An aerosol provision system and an article for use in an aerosol provision system

Technical field The present disclosure relates to an aerosol provision system and to an article for an aerosol provision device. The present disclosure also relates to a package of articles.

Background

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

Summary In accordance with some embodiments described therein, there is provided an aerosol provision system comprising: an article comprising an aerosol generating material and a first coupling portion; and, an aerosol provision device comprising a second coupling portion and a zone that is configured to receive the article, wherein the first and second coupling portions are configured such that the first coupling portion is magnetically attracted to the second coupling portion when the article is received in the zone.

In some embodiments, the zone is an aerosol-generating zone and, optionally, may be a heating zone. In accordance with some embodiments described herein, there is provided an aerosol provision system comprising: an article comprising an aerosol generating material and a first coupling portion; and, an aerosol provision device comprising a second coupling portion and a heating zone that is configured to receive the article for heating the aerosol generating material, wherein the first and second coupling portions are configured such that the first coupling portion is magnetically attracted to the second coupling portion when the article is received in the heating zone.

In some embodiments, one of the first and second coupling portions comprises a magnet and the other one of the first and second coupling portions comprises a ferromagnetic material and/ or a second magnet. In some embodiments, the other one of the first and second coupling portions comprises a ferrous material. The ferrous material may, for example, be iron or steel. In some embodiments, the second coupling portion comprises a second magnet. In some embodiments, the first and/or second magnets are permanent magnets.

In one embodiment, the second coupling portion comprises a ferromagnetic material and, optionally, comprises a ferrous material.

In some embodiments, one the second coupling portion is provided at an end of the zone (or heating zone, in embodiments comprising a heating zone).

In some embodiments, one the aerosol provision device comprises a chamber that comprises the zone (or heating zone).

In some embodiments, one the article protrudes from an end of the zone (or heating zone). In some embodiments, one the aerosol provision device comprises a heater that at least partially surrounds the zone (or heating zone) and, preferably, the heater comprises a magnetic field generator that is configured to generate a varying magnetic field to inductively heat the heating material. In some embodiments, the aerosol provision system is an electronic cigarette (also known as a vaping device or electronic nicotine delivery system (END)).

In some embodiments, the aerosol provision device comprises a mouthpiece and, preferably, the mouthpiece is removable from another portion of the aerosol provision device to facilitate access to the zone (or heating zone). Removal of the mouthpiece may therefore allow for the article to be inserted into and removed from the zone (or heating zone).

In some embodiments, one the mouthpiece comprises the second coupling portion. In some embodiments, one the aerosol provision device comprises a body that comprises the second coupling portion.

In some embodiments, one the first and second coupling portions are configured such that, when the article is received in the zone (or heating zone), the article is biased axially towards the second coupling portion.

In some embodiments, the first coupling portion contact the second coupling portion when the article is received in the zone (or heating zone). In other embodiments, the first coupling portion does not contact the second coupling portion when the article is received in the zone (or heating zone).

The first and second coupling portions may together form a magnetic coupling of the aerosol provision system.

According to the present disclosure, there is also provided an article for use with an aerosol provision device, wherein the aerosol provision device comprises a zone that is configured to receive the article, the article comprising: an aerosol generating material; and, a first coupling portion that is configured to be magnetically attracted to a second coupling portion of the aerosol provision device when the article is received in the zone.

In some embodiments, the zone is an aerosol-generating zone and, optionally, may be a heating zone. According to the present disclosure, there is also provided an article for use with an aerosol provision device, wherein the aerosol provision device comprises a heating zone that is configured to receive the article, the article comprising: an aerosol generating material; and, a first coupling portion that is configured to be magnetically attracted to a second coupling portion of the aerosol provision device when the article is received in the heating zone.

In some embodiments, one the first coupling portion comprises a magnet.

In some embodiments, one the first coupling portion comprises a ferromagnetic material. In some embodiments, the first coupling portion comprises a ferrous material.

In some embodiments, one the first coupling portion is provided over only a portion of the axial length of the article.

In some embodiments, one the first coupling portion is provided over substantially the entire axial length of the article.

In some embodiments, the first coupling portion is provided at the first and/or second ends of the article.

In some embodiments, one the first coupling portion is embedded within the article and, preferably, is embedded within the aerosol generating material of the article. In some embodiments, the first coupling portion is integral to the article. In some embodiments, the first coupling portion is permanently embedded in the article.

In some embodiments, one the first coupling portion comprises a heating material that is heatable by penetration with a varying magnetic field.

In some embodiments, one the article and/ or aerosol provision device further comprises a heating material in addition to the first coupling portion, wherein the heating material is heatable by penetration with a varying magnetic field. In some embodiments, the heating material is separate and/or distinct to the first coupling portion.

In some embodiments, one the aerosol generating material at least partially circumscribes the first coupling portion and, preferably, circumscribes the first coupling portion.

In some embodiments, the first coupling portion is provided along at least a portion of the central axis of the article. In some embodiments, the aerosol generating material comprises nicotine. In some embodiments, one the aerosol generating material comprises, consists of, or essentially consists of, tobacco.

In some embodiments, the aerosol generating material does not comprise tobacco. The aerosol generating material may be substantially tobacco free.

In some embodiments, the aerosol generating material is a liquid.

In some embodiments, the article comprises a reservoir that contains the aerosol generating material. The article may comprise a cartridge that comprises the reservoir. In one such embodiment, the article comprises a cartridge that contains nicotine (for example, liquid or powder comprising nicotine) in the reservoir of the cartridge.

In some embodiments, the aerosol generating material is a non-liquid (for example, a solid) or is a liquid. In some embodiments, the aerosol generating material may be a powder.

In some embodiments, one the article has an axial length of at most 36 mm and, preferably, an axial length of at most 34 mm, 32, mm, 30 mm, 28 mm, 26 mm, 24 mm or 23 mm.

In some embodiments, one the first coupling portion comprises one or more apertures to facilitate the flow of gas through the first coupling portion.

In some embodiments, the article comprises a plurality of first coupling portions and/ or the aerosol provision device comprises a plurality of second coupling portions.

In some embodiments, wherein the article comprises a plurality of regions of aerosol generating material. In some embodiments, the article comprises a substrate, wherein the plurality of regions of aerosol generating material are attached to the substrate.

In some embodiments, the substrate is generally planar. In some embodiments, the substrate comprises a metal, for example, aluminium. In some embodiments, the aerosol provision system is configured to start generating aerosol from at least one of the plurality of regions of aerosol generating material after starting generating aerosol from another one of the plurality of regions of aerosol generating material.

In some embodiments, the system is configured to start heating at least one of the plurality of regions of aerosol generating material after starting heating another one of the plurality of regions of aerosol generating material. In some embodiments, the system comprises a plurality of heaters each configured to heat a respective one of the regions of aerosol generating material.

In some embodiments, the package is hermetically sealed. In some embodiments, the aerosol provision system is a non-combustible aerosol provision system

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

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

According to the present disclosure, there is also provided an aerosol provision device comprising: a zone configured to receive an article comprising an aerosol generating material; and, a holder for securing the article in the zone, wherein the holder is configured to engage the article, and wherein the holder is configured to be removably connected to a component of the aerosol provision device. In some embodiments, the zone is an aerosol-generating zone and, optionally, may be a heating zone.

In some embodiments, the holder is configured to be removably connected to a component of the aerosol provision device to secure the article in the zone. - 1-

Optionally, in some embodiments the holder is configured to be removably connected to a component of the aerosol provision device such that, in use, once the holder has been engaged with the article, the holder and article can then be removably connected to the component, and wherein the user is able to disconnect the holder and article together from the component. For example, the article may comprise a rod comprising aerosol generating material (for example, tobacco) and the rod is connected to the component by the holder. In another example, the article may comprise a reservoir of aerosol generating material (for example, a reservoir that includes nicotine and glycerol) and wherein the reservoir is connected to the component by the holder.

The holder may engage the article by, for example, mechanically or magnetically coupling to the article. For example, the holder may mechanically couple to the article (which optionally may comprise, for example, a rod comprising aerosol generating material or a reservoir containing aerosol generating material) by clipping to the article, clamping or gripping the article, having a part (for example, a pin) that is inserted into the article, coupling to the article via a bayonet connection or coupling to the article via communicating threads on the holder and article. Additionally, or alternatively, one or both of the article or holder may comprise magnets to couple the article and holder together. Once the holder has been coupled to the article, the holder and article can then be removably coupled to the component of the device to secure the article within the zone (which may be an aerosol-generating zone such as a heating zone), and the user may decouple to holder and article together from the component (whilst the article is still coupled to the holder) to remove the article from the zone. In some embodiments, the article is a consumable.

According to the present disclosure, there is also provided, an aerosol provision device comprising: a heating zone configured to receive an article comprising an aerosol generating material; and, a holder for securing the article in the heating zone, wherein the holder is configured to engage the article, and wherein the holder is configured to be removably connected to a component of the aerosol provision device such that, in use, once the holder has been engaged with the article, the holder and article can then be removably connected to the component, and wherein the user is able to disconnect the holder and article together from the component. In some embodiments, in use, once the holder has been engaged with the article, the holder and article can then be removably connected to the component such that the article is held in position relative to the zone (or heating zone). In some embodiments, the user is able to remove the holder from the component to remove the article from the zone (or heating zone).

