a different form, so that the second aerosol-generating material 5 has a greater density than the first aerosol - generating materials 4.

In some embodiments, the first aerosol-generating material 4 has at least one (further) different characteristic to the second aerosol generating material 5. The different characteristic maybe one or more of form, size, , water content, amount (by weight), material or materials, or proportion of materials that make the first and second aerosolgenerating materials 4, 5 (including the recipe of the aerosol generating materials when each is manufactured from more than one material). In some embodiments, the first and second aerosol-generating materials 4, 5 do not have a different characteristic, other than their different densities. In some embodiments, the first aerosol-generating material 4 comprises one or more tobacco in the form of cut rag. This tobacco material may lamina or reconstituted tobacco material. In some embodiments, the first aerosol-generating material 4 is a blend comprising both lamina and reconstituted tobacco. For example, the ratio of lamina and reconstituted tobacco may from about 1:4 to about 4:1.

The second aerosol-generating material 5 has a greater density than the first aerosolgenerating material 4. In some embodiments, this more dense, second aerosolgenerating material 5 comprises particles or maybe in the form of beads or one or more sheets. Each bead or sheet may be formed from smaller particles that have been agglomerated. In some embodiments, the both of the first and second aerosol generating materials 4, 5 may be in the form of beads or one or more sheets and, optionally, may be processed such that the second aerosol generating material 5 has a higher density than the first aerosol generating materials 4. As used herein, the term “beads” is meant to include beads, pellets, or other discrete small units that have been shaped, moulded, compressed or otherwise fashioned into a desired shape. The beads may have smooth, regular outer shapes (e.g., spheres, cylinders, ovoids, etc.) and/or they may have irregular outer shapes. In some embodiments, the beads have a diameter (for example, as measured by sieving) of at least about 0.5 mm and, optionally at least about 1, 1.5, 2. 2.5 or 3 mm. The beads may have a diameter (for example, as measured by sieving) of no more than about 5 mm and, optionally no more than about 4.5, 4, 3.5, 3, 2.5, 2 or 1.5 mm. In some embodiments, the diameter of each bead may range from about 0.5 mm to about 3 mm, or from about 1 mm to about 2 mm. The size of the beads may refer to their average size, such as the number or volume mean size.

In some embodiments, the desired density of the aerosol-generating material 4, 5 is achieved or controlled through the formulation of the material and/or the method(s) by which the material is processed. Processes involving agglomeration, and especially agglomeration with the application of some of compressive forces will tend to increase the density of the material.

Thus, in some embodiments, the first and/ or second aerosol-generating material 4, 5 comprises particles of material that are agglomerated.

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

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

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

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

The particles to be extruded may have a size selected to produce a more dense aerosol- generating material (e.g. a more dense second aerosol generating material 5), which will have an impact on the heat transfer within the material and the release of the volatile components.

Extrusion involves feeding a composition (also referred to as a precursor composition) through a die to produce an extruded product. The process applies pressure to the composition combined with shear forces. Extrusion may be performed using one of the main classes of extruders: screw, sieve and basket, roll, ram and pin barrel extruders. A single screw or twin screw extruder may be used. Forming the tobacco beads by extrusion has the advantage that this processing combines compression, mixing, conditioning, homogenizing and moulding of the composition.

In some embodiments, during extrusion the free-flowing composition comprising particles, such as tobacco particles, is exposed to elevated pressure and temperature and is forced though an orifice, such as a shaping nozzle or die, to form an extrudate.

In some embodiments, the extrudate has a rod-like form and it may be cut into segments of a desired length.

In some embodiments, the composition is exposed to temperatures from about 4O°C to about 15O°C, or from about 8o°C to about 13O°C, or from about 6o°C to about 95°C within the extruder. In some embodiments, including those using double extrusion, the precursor composition is exposed to temperatures from about 7O°C to about 95°C within the extruder. In some embodiments, including those using single extrusion, the precursor composition is exposed to temperatures from about 6o°C to about 8o°C within the extruder.

