Articles for use in non-combustible aerosol provision systems

Technical Field

The invention relates to articles for use in non-combustible aerosol provision systems, and aerosol-generating materials for use in such articles.

Background

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Alternative smoking articles produce an inhalable aerosol or vapour by releasing compounds from a substrate material without burning. These articles maybe referred to as non-combustible smoking articles or aerosol provision systems. Such articles commonly include a portion comprising an aerosol generating composition. Summary

According to a first aspect of the disclosure, there is provided an article for use with a non-combustible aerosol provision system, wherein the article comprises an aerosolgenerating material prepared from one or more botanical materials, wherein at least one of the botanical materials has a fill value of greater than about 6 mL/g.

According to a second aspect of the disclosure, there is provide an article for use with a non-combustible aerosol provision system, wherein the article comprises an aerosolgenerating material comprising one or more botanical materials, wherein at least one of the botanical materials has a fill value of greater than about 6 mL/g.

According to a third aspect of the disclosure, there is provided an article for use with a non-combustible aerosol provision system, wherein the article comprises an aerosolgenerating material comprising a first botanical material prepared by a process comprising increasing a temperature of a second botanical material so as to cause release of at least some of a fluid from the second botanical material to form the first botanical material.

According to a fourth aspect of the disclosure, there is provided a process for manufacturing an article for use with a non-combustible aerosol provision system, the process comprising combining two or more botanical materials to form an aerosolgenerating material, wherein at least one of the botanical materials has a fill value of at least about 6 mL/g, and wrapping the aerosol-generating material with a wrapper to form a rod of aerosol-generating material.

According to a fifth aspect of the disclosure, there is provided a process for manufacturing an article for use with a non-combustible aerosol provision system, the process comprising increasing the temperature of a botanical material so as to cause release of at least some of the fluid from the botanical material to form an expanded botanical material, and wrapping an aerosol-generating material comprising the expanded botanical material with a wrapper to form a rod of aerosol-generating material.

According to a sixth aspect of the disclosure, there is provided an article for use with a non-combustible aerosol provision system prepared according to a process of the fourth or fifth aspects.

According to a seventh aspect of the disclosure, there is provided a non-combustible aerosol provision system comprising an article according to the first, second or sixth aspects and a non-combustible aerosol provision device. According to an eighth aspect of the disclosure, there is provided a use of a botanical material having a fill value of greater than about 6 mL/g in an article for use with a non-combustible aerosol provision system.

According to a ninth aspect of the disclosure, there is provided a use of a botanical material having a fill value of greater than about 6 mL/g in an article for use with a non-combustible aerosol provision system.

According to a tenth aspect of the disclosure, there is provided a use of a botanical material prepared by an expansion process in an article for use with a non-combustible aerosol provision system.

Brief Description of the Drawings

Figure i is a process flow diagram for the manufacture of reconstituted tobacco;

Figure 2 is a process flow diagram for the manufacture of extruded tobacco; Figure 3 is a process flow diagram for the manufacture of an article for use in a non- combustible aerosol provision system; Figure 4 is a process flow diagram for the manufacture of expanded tobacco;

Figure 5 is a process flow diagram for the manufacture of expanded stem tobacco;

Figure 6 is a process flow diagram for the manufacture of seared tobacco;

Figure 7 is a cross-sectional view of an article formed by the process depicted in Figure 3;

Figure 8 is a perspective illustration of a non-combustible aerosol provision device for generating aerosol from the aerosol generating material of the article of Figure 7;

Figure 9 illustrates the device of Figure 8 with the outer cover removed and without an article present; Figure 10 is a side view of the device of Figure 8 in partial cross-section;

Figure 11 is an exploded view of the device of Figure 8, with the outer cover omitted;

Figure 12A is a cross sectional view of a portion of the device of Figure 8; and

Figure 12B is a close-up illustration of a region of the device of Figure 8. Detailed Description

According to an aspect of the disclosure, there is provided an article for use with a noncombustible aerosol provision system. Non-combustible aerosol provision systems release compounds from an aerosol-generating material without combusting the aerosol-generating material. They are often known as “electronic cigarettes”, “tobacco heating products”, and “hybrid systems”, which generate aerosol using a combination of aerosol-generating materials.

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, for example, tobacco or a non-tobacco product.

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

In some embodiments, the non-combustible aerosol provision system, such as a non- combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which maybe 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 disclosure relates to articles comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These articles are sometimes referred to as consumables throughout the disclosure.

The articles disclosed herein may have a lower overall weight than conventional articles for use in non-combustible aerosol provision systems but yet have acceptable hardness/ firmness and sensory properties. It is desirable to reduce the overall weight of articles for use in non-combustible aerosol provision systems. Reducing the overall weight can provide numerous advantages, such as reduced transportation costs.

Furthermore, reducing the weight of articles may also have a positive impact on the environment because less energy may be required to transport articles. In addition, consumers may prefer to carry and use a lighter-weight article. In some embodiments, the non-combustible aerosol provision system may comprise 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. The consumable comprises a substance to be delivered, at least one of which is an aerosol-generating material. The consumable may also comprise another substance to be delivered, such as a material that is not intended to be aerosolised. As appropriate, either 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. An article for use in a non-combustible aerosol provision system comprises aerosolgenerating material. The article may also comprise 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.

An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. The aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants. In some embodiments, the aerosol- generating material may comprise an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). In some embodiments, the amorphous solid maybe a dried gel. An amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosolgenerating material may for example comprise from about 50wt%, 6owt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid.

The aerosol-generating material may comprise one or more aerosol formers and may comprise one or more active substances and/or flavours, and optionally one or more other functional materials. An aerosol former 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. Preferably, the aerosol former is glycerol or glycerine.

The aerosol-generating material can comprise an aerosol former in any suitable amount. In preferred embodiments, the aerosol-generating material comprises the aerosol former in an amount of from about 5% to about 30% by weight of the aerosolgenerating material. Preferably, the aerosol-generating material comprises the aerosol former material in an amount of from about 10% to about 20% by weight of the aerosol - generating material. More preferably, the aerosol-generating material comprises the aerosol former in an amount of from about 13% to about 18% by weight of the aerosol- generating material or about 14%, about 15%, about 17%, or about 18% by weight of the aerosol-generating material. In some embodiments, the aerosol-generating material is present in an amount of about 15% by weight of the aerosol-generating material.

The inclusion of aerosol former in an amount of between about 5% and about 30% by weight of the aerosol-generating material has been found to further enhance the sensory properties of the aerosol-generating material when heated by an aerosol generation device. Advantageously, the loading of the aerosol former of between about 10% and about 30% by weight of the aerosol-generating material may render the sensory properties of the composition similar to the sensory properties of a conventional combustible smoking article. The aerosol-generating material may comprise a flavour. As used herein, the terms "flavour" and "flavouring" refer to materials which, where local regulations permit, may be used to create a desired taste or aroma in a product for adult consumers. They may include extracts (e.g., liquorice, hydrangea, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, menthol, Japanese mint, aniseed, cinnamon, herb, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, scotch, whiskey, spearmint, peppermint, lavender, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, piment, ginger, anise, coriander, coffee, or a mint oil from any species of the genus Mentha), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, oil, liquid, or powder.

The aerosol-generating material may comprise a flavour in an amount of from about o.i% to about 5% by weight of the aerosol-generating material. Preferably, the aerosol- generating material comprises the flavour in an amount of from about 0.5% about 1.5%.

The aerosol-generating material is prepared from one or more botanical materials. The one or more botanical materials are used to make the aerosol-generating material. Thus, the aerosol-generating material may comprise or consist of the one or more botanical materials that are used to prepare it. In some embodiments, the aerosolgenerating composition consists of a composition comprising one or more botanical materials.

The aerosol-generating material maybe prepared from a composition comprising one botanical material or from two or more botanical materials, such as two, three, four, five or more botanical materials. The aerosol-generating composition can be prepared by blending two or more botanical materials.

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 maybe 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, bamboo, 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 preferred embodiments, the botanical material is tobacco. As used herein, the term “tobacco material” refers to a material derived from a plant of the Nicotiana species. The selection of the plant of the Nicotiana species is not limited, and the types of tobacco or tobaccos used may vary. 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, leaf tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract. As used herein, “leaf tobacco” means cut lamina tobacco.

In some embodiments, the tobacco material is selected from flue-cured or Virginia, Burley, sun-cured, Maryland, dark-fired, dark air cured, light air cured, Indian air cured, Red Russian and Rustica tobaccos, and mixtures thereof, as well as various other rare or specialty tobaccos, green or cured. Tobacco material produced via any other type of tobacco treatment which could modify the tobacco taste, such as fermented tobacco or genetic modification or crossbreeding techniques, is also within the scope of the present disclosure. For example, it is envisaged that tobacco plants may be genetically engineered or crossbred to increase or decrease production of components, characteristics or attributes.

In some embodiments, the tobacco material is sun-cured tobacco, selected from Indian Kurnool and Oriental tobaccos, including Izmir, Basma, Samsun, Katerini, Prelip,

Komotini, Xanthi and Yambol tobaccos. In some embodiments, the tobacco material is dark air cured tobacco, selected from Passanda, Cubano, Jatin and Besuki tobaccos. In some embodiments, the tobacco material is light air cured tobacco, selected from North Wisconsin and Galpao tobaccos.

In some embodiments, the tobacco material is selected from Brazilian tobaccos, including Mata Fina and Bahia tobaccos. In some embodiments, the tobacco material is selected from criollo, Piloto Cubano, Olor, Green River, Isabela DAC, White Pata, Eluru, Jatim, Madura, Kasturi, Connecticut Seed, Broad Leaf, Connecticut, Pennsylvanian, Italian dry air cured, Paraguayan dry air cured and One Sucker tobaccos.

For the preparation of smoking/vaping or smokeless tobacco products, plants of the

Nicotiana species may be subjected to a curing process. Certain types of tobaccos may be subjected to alternative types of curing processes, such as fire curing or sun curing.

Preferably, but not necessarily, harvested tobaccos that are cured are aged.

The tobacco can be harvested in different stages of growth, for example when the plant is has reached a level of maturity and the lower leaves are ready for harvest whilst the upper leaves are still in development.

In some embodiments, at least one portion of the plant of the Nicotiana species (e.g., at least a portion of the tobacco material) is employed in an immature form. That is, in some embodiments, the plant, or at least one portion of that plant, is harvested before reaching a stage normally regarded as ripe or mature.

In some embodiments, at least a portion of the plant of the Nicotiana species (e.g. at least a portion of the tobacco material) is employed in a mature form. That is, in some embodiments, the plant, or at least one portion of that plant, is harvested when that plant (or plant portion) reaches a point that is traditionally viewed as being ripe, over- ripe or mature, which can be accomplished through the use of tobacco harvesting techniques conventionally employed by farmers. Both Oriental tobacco and Burley tobacco plants can be harvested. Also, the Virginia tobacco leaves can be harvested or primed depending upon their stalk position.

The Nicotiana species maybe selected for the content of various compounds that are present in the plant. For example, plants may be selected on the basis that those plants produce relatively high quantities of one or more of the compounds desired to be isolated (i.e. the volatile compounds of interest). In certain embodiments, plants of the Nicotiana species are specifically cultivated for their abundance of leaf surface compounds. Tobacco plants may be grown in green-houses, growth chambers, or outdoors in fields, or grown hydroponically.

Various parts or portions of the plant of the Nicotiana species maybe utilised. In some embodiments, the whole plant, or substantially the whole plant, is harvested and employed as such. As used herein, the term “substantially the whole plant” means that at least 90% of the plant is harvested, such as at least 95% of the plant, such as at least

99% of the plant. Alternatively, in some embodiments, various parts or pieces of the plant are harvested or separated for further use after harvest. In some embodiments, the tobacco material is selected from the leaves, stems, stalks of the plant, and various combinations of these parts. The tobacco material of the disclosure may thus comprise an entire plant or any portion of a plant of the Nicotiana species.

The tobacco material can be paper reconstituted tobacco, extruded tobacco, bandcast reconstituted tobacco, or a combination of bandcast reconstituted tobacco and another form of tobacco, such as tobacco granules.

Paper reconstituted tobacco refers to tobacco material formed by a process in which tobacco feedstock is extracted with a solvent to afford an extract of solubles and a residue comprising fibrous material, and then the extract (usually after concentration, and optionally after further processing) is recombined with fibrous material from the residue (usually after refining of the fibrous material, and optionally with the addition of a portion of non-tobacco fibres) by deposition of the extract onto the fibrous material. The process of recombination resembles the process for making paper.

The paper reconstituted tobacco may be any type of paper reconstituted tobacco that is known in the art. In a particular embodiment, the paper reconstituted tobacco is made from a feedstock comprising one or more of tobacco strips, tobacco stems, and whole leaf tobacco. In a further embodiment, the paper reconstituted tobacco is made from a feedstock consisting of tobacco strips and/or whole leaf tobacco, and tobacco stems. However, in other embodiments, scraps, fines and winnowings can alternatively or additionally be employed in the feedstock.

In some embodiments, the paper-reconstituted tobacco is made from expanded tobacco. For example, the paper-reconstituted tobacco can be made from ground expanded tobacco. Examples of expanded tobaccos are provided herein. The paper reconstituted tobacco for use in the tobacco material described herein may be prepared by methods which are known to those skilled in the art for preparing paper reconstituted tobacco.

Referring to Figure 1, tobacco furnish such as leaf, strips, stems, scraps, fines, and/or winnowings (in some embodiments, leaf, strips and stems), are initially mixed with an aqueous solvent (e.g. water, water and water miscible solvents such as ethanol).