In some embodiments, in use, once the holder has been engaged with the article, the holder and article can then be removably connected to the component such that the article is held in position relative to the zone (or heating zone), and wherein the user is able to disconnect the holder and article together from the component.

In some embodiments, the aerosol provision device comprises a body that comprises the component of the aerosol provision device.

In some embodiments, the aerosol provision device comprises a mouthpiece.

In some embodiments, the mouthpiece comprises the component of the aerosol provision device.

In some embodiments, the mouthpiece is removable from a body of the aerosol provision device and, preferably, the mouthpiece is removable from the body to provide access to the holder. In some embodiments, the zone (or heating zone) is located at, or in proximity to, a mouth end of the aerosol provision device.

In some embodiments, the holder is configured to be magnetically removably connected to the component of the aerosol provision device.

In some embodiments, one of the holder and component comprises a first magnet and the other one of the holder and component comprises a ferromagnetic material and/or second magnet that is configured to be attracted to the first magnet to magnetically removably connect the holder to the component. In some embodiments, the other one of the holder and component comprises a ferrous material.

In some embodiments, the holder comprises an engaging member that is configured to be inserted into the article.

In some embodiments, the engaging member comprises a pin and, preferably, the pin is a solid pin. In some embodiments, the holder comprises a base portion and wherein the engaging member extends from the base portion.

In some embodiments, the engaging member is configured to extend along at least a portion of the length of the article. In some embodiments, the member is configured to extend along the entire, or substantially the entire, length of the article.

In some embodiments, the engaging member extends substantially linearly.

In some embodiments, the engaging member is configured to be inserted into the centre of the article. In some embodiments, the engaging member is configured to be inserted into the article to extend along the central axis of the article.

In some embodiments, the holder comprises a plurality of engaging members configured to be inserted into the article.

In some embodiments, the holder comprises a heating material that is heatable by penetration with a varying magnetic field.

In one embodiment, the engaging member comprises the heating material.

According to the present disclosure, there is also provided an aerosol provision system comprising an aerosol provision device as disclosed herein; and, an article comprising an aerosol generating material. In some embodiment, the aerosol generating material comprises nicotine. In some embodiments, the aerosol generating material comprises, consists of, or essentially consists of, tobacco.

In some embodiments, the aerosol generating material does not comprise tobacco. The aerosol generating material may be substantially tobacco free.

In some embodiments, the article comprises a reservoir that contains the aerosol generating material. The article may comprise a cartridge that comprises the reservoir. In one such embodiment, the article comprises a cartridge that contains nicotine (for example, liquid or powder comprising nicotine) in the reservoir of the cartridge.

In some embodiments, the aerosol generating material is a non-liquid (for example, a solid) or is a liquid. In some embodiments, the aerosol generating material may be a powder.

In some embodiments, the article has an axial length of at most 36 mm and, preferably, an axial length of at most 34 mm, 32, mm, 30 mm, 28 mm, 26 mm, 24 mm or 23 mm.

According to the present disclosure, there is also provided a package comprising a plurality of articles as described herein. In some embodiments, the package is hermetically sealed.

In some embodiments, the aerosol provision system is a non-combustible aerosol provision system

In some embodiments, the article does not comprise plastic.

In some embodiments, the article does not comprise cellulose acetate. In some embodiments, the article comprises an aerosol-former material.

In some embodiments, the article comprises first and second aerosol generating materials. In some embodiments, the density of the second aerosol-generating material is at least about 25% higher than the density of the first aerosol generating material. In some embodiments, the first aerosol generating material has a density of from about o.i g/cm3 to about i g/cm3. In some embodiments, the second aerosol generating material has a density of from about 0.4 g/cm3 to about 2 g/cm3.

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

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

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

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

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

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

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. In some embodiments, the aerosol provision system is an electronic cigarette (also known as a vaping device or electronic nicotine delivery system (END)).

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 cross-sectional side view of an embodiment of an article for use with an aerosol provision device;

Fig. 2 is a perspective view of a first coupling portion of the article of Fig. 1;

Fig. 3 is perspective view of the article of Fig. 1; Fig. 4 is a cross sectional view of an embodiment of a non-combustible aerosol provision device;

Fig. 5 a simplified schematic of the components within the housing of the aerosol provision device shown in Fig. 4;

Fig. 6 is a cross sectional view of a non-combustible aerosol provision system comprising the device shown in Fig. 4 with the article shown in Fig. 1 inserted into the device;

Fig. 7 is a cross-sectional side view of the device of Fig. 4, along the dashed line Z-Z shown in Fig. 4;

Fig. 8 is a cross-sectional side view of another embodiment of a non-combustible aerosol provision device, from the same perspective as the view of Fig. 4;

Fig. 9 is a cross-sectional side view of another embodiment of a non-combustible aerosol provision device, from the same perspective as the view of Fig. 4;

Fig. 10 is a cross sectional view of another embodiment of a non-combustible aerosol provision system; Fig. 11 is cross-sectional side view of another embodiment of an article for use with an aerosol provision device; Fig. 12 is cross-sectional side view of another embodiment of an article for use with an aerosol provision device;

Fig. 13 is cross-sectional side view of another embodiment of an article for use with an aerosol provision device; Fig. 14 is a perspective view of the article of Fig. 13;

Fig. 15 is cross-sectional side view of another embodiment of an article for use with an aerosol provision device;

Fig. 16 is a cross-sectional side view of another embodiment of an aerosol provision system; Fig. 17 is a perspective view of a holder of the aerosol provision system of Fig. 16;

Fig. 18 is a cross-sectional side view of the holder of Fig. 16 inserted into an article;

Fig. 19 is a top view of an article of another embodiments of an aerosol provision system;

Fig. 20 is a side view of the article of Fig. 19; and, Fig. 21 is a cross-sectional side view of an embodiment of an aerosol provision system comprising the article of Fig. 19.

Detailed description

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

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

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

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

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

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

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

The terms ‘upstream’ and ‘downstream’ used herein are relative terms defined in relation to the direction of mainstream aerosol drawn through an article or device in use. Reference to the ‘distal end’ refers to an upstream end of the device, whereas ‘proximal end’ refers to the downstream end of the device. In some embodiments, the non-combustible aerosol provision system, such as a noncombustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source. In some embodiments, the non-combustible aerosol provision system comprises an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/ or an aerosol-modifying agent.

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

The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or

B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical. In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12. As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint maybe chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia,

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

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

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

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel. In some embodiments, the substance to be delivered comprises a flavour. As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, maybe used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang- ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They maybe imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas. In some embodiments, the flavour comprises menthol, spearmint and/ or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis. In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

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

An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. An aerosol-generating material may be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants. The aerosol-generating material is incorporated into an article for use in the aerosol-generating system. As used herein, the term “tobacco material” refers to any material comprising tobacco or derivatives or substitutes thereof. The tobacco material may be in any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and/or tobacco extract.

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

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

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

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

The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants. A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/ or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor. A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor maybe both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

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

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

In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator maybe configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

The filamentary tow material described herein can comprise cellulose acetate fibre tow.

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

In the figures described herein, like reference numerals are used to illustrate equivalent features, articles or components. Fig. 1 is a cross-sectional side view of an article 1 for use in an aerosol delivery system 100 that includes an aerosol delivery device 200 (see Figs. 4 to 9).

The aerosol delivery system 100 comprises the article 1 and the aerosol delivery device 200.

The aerosol delivery system 100 comprises a magnetic coupling 2 configured to retain the article 1 in position relative to the aerosol delivery device 200. The magnetic coupling 2 comprises first and second coupling portions 5, 6, as explained in more detail below.

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. In some embodiments (not shown), the proximal end P of the article 1 forms the mouthpiece.

It should be recognised that in some embodiments, the article 1 can be used with the aerosol delivery device 200 in either orientation, such that it does not matter which end P, D of the article 1 is upstream and which is downstream.

The article 1 comprises a body of material 3 that comprises an aerosol generating material 4. In other embodiments, the article 1 comprises an aerosol generating material 4 that is not part of a body of material 3. That is, the body of material 3 may be omitted.

The article 1 further comprises the first coupling portion 5 of the magnetic coupling 2. In the present example, the body of material 3 of the article 1 is circumscribed by a wrapper 7. The wrapper 7 comprises a sheet material, which in the present example is paper.

Referring now to Figs. 4 to 7, an embodiment of an aerosol provision device 200 is shown.

The aerosol provision device 200 comprises a zone 202 that is configured to receive the article 1. The zone 202 may be an aerosol generating zone 202 configured such, when the article 1 is received in the zone 202, aerosol is generated when the aerosol provision device 200 is operated. In the present example, the aerosol provision device 200 comprises a heating zone 202 that is configured to receive the article 1 such that the aerosol generating material 4 of the article 1 is heated when the aerosol provision device 200 is operated. However, in each of the embodiments described herein, the zone 202 does not have to be a heating zone that heats the aerosol generating material to generate the aerosol. In some embodiments, the aerosol provision device 200 is an electronic cigarette. In the present example, the first connector potion 5 of the article 1 comprises a heating material that is heated by the aerosol provision device 200 in order to heat the aerosol generating material 4 of the article 1. The aerosol generating material 4 may be resistively and/or inductively heated. For example , the first coupling portion 5 may be resistively and/ or inductively heated to heat the aerosol generating material 4.

