WO2023118845A1

WO2023118845A1 - An article for use in an aerosol provision system and a method of manufacturing an article

Info

Publication number: WO2023118845A1
Application number: PCT/GB2022/053317
Authority: WO
Inventors: Barry DIMMICK; Cortney R JACKSON
Original assignee: Nicoventures Trading Limited
Priority date: 2021-12-20
Filing date: 2022-12-20
Publication date: 2023-06-29
Also published as: AU2022418379A1; EP4451934A1; CN118765166A; CA3241447A1; KR20240100466A; MX2024007492A; IL313256A

Abstract

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

Description

AN ARTICLE FOR USE IN AN AEROSOL PROVISION SYSTEM AND A METHOD OF MANUFACTURING AN ARTICLE

TECHNICAL FIELD

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

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 noncombustible smoking articles, aerosol generating assemblies, or aerosol provision devices, for example.

SUMMARY

In accordance with some embodiments described herein, there is provided an article for use in an aerosol provision system, the article comprising: an aerosol-generating material; a receiving member that comprises an end wall, an open end, and a peripheral wall that surrounds a storage area containing the aerosol-generating material; and, a blocking member comprising a body of material arranged to resist the aerosol-generating material from moving out of the storage area through the open end of the receiving member.

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

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

In some embodiments, the sheet material comprises a plurality of end portions that extend radially inwardly to form the end wall and, preferably, each end portion comprises a flap of the sheet material.

In some embodiments, the end portions are fixed together by adhesive.

In some embodiments, the end wall is gas permeable.

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

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

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

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

In some embodiments, the blocking member is generally cylindrical.

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

In some embodiments, said end of the rod has a density that is at least 10% higher than said another portion of the rod and, preferably, at least 20% higher than said another portion of the rod.

In some embodiments, the rod is a tobacco rod.

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

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

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

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

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

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

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

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

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

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

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

In some embodiments, the aerosol-generating material of the blocking member comprises a flavourant. In some embodiments, the aerosol generating material in the storage area is a first aerosol generating material and the aerosol generating material of the blocking member is a second aerosol generating material.

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

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

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

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

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

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

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

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

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

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

In some embodiments, the blocking member comprises tobacco material.

In some embodiments, the blocking member comprises paper.

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

In some embodiments, the sheet material is crimped.

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

In some embodiments, the blocking member comprises an end that contacts the aerosolgenerating material.

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

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

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

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

In some embodiments, the cooling section comprises a flavourant.

In some embodiments, the blocking member is upstream of the storage area. In other embodiments, the blocking member is downstream of the storage area. In some embodiments, the end wall is upstream of the storage area. In other embodiments, the end wall is downstream of the storage area.

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

According to the present disclosure, there is also provided an aerosol provision system comprising the article as disclosed herein and an aerosol provision device.

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

According to the present disclosure, there is also provided a method of manufacturing an article for use in an aerosol provision system, the method comprising: providing a receiving member that comprises an end wall, an open end, and a peripheral wall that surrounds a storage area containing an aerosol-generating material; and, providing a blocking member comprising a body of material arranged to resist the aerosol-generating material from moving out of the storage area through the open end of the receiving member.

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

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

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

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

In some embodiments, the method comprises forming a plurality of end portions in the sheet material and, preferably, forming the end portions comprising providing one or more cuts into the sheet material.

In some embodiments, the method comprises adhering the end portions together using an adhesive.

In some embodiments, the method comprises forming one or more apertures in the portion of the sheet material that comprises the end wall.

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

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

In some embodiments, the method comprises securing the blocking member relative to the receiving member using a wrapper and, preferably, wherein securing the blocking member relative to the receiving member using the wrapper comprises circumscribing the blocking member and receiving member with the wrapper.

In some embodiments, the blocking member is generally cylindrical.

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

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

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

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

In some embodiments, the blocking member comprises tobacco material.

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

In some embodiments, the sheet material is crimped and, preferably, the method comprises crimping the sheet material.

In some embodiments, the aerosol-generating material in the storage area is a loose material.

In some embodiments, the aerosol-generating material in the storage area comprises, consists of, or essentially consists of, tobacco material. In some embodiments, the tobacco material comprises tobacco beads and, preferably, wherein the tobacco material further comprises another tobacco material other than tobacco beads.

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

In some embodiments, the cooling section comprises a flavourant.

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

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

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

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

In some embodiments, the one or more regions of strength discontinuity are arranged such that the sheet material can be folded along the one or more regions of strength discontinuity to form the end wall.

In some embodiments, the one or more regions of strength discontinuity comprise one or more of: embossing; cuts (including cuts partially through the thickness of the sheet material or cuts through the entire thickness of the sheet material); pin holes; crease-lines; score lines; and/or, regions of reduced thickness of the sheet material.

In some embodiments, the one or more regions of strength discontinuity are regions of weakening.

In some embodiments, the one or more lines of strength discontinuity comprises regions of increased strength.

In some embodiments, the regions of strength discontinuity are continuous. In other embodiments, the regions of strength discontinuity are discontinuous.

In some embodiments, the one or more regions of strength discontinuity are lines of strength discontinuity.

In some embodiments, the sheet material has first and second edges and wherein, wherein at least one line of strength discontinuity extends substantially perpendicular to the first and second edges.

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

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

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

In some embodiments, sheet material comprises one or more flaps that are configured to be folded to form the end wall.

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

In some embodiments, at least one of the regions of strength discontinuity are arranged to promote folding of the one or more flaps to form the end wall.

In some embodiments, the sheet material comprises paper and/or foil. According to the present disclosure, there is also provided a receiving member for an aerosol provision system article, wherein the receiving member comprises an end wall, an open end, and a peripheral wall that surrounds a storage area for containing an aerosol-generating material, wherein the receiving member comprises the sheet material as disclosed herein, wherein the sheet material is arranged to form the peripheral wall and end wall.

According to the present disclosure there is also provided an article for use in an aerosol provision system comprising: the receiving member as disclosed herein; an aerosol-generating material provided in the storage area of the receiving member; and, a blocking member comprising a body of material arranged to resist the aerosol-generating material from moving out of the storage area through the open end of the receiving member.