The composition may be exposed to pressures (immediately before the die or nozzle) ranging from about 2 bar to about 100 bar, or from about 5 bar to about 60 bar, depending on the design of the die or nozzle being used. The higher the pressure, the greater the density of the extrudate is likely to be. Thus, the extrusion process may be adjusted to provide extruded aerosol-generating material with the desired density.

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

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

In some embodiments, liquids may be added to the composition prior to or during the extrusion process. For example, water may be added, for example as a processing aid to assist dissolution or solubilisation of components of the composition, or to aid binding or agglomeration. Alternatively or additionally, a wetting agent may be added to the composition. In some embodiments, the liquid may be an aerosol former material such as glycerol or others discussed herein. When liquid is added to the composition in this manner, the liquid is applied not only on the surface, but, as a result of the extruder pressure combined with the intensive mixing by high shear forces, the extrudate becomes impregnated with the liquid. Where the liquid is an aerosol former material, this can result in a high availability of the aerosol former material in the resultant beads to enhance evaporation of volatile components.

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

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

In some embodiments, processing by extrusion is sufficient to provide the higher density of the second aerosol-generating material 5, where desired. However, in other embodiments, the extrudate may be further treated to increase the density of the second aerosol-generating material 5.

For example, in some embodiments, the extruded aerosol-generating material undergoes spheronisation. In spheronisation, the extruded, cylindrically shaped particles are broken into uniform lengths and are gradually transformed into spherical shapes due to plastic deformation. Where the extrudate is first broken into uniform lengths, spheres with a uniform diameter will be produced by the spheronisation step. According to one specific example of the embodiments discussed herein, samples of the second aerosol-generating material 5 were produced as follows (but note that in some embodiments samples may be produced according to the below, which are instead used for the first aerosol generating material). Three sample formulations with and without binders are shown in Table 1, with the amounts indicated as percent wet weight basis (WWB).

Table 1 The tobacco was ground to produce a fine powder, taking care not to overheat the tobacco. The ground tobacco particles were sieved to select those with a desired size, for example a particle size of less than 250 pm, of less than too pm or less than 60 pm. Next, all of the dry (non-liquid) components of the formulation were combined and mixed or blended in a mixer. In this particular instance, the mixture was mixed for 1 minute at a speed to 75 RPM. This was to ensure that the dry components are homogenously distributed within the mixture.

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

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

The extrudate was broken into pieces of varying length as it came out of the extruder. These pieces were then spheronised. Spheronisation was carried out until spherical beads were formed. In this instance, the extrudate was initially spheronised in a Caleva Multilab operating at 2,500 RPM for 1 minute and then the beads were checked for any defects. Then, spheronisation continued for a further 1 to 2 minutes. This spheronisation step broke the extruded tobacco into the individual pieces and formed the dense, spherical beads. In a final step, the spheronised beads were dried in an oven at 65°C for 30 minute periods. After each drying period, the beads were weighed and drying was halted when the desired moisture weight loss was achieved. Generally, such drying will take about 1 hour. In some embodiments, the other one of the first and/or second aerosol-generating material 4, 5 is in the form of discrete particles, or in the form of an agglomerated body of particles. These particles may share various characteristics with the (denser) second aerosol-generating material 5, such as particle size, but will have a lower density. As described above, there are various ways to adjust the density of the aerosol -generating material 4, 5, such as the formulation and/or the processing of the material into particles, beads or pellets. In some embodiments, the first aerosol-generating material 4 comprises a combination of 60% reconstituted tobacco and 40% lamina tobacco, with the density of this material being in the range of from about 0.1 to about 0.9 g/cm³. The second aerosol- generating materials 5 comprises from about 30 to about 90% tobacco, with a density in the range of from about 0.4 to about 1.99 g/cm³. The amount of aerosol forming material included in said one of the first and second aerosol-generating materials 4, 5 maybe from about 8 to about 15%. The second aerosol-generating materials 5 may comprise largely spherical beads with a particle size between about 0.5 and about 3 mm. In some embodiments, the aerosol generating material in an article comprises approximately 50% of the first aerosol-generating material 4 and about 50% of the second aerosol-generating material 5, by weight. Thus, for example, an article comprising 260 mg of aerosol-generating material may comprise 130 mg of the first aerosol-generating material 4 and 130 mg of the second aerosol-generating material 5.

