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

Technical field The present disclosure relates to an article for use in an aerosol provision system and a method of manufacturing an article for use in an aerosol provision system. The present disclosure also relates to kit of parts comprising an article and an aerosol provision device, and 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 herein, there is provided an article for use in an aerosol provision system, the article comprising: a storage area containing an aerosol-generating material configured to be heated within the storage area to generate an aerosol; and, a first blocking member comprising a body of material arranged to resist the aerosol-generating material from moving out of the storage area through a first end of the storage area.

In some embodiments, the article further comprises a wall that surrounds the storage area.

In some embodiments, the wall comprises a sheet material and, preferably, wherein the sheet material comprises paper and/or foil. In some embodiments, the sheet material circumscribes the first and/or second blocking members. In some embodiments, the sheet material secures the first and/or second blocking members in position. In some embodiments, the first blocking member comprises a first wrapper that circumscribes the body of material of the first blocking member and, preferably, the first wrapper comprises paper or cardboard. In one such embodiment, the body of material of the first blocking member is a tobacco plug and the wrapper circumscribes the tobacco plug.

In some embodiments, the first blocking member does not comprise plastic. In some embodiments, the first and/or second blocking members do not comprise plastic.

In some embodiments, the first and/or second blocking members do not comprise cellulose acetate.

In some embodiments, the first and/or second blocking members comprises an aerosol-modifying agent.

In some embodiments, the first and/or second blocking members comprises a flavourant.

In some embodiments, the first blocking member is generally cylindrical.

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

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

In some embodiments, the body of material is disposed adjacent to a first end of the storage area. In some embodiments, at least a portion of the body of material is received within the open end of the wall of the article. In some embodiments, the body of material has an axial length in the range of 3 to 20 mm and, preferably in the range of 4 to 15 mm, 5 to 12 mm or 7 to 10 mm. In some embodiments, the body of material comprises an aerosol-generating material.

In some embodiments, the aerosol-generating material of the body of material comprises tobacco material. In some embodiments, the tobacco material is only tobacco lamina and no other types of tobacco material and/or the tobacco material has a nicotine level in the range of 0.5% to 2.5% by weight of the tobacco and, preferably, in the range of 1% to 2.1%.

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

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

In some embodiments, the aerosol-generating material of the blocking member comprises a flavourant.

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

In some embodiments, the sheet material is crimped. In some embodiments, the sheet material of the body of material comprises one or more of: paper and/or aerosol-generating material and, preferably, comprises tobacco.

In some embodiments, the first blocking member comprises an end that contacts the aerosol-generating material. In some embodiments, the first blocking member is upstream of the storage area. In other embodiments, the blocking member is downstream of the storage area.

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

In some embodiments, the article further comprises a second blocking member arranged to resist the aerosol-generating material from moving out of the storage area through a second end of the storage area.

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

In some embodiments, the second blocking member has any of the features of the first blocking member described above.

In some embodiments, the second blocking member is generally cylindrical.

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

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

In some embodiments, the body of material is disposed adjacent to a second end of the storage area. In some embodiments, at least a portion of the body of material is received within the open end of the wall of the article.

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

In some embodiments, the body of material comprises an aerosol-generating material. In some embodiments, the aerosol-generating material of the body of material comprises tobacco material. In some embodiments, the tobacco material is only tobacco lamina and no other types of tobacco material and/or the tobacco material has a nicotine level in the range of 0.5% to 2.5% by weight of the tobacco and, preferably, in the range of 1% to 2.1%.

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

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

In some embodiments, the aerosol-generating material of the second blocking member comprises a flavourant.

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

In some embodiments, the sheet material is crimped. In some embodiments, the sheet material of the body of material comprises one or more of: paper and/or aerosol-generating material and, preferably, comprises tobacco.

In some embodiments, the second blocking member comprises an end that contacts the aerosol-generating material.

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

In some embodiments, the second blocking member comprises a second wrapper that circumscribes the body of material of the second blocking member and, preferably, the second wrapper comprises paper or cardboard. In some embodiments, the first and second blocking members each at least partially define a boundary of the storage area. In some embodiments, the first and/or second blocking member is separate and distinct from the wall.

In some embodiments, the body of material of the second blocking member is a tobacco plug and the second wrapper circumscribes the tobacco plug.

In some embodiments, the first and/or second blocking member is gas permeable.

In some embodiments, the first and second blocking members are the same. In some embodiments the aerosol-generating material in the storage area is a first aerosol generating material and the first and/or second blocking member (in embodiments that comprise a second blocking member, otherwise the first blocking member) comprises a second aerosol generating material. In some embodiments, the density of one of the first and second aerosol-generating materials is at least about 25% higher than the density of the other one of the first and second aerosol generating materials. However, in other embodiments, the density of the first and second aerosol generating materials is the same. In some embodiments, one of the first and second aerosol generating materials has a density of from about 0.4 g/cm3 to about 2 g/cm3.

In some embodiments, the other one of the first and second aerosol generating materials has a density of from about 0.1 g/ cm ³ to about 1 g/cm ³ .

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

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

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

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

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

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

In some embodiments, the first and second blocking members each comprise, consist of, or essentially consist of tobacco and, preferably, each comprise a plug of tobacco.

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

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

In some embodiments, the aerosol-generating material in the storage area comprises a plurality of compressed or extruded bodies of aerosol generating material and, preferably, a plurality of compressed or extruded bodies of tobacco material.

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

In some embodiments, the tobacco material is only tobacco lamina and no other types of tobacco material.

In some embodiments, the tobacco material has a nicotine level in the range of 0.5% to 2.5% by weight of the tobacco and, preferably, in the range of 1% to 2.1%.

In some embodiments, the article further comprises a cooling section and, preferably, wherein the cooling section is arranged such that, in use of the consumable, the cooling section is downstream of the aerosol-generating material.

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

In some embodiments, the cooling section comprises a flavourant.

In some embodiments, the article further comprises a plug of material provided on the other side of the first and/or second blocking member to the storage area.

In some embodiments, the article has 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 article comprises aerosol-generating material along at least 90% of the length of the article and, preferably, along at least 92%, 94%, 96%, 98% or 99% of the length of the article and, preferably, along the entire length of the article. According to the present disclosure there is also provided a method of manufacturing an article for use in an aerosol provision system, the method comprising: providing an aerosol-generating material and a first blocking member comprising a body of material, wherein the aerosol-generating material and first blocking member are arranged such that the aerosol-generating material is contained in a storage area and the first blocking member resists the aerosol-generating material from moving out of the storage area through a first end of the storage area.

In some embodiments, the first blocking member has any of the features of the first blocking member described above.

In some embodiments, the method comprises wrapping a first wrapper about the body of material of the first blocking member. In some embodiments, the method comprises providing the aerosol-generating material and first blocking member comprises locating the aerosol-generating material and first blocking member on a sheet material and, preferably, wherein the sheet material comprises paper and/or foil. In some embodiments, the method comprises wrapping the sheet material about the aerosol-generating material and first blocking member.

In some embodiments, the method comprises providing a second blocking member arranged such that the second blocking member resists the aerosol-generating material from moving out of the storage area through a second end of the storage area and, preferably, the second blocking member comprises a body of material.

In some embodiments, the second blocking member has any of the features of the first blocking member described above.

In some embodiments, the first and second blocking members each at least partially define a boundary of the storage area.

In some embodiments, the first and/or second blocking member is separate and distinct from the wall. In some embodiments, the body of material of the second blocking member is a tobacco plug and the second wrapper circumscribes the tobacco plug.

In some embodiments, the first and/or second blocking member is gas permeable.

In some embodiments, the first and second blocking members have the same features and may be identical.

In some embodiments, the first and second blocking member each comprise tobacco and, preferably, each comprise a plug of tobacco.

In some embodiments, the first blocking member comprises a first end of the consumable and the second blocking member comprises a second end of the consumable.

In some embodiments, the method comprises forming the sheet material into a wall that surrounds the storage area.

In some embodiments, the method comprises wrapping a second wrapper about the body of material of the second blocking member.

In some embodiments, the method comprises positioning the first and second blocking members on the sheet material such that a gap is formed therebetween, and at least partially filling the gap with the aerosol-generating material.

In some embodiments, the sheet material with the first and second blocking members thereon is conveyed along a conveyance path.

In some embodiments, the gap is at least partially filled with the aerosol-generating material as the sheet material with the first and second blocking members passes a filling apparatus.

In some embodiments, the method comprises providing a plurality of first blocking members and second blocking members arranged sequentially on a web of the sheet material, and filling gaps between adjacent first and second blocking members with aerosol-generating material. In some embodiments, the method comprises wrapping the first and second blocking members and aerosol-generating material with the sheet material to form a rod, and then cutting the rod to form an article.

In some embodiments, the method comprises providing the first blocking member comprises providing a double-length first blocking member and providing the second blocking member comprises providing a double-length second blocking member. In some embodiments, the aerosol-generating material in the storage area is a solid material.

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

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

In some embodiments, the tobacco material is only tobacco lamina and no other types of tobacco material.

In some embodiments, the tobacco material has a nicotine level in the range of 0.5% to 2.5% by weight of the tobacco and, preferably, in the range of 1% to 2.1%. In some embodiments, the method comprises providing a cooling section and, preferably, arranging the cooling section such that, in use of the consumable, the cooling section is downstream of the aerosol-generating material.

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

In some embodiments, the method further comprises providing a plug of material on the other side of the first and/or second blocking member to the storage area. According to the present disclosure, there is also provided an article for use in an aerosol provision system, the article comprising aerosol-generating material along at least 90% of the length of the article. In some embodiments, the article comprises aerosol-generating material along at least 92% of the length of the article and, preferably, at least 94%, 96%, 98% or 99% of the length of the article.

