A consumable for use in an aerosol provision system

Technical field

The present disclosure relates to a consumable for use in an aerosol provision system. The present disclosure also relates to a method of manufacturing a consumable, a kit of parts comprising a consumable and an aerosol provision device, and to a package of consumables.

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

In accordance with some embodiments described herein, there is provided a consumable for use in an aerosol provision system, wherein the consumable comprises one or more pouches comprising first and second aerosol generating materials, wherein the second aerosol generating material has a higher density than the first aerosol generating material.

In some embodiments, the consumable comprises a first pouch that contains the first aerosol generating material and a second pouch that contains the second aerosol generating material.

In some embodiments, the consumable comprises a first pouch that contains both first and second aerosol generating materials. The consumable may optionally comprise a further pouch that may contain, for example, first and/ or second aerosol generating material.

According to the present disclosure, there is also provided a consumable for use in an aerosol provision system, wherein the consumable comprises a pouch and first and second aerosol generating materials that are contained in the pouch, wherein the second aerosol generating material has a higher density than the first aerosol generating material. In some embodiments, the or each pouch comprises a sheet material.

In some embodiments, the sheet material forms a wall of the pouch. In some embodiments, the sheet material comprises paper.

In some embodiments, the sheet material has a thickness in the range of 20 to 100 microns and, preferably, in the range of 30 to 80 microns, 35 to 55 microns or 40 to 50 microns.

In some embodiments, the sheet material is gas permeable.

In some embodiments, the sheet material has a permeability in the range of 10 TO 25000 Coresta Units and, optionally, has a permeability in the range of 25 to 100 Coresta Units.

In some embodiments, the sheet material is folded and/ or wrapped to form the or each pouch. In some embodiments, the sheet material is porous. In some embodiments, the sheet material has one or more apertures that permit the flow of gas through the sheet material.

In some embodiments, at least one edge of the sheet material is attached to another portion of the sheet material to retain the first and/ or second aerosol generating materials within the or each pouch.

In some embodiments, said a least one edge of the sheet material is attached by adhesive, crimping, stapling or sewing.

In some embodiments, the sheet material is a flexible material. In some embodiments, the first and second aerosol generating materials are different materials and/ or have one or more different properties. In some embodiments, the or each pouch is formed from a single piece of sheet material. In some embodiments, the or each pouch is formed from two or more pieces of sheet material that are joined together. In some embodiments, the two or more pieces of sheet material may be glued, stitched and/ or stapled together.

In some embodiments, the sheet material of the or each pouch completely envelopes the aerosol generating material contained in the pouch.

In some embodiments, the sheet material defines the entire boundary of a storage area that contains the aerosol generating material.

In some embodiments, no further components are required to retain the aerosol generating material within the or each pouch.

In some embodiments, the or each pouch forms an exterior surface of the consumable.

In some embodiments, the first and/or second aerosol generating material is a loose material.

In some embodiments, the second aerosol generating material comprises extruded and/or compressed aerosol generating material. In some embodiments, the second aerosol generating material comprises beads.

In some embodiments, the beads have a diameter in the range of 0.5 to 3 mm and, preferably, in the range of 1 to 2 mm. In some embodiments, the first aerosol generating material comprises, consists of, or essentially consists of tobacco material.

In some embodiments, tobacco material of the first aerosol generating material is derived only from tobacco lamina and no other types of tobacco material. In some embodiments, the first aerosol generating material comprises tobacco lamina and reconstituted tobacco.

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

In some embodiments, the first and second aerosol generating material together have an average nicotine level in the range of 0.5% to 2.5% by weight of the first and second aerosol generating material and, preferably, in the range of 1% to 2.1%.

In some embodiments, the tobacco material of the second aerosol generating material is derived from only tobacco lamina and no other types of tobacco material.

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

In some embodiments, consumable comprises in the range of about 20 to about 330 mg of the first aerosol generating material and, preferably, in the range of about 50 to about 300 mg, or about 40 to about 125 mg of the first aerosol generating material.

In some embodiments, consumable comprises in the range of about 20 to about 330 mg of the second aerosol generating material and, preferably, in the range of about 50 to about 300 mg, or about 40 to about 125 mg of the second aerosol generating material.

In some embodiments, the first and/or second aerosol generating material is a solid material.

In some embodiments, the consumable does not comprise plastic.

In some embodiments, the density of the second aerosol generating material is at least 25% higher than the density of the first aerosol generating material.

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

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

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

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

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

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

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

In some embodiments, one pouch contains the first and second aerosol generating materials. In some embodiments, the first and second aerosol generating materials are mixed together in said one pouch. In some embodiments, the first and second aerosol generating materials are provided in discrete regions within said one pouch. In some embodiments, one pouch contains the first and second aerosol generating materials, and wherein the consumable comprises a further pouch that may also contain first and/or second aerosol generating materials or a further aerosol generating material. In other embodiments, the one pouch that contains the first and second aerosol generating materials is the only pouch of the consumable.

In some embodiments, the first and second regions are discrete regions.

In some embodiments, the first region is provided towards a first end of the pouch and the second region is provided towards a second end of the pouch.

In some embodiments, one of the first or second regions surrounds, or at least partially surrounds, the other one of the first and second regions.

In some embodiments, the pouch comprises a divider that separates the first and second regions. The divider may be a dividing wall.

In some embodiments, the consumable comprises a first pouch that contains the first aerosol generating material and a second pouch that contains the second aerosol generating material.

In some embodiments, the first and second pouches are connected. For example, the first and second pouches may be directly connected, for example, by gluing, stitching or stapling the first and second pouches together or by forming the first and second pouches at least partially from the same piece of sheet material. In other embodiments, the first and second pouches may be j oined together by attaching the first and second pouches to the same substrate, for example, a paper substrate.

In some embodiments, the first and second aerosol generating materials are manufactured from the same aerosol generating starter materials that are processed to have different forms. In some embodiments, the first and/or second aerosol generating materials comprises an aerosol-former material.

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

In some embodiments, the first and/or second aerosol generating material comprises a flavourant.

According to the present disclosure, there is also provided a method of manufacturing a consumable for use in an aerosol provision system, the method comprising: forming one or more pouches comprising first and second aerosol generating materials wherein the second aerosol generating material has a higher density than the first aerosol generating material.

In some embodiments, one of the pouches contains the first aerosol generating material and the other one of the pouches contains the second aerosol generating material.

In some embodiments, the or each pouch contains the first and second aerosol generating materials.

In some embodiments, the or each pouch comprises a sheet material.

In some embodiments, the method comprises forming the sheet material of the or each pouch into a tube that contains the first and/or second aerosol generating material.

In some embodiments, the method comprises forming the sheet material into an arrangement that is closed at one end and open at the other end, and wherein first and/ or second aerosol generating material is provided within the arrangement of the sheet material.

In some embodiments, the arrangement is a continuous tube of the sheet material. The continuous tube is closed at one end. The first and/ or second aerosol generating material may be inserted into the continuous tube through the open end of the continuous tube.

In some embodiments, the method comprises feeding the first and/or second aerosol generating material into the arrangement under gravity.

In some embodiments, the method comprises feeding the first and/or second aerosol generating material into the open end of the arrangement. In some embodiment, the arrangement of the sheet material is a continuous tube of the sheet material.