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

According to the present disclosure, there is also provided a method of manufacturing a sheet material for an article for use in an aerosol provision system, the method comprising providing a sheet material and forming one or more regions of strength discontinuity in the sheet material arranged such that the regions of strength discontinuity promote folding of the sheet material in a predetermined manner to form an end wall of the receiving member.

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

BRIEF DESCRIPTION OF THE DRAWINGS

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

Fig. 1 is a side-on cross sectional view of an embodiment of an article for use with an aerosol provision device; Fig. 2 is an end view of a receiving member of the article of Fig. 1;

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

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

Fig. 5 is a side-on cross-sectional view of the sheet material rolled into a tube;

Fig. 6 is a side-on cross-sectional view of the sheet material rolled into a tube, with an end folded to form an end wall;

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

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

Fig. 9 is an alternative embodiment of a sheet material that is used to form a receiving member of an article for use with an aerosol provision device, wherein the sheet material is laid flat prior to forming the receiving member;

Fig. 10 is another alternative embodiment of a sheet material that is used to form a receiving member of an article for use with an aerosol provision device, wherein the sheet material is laid flat prior to forming the receiving member;

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

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

Fig. 13 is a cross sectional view of an embodiment of a non-combustible aerosol provision device;

Fig. 14 is a simplified schematic of the components within the housing of the aerosol provision device shown in Fig. 13;

Fig. 15 is a cross sectional view of the non-combustible aerosol provision device shown in Fig. 13 with the article shown in Fig. 1 inserted into the device; and, Fig. 16 is a side-on cross sectional view of another embodiment of an article for use with an aerosol provision device.

DETAILED DESCRIPTION

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

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

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

In some embodiments, the non-combustible aerosol provision system is an aerosolgenerating material heating system, also known as a heat-not-bum 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 aerosolgenerating material. The solid aerosol-generating material may comprise a plant based material, for example, tobacco or a non-tobacco product.

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

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

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

In some embodiments, the non-combustible aerosol provision system, such as a non- combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system comprises an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosolmodifying 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 may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, 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, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be 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 may be 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%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% 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 aerosolgenerating 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 aerosolgenerating 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 aerosolgenerating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

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

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

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be 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 aerosolgenerating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

The filamentary tow material described herein 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(l-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT), starch based materials, cotton, aliphatic polyester materials and polysaccharide polymers or a combination thereof. The filamentary tow may be plasticised with a suitable plasticiser for the tow, such as triacetin where the material is cellulose acetate tow, or the tow may be non-plasticised. The tow can have any suitable specification, such as fibres having a ‘Y’ shaped or other cross section such as ‘X’ shaped, filamentary denier values between 2.5 and 15 denier per filament, for example between 8.0 and 11.0 denier per filament and total denier values of 5,000 to 50,000, for example between 10,000 and 40,000.

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

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

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

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

The receiving member 2 comprises a peripheral wall 5 that surrounds a space 6 that contains the aerosol-generating material 3. The space 6 forms a storage area 6 for the aerosolgenerating material 3.

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

In some embodiments, the peripheral wall 5 and end wall 8 of the receiving member 2 are integrally formed. In the present example, the receiving member 2 comprises a sheet material 9. In some embodiments, the sheet material 9 comprises paper and/or foil, for example, a metallic foil such as aluminium foil. The sheet material 9 may optionally comprise a plurality of layers of materials, for example, a layer of paper with a layer of foil. In some embodiments, the sheet material 9 does not comprise any foil.

The sheet material 9 is rolled into a tube to form the peripheral wall 5 of the receiving member 2 (as shown in Fig. 5). In some embodiments, adhesive is applied to the sheet material 9 to retain the sheet material 9 as a tube. In other embodiments (not shown), the sheet material 9 is alternatively or additionally held in a tube shape by a wrapper that circumscribes the sheet material 9.

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

In the present example, the sheet material 9 comprises a plurality of end portions 10 that are each folded radially inwardly once the peripheral wall 5 has been formed such that the end portions 10 form the end wall 8. Alternatively, each end portion 10 is folded and then the sheet material 9 is rolled/wrapped to form the peripheral wall 5, wherein said rolling of the sheet material 9 causes the end portions 10 to come together, or towards each other, to form the end wall 8.

In some embodiments, each end portion 10 comprises a flap 10 of the sheet material 9. Each flap 10 may be generally triangular. However, the skilled person will recognise that other shapes of flap 10 are possible, for example, semi-circular or rectangular flaps.

The end portions 10 may be retained in a folded position forming the end wall 8 using adhesive. In alternative embodiments, the end portions 10 may be retained in position by the stiffness and/or ductility of the sheet material 9 or due to a further component (for example, a plug of material now shown) that is provided on the opposite side of the end portions 10 to the aerosol-generating material 3 and, for example, the further component may abut the end portions 10.

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

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

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

In some embodiments, the end wall 8 comprises one or more apertures 11 to permit the flow of gas through the end wall 8. The or each aperture 11 may be holes or slits through the sheet material 9. For example, one or more holes and/or slits may be provided in one or more of the end portions 10. In another embodiment (not shown), the or each aperture 11 may comprise one or more gaps between adjacent end portions 10 of the end wall 8. In yet another embodiment (not shown), the end portions 10 may be sized such that they do not meet in the axial centre of the article 1 when folded to form the end wall 8, such that an aperture is provided for the flow of gas therethrough.

The or each aperture 11 may be of sufficient size to permit the flow of gas through the end wall 8 whilst being small enough to resist aerosol-generating material 3 from flowing out of the end wall 8 via the or each aperture 11. In some embodiments, the or each aperture 11 has a diameter in the range of 0.1 to 1 mm and, preferably, in the range of 0.2 to 0. 8 mm.