Induction heating is a process in which an electrically-conductive object is heated by penetrating the object with a varying magnetic field. The process is described by Faraday’s law of induction and Ohm’s law. An induction heater may comprise an electromagnet and a device for passing a varying electrical current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are suitably relatively positioned so that the resultant varying magnetic field produced by the electromagnet penetrates the object, one or more eddy currents are generated inside the object. The object has a resistance to the flow of electrical currents. Therefore, when such eddy currents are generated in the object, their flow against the electrical resistance of the object causes the object to be heated. This process is called Joule, ohmic, or resistive heating. An object that is capable of being inductively heated is known as a susceptor. It has been found that, when the susceptor is in the form of a closed circuit, magnetic coupling between the susceptor and the electromagnet in use is enhanced, which results in greater or improved Joule heating.

Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by penetrating the object with a varying magnetic field. A magnetic material can be considered to comprise many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such material, the magnetic dipoles align with the magnetic field. Therefore, when a varying magnetic field, such as an alternating magnetic field, for example as produced by an electromagnet, penetrates the magnetic material, the orientation of the magnetic dipoles changes with the varying applied magnetic field.

Such magnetic dipole reorientation causes heat to be generated in the magnetic material.

When an object is both electrically-conductive and magnetic, penetrating the object with a varying magnetic field can cause both Joule heating and magnetic hysteresis heating in the object. Moreover, the use of magnetic material can strengthen the magnetic field, which can intensify the Joule heating.

In each of the above processes, as heat is generated inside the object itself, rather than by an external heat source by heat conduction, a rapid temperature rise in the object and more uniform heat distribution can be achieved, particularly through selection of suitable object material and geometry, and suitable varying magnetic field magnitude and orientation relative to the object. Moreover, as induction heating and magnetic hysteresis heating do not require a physical connection to be provided between the source of the varying magnetic field and the object, design freedom and control over the heating profile may be greater, and cost may be lower.

In the present example, the aerosol provision device 200 comprises an electromagnetic field generator 203 that is configured to generate an electromagnetic field in order to inductively heat the heating material of the first coupling portion 5. However, it should be recognised that in other embodiments the article 1 comprises a heating material that is a further component in addition to the first coupling portion 5. In some such embodiments, the heating material is distinct and/or separate to the first coupling portion 5. As shown in Fig. 5, 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.

In the present example, the magnetic field generator 203 comprises a coil (not shown). The electrical energy supply 204 may be configured to pass a varying electrical current, such as an alternating current, through the coil in order to inductively heat the heating material.

The coil may take any suitable form. In this embodiment, the coil is a helical coil of electrically-conductive material, such as copper. In some embodiments, the magnetic field generator 203 may comprise a magnetically permeable core around which the coil is wound. Such a magnetically permeable core concentrates the magnetic flux produced by the coil in use and makes a more powerful magnetic field. The magnetically permeable core may be made of iron, for example. In some embodiments, the magnetically permeable core may extend only partially along the length of the coil, so as to concentrate the magnetic flux only in certain regions. In some embodiments, the coil may be a flat coil. That is, the coil may be a two-dimensional spiral.

In the present example, first coupling portion 5 is embedded in the article 1 and comprises the heating material. In another embodiment, the aerosol provision device comprises a heating element (not shown) that at least partially surrounds the heating zone 202, for example, a heating chamber 202. The heating element 203 maybe resistively and/or inductively heated. In some embodiments, the article 1 does not comprise any heating material and instead is externally heated by the heating element. In other embodiments (not shown), the heating element instead comprises a blade or pin, for insertion into the article 1, for example, the blade or pin may be inserted through the body of material 3. In Fig. 4, the components of an embodiment of an aerosol provision device 200 are shown in a simplified manner. Particularly, the elements of the aerosol provision device 200 are not drawn to scale in Fig. 4. Elements that are not relevant for the understanding of this embodiment have been omitted to simplify Fig. 4. In the example of Fig. 4, 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 a heating zone 202 for receiving an article 1.

When the article 1 is received into the heating zone 202, the heating material of the first coupling portion sis heated by the heater 203, which in the present example, is a magnetic field generator 203.

In other embodiments (not shown), the heater comprises a heating element surrounding at least a portion of the heating zone, and wherein at least a portion of the article 1 comes into thermal proximity with the heating element. Thus, at least a portion of the aerosol generating material 4 is in thermal proximity with the heating element. In some embodiments, the heating element 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 heating element is in direct contact with the article 1, for example, contacting an outer surface of the wrapper 7 of the article 1. In another embodiment, the heating element comprises a blade or pin that contacts the inside of the article 1, for example, contacting the body of material 3. The heating element of the aerosol provision device 200 may be resistively and/ or inductively heated. That is, the heater may comprise a resistive heating element or may comprise a magnetic field generator that inductively heats the heating element.

The article 1 may be internally and/or externally heated.

When the article 1 is heated, the aerosol generating material 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.

Fig. 6 is a schematic cross-section of a non-combustible aerosol-provision device 200 of the type shown in Fig. 4, with the article 1 received in the heating area 202 of the device 200 for heating by the magnetic field generator 203. The non-combustible aerosol provision device 200 is illustrated receiving the aerosol-generating article 1 for consumption of the aerosol-generating article 1 by a user. The housing 201 of non-combustible aerosol provision device 200 defines a heating zone 202 in the form of a chamber, open at the proximal end (or mouth end), for receiving an aerosol-generating article 1 for consumption by a user.

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

As a user draws on the mouthpiece 207, air is drawn into the article 1 and the volatile substances condense to form an inhalable aerosol. This aerosol passes through the mouthpiece 207 of the device 200 and into the user's mouth.

It should be recognised that in other embodiments the mouthpiece 207 of the device 200 maybe omitted. In some embodiments, the article 1 may form a mouthpiece and may come into contact with a user’s mouth. In the above described embodiments, the body of material 3 extends between the ends P, D of the article 1. However, it should be recognised that in alternative embodiments (not shown), the article 1 may comprise one or more further segments, for example, a further segment upstream or downstream of the body of material 3. The aerosol provision device 200 comprises the second coupling portion 6 of the magnetic coupling 2. The first coupling portion 5 of the article 1 and the second coupling portion 6 of the aerosol provision device 200 are configured such that the first coupling portion 5 is magnetically attracted to the second coupling portion 6 when the article 1 is received in the heating zone 202. This helps to retain the article 1 in position within the heating zone 202. Therefore, the article 1 can be held in an optimal heating position within the heating zone 202 (for example, within the centre of the heating one 202) to promote a consistent and uniform heating of the article 1. The magnetic coupling 2 may also facilitate easier handling of the article 1, helping to prevent the article 1 from falling out of the heating zone 202, which is particularly advantageous when the article 1 is of a small size. Moreover, the coupling 2 may help to prevent the article 1 from coming loose during transport of the aerosol provision system 100.

The magnetic coupling 2 is advantageously easy to use because the user is able to insert the article 1 into the heating zone 202, wherein the first and second coupling portions 5, 6 are attracted together to retain the article 1 in position. To remove the article 1 from the heating zone 202, the user may, for example, pull on an end of the article 1.

Optionally, the housing 201 may comprise one or more cut-outs or slots (not shown) in the region of the heating zone 202 to facilitate the article 1 being gripped by the user and removed from the heating zone 202.

In some embodiments, one of the first and second coupling portions 5, 6 comprises a magnet and the other one of the first and second coupling portions 5, 6 comprises a ferromagnetic material and/or a second magnet. In some embodiments, the other one of the first and second coupling portions 5, 6 comprises a ferrous material.

For example, in one embodiment the first coupling portion 5 of the article 1 comprises a first magnet. The second coupling portion 6 of the aerosol provision device 200 comprises a ferromagnetic material arranged such that the first magnet is attracted to the ferromagnetic material. In another embodiment, the first coupling portion 5 of the article 1 comprises a ferromagnetic material and the second coupling portion 6 of the aerosol provision device 200 comprises a first magnet. One of the first and second coupling portions 5, 6 may comprise iron or steel.

In another embodiment, the first coupling portion 5 comprises a first magnet and the second coupling portion 6 comprises a second magnet (e.g. permanent magnets), wherein the poles of the first and second magnets are arranged such that the first and second magnets are attracted when the article 1 is received in the heating zone 202.

Embodiments wherein the first and second coupling portions 5, 6 comprise respective magnets may facilitate a stronger attraction between the first and second coupling portions 5, 6.

In some embodiments, the first coupling portion 5 of the article 1 comprises a ferrous material. Therefore, the article 1 may be less expensive to manufacture than other embodiments wherein the first coupling portion 5 comprises a magnet, which is particularly advantageous if the article 1 is disposable after use. The article 1 can also be inserted into the heating zone 202 in either orientation and will still be attracted to the magnet of the second coupling portion 6.