In some embodiments, the method comprises feeding a continuous stream of the first and/ or second aerosol generating material into the arrangement.

In some embodiments, the method comprises sealing and cutting the arrangement of the sheet material at a location spaced from the closed end of the arrangement to form a pouch. In some embodiments, sealing the arrangement comprises collapsing the arrangement and, preferably, comprises collapsing the arrangement such that opposing wall portions of the sheet material of the arrangement are brought together. Sealing the arrangement may optionally comprise crimping the sheet material of the arrangement. In some embodiments, sealing and cutting the arrangement of the sheet material forms a second closed end of the arrangement.

In some embodiments, the first and aerosol generating material is contained in the pouch between the closed end and the portion of the sheet material that has been subsequently sealed and cut.

In some embodiments, the arrangement of sheet material is repeatedly sealed and cut to form a plurality of pouches. In some embodiments, the arrangement of sheet material is sealed and cut simultaneously. In some embodiments, sealing the arrangement comprises manipulating the arrangement such that aerosol generating material in the arrangement is moved axially downstream and/or upstream of the portion of the arrangement being sealed.

In some embodiments, said manipulation of the arrangement may involve collapsing the arrangement.

In some embodiments, the method comprises depositing first and/or second aerosol generating material on the sheet material and, preferably, depositing a metered amount of first and/or second aerosol generating material on the sheet material.

In some embodiments, the method comprises wrapping the sheet material about the first and/or second aerosol generating material.

In some embodiments, the method comprises attaching first and second portions of sheet material together such that the first and/or second aerosol generating material is held between the first and second portions of sheet material. According to the present disclosure, there is also provided a consumable manufactured according to the method disclosed herein.

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

According to the present disclosure, there is also provided a kit of parts comprising a consumable as disclosed herein and an aerosol provision device. In some embodiments, the aerosol provision device comprises a heating zone for receiving the consumable to heat the first and second aerosol generating materials.

Brief Description of the Drawings

Embodiments will now be described, by way of example only, with reference to accompanying drawings, in which: Fig. i is a top view of an embodiment of a consumable for use with an aerosol provision system;

Fig. 2 is a cross-sectional side view of the consumable of Fig. 1;

Fig. 3 is a top view of a sheet material of the consumable of Fig. 1, wherein the sheet material is laid flat;

Fig. 4 is a perspective view of a bead of aerosol-generating material of the consumable of Fig. 1;

Fig. 5A is a top view of a first step of a method of manufacturing a consumable for use with an aerosol provision system; Fig. 5B is a top view of a second step of a method of manufacturing an article for use with an aerosol provision system;

Fig. 5C is a top view of a third step of a method of manufacturing an article for use with an aerosol provision system;

Fig. 6 is a cross-sectional schematic view of a continuous method of manufacturing an article for use with an aerosol provision system;

Fig. 7 is a schematic diagram of an apparatus for manufacturing an article for use with an aerosol provision system;

Fig. 8 is a cross-sectional side view of another embodiment of a consumable for use with an aerosol provision system; Fig. 9 is a cross-sectional side view of another embodiment of a consumable for use with an aerosol provision system;

Fig. 10 is a cross-sectional side view of another embodiment of a consumable for use with an aerosol provision system;

Fig. 11 is a cross sectional view of an embodiment of a non-combustible aerosol provision device;

Fig. 12 is a simplified schematic of the components within the housing of the aerosol provision device shown in Fig. 11; and,

Fig. 13 is a cross sectional view of the non-combustible aerosol provision device shown in Fig. 11 with the article shown in Fig. 1 inserted into the device.

Detailed description

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

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

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

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

In some embodiments, the non-combustible aerosol provision system is an aerosolgenerating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system. In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise a plant based material, for example, tobacco or a non-tobacco product. Typically, the non-combustible aerosol provision system may comprise a noncombustible aerosol provision device, and a consumable for use with the noncombustible aerosol provision device.

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

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

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

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

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/ or an aerosol-modifying agent.

The consumable comprises a substance to be delivered. The substance to be delivered is an aerosol-generating material. As appropriate, the material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.

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

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

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

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

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel. In some embodiments, the substance to be delivered comprises a flavour.

As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, maybe used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang- ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They maybe imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas. In some embodiments, the flavour comprises menthol, spearmint and/ or peppermint.

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

In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3. The aerosol-generating material may comprise or be an “amorphous solid”. In some embodiments, the aerosol-generating material comprises an aerosol-generating film that is an amorphous solid. The amorphous solid maybe a “monolithic solid”. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 6owt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid. An aerosol-generating material may also be referred to as an aerosolisable material. An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. An aerosol-generating material may be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants. The aerosol-generating material is incorporated into an article for use in the aerosol-generating system. As used herein, the term “tobacco material” refers to any material comprising tobacco or derivatives or substitutes thereof. The tobacco material may be in any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and/or tobacco extract.

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

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

The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants. A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/ or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor. A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein. An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosolmodifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent.

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent maybe in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material. An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol.

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

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

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

Fig. 1 is a top view of a consumable 1 for use in an aerosol delivery system that includes an aerosol delivery device 200 (see Figs. 11 to 13). Fig. 2 is a cross-sectional side view of the consumable 1 of Fig. 1. The consumable 1 has an upstream or distal end ‘D’ and a downstream or proximal end ‘P’. In some embodiments, the proximal end P is located relatively closer to a mouthpiece 207 of the aerosol delivery device 200 in use than the distal end D. In another embodiment (not shown), the proximal end P of the consumable 1 comprises a mouthpiece. In some embodiments (not shown), the proximal end P of the consumable 1 forms the mouthpiece. It should be recognised that in some embodiments, the consumable 1 can be used with the aerosol delivery device 200 in either orientation, such that it does not matter which end of the consumable 1 is upstream and which is downstream. The consumable 1 comprises a pouch 2 that comprises a space 3 containing first and second aerosol generating materials 4, 5. The second aerosol generating material 5 has a higher density than the first aerosol generating material 4, as explained in more detail below. The first and second aerosol-generating material 4, 5 are configured to be heated within the space 3 to generate an aerosol. The space 3 maybe filled, or at least partially filled, with the first and second aerosol-generating materials 4, 5. The space 3 may form a storage area 3 for the first and second aerosol generating materials 4, 5. In an alternate embodiment (not shown) the consumable comprises a first pouch that contains the first aerosol generating material and a second pouch that contains the second aerosol generating material. In some embodiments, the first and second pouches are connected. For example, the first and second pouches maybe directly connected, for example, by gluing, stitching or stapling the first and second pouches together or by forming the first and second pouches at least partially from the same piece of sheet material. In other embodiments, the first and second pouches maybe joined together by attaching the first and second pouches to the same substrate, for example, a paper substrate In the present example, the pouch 2 comprises a sheet material 6. In the present example, the sheet material 6 comprises paper. Optionally, the sheet material 6 may consist of, or essentially consist of, paper. It should be recognised that in other embodiments, the sheet material 6 may additionally, or alternatively, comprise an alternative material, for example, metal foil, a woven material (for example, cotton) or a laminate material (for example, a laminate of paper and metal foil). In some embodiments, the sheet material 6 does not comprise plastic.