Distilled water, deionized water, or tap water may be employed. The suspension of tobacco in the solvent is agitated by stirring or shaking for instance in order to increase the rate of extraction of the soluble portion from the fibrous portion of tobacco. The agitation is typically carried out for half an hour up to 6 hours. Agitation may be achieved in an agitator that comprises a vessel and a blade to achieve agitation. The amount of solvent in the suspension can vary widely from about 75 to 99% by weight of the suspension, depending on the tobacco furnish, the type of solvent and agitation equipment (in particular the blade type), and the temperature of the suspension. The typical range of suspension temperature is about io°C to about ioo°C.

The soluble portion of the tobacco furnish is separated from the insoluble fibrous portion of tobacco, for example by pressing with a pneumatic, hydraulic or mechanical press, or by filtration. After the separation, the fibrous portion of tobacco is typically subjected to mechanical refining to produce a fibrous pulp. Suitable refiners can be typically disc refiners or conical refiners. The fibrous pulp will be then formed into a base web comprising the tobacco fibrous pulp on a papermaking station, such as a Fourdrinier-type papermaking machine. It is typically laid onto a flat wire belt where excess water is removed by gravity drain and suction drain. Non-tobacco fibre, such as cellulose, wheat fibre or wood fibre, may be included with the tobacco-derived fibrous portion at this stage. The soluble portion of the tobacco feedstock is concentrated using any known type of concentrator such as film evaporator or vacuum evaporator. After concentration, ingredients such as aerosol forming materials (as defined herein), casings, for example cocoa, liquorice, and acids such as malic acid, or flavours (as defined herein) maybe added and mixed with the concentrated tobacco solubles. Then concentrated tobacco solubles potentially containing aerosol forming materials and/or casings and/or flavours are recombined with the dried tobacco fibrous sheet to form reconstituted tobacco. The concentrated solubles can be added back to the fibrous web with various methods, such as spraying, coating, saturating, sizing. Finally, the reconstituted tobacco is dried. It may optionally be cut into strips or wound into a roll and then slit into bobbins or shredded into cut rag.

The reconstituted tobacco may comprise one or more aerosol formers, as described herein. In some embodiments, the reconstituted tobacco may comprise an aerosol former in an amount of from about 5% to about 40% based on the weight of the reconstituted tobacco.

The aerosol-generating material maybe prepared from and/or comprise a composition comprising paper reconstituted tobacco in an amount of between about 0% to about 90% by weight of the composition. In some embodiments, the aerosol-generating material is prepared from and/or comprises a composition comprising paper reconstituted tobacco in an amount of from 10% to 90%, 10% to 80% or 20% to 70% by weight of the composition. In some embodiments, the aerosol-generating material is prepared from and/or comprises a composition comprising paper reconstituted tobacco in an amount of from about 50% to about 90% by weight of the composition.

In some embodiments, the aerosol-generating material is prepared from and/or comprises a composition comprising paper reconstituted tobacco in an amount of between of between about 10% and about 89%, about 20% and about 88%, about 30% and about 87%, about 40% and about 86%, about 50% and about 85%, about 60% and about 84%, about 70% and about 83% by weight of the composition. In some embodiments, the aerosol-generating material prepared from and/or comprises a composition comprising reconstituted tobacco in an amount of between about 75% and about 85% by weight of the composition. In some embodiments, the aerosol-generating material is prepared from and/or comprises a composition comprising reconstituted tobacco in an amount of about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84% or about 85% by weight of the composition.

In some embodiments, the aerosol-generating material is prepared from and/or comprises a composition comprising leaf tobacco and paper reconstituted tobacco. The weight ratio of the leaf tobacco relative to the paper reconstituted tobacco material may be 10:90, 11:89, 12:88, 13:87, 14:86, 15:85, 16:84, 17:83, 18:82, 19:81, 20:80, 21:79, 22:78, 23:77, 24:76, 25:75, 26:74, 27:73, 28:72, 29:71, 30:70, 31:69, 32:68, 33:67, 34:66, 35:65, 36:64, 37:63, 38:62, 39:61, 40:60, 41:59, 42:58, 43:57, 44:56, 45:55, 46:54, 47:53, 48:52, 49:51, 50:50, 51:49, 52:48, 53:47, 54:46, 55:45, 56:44, 57:43, 58:42, 59:41, 60:40, 61:39, 62:38, 63:37, 64:36, 65:35, 66:34, 67:33, 68:32, 69:31, 70:30, 71:29, 72:28, 73:27, 74:26, 75:25, 76:24, 77:23, 78:22, 79:21, 80:20, 81:19, 82:18,

83:17, 84:16, 85:15, 86:14, 87:13, 88:12, 89:11 or 90:10 (weight of leaf tobacco:weight paper reconstituted tobacco).

In some embodiments, the aerosol-generating material is prepared from and/or comprises a composition comprising expanded botanical material and a mixture of reconstituted tobacco and leaf tobacco.

The composition may comprise expanded botanical in an amount of about 10% and a mixture of reconstituted tobacco and leaf tobacco in an amount of about 90% by weight of the composition. The weight ratio of reconstituted tobacco to leaf tobacco can be

90:10, 80:20, 70:30, 60:40, 50:50, 40:60, 30:70, 20:80 or 10:90.

The reconstituted tobacco material may have a density of less than about 700 milligrams per cubic centimetre (mg/cc).

Such tobacco material has been found to be particularly effective at providing an aerosol-generating material which can be heated quickly to release an aerosol, as compared to denser materials. For instance, the properties of various aerosolgenerating materials, such as bandcast reconstituted tobacco material and paper reconstituted tobacco material, were tested when heated. It was found that, for each given aerosol-generating material, there is a particular zero heat flow temperature below which net heat flow is endothermic, in other words more heat enters the material than leaves the material, and above which net heat flow is exothermic, in other words more heat leaves the material than enters the material, while heat is applied to the material. Materials having a density less than 700 mg/cc had a lower zero heat flow temperature. Since a significant portion of the heat flow out of the material is via the formation of aerosol, having a lower zero heat flow temperature has a beneficial effect on the time it takes to first release aerosol from the aerosol-generating material. For instance, aerosol-generating materials having a density of less than 700 mg/cc were found to have a zero heat flow temperature of less than 164°C, as compared to materials with a density over 700 mg/ cc, which had zero heat flow temperatures greater than

164°C.

The density of the botanical material also has an impact on the speed at which heat conducts through the material, with lower densities, for instance those below 700 mg/cc, conducting heat more slowly through the material, and therefore enabling a more sustained release of aerosol.

In some embodiments, the botanical material is extruded tobacco. The aerosolgenerating material may be prepared from or comprise extruded tobacco in an amount of from 10 to 30% by weight, or 10 to 20% by weight, of the aerosol-generating material. The extruded tobacco which may be used in the tobacco compositions described herein may be prepared by methods which are known to those skilled in the art for preparing extruded tobacco. In some embodiments, extruded tobacco can be prepared as follows. The tobacco furnish may include Virginia (flue cured) tobacco, Burley tobacco, and/or Oriental tobacco. The tobacco furnish may be stems, scraps, strips, fines, or winnowings. Additional components may include non-tobacco fibre, such as straw fibre or wheat fibres; binders, for example celluloses or modified celluloses such ashydroxypropyl cellulose and carboxymethylcellulose; and casings, for example acids such as malic acid.

As shown in Figure 2, the tobacco furnish and any additional components are mixed in a mixing silo, and conveyed by a dosing screw and conveyor screw to an extruder, where they are mixed with water, and at this stage an aerosol forming material may also be added. After extrusion, the extruded tobacco is cooled on a cooling belt. An analogous material to those described in the above section, but made using only non-tobacco fibres, such as wheat fibre or wood fibre, maybe used in the filler component of the tobacco composition. As used herein, the term “fill value” is a measure of the ability of a material to occupy a specific volume at a given moisture content. A high fill value indicates that a lower weight of material is required to produce a rod at acceptable hardness/firmness levels of a given circumference, volume and length than is required with a material of lower fill value.

Many of the botanical materials noted above typically have fill values of less than about 6 mL/g. For example, leaf tobacco, paper reconstituted tobacco and extruded tobacco typically may have a fill value of less than 6 mL/g. These materials may have a fill value of between about 3 mL/g to about 5.9 mL/g. For example, paper reconstituted tobacco typically may have a fill value of between about 2.5 and about 5.6 mL/g. Lamina tobacco, e.g. Virginia leaf, typically may have a fill value of about around 4.5 ml/g to about 5.6 mL/g.

At least one of the botanical materials has a fill value that is greater than about 6 mL/g. In some embodiments, at least one of the botanical materials has a fill value of at least about 7 mL/g, at least about 8 mL/g or at least about 9 mL/g up to about 10 mL/g. For example, the fill value of at least one of the botanical materials can be from about 6 mL/g up to about 10 mL/g, from about 6.5 mL/g up to about 9 mL/g or from about 7 mL/g up to about 8 mL/g.

Any botanical material having a fill value of at least 6 mL/g may be used in the invention. In particular, the botanical material may be formed from expanded botanical material having a fill value of at least about 6 mL/g. As shown in Figure 3, the aerosol-generating material may be prepared by combining a botanical material having a fill value of at least 6 mL/g and a botanical material having a filler value of less than 6 mL/g. Optionally, one or more flavours or aerosol formers can be added. The aerosol-generating material can then be incorporated into an article for use in a non-combustible aerosol provision system.

The composition can be formed by blending two or more different botanical materials. For example, a first botanical material comprising leaf tobacco maybe mixed with a second botanical material comprising expanded tobacco material. The aerosolgenerating material may by formed from a combination of a third botanical material with the first and second botanical materials. For example, in one embodiment, the aerosol-generating material can be formed by combining leaf tobacco, reconstituted tobacco and expanded tobacco material.

The aerosol-generating material may be formed entirely from botanical material having a fill value of greater than about 6 mL/g, such as expanded botanical material. For example, the aerosol-generating material may be formed from botanical material having a fill value of greater than about 6 mL/g in an amount of 1% to io%, or around 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80% or 90% by weight of the aerosol-generating material. Using botanical material having a relatively high fill value may lead to reductions in the weight of the aerosol-generating material and thus the article because a lower mass of the expanded botanical material is required to fill a given volume of the article compared with botanical materials that have a relatively low fill value. However, using too much botanical material having a relatively high fill value, such as a fill value of greater than about 6 mL/g (e.g. expanded tobacco), can negatively impact the sensory properties of the aerosol-generating material when it is used in an article for use with a non-combustion aerosol provision system. Furthermore, the relatively low density of this botanical material can reduce the hardness or firmness of an aerosol-generating section of an article and negatively affect the pressure drop across the aerosol-generating section of the article when it is incorporated in relatively high quantities. The hardness of the aerosol-generating section of the article is important because the article articles are for use with non-combustible aerosol provision systems. If the hardness of the aerosol-generating section is too low, then the article may have poor structural integrity. Articles having poor structural integrity may be unsuitable for use with non-combustible aerosol provision systems.

The inventors have found that a balance may be struck between the beneficial weight savings afforded by utilising botanical material having a relatively high fill value and the negative effects observed when using relatively high quantities of the material. In particular, the inventors have found that preparing the aerosol-generating material from a composition comprising up to about 30 wt%, preferably up to about 25% and more preferably up to about 20% botanical material having a fill value of greater than about 6 mL/g gives satisfactory sensory results and an article of acceptable firmness, whilst achieving a desirable reduction in weight. The aerosol-generating material can be prepared from a composition comprising botanical material having a fill value of greater than about 6 mL/g in an amount of from about 1% to about 30%, about 25%, about 20% or about 15% by weight of the composition. In some embodiments, the aerosol-generating material is prepared from a composition comprising botanical material having a fill value of greater than about 6 mL/g in an amount of from about 2% to about 14%, from about 3% to about 13%, from about 4% to about 12% or from about 5% to about 11% by weight of the composition. In some embodiments, the composition comprises or is prepared from botanical material having a filler value of greater than about 6 mL/g in an amount of about 10% by weight of the composition.

When incorporated into an article, the hardness of the aerosol-generating section comprising the aerosol-generating material can be between about 55% and about 75%. Preferably, the hardness is as close as possible to about 70%. In some embodiments, the hardness is around 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69% or 70%.

The botanical material used to form the aerosol-generating material is preferably a mixture of two or more botanical materials. The botanical material may comprise a first botanical material having a fill value of greater than 6 mL/g in an amount of from about 1% to about 30% or from about 1% to about 25% by weight of the botanical material.

The remainder of the composition used to form the aerosol-generating material may comprise one or more other botanical materials as described herein. As a consequence, the botanical materials can have different properties, such as different fill values. For example, the aerosol-generating material can be prepared from a composition comprising first botanical material having a fill value of greater than about 6 mL/g and a second botanical material having a lower fill value. The relatively high fill value of the first botanical material may lower the overall mass of tobacco material that is needed to fill the volume of the aerosol-generating section of the article. Consequentially, the overall weight of the article may be reduced by using a botanical material having a relatively high fill value. The aerosol-generating section of the article may define a continuous volume comprising aerosol-generating material. The aerosol-generating material can substantially fill the volume. The aerosol-generating material may fill at least about 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95% or 98% of the volume of the aerosol- generating section. The aerosol-generating section may consist of, or consist essentially of, aerosol-generating material. The article may comprise a single continuous aerosolgenerating section defining a volume substantially filled with the aerosol-generating material. The aerosol-generating section may comprise further components, such as a wrapper circumscribing the aerosol-generating material and/or a heater, such as a susceptor.