In some embodiments, the first coupling portion 5 acts as a heating material that is heatable by penetration with a varying magnetic field. Thus, the magnetic field generator 203 of the aerosol provision device 200 can be operated to heat the heating material of the first coupling portion 5. This has the advantage of reducing the size of the article 1 and/or increasing the amount of aerosol generating material 4 of the article 1 in comparison to embodiments that comprise a first coupling portion 5 and also a separate heating element. In one embodiment, the first coupling portion 5 comprises a ferrous material, for example, iron or steel.

In the present example, the second coupling portion 6 is disposed at an end of the heating zone 202. The heating zone 202 comprises an opening 202A into which the article 1 may be inserted into, and removed, from the heating zone 1. The second coupling portion 6 may be at the opposite end of the heating zone 202 to the opening 202A. It should be recognised that in other embodiments (not shown), the second coupling portion 6 may be provided radially outwardly of the heating zone 202, for example, at least partially circumscribing the heating zone 202. In the present example, the mouthpiece 207 is removably attached to the housing 201 of the device 200, for example, by a screw thread or bayonet connection. The mouthpiece 207 may be removed to provide access to the heating zone 202 such that the article 1 can be inserted into, and removed from, the heating zone 202. In one embodiment (not shown) the mouthpiece 207 comprises the second coupling portion 6 such that the first coupling portion 5 of the article 1 is attracted towards the second coupling portion 6 of the mouthpiece 207. An advantage of the mouthpiece 207 comprising the second coupling portion 6 is that removal of the mouthpiece 207 can cause removal of the article 1 from the heating zone 202. In one embodiment in which the mouthpiece 207 comprises the second coupling portion 6, the article 1 may be magnetically coupled to the mouthpiece 207 via the magnetic coupling 202, and then the mouthpiece 207 may be attached to the remainder of the aerosol provision device 200 to secure the mouthpiece 207 and article 1 in position such that the article 1 is held within the heating zone 202. In another embodiment, the article 1 is inserted into the heating zone 202 and then the mouthpiece 207 is attached to remainder of the aerosol provision device 200 to retain the article 1 in positon within the heating zone 202.

In the present example, the aerosol provision device 200 comprises a body 208 that comprises the second coupling portion 6.

The second coupling portion 6 may be fixed relative to the body 6.

In the present example, the first and second coupling portions 5, 6 are configured such that, when the article 1 is received in the heating zone 202, the article 1 is biased axially towards the second coupling portion 6 (in the direction of arrow ‘A’ shown in Fig. 6). That is, the magnetic attraction between the first and second coupling portions 5, 6 causes the article 1 to be biased in a direction of its central axis towards the second coupling portion 6.

In the present example, the first coupling portion 5 contacts the second coupling portion 6 when the article 1 is received in the heating zone. This results in a relatively strong retaining force between the first and second coupling portions 5, 6 to hold the article 1 in positon within the heating zone 202. However, it should be recognised that in other embodiments, the first coupling portion 5 does not contact the second coupling portion 6 when the article 1 is received in the heating zone 202. For example, the second coupling portion 6 maybe spaced from the axial ends P, D of the article 1. In one such embodiment, the end of the article 1 may comprise a portion of aerosol generating material 4 that is disposed between the first and second coupling portions 5, 6 when the article 1 is received in the heating zone 202. The first coupling portion 5 may extend to the first and/ or second ends P, D of the article 1. In one embodiment, the first coupling portion 5 is provided at one of the first and second ends P, D of the article 1 and the other one of the first and second ends P, D may not comprise a coupling portion. The first coupling portion may be provided over only a portion of the axial length (shown by arrow ‘X’ in Fig. 1) of the article 1.

In one embodiment, the first coupling portion 5 extends between the first and second ends P, D of the article 1. The first coupling portion 5 may be extend over substantially the entire axial X length of the article 1. This is particularly advantageous if the first coupling portion 5 comprises heating material that is heated during operation of the device 200, because then a more uniform heating of the aerosol generating material 4 can be achieved.

In the present example, the first coupling portion 5 extends along the central axis of the article 1.

In some embodiments, the first coupling portion 5 is embedded within the article 1 and, preferably, is embedded within the body of material 3 of the article 1 and/or embedded within the aerosol generating material 4 of the article 1. Embedding the first coupling portion 5 within the aerosol generating material 4 of the article 1 is particularly advantageous when the first coupling portion 5 comprises a heating material that is heated by penetration with a magnetic field during operation of the device 200. In some embodiments, the first coupling portion 5 is integral to the article 1. In some embodiments, the first coupling portion 5 is permanently embedded in the article 1.

In some embodiments, the aerosol generating material 4 at least partially circumscribes the first coupling portion 5 and, preferably, entirely circumscribes the first coupling portion 5. In some embodiments, the first coupling portion 5 comprises a susceptor that is configured to be inductively heated by the aerosol provision device 200. In other embodiments, the article 1 comprises the first coupling portion 5 and further comprises a susceptor that is configured to be inductively heated by the aerosol provision device 200. In some embodiments, the aerosol generating material 4 comprises, consists of, or essentially consists of, tobacco material. The tobacco material may comprise, for example, one or more of lamina tobacco, stem tobacco, reconstituted tobacco, tobacco beads or extruded or compressed tobacco.

The body of material 3 and/ or aerosol generating material 4 may have, for example, any of the features and/or configurations described herein.

The article 1 may have an axial length (shown by arrow ‘X’ in Fig. 1) 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.

Referring now to Fig. 7, a cross-sectional side view of a portion of the aerosol provision device 200 is shown (taken along the dashed line Z-Z in Fig. 4). The second coupling portion 6 is in the form of a magnet 6, which in the present example, is generally circular. The skilled person will recognise that in alternative embodiments the second coupling portion 6 may have an alternative shape, for example, square, triangular or oval. A plurality of flow holes 210 are disposed about the magnet 6 to facilitate the flow of gas through the aerosol provision device 200. In other embodiments, the flow holes 210 may be omitted. In some embodiments, the air may flow into the end of the mouthpiece 207 and around the outside of the article 1, and then enter a first end of the article 1 and flow through the article 1 to a mouth end of the article 1 for inhalation by a user. Referring now to Fig. 8, an alternative embodiment of an aerosol provision device 200 is shown, which has the same features as the embodiment described above in relation to Figs. 1 to 7, except that the second coupling portion 6 is annular and one or more flow holes 210 are provided in the centre of the second coupling portion 6. Optionally, the second coupling portion 6 is a magnet. Again, the flow holes 210 may be omitted. Referring now to Fig. 9, another embodiment of aerosol provision device 200 is shown, which has the same features as the embodiment of Fig. 8, except that the aerosol provision device 200 comprises a plurality of second coupling portions 6. One or more of the second coupling portions 6 may comprise a magnet.

It should be recognised that in alternatives to the embodiments described above, the flow hole(s) 210 maybe omitted. In one such alternative embodiment, one or more gaps or ventilation holes maybe provided in the chamber housing 201 that surrounds the heating zone 202 in order to permit air to be drawn into the heating zone 202.

Referring now to Fig. 10, another embodiment of an aerosol provision system 100 is shown. The aerosol provision system 100 is similar to the aerosol provision system 100 described above in relation to Figs. 1 to 7, with like features retaining the same reference numerals. A difference is that the mouthpiece 207 is omitted. In the present example, the article 1 protrudes from an opening 202A of the heating zone 202. The proximal end P of the article 1 may itself form a mouthpiece that comes into contact with the mouth of the user. In another embodiment (not shown), the separate mouthpiece 207 is omitted but the article 1 does not extend from an end of the heating zone 202. In yet another embodiment (not shown), the article 1 protrudes from the heating zone 202 and the aerosol provision device 200 comprises a mouthpiece 207.

Referring now to Fig. 11, an alternative embodiment of an article 1 for use with an aerosol provision device 200 (for example, the device of any of Figs. 4 to 10) is shown. The article 1 is similar to the article 1 of the embodiment described above in relation to Figs. 1 to 7, with like features retaining the same reference numerals. A difference is that the article 1 comprises a first coupling portion 5 and further comprises a heating material 8 that is heatable by penetration with a varying magnetic field. In the present example, the heating material 8 is in the form of an element 8 that extends along the central axis of the article 1. The first coupling portion 5 is provided as an annular element 5, which may comprise a magnet and/ or ferromagnetic material and/ or ferrous material. Optionally, the first coupling portion 5 circumscribes the body of material 3 and the heating material 8 is provided in the centre of the body of material 3. In one such embodiment, the second coupling portion 6 is generally annular to correspond to the annular shape of the first coupling portion 5. In an alternative embodiment (not shown), the first coupling portion 5 extends along the central axis of the article 1 and the heating material 8 is provided as an annular element that circumscribes the body of material 3. Referring now to Fig. 12, an alternative embodiment of an article 1 for use with an aerosol provision device 200 (for example, the device of any of Figs. 4 to 10) is shown. The article 1 is similar to the article 1 of the embodiment described above in relation to Figs. 1 to 7, with like features retaining the same reference numerals. A difference is that the article 1 comprises a plurality of first coupling portions 5, wherein a first coupling portion 5 is provided at each end P, D of the article 1. Each first coupling portion 5 may comprise a magnet and/or ferromagnetic material and/or ferrous material. In the present example, each first coupling member 5 is annular. However, in other embodiments, one or both of the first coupling members 5 may not be annular and, for example, may be located on the central axis of the article 1.