In some embodiments, the sheet material 6 is gas permeable. This allows for gas to enter the pouch 2 via the permeable sheet material 6 and interact with the first and second aerosol generating materials 4, 5, and then exit the pouch 2 for inhalation by the user. In some embodiments, the sheet material 6 has a permeability in the range of 10 to 25000 Coresta Units. In some embodiments, the sheet material 6 has a permeability of at least 10 Coresta Units and, preferably, at least 100, 200, 500, 1000, 2000, 5000, 10000, 15000, 20000 or 25000 Coresta Units. In some embodiments, the sheet material 6 has a permeability of at most 25000 Coresta Units and, preferably, at most 20000, 15000, 10000, 5000, 2000, 1000, 500, 200, 100, 75 or 50 Coresta Units. In some embodiments, the sheet material 6 has a permeability in the range of 25 to 100 Coresta Units.

In some embodiments, the sheet material 6 is porous which facilitates the permeability of the sheet material 6. Alternatively, or additionally, in some embodiments, the sheet material 6 has one or more apertures (not shown) that permit the flow of gas through the sheet material 6.

In some embodiments, the sheet material 6 has a thickness (and thus the wall of the pouch has a thickness) in the range of 20 to 100 microns and, optionally, in the range of 30 to 80 microns, in the range of 35 to 55 microns, or in the range of 40 to 50 microns. In some embodiments, the thickness of the sheet material 6 (and thus the thickness of the wall of the pouch) is at least 20 microns and, preferably, at least 30, 40 or 50 microns. In some embodiments, the thickness of the sheet material 6 (and thus the thickness of the wall of the pouch) is at most too microns and, preferably, at most 90,

80, 70, 60 or 50 microns.

It has been found that increasing the permeability of the sheet material 6 increases the heat transfer through the sheet material 6 to the aerosol generating materials 4, 5. It has also been found that decreasing the thickness of the sheet material 6 increases the heat transfer through the sheet material 6 to the aerosol generating materials 4, 5. Increasing the heat transfer through the sheet material 6 advantageously improves the efficiency of the heating of the first and second aerosol generating materials 4, 5. The sheet material 6 is arranged to form the pouch 2, for example, by folding and/or wrapping the sheet material 6 to form the pouch 2.

In some embodiments, at least one edge 6A, 6B, 6C, 6D of the sheet material 6 is attached to another portion of the sheet material 6 to retain the first and second aerosol generating material 4, 5 within the space 3 of the pouch 2. In some embodiments, said at least one edge 6A, 6B, 6C, 6D of the sheet material 6 is attached by adhesive, crimping, stapling or sewing.

In the present example, the sheet material 6 is a flexible material. In the present example, the walls of the pouch 2 are flexible.

In some embodiments, the pouch 2 forms an exterior surface of the consumable i. In the present example, a first side of the sheet material 6 faces inwardly to form a boundary of the space 3 and a second side of the sheet material 6 faces outwardly to form said exterior surface 1A of the consumable 1.

In some embodiments, the first and/or second aerosol generating material 4, 5 is a loose material. The first and/or second aerosol generating material 4, 5 maybe in the form of discrete particles.

In the present example, the second aerosol generating material 5 comprises extruded and/ or compressed aerosol generating material, as explained in more detail below. However, it should be recognised that in other embodiments, the second aerosol generating material 5 may have a different form.

In some embodiments, the first and/or second aerosol generating material 4, 5 comprises beads. The beads maybe cylindrical, or may have an alternative shape, for example, spherical, pyramid or cuboid shaped. In the present example, the second aerosol generating material 5 comprises beads 5 (as shown in Fig. 3).

In some embodiments, the beads 5 have a diameter (shown by arrow ‘D’ in Fig. 4) in the range of 0.5 to 3 mm and, preferably, in the range of 1 to 2 mm.

In some embodiments, the beads 5 have an axial length (shown by arrow ‘L’ in Fig. 4) in the range of 0.5 to 3 mm and, preferably, in the range of 1 to 2 mm.

In some embodiments, the beads 5 have a particle size (which may be measured by sieving) in the range of 0.5 to 3 mm and, preferably, in the range of 1 to 2 mm. In some embodiments, the first and/or second aerosol generating material 4, 5 comprises, consists of, or essentially consists of tobacco material.

In some embodiments, the tobacco material of the first and/or second aerosol generating material 4, 5 is derived only from tobacco lamina and no other types of tobacco material.

In some embodiments, the first and/or second aerosol generating material 4, 5 comprises tobacco lamina and reconstituted tobacco.

In some embodiments, the first and second aerosol generating material 4, 5 together have an average nicotine level in the range of 0.5% to 2.5% by volume of the first and second aerosol generating material 4, 5 and, preferably, in the range of 1% to 2.1%. In some embodiments, the first aerosol generating material 4 has a nicotine level in the range of 0.5% to 2.5% by volume of the first aerosol generating material 4 and, preferably, in the range of 1% to 2.1%.

In some embodiments, the second aerosol generating material 5 has a nicotine level in the range of 0.5% to 2.5% by volume of the second aerosol generating material 5 and, preferably, in the range of 1% to 2.1%.

In some embodiments, the article comprises from about 20 to about 330 mg of the first aerosol generating material 4 and, preferably, from about 50 to about 300 mg, from about too to 200 mg, or from about 40 to about 125 mg of the first aerosol generating material 4.

In some embodiments, the article comprises from about 20 to about 330 mg of the second aerosol generating material 5 and, preferably, from about 50 to about 300 mg, from about too to 200 mg, or from about 40 to about 125 mg of the second aerosol generating material 5.

In some embodiments, the total mass of aerosol generating material 4, 5 in the space 3 is in the range of 80 to 300 mg. In some embodiments, the total mass of tobacco material in the space 3 is in the range of 80 to 300 mg or 150 to 270 mg. In some embodiments, the first and/or second aerosol generating material 4, 5 is a solid material.

In some embodiments, the first and second aerosol generating materials 4, 5 are different materials and/or have one or more different properties.

The consumable 1 may have an axial length (shown by arrow ‘X’ in Fig. 1) of at least 10 mm and, preferably, at least 12, 14, 16, 18, 20, 22 or 23 mm. The consumable 1 may have an axial length of at most 36 mm and, preferably, at most 34, 32, 30, 28, 26, 24 or 23 mm.

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

In some embodiments, the sheet material 6 does not comprise plastic. This makes the consumable 1 more environmentally friendly, and is also advantageous in embodiments wherein the entire consumable 1 is heated by the aerosol delivery device 200 (as described below).

In some embodiments, the sheet material 6 does not comprise cellulose acetate.

In some embodiments, the entire consumable 1 does not comprise plastic. In some embodiments, the sheet material 6 or entire consumable 1 does not comprise cellulose acetate.

In some embodiments, the first and/or second aerosol-generating material 4, 5 may comprise, consist of, or essentially consist of, tobacco material. The term “tobacco material” refers to any material comprising tobacco or derivatives or substitutes thereof. The tobacco material may be in any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and/ or tobacco extract. In some embodiments, the first and/or second aerosol generating material 4, 5 or another material (not shown) within the space 6 may comprise one or more aerosolformer materials. For example, the first and/or second aerosol generating material 4, 5 or said another material may comprise one or more constituents capable of forming an aerosol. The aerosol-former material comprises one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol-former material can be glycerol or propylene glycol.