In some embodiments, the article comprises aerosol-generating material along substantially the entire length of the article.

In some embodiments, the article comprises one or more bodies of material, and wherein the or each body of material of the article comprises aerosol-generating material.

In embodiments wherein the article comprises a plurality of bodies of material, every body of material comprises aerosol-generating material.

In some embodiments, the aerosol generating material comprises first and second aerosol generating materials.

In some embodiments, the first and second aerosol generating materials are mixed together over at least a portion of the axial length of the article and, preferably, over the entire axial length of the article.

In some embodiments, the article comprises a first region that comprises the first aerosol generating material and a second region that comprises the second aerosol generating material and, preferably, wherein the first region is disposed along a first portion of the axial length of the article and the second region is disposed along a second portion of the axial length of the article.

In some embodiments, the aerosol generating material comprises one or more extruded or compressed bodies of aerosol generating material and, preferably, wherein the or each extruded or compressed body of aerosol generating material is a bead of aerosol generating material. In some embodiments, the first aerosol generating material comprises the one or more extruded or compressed bodies of aerosol generating material.

In some embodiments, the aerosol generating material comprises a sheet of aerosol generating material and, preferably, wherein the sheet is shredded or cut into strips.

In some embodiments, the sheet of aerosol generating material comprises reconstituted tobacco. In some embodiments, the aerosol generating material comprises lamina tobacco and, preferably, shredded lamina tobacco.

In some embodiments, the second aerosol generating material comprises the sheet of aerosol generating material and/or the lamina tobacco.

In some embodiments, the article comprises first and second blocking members that each comprise aerosol generating material, wherein a storage area is disposed between the first and second blocking members and wherein the storage area contains aerosol generating material.

In some embodiments, the aerosol generating material in the storage area is the first aerosol generating material and wherein the aerosol generating material of the first and/or second blocking members is the second aerosol generating material. In some embodiments, the aerosol-generating material comprises, consists of, or essentially consists of, tobacco material.

In some embodiments, tobacco material is provided along at least 90% of the axial length of the article and, preferably, at least 92%, 94%, 96%, 98% or 99% of the length of the article and, preferably, the entire axial length of the article.

In some embodiments, the tobacco material is manufactured from only tobacco lamina and no other types of tobacco material. In some embodiments, tobacco material has a nicotine level in the range of 0.5% to 2.5% by weight of the tobacco and, preferably, in the range of 1% to 2.1%. In some embodiments, the aerosol generating material comprises extruded or compressed bodies of tobacco material and, preferably, the extruded or compressed bodies of tobacco material comprise beads of tobacco material.

In some embodiments, the aerosol generating material comprises reconstituted tobacco and, preferably, comprises a shredded sheet of reconstituted tobacco.

In some embodiments, the aerosol generating material comprises lamina tobacco and, preferably, comprises shredded lamina tobacco.

In some embodiments, the aerosol generating material comprises reconstituted tobacco and lamina tobacco and, preferably, the reconstituted tobacco and lamina tobacco are mixed together.

In some embodiments, the aerosol generating material comprises a sheet of aerosol generating material that is gathered to form a body of material and, preferably, the sheet material is crimped. Preferably, the sheet is a sheet of reconstituted tobacco. In some embodiments, the aerosol generating material comprises a sheet of material that is cut into strips. Preferably, the sheet is a sheet of reconstituted tobacco.

In some embodiments, the aerosol generating material is in the form of a rod. In some embodiments, the article comprises first and second ends, wherein at least one of the first and second ends comprises aerosol generating material and, preferably, both of the first and second ends comprise aerosol generating material.

In some embodiments, the article has 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.

According to the present disclosure, there is also provided a kit of parts comprising: the article as described herein; and, an aerosol provision device. According to the present disclosure, there is also provided a package comprising a plurality of articles as described herein. Preferably, the package is hermetically sealed.

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

Fig. 1 is a side-on cross sectional view of an embodiment of an article for use in an aerosol provision system;

Fig. 2 is a top view of a sheet material of the article of Fig. 1, wherein the sheet material is laid flat;

Fig. 3 is a perspective view of a first body of material of a first blocking member of the article of Fig. 1;

Fig. 4 is a perspective view of a second body of material of a second blocking member of the article of Fig. 1; Fig- 5 is a block diagram depicting a method of manufacturing an article for use in an aerosol provision system;

Fig. 6A is a top view of a first step of a method of manufacturing an article for use in an aerosol provision system;

Fig. 6B is a top view of a second step of a method of manufacturing an article for use in an aerosol provision system;

Fig. 6C is a top view of a third step of a method of manufacturing an article for use in an aerosol provision system;

Fig. 7A is a top view of a first step of another method of manufacturing an article for in with an aerosol provision system; Fig. 7B is a top view of a second step of said another method of manufacturing an article for use in an aerosol provision system;

Fig. 7C is a top view of a third step of said another method of manufacturing an article for use in an aerosol provision system;

Fig. 7D is a top view of a fourth step of said another method of manufacturing an article for use in an aerosol provision system;

Fig. 8 is a side view of the second step of said another method of manufacturing an article for use in an aerosol provision system;

Fig. 9 is cross-sectional side view of an alternative blocking member;

Fig. 10 is a cross-sectional side view of another alternative blocking member; Fig. 11 is a cross sectional view of an embodiment of a non-combustible aerosol provision device;

Fig. 12 is a simplified schematic of the components within the housing of the aerosol provision device shown in Fig. 11; Fig. 13 is a cross sectional view of the non-combustible aerosol provision device shown in Fig. 11 with the article shown in Fig. 1 inserted into the device;

Fig. 14 is a side-on cross sectional view of another embodiment of an article for use in an aerosol provision system;

Fig. 15 is a side-on cross sectional view of another embodiment of an article for use in an aerosol provision system;

Fig. 16 is a side-on cross sectional view of another embodiment of an article for use in an aerosol provision system; and,

Fig. 17 is a side-on cross sectional view of another embodiment of an article for use in an aerosol provision system.

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 maybe naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical. In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12. As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia,

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

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

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

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel. In some embodiments, the substance to be delivered comprises a flavour. As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts ofbotanicals, 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 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 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 may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy. The filamentary tow material described herein can comprise cellulose acetate fibre tow. The filamentary tow can also be formed using other materials used to form fibres, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(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 side-on cross-sectional view of an article 1 for use in an aerosol delivery system that includes an aerosol delivery device 200 (see Figs. 11 to 13).

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.

The article 1 comprises a space 2 containing an aerosol-generating material 3. The space 2 forms a storage area 2 for the aerosol-generating material 3. The article 1 further comprises first and second blocking members 4, 5 at opposite ends of the space

2.

The aerosol-generating material 3 is configured to be heated within the space 2 to generate an aerosol.

The first blocking member 4 comprises a first body of material 6 that, optionally, is circumscribed by a first wrapper 8. The first wrapper 8 may comprise, for example, paper or cardboard. The second blocking member 5 comprises a second body of material 7 that, optionally, is circumscribed by a second wrapper 9. The second wrapper 9 may comprise, for example, paper or cardboard.

The first body of material 6 is arranged to resist the aerosol-generating material 3, which may optionally be a loose material, from falling out of a first end 2A of the space

2. The second body of material 7 is arranged to resist the aerosol-generating material 3 from falling out of a second end 2B of the space 2. Therefore, the first and second blocking members 4, 5 help to retain aerosol-generating material 3 within the space 2. The aerosol-generating material 3 may be in the form of discrete particles. The first and/or second body of material 6, 7 may be generally cylindrical. However, it should be recognised that either or both body of material 6, 7 may have a different shape.

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.

The first body of material 6 may have an axial length of at least 3 mm and, preferably, at least 4, 5, 6 or 7 mm.

The first body of material 6 may have an axial length of at most 20 mm and, preferably, at most 15, 12, 10, or 8 mm.

The first body of material 6 may have an axial length in the range of 3 to 20 mm and, preferably in the range of 4 to 15 mm, 5 to 12 mm, or 7 to 10 mm..

The second body of material 7 may have an axial length of at least 3 mm and, preferably, at least 4, 5, 6, or 7 mm. The second body of material 7 may have an axial length of at most 20 mm and, preferably, at most 15, 12, 10 or 8 mm.

The second body of material 7 may have an axial length in the range of 3 to 20 mm and, preferably in the range of 4 to 15 mm, 5 to 12 mm, or 7 to 10 mm. The first and second bodies of material 6, 7 may be axially spaced by a distance of at least 4 mm and, preferably, at least 5 or 6 mm.

The first and second bodies of material 6, 7 may be axially spaced by a distance of at most 22 mm and, preferably, at most 20, 18, 16, 14 or 12 mm.

The first and second bodies of material 6, 7 may be axially spaced by a distance in the range of 4 to 22 mm and, preferably, in the range of 6 to 12 mm. In some embodiments, the total weight of aerosol generating material in the article is in the range of 150 to 350 mg and, preferably, in the range of 200 to 300 mg, 220 to 280 mg, or 230 to 260 mg.

In some embodiments, the first and/or second bodies comprise in the range of 7 mg per mm to 13 mg of aerosol generating material per mm length of the first and/or second body 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 first and/or second body.

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

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

The article 1 comprises a sheet material 10 that forms a wrap 10 that circumscribes the first and second blocking members 4, 5 and the aerosol-generating material 3. Thus, the sheet material 10 forms a generally tubular peripheral wall 10A that surrounds the space 2. That is, the space 2 is formed by a gap between the axially spaced first and second blocking members 4, 5, and wherein the peripheral wall 10A surrounds the space 2. The space 2 is filled, or at least partially filled, with the aerosol-generating material 3. The first and second blocking members 4, 5 and the sheet material 10 may define, or at least partially define, a boundary of the space 2.