The aerosol-generating material in the aerosol-generating section comprises a botanical material having a fill value of greater than about 6 mL/g. The aerosol-generating material may comprise other botanical materials having a fill value of less than 6 mL/g. Thus, the fill value of the aerosol-generating material in the aerosol-generating section may be greater than, equal to or less than about 6 mL/g. The aerosol-generating material can have a fill value of from about 2 mL/g to about 10 mL/g, 2 mL/g to about 9 mL/g, 2 mL/g to about 8 mL/g, 2 mL/g to about 7 mL/g, 3 mL/g to about 6 mL/g or about 4 mL/g to about 6 mL/g. For example, the aerosol-generating material may have a fill value of from about 5 mL/g to about 6 mL/g. The fill value of the aerosolgenerating material may be controlled by altering the relative amounts of botanical material having a fill value of greater than 6 mL/g and a botanical material having a fill value of less than 6 mL/g.

The fill value of the aerosol-generating material of the aerosol-generating section may be determined by separating it from other components of the article (for example, if present, the wrapper, susceptor, filter etc.) and then measuring the fill value according to the fill value measurement method described herein.

Any botanical material having a fill value of greater than about 6 mL/ g may be used. A particular material that may be used is expanded botanical material.

Expanded botanical material is botanical material that has been subjected to an expansion process. Expansion involves an increase in the area and spacing between fibres of the botanical material. After being subjected to the expansion process, the botanical material has a higher fill value, but lower density, than the botanical material prior to the expansion process.

Typically, an expansion process involves rapidly increasing the temperature and/or the pressure of a solid material comprising a fluid (e.g. water) such that the fluid is rapidly released from the material. This usually involves a change in phase of the fluid (e.g. water turns from a liquid to a gas) and an increase in the volume of the fluid. The rapid release and expansion in the fluid causes it to be released from the solid material. At the same time, the solid material expands to occupy a greater volume. Whilst fluid is often present in the solid material naturally, additional fluid can be introduced by impregnation or absorption of the fluid into the solid material (optionally under pressure).

One such expansion process that can be used to prepare the botanical material is dry ice expansion.

Dry ice expansion involves permeating the botanical material with liquid carbon dioxide before warming. The resulting carbon dioxide gas forces the botanical material to expand. Additional methods include the treatment of botanical material with solid materials which, when heated, decompose to produce gases which serve to expand the botanical material. Other methods include the treatment of botanical material with gas-containing liquids, such as carbon dioxide-containing water, under pressure to impregnate the botanical material with the liquid. The impregnated botanical material is then heated or the pressure reduced to cause release of the gas and expansion of the tobacco. Additional techniques have been developed for expanding botanical material which involve the treatment of botanical material with gases which react to form solid chemical reaction products within the botanical material, for example carbon dioxide and ammonia to form ammonium carbonate. These solid reaction products may subsequently be decomposed by heat to produce gases within the botanical material which cause expansion of the botanical material upon their release.

The botanical material to be expanded can be in a variety of forms, such as lamina or stem. For example, tobacco stems may be expanded by utilizing various types of heat treatment or microwave energy. Freeze-drying of botanical material can also be employed to obtain an increase in volume (and thus fill value). Consecutive drying techniques may also be used to expand cut stems, such as air drying, and fluidized bed drying, etc.

The botanical material may be tobacco. In preferred embodiments, the botanical material is dry ice expanded tobacco material (DIET) or expanded tobacco stem.

The process of expansion reduces the density of the botanical material. The expansion process also provides a botanical material that has a higher fill value than the botanical material prior to the expansion process.

Expanded botanical material may have a fill value of at least about 6 mL/g, at least about 7 mL/g, at least about 8 mL/g or at least about 9 mL/g up to about 15 mL/g, up to about 14 mL/g, up to about 13 mL/g, up to about 12 mL/g, up to about 11 mL/g or up to about 10 mL/g.

Figure 4 depicts a process for preparing dry ice expanded tobacco. The process could be applied to other botanical materials. Bales of tobacco material are sliced and then the bales are conditioned using water and steam. The tobacco material can be any of the tobacco materials described herein. Lamina tobacco, in particular lamina Virginia tobacco, is particularly preferred. One reason for this is that it exhibits desirable organoleptic properties and, compared with other tobacco varieties, relatively low levels of compounds considered to be undesirable. Another benefit of using Virginia tobacco is that it tends to readily expand during the expansion process. In some embodiments, stem tobacco may be used rather than, or even in addition to, lamina. After conditioning, the conditioned tobacco material is blended with other conditioned tobacco materials or mixed before being fed into a cutter. Preferably, the cutter cuts the tobacco material at 25 to 28 cuts per inch (CPI). A cut width of 25 CPI is particularly preferred, although other cut widths could be used. Cutting the tobacco material increases its surface area and thus reduces the time it takes to become impregnated with liquid during the impregnation step. These cut widths may also increase the fill value of the final material.

After wetting the cut material and blending the wet cut material, the material has a moisture content of around 26%. This material is then fed into an impregnator vessel, which is subsequently charged with carbon dioxide at a temperature of -20 °C for around 6 minutes under pressure. These conditions ensures that the carbon dioxide stays in a liquid form and has enough time to penetrate and be absorbed into the tobacco material. Following on from this, the impregnated tobacco material is fed into a sublimator, where it is immediately heated in a gas stream at a temperature of 330 °C. This results in rapid volatilisation of the moisture and carbon dioxide in the tobacco material, which causes it to expand.

Other gas temperatures may be used. For example, the gas temperature may be between about 250 °C and about 400 °C or more. The maximum temperature is preferably below the combustion temperature of the botanical material. High temperatures may improve the rate of expansion and thus the efficiency of the process.

The fill value of the botanical material may also be controlled by changing the temperature. Increasing the temperature may lead to more moisture being driven off from the material and thus a higher fill value of the final material. Conversely, using lower temperatures may decrease the fill value of the final material.

The high gas temperatures can be achieved by any suitable means (e.g. by heating air using a hot plate or burner). The tobacco material at the end of the sublimation is relatively dry and has a moisture content of around 6%. The water content is increased to around 12% to 14% (the target is often 13.6%) by hydrating it in a reordering cylinder to produce the final expanded tobacco material. The expanded material may have a fill value of at least about 6 mL/g.

When referring to “moisture” it is important to understand that there are widely varying and conflicting definitions and terminology in use. It is common for “moisture” or “moisture content” to be used to refer to water content of a material but in relation to the certain industries, such as the tobacco industry, it is necessary to differentiate between “moisture” as water content and “moisture” as oven volatiles. Water content is defined as the percentage of water contained in the total mass of a solid substance. Volatiles are defined as the percentage of volatile components contained in the total mass of a solid substance. This includes water and all other volatile compounds. Oven dry mass is the mass that remains after the volatile substances have been driven off by heating. It is expressed as a percentage of the total mass. Oven volatiles (OV) are the mass of volatile substances that were driven off. Moisture content (oven volatiles) may be measured as the reduction in mass when a sample is dried in a forced draft oven at a temperature regulated to no°C ± 1°C for three hours ± 0.5 minutes. After drying, the sample is cooled in a desiccator to room temperature for approximately 30 minutes, to allow the sample to cool.

Unless stated otherwise, references to moisture content herein are references to oven volatiles (OV).

The botanical material may comprise expanded botanical stem, such as expanded tobacco stem. The process of forming expanded stem typically involves treating the stem with steam, which causes expansion of the material and an increase in its fill value.

Figure 5 illustrates one such process for expanding tobacco stem. The process could be applied to other botanical materials. Tobacco is loaded into a feeder. The tobacco stem can be derived from any of the varieties of tobacco described herein. After the addition of water, the moisture content of the stem is around 34%. The mixture is then blended with stem from other batches and/ or mixed thoroughly, at which point the stem has a moisture content of between around 30% and around 40%, preferably around 32% to around 36% and preferably around 36%. The material is then cut to ensure the portions of stem are of consistent dimensions. This cutting may help to further increase the fill value of the material. Water is then applied to the cut stem to increase its moisture content to between about 35% and about 45%, preferably around 38% to around 40%. The relatively high moisture levels attained in this step help to increase the expansion of the stem during the subsequent expansion steps. Following this, the material is subjected to steam treatment at temperatures in excess of 100 °C (e.g. using steam or superheated steam). This results in expansion of the stem and an increase in its fill value. The steam can be applied at a rate of at least 200 kg/hr, preferably greater than 300 kg/hr and more preferable greater than 350 kg/hr. In some embodiments, the steam is applied at a rate of around 375 kg/hr to around 500 kg/hr. Higher applications rates may also be used. The rate of throughput can be increased by using higher steam application rates. After dust removal using a dust extractor, the expanded stem can be stored.

The botanical material may comprise seared botanical material, such as tobacco, such as seared stem tobacco. The flow chart shown in Figure 6 summarises exemplary processes for manufacturing seared tobacco material. The tobacco starting material may optionally have undergone pre-treatment, such as the conventional primary manufacturing (PMD) processes, which include, for example, one or more of: conditioning of raw stem, subsequent rolling, cutting and expansion/drying and mixing. In some embodiments, the pretreatment of lamina may include slicing, conditioning, casing (optional), cutting, drying, cooling and mixing.

The moisture content of the tobacco starting material may be in the region of 14.5% OV, for example. The starting material (e.g. stem) is fed into the treatment apparatus where it is treated by intermittent contact with a heated surface. During the treatment, the tobacco material is agitated to create the intermittent contact with the heated surface. The treatment results in a reduction in the moisture content to as low as 0% OV. Once the treatment of the tobacco material by intermittent contact with the heated surface has been completed, the treated tobacco material may optionally undergo conditioning.

In the illustrated process, this involves adding water or steam to the treated tobacco material to increase its moisture content to in the region of 14.5% OV, for example, and produce a seared tobacco material The seared stem tobacco may have a fill value of greater than about 6 mL/g. In some embodiments, the seared stem tobacco has a fill value of greater than about 7 mL/g, greater than 8 mL/g or greater than 9 mL/g.

In some embodiments, the botanical material having a fill value of greater than about 6 mL/g has a moisture content of between about 10% and about 20% oven volatiles

(OV). In general, the moisture content of this botanical material is between about 11% and about 16% oven volatiles. Preferably, the moisture content of the botanical material is between about 11.5% and about 14.5% oven volatiles. Expanded botanical materials, such as expanded tobacco, typically have such moisture contents. In some embodiments, the botanical material has a fill value of about 7.4 mL/g and a moisture content of about 13.4% oven volatiles (OV). In some embodiments, the botanical material has a fill value of about 7.4 mL/g and a moisture content of about 12.5% oven volatiles (OV). In some embodiments, the botanical material has a fill value of from about 6 mL/g to about 10 mL/g, 6 mL/g to about 9 mL/g, 6 mL/g to about 8 mL/g or about 6 mL/g to about 7 mL/g and a moisture content of from about 10% to about 20%. In some embodiments, the botanical material has a fill value of from about 6 mL/g to about 10 mL/g, 6 mL/g to about 9 mL/g, 6 mL/g to about 8 mL/g or about 6 mL/g to about 7 mL/g and a moisture content of from about 10% to about 15%.

In some embodiments, the aerosol-generating material comprises an amorphous solid, such as a dried gel.

The amorphous solid may comprise a gelling agent. In some embodiments, the gelling agent comprises one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some embodiments, the gelling agent comprises a hydrocolloid. In some cases, the gelling agent comprises alginate and/or pectin, and maybe combined with a setting agent (such as a calcium source) during formation of the amorphous solid. In some cases, the amorphous solid may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.

In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of from 10 - 3Owt%, 2O-35wt% or 25 - 30wt% of the slurry / amorphous solid (calculated on a dry weight basis). In some embodiments, alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one further gelling agent, such as pectin.

The gelling agent may comprise one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum and mixtures thereof.

In some embodiments, the cellulosic gelling agent is selected from the group consisting of: hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP) and combinations thereof.

In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose, guar gum, or acacia gum.

In some embodiments, the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum Arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In preferred embodiments, the non-cellulose based gelling agent is alginate or agar.

The amorphous solid may be formed by forming a slurry, which is then dried to form the amorphous solid. The inclusion of a gelling agent in the slurry results in the aerosol-generating material being formed from a dried gel. It has been found that, by including a gel in the aerosol-generating material, flavourant compounds, for example, menthol, are stabilised within the gel matrix allowing a higher flavourant loading to be achieved than in non-gel compositions. The flavouring (e.g. menthol) is stabilised at high concentrations and the products have a good shelflife. In some examples, alginate is comprised in the gelling agent in an amount of from about 5 to 40 wt% of the amorphous solid, or 15 to 40 wt%. That is, the amorphous solid comprises alginate in an amount of about 5 to 40 wt% by dry weight of the amorphous solid, or 15 to 4Owt%. In some examples, the amorphous solid comprises alginate in an amount of from about 20 to 40 wt%, or about 15 wt% to 35 wt% of the amorphous solid.

In some examples, pectin is comprised in the gelling agent in an amount of from about 3 to 15 wt% of the amorphous solid. That is, the amorphous solid comprises pectin in an amount of from about 3 to 15 wt% by dry weight of the amorphous solid. In some examples, the amorphous solid comprises pectin in an amount of from about 5 to iowt% of the amorphous solid.