The first and/or second aerosol generating material 4, 5 maybe provided in the space 3 as a loose material, that is retained in the space 3 by the sheet material 6 that forms a wall of the pouch 2. The first and/or second aerosol generating material 4, 5 may, for example, be discrete strands or particles of aerosol generating material. Another example of loose aerosol generating material is beads/pellets of aerosol generating material, including aerosol generating material that has been extruded and then cut into beads/pellets. Yet another example of aerosol generating material is a sheet of aerosol generating material that has been cut into individual pieces, for example, cut into individual strips of aerosol generating material. The sheet of aerosol generating material maybe a sheet of reconstituted tobacco.

In the present example, the first aerosol generating material 4 comprises shredded tobacco material (for example, shredded lamina and/ or shredded reconstituted tobacco).

In the present example, the second aerosol generating material 5 comprises extruded and/or compressed tobacco. In such embodiments, the second aerosol generating material 5 may comprise a single body of aerosol generating material or a plurality of bodies of aerosol generating material.

In the present example, the second aerosol generating material 5 comprises beads/ pellets/ granules of aerosol generating material (hereinafter referred to as ‘beads’ of aerosol generating material). The second aerosol generating material 5 has a higher density than the first aerosol generating material 4. It has been found that this causes the second aerosol generating material 5 to heat up slower than the first aerosol generating material 4 when the heater of the device 200 is operated to heat the consumable 1. This means that the first aerosol generating material 4 will initially release one or more volatile compounds (e.g. nicotine) at a higher rate than the second aerosol generating material 5 if both materials are subjected to the same heating power. This also means that the first aerosol generating material 4 will become relatively depleted of said volatile compound(s) more quickly than the second aerosol generating material 5. However, as the first aerosol generating material 4 starts to become relatively depleted of said volatile compound(s), the second aerosol generating material 5 will begin to reach a temperature wherein it begins to release volatile compound(s) at a higher rate. The effect of this is a more consistent release of the volatile compound(s) over the period of consumption of the consumable 1, with the first aerosol generating material 4 releasing a greater proportion of volatile compound(s) towards the beginning of the consumption of the consumable 1 and the second aerosol generating material 5 releasing a greater proportion of volatile compound(s) towards the end of the consumption of the consumable 1. This is particularly advantageous because the pouch 1 can be made relatively small whilst still achieving a relatively consistent and/ or sufficient release of volatile compound(s) over the period of consumption.

In some embodiments, the density of the second aerosol generating material 5 is at least 25% higher than the density of the first aerosol generating material 4. In some embodiments, the first aerosol generating material 4 has a density of from about 0.1 g/cm3 to about 1 g/cm3.

In some embodiments, the second aerosol generating material 5 has a density of from about 0.4 g/cm3 to about 2 g/cm3.

In some embodiments, said one or more volatile compound(s) released by the first aerosol generating material 4 are the same as the volatile compound(s) released by the second aerosol generating material 5. In some embodiments, the first aerosol generating material 4 is heated during a first period of the consumption session (e.g. by a first heater) and the second aerosol generating material 5 is heated during a second period (e.g. by a second heater). For example, in some embodiments the first and second aerosol generating materials 4, 5 are provided in separate regions that are heated separately. In other embodiments, the first and second aerosol generating materials 4, 5 are heated at the same time and, for example, may be mixed together.

In some embodiments, the second aerosol generating material 5 comprises aerosol generating material that has been compressed or extruded (without subsequent expansion or with a relatively low/ minimal expansion) such that the density of the second aerosol generating material 5 is higher than the first aerosol generating material

4-

In some embodiments, the first aerosol generating material 4 comprises one or more of: tobacco lamina; tobacco stems or reconstituted tobacco. In one such embodiment, the first aerosol generating material 4 comprises a mixture of tobacco lamina and reconstituted tobacco. The first aerosol generating material 4 may comprise shredded or cut material. However, it should be recognised that in other embodiments, the first aerosol generating material 4 comprises a compressed or extruded aerosol generating material that has a lower density than the second aerosol generating material 5 (for example, having a lower compression than the second aerosol generating material 5, which optionally may also be extruded or compressed).

In some embodiments, the first and second aerosol-generating material 4, 5 may comprise the same material, for example, tobacco, but are processed to have different densities. In one such embodiment, the first and second aerosol generating materials 4,

5 may be in different forms. For example, the first aerosol generating material 4 may be a loose shredded material (for example, shredded lamina tobacco and/or shredded reconstituted tobacco), whereas the second aerosol generating material 5 maybe compressed or extruded (without or with minimal expansion) such that the second aerosol generating material 5 has a higher density than the first aerosol generating material 4.

For example, the second aerosol generating material 5 may be in the form of extruded/compressed beads of aerosol generating material (for example, tobacco or another material) and the first aerosol generating material 4 may be in the form of, for example: strands or strips of aerosol generating material (for example, tobacco or - ‘2.5 - another material); a sheet of aerosol generating material that is gathered into a plug or is cut into strips; loose material (e.g. cut rag tobacco); a dense end of a rod of aerosol generating material (e.g. tobacco); or, tobacco lamina and/or stem material that has been formed into a plug. However, it should be recognised that the first second, and/or third aerosol generating material 4, 5 may alternatively have the same form (e.g. both being cut rag tobacco) but still have different densities.

In some embodiments, the first aerosol-generating material 4 has at least one further different characteristic to the second aerosol generating material 5. The different characteristic may be one or more of form, size, , water content, amount (by weight), material or materials, or proportion of materials that make the first and second aerosolgenerating materials 4, 5 (including the recipe of the aerosol generating materials 4, 5 when each is manufactured more than one material). In a preferred embodiment, the first and second aerosol-generating materials 4, 5 do not have a different characteristic, other than density, and instead are the same.

The first and/or second aerosol-generating material 4, 5 may comprise a plurality of strands or strips of aerosol-generating material. For example, the first and/or second aerosol-generating material 4, 5 may comprise a plurality of strands or strips of an aerosolisable material and/or a plurality of strands or strips of an amorphous solid.

The first and/or second aerosol-generating material 4, 5 may comprise a plant based material, such as a tobacco material. The first and/or second aerosol-generating material 4, 5 maybe a sheet or shredded sheet of aerosolisable material comprising a plant based material, such as a tobacco material. The sheet material may be processed such that the second aerosol generating material 5 has a higher density than the first aerosol generating material 4.

The plant based material may be a particulate or granular material. In some embodiments, the plant based material is a powder. Alternatively, or in addition, the plant based material may comprise may comprise strips, strands or fibres of tobacco. For example, where tobacco material is provided, the tobacco material may comprise particles, granules, fibres, strips and/or strands of tobacco. In some embodiments, the tobacco material consists of particles or granules of tobacco material. The tobacco material of the first and/ or second aerosol-generating material 4, 5 may comprise tobacco obtained from any part of the tobacco plant. In some embodiments, the tobacco material comprises tobacco leaf. The sheet or shredded sheet can comprise from 5% to about 90% by weight tobacco leaf.

In some embodiments, both of the first and/or second aerosol-generating material 4, 5 comprise, consist of, or essentially consist of tobacco material.