The sheet material 10 may comprise, for example, paper and/or foil. In some embodiments, the sheet material 10 comprises paper without foil. In some embodiments, the sheet material 10 comprises a metallic foil such as aluminium foil. The sheet material 10 may optionally comprise a plurality of layers of materials, for example, a layer of paper with a layer of foil. In some embodiments, the sheet material 10 secures the first and second blocking members 4, 5 in position. The sheet material 10 may be wrapped about the wrappers 8, 9 of the first and second blocking members 4,5 or the wrappers 8, 9 may be omitted and the sheet material 10 may be wrapped directly about the bodies of material 6, 7. In some embodiments, the sheet material 10 is adhered to the first and/or second blocking members 4, 5. However, the skilled person will recognise that in other embodiments the sheet material 10 may not be adhered to the first and/or second blocking members 4, 5 and may be held in place, for example, by friction. In the present example, the sheet material 10 circumscribes the first and second blocking members 4, 5. The sheet material 10 maybe wrapped around the entire axial length of the first and/or second blocking members 4, 5. In other embodiments, the sheet material 10 maybe wrapped around only a portion of the axial length of the first and/or second blocking members 4, 5 and, for example, maybe provided as a strip of material that overlaps the first blocking member 4 without extending the full axial length of the first blocking member 4 and/or overlaps the second blocking member 5 without extending the full axial length of the second blocking member 5.

In other embodiments (not shown), the article 1 may comprise a cylindrical tube that forms the peripheral wall 10A, wherein the space 2 is provided within the cylindrical tube and wherein the first and second blocking members 4, 5 are provided adjacent to opposite ends of the cylindrical tube to resist the aerosol-generating material 3 from falling out of first and second ends of the tube respectively. The tube may be formed from a sheet material such as paper or foil. The tube may be a cardboard tube or may be plastic (for example, being injection moulded). In some embodiments, the tube may be connected to the first and second blocking members 4, 5 by a wrapper that circumscribes the tube and first and second blocking members 4, 5.

In some embodiments, the first and second blocking members 4, 5 do not comprise plastic. 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 first and second blocking members 4, 5 do not comprise cellulose acetate. In some embodiments, the entire article 1 does not comprise plastic. In some embodiments, the entire article 1 does not comprise cellulose acetate.

In the present example, the bodies of material 6, 7 of the first and second blocking members 4, 5 are gas permeable. Therefore, in embodiments wherein the first blocking member 4 is upstream of the second blocking member 5 during use of the article 1 in the device 200, gas can pass through the body of material 6 of the first blocking member 4, pass through the aerosol-generating material 3, and then pass through the body of material 7 of the second blocking member 5 for inhalation by the user.

Alternatively, in embodiments wherein the first blocking member 4 is downstream of the second blocking member 5 during use of the article 1 in the device 200, gas can pass through the body of material 7 of the second blocking member 5, pass through the aerosol-generating material 3, and then pass through the body of material 6 of the first blocking member 4 for inhalation by the user. In the present embodiment, the first body of material 6 of the first blocking member 4 is a plug of material and the second body of material 7 of the second blocking member 5 is a plug of material.

In the present embodiment, the first blocking member 4 comprises aerosol-generating material 11 and the second blocking member 5 comprises aerosol-generating material 12. In the present example, the first body of material 6 of the first blocking member 4 comprises aerosol-generating material 11 and the second body of material 7 of the second blocking member 5 comprises aerosol-generating material 12. In the present example, the first body of material 6 is a plug of aerosol-generating material 11 and the second body of material 7 is a plug of aerosol-generating material 12. It should be recognised that in other embodiments, one or both of the first and second blocking members 4, 5 does not comprise aerosol-generating material.

An advantage of the first and/or second blocking members 4, 5 comprising aerosol- generating material 11, 12 is that the first and/or second blocking member 4, 5 is able to resist aerosol-generating material 3 from falling out of the space 2 and the first and/or second blocking member 4, 5 is also able to itself generate aerosol, thereby saving space and materials in comparison to arrangements wherein a separate blocking member and further aerosol generating region are provided. Also, the aerosol generating material 11, 12 of the first and/or second blocking member 4, 5 can be provided with one or more properties that are different to the aerosol-generating material 3 in the space 2.

In some embodiments, the aerosol-generating material 11, 12 of the first and/or second blocking members 4, 5 may comprise, consist of, or essentially consist of, tobacco material. As explained previously, the term “tobacco material” refers to any material comprising tobacco or derivatives or substitutes thereof. The tobacco material maybe in any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and/or tobacco extract.

In some embodiments, the body of material 6, 7 of the first and/or second blocking member 4, 5 additionally, or alternatively, comprises one or more aerosol-former materials. For example, the first and/ or second body of material 6, 7 may additionally or alternatively 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.

The first body of material 6 of the first blocking member 4 comprises a first end 6A that faces towards the space 2 and contacts the aerosol-generating material 3 in the space 2.

The first body of material 6 comprises a second end 6B that faces away from the space 2. In the present example, the second end 6B forms a first end 1A of the article i (that is, no component of the article 1 is provided on the opposite side of the first body of material 6 to the space 2). The second body of material 7 of the second blocking member 5 comprises a first end 7A that faces towards the space 2 and contacts the aerosol-generating material 3 in the space 2. The second body of material 7 comprises a second end 7B that faces away from the space 2. In the present example, the second end 7B forms a second end 1B of the article 1 (that is, no component of the article 1 is provided on the opposite side of the second body of material 7 to the space 2).

The first and second ends 1A, 1B of the article 1 are at outer extremities of the article 1. One of the first and second ends 1A, 1B is the upstream end P of the article 1 and the other one of the first and second ends 1A, 1B is the downstream end D of the article 1.

The aerosol generating material 3 may be provided in the space 2 as a loose material, that is retained in the space 2 by the first and second blocking members 4, 5. The aerosol generating material 3 may, for example, be discrete strands or particles of aerosol generating material 3. Another example of loose aerosol generating material 3 is beads/pellets of aerosol generating material 3, including aerosol generating material that has been extruded and then cut into beads/pellets. Yet another example of aerosol generating material 3 is a sheet of aerosol generating material that has been cut into individual pieces, for example, cut into individual strips of aerosol generating material

3. The sheet of aerosol generating material may be a sheet of reconstituted tobacco.

The aerosol generating material 3 in the space 2 may be referred to as a first aerosol generating material 3. In embodiments wherein the body of material 6 of the first blocking member 4 comprises an aerosol generating material 11, this maybe referred to as a second aerosol generating material 11. In embodiments wherein the body of material 7 of the second blocking member 5 comprises an aerosol generating material

12, this maybe referred to as a third aerosol generating material 12. It should be noted that the first, second and/or third aerosol-generating material 3, 11, 12 maybe the same. The article 1 may comprise first, second and third regions 3A, 11A, 12A that respectively comprise the first, second and third aerosol generating material 3, 11, 12. The first, second and third regions 3A, 11A, 12A may be discrete regions. In some embodiments, the first aerosol-generating material 3 has at least one different characteristic to the second and/ or third aerosol generating materials 11, 12. The different characteristic may be one or more of form, size, density, water content, amount (by weight), material or materials, or proportion of materials that make the first, second and third aerosol-generating materials 3, 11, 12 (including the recipe of the aerosol generating materials 3, 11, 12 when each is manufactured more than one material). In a preferred embodiment, the second and third aerosol-generating materials 11, 12 are the same, and the first aerosol-generating material has said at least one different characteristic from the second and third aerosol-generating materials 11, 12. In other embodiments, the first, second and third aerosol-generating materials 3, 11, 12 do not have a different characteristic and instead are the same.

In some embodiments, the first, second and/or third aerosol-generating material 3, 11, 12 may comprise the same material, for example, tobacco, that has a different characteristic. In one such embodiment, the first, second and/or third aerosol generating material 3, 11, 12 maybe in different forms and, preferably, the second and third aerosol-generating material 11, 12 have the same form which is different to the form of the first aerosol-generating material 3.

For example, the first aerosol generating material 3 maybe in the form of beads or pellets of aerosol generating material (for example, tobacco or another material) and the second and/or third aerosol generating material 11, 12 maybe in the form of, for example: strands or strips of aerosol generating material (for example, tobacco or another material); a sheet of aerosol generating material that is gathered into a plug or is cut into strips; loose material (e.g. cut rag tobacco); a dense end of a rod of aerosol generating material (e.g. tobacco); or, tobacco lamina and/or stem material that has been formed into a plug. However, it should be recognised that the first second, and/or third aerosol generating material 3, 11, 12 may alternatively have the same form (e.g. both being cut rag tobacco) and have some other differing characteristic (e.g. different densities of material). In some embodiments, the first, second and/or third aerosol generating materials 3, 11, 12 may release one or more volatile compounds at different rates when heated. This allows for a more consistent delivery of said compounds over the duration of the consumption session of the article 1. For example, the second aerosol generating material 11 may reach a given temperature more quickly than the first aerosol generating material 3 when heated by a particular power of heater. This may cause the second aerosol generating material 11 to initially release volatile compounds at a greater rate than the first aerosol generating material 3. In one such embodiment, the second aerosol generating material 11 may provide the release of volatile compounds during a first period of the consumption session and the first aerosol generating material 3 may provide the release of volatile compounds during a later second period of the consumption session. In one such embodiment, the second aerosol generating material 11 is heated during the first period and the first aerosol generating material 3 is heated during the second period of the consumption session. Alternatively, or additionally, the third aerosol generating material 12 may reach a given temperature more quickly than the first aerosol generating material 3 when heated by a particular power of heater. This may cause the second aerosol generating material 11 to initially release volatile compounds at a greater rate than the first aerosol generating material. In some embodiments, the second and third aerosol generating materials 11, 12 may release volatile compounds at the same rate, or substantially the same rate, when heated to a given temperature.