In some embodiments where the aerosol-generating material comprises tobacco, the tobacco is present in an amount of between about 10% and about 90% by weight of the aerosol generating material. In some embodiments, the tobacco may be present in an amount of at least about 10%,

11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, or at last about 35% tobacco based on the weight of the aerosol generating material. In some embodiments, the tobacco may be present in an amount of no more than about

90%, 89%, 88%, 87%, 86%, 85%, 84%, 83%, 82%, 81%, 80%, 75%, 70%, 65%, 60%, 55%? 50%, 45%, or no more than about 40% tobacco based on the weight of the aerosol generating material. The tobacco described herein may contain nicotine. In some embodiments, the nicotine content is from 0.5 to 2% by volume of the tobacco, and maybe, for example, from 0.5 to 1.75% by volume of the tobacco, from 0.8 to 1.2% by volume of the tobacco or from about 0.8 to about 1.75% by volume of the tobacco. In some embodiments, the nicotine content may be from 0.8 to 1% by volume of the tobacco. In some embodiments, the first and second aerosol-generating materials 4, 5 have the same nicotine content.

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

In some embodiments, the first and/or second aerosol-generating materials 4, 5 comprise tobacco. For example, the first and/or second aerosol-generating materials 4, 5 may comprise from about 80 to about 350 mg of tobacco. In some specific embodiments, the aerosol-generating material in an article or consumable has a weight of 260 mg, comprising a combination of 130 mg of a first aerosol-generating material 4, for example comprising a blend of lamina and reconstituted tobacco, and 130 mg of a second aerosol-generating material 5, for example comprising higher density tobacco beads.

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

According to 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 provision device. According to the present disclosure, there is also provided a package (not shown) comprising a plurality of articles according to any of the examples described herein. In some embodiments, the package is hermetically sealed. The package may comprise a container comprising a body and a lid, wherein a space is provided within the container body to receive the plurality of articles. The lid may, for example, be a hinged lid, a snap-fit lid or lid that is connected by a screw thread. The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

- 59 - Claims

1. An apparatus for manufacturing a rod of aerosol generating material, the apparatus comprising: a suction belt for conveying aerosol generating material, the suction belt comprising suction holes to retain aerosol generating material on the suction belt, and wherein the apparatus is arranged such that the suction belt receives a first aerosol generating material at a first supply zone; and, a blocking member configured to block some of the suction holes in the suction belt at the first supply zone such that the first aerosol generating material is arranged in a profile comprising a plurality of first regions of the first aerosol generating material, with no or a reduced amount of first aerosol generating material provided between the first regions; and, a first feeding device configured to supply at least one of beads, pellets or granules of a second aerosol generating material between said first regions.

2. The apparatus of claim i, wherein the profile is arranged such that substantially no first aerosol generating material is disposed between the first regions such that the first regions are discrete and spaced apart from each other.

3. The apparatus of claim i, wherein the profile is arranged such that a connection region is provided between each first region, wherein each connection region comprises a reduced amount of the first aerosol generating material than the first region.

4. The apparatus of any one of the preceding claims, wherein the first feeding device comprises a drum comprising a plurality of receiving spaces configured to receive the beads, pellets and/or granules and transfer the beads, pellets and/or granules between said first regions.

5. The apparatus of claim 4, configured such that the beads, pellets and/ or granules are blown and/or sucked from the receiving spaces.

6. The apparatus of claim 4 or claim 5, comprising a plurality of mesh sections that define the receiving spaces. - 6o -

7. The apparatus of any one of the preceding claims, wherein the feeding device is configured to supply the beads, pellets and/or granules to the suction belt.

8. The apparatus of any one of claims 1 to 6, wherein the feeding device is configured to supply the beads, pellets and/ or granules downstream of the suction belt.

9. The apparatus of any preceding claim, further comprising a garniture arranged to receive the profile of first aerosol generating material from the suction belt.