In some embodiments, the first and/or second aerosol-generating material 4, 5 comprises a sheet or shredded sheet of aerosolisable material that comprises an aerosol-former material. Optionally, the aerosol-former material is provided in an amount of up to about 50% on a dry weight base by weight of the sheet or shredded sheet. In some embodiments, the aerosol-former material is provided in an amount of from about 5% to about 40% on a dry weight base by weight of the sheet or shredded sheet, from about 10% to about 30% on a dry weight base by weight of the sheet or shredded sheet or from about 10% to about 20% on a dry weight base by weight of the sheet or shredded sheet.

The first and/or second aerosol-generating material 4, 5 may comprise a filler. The filler is generally a non-tobacco component, that is, a component that does not include ingredients originating from tobacco. The filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may be a non-tobacco fibre such as wood fibre or pulp or wheat fibre. The filler can be a material comprising cellulose or a material comprises a derivate of cellulose. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material. In some embodiments, first and/or second aerosol generating materials 4, 5 are in the form of a sheet or shredded sheet that comprises the filler.

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

In some embodiments, the article 1 comprises an aerosol-generating composition comprising aerosol-generating material. The aerosol-generating material may comprise the first and/or second aerosol-generating material 4, 5. An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material (for example, the first and/or second aerosol generating material 4, 5) may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants.

The aerosol-generating material (for example, the first and/or second aerosol generating material 4, 5) may comprise a binder and an aerosol former. Optionally, an active and/ or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material (for example, the first and/or second aerosol generating material 4, 5) is substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material (for example, the first and/ or second aerosol generating material 4, 5) is substantially tobacco free.

The aerosol-generating material (for example, the first and/or second aerosol generating material 4, 5) may comprise or be an “amorphous solid”. The amorphous solid maybe a “monolithic solid”. In some embodiments, the amorphous solid maybe a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating material may, for example, comprise from about 50wt%, 6owt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid. The amorphous solid may be substantially non-fibrous. The aerosol-generating material (for example, the first and/or second aerosol generating material 4, 5) may comprise or be an aerosol-generating film. The aerosol- generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as active substances, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film. The slurry may be heated to remove at least about 6o wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent. The aerosolgenerating film may be a continuous film or a discontinuous film, such an arrangement of discrete portions of film on a support. The aerosol-generating film maybe substantially tobacco free. The aerosol-generating film may comprise or be a sheet, which may optionally be shredded to form a shredded sheet.

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

In each of the embodiments of article 1 described herein, the article may comprise such a first and/or second aerosol generating material 4, 5, and may comprise such an aerosol-generating composition.

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

Where the first and/or second aerosol generating material 4, 5 comprises an amorphous solid material, the amorphous solid material may be a dried gel comprising menthol. In some embodiments, the first and/or second aerosol generating material 4, 5 comprises an extruded aerosol generating material that is then cut into beads of pellets. Referring now to Figs. 5A to 5C, a method of manufacturing a consumable 1 for an aerosol provision device 200 is shown. In a first step, a sheet material 6 is provided and is laid flat or in a U-shape. In a second step, the first and second aerosol generating materials 4, 5 are deposited on the sheet material 6 (as shown in Fig. 5A). In some embodiments, a predetermined amount or charge of each of the first and second aerosol generating materials 4, 5 is deposited on the sheet material 6, for example, pneumatically or by a metering drum, which may include a pocket wheel.

The first and second aerosol generating materials 4, 5 may be pre-mixed prior to depositing on the sheet material 6. Alternatively, the first and second aerosol generating materials 4, 5 may be mixed together whilst being deposited on the sheet material 6 or after being deposited on the sheet material 6. In some embodiments, the first and second aerosol generating material 4, 5 may become mixed during storage, transport and/ or use of the consumables 1. In yet further embodiments, the first and second aerosol generating materials 4, 5 may be provided in separate regions 4A, 5A to form, for example, the consumables 1 of any of Figs. 8 to 10.

In a third step, the sheet material 6 is wrapped about the first and second aerosol generating materials 4, 5 to form an arrangement that is generally tube-shaped and is open at both ends (as shown in Fig. 5B). In the present example, a first edge 6A of the sheet material 6 is arranged to overlap an opposite second edge 6B to form a tube, and the sheet material 6 is then retained in position, for example, by the application of adhesive to the sheet material 6 in the region of one or both of the first and second edges 6A, 6B or by stapling, welding or sewing the sheet material 6 in the region of the first and second edges 6A, 6B. In a fourth step, the open ends of the tube are sealed to form the pouch 2 that contains the first and second aerosol generating materials 4, 5. In the present example, a third edge 6C of the sheet material 6 is folded over itself and is held in positon by, for example, adhesive, sewing or stapling of the sheet material 6. Similarly, an opposite fourth edge 6D of the sheet material 6 is folded over itself and is held in positon by, for example, adhesive, sewing or stapling of the sheet material 6. However, it should be recognised that in alternative embodiments one or both of the open ends are not folded, and instead are sealed (for example, by adhesive, welding, sewing or stapling of the sheet material 6) without first folding the third and fourth edges 6C, 6D of the sheet material 6. Referring now to Figs. 6 and 7, another method of manufacturing a consumable 1 for an aerosol provision device 200 is shown, and an apparatus 300 for carrying out the method is shown.

A continuous web W of sheet material is provided from a reel R of sheet material 6. The web W is fed along a conveyance path (shown by arrow ‘P’ in Figs. 6 and 7). For example, the web W maybe transported along the conveyance path P by one or more rollers 301, 302.

At a first step Si, the web W is formed into an arrangement of sheet material 6 which, in the present example, is a continuous tube T of sheet material 6. For example, the web W maybe fed through a shaping device 303, for example, a cone, garniture or tongue, that shapes the initially flat web W into a tube T. The shaping device 303 may comprise a conical or O-shaped cross-section that shapes the web W into the tube T. The shaping device 303 may be configured to apply adhesive to the web W to retain the web W in the shape of a tube. Alternatively, or additionally, adhesive may be preapplied to the web W and is activated after, or during, the portion of the web W has been formed into the tube T in order to retain the web W in the shape of a tube. In some embodiments, adhesive is applied to the tube T downstream of the shaping device 303, for example, by a separate adhesive applicator (now shown).

At a second step S2, the first and second aerosol generating materials 4, 5 are fed into the tube T. In the present example, first and second aerosol generating materials 4, 5 are fed into the tube T from above such that the first and second aerosol generating materials 4, 5 fall under the effect of gravity and settle in a lower region of the tube T. However, it should be recognised that in other embodiments the first and second aerosol generating materials 4, 5 may additionally or alternatively be fed, for example, pneumatically. In the present example, the first and/or second aerosol generating materials 4, 5 are fed into the tube T as a continuous stream of the first and/or second aerosol generating materials 4, 5. In the present example, the first and second aerosol generating materials 4, 5 are fed into the tube T through the shaping device 303. For example, the first and second aerosol generating materials 4, 5 may be supplied through the conical member that shapes the web W into the tube T. The first and second aerosol generating materials 4, 5 are located within the tube T such that at least a portion of the tube T is conveyed continuously with the first and second aerosol generating materials 4, 5 located therein.

In the present example, the first aerosol generating material 4 is fed into the tube T by a first supply device 304 and the second aerosol generating material 4 is fed into the tube

T by a second supply device 305. However, it should be recognised that in other embodiments, the first and second aerosol generating materials 4, 5 may be pre-mixed and then supplied to the tube T together via a single supply device (now shown). The or each supply device 304, 305 may be gravity fed and/ or may be configured to transport the aerosol generating material 4, 5 by alternative or additional means, for example, pneumatically. The or each supply device 304, 305 maybe configured to supply a continuous stream of the aerosol generating material or may be configured to metered doses of the aerosol generating material (for example, using a metering wheel).