In some embodiments, the first aerosol generating material 3 initially releases one or more volatile compounds at a faster rate than the second aerosol generating material 11 when subjected to a given heating power. In other embodiments, the first aerosol generating material 3 releases one or more volatile compounds at a slower rate than the second aerosol generating material 11 when subjected to a given heating power.

Additionally, or alternatively, in some embodiments the first aerosol generating material 3 releases one or more volatile compounds at a faster rate than the third aerosol generating material 12 when subjected to a given heating power. In other embodiments, the first aerosol generating material 3 releases one or more volatile compounds at a slower rate than the third aerosol generating material 12 when subjected to a given heating power. In one embodiment, the first, second and/ or third aerosol generating material 3, 11, 12 may comprise beads/pellets of aerosol generating material, which have been found to release volatile compounds at a relatively slow rate. In some such embodiments, the other(s) of the first, second and/or third aerosol generating material(s) 3, 11, 12 comprises one or more of: tobacco lamina; tobacco stems or reconstituted tobacco. In one such embodiment, said other(s) of the first, second and/or third aerosol generating material(s) 3, 11, 12 comprises a mixture of tobacco lamina and reconstituted tobacco.

In the present example, the first aerosol-generating material 3 comprises tobacco beads and the second and third aerosol-generating materials 11, 12 comprise another tobacco material, for example, tobacco lamina, reconstituted tobacco or a mixture of tobacco lamina and reconstituted tobacco.

In other embodiments, the first, second and third aerosol generating materials 3, 11, 12 are the same.

Advantageously, the body of material 6 of the first blocking member 4 is arranged to resist the aerosol generating material 3 from falling out of the first end 2A of the space 2. This reduces the size and weight of the article 1 and the amount of materials required to manufacture the article 1, because the article 1 does not require a further component (e.g. a separate blocking member) to resist the aerosol generating material 3 from falling out of the first end 2A the space 2.

In addition, the first body of material 6 can perform a further function of the article 1 in addition to retaining the aerosol generating material 3 in the space 2. In the present example, the first body of material 6 comprises an aerosol generating material 11 and thus the first body of material 6 performs both the function of retaining the aerosol generating material 3 in the space 2 and also the function of releasing one or more volatile compounds when heated. Similarly, the first body of material 6 may alternatively or additionally comprise an aerosol-former material and thus performs the function of forming an aerosol in addition to retaining the aerosol generating material 3 in the space 2. In other embodiments, the first body of material 6 may comprise a filter (for example, paper gathered into a plug) that performs the function of filtering the flow of gas as it passes through the article 1 in addition to retaining the aerosol generating material 3 in the space 2. Advantageously, the body of material 7 of the second blocking member 5 is arranged to resist the aerosol generating material 3 from falling out of the second end 2B of the space 2. This reduces the size and weight of the article 1 and the amount of materials required to manufacture the article 1, because the article 1 does not require a further component (e.g. a separate blocking member) to resist the aerosol generating material

3 from falling out of the second end 2B of the space 2.

In addition, the second body of material 7 can perform a further function of the article 1 in addition to retaining the aerosol generating material 3 in the space 2. In the present example, the second body of material 7 comprises an aerosol generating material 12 and thus the second body of material 7 performs both the function of retaining the aerosol generating material 3 in the space 2 and also the function of releasing one or more volatile compounds when heated. Similarly, the second body of material 7 may alternatively or additionally comprise an aerosol-former material and thus also performs the function of forming an aerosol in addition to retaining the aerosol generating material 3 in the space 2. In other embodiments, the second body of material 7 may comprise a filter (for example, paper gathered into a plug) that also performs the function of filtering the flow of gas as it passes through the article 1 in addition to retaining the aerosol generating material in the space 2.

It should be recognised that in other embodiments (not shown), the second blocking member 5 may not comprise the second body of material 7 and, for example, may instead comprise a mesh, sheet material or label that is applied to the second end of the space 2 to prevent the aerosol-generating material 3 from falling out of the second end 2B of the space 2 (and, for example, the sheet material/label may comprise one or more apertures to allow for the flow of gas therethrough). In some embodiments (not shown), the second blocking member 5 may be omitted entirely. However, it has been found that the first and second blocking members 4, 5 comprising respective bodies of material 6, 7 makes it relatively easy to retain the blocking members 4, 5 in position relative to the space 2 by using, for example, the sheet material 10 that circumscribes the first and second blocking members 4, 5.

The first, second and/or third aerosol-generating material 3, 11, 12 may comprise a plurality of strands or strips of aerosol-generating material. For example, the first, second and/or third aerosol-generating material 3, 11, 12 may comprise a plurality of strands or strips of an aerosolisable material and/or a plurality of strands or strips of an amorphous solid.

The first, second and/or third aerosol-generating material 3, 11, 12 may comprise a plant based material, such as a tobacco material. The first, second and/ or third aerosolgenerating material 3, 11, 12 maybe 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 of the first, second and/or third aerosol-generating material 3, 11, 12 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, all of the first, second and third aerosol generating materials 3, 11, 12 comprise, consist of, or essentially consist of tobacco material.

An aerosol-former material may be mixed with, or otherwise added to, the first, second and/or third aerosol-generating material 3, 11, 12. The aerosol-former material comprises one or more constituents capable of forming an aerosol. The aerosol-former material comprises one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso- Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol-former material can be glycerol or propylene glycol. In some embodiments, the first, second and/or third aerosol-generating material 3, 11, 12 comprises a sheet or shredded sheet of aerosolisable material that comprises an aerosol-former material. Optionally, the aerosol-former material is provided in an amount of up to about 50% on a dry weight base by weight of the sheet or shredded sheet. In some embodiments, the aerosol-former material is provided in an amount of from about 5% to about 40% on a dry weight base by weight of the sheet or shredded sheet, from about 10% to about 30% on a dry weight base by weight of the sheet or shredded sheet or from about 10% to about 20% on a dry weight base by weight of the sheet or shredded sheet.

The first, second and/or third aerosol-generating material 3, 11, 12 may comprise a filler. In some embodiments, the sheet or shredded sheet comprises the filler. The filler is generally a non-tobacco 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 maybe a non-tobacco fibre such as wood fibre or pulp or wheat fibre. The filler can be a material comprising cellulose or a material comprises a derivate of cellulose. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material.

The first, second and/or third aerosol-generating material 3, 11, 12 herein can comprise an aerosol modifying agent, such as any of the flavours described herein. In one embodiment, the first, second and/or third aerosol-generating material 3, 11, 12 comprises menthol. When the first, second and/or third aerosol-generating material 3, 11, 12 is incorporated into an article 1 for use in an aerosol-provision system, the article may be referred to as a mentholated article 1. The first, second and/ or third aerosolgenerating material 3, 11, 12 can comprise from o.smg 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. The aerosol-generating material may comprise the first, second and/or third aerosol-generating material 3, 1112. An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material (for example, the first, second and/or third aerosol-generating material 3, 11 12) may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants. The aerosol-generating material (for example, the first, second and/or third aerosolgenerating material 3, 1112) may comprise a binder and an aerosol former. Optionally, an active and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material (for example, the first, second and/or third aerosol-generating material 3, 11 12) is substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material (for example, the first, second and/or third aerosolgenerating material 3, 1112) is substantially tobacco free. The aerosol-generating material (for example, the first, second and/or third aerosolgenerating material 3, 1112) may comprise or be an “amorphous solid”. The amorphous solid maybe a “monolithic solid”. In some embodiments, the amorphous solid maybe a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating material may, for example, comprise from about 50wt%, 6owt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid. The amorphous solid maybe substantially non-fibrous.

The aerosol-generating material (for example, the first, second and/ or third aerosol- generating material 3, 1112) may comprise or be an aerosol-generating film. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as active substances, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film. The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent. The aerosol-generating film may be a continuous film or a discontinuous film, such an arrangement of discrete portions of film on a support. The aerosol-generating film may be substantially tobacco free. The aerosol-generating film may comprise or be a sheet, which may optionally be shredded to form a shredded sheet. The aerosol-generating material (for example, the first, second and/or third aerosolgenerating material 3, 1112) may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

In each of the embodiments of article 1 described herein, the article may comprise such a first, second and/or third aerosol-generating material 3, 1112, and may comprise such an aerosol-generating composition. The first, second and/or third aerosol-generating material 3, 11, 12 can comprise a paper reconstituted tobacco material. The composition can alternatively or additionally comprise any of the forms of tobacco described herein. The first, second and/or third aerosol-generating material 3, 11, 12 can comprise a sheet or shredded sheet comprising tobacco material comprising between 10% and 90% by weight tobacco leaf, wherein an aerosol-former material is provided in an amount of up to about 20% by weight of the sheet or shredded sheet, and the remainder of the tobacco material comprises paper reconstituted tobacco.

Where the first, second and/or third aerosol-generating material 3, 11, 12 comprises an amorphous solid material, the amorphous solid material may be a dried gel comprising menthol.

In some embodiments, the first, second and/or third aerosol-generating material 3, 11, 12 comprises an extruded aerosol generating material that is then cut into beads of pellets.