10. The apparatus of claim 9, when dependent on claim 8, wherein the feeding device is configured to supply the beads, pellets and/or granules to the profile on the garniture.

11. The apparatus of claim 9 or claim 10, wherein the garniture is adapted to wrap a ribbon of paper about the first aerosol generating material and the beads, pellets and/or granules to form a continuous rod of aerosol generating material.

12. The apparatus of claim 11, further comprising a cutter adapted to cut the continuous rod of aerosol generating material.

13. The apparatus of any one of the preceding claims, wherein the first feeding device is configured to supply at least one of extruded beads, pellets or granules and, preferably, at least one of beads, pellets or granules that have been extruded and subject to spheronisation.

14. The apparatus of any one of the preceding claims, wherein the first feeding device is configured to supply beads, pellets and/or granules having a density from at least about 0.4 g/cm3 and, preferably, from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3 .

15. The apparatus of any one of the preceding claims, wherein the first feeding device is configured to supply beads, pellets and/or granules having a particle size in the range of 0.5 to 3 mm and, preferably, in the range of 1 to 2 mm. - 61 -

16. The apparatus of any one of the preceding claims, wherein the first and/ or second aerosol generating materials comprise, consist of, or essentially consist of tobacco material.

17. The apparatus of any of the preceding claims, wherein the suction belt is arranged to retain the first aerosol generating material on an underside of the suction belt.

18. The apparatus of any one of the preceding claims, further comprising a second feeding device arranged to feed the first aerosol generating material onto the suction belt in the first supply zone and, preferably, the second feeding device is disposed below the suction belt.

19. The apparatus of any one of the preceding claims, wherein the first feeding device is disposed below the suction belt.

20. The apparatus of any one of the preceding claims, wherein the blocking member comprises a profile belt arranged to overlap the suction belt in the first region, the profile belt being configured to block some of the suction holes in the suction belt such that the first aerosol generating material is retained on the suction belt in the profile.

21. The apparatus of claim 20, wherein the profile belt comprises a plurality of suction regions and a plurality of blocking regions arranged along the length of the profile belt.

22. The apparatus of claim 21, wherein the profile belt further comprises connecting suction regions disposed between the suction regions, each of the connecting suction regions being smaller than the suction regions such that less aerosol generating material is retained on the suction belt in each connecting suction region than in each suction region.

23. The apparatus of any one of claims 20 to 22, wherein the suction belt has a first width and the profile belt has a second width, and wherein the second width is less than the first width. - 62 -

24. A method of manufacturing a rod of aerosol generating material, the method comprising: applying suction to a suction belt having suction holes to retain a first aerosol generating material on the suction belt in a first supply zone; blocking some suction holes of the suction belt in the first region such that the first aerosol generating material is retained on the suction belt in a profile comprising a plurality of first regions of the first aerosol generating material, with no or a reduced amount of first aerosol generating material provided between the first regions; and, supplying at least one of beads, pellets or granules of a second aerosol generating material between said first regions.

25. The method of claim 24, wherein the beads, pellets and/ or granules are supplied to the suction belt.

26. The method of claim 24, wherein the beads, pellets and/ or granulesare supplied downstream of the suction belt.

27. The method of any one of claims 24 to 26, further comprising transferring the first aerosol generating material to a garniture.

28. The method of claim 27, when dependent on claim 26, wherein the beads, pellets and/or granules are supplied to the garniture.

29. The method of claim 27 or claim 28, further comprising wrapping the aerosol generating material in a ribbon of paper to form a continuous rod of aerosol generating material.

30. The method of claim 29, further comprising cutting the continuous rod of aerosol generating material.

31. The method of any one of claims 24 to 30, wherein the first feeding device is configured to supply extruded beads, pellets and/or granules and, preferably, beads, pellets and/or granules that have been extruded and subject to spheronisation.

32. The method of any one of claims 24 to 31, wherein the first feeding device is configured to supply beads, pellets and/or granules having a density from at least about - 63 -

0.4 g/cm3 and, preferably, from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3.