At a third step S3, the portion of the tube T containing the first and second aerosol generating materials 4, 5 passes a sealing device 306. The sealing device 306 is configured to collapse the tube T such that the first and second aerosol generating materials 4, 5 contained therein are pushed axially upstream and downstream of the sealing device 306 (i.e. upstream and downstream in the direction of the conveyance path P) such that the wall of the tube T can be sealed against itself. For instance, the end of the tube T can be crimped to seal the tube T.

In the present example, the tube T is sealed at the dashed line ‘Z1-Z1’ shown in Fig. 6 The sealing device 306 is configured such that the end of the tube T is retained in a sealed configuration. For example, the sealing device 306 maybe configured to apply adhesive (for example, PVA or other suitable adhesive), stitching, or staples to the crimped/compressed portion of the tube T or to weld said portion of the tube T. In some embodiments, the web W has an adhesive pre-applied thereto. In one such embodiment, the sealing device 306 is configured to activate the hot-melt adhesive at the crimped/compressed portion of the tube T such that the adhesive retains the tube T in a sealed configuration. In the present example, the sealing device 306 comprises a pair of sealing members 307, 308 that are moved in a reciprocating manner towards each other to intermittently compress and seal portions of the tube T and then are moved away from each other to allow a portion of the tube T with aerosol generating material 4, 5 therein to pass without being compressed. In other embodiments (not shown), the sealing members are provided on rotating wheels, such that successive pairs of the sealing members intermittently align to compress and seal portions of the tube T.

In the present example, each sealing member 307, 308 comprises a wedge shaped member 307A, 308A. The shape of each wedge shaped member 307A, 308A is such that the first and second aerosol generating materials 4, 5 contained in the tube T is pushed axially upstream and downstream of the sealing device wedge shaped members 307A, 308A (i.e. upstream and downstream in the direction of the conveyance path P).

At a fourth step S4, the sealed portion of the tube T passes a cutting device 309 that cuts the tube T at the sealed portion to form an individual consumable 1 (for example, the tube T may be cut along the dashed line ‘Z2-Z2’ shown in Fig. 6).

In the present example, the cutting device 309 comprises a pair of cutting rollers 310, 311 with respective cutting blades 310A, 311A that intermittently meet to cut the tube T at the sealed end thereof. However, it should be recognised that in alternative embodiments (not shown), the cutting device 309 may have an alternative configuration, for example, comprises one or more reciprocating cutting knives or a one or more lasers that intermittently cut the tube T. It should be recognised that in alternative embodiments, a single device performs the functions of both the sealing device 306 and cutting device 309 described above. For instance, in one alternative embodiment the cutting device 309 is omitted and instead the wedge-shaped members 307A, 308A each have a sharpened cutting tip that cuts the tube T when the sharpened tips 307A, 308A meet. In the consumable shown in Figs. 1 and 2, the first and second aerosol generating materials 4, 5 are mixed together in the space 3 of the pouch 2. In other embodiments, one of the first and second aerosol generating materials 4, 5 may be interspersed within a portion, or throughout, the other one of the first and second aerosol generating materials 4, 5.

Referring now to Fig. 8, an alternative embodiment of a consumable 1 is shown. The consumable 1 has similar features to the consumable 1 described above in relation to Figs. 1 and 2, with like features retaining the same reference numerals. The difference is that, rather than the first and second aerosol generating materials 4, 5 being mixed together, the first aerosol generating material 4 is provided in a first region 4A and the second aerosol generating material 5 is provided in a second region 5A. The first and second regions 4A, 5A may be discrete and optionally may be spaced from each other. In the present example, the first and second regions 4A, 5A are in contact with each other rather than being spaced apart.

The first region 4A is provided towards a first end of the consumable 1 and the second region 5A is provided towards a second end of the consumable 1. For example, the first region 4A may be provided towards one of the proximal end P and distal end D of the consumable 1 and the second region 5A may be provided towards the other one of the proximal end P and distal end D of the consumable 1.

Referring now to Fig. 9, another embodiment of a consumable 1 is shown. The consumable 1 has similar features to the consumable 1 described above in relation to Fig. 8, with like features retaining the same reference numerals. Again, the first and second aerosol generating materials 4, 5 are provided in respective first and second regions 4A, 5A. The difference is that, rather than the first region 4A being provided towards a first end of the consumable 1 and the second region 5A being provided towards a second end of the consumable 1, both of the regions 4A, 5A extend between the first and second ends of the consumable 1. In some embodiments, the first and second regions 4A, 5A are on opposite of a central axis of the consumable 1. Referring now to Fig. 10, another embodiment of a consumable 1 is shown. The consumable 1 has similar features to the consumable 1 described above in relation to Fig. 8, with like features retaining the same reference numerals. Again, the first and second aerosol generating materials 4, 5 are provided in respective first and second regions 4A, 5A. The difference is that a divider 7 is provided that facilitates separation of the first and second aerosol generating materials 4, 5. The divider 7 maybe gas permeable and may, for example, comprise a mesh or a section of sheet material (which may optionally be porous or provided with one or more apertures to facilitate gas flow through the consumable 1). Optionally, the divider 7 may be sheet material that is integrally formed with the remainder of the sheet material 6 of the pouch 2.

Providing the first and second aerosol generating materials 4, 5 in separate regions 4A, 5A (for example, as shown in Figs. 8 to 10) allows for the first and second aerosol generating materials 4, 5 to be heated separately, for example, at different times using first and second heaters. For example, the first region 4A, which comprises first aerosol generating material 4 of a relatively low density, can be heated initially by the first heater to generate aerosol towards the start of the consumption session. The second region 5A, which comprises second aerosol generating material 5 of a relatively high density, can be heated later, or at the same time but for longer, to generate aerosol toward the end of the consumption session, thereby facilitating a more consistent aerosol generation over the duration of the consumption session. However, it should be recognised that in other embodiments, the first and second aerosol generating materials 4, 5 are not in separate regions, and the different densities of the first and second aerosol generating materials 4, 5 will still promote a more consistent aerosol generation over the duration of the consumption session.

It should be recognised that the above methods and apparatus can be modified such that a first aerosol generating material 4 is contained in a first pouch and a second aerosol generating material 5 is contained in a second pouch. The first and second pouches may be connected, for example, by staples, stitching, welding and/ or adhesive.

In another embodiment, the first and second pouches maybe formed from the same sheet material. For instance, the method and apparatus of Figs. 6 and 7 could be modified such that an amount of a first aerosol generating material 4 is first fed into the arrangement of sheet material (e.g. the continuous tube) and is then sealed within a portion of the sheet material 6 to form a first pouch containing the first aerosol generating material 4, and then an amount of a second aerosol generating material 5 is fed into the arrangement of sheet material (e.g. the continuous tube) and is then sealed within a portion of the sheet material 6 to form a second pouch, adjacent to the first pouch, and containing the second aerosol generating material 5. The sheet material may then be cut so as to form a consumable that comprises the first and second patches (for example, being cut downstream of the first pouch and upstream of the second pouch). In other embodiments, first and second pouches containing the first and second aerosol generating materials 4, 5 respectively may be manufactured separately and then the first and second pouches are joined together to form the consumable. Referring now to Figs. 11 to 13, an embodiment of an aerosol provision device 200 is shown.