In some examples, guar gum is comprised in the gelling agent in an amount of from about 3 to 40 wt% of the amorphous solid. That is, the amorphous solid comprises guar gum in an amount of from about 3 to 40 wt% by dry weight of the amorphous solid. In some examples, the amorphous solid comprises guar gum in an amount of from about 5 to 10 wt% of the amorphous solid. In some examples, the amorphous solid comprises guar gum in an amount of from about 15 to 40 wt% of the amorphous solid, or from about 20 to 40wt%, or from about 15 to 35 wt%. In examples, the alginate is present in an amount of at least about 50 wt% of the gelling agent. In examples, the amorphous solid comprises alginate and pectin, and the ratio of the alginate to the pectin is from 1:1 to 10:1. The ratio of the alginate to the pectin is typically >1:1, i.e. the alginate is present in an amount greater than the amount of pectin. In examples, the ratio of alginate to pectin is from about 2:1 to 8:1, or about 3:1 to 6:1, or is approximately 4:1.

The amorphous solid typically comprises an aerosol former (also referred to herein as an aerosol former material) in an amount of up to about 8owt% of the amorphous solid, such as from about o.iwt%, o.5wt%, iwt%, 3wt%, 5wt%, 7wt% or 10% to about 8owt%, 75wt%, 70wt%, 6swt%, 6owt%, 55wt%, 50wt%, 45wt%, 40wt%, 35wt%, 30wt% or 25wt% of an aerosol former material. In some embodiments, the amorphous solid comprises an aerosol former in an amount of about 40 to 8owt%, 40 to 75wt%, 50 to 70wt%, or 55 to 65wt%. The aerosol former material may act as a plasticiser. In some cases, the aerosol former material comprises one or more compound selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases, the aerosol former material comprises, consists essentially of, or consists of glycerol. It has been established that if the content of the plasticiser is too high, the amorphous solid may absorb water resulting in a material that does not create an appropriate consumption experience in use. It has been established that if the plasticiser content is too low, the amorphous solid maybe brittle and easily broken. The plasticiser content specified herein provides an amorphous solid flexibility which allows the sheet to be wound onto a bobbin, which is useful in manufacture of consumables or can allow the sheet to be transported prior to shredding.

The aerosol former material typically comprises one or more of 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. In particular examples, the aerosol former material comprises or consists of glycerol.

In some embodiments, the aerosol former material comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and/or aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. The aerosol former may enhance the mouthfeel, as well as the organoleptic properties in general, of the aerosol produced by the aerosol-generating material when heated and inhaled by a user, particularly where the amorphous solid comprises relatively high quantities (e.g. >40 wt%) of aerosol former. The capability of amorphous solids to retain high quantities of aerosol former may reduce the need for other components of the aerosol-generating material, such as the expanded botanical material, to be loaded with high quantities of aerosol former. This may improve manufacturing efficiency.

The amorphous solid may comprise a flavour. The inventors have found that using the component proportions described herein means that as the gel sets, flavour compounds are stabilised within the gel matrix allowing a higher flavour loading to be achieved than in non-gel compositions. The flavouring (e.g. menthol) is stabilised at high concentrations and the products have a good shelflife.

The amorphous solid may comprise a filler. In some cases, the amorphous solid comprises 5-50wt%, io-4owt% or i5~3Owt% of the filler. In some such cases the amorphous solid comprises at least iwt% of the filler, for example, at least 5 wt%, at least iowt%, at least 20wt% at least 30wt%, at least 40wt%, or at least 50wt% of a filler. In exemplary embodiments the amorphous solid comprises from 5-25wt% of a filler comprising fibres. Suitably the filler consists of fibres, or is in the form of fibres. In some embodiments, the amorphous solid comprises less than 6owt% of the filler, such as from iwt% to 6owt%, or 5wt% to 50wt%, or 5wt% to 30wt%, or iowt% to 20wt%.

In other embodiments, the amorphous solid comprises less than 2owt%, suitably less than iowt% or less than 5 wL% of the filler. The filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)). An inorganic filler, such as calcium carbonate or chalk may be used. In particular cases, the amorphous solid comprises no calcium carbonate such as chalk.

Suitably, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)). Without wishing to be bound by theory, it is believed that including fibrous filler in an amorphous solid may increase the tensile strength of the material. Additionally, including a fibrous filler has been found to improve the handling of the amorphous solid during manufacturing. In particular, it has been found that the resulting amorphous solid is less “tacky” and consequently is easier to shred during manufacturing. Including a fibrous filler can therefore increase manufacturing efficiency, reducing the likelihood of machine stops during shredding. Including a fibrous filler in the amorphous solid also means that the amorphous solid is less likely to clump together (e.g. agglomerate) once it has been shredded. When the shredded amorphous solid is included in consumables, reduced agglomeration optimises the distribution of the shredded amorphous solid in the consumables. It is therefore more likely that each consumable will contain a similar quantity of shredded amorphous solid, which may improve homogeneity of the flavourant loading within batches of consumables and/or within a given consumable. In some embodiments, the amorphous solid may comprise up to about 8owt%, 70wt%, 6owt%, 55wt%, 50wt% or 45wt% of flavourant. In some cases, the amorphous solid may comprise at least about o.iwt%, iwt%, iowt%, 20wt%, 30wt%, 35wt% or 40wt% of flavourant (all calculated on a dry weight basis). For example, the amorphous solid may comprise i-8owt%, io-8owt%, 20-70wt%, 3O-6owt%, 35-,55wt% or 3O-45wt% of flavourant. In exemplary embodiments, the amorphous solid comprises 35 - 50wt% of flavourant. In some cases, the flavourant comprises, consists essentially of or consists of menthol.

In some embodiments, the amorphous solid alternatively or additionally comprises an active substance. For example, in some cases, the amorphous solid additionally comprises a tobacco material and/or nicotine. In some cases, the amorphous solid may comprise 5-6owt% (calculated on a dry weight basis) of a tobacco material and/or nicotine. In some cases, the amorphous solid may comprise from about iwt%, 5 t%, iowt%, I5wt%, 20wt% or 25wt% to about 70wt%, 6owt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of an active substance. In some cases, the amorphous solid may comprise from about iwt%, 5wt%, iowt%, I5wt%,

20wt% or 25wt% to about 70wt%, 6owt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of a tobacco material. For example, the amorphous solid may comprise io-5Owt%, i5-40wt% or 2O-35wt% of a tobacco material. In some cases, the amorphous solid may comprise from about iwt%, 2wt%, 3wt% or 4 t% to about 2owt%, i8wt%, iswt% or i2wt% (calculated on a dry weight basis) of nicotine.

For example, the amorphous solid may comprise i-2Owt%, 2-i8wt% or 3-i2wt% of nicotine.

In some cases, the amorphous solid comprises an active substance such as tobacco extract. In some cases, the amorphous solid may comprise 5-6owt% (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid may comprise from about 5wt%, iowt%, I5wt%, 20wt% or 25wt% to about 6owt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) tobacco extract. For example, the amorphous solid may comprise io-5Owt%, i5-40wt% or 2O-35wt% of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the amorphous solid comprises iwt% i.5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%, 4-5wt% or 4wt% (calculated on a dry weight basis) of nicotine. In some cases, there may be no nicotine in the amorphous solid other than that which results from the tobacco extract.

In some embodiments the amorphous solid comprises no tobacco material but does comprise nicotine. In some such cases, the amorphous solid may comprise from about iwt%, 2wt%, 3wt% or 4wt% to about 20wt%, i8wt%, I5wt% or I2wt% (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may comprise 1- 20wt%, 2-i8wt% or 3-i2wt% of nicotine.

In some cases, the total content of active substance and/or flavourant maybe at least about o.iwt%, iwt%, 5wt%, iowt%, 20wt%, 2§wt% or 30wt% of the amorphous solid. In some cases, the total content of active substance and/or flavourant maybe less than about 9Owt%, 8owt%, 70wt%, 6owt%, 5Owt% or 4Owt% (all calculated on a dry weight basis). The aerosol-generating composition or amorphous solid may comprise an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monoprotic acid, a diprotic acid and a triprotic acid. In some such embodiments, the acid may contain at least one carboxyl functional group. In some such embodiments, the acid maybe at least one of an alpha-hydroxy acid, carboxylic acid, dicarboxylic acid, tricarboxylic acid and keto acid. In some such embodiments, the acid maybe an alpha-keto acid. In some such embodiments, the acid maybe at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic and pyruvic acid.

Suitably the acid is lactic acid. In other embodiments, the acid is benzoic acid. In other embodiments the acid may be an inorganic acid. In some of these embodiments the acid maybe a mineral acid. In some such embodiments, the acid maybe at least one of sulphuric acid, hydrochloric acid, boric acid and phosphoric acid. In some embodiments, the acid is levulinic acid. The inclusion of an acid is particularly preferred in embodiments in which the aerosolgenerating composition or amorphous solid comprises nicotine. In such embodiments, the presence of an acid may stabilise dissolved species in the slurry from which the aerosol-generating composition or amorphous solid is formed. The presence of the acid may reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing loss of nicotine during manufacturing.

In certain embodiments, the aerosol-generating composition or amorphous solid comprises a gelling agent comprising a cellulosic gelling agent and/or a non-cellulosic gelling agent, an active substance and an acid.

The amorphous solid may comprise a colourant. The addition of a colourant may alter the visual appearance of the amorphous solid. The presence of colourant in the amorphous solid may enhance the visual appearance of the amorphous solid and the aerosol-generating composition. By adding a colourant to the amorphous solid, the amorphous solid may be colour-matched to other components of the aerosol- generating composition or to other components of an article comprising the amorphous solid.

A variety of colourants may be used depending on the desired colour of the amorphous solid. The colour of amorphous solid may be, for example, white, green, red, purple, blue, brown or black. Other colours are also envisaged. Natural or synthetic colourants, such as natural or synthetic dyes, food-grade colourants and pharmaceutical-grade colourants may be used. In certain embodiments, the colourant is caramel, which may confer the amorphous solid with a brown appearance. In such embodiments, the colour of the amorphous solid may be similar to the colour of other components (such as tobacco material) in an aerosol-generating composition comprising the amorphous solid. In some embodiments, the addition of a colourant to the amorphous solid renders it visually indistinguishable from other components in the aerosol-generating composition.

The colourant maybe incorporated during the formation of the amorphous solid (e.g. when forming a slurry comprising the materials that form the amorphous solid) or it may be applied to the amorphous solid after its formation (e.g. by spraying it onto the amorphous solid).

The amorphous solid may comprise 1 to 6o wt% of a gelling agent, 0.1 to 70 wt% of an aerosol former material, 5 to 50 % of filler in the form of fibres, and 0.1 to 80 wt% of a flavourant and/or active substance. The amorphous solid may comprise 10 to 40 wt% gelling agent, 10 to 70 wt% of an aerosol former material, 20 to 40 wt% of filler and optionally 10 to 50 wt% of a flavourant.

In an embodiment, the amorphous solid comprises alginate in an amount of 32.8 w%, glycerol in an amount of 19.2 wt% and menthol in an amount of 48 wt%.

In an embodiment, the amorphous solid comprises alginate in amount of 26.2 wt%, glycerol in an amount of 15.4 wt%, menthol in an amount of 38.4 wt% and fibres (from wood pulp) in an amount of 20 wt%. In an embodiment, the amorphous solid comprises alginate in an amount of 32 wt%, pectin in an amount of 8 wt% and glycerol in an amount of 60 wt%.

In an embodiment, the amorphous solid comprises alginate in an amount of 24 wt%, pectin in an amount of 6 wt%, cellulose fibres in an amount of 10 wt% and glycerol in an amount of 60 wt%.

In an embodiment, the amorphous solid comprises carboxymethyl cellulose (CMC) in an amount of about 7 wt%, cellulose fibres (from wood pulp) in an amount of about 43 wt % and glycerol in an amount of about 50 wt%.

The amorphous solid may be prepared by (a) forming a slurry comprising components of the amorphous solid or precursors thereof, (b) forming a layer of the slurry, (c) setting the slurry to form a gel, and (d) drying to form an amorphous solid. Optionally, the setting the slurry comprises applying a setting agent to the slurry. In some embodiments, a setting agent is sprayed on on the slurry, such as a top surface of the slurry.

In examples, the setting agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the setting agent comprises or consists of calcium formate and/or calcium lactate. In particular examples, the setting agent comprises or consists of calcium formate. It has been identified that, typically, employing calcium formate as a setting agent results in an amorphous solid having a greater tensile strength and greater resistance to elongation.

The total amount of the setting agent, such as a calcium source, may be o.5-swt% (calculated on a dry weight basis). Suitably, the total amount maybe from about iwt%, 2.5wt% or 4wt% to about 4.8wt% or 4-5wt%. It has been found that the addition of too little setting agent may result in an amorphous solid which does not stabilise the amorphous solid components and results in these components dropping out of the amorphous solid. It has been found that the addition of too much setting agent results in an amorphous solid that is very tacky and consequently has poor handleability. When the amorphous solid does not contain tobacco, a higher amount of setting agent may need to be applied. In some cases the total amount of setting agent may therefore be from o.5-i2wt% such as 5-iowt%, calculated on a dry weight basis. Suitably, the total amount may be from about 5wt%, 6wt% or 7wt% to about I2wt% or iowt%. In this case the amorphous solid will not generally contain any tobacco. The (b) forming a layer of the slurry typically comprises spraying, casting or extruding the slurry. In examples, the slurry layer is formed by electrospraying the slurry. In examples, the slurry layer is formed by casting the slurry.