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

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

In another embodiment, sheet material 9 at the end wall 8 comprises a gas permeable material to permit the flow of gas through the end wall 8. The permeable material may be, for example, paper and may have a porosity of at least 100 Coresta Units and, preferably, at least 200, 300, 400, 500, 1000, 2000, 3000, 5000 , 7000, 10000 or 20000 Coresta Units. In some embodiments, the entire sheet material 9 is manufactured from said gas permeable material. In other embodiments, only the sheet material 9 in the region of the end portions 10 is manufactured from said gas permeable material. In some embodiments, the permeability of the sheet material 9 is selected based on the desired resistance to draw of the article 1 (with a higher permeability resulting in a lower resistance to draw).

The blocking member 4 comprises a body of material 12 arranged to resist the aerosolgenerating material 3 from falling out of the open end 7 of the receiving member 2.

In the present example, the body of material 12 of the blocking member 4 is generally cylindrical. However, it should be recognised that the body of material 12 may have a different shape. The article 1 further comprises a wrapper 13 that secures the blocking member 4 relative to the receiving member 2. In the present example, the wrapper 13 circumscribes both of the receiving member 2 and blocking member 4. The wrapper 13 may be wrapped around the entire axial length of the receiving member 2 and/or blocking member 4. In other embodiments, the wrapper 13 may be wrapped around only a portion of the axial length of the receiving member 2 and/or blocking member 4 and, for example, may be provided as a strip of material that overlaps the joint between the receiving member 2 and blocking member 4 without extending to the other ends of the receiving member 2 and/or blocking member 4.

In some embodiments, the wrapper 13 is adhered to the receiving member 2 and/or blocking member 4. However, the skilled person will recognise that in other embodiments the wrapper 13 may not be adhered to the receiving member 2 and/or blocking member 4 and may be held in place, for example, by friction.

In the present embodiment, the body of material 12 is a plug of material. In the present embodiment, the plug of material comprises aerosol-generating material 14. For example, the aerosol-generating material 14 may comprise, consist of, or essentially consist of, tobacco material. As explained previously, the term “tobacco material” refers to any material comprising tobacco or derivatives or substitutes thereof. The tobacco material may be in any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and/or tobacco extract.

In some embodiments, the body of material 12 additionally, or alternatively, comprises one or more aerosol-former materials. For example, the body of material 12 may additionally or alternatively comprise one or more constituents capable of forming an aerosol. The aerosolformer material comprises one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol-former material can be glycerol or propylene glycol.

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

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

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

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

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

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

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

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

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

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

In some embodiments, the aerosol generating material 3 in the space 6 of the receiving member 2 is a first aerosol generating material 3. In embodiments wherein the body of material 12 of the blocking member 4 comprises an aerosol generating material 14, this is a second aerosol generating material 14. Thus, the article 1 may comprise first and second regions 3A, 14A of aerosol generating material 3, 14. The first and second regions 3A, 14A may be discrete regions. In some embodiments, the first aerosol generating material 3 has at least one different characteristic to the second aerosol generating material 14. The different characteristic may be one or more of form, size, density, water content, amount (by weight), material or materials, or proportion of materials that make each aerosol generating material 3, 14 (including the recipe of each aerosol generating material 3, 14 when each is manufactured more than one material). In other embodiments, the first and second aerosol generating material 3, 14 do not have a different characteristic and instead are the same.

In some embodiments, the first and second aerosol generating material 3, 14 may comprise the same material, for example, tobacco, that has a different characteristic. In one such embodiment, the first and second aerosol generating material 3, 14 may be in different forms. For example, the first aerosol generating material 3 may be in the form of beads or pellets of aerosol generating material (for example, tobacco or another material) and the second aerosol generating material 14 may be in the form of, for example: strands or strips of aerosol generating material (for example, tobacco or another material); a sheet of aerosol generating material that is gathered into a plug or is cut into strips; loose material (e.g. cut rag tobacco); a dense end of a rod of aerosol generating material (e.g. tobacco); or, tobacco lamina and/or stem material that has been formed into a plug. However, it should be recognised that the first and second aerosol generating material 3, 14 may alternatively have the same form (e.g. both being cut rag tobacco) and have some other differing characteristic (e.g. different densities of material).

In some embodiments, the first and second aerosol generating materials 3, 14 may release one or more volatile compounds at different rates when heated. This allows for a more consistent delivery of said compounds over the duration of the consumption session of the article 1. For example, the second aerosol generating material 14 may reach a given temperature more quickly than the first aerosol generating material 3 when heated by a particular power of heater. This may cause the second aerosol generating material to initially release volatile compounds at a greater rate than the first aerosol generating material 3. In one such embodiment, the second aerosol generating material 14 may provide the release of volatile compounds during a first period of the consumption session and the first aerosol generating material 3 may provide the release of volatile compounds during a later second period of the consumption session. In one such embodiment, the second aerosol generating material 14 is heated during the first period and the first aerosol generating material 3 is heated during the second period of the consumption session.

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

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

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

Advantageously, the body of material 12 is arranged to resist the aerosol generating material 3 from falling out of the open end 7 of the receiving member 2. This reduces the size and weight of the article 1 and the amount of materials required to manufacture the article 1 , because the article 1 does not require a further component to retain the aerosol generating material 3 in the receiving member 2. For example, arranging the body of material 12 to retain the aerosol generating material 3 in the receiving member 2 means that the receiving member 2 can have an open end 7, rather than comprising a second end wall (on the opposite side of the space 6 to the end wall 8) to enclose the space 6, and thus requires less material.

In addition, the body of material 12 can perform a further function of the article 1 in addition to retaining the aerosol generating material 3 in the space 6. In the present example, the body of material 12 comprises an aerosol generating material 14 and thus the body of material 12 performs both the function of retaining the aerosol generating material 3 in the space 6 and also the function of releasing one or more volatile compounds when heated. Similarly, the body of material 12 may alternatively or additionally comprise an aerosol former material and thus also performs the function of forming an aerosol. In other embodiments, the body of material 12 may comprise a filter (for example, paper gathered into a plug) that also performs the function of filtering the flow of gas as it passes through the article 1.