In the present example, the first aerosol-generating material 3 (i.e. provided in the space 2) comprises tobacco beads, the second aerosol-generating material 11 (i.e. of the first body of material 6) comprises a plug of tobacco lamina and/or shredded reconstituted tobacco and the third aerosol -generating material 12 (i.e. of the second body of material 7) comprises a plug of tobacco lamina and/or shredded reconstituted tobacco.

In the above described embodiments, the body of material 6, 7 of the first and/or second blocking member 4, 5 comprises a plug of aerosol generating material 11, 12, for example, a plug of tobacco fibres, or strips of reconstituted tobacco, or a sheet of reconstituted tobacco that is gathered into a plug. In one embodiment, the body of material 6 , 7 of the first and/ or second blocking member 4, 5 is formed from a crimped sheet of aerosol generating material (for example, reconstituted tobacco). Apparatus and methods for manufacturing a crimped web for use in an aerosol- generating article 1 are known in the art and generally involve feeding the web or sheets between a pair of interleaved rollers that apply a plurality of parallel, equidistant longitudinally extending crimp corrugations to the web or sheet. Once crimped, the sheet or web is gathered to form a continuous rod. In some embodiments, the body of material 6, 7 of the first and/or second blocking member 4, 5 is formed from a sheet of material that has aerosol generating material 11, 12 added during casting of the sheet. For example, the sheet material maybe cast from a slurry, wherein aerosol generating material (e.g. fibres, granules, pellets, beads or dust, including tobacco fibres, granules, pellets, beads or dust and/or other plant materials) is added to the slurry during casting. In other embodiments, the aerosol generating material is added to the sheet material once the sheet material has been formed. For example, aerosol generating material (e.g. fibres, granules, pellets, beads or dust, including tobacco fibres, granules, pellets, beads or dust and/or other plant materials) is adhered to the sheet material using an adhesive or is applied to the sheet material and then held within the sheet material when it is gathered into a plug. In some embodiments, the sheet material comprises a paper or gel sheet and the aerosol generating material is incorporated within or applied to the sheet.

It should be recognised that in other embodiments the body of material 6, 7 of the first and/or second blocking member 4, 5 does not comprise an aerosol generating material.

For example, in one alternative embodiment the body of material 6, 7 of the first and/or second blocking member 4, 5 comprises paper formed into a plug (for example, being crimped or cut into strips and formed into the plug), without any aerosol generating material applied to or incorporated within the sheet material of the plug.

An example of a blocking member that comprises a sheet material is shown in Fig. 9. In Fig. 9, the first blocking member 4 is shown, but additionally, or alternatively, the second blocking member 5 could have the configuration shown in Fig. 9. In the embodiment of Fig. 9, the body of material 6 of the first blocking member 4 comprises a sheet material 11B that has been gathered to form the body of material 6. The first blocking member 4 may have any of the features previously described. For example, the sheet material 11B may comprise an aerosol generating material 11 and/or aerosol-former material (the aerosol generating material and/or aerosol formermaterial either being formed with the sheet material during manufacture of the sheet material or subsequently applied to the sheet material). In one embodiment, the sheet material 11B comprises aerosol generating material. In some embodiments, the sheet material 11B comprises tobacco material and/or a gel. In one embodiment, the sheet material 11B comprises paper. The sheet material may be crimped and gathered to form a plug. In other embodiments, the sheet material may be rolled-up (e.g. in a spiral) to form the body of material 6. In yet further embodiments, the sheet material 11B maybe cut into strips and/or strands which are then formed into the body of material 6. In some embodiments, the first blocking member 4 further comprises wrapper 8 that circumscribes the body of material 6. The body of material 6 resists the aerosol-generating material 3 in the space 2 from falling out of the end of the space 2.

Another example of a blocking member 4 is shown in Fig. 10. In Fig. 10, the first blocking member 4 is shown, but additionally, or alternatively, the second blocking member 5 could have the configuration shown in Fig. 10.

In the embodiment of Fig. 10, the first blocking member 4 comprises the end portion 17 of a body of material 6 that is in the form of a rod 6 of aerosol generating material 11. Optionally, said end portion 17 of the rod 6 has a higher density than another portion 18 of the rod 6. For example, the end portion 17 may be at least 10% and, preferably, at least 20%, denser than said another portion 18 of the rod 16 (and said another portion 18 may be adjacent to said end portion 17).

In some embodiments, the rod 6 is a tobacco rod. In some embodiments, said another portion 18 of the rod 6 is the remaining length of the rod 6. The end portion 17 may extend a first region along the length of the rod 6 and the another portion 18 may extend a second region along the length of the rod 6, which may be the remaining axial length of the rod 6. In some embodiments, article 1 comprises a wrapper 8 that circumscribes the rod 6. The end portion 17 of the rod 6 having an increased density helps to prevent the aerosol-generating material 3 from falling out of the space 2. Furthermore, the end portion 17 of the rod 6 having an increased density helps to prevent material of the end portion 17 from falling out of the end portion 17 and mixing with the aerosol generating material 3 in the space 2.

In some embodiments, the end portion 17 of the rod 6 comprises a greater amount of material per unit axial length (e.g. per mm) of the rod 6 than said another portion 18. That is, the end portion of the rod 17 has a greater mass of material per unit axial length (e.g. per mm) than said another portion 18. For example, the end portion 17 comprises a greater amount of aerosol generating material 11, aerosol-former material, filler material and/or other material. Thus, when the aerosol generating material 11 is formed into the rod 6 (for example, using a rod forming apparatus as will be known to a person killed in the art), the increased amount of material at the end portion 17 causes the rod 6 to have an increased density at the end portion 17 compared to said another portion 18 of the rod 6. In some embodiments, the end portion 17 of the rod 16 comprises at least 10% (by weight) and, preferably, at least 20 % (by weight) of material per mm of length of the rod 16 than said another portion 18 of the rod 16. According to the present disclosure, there is also provided a method of manufacturing an article 1 for an aerosol provision device 200. The method comprises providing an aerosol-generating material 3 and a first blocking member 4 comprising a body of material 6, wherein the aerosol-generating material 3 and first blocking member 4 are arranged such that the aerosol-generating material 3 is contained in a space 2 and the first blocking member 4 resists the aerosol-generating material 3 from moving out of (e.g. falling out of) a first end 2A of the space 2.

The first blocking member 4 may have any of the features described herein. The method may further comprise wrapping a first wrapper 8 about the body of material 6 of the first blocking member 4.

In some embodiments, providing the aerosol-generating material 3 and first blocking member 4 comprises locating the aerosol-generating material 3 and first blocking member 4 on a sheet material 10 and, preferably, wherein the sheet material 10 comprises paper and/or foil. In some embodiments, the method comprises wrapping the sheet material 10 about the aerosol-generating material 3 and first blocking member 4.

In some embodiments, the method further comprises providing a second blocking member 5 arranged such that the second blocking member 5 resists the aerosolgenerating material 3 from moving out of (e.g. falling out of) a second end 2B of the space 2 and, preferably, the second blocking member 5 comprises a body of material 7.

In some embodiments, the second blocking member 5 has any of the features described herein, including any of the features of the first blocking member 4.

In some embodiments, the first and second blocking members 4, 5 each at least partially define a boundary of the space 2. In some embodiments, the first and/or second blocking member 4, 5 is separate and distinct from the sheet material 10.

In some embodiments, the method comprises forming a body of material 6 and, optionally, wrapping the body of material 6 in a first wrapper 8.

In some embodiments, the body of material 6 of the first blocking member 4 is a tobacco plug 6 and the first wrapper 8 circumscribes the tobacco plug 6.

In some embodiments, the method comprises forming a body of material 7 and, optionally, wrapping the body of material 7 in a second wrapper 9.

In some embodiments, the body of material 7 of the second blocking member 5 is a tobacco plug 7 and the second wrapper 9 circumscribes the tobacco plug 7. In some embodiments, the body of material 6, 7 of the first and/or second blocking member 4, 5 is gas permeable.

In some embodiments, the first and second blocking members 4, 5 have the same form and/or composition. In some embodiments, the first and second blocking members 4, 5 have the same features and maybe identical.

In some embodiments, the first and second blocking members 4, 5 each comprise tobacco and, preferably, each comprise a plug of tobacco.

In some embodiments, the first blocking member 4 comprises a first end 1A of the article 1 and the second blocking member 5 comprises a second end 1B of the article 1. In some embodiments, the method comprises wrapping a second wrapper 9 about the body of material 7 of the second blocking member 5.

It should be recognised that in other embodiments, the first and/ or second wrapper 8, 9 maybe omitted.

In some embodiments, the method comprises positioning the first and second blocking members 4, 5 on the sheet material 10 such that a gap G is formed therebetween, and at least partially filling the gap G with the aerosol-generating material 3. In some embodiments, the sheet material 10 with the first and second blocking members 4, 5 thereon is conveyed along a conveyance path.

In some embodiments, the gap G is at least partially filled with the aerosol-generating material 3 as the sheet material 10 with the first and second blocking members 4, 5 thereon passes a filling apparatus.

In some embodiments, the method comprises providing a plurality of first blocking members 4 and second blocking members 5 arranged sequentially on a web W of the sheet material 10, and filling gaps G between adjacent first and second blocking members 4, 5 with aerosol-generating material 3.

In some embodiments, the method comprises wrapping the first and second blocking members 4, 5 and aerosol-generating material 3 with the sheet material 10 to form a rod, and then cutting the rod to form an article 1. In some embodiments, the method comprises forming the sheet material 10 into a wall loAthat surrounds the space 2 containing the aerosol generating material 3.

In some embodiments, the aerosol-generating material 3 in the space is a solid material.