In some examples, (b) and/or (c) and/or (d), at least partially, occur simultaneously (for example, during electrospraying). In some examples, (b), (c) and (d) occur sequentially.

In some examples, the slurry is applied to a support. The layer may be formed on a support.

The amorphous solid may be provided as a shredded sheet. The shredded sheet may be formed by shredding the amorphous solid after it has been dried. In particular examples, the providing the amorphous solid comprises shredding a sheet of the amorphous solid to provide the amorphous solid as a shredded sheet.

Alternatively, the amorphous solid may be provided as an inner wrap in an article for use in a non-combustible aerosol-provision device. For example, the amorphous solid maybe a continuous sheet of material that circumscribes a rod comprising other components of the aerosol-generating material, such as expanded botanical material. The inclusion of an amorphous solid in the aerosol-generating material map help to enhance the organoleptic properties, such as the mouthfeel and taste, of the aerosol that is produced when the aerosol-generating material is heated. The incorporation of expanded botanical material into the aerosol-generating material may result in a reduction in the organoleptic properties of the aerosol compared with a composition of that does not comprise expanded botanical material. The inclusion of an amorphous solid in the aerosol-generating material, in addition to expanded material, may help to counter any reduction in the organoleptic properties that may be attributed to the inclusion of the expanded botanical material. The amorphous solid may have a lower fill value than expanded botanical material and so the inclusion of amorphous solid in the aerosol-generating material may contribute to maintaining the firmness and structural integrity of a rod of the aerosol-generating material.

The aerosol generating material maybe prepared by combining and blending a shredded sheet of amorphous solid and expanded botanical material.

The aerosol-generating material may comprise expanded botanical material and amorphous solid. In some embodiments, the aerosol-generating material comprises DIET and amorphous solid; DIET, expanded/seared stem and amorphous solid; or expanded/seared stem and amorphous solid.

In an embodiment, the aerosol generating material comprises DIET, expanded and/or seared stem and an amorphous solid comprising alginate in an amount of 32.8 w%, glycerol in an amount of 19.2 wt% and menthol in an amount of 48 wt%.

In an embodiment, the aerosol generating material comprises DIET, expanded and/or seared stem and an amorphous solid comprising alginate in amount of 26.2 wt%, glycerol in an amount of 15.4 wt%, menthol in an amount of 38.4 wt% and fibres (wood pulp) in an amount of 20 wt%.

In an embodiment, the aerosol generating material comprises DIET, expanded and/or seared stem and an amorphous solid comprising alginate in an amount of 32%, pectin in an amount of 8% and glycerol in an amount of 60%. In an embodiment, the aerosol generating material comprises DIET, expanded and/or seared stem and an amorphous solid comprising alginate in an amount of 24%, pectin in an amount of 6%, cellulose fibres in an amount of 10% and glycerol in an amount of 60%. In an embodiment, the aerosol generating material comprises DIET, expanded and/or seared stem and an amorphous solid comprising carboxymethyl cellulose (CMC) in an amount of about 7 wt%, cellulose fibres (from wood pulp) in an amount of about 43 wt% and glycerol in an amount of about 50 wt%. The amorphous solid may be included in the aerosol-generating material in combination with the expanded botanical material in any suitable amount. In some embodiments, the aerosol-generating material may for example comprise the amorphous solid in an amount of from about 1 wt% to about 90 wt%, from 1 wt% to about 80 wt%, from 1 wt% to about 70 wt%, from 1 wt% to about 60 wt%, from 1 wt% to about 50 wt%, from 1 wt% to about 40 wt%, from 1 wt% to about 30 wt%, from 1 wt% to about 20 wt% or from 1 wt% to about 10 wt,% and the remainder may comprise or consist of expanded botanical material and lamina and/or reconstituted tobacco material.

In some embodiments, the amorphous solid comprises from about 1% to about 50% amorphous solid and from about 1% to about 50% expanded botanical material.

The weight ratio of the amorphous solid to expanded botanical may be 1:1, 1:2, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8 or 1:9, or the weight ratio of the expanded botanical material to the amorphous solid maybe 1:2, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8 or 1:9.

In some embodiments, the aerosol-generating material comprises up to about 20 wt% or up to about 30 wt% amorphous solid. In some embodiments, the aerosol-generating material comprises the amorphous solid in an amount of between about 10 wt% and about 25 wt%.

In some embodiments, the aerosol-generating material comprises up to about 30 wt% amorphous solid, around 1 wt% to 30 wt% expanded botanical material and lamina and/or reconstituted tobacco as the remainder. For example, the aerosol-generating material may comprise between about 10 wt% and about 20 wt% amorphous solid, about 10 wt% expanded botanical material (e.g. DIET) and between about 70 wt% and 80 wt% lamina and/or reconstituted tobacco.

In some embodiments, the aerosol-generating material comprises up to about 30 wt% amorphous solid, around 1 wt% to 30 wt% expanded botanical material and a mixture of lamina and reconstituted tobacco as the remainder.

For example, the aerosol-generating material may comprise about 10 wt% amorphous solid, about 10 wt% expanded botanical material comprising DIET and a mixture comprising 80% lamina and reconstituted tobacco. In some embodiments, the aerosol- generating material comprises about 10 wt% amorphous solid, about 10 wt% expanded botanical material comprising DIET and about 80 wt% lamina tobacco. The weight ratio of reconstituted tobacco to lamina can be, for example, 90:10, 80:20, 70:30, 60:40, 50:50, 40:60, 30:70, 20:80 or 10:90. Using higher quantities of lamina relative to reconstituted tobacco may improve the sensory properties of the aerosol- generating material and provide a more authentic flavour.

When the aerosol-generating material is incorporated into the article for use in a noncombustible aerosol provision system, the aerosol-generating material maybe compressed.

In addition to the aerosol-generating material, the article may also comprise 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.

An article for use in a non-combustible aerosol provision system is depicted in Figure 7.

The article 1 comprises a mouthpiece 2, and a cylindrical rod of aerosol-generating material 3 in an aerosol-generating section of the article connected to the mouthpiece 2.

The aerosol-generating material comprises expanded tobacco (in this case, DIET) in an amount of about 10% by weight of the aerosol-generating material. The aerosolgenerating section of the article can have a pressure drop of across it of from about 35 to about 70 mm Wg.

The aerosol-generating section may define a volume of from about 100 mm3, 200 m3, 300 mm3, 400 mnU, 500 mm3, 600 mm3 or 700 mm3 up to about 800 mm3, 900 mm3, 1000 mm3, 1100 mm3, 1200 mm3, 1300 mm3, 1400 mm3 or 1500 mm3, in some embodiments, the volume of the aerosol-generating section is from about 800 mm ³ to about 1300 mm ³ .

In the illustrated embodiment, the aerosol-generating material 3 comprises at least one aerosol former. In the present example, the aerosol former is glycerol. In alternative examples, the aerosol former can be another material as described herein or a combination thereof. The aerosol former has been found to improve the sensory performance of the article, by helping to transfer compounds such as flavour compounds from the aerosol-generating material to the consumer. However, an issue with adding such aerosol formers to the aerosol-generating material within an article for use in a non-combustible aerosol provision system can be that, when the aerosol former is aerosolised upon heating, it can increase the mass of aerosol which is delivered by the article, and this increased mass can maintain a higher temperature as it passes through the mouthpiece. As it passes through the mouthpiece, the aerosol transfers heat into the mouthpiece and this warms the outer surface of the mouthpiece, including the area which comes into contact with the consumers lips during use. The mouthpiece temperature can be significantly higher than consumers may be accustomed to when smoking, for instance, conventional cigarettes, and this can be an undesirable effect caused by the use of such aerosol formers.

The part of the mouthpiece which comes into contact with a consumer’s lips has usually been a paper tube, which is either hollow or surrounds a cylindrical body of filter material.

As shown in Figure 7, the mouthpiece 2 of the article 1 comprises an upstream end 2a adjacent to the aerosol generating substrate 3 and a downstream end 2b distal from the aerosol generating substrate 3. At the downstream end 2b, the mouthpiece 2 has a hollow tubular element 4 formed from filamentary tow. This has advantageously been found to significantly reduce the temperature of the outer surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece which comes into contact with a consumer’s mouth when the article 1 is in use. In addition, the use of the tubular element 4 has also been found to significantly reduce the temperature of the outer surface of the mouthpiece 2 even upstream of the tubular element 4. Without wishing to be bound by theory, it is hypothesised that this is due to the tubular element 4 channelling aerosol closer to the centre of the mouthpiece 2, and therefore reducing the transfer of heat from the aerosol to the outer surface of the mouthpiece 2. In the present example, the article 1 has an outer circumference of about 21 mm (i.e. the article is in the demi-slim format). In other examples, the article can be provided in any of the formats described herein, for instance having an outer circumference of between 15mm and 25mm. Since the article is to be heated to release an aerosol, improved heating efficiency can be achieved using articles having lower outer circumferences within this range, for instance circumferences of less than 23mm. To achieve improved aerosol via heating, while maintaining a suitable product length, article circumferences of greater than 19mm have also been found to be particularly effective. Articles having circumferences of between 19mm and 23mm, and more preferably between 20mm and 22mm, have been found to provide a good balance between providing effective aerosol delivery while allowing for efficient heating. The outer circumference of the mouthpiece 2 is substantially the same as the outer circumference of the rod of aerosol-generating material 3, such that there is a smooth transition between these components. In the present example, the outer circumference of the mouthpiece 2 is about 20.8mm. A tipping paper 5 is wrapped around the full length of the mouthpiece 2 and over part of the rod of aerosol-generating material 3 and has an adhesive on its inner surface to connect the mouthpiece 2 and rod 3. In the present example, the tipping paper 5 extends 5 mm over the rod of aerosol-generating material 3 but it can alternatively extend between 3 mm and 10 mm over the rod 3, or more preferably between 4 mm and 6 mm, to provide a secure attachment between the mouthpiece 2 and rod 3. The tipping paper 5 can have a basis weight which is higher than the basis weight of plug wraps used in the article 1, for instance a basis weight of 40 gsm to 80 gsm, more preferably between 50 gsm and 70 gsm, and in the present example 58 gsm. These ranges of basis weights have been found to result in tipping papers having acceptable tensile strength while being flexible enough to wrap around the article 1 and adhere to itself along a longitudinal lap seam on the paper. The outer circumference of the tipping paper 5, once wrapped around the mouthpiece 2, is about

21mm.

The "wall thickness" of the hollow tubular element 4 corresponds to the thickness of the wall of the tube 4 in a radial direction. This may be measured, for example, using a calliper. The wall thickness is advantageously greater than 0.9mm, and more preferably 1.0mm or greater. Preferably, the wall thickness is substantially constant around the entire wall of the hollow tubular element 4. However, where the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9 mm at any point around the hollow tubular element 4, more preferably 1.0mm or greater.

Preferably, the length of the hollow tubular element 4 is less than about 20 mm. More preferably, the length of the hollow tubular element 4 is less than about 15 mm. Still more preferably, the length of the hollow tubular element 4 is less than about 10 mm. In addition, or as an alternative, the length of the hollow tubular element 4 is at least about 5 mm. Preferably, the length of the hollow tubular element 4 is at least about 6 mm. In some preferred embodiments, the length of the hollow tubular element 4 is from about 5 mm to about 20 mm, more preferably from about 6 mm to about 10 mm, even more preferably from about 6 mm to about 8 mm, most preferably about 6 mm, 7 mm or about 8 mm. In the present example, the length of the hollow tubular element 4 is 6 mm.

Preferably, the density of the hollow tubular element 4 is at least about 0.25 grams per cubic centimetre (g/cc), more preferably at least about 0.3 g/cc. Preferably, the density of the hollow tubular element 4 is less than about 0.75 grams per cubic centimetre Cg/ cc), more preferably less than 0.6 g/cc. In some embodiments, the density of the hollow tubular element 4 is between 0.25 and 0.75 g/cc, more preferably between 0.3 and 0.6 g/cc, and more preferably between 0.4 g/cc and 0.6 g/cc or about 0.5 g/cc.

These densities have been found to provide a good balance between improved firmness afforded by denser material and the lower heat transfer properties of lower density material. For the purposes of the present invention, the "density" of the hollow tubular element 4 refers to the density of the filamentary tow forming the element with any plasticiser incorporated. The density maybe determined by dividing the total weight of the hollow tubular element 4 by the total volume of the hollow tubular element 4, wherein the total volume can be calculated using appropriate measurements of the hollow tubular element 4 taken, for example, using callipers. Where necessary, the appropriate dimensions may be measured using a microscope.

The filamentary tow forming the hollow tubular element 4 preferably has a total denier of less than 45,000, more preferably less than 42,000. This total denier has been found to allow the formation of a tubular element 4 which is not too dense. Preferably, the total denier is at least 20,000, more preferably at least 25,000. In preferred embodiments, the filamentary tow forming the hollow tubular element 4 has a total denier between 25,000 and 45,000, more preferably between 35,000 and 45,000.

Preferably the cross-sectional shape of the filaments of tow are ‘Y’ shaped, although in other embodiments other shapes such as ‘X’ shaped filaments can be used.

The filamentary tow forming the hollow tubular element 4 preferably has a denier per filament of greater than 3. This denier per filament has been found to allow the formation of a tubular element 4 which is not too dense. Preferably, the denier per filament is at least 4, more preferably at least 5. In preferred embodiments, the filamentary tow forming the hollow tubular element 4 has a denier per filament between 4 and 10, more preferably between 4 and 9. In one example, the filamentary tow forming the hollow tubular element 4 has an 8Y4O,OOO tow formed from cellulose acetate and comprising 18% plasticiser, for instance triacetin.