An advantage of providing a plurality of first connector potions 5 is that each first coupling portion 5 can be a magnet (e.g. a permanent magnet) and the second coupling portion 6 can be a magnet (e.g. a permanent magnet) whilst allowing for either end of the article 1 to be inserted into the heating zone 202. For example, the first coupling portions 5 can be orientated in the article 1 such that either both ‘North’ of both ‘South’ pole ends of the respective magnets 5 face outwardly at the respective ends P, D of the article. Meanwhile, the magnet 6 of the second coupling portion 6 is orientated to attract said outwardly orientated poles of the magnets 5 of the first coupling portions 5. That is, if the ‘North’ pole end of the magnet 5 of each first coupling portion 5 faces outwardly from the respective ends P, D of the article 1 (and thus the ‘South’ pole ends of the first coupling portions 5 face towards each other), then the ‘South’ pole end of the magnet 6 of the second coupling portion 6 faces towards the article 1 when the article 1 is received in the heating zone 202 in order to attract the ‘North’ pole end of the nearest magnet 5. Therefore, the article 1 will be attracted towards the second coupling portion 6 of the aerosol provision device 200 regardless of which end P, D of the article 1 is inserted first into the heating zone 202.

It should be recognised that in other embodiments, the coupling 2 is configured such that the article 1 is only attracted to the second coupling portion 6 when inserted into the heating zone 202 in the correct orientation, and is repelled from the second coupling portion 6 when inserted into the heating zone 202 in the other, incorrect, orientation. This can be achieved, for example, if second coupling portion 6 comprises a magnet and the article i comprises single magnet that has opposite pole ends at opposite ends P, D of the article i. This can also be achieved, for example, if the second coupling portion 6 comprises a magnet and the article i comprises a magnet at each end of the article i wherein one of the magnets has its ‘North’ pole end at one end P, D of the article i and the other one of the magnets has its ‘South’ pole end at the other end P, D of the article i. Thus, the article i will only be attracted to the second coupling portion 6 when the article 1 is orientated such that the end P, D with the opposing pole to the nearest pole of the second coupling portion 6 is inserted first into the heating zone 202.

Referring now to Figs. 13 and 14, another embodiment of an article 1 for use with an aerosol provision device 200 (for example, the device of any of Figs. 4 to 10) is shown. The article 1 is similar to the article 1 of the embodiment described above in relation to Figs. 1 to 7, with like features retaining the same reference numerals. A difference is that the first coupling portion 5 comprises a plate 9 with a plurality of apertures 10 that facilitate gas flow through the first coupling portion 5 to enter and/or exit the article 1.

The first coupling portion 5 may comprise a magnet and/ or ferromagnetic material and/or ferrous material. In the present example, the first coupling portion 5 is only provided at one of the ends P, D of the article. However, in other embodiments, a first coupling portion 5, is provided at each of the ends P, D of the article 1.

In the present example, the article 1 is heated externally by, for example, a heating element that circumscribes the article 1 received in the heating zone 200 and which is resistively and/ or inductively heated to heat the aerosol generating material 4 of the article 1. In another embodiment (not shown), the article 1 is not externally heated and instead may comprise a strip of heating material that extends the axial length of the body of material 3 and which is heated by penetration by a varying magnetic field. Referring now to Fig. 15, an alternative embodiment of an article 1 for use with an aerosol provision device 200 (for example, the device of any of Figs. 4 to 10) is shown. The article 1 is similar to the article 1 of the embodiment described above in relation to Figs. 1 to 7, with like features retaining the same reference numerals. A difference is that the first coupling portion 5 is provided on the central axis of the article 1 at the distal end D of the article 1. However, the first coupling portion 5 may have the configuration of any of the articles 1 described herein. The article i of Fig. 15 further comprises a cooling section 25, also referred to as a cooling element, positioned immediately downstream of the body of material 3. In the present example, the cooling element 25 is immediately downstream of and adjacent to the body of material 3. In some such embodiments, the cooling element 25 is in an abutting relationship with the body of material 3. The article 1 may additionally or alternatively include a further body of material 26 downstream of the cooling element 25. The further body of material 26 may comprise flavouring and/or filtering material and/ or may be provided to obscure the view of the cooling element 25.

The cooling element 25 comprises a hollow channel, having an internal diameter of between about 1 mm and about 4 mm, for example between about 2 mm and about 4 mm. The hollow channel may have an internal diameter of about 3 mm. The hollow channel extends along the full length of the cooling element 25. The cooling element 25 may comprise a single hollow channel. In alternative embodiments, the cooling element 25 can comprise multiple channels, for example, 2, 3 or 4 channels. The single hollow channel may be substantially cylindrical, although in alternative embodiments, other channel geometries/cross-sections maybe 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 first and/ or second aerosol generating material 4, 5 can pass longitudinally through the one or more hollow channels.

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

The body of material 26 defines a substantially cylindrical overall outer shape and is wrapped in a plug wrap 28. The plug wrap 28 can have a basis weight of less than 50 gsm, or between about 20 gsm and 40 gsm. The plug wrap 28 can have a thickness of between 30 pm and 60 pm, or between 35 pm and 45 pm. The plug wrap 28 may be a non-porous plug wrap, for instance having a permeability of less than too 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 greater than too Coresta Units and, preferably, greater than 200 Coresta Units. The cooling element 25 and/ or body of material 26 may form a mouthpiece of the article 1 that is configured to be received within the mouth of the user. In some embodiments, the mouthpiece 207 of the device 200 may be omitted.

In some embodiments, a tipping paper (not shown) is wrapped around the cooling element 25 and body of material 26 and also circumscribes the wrapper 7 that circumscribes the body of material 3, and may be connected to these components by adhesive. Thus, the tipping paper connects the cooling element 25 and body of material 26 to the body of material 3. In other embodiments, the tipping paper is omitted and instead the wrapper 7 extends to circumscribe the cooling element 25 and body of material 26 to connect these components to the body of material 3.

Referring now to Figs. 16 to 18, another embodiment of an aerosol provision system 100 is shown. The aerosol provision system 100 is similar to the aerosol provision system 100 described above in relation to Figs. 1 to 7, with like features retaining the same reference numerals. A difference is that the aerosol provision device 200 of the system 100 comprises a holder 300.

The holder 300 is configured for securing the article 1 in the heating zone 202 of the aerosol provision device 200. The holder 300 is configured to engage the article 1. The holder 300 is configured to be removably connected to a component of the aerosol provision device 200 such that, in use, once the holder 300 has been engaged with the article 1, the holder 300 and article 1 can then be removably connected to the component such that the article 1 is held in position relative to the heating zone 202. The user is able to disconnect the holder 300 and article too together from the component. The holder 300 can therefore make it easier to handle the article 1 and retain the article 1 in position within the heating zone 202. In embodiments comprising a holder 300, the article 1 itself may not comprise any coupling portion. An advantage of the holder 300 is that the holder 300 can be reused. In some embodiments, the aerosol provision device 200 comprises a housing or body 201 (hereinafter referred to as a body 201). In the present example, the holder 300 is relesably connected to the body 201.

In some embodiments, the aerosol provision device 200 comprises a mouthpiece 207. In some embodiments, the holder 300 is relesably connected to the mouthpiece 207.

In some embodiments the mouthpiece 207 is removable from a body 201 of the aerosol provision device 200 and, preferably, the mouthpiece 207 is removable from the body 201 to provide access to the holder 300. In some embodiments, the heating zone 202 is located at, or in proximity to, a mouth end of the aerosol provision device 200.

In the present example, the holder 300 comprises an engaging member 301 that is configured to be inserted into the article 1 such that the engaging member 301 engages the article 1 and thus the holder 300 is removable connected to the article 1. The holder 300 maybe disconnected from the article 1 by pulling the engaging member 301 out of the article 1. In some embodiments, the engaging member 301 maybe inserted into the body of material 3 of the article 1.

In some embodiments, the engaging member 301 comprises a pin 301 and, preferably, the pin is a solid pin. The engaging member 301 may comprise a pointed tip (not shown) that facilitates insertion of the engaging member 301 into the article 1. In some embodiments, the holder 300 comprises a base portion 302 and wherein the engaging member 301 extends from the base portion 302.

The base portion 302 maybe shaped to allow for inhalant to pass around or through the base portion 302. For example, the base portion 302 may comprise one or more cut-outs to allow for inhalant to pass around or through the base portion 302. In the present example, the base portion 302 comprises one or more apertures 303 that allow for the inhalant to pass through the base portion 302.

In some embodiments, the engaging member 301 is configured to extend along at least a portion of the length of the article 1. In some embodiments, the engaging member 301 is configured to extend along the entire, or substantially the entire, length of the article 1.

In some embodiments, the engaging member 301 extends substantially linearly.

In the present example, the engaging member 301 is configured to be inserted into the centre of the article 1. The engaging member 301 may be configured to be inserted into the article 1 to extend along the central axis 1 of the article. In some embodiments (not shown), the holder 300 comprises a plurality of engaging members 301 configured to be inserted into the article 1. In some embodiments, the holder 300 is configured to be magnetically removably connected to said component (for example, the body 201 or mouthpiece 207) of the aerosol provision device 200. In other embodiments, the holder 300 maybe connected to said component by a mechanical fastening, for example, a screw thread, bayonet connection or clip.