The first and/or second aerosol-generating material 3, 14 may comprise a plurality of strands or strips of aerosol-generating material. For example, the first and/or second aerosolgenerating material 3, 14 may comprise a plurality of strands or strips of an aerosolisable material and/or a plurality of strands or strips of an amorphous solid. The first and/or second aerosol- generating material 3, 14 may comprise a plant based material, such as a tobacco material. The first and/or second aerosol-generating material 3, 14 may be a sheet or shredded sheet of aerosolisable material comprising a plant based material, such as a tobacco material.

The plant based material may be a particulate or granular material. In some embodiments, the plant based material is a powder. Alternatively, or in addition, the plant based material may comprise may comprise strips, strands or fibres of tobacco. For example, where tobacco material is provided, the tobacco material may comprise particles, granules, fibres, strips and/or strands of tobacco. In some embodiments, the tobacco material consists of particles or granules of tobacco material.

The tobacco material may comprise tobacco obtained from any part of the tobacco plant. In some embodiments, the tobacco material comprises tobacco leaf.

The sheet or shredded sheet can comprise from 5% to about 90% by weight tobacco leaf. In some embodiments, both of the first and second aerosol generating materials 3, 14 comprise, consist of, or essentially consist of tobacco material.

The first and/or second aerosol-generating material 3, 14 may comprise an aerosolformer material. The aerosol-former material comprises one or more constituents capable of forming an aerosol. The aerosol-former material comprises one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol-former material can be glycerol or propylene glycol. In some embodiments, the first and/or second aerosol-generating material 3, 14 comprises a sheet or shredded sheet of aerosolisable material that comprises an aerosol-former material. Optionally, the aerosol-former material is provided in an amount of up to about 50% on a dry weight base by weight of the sheet or shredded sheet. In some embodiments, the aerosol-former material is provided in an amount of from about 5% to about 40% on a dry weight base by weight of the sheet or shredded sheet, from about 10% to about 30% on a dry weight base by weight of the sheet or shredded sheet or from about 10% to about 20% on a dry weight base by weight of the sheet or shredded sheet.

The first and/or second aerosol-generating material 3, 14 may comprise a filler. In some embodiments, the sheet or shredded sheet comprises the filler. The filler is generally a nontobacco component, that is, a component that does not include ingredients originating from tobacco. The filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may be a non-tobacco fibre such as wood fibre or pulp or wheat fibre. The filler can be a material comprising cellulose or a material comprises a derivate of cellulose. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material.

The first and/or second aerosol-generating material 3, 14 herein can comprise an aerosol modifying agent, such as any of the flavours described herein. In one embodiment, the first and/or second aerosol-generating material 3, 14 comprises menthol. When the first and/or second aerosol-generating material 3, 14 is incorporated into an article 1 for use in an aerosolprovision system, the article may be referred to as a mentholated article 1. The first and/or second aerosol-generating material 3, 14 can comprise from 0.5mg to 20mg of menthol, from 0.7 mg to 20 mg of menthol, between Img and 18mg or between 8mg and 16mg of menthol. In some embodiments, the article 1 comprises an aerosol-generating composition comprising aerosol-generating material. The aerosol-generating material may comprise the first and/or second aerosol-generating material 3, 14.

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 3, 14) 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 3, 14) 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 3, 14) 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 3, 14) is substantially tobacco free.

The aerosol-generating material (for example, the first and/or second aerosol generating material 3, 14) may comprise or be an “amorphous solid”. The amorphous solid may be a “monolithic solid”. In some embodiments, the amorphous solid may be a 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%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% 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 3, 14) 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 aerosolgenerating 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 aerosolgenerating film may be 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 3, 14) 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 3, 14, and may comprise such an aerosolgenerating composition.

The first and/or second aerosol-generating material 3, 14 can comprise a paper reconstituted tobacco material. The composition can alternatively or additionally comprise any of the forms of tobacco described herein. The first and/or second aerosol-generating material 3, 14 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 3, 14 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 3, 14 comprises an extruded aerosol generating material that is then cut into beads of pellets.

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

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

It should be recognised that in other embodiments the body of material 12 does not comprise an aerosol generating material. For example, in one alternative embodiment the body of material 12 comprises paper formed into a plug (for example, being crimped or cut into strips and formed into the plug), without any aerosol generating material applied to or incorporated within the sheet material of the plug.

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

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

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

In some embodiments, the rod 16 comprises a plug warp 15 that circumscribes the body of material 12 of the rod 16.

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

In some embodiments, the end portion 17 of the rod 16 comprises a greater amount of material per unit axial length (e.g. per mm) of the rod 16 than said another portion 18. For example, the end portion 17 comprises a greater amount of aerosol generating material 14, aerosol-former material, filler material and/or other material. Thus, when the aerosol generating material 14 is formed into the rod 16 (for example, using a rod forming apparatus as will be known to a person skilled in the art), the increased amount of material at the end portion 17 causes the rod 16 to have an increased density at the end portion 17 compared to said another portion 18 of the rod 16. In some embodiments, the end portion 17 of the rod 16 comprises at least 10% (by weight) and, preferably, at least 20 % (by weight) of material per mm of length of the rod 16 than said another portion 18 of the rod 16. Referring now to Fig. 8, block diagram depicting an embodiment of a method 100 of manufacturing an article 1 for an aerosol provision device is shown.

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

In some embodiments, the step SI of providing the receiving member 2 comprises forming the receiving member 2 and then providing the aerosol-generating material 3 in the space 6. For example, the aerosol-generating material 3 may be poured into the open end 7 of the receiving member 2. In one such embodiment, the receiving member 2 is orientated such that the central axis of the receiving member 2 is substantially vertical with the open end 7 facing upwardly, and then the space 6 of the receiving member 2 is filled, or at least partially filled, with the aerosol generating material 3. In some embodiments, a plurality of receiving members 2 are moved along a conveyance path to pass a filling machine (not shown), wherein the filling machine is configured to deposit an aerosol generating material 3 in each receiving member 2 as it passes the filling machine. Optionally, the filling machine may deposit a metered amount of aerosol generating material 3 in each receiving member 2. The filling machine may comprise, for example, a dosage wheel configured to deposit aerosol generating material 3 in the receiving members 2. Alternatively, the filling machine may supply a continuous stream of aerosol generating material 3 (for example, using one or more hoppers), and aerosol generating material 3 that does not enter the space 6 of one of the receiving members 2 is collected and disposed of or recycled. In other embodiments, the step SI of providing the receiving member 2 comprises forming the receiving member 2 around the aerosol-generating material 3. For example, a aerosol generating material 3 may be deposited on the sheet material 9, and then the sheet material 9 is wrapped around the aerosol generating material 3 and formed into the receiving member 2. In some embodiments, a metered amount of aerosol generating material 3 may be deposited on the sheet material 9, for example, using a dosage wheel (not shown) or any other suitable apparatus.