The hollow tubular element 4 preferably has an internal diameter of greater than 3.0mm. Smaller diameters than this can result in increasing the velocity of aerosol passing though the mouthpiece 2 to the consumer’s mouth more than is desirable, such that the aerosol becomes too warm, for instance reaching temperatures greater than 4O°C or greater than 45°C. More preferably, the hollow tubular element 4 has an internal diameter of greater than 3.1mm, and still more preferably greater than 3.5mm or 3.6mm. In one embodiment, the internal diameter of the hollow tubular element 4 is about 3.9mm.

The hollow tubular element 4 preferably comprises from 15% to 22% by weight of plasticiser. For cellulose acetate tow, the plasticiser is preferably triacetin, although other plasticisers such as polyethylene glycol (PEG) can be used. More preferably, the tubular element 4 comprises from 16% to 20% by weight of plasticiser, for instance about 17%, about 18% or about 19% plasticiser.

The pressure drop or difference (also referred to a resistance to draw) across the mouthpiece, for instance the part of the article 1 downstream of the aerosol-generating material 3, is preferably less than about 40 mmH ₂ o. Such pressure drops have been found to allow sufficient aerosol, including desirable compounds such as flavour compounds, to pass through the mouthpiece 2 to the consumer. More preferably, the pressure drop across the mouthpiece 2 is less than about 32mmH ₂ o. In some embodiments, particularly improved aerosol has been achieved using a mouthpiece 2 having a pressure drop of less than 31 mmH ₂ o, for instance about 29 mmH ₂ o, about 28 mmH ₂ o or about 27.5 mmH ₂ o. Alternatively or additionally, the mouthpiece pressure drop can be at least 10 mmH ₂ o, preferably at least 15 mmH ₂ o and more preferably at least 20 mmH ₂ o. In some embodiments, the mouthpiece pressure drop can be between about 15 mmHzO and 40 mmH ₂ o. These values enable the mouthpiece 2 to slow down the aerosol as it passes through the mouthpiece 2 such that the temperature of the aerosol has time to reduce before reaching the downstream end 2b of the mouthpiece 2.

The mouthpiece 2, in the present example, includes a body of material 6 upstream of the hollow tubular element 4, in this example adjacent to and in an abutting relationship with the hollow tubular element 4. The body of material 6 and hollow tubular element 4 each define a substantially cylindrical overall outer shape and share a common longitudinal axis. The body of material 6 is wrapped in a first plug wrap 7. Preferably, the first plug wrap 7 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. Preferably, the first plug wrap 7 has a thickness of between 30 pm and 60 pm, more preferably between 35 pm and 45 pm. Preferably, the first plug wrap 7 is 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 first plug wrap 7 can be a porous plug wrap, for instance having a permeability of greater than 200 Coresta Units.

Preferably, the length of the body of material 6 is less than about 15 mm. More preferably, the length of the body of material 6 is less than about 10 mm. In addition, or as an alternative, the length of the body of material 6 is at least about 5 mm. Preferably, the length of the body of material 6 is at least about 6 mm. In some preferred embodiments, the length of the body of material 6 is from about 5 mm to about 15 mm, more preferably from about 6 mm to about 12 mm, even more preferably from about 6 mm to about 12 mm, most preferably about 6 mm, 7 mm, 8 mm, 9 mm or 10 mm. In the present example, the length of the body of material 6 is 10 mm. In the present example, the body of material 6 is formed from filamentary tow. In the present example, the tow used in the body of material 6 has a denier per filament (d.p.f.) of 8.4 and a total denier of 21,000. Alternatively, the tow can, for instance, have a denier per filament (d.p.f.) of 9.5 and a total denier of 12,000. In the present example, the tow comprises plasticised cellulose acetate tow. The plasticiser used in the tow comprises about 7% by weight of the tow. In the present example, the plasticiser is triacetin. In other examples, different materials can be used to form the body of material 6. For instance, rather than tow, the body 6 can be formed from paper, for instance in a similar way to paper filters known for use in cigarettes. Alternatively, the body 6 can be formed from tows other than cellulose acetate, for instance polylactic acid (PLA), other materials described herein for filamentary tow or similar materials. The tow is preferably formed from cellulose acetate. The tow, whether formed from cellulose acetate or other materials, preferably has a d.p.f. of at least 5, more preferably at least 6 and still more preferably at least 7. These values of denier per filament provide a tow which has relatively coarse, thick fibres with a lower surface area which result in a lower pressure drop across the mouthpiece 2 than tows having lower d.p.f. values. Preferably, to achieve a sufficiently uniform body of material 6, the tow has a denier per filament of no more than 12 d.p.f., preferably no more than 11 d.p.f. and still more preferably no more than 10 d.p.f. The total denier of the tow forming the body of material 6 is preferably at most 30,000, more preferably at most 28,000 and still more preferably at most 25,000. These values of total denier provide a tow which takes up a reduced proportion of the cross sectional area of the mouthpiece 2 which results in a lower pressure drop across the mouthpiece 2 than tows having higher total denier values. For appropriate firmness of the body of material 6, the tow preferably has a total denier of at least 8,000 and more preferably at least 10,000. Preferably, the denier per filament is between 5 and 12 while the total denier is between 10,000 and 25,000. More preferably, the denier per filament is between 6 and 10 while the total denier is between 11,000 and 22,000. Preferably the cross-sectional shape of the filaments of tow are Y shaped, although in other embodiments other shapes such as ‘X’ shaped filaments can be used, with the same d.p.f. and total denier values as provided herein.

In the present example the hollow tubular element 4 is a first hollow tubular element 4 and the mouthpiece includes a second hollow tubular element 8, also referred to as a cooling element, upstream of the first hollow tubular element 4. In the present example, the second hollow tubular element 8 is upstream of, adjacent to and in an abutting relationship with the body of material 6. The body of material 6 and second hollow tubular element 8 each define a substantially cylindrical overall outer shape and share a common longitudinal axis. The second hollow tubular element 8 is formed from a plurality of layers of paper which are parallel wound, with butted seams, to form the tubular element 8. In the present example, first and second paper layers are provided in a two-ply tube, although in other examples 3, 4 or more paper layers can be used forming 3, 4 or more ply tubes. Other constructions can be used, such as spirally wound layers of paper, cardboard tubes, tubes formed using a papier-mache type process, moulded or extruded plastic tubes or similar. The second hollow tubular element 8 can also be formed using a stiff plug wrap and/ or tipping paper as the second plug wrap 9 and/or tipping paper 5 described herein, meaning that a separate tubular element is not required. The stiff plug wrap and/or tipping paper 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. For instance, the stiff plug wrap and/or tipping paper can have a basis weight between 70 gsm and 120 gsm, more preferably between 80 gsm and 110 gsm. Additionally or alternatively, the stiff plug wrap and/or tipping paper can have a thickness between 80 pm and 200 pm, more preferably between 100 pm and 160 pm, or from 120 pm to 150 pm. It can be desirable for both the second plug wrap 9 and tipping paper 5 to have values in these ranges, to achieve an acceptable overall level of rigidity for the second hollow tubular element 8.

The second hollow tubular element 8 preferably has a wall thickness, which can be measured in the same way as that of the first hollow tubular element 4, of at least about 100 pm and up to about 1.5mm, preferably between 100 pm and 1 mm and more preferably between 150 pm and 500 pm, or about 300 pm. In the present example, the second hollow tubular element 8 has a wall thickness of about 290 pm.

Preferably, the length of the second hollow tubular element 8 is less than about 50 mm. More preferably, the length of the second hollow tubular element 8 is less than about 40 mm. Still more preferably, the length of the second hollow tubular element 8 is less than about 30 mm. In addition, or as an alternative, the length of the second hollow tubular element 8 is preferably at least about 10 mm. Preferably, the length of the second hollow tubular element 8 is at least about 15 mm. In some preferred embodiments, the length of the second hollow tubular element 8 is from about 20 mm to about 30 mm, more preferably from about 22 mm to about 28 mm, even more preferably from about 24 to about 26 mm, most preferably about 25 mm. In the present example, the length of the second hollow tubular element 8 is 25 mm. The second hollow tubular element 8 is located around and defines an air gap within the mouthpiece 2 which acts as a cooling segment. The air gap provides a chamber through which heated volatilised components generated by the aerosol-generating material 3 flow. The second hollow tubular element 8 is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article 1 is in use.

The second hollow tubular element 8 provides a physical displacement between the aerosol-generating material 3 and the body of material 6. The physical displacement provided by the second hollow tubular element 8 will provide a thermal gradient across the length of the second hollow tubular element 8. Preferably, the mouthpiece 2 comprises a cavity having an internal volume greater than 450 mm3. Providing a cavity of at least this volume has been found to enable the formation of an improved aerosol. Such a cavity size provides sufficient space within the mouthpiece 2 to allow heated volatilised components to cool, therefore allowing the exposure of the aerosol-generating material 3 to higher temperatures than would otherwise be possible, since they may result in an aerosol which is too warm. In the present example, the cavity is formed by the second hollow tubular element 8, but in alternative arrangements it could be formed within a different part of the mouthpiece 2. More preferably, the mouthpiece 2 comprises a cavity, for instance formed within the second hollow tubular element 8, having an internal volume greater than 500 mm3, and still more preferably greater than 550 mm3, allowing further improvement of the aerosol. In some examples, the internal cavity comprises a volume of between about 550 mm ³ and about 750 mm ³ , for instance about 600 mm ³ or 700 mm ³ . The second hollow tubular element 8 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 second hollow tubular element 8 and a heated volatilised component exiting a second, downstream end of the second hollow tubular element 8. The second hollow tubular element 8 is preferably configured to provide a temperature differential of at least 60 degrees Celsius, preferably at least 80 degrees Celsius and more preferably at least 100 degrees Celsius between a heated volatilised component entering a first, upstream end of the second hollow tubular element 8 and a heated volatilised component exiting a second, downstream end of the second hollow tubular element 8. This temperature differential across the length of the second hollow tubular element 8 protects the temperature sensitive body of material 6 from the high temperatures of the aerosol-generating material 3 when it is heated.

In alternative articles, the second hollow tubular element 8 can be replaced with an alternative cooling element, for instance an element formed from a body of material which allows aerosol to pass through it longitudinally, and which also performs the function of cooling the aerosol.

In the present example, the first hollow tubular element 4, body of material 6 and second hollow tubular element 8 are combined using a second plug wrap 9 which is wrapped around all three sections. Preferably, the second plug wrap 9 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 45 gsm. Preferably, the second plug wrap 9 has a thickness of between 30 pm and 60 pm, more preferably between 35 pm and 45 pm. The second plug wrap 9 is preferably a non- porous plug wrap having a permeability of less than 100 Coresta Units, for instance less than 50 Coresta Units. However, in alternative embodiments, the second plug wrap 9 can be a porous plug wrap, for instance having a permeability of greater than 200 Coresta Units.

In the present example, the aerosol-generating material 3 is wrapped in a wrapper 10.

The wrapper 10 can, for instance, be a paper or paper-backed foil wrapper. In the present example, the wrapper 10 is substantially impermeable to air. In alternative embodiments, the wrapper 10 preferably has a permeability of less than 100 Coresta Units, more preferably less than 60 Coresta Units. It has been found that low permeability wrappers, for instance having a permeability of less than 100 Coresta Units, more preferably less than 60 Coresta Units, result in an improvement in the aerosol formation in the aerosol-generating material 3. Without wishing to be bound by theory, it is hypothesised that this is due to reduced loss of aerosol compounds through the wrapper 10. The permeability of the wrapper 10 can be measured in accordance with ISO 2965:2009 concerning the determination of air permeability for materials used as cigarette papers, filter plug wrap and filter joining paper.

In the present embodiment, the wrapper 10 comprises aluminium foil. Aluminium foil has been found to be particularly effective at enhancing the formation of aerosol within the aerosol-generating material 3. In the present example, the aluminium foil has a metal layer having a thickness of about 6 pm. In the present example, the aluminium foil has a paper backing. However, in alternative arrangements, the aluminium foil can be other thicknesses, for instance between 4 pm and 16 pm in thickness. The aluminium foil also need not have a paper backing, but could have a backing formed from other materials, for instance to help provide an appropriate tensile strength to the foil, or it could have no backing material. Metallic layers or foils other than aluminium can also be used. The total thickness of the wrapper is preferably between 20 pm and 60 pm, more preferably between 30 pm and 50 pm, which can provide a wrapper having appropriate structural integrity and heat transfer characteristics. The tensile force which can be applied to the wrapper before it breaks can be greater than 3,000 grams force, for instance between 3,000 and 10,000 grams force or between 3,000 and 4,500 grams force. The article may have a ventilation level of about 75% of the aerosol drawn through the article. In alternative embodiments, the article can have a ventilation level of between 50% and 80% of aerosol drawn through the article, for instance between 65% and 75%. Ventilation at these levels helps to slow down the flow of aerosol drawn through the mouthpiece 2 and thereby enable the aerosol to cool sufficiently before it reaches the downstream end 2b of the mouthpiece 2. The ventilation is provided directly into the mouthpiece 2 of the article 1. In the present example, the ventilation is provided into the second hollow tubular element 8, which has been found to be particularly beneficial in assisting with the aerosol generation process. The ventilation is provided via first and second parallel rows of perforations 12, in the present case formed as laser perforations, at positions 17.925 mm and 18.625 ^mm respectively from the downstream, mouth-end 2b of the mouthpiece 2. These perforations pass though the tipping paper 5, second plug wrap 9 and second hollow tubular element 8. In alternative embodiments, the ventilation can be provided into the mouthpiece at other locations, for instance into the body of material 6 or first tubular element 4.