33. The method of any one of claims 24 to 32, wherein the first feeding device is configured to supply beads, pellets and/ or granules having a particle size in the range of

0.5 to 3 mm and, preferably, in the range of 1 to 2 mm.

34. The method of any one of claims 24 to 33, wherein the first aerosol generating material and/or the beads, pellets and/or granules comprise, consist of, or essentially consist of tobacco material.

35. A method of manufacturing an article for an aerosol provision system, the method comprising manufacturing a rod of aerosol generating material according to the method of any of claims 24 to 34, wherein first and second ends of the rod of aerosol generating material comprises first and second ends of the article.

36. A method of manufacturing rods of aerosol generating material, the method comprising: providing at least one of beads, pellets or granules of tobacco material; entraining the beads, pellets and/ or granules in a continuous pressurised fluid stream; and feeding the stream into a first aerosol generating material.

37. A method according to claim 36, wherein entraining the beads, pellets and/ or granules in a continuous pressurised fluid stream comprises using a venturi device to entrain the beads, pellets and/or granules.

38. A method according to claim 36, wherein entraining the beads, pellets and/ or granules in a continuous pressurised fluid stream comprises propelling the beads, pellets and/ or granules in a high pressure j et.

39. A method according to any of claim 36, wherein entraining the beads, pellets and/or granules in a continuous pressurised fluid stream comprises using a vacuum pump to propel the beads, pellets and/or granules.

40. A method according to any one of claims 36 to 39, wherein feeding the stream into a first aerosol generating material comprising feeding the stream into a body or rod of first aerosol generating material.

41. A method according to claim 30, wherein feeding the stream comprises positioning the stream substantially parallel to a longitudinal axis of the body or rod.

42. A method according to any one of claims 36 to 41, wherein providing the beads, pellets and/or granules of tobacco material comprises storing beads, pellets and/or granules of tobacco material in a storage unit and receiving the beads, pellets and/or granules from the storage unit.

43. A method according to claim 42, wherein storing the beads, pellets and/or granules comprises storing the beads, pellets and/ or granules in a conical hopper.

44. A method according to any of claims 36 to 43, wherein the beads, pellets and/ or granules are extruded and, preferably, beads, pellets and/or granules have been extruded and subject to spheronisation.

45. A method according to any of claims 36 to 44, wherein the beads, pellets and/ or granules have a density from at least about 0.4 g/cm3 _and, preferably, from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3.

46. A method according to any of claims 36 to 45, wherein the beads, pellets and/ or granules have a particle size in the range of 0.5 to 3 mm and, preferably, in the range of about 1 to 2 mm.

47. A method according to any of claims 36 to 46, wherein the first aerosol generating material comprise, consist of, or essentially consist of tobacco material.

48. A method of manufacturing an article for an aerosol provision system, the method comprising manufacturing a rod of aerosol generating material according to the method of any of claims 36 to 47, wherein first and second ends of the rod of material comprises first and second ends of the article.

49. A pack comprising a plurality of articles manufactured according to any one of claims 24 to 48.

50. An article manufactured from a rod of aerosol generating material manufactured according to the method of any one of claims 24 to 48.

51. An article for an aerosol provision system comprising a rod of aerosol generating material, wherein the rod of aerosol generating material comprises a first region of a first aerosol generating material and a second region of a second aerosol generating material comprising at least one of beads, pellets and/or granules.

52. An article according to claim 51, wherein the beads, pellets or granules are inserted into the first aerosol generating material.

53- An article according to claim 51, wherein the article is manufactured by an apparatus according to of any one of claims 1 to 23 or according to the method of any one of claims 24 to 35.

54. An article according to claim 51 or claim 52, wherein the article is manufactured according to the method of any one of claims 36 to 48.

55. An article according to any one of claims 51 to 54, wherein first and second ends of the rod of aerosol generating material comprise first and second ends of the article.

56. An article according to any one of claims 51 to 55, wherein the beads, pellets and/or granules have a density from at least about 0.4 g/cm3 _and, preferably, from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3.