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

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

In some embodiments (not shown), a web of sheet material 9 is formed into a continuous tube, an end of the continuous tube is folded to form an end wall 8, and then a portion of the sheet material 9 comprising the end wall 8 and peripheral wall 5 is cut from the remainder of the continuous tube such that a receiving member 2 is formed. The process can then be repeated with the remainder of the continuous tube to form further receiving members 2. That is, the new end of the continuous tube is folded to form an end wall 8, and then a portion of the sheet material 9 comprising the end wall 8 and peripheral wall 5 is cut from the remainder of the continuous tube such that a further receiving member 2 is formed, and again the process can be repeated to form further receiving members 2. In some embodiments, the step SI of providing the receiving member 2 comprises folding the sheet material 9 to form the end wall 8 of the receiving member 2. The folding of the sheet material 9 to form the end wall 8 of the receiving member 2 may take place before or after said rolling of the sheet material 9.

An example of folding of the sheet material 9 to form the end wall 8 is depicted in Fig. 6. An end of the sheet material 9 is folded along a fold line (depicted by dashed line ‘X-X’ in Fig. 6) in a radially inwards direction (in the direction of arrows ‘Y’ in Fig. 6) to form the end wall 8 of the receiving member 2. In some embodiments, the end portion 10 of the sheet material 9 partially overlap when folded to form the end wall 8. In other embodiments, the end portions 10 do not overlap and, in some embodiments, one or more gaps (not shown) may be formed between the end portions 10 to form apertures to permit the flow of gas through the end wall 8.

In some embodiments, the step SI of providing the receiving member 2 comprises forming a plurality of end portions 10 in the sheet material 9 and folding the end portions 10 to form the end wall 8 of the receiving member 2. Preferably, forming the end portions 10 comprising providing one or more cuts into the sheet material 9. In one such example, a generally zig-zag arrangement of cuts is provided in the sheet material 9, which form cut edges 10A, in order to form the end potions 10.

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

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

In some embodiments, the step SI of providing the receiving member 2 comprises securing the end portions 10 together using an adhesive. The adhesive may be provided on one or more of the end portions 10 prior to folding the end portions 10. Alternatively, the adhesive may be provided on one or more of the end portions 10 after folding the end portions 10. In other examples, the end portions 10 may be welded together or held in positon by one or more securing member(s), for example, a staple, sticker or label.

In some embodiments, the step SI of providing the receiving member 2 comprises forming one or more apertures 11 into the portion of the sheet material 9 that comprises the end wall 8.

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

In some embodiments, the or each aperture 11 is formed into one or more of the end portions 10 of the sheet material 9.

In some embodiments, the or each aperture 11 is formed by cutting, tearing, punching or burning the sheet material, and/or by forming gaps between end portions 10 of the sheet material 9. For example, the or each aperture 11 may be formed by cutting using a knife or laser. In some embodiments, the or each aperture 11 comprises a hole, for example, a round hole, in the sheet material 9. In other embodiments, the or each aperture 11 comprises a slit in the sheet material 9. In some embodiments, the method further comprises forming one or more regions of strength discontinuity of the sheet material 9 arranged such that the sheet material 9 can be folded along the one or more regions of strength discontinuity to form said end wall 8, as is described in more detail in reference to Figs. 9 and 10. However, in other embodiments, the method does not comprise forming such regions of strength discontinuity.

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

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

In some embodiments, the step S2 of providing a blocking member 4 comprises securing the blocking member 4 relative to the receiving member 2 using a wrapper 13. In one such embodiment, securing the blocking member 4 relative to the receiving member 2 using the wrapper 13 comprises circumscribing the blocking member 4 and receiving member 2 with the wrapper 13.

In some embodiments, the wrapper 13 is adhered to the receiving member 2 and/or the blocking member 4. However, in other embodiments the wrapper 13 may hold the receiving member 2 and/or blocking member 4 in position using friction.

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

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

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

The end portion 17 of the rod 16 may have a higher density of material per mm axial length of the rod 16 than said another portion 18.

In some embodiments, the end portion 17 of the rod 16 may have a higher mass of material per mm axial length of the rod 16 than said another portion 18.

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

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

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

As explained previously, the body of material 12 may comprise an aerosol-generating material 14 and/or may comprise an aerosol-former material.

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

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

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

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

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

In some embodiments, the sheet material of the blocking member 4 is crimped. The step S2 of providing the blocking member 4 may comprise crimping the sheet material. For example, step S2 may comprise passing the sheet material used to form the blocking member 4 through a pair of crimping rollers.

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

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

In some embodiment, the blocking member 4 comprises an end surface 4A that contacts the aerosol-generating material 3.

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

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

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

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

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

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

Referring now to Fig. 9, an alternative embodiment of sheet material 9 for forming a receiving member 2 of an article 1 is shown. The sheet material 9 may have any of the features of the sheet material 9 of the article 1 described herein, including any of the features of the sheet material 9 described above in reference to Figs. 1 to 8. A difference is that the sheet material 9 further comprises one or more regions of strength discontinuity 20.

The one or more regions of strength discontinuity 20 are arranged such that the sheet material 9 can be folded along the one or more regions of strength discontinuity 20 to form the end wall 8 of the receiving member 2.