In the present example, the aerosol former added to the aerosol generating substrate 3 comprises 15% by weight of the aerosol generating substrate 3. Preferably, the aerosol former comprises at least 5% by weight of the aerosol generating substrate, more preferably at least 10%. Preferably, the aerosol former comprises less than 25% by weight of the aerosol generating substrate, more preferably less than 20%, for instance between 10% and 20%, between 12% and 18% or between 13% and 16%. Preferably the aerosol-generating material 3 is provided as a cylindrical rod of aerosolgenerating material. Irrespective of the form of the aerosol-generating material, it preferably has a length of about 10 mm to 100 mm. In some embodiments, the length of the aerosol-generating material is preferably in the range about 25 mm to 50 mm, more preferably in the range about 30 mm to 45 mm, and still more preferably about 30 mm to 40 mm.

The volume of aerosol-generating material 3 provided can vary from about 200 mm3 to about 4300 mm3, preferably from about 500 mm3 to 1500 mm3, more preferably from about 1000 mm3 to about 1300 mm3. The provision of these volumes of aerosol- generating material, for instance from about 1000 mm3 to about 1300 mm3, has been advantageously shown to achieve a superior aerosol, having a greater visibility and sensory performance compared to that achieved with volumes selected from the lower end of the range.

The mass of aerosol-generating material 3 provided can be greater than 200 mg, for instance from about 200 mg to 400 mg, preferably from about 230 mg to 360 mg, more preferably from about 250 mg to 360 mg. It has been advantageously found that providing a higher mass of aerosol-generating material results in improved sensory performance compared to aerosol generated from a lower mass of tobacco material. Preferably the aerosol-generating material is formed from tobacco material as described herein, which includes a tobacco component.

In some embodiments, the aerosol-generating material is a sheet or shredded sheet of material comprising first and second botanical materials.

In some embodiments, the aerosol-generating material comprises an intimate mixture of the first botanical material and the second botanical material.

Including a botanical material having a fill value of greater than about 6 mL/g into the rod increases the tendency for aerosol-generating material to fall or spill out of the rod.

Without wishing to be bound by theory, this may be due to the relatively small particle size of the expanded botanical material and lower overall weight of the aerosolgenerating material. In order to limit the amount of aerosol-generating material falling out of the rod, the packing density of the aerosol-generating material can be higher at the distal end of the rod.

Thus, the packing density of aerosol-generating material 3 can vary throughout the rod. In particular, the density of the aerosol-generating material 3 can be greater at the distal end of the rod of aerosol-generating material than the proximal end. The packing density of the aerosol-generating material at the distal end of the rod may be increased by applying pressure to the tobacco material in this region of the rod during manufacture.

A non-combustible aerosol provision device is used to heat the aerosol generating material of the articles described herein. The non-combustible aerosol provision device preferably comprises a coil, since this has been found to enable improved heat transfer to the article as compared to other arrangements.

In some examples, the coil is configured to, in use, cause heating of at least one electrically-conductive heating element, so that heat energy is conductible from the at least one electrically-conductive heating element to the aerosol generating material to thereby cause heating of the aerosol generating material.

In some examples, the coil is configured to generate, in use, a varying magnetic field for penetrating at least one heating element, to thereby cause induction heating and/ or magnetic hysteresis heating of the at least one heating element. In such an arrangement, the or each heating element maybe termed a “susceptor” as defined herein. A coil that is configured to generate, in use, a varying magnetic field for penetrating at least one electrically-conductive heating element, to thereby cause induction heating of the at least one electrically-conductive heating element, may be termed an “induction coil” or “inductor coil”.

The device may include the heating element(s), for example electrically-conductive heating element(s), and the heating element(s) maybe suitably located or locatable relative to the coil to enable such heating of the heating element(s). The heating element(s) may be in a fixed position relative to the coil. Alternatively, the at least one heating element, for example at least one electrically-conductive heating element, may be included in the article for insertion into a heating zone of the device, wherein the article also comprises the aerosol generating material 3 and is removable from the heating zone after use. Alternatively, both the device and such an article may comprise at least one respective heating element, for example at least one electrically-conductive heating element, and the coil may be to cause heating of the heating element(s) of each of the device and the article when the article is in the heating zone. In some examples, the coil is helical. In some examples, the coil encircles at least a part of a heating zone of the device that is configured to receive aerosol generating material. In some examples, the coil is a helical coil that encircles at least a part of the heating zone. In some examples, the device comprises an electrically-conductive heating element that at least partially surrounds the heating zone, and the coil is a helical coil that encircles at least a part of the electrically-conductive heating element. In some examples, the electrically-conductive heating element is tubular. In some examples, the coil is an inductor coil. In some examples, the use of a coil enables the non-combustible aerosol provision device to reach operational temperature more quickly than a non-coil aerosol provision device. For instance, the non-combustible aerosol provision device including a coil as described above can reach an operational temperature such that a first puff can be provided in less than 30 seconds from initiation of a device heating program, more preferably in less than 25 seconds. In some examples, the device can reach an operational temperature in about 20 seconds from the initiation of a device heating program.

The use of a coil as described herein in the device to cause heating of the aerosol generating material has been found to enhance the aerosol which is produced. For instance, consumers have reported that the aerosol generated by a device including a coil such as that described herein is sensorially closer to that generated in factory made cigarette (FMC) products than the aerosol produced by other non-combustible aerosol provision systems. Without wishing to be bound by theory, it is hypothesised that this is the result of the reduced time to reach the required heating temperature when the coil is used, the higher heating temperatures achievable when the coil is used and/or the fact that the coil enables such systems to simultaneously heat a relatively large volume of aerosol generating material, resulting in aerosol temperatures resembling FMC aerosol temperatures. In FMC products, the burning coal generates a hot aerosol which heats tobacco in the tobacco rod behind the coal, as the aerosol is drawn through the rod. This hot aerosol is understood to release flavour compounds from tobacco in the rod behind the burning coal. A device including a coil as described herein is thought to also be capable of heating aerosol generating material, such as tobacco material described herein, to release flavour compounds, resulting in an aerosol which has been reported to more closely resemble an FMC aerosol.

Using an aerosol provision system including a coil as described herein, for instance an induction coil which heats at least some of the aerosol generating material to at least 2oo°C, more preferably at least 22O°C, can enable the generation of an aerosol from an aerosol generating material that has particular characteristics which are thought to more closely resemble those of an FMC product. For example, when heating an aerosol generating material, including nicotine, using an induction heater, heated to at least 25O°C, for a two-second period, under an airflow of at least l.soL/m during the period, one or more of the following characteristics has been observed: at least 10 pg of nicotine is aerosolised from the aerosol generating material; the weight ratio in the generated aerosol, of aerosol forming material to nicotine is at least about 2.5:1, suitably at least 8.5:1; at least 100 pg of the aerosol forming material can be aerosolised from the aerosol generating material; the mean particle or droplet size in the generated aerosol is less than about 1000 nm; and the aerosol density is at least 0.1 pg/ cc.

In some cases, at least 10 pg of nicotine, suitably at least 30 pg or 40 pg of nicotine, is aerosolised from the aerosol generating material under an airflow of at least i.50L/m during the period. In some cases, less than about 200 pg, suitably less than about 150 pg or less than about 125 pg, of nicotine is aerosolised from the aerosol generating material under an airflow of at least l.soL/m during the period.

In some cases, the aerosol contains at least 100 pg of the aerosol forming material, suitably at least 200 pg, 500 pg or 1 mg of aerosol forming material is aerosolised from the aerosol generating material under an airflow of at least l.soL/m during the period. Suitably, the aerosol forming material may comprise or consist of glycerol.

As defined herein, the term “mean particle or droplet size” refers to the mean size of the solid or liquid components of an aerosol (i.e. the components suspended in a gas).

Where the aerosol contains suspended liquid droplets and suspended solid particles, the term refers to the mean size of all components together.

In some cases, the mean particle or droplet size in the generated aerosol may be less than about 900 nm, 800 nm, 700, nm 600 nm, soonm, 450nm or 400 nm. In some cases, the mean particle or droplet size maybe more than about 25 nm, 50 nm or loonm.

In some cases, the aerosol density generated during the period is at least 0.1 pg/cc. In some cases, the aerosol density is at least 0.2 pg/cc, 0.3 pg/cc or 0.4 pg/cc. In some cases, the aerosol density is less than about 2.5 pg/cc, 2.0 pg/cc, 1.5 pg/cc or 1.0 pg/cc. The non-combustible aerosol provision device is preferably arranged to heat the aerosol generating material 3 of the article 1, to a maximum temperature of at least i6o°C. Preferably, the non-combustible aerosol provision device is arranged to heat the aerosol forming material 3 of the article 1, to a maximum temperature of at least about 200°C, or at least about 220°C, or at least about 24O°C, more preferably at least about 27O°C, at least once during the heating process followed by the non-combustible aerosol provision device.

Using an aerosol provision system including a coil as described herein, for instance an induction coil which heats at least some of the aerosol generating material to at least 200°C, more preferably at least 220°C, can enable the generation of an aerosol from an aerosol generating material in an article 1 as described herein that has a higher temperature as the aerosol leaves the mouth end of the mouthpiece 2 than previous devices, contributing to the generation of an aerosol which is considered closer to an FMC product. For instance, the maximum aerosol temperature measured at the mouth-end of the article 1 can preferably be greater than 5O°C, more preferably greater than 55°C and still more preferably greater than 56°C or 57°C. Additionally or alternatively, the maximum aerosol temperature measured at the mouth-end of the article 1 can be less than 62°C, more preferably less than 6o°C and more preferably less than 59°C. In some embodiments, the maximum aerosol temperature measured at the mouth-end of the article 1 can preferably be between 5O°C and 62°C, more preferably between 56°C and 6o°C.

Figure 8 shows an example of a non-combustible aerosol provision device 100 for generating aerosol from an aerosol generating medium/material such as the aerosol generating material 3 of the articles 1 described herein. In broad outline, the device 100 maybe used to heat a replaceable article 110 comprising the aerosol generating medium, for instance the articles 1 described herein, to generate an aerosol or other inhalable medium which is inhaled by a user of the device 100. The device 100 and replaceable article no together form a system.

The device 100 comprises a housing 102 (in the form of an outer cover) which surrounds and houses various components of the device 100. The device 100 has an opening 104 in one end, through which the article 110 maybe inserted for heating by a heating assembly. In use, the article no may be fully or partially inserted into the heating assembly where it may be heated by one or more components of the heater assembly. The heater assembly comprises a heater which is configured to supply heat to the article and volatilise at least a portion of the aerosol-generating material.

The heater may comprise one or more electrically resistive heaters, including for example one or more nichrome resistive heater(s) and/or one or more ceramic heater(s). The one or more heaters may comprise one or more induction heaters which includes an arrangement comprising one or more susceptors which may form a chamber into which an article comprising aerosolisable material is inserted or otherwise located in use. Alternatively or in addition, one or more susceptors may be provided in the aerosolisable material. Other heating arrangements may also be used.

The device 100 of this example comprises a first end member 106 which comprises a lid 108 which is moveable relative to the first end member 106 to close the opening 104 when no article 110 is in place. In Figure 8, the lid 108 is shown in an open configuration, however the lid 108 may move into a closed configuration. For example, a user may cause the lid 108 to slide in the direction of arrow “B”. The device 100 may also include a user-operable control element 112, such as a button or switch, which operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the switch 112.

The device 100 may also comprise an electrical component, such as a socket/port 114, which can receive a cable to charge a battery of the device 100. For example, the socket

114 maybe a charging port, such as a USB charging port.

Figure 9 depicts the device 100 of Figure 8 with the outer cover 102 removed and without an article 110 present. The device 100 defines a longitudinal axis 134. As shown in Figure 9, the first end member 106 is arranged at one end of the device 100 and a second end member 116 is arranged at an opposite end of the device 100. The first and second end members 106, 116 together at least partially define end surfaces of the device 100. For example, the bottom surface of the second end member 116 at least partially defines a bottom surface of the device 100. Edges of the outer cover 102 may also define a portion of the end surfaces. In this example, the lid 108 also defines a portion of a top surface of the device 100. The end of the device closest to the opening 104 may be known as the proximal end (or mouth end) of the device 100 because, in use, it is closest to the mouth of the user. In use, a user inserts an article 110 into the opening 104, operates the user control 112 to begin heating the aerosol generating material and draws on the aerosol generated in the device. This causes the aerosol to flow through the device 100 along a flow path towards the proximal end of the device 100.

The other end of the device furthest away from the opening 104 may be known as the distal end of the device 100 because, in use, it is the end furthest away from the mouth of the user. As a user draws on the aerosol generated in the device, the aerosol flows away from the distal end of the device 100.

The device 100 further comprises a power source 118. The power source 118 maybe, for example, a battery, such as a rechargeable battery or a non-rechargeable battery.

Examples of suitable batteries include, for example, a lithium battery (such as a lithium-ion battery), a nickel battery (such as a nickel-cadmium battery), and an alkaline battery. The battery is electrically coupled to the heating assembly to supply electrical power when required and under control of a controller (not shown) to heat the aerosol generating material. In this example, the battery is connected to a central support 120 which holds the battery 118 in place.