In some embodiments, the aerosol-generating material 3 in the space is a loose material. In some embodiments, the aerosol-generating material 3 in the space is in the form of discrete particles.

In some embodiments, the aerosol-generating material 3 is provided in metered amounts, for example, using a dosage wheel that supplies the aerosol generating material 10 on to the sheet material 10.

In some embodiments, the aerosol-generating material 3 in the space comprises, consists of, or essentially consists of, tobacco material. In some embodiments, the tobacco material is only tobacco lamina and no other types of tobacco material.

In some embodiments, the tobacco material has a nicotine level in the range of 0.6% to 2.5% and, preferably, in the range of 1% to 2.1%.

In some embodiments, the method further comprises providing a cooling section and, preferably, arranging the cooling section such that, in use of the article 1, the cooling section is downstream of the aerosol-generating material 3. In some embodiments, the cooling section comprises aerosol-generating material and, preferably, comprises a plug of aerosol generating material. In some embodiments, the cooling section comprises a flavourant, for example, the aerosol-generating material of the cooling section may comprise flavourant. The cooling section may comprise gel, for example, a gel plug.

In some embodiments, the method further comprises providing a plug of material or other component on the other side of the first and/or second blocking member 4, 5 to the space 2. Referring now to Fig. 5, block diagram depicting an exemplary embodiment of a method 100 of manufacturing an article 1 for an aerosol provision device is shown.

The method 100 comprises the step (Si) of arranging first and second blocking members 4, 5 on a sheet material 10 such that the first and second blocking members 4, 5 are axially spaced to form a gap G therebetween. The method 100 comprises the step (S2) of providing an aerosol-generating material 3 in the gap G between the first and second blocking members 4, 5. The method 100 comprises the step (S3) of wrapping the sheet material 10 about the aerosol-generating material 3 and the first and second blocking members 4, 5 such that the sheet material 10 forms a wall that surrounds the aerosol-generating material and the first and second blocking members 4, 5.

Optionally, the method 100 may comprise manufacturing a plurality of articles 1 according to a continuous process.

The step (Si) may comprise providing a plurality of double-length first blocking members 104 and a plurality of double-length second blocking members 105 on a web W of sheet material 10 such that the double-length first and second blocking members 104, 105 are alternately arranged on the sheet material 10 with a gap G between adjacent double-length first and second blocking members 104, 105. Step (Si) is depicted in Fig. 7A. Each gap G forms a space 2 that is filled, or at least partially filled, with aerosol-generating material 3.

The step (S2) may comprise providing aerosol-generating material 3 in the plurality of gaps G. For example, the web W may be conveyed along a conveyance path P such that each gap G passes a filling apparatus F that provides each gap G with aerosolgenerating material 3 as it passes. The filling apparatus F may comprise, for example, a hopper, conveyor belt, pneumatic pipe feeding system or filling drum that is configured to provide each gap G with aerosol-generating material 3. In some embodiments, the section of the web W passing the filling apparatus F maybe gathered in a U-shaped tongue or garniture that bends the sheet material 10 to help collect the aerosolgenerating material 3 in the gap G. Step (S2) is depicted in Figs. 7B and 8.

The step (S3) may comprise wrapping the sheet material 10 of the web W about the end (i.e. two most forward) double-length first and second blocking members 104, 105 after the aerosol-generating material 3 has been provided therebetween to form a rod 106. For example, the end of the web W and the end double-length first and second blocking members 104, 105 may be fed through a wrapping apparatus, as will be known to a person skilled in the art. Step (S3) is depicted in Fig. 7C. The wrapping apparatus (not shown) may, for example, comprise a garniture tongue (not shown), a garniture belt (not shown) and a belt drive (not shown) that drives the garniture belt (not shown). The belt drive may comprise, for example, one or more pulleys or wheels that are driven by an electric motor to drive the garniture belt. The garniture belt extends through the garniture tongue. The web W overlies the garniture belt such that operation of the belt drive feeds the web W through the garniture tongue.

The garniture tongue comprises a first portion (not shown) that is shaped to form the web W into a U-shape as it passes through the garniture tongue. Optionally, the filling apparatus F is configured to deposit the aerosol-generating material 3 on the U-shaped web W between adjacent double-length plugs 104, 105. In alternative embodiments, the aerosol-generating material 3 is deposited on the web W at another position, for example, upstream of the first portion of the garniture tongue.

The U-shaped web W then passes through a second portion (not shown) of the garniture tongue that is shaped to fold a first longitudinal edge (not shown) of the web W over an opposite second longitudinal edge (not shown) such that the web W exiting the garniture tongue is formed into a cylinder. In some embodiments, the first portion of the garniture tongue is generally U-shaped in cross-section and the second portion of the garniture tongue is generally O-shaped in cross-section. In some embodiments, the wrapping apparatus further comprises an adhesive applicator (not shown) configured to apply a line of adhesive to the web W such that when the W passes through the second portion (not shown) of the garniture tongue, the first longitudinal edge is folded over the opposite second longitudinal edge of the web W and is glued in position by the line of adhesive. Thus, a continuous rod 106 is formed comprising the first and second double-length blocking members 4, 5 with the aerosolgenerating material 3 in the gap G therebetween and circumscribed by the web W.

In alternative embodiments (not shown), the wrapping apparatus has a different arrangement, for example, comprising a drum or conveyor belt that is configured to advance the double-length blocking members 104, 105 and web W along a conveyance path. In one such embodiment, the double-length blocking members 104, 105 are disposed on a wrapper that is located in the flute of a drum that is rotated to move the blocking members and wrapper along an arcuate conveyance path. The first/second filler material is fed onto the wrapper between the double-length blocking members the drum is rotated to move the wrapper and double-length blocking members along the conveyance path.

The method 100 may further comprise cutting the continuous rod 106 to form an article 1. Initially, the continuous rod 106 will have a double-length first blocking member 104 and a double-length second blocking member 105, wherein the double- length first blocking member 104 is cut along a first cut line (shown by dashed-line Yi-

Yi in Fig. 7C) and the double-length second blocking member 105 is cut along a second cut line (shown by dashed line Y2-Y2 in Fig. 7C). Thereafter, the continuous rod 106 will comprise a single first or second blocking member 4, 5 at its end (as shown in Fig. 7D), such that a single cut can be provided through the adjacent double-length first or second blocking member 104, 105 in order to form the article 1.

In some embodiments, the rod 106 is continuously formed and the end of the rod 106 is repeatedly cut to form a plurality of articles 1. In some embodiments, the rod 106 is cut so as to form a collation of double-length first and second blocking members 104, 105. The collation is then further cut to form individual articles 1.

In the above described example, the method 100 comprises providing double-length first and second blocking members 104, 105 on the sheet material 10. However, it should be recognised that in alternative embodiments the method 100 may comprise providing single-length blocking members 4, 5 on the sheet material 10 with a gap G therebetween and filling the gap G with aerosol-generating material 3. For example, Fig. 6A shows first and second blocking members 4, 5 being positioned on a sheet material 10; Fig. 6B shows an aerosol-generating material 3 being provided on the sheet material 10 in the space 2 between the first and second blocking members 4, 5; and, Fig. 6C shows the sheet material 10 being wrapped about the first and second blocking members 4, 5 to form the article 1. In some embodiments, the method 100 further comprises providing a cooling section and incorporating the cooling section into the article and, preferably, wherein the cooling section is disposed such that, in use of the article 1, the cooling section is downstream of the blocking members 4, 5. In some embodiments, the cooling section comprises aerosol-generating material and, preferably, comprises a plug of aerosol generating material. In some embodiments, the cooling section comprises a flavourant, for example, the aerosol-generating material of the cooling section may comprise flavourant. The cooling section may comprise gel, for example, a gel plug.

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

In some embodiments, the method 100 further comprises providing one or more further plugs of material (not shown) or other component(s) on the other side of the first and/or second blocking member 4, 5 to the space 2. The further plug of material may comprise, for example, a section of filtration material or a cooling section and/or flavouring section.

Referring now to Figs. 11 to 13, an embodiment of an aerosol provision device 200 is shown.

The article 1 is configured for use in an aerosol provision device 200 (see Fig. 11) comprising an aerosol generator in the form of a heating element 203 for heating the article 1. In the present example, the heating element 203 at least partially surrounds a heating area 202, for example, a heating chamber 202. The heating element 203 may be resistively and/or inductively heated.

In other embodiments (not shown), the heating element 203 instead comprises a blade or pin, for insertion into the article 1, for example, the blade or pin maybe inserted into one or both of the first and second blocking members 4, 5 and optimally also the aerosol generating material 3 in the space 2. In other embodiments (not shown), the article 1 may comprise the heating element which, for example, maybe embedded in the aerosol generating material 3 and/or first and/ or second blocking members 4, 5.

In Fig. 11, 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. 11. Elements that are not relevant for the understanding of this embodiment have been omitted to simplify Fig. 11.

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

When the article 1 is received into the heating area 202, at least a portion of the article 1 comes into thermal proximity with the heater 203. Thus, at least a portion of the aerosol generating material 3 in the space 2 and/or the aerosol generating material 11, 12 of the first and/or second blocking members 4, 5 is in thermal proximity with the heater 203. In some embodiments, the heater 203 is spaced from the article 1, for example, circumscribing the article 1 but having a larger diameter and being spaced therefrom. In other embodiments, the heater 203 is in direct contact with the article 1, for example, contacting an outer surface of the wrapper 10 of the article 1. In another embodiment, the heater 203 comprises a blade or pin that contacts the inside of the article 1, for example, contacting the aerosol generating material 3 in the space 2 and/or the body of material 6, 7 of the first and/or second blocking member 4, 5. When the article 1 is heated, the aerosol generating material 3 in the space 2 and/or the aerosol generating material 11, 12 of the first and/ or second blocking member 4, 5 will release one or more volatile compounds and may release a range of volatile compounds at different temperatures. By controlling the maximum operation temperature of the electrically heated aerosol generating system 200, the selective release of undesirable compounds may be controlled by preventing the release of select volatile compounds.