In some embodiments, the region(s) of strength discontinuity 20 comprise regions of weakening of the sheet material 9. Therefore, when the sheet material 9 is folded, the sheet material 9 folds along the region(s) of weakening. For example, the regions of weakening may comprise one or more of: cuts partially or entirely through the thickness of the sheet material 9; embossing; pin holes; pre-formed crease lines; score lines; and/or, regions of reduced thickness of the sheet material 9. In one embodiment (not shown), the region of reduced strength is achieved by strengthening at least a portion of the remainder of the sheet material 9, for example, applying a strengthening coating (e.g. a varnish) to the sheet material 9 in areas about the region(s) of weakening or to the entire rest of the sheet material 9.

In some embodiments, the region(s) of strength discontinuity 20 comprise regions of increased strength of the sheet material 9. Therefore, when the sheet material 9 is folded, the sheet material 9 folds in proximity to the regions of increased strength. For example, the region(s) of increased strength may comprise embossing, a coating (for example, a varnish or other coating) or regions of increased thickness of the sheet material.

In some embodiments, the one or more regions of strength discontinuity 20 comprise embossing.

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

In some embodiments, the one or more regions of strength discontinuity 20 are lines of strength discontinuity 20. The regions of strength discontinuity 20 may extend substantially linearly.

In some embodiments, the sheet material 9 has a first axis A- A that extends parallel to the first and second ends 9A, 9B of the sheet material 9, wherein at least one line of strength discontinuity 20 extends substantially perpendicular to the first axis A-A. In some embodiments, the first axis A-A extends from the end portions 10 to an opposite end of the sheet material 9. It should be recognised that in other embodiments (not shown), the or each region 20 of strength discontinuity 20 extends at an angle to said first axis A-A. In some embodiments, the sheet material 9 has basis weight of at least 35 GSM and, preferably, at least 100, 150 or 200 GSM.

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

In the present example, the sheet material 9 comprises a plurality of end portions 10 that are each folded radially inwardly once the peripheral wall 5 has been formed such that the end portions 10 form the end wall 8. Alternatively, each end portion 10 may be folded and then the sheet material 9 is rolled to form the peripheral wall 5, wherein said rolling of the sheet material 9 causes the end portions 10 to come together to form the end wall 8.

In some embodiments, each end portion 10 comprises a flap 10 of the sheet material 9. Each flap 10 may be generally triangular. That is, a plurality of triangular cut-outs may be formed into the sheet material. However, the skilled person will recognise that other shapes of flap 10 are possible, for example, semi-circular or rectangular flaps.

In the present example, the sheet material 9 comprises a plurality of regions of strength discontinuity 20 that are discrete and spaced from each other. In the present example, the regions comprise lines of weakening 20 formed by embossing the sheet material 9. Each region of strength discontinuity 20 is disposed at an edge of a corresponding end portion 10, where said end portion 10 is joined to the remainder of the sheet material 9. Thus, each region 20 facilitates the folding of a respective end portion 10 to form the end wall 8 of the receiving member 2.

Referring now to Fig. 10, yet embodiment of sheet material 9 for forming a receiving member 2 of an article 1 is shown. The sheet material 9 may have any of the features of the sheet material 9 of the article 1 described above in reference to Figs. 1 to 8 or Fig. 9. A difference is that the sheet material 9 comprises a single region of strength discontinuity 20 that extends across the entire width of the sheet material 9. Also, the end portions 10 are rectangular and are formed by cuts 10A that are substantially parallel to the first and second ends 9 A, 9B of the sheet material 9.

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

The article 1 is configured for use in an aerosol provision device 200 (see Figure 13) comprising an aerosol generator in the form of a heating element 203 for heating the article 1. In the present example, the heating element 203 at least partially surrounds a heating area 202, for example, a heating chamber 202. The heating element 203 may be resistively and/or inductively heated.

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

In Figure 13, 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 13. Elements that are not relevant for the understanding of this embodiment have been omitted to simplify Figure 13.

In the example of Figure 13, the aerosol provision device 200 is a non-combustible aerosol provision device 200. The non-combustible aerosol provision device 200 comprises a housing 201 comprising an area 202 for receiving an article 1.

When the article 1 is received into the heating area 202, at least a portion of the article 1 comes into thermal proximity with the heater 203. Thus, at least a portion of the aerosol generating material 3 in the space 6 and/or the aerosol generating material 14 of the body of material 12 is in thermal proximity with the heater 203. In some embodiments, the heater 203 is spaced from the article 1, for example, circumscribing the article 1 but having a larger diameter and being spaced therefrom. In other embodiments, the heater 203 is in direct contact with the article 1, for example, contacting an outer surface of the wrapper 13 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 aerosol generating material 3 in the space 6 and/or the body of material 12 of the blocking member 4.

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

As shown in Figure 14, 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 15 is a schematic cross-section of a non-combustible aerosol-provision device 200 of the type shown in Figure 13, 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 aerosolgenerating 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 aerosolgenerating 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.

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

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

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

The cooling element 25 may have a wall thickness in a radial direction. The wall thickness of the cooling element 25, for a given outer diameter of cooling element 25, defines the internal diameter for the chamber surrounded by the walls of the cooling element 25. The cooling element 25 can have a wall thickness of at least about 1.5 mm and up to about 2 mm. In the present example, the cooling element 25 has a wall thickness of about 2 mm.

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

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

The cooling element 25 can be configured to provide a temperature differential of at least 40 degrees Celsius between a heated volatilised component entering a first, upstream end of the cooling element 25 and a heated volatilised component exiting a second, downstream end of the cooling element 25. The cooling element 25 can be configured to provide a temperature differential of at least 60 degrees Celsius, or at least 80 degrees Celsius, or at least 100 degrees Celsius between a heated volatilised component entering a first, upstream end of the cooling element 25 and a heated volatilised component exiting a second, downstream end of the cooling element 25. This temperature differential across the length of the cooling element 25 protects the temperature sensitive body of material 26 from the higher temperatures of the aerosol-generating material 3 when it is heated.