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

In other embodiments (not shown), the heating element 203 instead comprises a blade or pin, for insertion into the consumable 1, for example, the blade or pin may be inserted through the sheet material 10 (e.g. penetrating the sheet material 10) and optimally also the first and/or second aerosol generating material 4, 5. In other embodiments (not shown), the consumable 1 may comprise the heating element which, for example, may be embedded in the first and/or second aerosol generating material 4, 5-

In Fig. 11, the components of an embodiment of an aerosol provision device 200 are shown in a simplified manner. Particularly, the elements of the aerosol provision device 200 are not drawn to scale in Fig. 11. Elements that are not relevant for the understanding of this embodiment have been omitted to simplify Fig. 11.

In the example of Fig. 11, the aerosol provision device 200 is a non-combustible aerosol provision device 200. The non-combustible aerosol provision device 200 comprises a housing 201 comprising an area 202 for receiving a consumable 1. When the consumable 1 is received into the heating area 202, at least a portion of the consumable 1 comes into thermal proximity with the heater 203. Thus, at least a portion of the aerosol generating material 4, 5 is in thermal proximity with the heater 203. In some embodiments, the heater 203 is spaced from the consumable 1, for example, circumscribing the consumable 1 but having a larger diameter and being spaced therefrom. In other embodiments, the heater 203 is in direct contact with the consumable 1, for example, contacting an outer surface of the sheet material 6 of the consumable 1. In another embodiment, the heater 203 comprises a blade or pin that contacts the inside of the consumable 1, for example, contacting the aerosol generating material 4, 5.

When the consumable 1 is heated, the first and/or second aerosol generating material 4, 5 in the space 3 of the pouch 2 will release one or more volatile compounds and may release a range of volatile compounds at different temperatures. By controlling the maximum operation temperature of the electrically heated aerosol generating system

200, the selective release of undesirable compounds may be controlled by preventing the release of select volatile compounds.

As shown in Fig. 12, within the housing 201 there is an electrical energy supply 204, for example a rechargeable lithium ion battery. A controller 205 is connected to the heater 203, the electrical energy supply 204, and a user interface 206, for example a button or display. The controller 205 controls the power supplied to the heater 203 in order to regulate its temperature. Typically, the aerosol-forming substrate is heated to a temperature of between 250 and 450 degrees centigrade.

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

The housing 201 of non-combustible aerosol provision device 200 defines an area 202 in the form of a cavity, open at the proximal end (or mouth end), for receiving an aerosol-generating consumable 1 for consumption by a user. In the present example, the aerosol-provision device 200 comprises a mouthpiece 207 that is detachable from the remainder of the device 200 to allow access to the area 202 such that a consumable 1 can be interested into and removed from the area 202. Once a consumable 1 has been provided in the area 202, the mouthpiece 207 can be reattached. In some embodiments, the mouthpiece 207 is removably attached to the housing 201 of the device 200, for example, by a screw thread or bayonet connection.

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

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

In all of the above examples, the first and/or second aerosol generating material 4, 5 may comprise, consist of, or essentially consist of extruded or compressed bodies of tobacco material and, preferably, the extruded or compressed bodies of tobacco material comprise beads of tobacco material.

In each of the above examples, the first and/or second aerosol generating material 4, 5 may comprise a body or rod of aerosol generating material.

In each of the above examples, the first and/or second aerosol generating material 4, 5 may comprise, consist of, or essentially consist of reconstituted tobacco and, preferably, comprises a shredded sheet of reconstituted tobacco.

In all of the above examples, the first and/or second aerosol generating material 4, 5 may comprise, consist of, or essentially consist of lamina tobacco.

In all of the above examples, the first and/or second aerosol generating material 4, 5 may comprise, consist of, or essentially consist of reconstituted tobacco and lamina tobacco and, preferably, the reconstituted tobacco and lamina tobacco are mixed together. In all of the above examples, the first and/or second aerosol generating material 4, 5 may comprise, consist of, or essentially consist of a sheet of aerosol generating material that is gathered to form a body of material and, preferably, the sheet material is crimped. Preferably, the sheet is a sheet of reconstituted tobacco.

In all of the above examples, the first and/or second aerosol generating material 4, 5 may comprise, consist of, or essentially consist of a sheet of aerosol generating material that is cut into strips. Preferably, the sheet is a sheet of reconstituted tobacco. In all of the above examples, the first and/or second aerosol generating material 4, 5 may comprise tobacco material, and wherein the tobacco material is manufactured only from tobacco lamina and no other types of tobacco material.

In all of the above examples, the first and second aerosol generating materials 4, 5 are manufactured from the same aerosol generating starter materials that are processed to have different forms.

In each of the examples of article described above (including each of the articles shown in Figs. 1 to 10 and 13), the second aerosol generating material 5 has a greater density than the first aerosol generating material 4. Otherwise, the aerosol-generating materials of the article may be the same or different.

It has been found that the second aerosol generating material 5 having a higher density than the first aerosol generating material 4 means that the higher density material heats up slower when both materials are exposed to the same heating and thus the higher density material will release its volatile compounds (e.g. nicotine) at a slower rate than the lower density material. Thus, the second aerosol-generating material 5 has a greater density than the first aerosol-generating material 4 so that the second aerosol generating material 5 heats up slower than the first aerosol generating material 4 when exposed to the same heating and will release its volatile compounds (e.g. nicotine) at a slower rate than the first aerosol-generating material 4. Thus, combining aerosol-generating materials with different densities provides a more consistent and longer-lasting release of volatile compound(s). In some embodiments, the aerosolgenerating materials of different densities are combined with separate heating of these materials at optionally different times and/ or different temperatures, thereby allowing the provision of a more tailored release of the volatile compound(s) over the period of consumption of the article, for example. Alternatively, it may be desirable to have a more rapid or greater release of volatiles towards the beginning of the consumption of the article, to provide the user with a greater initial impact from use. The capacity to control the aerosol generation and volatile compound release maybe particularly advantageous because the article can be made relatively small whilst still achieving a particular desired release of volatile compound(s) over the period of consumption.

In some embodiments, the second aerosol generating material 5 has a density that is at least about 25% higher than the density of the first aerosol generating material 4 and, optionally, at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70% or 75% higher. The second aerosol generating material 5 may have a density that is no more than about 200% higher than the density of the first and second aerosol generating material 4 and, optionally, no more than about 150%, 125%, 100% or 75% higher. In some embodiments, the second aerosol generating material 5 has a density that is from about 25% to about 75% higher than the density of the first aerosol generating material

4-

In some embodiments, the second aerosol generating material 5 has a density of from at least about 0.4 g/cm3 and optionally from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3. The second aerosol generating material 5 may have a density of no more than about 2 g/cm3 and, optionally no more than about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6 or 0.5 g/cm3. In some embodiments, the density of the second aerosol generating material 5 is from about 0.4 to 1.99 g/cm3.

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

In some embodiments, the first and second aerosol-generating materials 4, 5 comprise the same components. Upon heating, they will therefore release very similar aerosols, potentially having the same content of active substance and/ or flavour, etc. Their different densities allow the aerosol to be generated from the two materials at different speeds and/or different times during heating.