In some embodiments, the system 100 comprises a coupling 304 comprises first and second coupling portions 305, 306. The holder 300 comprises the first coupling portion 305. The device 200 comprises the second coupling portion 306. In some embodiments, the coupling 304 is a magnetic coupling, wherein the first and second coupling portions 305, 306 are magnetically attracted. In the present example, the base 302 comprises the first coupling portion 305. The entire base 302 may form the first coupling portion 305 (for example, being manufactured from a magnetic and/or ferrous material) or alternatively the first coupling portion 305 may be attached to the base 302.

The component (for example, the mouthpiece 207 or body 201) of the device 200 may form the second coupling portion 306 (for example, being manufactured from a magnetic and/ or ferrous material) or alternatively the second coupling portion 306 may be attached to said component.

In some embodiments, one of the holder 200 and said component comprises a first magnet and the other one of the holder 200 and said component comprises a ferromagnetic material and/ or second magnet that is configured to be attracted to the first magnet to magnetically removably connect the holder 200 to the component. In some embodiments, the other one of the holder and component comprises a ferrous material. In some embodiments, the holder 300 comprises a heating material that is heatable by penetration with a varying magnetic field. For example, the engaging member 301 may comprise such a heating material. The engaging member 301 may thus form a susceptor that heats the body of material 3 of the article 1. Alternatively, or additionally, the engaging member 301 may comprise a resistive heating element that is powered to heat the article 1 when the holder 300 is attached to the device 200. For example, attaching the holder 300 to the device 200 may cause the holder 300 to be electrically connected to a circuit of the device 200 such that power flows through the holder 300 to power the heater.

In some embodiments, connecting the holder 300 to the component of the aerosol provision device 200 may cause one or more of: the (inductive or resistive) heater to be powered; an indicator to be activated such that an indication is provided to the user (e.g. an audible beep or operation of a light); the circuitry of the device to be powered; and/ or a pre-heating routing to be operated such that the heater is pre-heated. The article 1 of the aerosol provision system 100 of Figs. 16 to 18 may have any of the features of any of the other articles described herein. In some embodiments, the aerosol generating material of the article 1 comprises, consists of, or essentially consists of, tobacco. In some embodiments, the article 1 may comprise a rod comprising aerosol generating material (for example, tobacco) and the rod is connected to the component of the device 200 by the holder 300. In another example, the article 1 may comprise a reservoir of aerosol generating material (for example, a reservoir that includes nicotine and glycerol) and wherein the reservoir is connected to the component by the holder 300.

In some embodiments, the holder 300 may engage the article 1 by, for example, mechanically or magnetically coupling to the article 1. For example, the holder 300 may mechanically couple to the article 1 (which optionally may comprise, for example, a rod comprising aerosol generating material or a reservoir containing aerosol generating material) by clipping to the article 1, clamping or gripping the article, having a part (for example, a pin) that is inserted into the article 1, coupling to the article 1 via a bayonet connection or coupling to the article 1 via communicating threads on the holder 300 and article 1. Additionally, or alternatively, one or both of the article 1 or holder 300 may comprise magnets to couple the article 1 and holder 300 together. Once the holder 300 has been coupled to the article 1, the holder 300 and article 1 can then be removably coupled to the component of the device 200 to secure the article 1 within the zone (which may be an aerosol-generating zone such as a heating zone 202), and the user may decouple the holder 300 and article 1 from the component of the device 200 (whilst the article 1 is still engaged with the holder 300) to remove the article 1 from the zone 202. In other embodiments, the device 200 may be configured such that the user disconnects the holder 300 from the component of the device 200 and then, after the holder 300 has been disconnected, the user removes the article 1 from the zone 202. Referring now to Figs. 19 to 21, another embodiment of an aerosol provision system 100 is shown. The aerosol provision system 100 is similar to the aerosol provision system 100 described above in relation to Figs. 1 to 7, with like features retaining the same reference numerals. A difference is that the article 1 is omitted and is replaced with an alternative article 400.

The article 400 comprises a plurality of regions 403A, 403B, 403C of aerosol generating material 403. In the present example, the plurality of regions 403A, 403B, 403C of aerosol generating material 403 are provided on a substrate 401. The substrate 401 maybe substantially planar.

The aerosol provision device 200 is configured to selectively heat each of the regions 403A, 403B, 403C. For example, the device 200 may comprise a respective heater 203A, 203B, 203C to heat each of the regions 403A, 403B, 403C. Each heater 203A, 203B, 203 may be a resistive heating element or may be an electric field generator, as described previously. The device 200 may have the same components as the device 200 described above in reference to Figs. 1 to 7, which are not shown in Figs. 19 to 21 for brevity. For example, the device 200 of Figs. 19 to 21 may comprise an electrical energy supply, a controller connected to the heaters 203A, 203B, 302C, the electrical energy supply, and a user interface, for example a button or display.

The controller may controls the power supplied to the heater 203 A, 203B, 2O3Cin order to regulate its temperature.

The heaters 203A, 203B, 203C maybe operated sequentially to allow for a more consistent release of aerosol. For example, the first heater may 203A may be operated to heat the first region 403A of aerosol generating material until the rate of aerosol released therefrom reduces (for example, due to the region 403A being depleted). Next, the second first heater may 203B maybe operated to heat the second region 403B of aerosol generating material until the rate of aerosol released therefrom reduces, and then the third first heater may 203C may be operated to heat the third region 403C of aerosol generating material until the rate of aerosol released therefrom reduces. In some embodiments, the system 100 comprises a coupling 404 comprises first and second coupling portions 405, 406. The article 404 comprises the first coupling portion 405. In the present embodiment, the article 404 comprises two first coupling portions 405 at opposite ends of the article 400. However, it should be recognised that in other embodiments one of the first coupling portions 405 may be omitted, or the first coupling portion(s) maybe provided at a different location.

The device 200 comprises the second coupling portion 406. In the present embodiment, the device comprises two second coupling portions 406 that correspond to the first coupling portions 405 of the article 400. Again, the number or locations of the second coupling portions 406 may vary.

In some embodiments, the coupling 404 is a magnetic coupling, wherein the first and second coupling portions 405, 406 are magnetically attracted. In the present example, the substrate 401 comprises the first coupling portions 405.

In the present example, the second coupling portions 405 are provided inside the body 201 of the device 200.

In some embodiments, the article 400 is slid into the heating zone 202 of the device 200. For example, the mouthpiece 207 maybe removed and then the article 400 may be slid into the heating zone 202 (in the direction of arrow ‘A’ in Fig. 21) until each region 403A, 403B, 403C of aerosol generating material aligns with a respective heater 203A, 203B, 203C.

The first and second coupling portions 405, 406 may become aligned when the article 400 is inserted into the heating zone 202 and will become magnetically attracted. This helps to align the article 400 within the heating zone 202, which is particularly advantageous when a plurality of regions 404A, 404B, 404C are provided because it means that each region 404A, 404B, 404C can be aligned with a respective heater 203A, 203B, 203C more easily. In some embodiments, the coupling 404 is such that the article 400 will “snap” into position within the heating zone 202. The article 400 may be removed from the heating zone 202, by pulling the article 400 out of the heating zone 202 against the magnetic force of the coupling 404. In all of the examples described above, the body of material 3 may be a tobacco rod 3.

For example, the body of material 3 maybe a rod comprising shredded lamina tobacco and/ or shredded reconstituted tobacco (for example, shredded reconstituted tobacco sheet).

In another embodiment (not shown), the body of material 3 comprises a sheet material that is gathered to form the body of material 3. The sheet material may comprise the aerosol generating material 4, which optionally may comprise, consist of, or essentially consist of, a tobacco material. For example, the sheet material may be reconstituted tobacco that is gathered to form the body of material 3.

In some embodiments, the sheet material is crimped to promote gathering of the third sheet material to form the body of material 3.

In some embodiments, the sheet material is cut into strips and then the strips are formed into the body of material 3.

In the present example, the body of material 3 extends over a portion of the length of the article 1 (shown by arrow ‘X’ in Fig. 1). In an alternative embodiment, the body of material 3 extends over the entire length X of the article 1.

In the present example, the wrapper 7 has a permeability of at most too Coresta Units.

In other embodiments, the wrapper 7 has a permeability of at least too Coresta Units..

In some embodiments, the wrapper 7 has a thickness in the range of 20 to too microns.

It has been found that reducing the thickness of wrapper 7 helps to facilitate heat transfer to the aerosol generating material 4. Increasing the heat transfer through the wrapper 7 advantageously improves the efficiency of the heating of the aerosol generating material 4.

In the present example, the aerosol generating material 4 comprises extruded and/ or compressed aerosol generating material. However, it should be recognised that in other embodiments, the aerosol generating material 4 may have a different form. In some embodiments, the aerosol generating material 4 comprises beads. The beads maybe cylindrical, or may have an alternative shape, for example, spherical, pyramid or cuboid shaped. In some embodiments, the aerosol generating material 4 of the article 1 is derived only from tobacco lamina and no other types of tobacco material.