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

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

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

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

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

It has been found that providing different densities of first and second aerosol generating materials 3, 14 means that the higher density material heats up slower when both materials are exposed to the same heating and thus the higher density material will release its volatile compounds (e.g. nicotine) at a slower rate than the lower density material. In some embodiments, the first aerosol-generating material 3 has a greater density than the second aerosol-generating material 14 so that the first aerosol generating material 3 heats up slower than the second aerosol generating material 14 when exposed to the same heating and will release its volatile compounds (e.g. nicotine) at a slower rate than the second aerosol-generating material 14 (however, in other embodiments the reverse may be true such that the second aerosol generating material 14 has a higher density than the first aerosol generating material 3). Thus, combining aerosol-generating materials with different densities provides a more consistent and longer-lasting release of volatile compound(s). In some embodiments, the aerosol-generating materials of different densities are combined with separate heating of these materials at optionally different times and/or different temperatures, thereby allowing the provision of a more tailored release of the volatile compound(s) over the period of consumption of the article, for example Alternatively, it may be desirable to have a more rapid or greater release of volatiles towards the beginning of the consumption of the article, to provide the user with a greater initial impact from use. The capacity to control the aerosol generation and volatile compound release may be particularly advantageous because the article can be made relatively small whilst still achieving a particular desired release of volatile compound(s) over the period of consumption.

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

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

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

In some embodiments, the first and second aerosol-generating materials 3, 14 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 3, 14 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 3 and the second aerosolgenerating material 14 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 dryice expanded tobacco (DIET), or processed by any other means. In some embodiments, the tobacco material may be reconstituted tobacco material. The tobacco may be pre-processed or unprocessed, and may be, for instance, solid stems (SS); shredded dried stems (SDS); steam treated stems (STS); or any combination thereof. The tobacco material may be fermented, cured, uncured, toasted, or otherwise pre-treated.

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

In some embodiments, the first aerosol-generating material 3 has at least one (further) different characteristic to the second aerosol generating material 14. The different characteristic may be one or more of form, size, , water content, amount (by weight), material or materials, or proportion of materials that make the first and second aerosol-generating materials 3, 14 (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 3, 14 do not have a different characteristic, other than their different densities. In other embodiments, the densities are the of the first and second aerosol generating materials is the same. In some embodiments, the second aerosol-generating material 14 comprises one or more tobacco in the form of cut rag. This tobacco material may lamina or reconstituted tobacco material. In some embodiments, the second aerosol-generating material 14 is a blend comprising both lamina and reconstituted tobacco. For example, the ratio of lamina and reconstituted tobacco may from about 1:4 to about 4:1.

In some embodiments, the first aerosol-generating material 3 has a greater density than the second aerosol-generating material 14. In some embodiments, this more dense, first aerosol-generating material 3 comprises particles or may be in the form of beads or one or more sheets. Each bead or sheet may be formed from smaller particles that have been agglomerated. However, it should be recognised that in other embodiments, the second aerosol-generating material 14 may be denser than the first aerosol generating material 3 and, for example, may be in the form of beads or one or more sheets. In some embodiments, the both of the first and second aerosol generating materials 3, 14 may be in the form of beads or one or more sheets and, optionally, may be processed such that one of the first and second aerosol generating materials 3, 14 has a higher density than the other one of the first and second aerosol generating materials 3, 14.

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 3, 14 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 3, 14 comprises particles of material that are agglomerated.

In the case of a sheet material, the sheet may be 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 may be formed by agitation and as the particles are rolled and tumbled in the presence of appropriate quantities of a liquid, agglomerates are formed. Balling may involve the use of apparatus such as pans, discs, drums or mixers to produce pellets. Compaction pelletisation is a form of pressure agglomeration, in which the particles are forced together by a mechanical force, optionally with formulation aids. The compressive forces mean that the pellets formed have increased density compared to the starting material.

In some embodiments, the agglomeration is by extrusion. In some embodiments, pellets formed by pelletisation may be extruded to form higher density extrudates. The particles to be extruded may have a size selected to produce a more dense aerosolgenerating material (e.g. a more dense first or second aerosol generating material 3, 14), 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 40°C to about 150°C, or from about 80°C to about 130°C, or from about 60°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 70°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 60°C to about 80°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 may be 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, may be sufficient where the beads’ primary function is to release volatile constituents carried by the beads into an existing aerosol or air flow.

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

In some embodiments, processing by extrusion is sufficient to provide the higher density of the first or second aerosol-generating material 3, 14, where desired. However, in other embodiments, the extrudate may be further treated to increase the density of the first or second aerosol-generating material 3, 14.

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 first aerosol-generating material 3 were produced as follows (but note that in some embodiments samples may be produced according to the below, which are instead used for the second 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 100 pm or less than 60 pm.

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

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

The mixture was then extruded using a Caleva Multilab. The extruder was operated at approximately 1500 rpm to produce lengths of extrudate resembling spaghetti. The extrudate was broken into pieces of varying length as it came out of the extruder.

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

In a final step, the spheronised beads were dried in an oven at 65°C for 30 minute periods. After each drying period, the beads were weighed and drying was halted when the desired moisture weight loss was achieved. Generally, such drying will take about 1 hour.

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

In some embodiments, said one of the first and second aerosol-generating materials 3, 14 comprises a combination of 60% reconstituted tobacco and 40% lamina tobacco, with the density of this material being in the range of from about 0.1 to about 0.9 g/cm³. The other one of the first and second aerosol-generating materials 3, 14 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 3, 14 may be from about 8 to about 15%. The said one of the first and second aerosolgenerating materials 3, 14 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 3 and about 50% of the second aerosol-generating material 14, by weight. Thus, for example, an article comprising 260 mg of aerosol-generating material may comprise 130 mg of the first aerosol-generating material 3 and 130 mg of the second aerosol-generating material 14.

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 2.5% or 0.5 to 2% by weight of the tobacco, and may be, for example, from 0.5 to 1.75% by weight of the tobacco, from 0.8 to 1.2% by weight of the tobacco or from about 0.8 to about 1.75% by weight of the tobacco. In some embodiments, the nicotine content may be from 0.8 to 1% by weight of the tobacco.