In other embodiments, the first and second aerosol-generating materials 4, 5 comprise different components (and may have the same or different densities). Upon heating, they will therefore release different aerosols, potentially having different make-up of active substance and/or flavour, etc. Their different densities allow the different aerosols to be generated from the two materials at different speeds and/ or different times during heating, potentially providing an aerosol that changes over the period of use.

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

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

In some embodiments, the first aerosol-generating material 4 has at least one (further) different characteristic to the second aerosol generating material 5. The different characteristic maybe one or more of form, size, , water content, amount (by weight), material or materials, or proportion of materials that make the first and second aerosol- generating materials 4, 5 (including the recipe of the aerosol generating materials when each is manufactured from more than one material). In some embodiments, the first and second aerosol-generating materials 4, 5 do not have a different characteristic, other than their different densities.

In some embodiments, the first aerosol-generating material 4 comprises one or more tobacco in the form of cut rag. This tobacco material may lamina or reconstituted tobacco material. In some embodiments, the first aerosol-generating material 4 is a blend comprising both lamina and reconstituted tobacco. For example, the ratio of lamina and reconstituted tobacco may from about 1:4 to about 4:1. The second aerosol-generating material 5 has a greater density than the first aerosolgenerating material 4. In some embodiments, this more dense, second aerosolgenerating material 5 comprises particles or maybe in the form of beads or one or more sheets. Each bead or sheet may be formed from smaller particles that have been agglomerated. In some embodiments, the both of the first and second aerosol generating materials 4, 5 may be in the form of beads or one or more sheets and, optionally, may be processed such that the second aerosol generating material 5 has a higher density than the first aerosol generating materials 4.

As used herein, the term “beads” is meant to include beads, pellets, or other discrete small units that have been shaped, moulded, compressed or otherwise fashioned into a desired shape. The beads may have smooth, regular outer shapes (e.g., spheres, cylinders, ovoids, etc.) and/or they may have irregular outer shapes.

In some embodiments, the beads have a diameter (for example, as measured by sieving) of at least about 0.5 mm and, optionally at least about 1, 1.5, 2. 2.5 or 3 mm. The beads may have a diameter (for example, as measured by sieving) of no more than about 5 mm and, optionally no more than about 4.5, 4, 3.5, 3, 2.5, 2 or 1.5 mm. In some embodiments, the diameter of each bead may range from about 0.5 mm to about 3 mm, or from about 1 mm to about 2 mm. The size of the beads may refer to their average size, such as the number or volume mean size.

In some embodiments, the desired density of the aerosol-generating material 4, 5 is achieved or controlled through the formulation of the material and/or the method(s) by which the material is processed. Processes involving agglomeration, and especially agglomeration with the application of some of compressive forces will tend to increase the density of the material. Thus, in some embodiments, the first and/ or second aerosol-generating material 4, 5 comprises particles of material that are agglomerated. In the case of a sheet material, the sheet may be formed from particles of material that are bound and optionally compressed to form a sheet with the desired dimensions and density.

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

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

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

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

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

In some embodiments, during extrusion the free-flowing composition comprising particles, such as tobacco particles, is exposed to elevated pressure and temperature and is forced though an orifice, such as a shaping nozzle or die, to form an extrudate. In some embodiments, the extrudate has a rod-like form and it may be cut into segments of a desired length.

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

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

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

In some embodiments, the extrusion may be a generally dry process, with the composition including aerosol generating particles that are dry or substantially dry. The composition may optionally include other particulate materials including, for example, base, diluent, solid aerosol forming agents, solid flavour modifiers, etc. In some embodiments, liquids maybe added to the composition prior to or during the extrusion process. For example, water may be added, for example as a processing aid to assist dissolution or solubilisation of components of the composition, or to aid binding or agglomeration. Alternatively or additionally, a wetting agent may be added to the composition.

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

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

In some embodiments, the agglomerates do not include a binder or binding additive.

For example, extruded beads may not require a binder to maintain their structural integrity. In other embodiments, the agglomerates comprise a binder or binding additive. The binding additive may be selected to assist in the formation of an agglomerated structure by helping to adhere the particles to each other and to other components in the composition. Suitable binding additives include, for example, thermoreversible gelling agents such as gelatin, starches, polysaccharides, pectins, alginates, wood pulp, celluloses, and cellulose derivatives such as carboxymethylcellulose. In some embodiments, processing by extrusion is sufficient to provide the higher density of the second aerosol-generating material 5, where desired. However, in other embodiments, the extrudate may be further treated to increase the density of the second aerosol-generating material 5.

For example, in some embodiments, the extruded aerosol-generating material undergoes spheronisation. In spheronisation, the extruded, cylindrically shaped particles are broken into uniform lengths and are gradually transformed into spherical shapes due to plastic deformation. Where the extrudate is first broken into uniform lengths, spheres with a uniform diameter will be produced by the spheronisation step.

According to one specific example of the embodiments discussed herein, samples of the second aerosol-generating material 5 were produced as follows (but note that in some embodiments samples may be produced according to the below, which are instead used for the first aerosol generating material).

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

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

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

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

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

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

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

In some embodiments, the other one of the first and/or second aerosol-generating material 4, 5 is in the form of discrete particles, or in the form of an agglomerated body of particles. These particles may share various characteristics with the (denser) second aerosol-generating material 5, such as particle size, but will have a lower density. As described above, there are various ways to adjust the density of the aerosol -generating material 4, 5, such as the formulation and/or the processing of the material into particles, beads or pellets. In some embodiments, the first aerosol-generating material 4 comprises a combination of 60% reconstituted tobacco and 40% lamina tobacco, with the density of this material being in the range of from about o.i to about 0.9 g/cm ³ . The second aerosolgenerating materials 5 comprises from about 30 to about 90% tobacco, with a density in the range of from about 0.4 to about 1.99 g/cm ³ . The amount of aerosol forming material included in said one of the first and second aerosol-generating materials 4, 5 maybe from about 8 to about 15%. The second aerosol-generating materials 5 may comprise largely spherical beads with a particle size between about 0.5 and about 3 mm. In some embodiments, the aerosol generating material in an article comprises approximately 50% of the first aerosol-generating material 4 and about 50% of the second aerosol-generating material 5, by weight. Thus, for example, an article comprising 260 mg of aerosol-generating material may comprise 130 mg of the first aerosol-generating material 4 and 130 mg of the second aerosol-generating material 5.

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

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

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

The tobacco described herein may contain nicotine. In some embodiments, the nicotine content is from 0.5 to 2% by volume of the tobacco, and maybe, for example, from 0.5 to 1.75% by volume of the tobacco, from 0.8 to 1.2% by volume of the tobacco or from about 0.8 to about 1.75% by volume of the tobacco. In some embodiments, the nicotine content may be from 0.8 to 1% by volume of the tobacco.

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

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

According to the present disclosure, there is also provided a kit of parts comprising a consumable 1 according to any of the examples described herein and an aerosol provision device 200.

According to the present disclosure, there is also provided a package comprising a plurality of consumables according to any of the examples described herein. In some embodiments, the package is hermetically sealed. The package may comprise a container comprising a body and a lid, wherein a space is provided within the container body to receive the plurality of consumables. The lid may, for example, be a hinged lid, a snap-fit lid or lid that is connected by a screw thread.

The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.