The device further comprises at least one electronics module 122. The electronics module 122 may comprise, for example, a printed circuit board (PCB). The PCB 122 may support at least one controller, such as a processor, and memory. The PCB 122 may also comprise one or more electrical tracks to electrically connect together various electronic components of the device 100. For example, the battery terminals maybe electrically connected to the PCB 122 so that power can be distributed throughout the device 100. The socket 114 may also be electrically coupled to the battery via the electrical tracks.

In the example device 100, the heating assembly is an inductive heating assembly and comprises various components to heat the aerosol generating material of the article 110 via an inductive heating process. Induction heating is a process of heating an electrically conducting object (such as a susceptor) by electromagnetic induction. An induction heating assembly may comprise an inductive element, for example, one or more inductor coils, and a device for passing a varying electric current, such as an alternating electric current, through the inductive element. The varying electric current in the inductive element produces a varying magnetic field. The varying magnetic field penetrates a susceptor suitably positioned with respect to the inductive element, and generates eddy currents inside the susceptor. The susceptor has electrical resistance to the eddy currents, and hence the flow of the eddy currents against this resistance causes the susceptor to be heated by Joule heating. In cases where the susceptor comprises ferromagnetic material such as iron, nickel or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e. by the varying orientation of magnetic dipoles in the magnetic material as a result of their alignment with the varying magnetic field. In inductive heating, as compared to heating by conduction for example, heat is generated inside the susceptor, allowing for rapid heating. Further, there need not be any physical contact between the inductive heater and the susceptor, allowing for enhanced freedom in construction and application.

The induction heating assembly of the example device 100 comprises a susceptor arrangement 132 (herein referred to as “a susceptor”), a first inductor coil 124 and a second inductor coil 126. The first and second inductor coils 124, 126 are made from an electrically conducting material. In this example, the first and second inductor coils 124, 126 are made from Litz wire/ cable which is wound in a helical fashion to provide helical inductor coils 124, 126. Litz wire comprises a plurality of individual wires which are individually insulated and are twisted together to form a single wire. Litz wires are designed to reduce the skin effect losses in a conductor. In the example device 100, the first and second inductor coils 124, 126 are made from copper Litz wire which has a rectangular cross section. In other examples the Litz wire can have other shape cross sections, such as circular.

The first inductor coil 124 is configured to generate a first varying magnetic field for heating a first section of the susceptor 132 and the second inductor coil 126 is configured to generate a second varying magnetic field for heating a second section of the susceptor 132. In this example, the first inductor coil 124 is adjacent to the second inductor coil 126 in a direction along the longitudinal axis 134 of the device 100 (that is, the first and second inductor coils 124, 126 to not overlap). The susceptor arrangement 132 may comprise a single susceptor, or two or more separate susceptors. Ends 130 of the first and second inductor coils 124, 126 can be connected to the PCB 122. It will be appreciated that the first and second inductor coils 124, 126, in some examples, may have at least one characteristic different from each other. For example, the first inductor coil 124 may have at least one characteristic different from the second inductor coil 126. More specifically, in one example, the first inductor coil 124 may have a different value of inductance than the second inductor coil 126. In Figure 9, the first and second inductor coils 124, 126 are of different lengths such that the first inductor coil 124 is wound over a smaller section of the susceptor 132 than the second inductor coil 126. Thus, the first inductor coil 124 may comprise a different number of turns than the second inductor coil 126 (assuming that the spacing between individual turns is substantially the same). In yet another example, the first inductor coil 124 may be made from a different material to the second inductor coil 126. In some examples, the first and second inductor coils 124, 126 maybe substantially identical.

In this example, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. This can be useful when the inductor coils are active at different times. For example, initially, the first inductor coil 124 maybe operating to heat a first section/portion of the article 110, and at a later time, the second inductor coil 126 may be operating to heat a second section/portion of the article 110. Winding the coils in opposite directions helps reduce the current induced in the inactive coil when used in conjunction with a particular type of control circuit. In Figure 9 the device 100, the first inductor coil 124 is a right-hand helix and the second inductor coil 126 is a left-hand helix. However, in another embodiment, the inductor coils 124, 126 maybe wound in the same direction, or the first inductor coil 124 may be a left-hand helix and the second inductor coil 126 may be a right-hand helix.

The susceptor 132 of this example is hollow and therefore defines a receptacle within which aerosol generating material is received. For example, the article 110 can be inserted into the susceptor 132. In this example the susceptor 120 is tubular, with a circular cross section.

The susceptor 132 maybe made from one or more materials. Preferably the susceptor 132 comprises carbon steel having a coating of Nickel or Cobalt.

In some examples, the susceptor 132 may comprise at least two materials capable of being heated at two different frequencies for selective aerosolization of the at least two materials. For example, a first section of the susceptor 132 (which is heated by the first inductor coil 124) may comprise a first material, and a second section of the susceptor 132 which is heated by the second inductor coil 126 may comprise a second, different material. In another example, the first section may comprise first and second materials, where the first and second materials can be heated differently based upon operation of the first inductor coil 124. The first and second materials maybe adjacent along an axis defined by the susceptor 132, or may form different layers within the susceptor 132.

Similarly, the second section may comprise third and fourth materials, where the third and fourth materials can be heated differently based upon operation of the second inductor coil 126. The third and fourth materials maybe adjacent along an axis defined by the susceptor 132, or may form different layers within the susceptor 132. Third material may the same as the first material, and the fourth material may be the same as the second material, for example. Alternatively, each of the materials may be different. The susceptor may comprise carbon steel or aluminium for example. The device 100 of Figure 9 further comprises an insulating member 128 which may be generally tubular and at least partially surround the susceptor 132. The insulating member 128 may be constructed from any insulating material, such as plastic for example. In this particular example, the insulating member is constructed from polyether ether ketone (PEEK). The insulating member 128 may help insulate the various components of the device 100 from the heat generated in the susceptor 132.

The insulating member 128 can also fully or partially support the first and second inductor coils 124, 126. For example, as shown in Figure 9, the first and second inductor coils 124, 126 are positioned around the insulating member 128 and are in contact with a radially outward surface of the insulating member 128. In some examples the insulating member 128 does not abut the first and second inductor coils 124, 126. For example, a small gap may be present between the outer surface of the insulating member 128 and the inner surface of the first and second inductor coils 124, 126.

In a specific example, the susceptor 132, the insulating member 128, and the first and second inductor coils 124, 126 are coaxial around a central longitudinal axis of the susceptor 132. Figure 10 shows a side view of device 100 in partial cross-section. The outer cover 102 is present in this example. The rectangular cross-sectional shape of the first and second inductor coils 124, 126 is more clearly visible. The device 100 further comprises a support 136 which engages one end of the susceptor 132 to hold the susceptor 132 in place. The support 136 is connected to the second end member 116.

The device may also comprise a second printed circuit board 138 associated within the control element 112.

The device 100 further comprises a second lid/cap 140 and a spring 142, arranged towards the distal end of the device 100. The spring 142 allows the second lid 140 to be opened, to provide access to the susceptor 132. A user may open the second lid 140 to clean the susceptor 132 and/or the support 136.

The device 100 further comprises an expansion chamber 144 which extends away from a proximal end of the susceptor 132 towards the opening 104 of the device. Located at least partially within the expansion chamber 144 is a retention clip 146 to abut and hold the article 110 when received within the device 100. The expansion chamber 144 is connected to the end member 106.

Figure 11 is an exploded view of the device 100 of Figure 8, with the outer cover 102 omitted.

Figure 12A depicts a cross section of a portion of the device 100 of Figure 8. Figure 12B depicts a close-up of a region of Figure 12A. Figures 12A and 12B show the article 110 received within the susceptor 132, where the article 110 is dimensioned so that the outer surface of the article 110 abuts the inner surface of the susceptor 132. This ensures that the heating is most efficient. The article 110 of this example comprises aerosol generating material 110a. The aerosol generating material 110a is positioned within the susceptor 132. The article 110 may also comprise other components such as a filter, wrapping materials and/ or a cooling structure. Figure 12B shows that the outer surface of the susceptor 132 is spaced apart from the inner surface of the inductor coils 124, 126 by a distance 150, measured in a direction perpendicular to a longitudinal axis 158 of the susceptor 132. In one particular example, the distance 150 is about 3mm to 4mm, about 3-3.5mm, or about 3.25mm.

Figure 12B further shows that the outer surface of the insulating member 128 is spaced apart from the inner surface of the inductor coils 124, 126 by a distance 152, measured in a direction perpendicular to a longitudinal axis 158 of the susceptor 132. In one particular example, the distance 152 is about 0.05mm. In another example, the distance 152 is substantially omm, such that the inductor coils 124, 126 abut and touch the insulating member 128.

In one example, the susceptor 132 has a wall thickness 154 of about 0.025mm to imm, or about 0.05mm.

In one example, the susceptor 132 has a length of about 40mm to 60mm, about 40mm to 45mm, or about 44.5mm.

In one example, the insulating member 128 has a wall thickness 156 of about 0.25mm to 2mm, 0.25mm to imm, or about 0.5mm. In use, the articles 1 described herein can be inserted into a non-combustible aerosol provision device such as the device 100 described with reference to Figures 8 to 12. At least a portion of the mouthpiece 2 of the article 1 protrudes from the non-combustible aerosol provision device 100 and can be placed into a user’s mouth. An aerosol is produced by heating the aerosol generating material 3 using the device 100. The aerosol produced by the aerosol generating material 3 passes through the mouthpiece 2 to the user’s mouth.

The articles 1 described herein have particular advantages, for instance when used with non-combustible aerosol provision devices such as the device 100 described with reference to Figures 8 to 12. In particular, the first tubular element 4 formed from filamentary tow has surprisingly been found to have a significant influence on the temperature of the outer surface of the mouthpiece 2 of the articles 1. For instance, where the hollow tubular element 4 formed from filamentary tow is wrapped in an outer wrapper, for instance the tipping paper 5, an outer surface of the outer wrapper has been found to reach a maximum temperature of less than 42°C during use, suitably less than 40°C and more suitably less than 38°C or less than 36°C.

Examples

Test Method A In the below examples, the fill value of the botanical material was measured according to the following process.

A 15 g sample of the botanical material was deposited into a 60 mm diameter cylinder of a densimeter and then the botanical material was compressed with a 1 kg piston for 30 seconds. The height of the piston in the densimeter as well as the moisture content of the samples were measured. The fill values of the samples were calculated according to the following formulae.

The volume occupied by the botanical material when compressed was determined using Formula 1:

Formula 1

Volume r = radius of cylinder (cm) h = measured height

The fill value was then determined using the measured volume and mass of botanical material according to Formula 2: Formula 2

The fill value was corrected to account for its moisture content using Formula 3: Formula 3

Fv ₀ = Fill value at moisture content M _o %

FV = Fill value determined at moisture content M% (citf/ 10 g) Mo = 13.5% (target moisture content)

M = Actual moisture content of botanical material (%)

0.8 = constant

Moisture content (oven volatiles) is measured as the reduction in mass when a sample is dried in a forced draft oven at a temperature regulated to no°C ± i°C for three hours ± 0.5 minutes. After drying, the sample is cooled in a desiccator to room temperature for approximately 30 minutes, to allow the sample to cool.

Example 1 A selection of aerosol-generating materials were prepared and these are shown in Table 1. Each material comprised glycerol in an amount of 15% by weight of the material and 2% flavour by weight of the material. The fill value of the expanded material (DIET) was 7.3 mL/g at 12.5% moisture. Table 1

*In all cases, the ratio of leaf tobacco to reconstituted tobacco was 80:20 (leaf to reconstituted tobacco).

A selection of articles for use in a non-combustible aerosol provision system were prepared using the aerosol-generating materials listed in Table 1. The properties of these articles are shown in Table 2. Hardness was measured using a Sodimat device. Table 2

*DS = Demi-slim (75 mm long, 21 mm circumference) KSSS = King Size Super-slim (83 mm long, 16.96 circumference) Tables 2 shows that aerosol-generating material comprising expanded tobacco material can be incorporated into an article at a lower weight than aerosol-generating material that does not contain expanded tobacco material, but without significantly adversely affecting the hardness of the aerosol-generating section of the article. Moreover, the inclusion of relatively high levels of expanded tobacco material did not adversely affect the sensory (e.g. organoleptic) properties of the aerosol-generating material when aerosolised.

Example 2

Two amorphous solids, Amorphous Solid A and Amorphous Solid B, were prepared by forming a slurry of the components in water, setting the slurry, drying the slurry to form a sheet and then shredding the sheet.

Amorphous Solid A comprised: alginate/pectin mix (26.2%), glycerol (15.4%), cellulose fibres (20%) and menthol (38.4%). The slurry was set by spraying calcium lactate onto its surface. Amorphous Solid B comprised: alginate (24%), pectin (6%), cellulose fibres (10%) and glycerol (60%).

A selection of articles for use in a non-combustible aerosol provision system may be prepared comprising an aerosol-generating material comprising amorphous solid A or amorphous solid B and DIET, such as those shown in Table 3.

Table 3 Compared with the Comparative Article, Amorphous solids A and B would be expected to enhance the organoleptic properties of aerosol produced by the aerosol-generating material when heated in a non-combustible aerosol-provision device. In addition, the articles would be expected to exhibit acceptable firmness. In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed inventions may be practiced and provide for superior methods, apparatus and treated tobacco materials and extracts therefrom. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope and/ or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which may be claimed in future.