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

In some embodiments, the first and second aerosol-generating materials 3, 14 comprise one or more volatile components. In some embodiments, the first and second aerosolgenerating materials 3, 14 have the same volatile component content. In some embodiments, the first and/or second aerosol-generating materials 3, 14 comprise tobacco. For example, the first and/or second aerosol-generating materials 3, 14 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 second aerosol-generating material 14, for example comprising a blend of lamina and reconstituted tobacco, and 130 mg of a first aerosol-generating material 3, 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 aerosolgenerating 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

1. An article for use in an aerosol provision system, the article comprising: an aerosol-generating material; a receiving member that comprises an end wall, an open end, and a peripheral wall that surrounds a storage area containing the aerosol-generating material; and, a blocking member comprising a body of material arranged to resist the aerosol-generating material from moving out of the storage area through the open end of the receiving member.

2. An article according to claim 1, wherein the receiving member comprises a sheet material.

3. An article according to claim 2, wherein the sheet material comprises paper and/or foil.

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

5. An article according to any one of claims 2 to 4, wherein the sheet material comprises a plurality of end portions that extend radially inwardly to form the end wall and, preferably, each end portion comprises a flap of the sheet material.

6. An article according to claim 5, wherein the end portions are fixed together by adhesive.

7. An article according to any one of the preceding claims, wherein the end wall is gas permeable.

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8. An article according to claim 7, wherein the end wall comprises one or more apertures.

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

10. An article according to any one of the preceding claims, further comprising a wrapper that secures the blocking member relative to the receiving member and, preferably, wherein the wrapper circumscribes the receiving member and the blocking member.

11. An article according to any one of the preceding claims, wherein the blocking member is generally cylindrical.

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

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

14. An article according to any one of the preceding claims, wherein the body of material is disposed adjacent to the open end of the receiving member.

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

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

17. An article according to any one of the preceding claims, wherein the aerosol-generating material in the storage area has a density in the range of about 0.4 g/cm³ to about 2 g/cm³.

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

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

20. An article according to any one of the preceding claims, wherein the blocking member comprises an aerosol-generating material comprising: from about 10 to about 50 wt% aerosolformer material; from about 15 to about 60 wt% gelling agent; and optionally filler; wherein the wt% values are calculated on a dry weight basis and, preferably, wherein the aerosolgenerating material of the blocking member comprises a flavourant.

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21. An article according to any one of the preceding claims, wherein the blocking member comprises tobacco material.

22. An article according to any one of the preceding claims, wherein the blocking member comprises paper.

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

24. An article according to claim 23, wherein the sheet material is crimped.

25. An article according to any one of the preceding claims, wherein the blocking member comprises an end that contacts the aerosol-generating material.

26. An article according to any one of the preceding claims, wherein the aerosol-generating material is a loose material.

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

28. An article according to any one of the preceding claims, further comprising a cooling section and, preferably, wherein the cooling section is arranged such that, in use of the article with an aerosol provision device, the cooling section is downstream of the receiving member.

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

30. An article according to claim 29, wherein the cooling section comprises a flavourant.

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

32. An aerosol provision system comprising the article of any one of the preceding claims and an aerosol provision device.

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

34. A method of manufacturing an article for use in an aerosol provision system, the method comprising: providing a receiving member that comprises an end wall, an open end, and a peripheral wall that surrounds a storage area containing an aerosol-generating material; and, providing a blocking member comprising a body of material arranged to resist the aerosol-generating material from moving out of the storage area through the open end of the receiving member.

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

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

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

38. A method according to claim 37, wherein providing the receiving member comprising arranging the sheet material to form the peripheral wall such that the peripheral wall is generally cylindrical and, preferably, comprising rolling the sheet material to form the peripheral wall.

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

40. A method according to any one of claims 37 to 39, comprising forming a plurality of end portions in the sheet material and, preferably, forming the end portions comprising providing one or more cuts into the sheet material.

41. A method according to claim 40, comprising adhering the end portions together using an adhesive.

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

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

44. A method according to any one of claims 34 to 43, further comprising securing the blocking member relative to the receiving member using a wrapper and, preferably, wherein securing the blocking member relative to the receiving member using the wrapper comprises circumscribing the blocking member and receiving member with the wrapper.

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

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

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

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

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

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

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

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

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

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

55. A method according to claim 54, wherein the sheet material is crimped and, preferably, the method comprises crimping the sheet material.

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

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

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

59. A method according to claim 58, wherein the tobacco material comprises tobacco beads and, preferably, wherein the tobacco material further comprises another tobacco material other than tobacco beads.

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

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

62. A method according to claim 61, wherein the cooling section comprises a flavourant.

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

64. A sheet material for forming a receiving member for an aerosol provision system article, wherein the sheet material comprises one or more regions of strength discontinuity configured to promote folding of the sheet material in a predetermined manner to form an end wall of the receiving member.

65. A sheet material according to claim 64, wherein the one or more regions of strength discontinuity comprise one or more of: embossing; cuts partially through the thickness of the sheet material; cuts through the entire thickness of the sheet material; pin holes; crease-lines; score lines; and/or, regions of reduced thickness of the sheet material .

66. A sheet material according to claim 64 or claim 65, wherein the one or more regions of strength discontinuity are regions of weakening.

67. A sheet material according to any one of claims 64 to 66, wherein the one or more regions of strength discontinuity are lines of strength discontinuity.

68. A sheet material according to claim 67, wherein the sheet material has first and second edges and wherein, wherein at least one line of strength discontinuity extends substantially perpendicular to the first and second edges.

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

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

71. A sheet material according to any one of claims 64 to 70, wherein sheet material comprises one or more flaps that are configured to be folded to form the end wall.

72. A sheet material according to claim 71, wherein the one or more flaps are generally triangular.

73. A sheet material according to claim 71 or claim 72, wherein at least one of the regions of strength discontinuity are arranged to promote folding of the one or more flaps to form the end wall.

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

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

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76. An article for use in an aerosol provision system, the article comprising: the receiving member of claim 75; an aerosol-generating material provided in the storage area of the receiving member; and, a blocking member comprising a body of material arranged to resist the aerosol-generating material from moving out of the storage area through the open end of the receiving member.

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

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

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

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