As shown in Fig. 12, 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.

Fig. 13 is a schematic cross-section of a non-combustible aerosol-provision device 200 of the type shown in Fig. 11, with the article 1 received in the heating area 202 of the device 200 for heating by the heater 203. The non-combustible aerosol provision device 200 is illustrated receiving the aerosol-generating article 1 for consumption of the aerosol-generating article 1 by a user.

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

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

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

In the above described embodiments, the first and second blocking members 4, 5 form first and second ends 1A, 1B of the article 1 (i.e. the proximal end P or distal end D). However, it should be recognised that in alternative embodiments (not shown), the article 1 may comprise one or more further segments, for example, a further segment that is on the opposite side of the first blocking member 4 to the space 2 and/or on the opposite side of the second blocking member 5 to the space 2. For example, an alternative embodiment of an article 1 is shown in Fig. 14 which further comprises a cooling section 25, also referred to as a cooling element, positioned immediately downstream of and adjacent to the second blocking member 5. In the present example, the cooling element 25 is immediately downstream of and adjacent to the second blocking member 5. In some such embodiments, the cooling element 25 is in an abutting relationship with the second blocking member 5. 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 aerosol generating material 3 can pass longitudinally through the one or more hollow channels.

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

The body of material 26 defines a substantially cylindrical overall outer shape and is wrapped in a plug wrap 28. The plug wrap 28 can have a basis weight of less than 50 gsm, or between about 20 gsm and 40 gsm. The plug wrap 28 can have a thickness of between 30 pm and 60 pm, or between 35 pm and 45 pm. The plug wrap 28 may be a non-porous plug wrap, for instance having a permeability of less than 100 Coresta units, for instance less than 50 Coresta units. However, in other embodiments, the plug wrap 28 can be a porous plug wrap, for instance having a permeability of at least 100 Coresta Units or at least 200 Coresta Units. The cooling element 25 and/or body of material 26 may form a mouthpiece of the article 1 that is configured to be received within the mouth of the user. In some embodiments, the mouthpiece 207 of the device 200 may be omitted.

In some embodiments, a tipping paper (not shown) is wrapped around the cooling element 25 and body of material 26 and also circumscribes the wrapper 10 that circumscribes the first and second blocking members 4, 5, and maybe connected to these components by adhesive. Thus, the tipping paper connects the cooling element 25 and body of material 26 to the blocking members 4, 5. In other embodiments, the tipping paper is omitted and instead the sheet material 10 extends to circumscribe the cooling element 25 and body of material 26 to connect these components to the first and second blocking members 4, 5. In the embodiment of the article 1 described above in relation to Fig. 1, the article i comprises aerosol-generating material along the entire axial length (shown by arrow ‘X’ in Fig. 1) of the article 1. That is, the first aerosol generating material 3 extends over a first portion of the axial length of the article 1, the second aerosol generating material n extends over a first portion of the axial length of the article 1, and, the third aerosol generating material 12 extends over a first portion of the axial length of the article 1. The first, second and third portions of the axial length of the article 1 comprise the entire axial length of the article 1.

The aerosol generating material 3, 11, 12 extending along the entire length of the article 1 has the advantage of increasing the amount of volatile compounds that are released by the article 1 when the article 1 is heated for a given size of article 1. This means that the article 1 can be transported and stored more easily.

Although in embodiment of Fig. 1 the aerosol generating material 3, 11, 12 extends over the entire axial length of the article 1, it should be recognised that in other embodiments the aerosol generating material may extend over at least 90% of the article. Such an arrangement has still been found to beneficially increase the release of volatile compounds in comparison to articles that have aerosol generating material provided over less than 90% of the axial length of the article. Preferably, aerosol generating material is provided over at least 92%, 94%, 96%, 98% or 99% of the length of the article and, preferably, over substantially the entire length of the article. Examples of three further embodiments of article 1 that comprise aerosol generating material over the entire length of the article are described below in relation to Figs. 15 to 17.

Referring to Fig. 15, an embodiment of an article 1 for an aerosol provision device 200 is shown that comprises aerosol generating material 3 over the entire axial length (shown by arrow ‘X’ in Fig. 15) of the article 1. In particular, the article 1 comprises a rod of aerosol generating material 3 that extends from the first end 1A of the article 1 to the second end 1B of the article 1. In the present example, the aerosol generating material 3 comprises tobacco material. In the present example, the tobacco material is a mixture of shredded reconstituted tobacco and shredded lamina tobacco that is mixed together. However, in other embodiments, the tobacco material maybe one of shredded reconstituted tobacco or shredded lamina tobacco, or may alternatively or additionally comprise another tobacco material. A sheet material 10 circumscribes the aerosol generating material 3 and comprises, for example, paper. Referring to Fig. 16, another embodiment of an article 1 for an aerosol provision device 200 is shown that comprises aerosol generating material 31, 32 over the entire axial length (shown by arrow ‘X’ in Fig. 16) of the article 1. In particular, the article 1 comprises a rod of a first aerosol generating material 31 that extends from the first end 1A of the article 1 to the second end 1B of the article 1. Moreover, the article 1 comprises a second aerosol generating material comprising compressed or extruded bodies of aerosol generating material 32 that are interspersed in the rod of the first aerosol generating material 31.

In the present example, the first and/or second aerosol generating material 31, 32 comprises tobacco material.

In the present example, first aerosol generating 31 is a mixture of shredded reconstituted tobacco and shredded lamina tobacco that is mixed together. However, in other embodiments, the tobacco material of the first aerosol generating material 31 may be one of shredded reconstituted tobacco or shredded lamina tobacco, or may alternatively or additionally comprise another tobacco material.

In the present example, second aerosol generating 32 is compressed or extruded tobacco. In the present example, the second aerosol generating material 32 is beads of tobacco material.

A sheet material 10 circumscribes the aerosol generating material 3 and comprises, for example, paper. Referring to Fig. 17, another embodiment of an article 1 for an aerosol provision device 200 is shown that comprises aerosol generating material 41, 42 over the entire axial length (shown by arrow ‘X’ in Fig. 17) of the article 1. In particular, the article 1 comprises a first body or rod of aerosol generating material 41 that extends over a first portion of the axial length of the article 1 and a further comprises a second body or rod of aerosol generating material 42 that extends over a remaining second portion of the axial length of the article 1. The first and second rods of aerosol generating material 41, 42, may comprise the same or different aerosol generating materials. In the present example, the first and second rods of aerosol generating material 41, 42 each comprise tobacco material. For example, the first rod of aerosol generating material 41 may comprise shredded lamina tobacco and the second rod of aerosol generating material 42 may comprise shredded reconstituted tobacco material. However, the first or second rods 41, 42 may alternatively comprise a different tobacco material. A sheet material 10 circumscribes the aerosol generating material 3 and comprises, for example, paper.

It should be recognised that in other embodiments (not shown), the article 1 may comprise three, four or more bodies or rods of aerosol generating material.

In all of the above examples, the aerosol generating material 3, 11, 12, 31, 32, 41, 42 may comprise, consist of, or essentially consist of extruded or compressed bodies of tobacco material and, preferably, the extruded or compressed bodies of tobacco material comprise beads of tobacco material.

In each of the above examples, 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.

In each of the above examples, 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.

In each of the above examples, 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 each of the above examples, the aerosol generating material 3, 11, 12, 31, 32, 41, 42 may comprise, consist of, or essentially consist of reconstituted tobacco and, preferably, comprises a shredded sheet of reconstituted tobacco. In all of the above examples, the aerosol generating material 3, 11, 12, 31, 32, 41, 42 may comprise, consist of, or essentially consist of lamina tobacco. In all of the above examples, the aerosol generating material 3, 11, 12, 31, 32, 41, 32 may comprise, consist of, or essentially consist of reconstituted tobacco and lamina tobacco and, preferably, the reconstituted tobacco and lamina tobacco are mixed together.

In all of the above examples, the aerosol generating material 3, 11, 12, 31, 32, 41, 42 may comprise, consist of, or essentially consist of a sheet of aerosol generating material that is gathered to form a body of material and, preferably, the sheet material is crimped. Preferably, the sheet is a sheet of reconstituted tobacco.

In all of the above examples, the aerosol generating material 3, 11, 12, 31, 32, 41, 42 may comprise, consist of, or essentially consist of a sheet of aerosol generating material that is cut into strips. Preferably, the sheet is a sheet of reconstituted tobacco. In all of the above examples, the aerosol generating material 3, 11, 12, 31, 32, 41, 42 may comprise tobacco material, and wherein the tobacco material is manufactured only from tobacco lamina and no other types of tobacco material.

In all of the above examples, the aerosol generating material 3, 11, 12, 31, 32, 41, 42 may comprise tobacco material that a nicotine level in the range of 0.6% to 2.5% and, preferably, in the range of 1% to 2.1%.

In each of the examples of article described above (including each of the articles shown in Figs. 1 to 14, 16 and 17), the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 may have different densities. Otherwise, the aerosol-generating materials 3, 11, 12, 31, 32,

41, 42 of the article may be the same or different. In other embodiments, the densities of the varoius aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 maybe the same.

In some examples, at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 has a higher density than at least one of the other aerosol generating material(s) 3,

11, 12, 31, 32, 41, 42.