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

In some embodiments, the aerosol generating material 4 of the article 1 has an average nicotine level in the range of 0.6% to 2.5% by weight of the aerosol generating material 4and, preferably, in the range of 1% to 2.1%. In some embodiments, the aerosol generating material 4 is a solid material.

The article 1 may have an axial length (shown by arrow ‘X’ in Fig. 1) 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 aerosol generating material does not comprise tobacco. The aerosol generating material may be substantially tobacco free.

In some embodiments, the aerosol generating material is a liquid.

In some embodiments, the article comprises a reservoir that contains the aerosol generating material. The article may comprise a cartridge (not shown) that comprises the reservoir. The cartridge/reservoir may comprise, for example, the first coupling portion 5, 405 which optionally maybe a magnet. The first coupling portion 5, 405 is magnetically attracted to the second coupling portion 6, 406 when the cartridge/reservoir is received in the zone (or heating zone). In one such embodiment, the article comprises a cartridge that contains nicotine (for example, liquid or powder comprising nicotine) in the reservoir of the cartridge. In some embodiments, the aerosol generating material is a non-liquid (for example, a solid) or is a liquid. In some embodiments, the aerosol generating material may be a powder.

In some embodiments, the entire article i does not comprise plastic. In some embodiments, the body of material 3 or the entire article 1 does not comprise cellulose acetate. This makes the article 1 more environmentally friendly, and is also advantageous in embodiments wherein the entire article 1 is heated by the aerosol delivery device 200 (as described below). In some embodiments, the aerosol-generating material 4 may comprise, consist of, or essentially consist of, tobacco material. The term “tobacco material” refers to any material comprising tobacco or derivatives or substitutes thereof. The tobacco material may be in any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and/or tobacco extract.

In some embodiments, the aerosol generating material 4 or another material (not shown) of the article 1, for example, another material of the body of material 3, may comprise one or more aerosol-former materials. For example, the first and/or second aerosol generating material 4, 5 or said another material may comprise one or more constituents capable of forming an aerosol. The aerosol-former material comprises one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol-former material can be glycerol or propylene glycol. In some embodiments, the article 1 comprises first and second aerosol generating materials. For example, the body of material 3 may comprise shredded lamina and/or reconstituted tobacco that is mixed with tobacco beads. Optionally, the first aerosol generating material has a higher density than the second aerosol generating material. It has been found that this causes the first aerosol generating material to heat up slower than the second aerosol generating material when the heater of the device 200 is operated to heat the article 1. This means that the second aerosol generating material will initially release one or more volatile compounds (e.g. nicotine) at a higher rate than the first aerosol generating material. This also means that the second aerosol generating material will become relatively depleted of said volatile compound(s) more quickly than the first aerosol generating material. However, as the second aerosol generating material starts to become relatively depleted of said volatile compound(s), the first aerosol generating material will begin to reach a temperature wherein it begins to release volatile compound(s) at a higher rate. The effect of this is a more consistent release of the volatile compound(s) over the period of consumption of the article 1, with the second aerosol generating material releasing a greater proportion of volatile compound(s) towards the beginning of the consumption of the article 1 and the first aerosol generating material releasing a greater proportion of volatile compound(s) towards the end of the consumption of the article 1. This is particularly advantageous because the article 1 can be made relatively small whilst still achieving a relatively consistent and/or sufficient release of volatile compound(s) over the period of consumption. In some embodiments, said one or more volatile compound(s) released by the first aerosol generating material are the same as the volatile compound(s) released by the second aerosol generating material 5.

In some embodiments, the first aerosol generating material comprises aerosol generating material that has been compressed or extruded (without subsequent expansion or with a relatively low/ minimal expansion) such that the density of the first aerosol generating material is higher than the density of the second aerosol generating material. In some embodiments, the second aerosol generating material comprises one or more of: tobacco lamina; tobacco stems or reconstituted tobacco. In one such embodiment, the second aerosol generating material comprises a mixture of tobacco lamina and reconstituted tobacco. The second aerosol generating material may comprise shredded or cut material. However, it should be recognised that in other embodiments, the second aerosol generating material comprises a compressed or extruded aerosol generating material that has a lower density than the first aerosol generating material (for example, having a lower compression than the first aerosol generating material 4, which optionally may also be extruded or compressed). For instance, the body of material 3 may comprise an extruded/ compressed body of the second aerosol generating material.

In some embodiments, the first and second aerosol-generating material may comprise the same material, for example, tobacco, but are processed to have different densities. In one such embodiment, the first and second aerosol generating materials may be in different forms. For example, the second aerosol generating material maybe a shredded material (for example, shredded lamina tobacco and/or shredded reconstituted tobacco) that is formed into a body 3, whereas the first aerosol generating material maybe compressed or extruded (without or with minimal expansion) such that the first aerosol generating material has a higher density than the second aerosol generating material.

For example, the first aerosol generating material may be in the form of extruded/compressed beads of aerosol generating material (for example, tobacco or another material) and the second aerosol generating material 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; a rod of aerosol generating material (e.g. a rod formed from cut rag tobacco); or, tobacco lamina and/or stem material that has been formed into a plug. However, it should be recognised that the first and/or second aerosol generating material may alternatively have the same form (e.g. both being cut rag tobacco).

It should be recognised that in alternative embodiments, the density of the first aerosol generating material is lower than the density of the second aerosol generating material. In yet another embodiment, the densities of the first and second aerosol generating materials are the same. In other embodiments, the article 1 comprises a single aerosol generating material. In some embodiments, the first aerosol-generating material has at least one further different characteristic to the second aerosol generating material. The different characteristic maybe one or more of form, size, , water content, amount (by weight), material or materials, or proportion of materials that make the first and second aerosol- generating materials (including the recipe of the aerosol generating materials when each is manufactured more than one material). In some embodiments, the first and second aerosol-generating materials do not have a different characteristic, other than being in a different form. The aerosol-generating material(s) may comprise a plurality of strands or strips of aerosol-generating material. For example, the aerosol-generating material(s) 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 aerosol-generating material(s) may comprise a plant based material, such as a tobacco material. The aerosol-generating material(s) 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, the aerosol-generating material(s) comprises a sheet or shredded sheet of aerosolisable material that comprises an aerosol-former material. 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 aerosol-generating material(s) may comprise a 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. In some embodiments, aerosol generating material(s)are in the form of a sheet or shredded sheet that comprises the filler.

The aerosol generating material(s) can comprise an aerosol modifying agent, such as any of the flavours described herein. In one embodiment, the aerosol generating material(s) comprises menthol. When the aerosol generating material(s) is incorporated into an article 1 for use in an aerosol-provision system, the article may be referred to as a mentholated consumable or article 1. The aerosol generating material(s) can comprise from o.5mg to 20mg of menthol, from 0.7 mg to 20 mg of menthol, between img and i8mg or between 8mg and i6mg of menthol. In some embodiments, the article 1 comprises an aerosol-generating composition comprising aerosol-generating material 4.

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 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 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 is substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

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

The aerosol-generating material may comprise or be an aerosol-generating film. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as active substances, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film. The slurry may be heated to remove at least about 6o wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent. The aerosol-generating film may be a continuous film or a discontinuous film, such an arrangement of discrete portions of film on a support. The aerosol-generating film 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. In some examples, the amorphous solid comprises:

- 1-60 wt% of a gelling agent;

- 0.1-50 wt% of an aerosol-former material; and

- 0.1-80 wt% of a flavour; wherein these weights are calculated on a dry weight basis.

In some further embodiments, the amorphous solid comprises:

- 1-50 wt% of a gelling agent;

- 0.1-50 wt% of an aerosol-former material; and

- 30-60 wt% of a flavour; wherein these weights are calculated on a dry weight basis. The aerosol generating material(s) can comprise a paper reconstituted tobacco material. The composition can alternatively or additionally comprise any of the forms of tobacco described herein. The aerosol generating material(s) 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 aerosol generating material(s) comprises an amorphous solid material, the amorphous solid material may be a dried gel comprising menthol.

In each of the embodiments describe herein, the article 1 may comprise first and second aerosol generating material. The first and second aerosol-generating materials of the article have may optionally different densities. Otherwise, the aerosol-generating materials in the article may be the same or different.

It has been found that providing regions comprising a second aerosol-generating material with a greater density than the first aerosol-generating material, the different densities cause the second aerosol generating material to heat up slower than the first aerosol generating material when exposed to the same heating and will release its volatile compounds (e.g. nicotine) at a slower rate than the first aerosol-generating material. Thus, combining the aerosol-generating materials with different densities with separate heating of these materials at optionally different times and/or different temperatures allows the provision of a more tailored release of the volatile compound(s) over the period of consumption of the article, for example providing a more consistent and longer-lasting release of volatile compound(s). Alternatively, it may be desirable to have a more rapid or greater release of volatiles towards the beginning of the consumption of the article, to provide the user with a greater initial impact from use. The capacity to control the aerosol generation and volatile compound release maybe particularly advantageous because the article can be made relatively small whilst still achieving a particular desired release of volatile compound(s) over the period of consumption. In some embodiments, the second aerosol generating material has a density that is at least about 25% higher than the density of the first aerosol generating material and, optionally, at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70% or 75% higher than the density of the first aerosol-generating material. The second aerosol generating material may have a density that is no more than about 200% higher than the density of the first aerosol generating material and, optionally, no more than about 150%, 125%, 100% or 75% higher than the density of the first aerosol-generating material. In some embodiments, the second aerosol generating material has a density that is from about 25% to about 75% higher than the density of the first aerosol generating material.