It has been found that providing different densities of aerosol generating materials 3, 11, 12, 31, 32, 41, 42 means that the higher density material heats up slower when both materials are exposed to the same heating and thus the higher density material will release its volatile compounds (e.g. nicotine) at a slower rate than the lower density material.

For example, in the article 1 shown in Fig. 1, the first aerosol generating material 3 may have a greater density than the second and third aerosol generating materials 11, 12

(and optionally the second and third aerosol generating materials 11, 12 may have the same density) so that the first aerosol generating material 3 heats up slower than the second and third aerosol generating materials 11, 12 when exposed to the same heating and will release its volatile compounds (e.g. nicotine) at a slower rate than the second and third aerosol-generating materials 11, 12 (however, in other embodiments the reverse maybe true such that the second and/or third aerosol generating materials 11, 12 have a higher density than the first aerosol generating material 3). Thus, combining aerosol-generating materials with different densities provides a more consistent and longer-lasting release of volatile compound(s). In some embodiments, the aerosol- generating materials of different densities are combined with separate heating of these materials at optionally different times and/or different temperatures, thereby allowing the provision of a more tailored release of the volatile compound(s) over the period of consumption of the article, for example. Alternatively, it may be desirable to have a more rapid or greater release of volatiles towards the beginning of the consumption of the article, to provide the user with a greater initial impact from use. The capacity to control the aerosol generation and volatile compound release 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 another example, the article 1 of Fig. 16 or 17 may optionally comprise a first aerosol generating material 31, 41 that has a greater density than that of the second aerosol generating material 42.

In some embodiments, at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 has a density that is at least about 25% higher than the density of at least one of the other aerosol generating material(s) 3, 11, 12, 31, 32, 41, 42 and, optionally, at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70% or 75% higher. The said at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 may have a density that is no more than about 200% higher than the density of the at least one other aerosol generating material(s) 3, 11, 12, 31, 32, 41, 42 and, optionally, no more than about

150%, 125%, 100% or 75% higher. In some embodiments, said at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 has a density that is from about 25% to about 75% higher than the density of the at least one other aerosol generating material(s) 3, 11, 12, 31, 32, 41, 42. In some embodiments, said at least one of the aerosol generating materials 3, 11, 12, 31,

32, 41, 42 has a density of from at least about 0.4 g/ cm3 and optionally from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3. The said at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 may have a density of no more than about 2 g/cm3 and, optionally no more than about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6 or 0.5 g/cm3. In some embodiments, the density of said at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 is from about 0.4 to 1.99 g/cm3.

In some embodiments, the said at least one other aerosol generating material(s) 3, 11, 12, 31, 32, 41, 42 has a density of from at least about 0.1 g/ cm3 and optionally from at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8 or 0.9 g/cm3. The said at least one other aerosol generating material(s) 3, 11, 12, 31, 32, 41, 42 may have a density of no more than about 1 g/cm3 and, optionally no more than about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3 or 0.2 g/cm3. In some embodiments, the density of the said at least one other aerosol generating material(s) 3, 11, 12, 31, 32, 41, 42 is from about 0.1 to 0.9 g/cm3.

In some embodiments, the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 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 aerosol generating materials 3, 11, 12, 31, 32, 41, 42 comprise different components (and may have the same or different densities). Upon heating, they will therefore release different aerosols, potentially having different make-up of active substance and/ or flavour, etc. Their different densities allow the different aerosols to be generated from the different materials at different speeds and/or different times during heating, potentially providing an aerosol that changes over the period of use. In some embodiments, one, more than one, or each of the aerosol generating materials 3, n, 12, 31, 32, 41, 42 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 may be expanded, such as dry-ice expanded tobacco (DIET), or processed by any other means. In some embodiments, the tobacco material may be reconstituted tobacco material. The tobacco may be pre-processed or unprocessed, and may be, for instance, solid stems (SS); shredded dried stems (SDS); steam treated stems (STS); or any combination thereof. The tobacco material may be fermented, cured, uncured, toasted, or otherwise pre-treated. The aerosol generating materials 3, 11, 12, 31, 32, 41, 42 may comprise different tobacco. Alternatively, the tobacco maybe the same, but is provided in a different form, so that at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 has a greater density than the at least one other aerosol generating material(s) 3, 11, 12, 31, 32, 41, 42.

In some embodiments, said at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 has at least one (further) different characteristic to said at least one other aerosol generating material(s) 3, 11, 12, 31, 32, 41, 42. 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 aerosol generating materials 3, 11, 12, 31, 32, 41, 42 (including the recipe of the aerosol generating materials when each is manufactured from more than one material). In some embodiments, the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 do not have a different characteristic, other than their different densities. In other embodiments, the densities of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 is the same.

In some embodiments, said at least one other aerosol generating material(s) 3, 11, 12, 31, 32, 41, 42 comprises one or more tobacco in the form of cut rag. This tobacco material may lamina or reconstituted tobacco material. - 6o -

In some embodiments, said at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 is a blend comprising both lamina and reconstituted tobacco. For example, the ratio of lamina and reconstituted tobacco may from about 1:4 to about 4:1. In some embodiments, said at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 has a greater density than said at least one other aerosol generating material(s) 3, 11, 12, 31, 32, 41, 42. In some embodiments, this more dense, said at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 comprises particles or may be in the form of beads or one or more sheets. Each bead or sheet may be formed from smaller particles that have been agglomerated. However, it should be recognised that in other embodiments, said at least one other aerosol generating materials 3, 11, 12,

31, 32, 41, 42 maybe denser than said at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 and, for example, maybe in the form of beads or one or more sheets. In some embodiments, each of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 may be in the form of beads or one or more sheets and, optionally, may be processed such that at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 has a higher density than at least one other aerosol generating material(s) 3, 11, 12,

31, 32, 41, 42. 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 materials 3, 11, 12,

31, 32, 41, 42 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, one or more of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 comprises particles of material that are agglomerated.

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

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

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

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

The particles to be extruded may have a size selected to produce a more dense aerosol- generating material (e.g. a more dense first, second and/ or third aerosol generating materials 3, 11, 12, 31, 32, 41, 42), 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 maybe performed using one of the main classes of extruders: screw, sieve and basket, roll, ram and pin barrel extruders. A single screw or twin screw extruder may be used. Forming the tobacco beads by extrusion has the advantage that this processing combines compression, mixing, conditioning, homogenizing and moulding of the composition.

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

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

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

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

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

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

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

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

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

In some embodiments, processing by extrusion is sufficient to provide the higher density of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42, where desired.

However, in other embodiments, the extrudate may be further treated to increase the density of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42, if desired.

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 aerosol-generating material were produced as follows (and may be used for the aerosol generating material of any of the articles described herein).

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

Table 1

The tobacco was ground to produce a fine powder, taking care not to overheat the tobacco. The ground tobacco particles were sieved to select those with a desired size, for example a particle size of less than 250 pm, of less than 100 pm or less than 60 pm. Next, all of the dry (non-liquid) components of the formulation were combined and mixed or blended in a mixer. In this particular instance, the mixture was mixed for 1 minute at a speed to 75 RPM. This was to ensure that the dry components are homogenously distributed within the mixture.

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

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

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

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

In a final step, the spheronised beads were dried in an oven at 6s°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 at least one other aerosol generating material(s) 3, 11, 12, 31, 32, 41, 42 is in the form of discrete particles, or in the form of an agglomerated body of particles. These particles may share various characteristics with the (denser) at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42, such as particle size, but will have a lower density. As described above, there are various ways to adjust the density of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42, such as the formulation and/or the processing of the material into particles, beads or pellets. In some embodiments, said at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 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 at least one other aerosol generating material(s) 3, 11, 12, 31, 32, 41, 42 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 said at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 maybe from about 8 to about 15%. The said at least one of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 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 a first type of aerosol-generating material 3, 31, 41 and about 50% of a second type of aerosol-generating material 11, 12, 32, 42, by weight. Thus, for example, an article comprising 260 mg of aerosol-generating material may comprise 130 mg of the first type of aerosol-generating material 3, 31, 41 and 130 mg of the second type of aerosol-generating material 11, 12, 32, 42.

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

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

The tobacco described herein may contain nicotine. In some embodiments, the nicotine content is from 0.5 to 2.5% or 0.5 to 2% by weight of the tobacco, and may be, for example, from 0.5 to 1.75% by weight of the tobacco, from 0.8 to 1.2% by weight of the tobacco or from about 0.8 to about 1.75% by weight of the tobacco. In some embodiments, the nicotine content may be from 0.8 to 1% by weight of the tobacco. In some embodiments, each of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 have the same nicotine content.

In some embodiments, the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 comprise one or more volatile components. In some embodiments, each of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 have the same volatile component content.

In some embodiments, each of the aerosol generating materials 3, 11, 12, 31, 32, 41, 42 comprises tobacco. For example, the article 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 3, for example comprising higher density tobacco beads, and 130 mg of remaining aerosol generating material (e.g. second aerosol generation material and, optionally, also a third aerosol generating material, combined), for example comprising a blend of lamina and reconstituted tobacco.

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

According to the present disclosure, there is also provided a kit of parts comprising an article according to any of the examples described herein and an aerosol provision device. According to the present disclosure, there is also provided a package (not shown) comprising a plurality of articles according to any of the examples described herein. In some embodiments, the package is hermetically sealed. The package may comprise a container comprising a body and a lid, wherein a space is provided within the container body to receive the plurality of articles. The lid may, for example, be a hinged lid, a snap-fit lid or lid that is connected by a screw thread. The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments maybe utilised and modifications maybe 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.