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

In some embodiments, the second aerosol generating material has a density of from at least about 0.4 g/cm3 _an d optionally from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2,

1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3. The second aerosol generating material may have a density of no more than about 2 g/cm3 _an d, optionally no more than about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6 or 0.5 g/cm3, in some embodiments, the density of the first aerosol-generating material is from about 0.4 to 1.99 g/cm3.

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

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

In some embodiments, the first aerosol-generating material has at least one further different characteristic to the second aerosol generating material. The different characteristic may be one or more of form, size, , water content, amount (by weight), material or materials, or proportion of materials that make the first and second aerosolgenerating materials (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 do not have a different characteristic, other than their different densities.

In some embodiments, the first aerosol-generating material comprises one or more tobacco in the form of cut rag. This tobacco material may lamina or reconstituted tobacco material. In some embodiments, the first aerosol-generating material is a blend comprising both lamina and reconstituted tobacco. For example, the ratio of lamina and reconstituted tobacco may from about 1:4 to about 4:1. The second aerosol-generating material has a greater density than the first aerosolgenerating material. In some embodiments, this more dense, second aerosolgenerating material 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.

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 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 aerosol-generating material 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, which will have an impact on the heat transfer within the material and the release of the volatile components. Extrusion involves feeding a composition (also referred to as a precursor composition) through a die to produce an extruded product. The process applies pressure to the composition combined with shear forces.

Extrusion may be performed using one of the main classes of extruders: screw, sieve and basket, roll, ram and pin barrel extruders. A single screw or twin screw extruder may be used. Forming the tobacco beads by extrusion has the advantage that this processing combines compression, mixing, conditioning, homogenizing and moulding of the composition. In some embodiments, during extrusion the free-flowing composition comprising particles, such as tobacco particles, is exposed to elevated pressure and temperature and is forced though an orifice, such as a shaping nozzle or die, to form an extrudate. In some embodiments, the extrudate has a rod-like form and it may be cut into segments of a desired length. In some embodiments, the composition is exposed to temperatures from about 4O°C to about 15O°C, or from about 8o°C to about 13O°C, or from about 6o°C to about 95°C within the extruder. In some embodiments, including those using double extrusion, the precursor composition is exposed to temperatures from about 7O°C to about 95°C within the extruder. In some embodiments, including those using single extrusion, the precursor composition is exposed to temperatures from about 6o°C to about 8o°C within the extruder.

The composition may be exposed to pressures (immediately before the die or nozzle) ranging from about 2 bar to about 100 bar, or from about 5 bar to about 60 bar, depending on the design of the die or nozzle being used. The higher the pressure, the greater the density of the extrudate is likely to be. Thus, the extrusion process may be adjusted to provide extruded aerosol-generating material with the desired density. In some embodiments where tobacco particles are extruded, due to the relatively high density of the extrudate and the relatively open surface of the tobacco particles within it, the tobacco beads formed from the extrudate exhibit good heat transfer and mass transfer, which has a positive impact on the release of tobacco constituents, such as flavours and nicotine.

In some embodiments, the extrusion may be a generally dry process, with the composition including aerosol generating particles that are dry or substantially dry.

The composition may optionally include other particulate materials including, for example, base, diluent, solid aerosol forming agents, solid flavour modifiers, etc.

In some embodiments, liquids may be added to the composition prior to or during the extrusion process. For example, water may be added, for example as a processing aid to assist dissolution or solubilisation of components of the composition, or to aid binding or agglomeration. Alternatively or additionally, a wetting agent may be added to the composition.

In some embodiments, the liquid may be an aerosol former material such as glycerol or others discussed herein. When liquid is added to the composition in this manner, the liquid is applied not only on the surface, but, as a result of the extruder pressure combined with the intensive mixing by high shear forces, the extrudate becomes impregnated with the liquid. Where the liquid is an aerosol former material, this can result in a high availability of the aerosol former material in the resultant beads to enhance evaporation of volatile components.

In some embodiments, the amount of aerosol former material incorporated into the extruded beads may be up to about 30% by weight and even up to about 40% by weight. Ordinarily, such high amounts of aerosol former material could render the composition difficult to handle. However, this is less of an issue where extrusion results in the particles being impregnated with the aerosol former material. It maybe desirable to include an aerosol former material in an amount such as at least about 10% or at least about 20% by weight where the beads are to generate an aerosol in addition to releasing the volatile components. Smaller amounts of aerosol former material, such as up to about 5% by weight, maybe sufficient where the beads’ primary function is to release volatile constituents carried by the beads into an existing aerosol or air flow. In some embodiments, the agglomerates do not include a binder or binding additive. For example, extruded beads may not require a binder to maintain their structural integrity. In other embodiments, the agglomerates comprise a binder or binding additive. The binding additive may be selected to assist in the formation of an agglomerated structure by helping to adhere the particles to each other and to other components in the composition. Suitable binding additives include, for example, thermoreversible gelling agents such as gelatin, starches, polysaccharides, pectins, alginates, wood pulp, celluloses, and cellulose derivatives such as carboxymethylcellulose. In some embodiments, processing by extrusion is sufficient to provide the desired higher density of the second aerosol-generating material. However, in other embodiments, the extrudate may be further treated to increase the density of aerosolgenerating material. For example, in some embodiments, the extruded aerosol-generating material undergoes spheronisation. In spheronisation, the extruded, cylindrically shaped particles are broken into uniform lengths and are gradually transformed into spherical shapes due to plastic deformation. Where the extrudate is first broken into uniform lengths, spheres with a uniform diameter will be produced by the spheronisation step. According to one specific example of the embodiments discussed herein, samples of the second aerosol-generating material were produced as follows.

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

Table i

The tobacco was ground to produce a fine powder, taking care not to overheat the tobacco. The ground tobacco particles were sieved to select those with a desired size, for example a particle size of less than 250 pm, of less than 100 pm or less than 60 pm.

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

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

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

The extrudate was broken into pieces of varying length as it came out of the extruder.

These pieces were then spheronised. Spheronisation was carried out until spherical beads were formed. In this instance, the extrudate was initially spheronised in a Caleva Multilab operating at 2,500 RPM for 1 minute and then the beads were checked for any defects. Then, spheronisation continued for a further 1 to 2 minutes. This - 6o - 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 first aerosol-generating material 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 second aerosol-generating material, such as particle size, but will have a lower density than the second aerosol-generating material. As described above, there are various ways to adjust the density of the aerosolgenerating material, such as the formulation and/ or the processing of the material into particles, beads or pellets.

In some embodiments, the first aerosol-generating material 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/cm ³ . The second aerosol- generating material comprises from about 30 to about 90% tobacco, with a density in the range of from about 0.4 to about 1.99 g/cm ³ . The amount of aerosol forming material included in the second aerosol-generating material may be from about 8 to about 15%. The second aerosol-generating material 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 and about 50% of the second aerosol-generating material, by weight. Thus, for example, an article comprising 260 mg of aerosol-generating material may comprise 130 mg of the first aerosol-generating material and 130 mg of the second aerosol-generating material.

In some embodiments were the aerosol-generating material comprises tobacco, the tobacco is present in an amount of between about 10% and about 90% by weight of the aerosol generating material. In some embodiments, the tobacco may be present in an amount of at least about 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, or at last about 35% tobacco based on the weight of the aerosol generating material.

In some embodiments, the tobacco may be present in an amount of no more than about 90%, 89%, 88%, 87%, 86%, 85%, 84%, 83%, 82%, 81%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, or no more than about 40% tobacco based on the weight of the aerosol generating material.

The tobacco described herein may contain nicotine. In some embodiments, the nicotine content is from 0.5 to 2% by weight of the tobacco, and may be, for example, from 0.5 to 1.75% by weight of the tobacco, from 0.8 to 1.2% by weight of the tobacco or from about 0.8 to about 1.75% by weight of the tobacco. In some embodiments, the nicotine content may be from 0.8 to 1% by weight of the tobacco. In some embodiments, the first and second aerosol-generating materials have the same nicotine content.

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

In some embodiments, the first and/or second aerosol-generating materials comprise tobacco. For example, the first and/or second aerosol-generating materials may comprise from about 80 to about 350 mg of tobacco. In some specific embodiments, the aerosol-generating material in an article or consumable has a weight of 260 mg, comprising a combination of 130 mg of a first aerosol-generating material, for example comprising a blend of lamina and reconstituted tobacco, and 130 mg of a second aerosol-generating material, for example comprising higher density tobacco beads. In some embodiments, each of the regions comprising aerosol-generating material contain an equal amount of tobacco. In alternative embodiments, the regions may contain different amounts of tobacco. Where the total amount of tobacco is from about 80 to about 350 mg, , one region of aerosol-generating material comprises from about 20 to about 330 mg, or from about 50 to about 300 mg, or from about 40 to about 125 mg of tobacco and the other region of aerosol-generating material comprises from about 20 to about 330 mg, or from about 30 to about 300 mg or from about 40 to about 125 mg of tobacco.

According to the present disclosure, there is also provided a 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.