WO2025104020A1

WO2025104020A1 - Articles, aerosol provision systems and methods for forming articles

Info

Publication number: WO2025104020A1
Application number: PCT/EP2024/082046
Authority: WO
Inventors: Craig APPLEBY; Anthony Cunningham; Barry DIMMICK; Joanna SOFFE
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2023-11-13
Filing date: 2024-11-12
Publication date: 2025-05-22
Anticipated expiration: 2026-05-13
Also published as: GB202317357D0

Abstract

The invention relates to articles (1) for use in an aerosol provision system, comprising an aerosol-generating portion comprising a rod of aerosol-generating material (2) and a mouthpiece (3), wherein the mouthpiece (3) is provided with a surface to reduce adhesion of the lips of the user to the article and the lip adhesion-reducing surface is distanced from the rod of aerosol-generating material (2) by at least about 5 mm. The invention further relates to aerosol provision systems, and to methods for forming the articles (1).

Description

Articles, aerosol provision systems and methods for forming articles

Technical Field

The present invention relates to articles for use in an aerosol provision system, aerosol provision systems, and methods for forming articles.

Background

Certain tobacco industry products produce an aerosol during use, which is inhaled by a user. For example, tobacco heating devices heat an aerosol generating substrate such as tobacco to form an aerosol by heating, but not burning, the substrate. Such tobacco industry products commonly include mouthpieces through which the aerosol passes to reach the user's mouth.

Summary

In accordance with a first aspect of the invention, there is provided an article for use in an aerosol provision system comprising an aerosol-generating portion comprising a rod of aerosol-generating material and a mouthpiece, wherein the mouthpiece is provided with a surface to reduce adhesion of the lips of the user to the article and the lip adhesion-reducing surface is distanced from the rod of aerosol-generating material by at least about 5 mm.

In some embodiments, the lip adhesion-reducing surface does not extend beyond about 25 mm from the mouth end of the article.

In some embodiments, the lip adhesion-reducing surface is distanced from the mouth end of the article by no more than about 5 mm.

In some embodiments, the mouthpiece and aerosol-generating portion are joined by tipping paper that circumscribes at least a portion of both of these parts of the article. In some embodiments, the lip adhesion-reducing surface is provided on the tipping paper.

In some embodiments, the lip adhesion-reducing surface is provided by a mouthpiece wrapper that circumscribes only a portion of the length of the mouthpiece. In some embodiments, the lip adhesion-reducing surface is provided over an entire surface of the mouthpiece wrapper In some embodiments, the lip adhesion-reducing surface comprises a coating. In some embodiments, the coating comprises a hydrophobic material.

In some embodiments, the coating comprises one or more selected from the group consisting of: nitrocellulose, waxes, silicone compounds and polyvinyl acetate/butylacrylate copolymers, diatomite, sodium oleate or hydroxyl polysiloxane copolymers.

In some embodiments, the coating comprises a gloss or lacquer.

In some embodiments, the lip adhesion-reducing surface comprises a textured surface reducing the area of contact between the article and the lips of the user. In some embodiments, wherein the textured surface is embossed, moulded, cut or roughened.

In some embodiments, the textured surface comprises a discontinuous layer providing a raised profile where the layer is present.

In some embodiments, the mouthpiece comprises one or more sections selected from: a mouthpiece body, a cooling section and a hollow tubular element. In some embodiments, the one or more sections of the mouthpiece are circumscribed by a combining wrapping material.

In some embodiments, the rod of aerosol-generating material is circumscribed by a rod wrapper.

In some embodiments, a tipping paper extends the entire length of the article.

In some embodiments, the article comprises a distal end plug. In some embodiments, the distal end plug comprises one or more selected from the group consisting of: a flavour carrier, glycerol, a salt gel, and lactic acid. In some embodiments, the distal end plug comprises aerosol former in an amount less than 5% by weight or in an amount between 5% and 25% by weight on a dry weight basis.

In some embodiments, ventilation is provided into the article, and the level of ventilation is between 40% and 75%. In some embodiments, the aerosol-generating portion comprises aerosol former in an amount from about 8% to about 25%, or from about 12% to about 20% by weight on a dry weight basis.

In some embodiments, the aerosol-generating portion comprises tobacco material or non-tobacco botanical material.

According to a second aspect of the invention there is provided a system comprising: an article according to the first aspect of the invention, and a heating device configured to receive the aerosol-generating portion, wherein the heating device is configured to externally heat the aerosol-generating portion, and/or inductively heat the aerosol-generating portion, and/or resistively heat the aerosol-generating portion.

According to a third aspect of the invention there is provided a method for forming an article according to the first aspect of the invention, comprising the steps: providing an aerosol generating portion, a mouthpiece, and a wrapping material; combining the aerosol generating portion and mouthpiece with the wrapping material to form a component; wherein the wrapping material comprises a lip adhesion-reducing surface on a portion of a surface so that, when the wrapper is included in the article, the lip adhesion-reducing surface is distanced from the rod of aerosol-generating material by at least about 5 mm.

According to a fourth aspect of the invention there is provided a method for forming an article according to first aspect of the invention, comprising the steps: providing an aerosol generating portion, a mouthpiece, and a wrapping material; combining the aerosol generating portion and mouthpiece with the wrapping material to form a component;

(b) wrapping a portion of the mouthpiece with a further wrapper comprising a lip adhesion-reducing surface, so that the lip adhesion-reducing surface is distanced from the rod of aerosol-generating material by at least about 5 mm.

Brief Description of the Drawings

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a side-on cross-sectional view of an article for use in an aerosol provision system, comprising an aerosol generating portion and a mouthpiece surrounded by tipping paper with a partial coating to reduce lip adhesion;

Figure 2 is a side-on cross-sectional view of an article for use in an aerosol provision system, comprising an aerosol generating portion and a mouthpiece surrounded by tipping paper with a partial coating to reduce lip adhesion that does not extend to the mouth end of the article;

Figure 3 is a side-on cross-sectional view of an alternative article comprising an aerosol generating portion and a mouthpiece, wherein tipping paper with a partial coating to reduce lip adhesion extends the entire length of the article;

Figure 4 is a side-on cross-sectional view of another article, comprising an aerosol generating portion, a mouthpiece, and tipping paper extending the entire length of the article, with a further wrapper circumscribing the mouth end portion of the mouthpiece;

Figure 5 is a side-on cross-sectional view of a further article comprising an aerosol generating portion, a mouthpiece and a distal end plug, each of these portions being wrapped and the mouthpiece and distal end plug being attached to the aerosolgenerating portion by tipping papers, only the mouth end tipping paper having a partial coating to reduce lip adhesion;

Figure 6 is a side-on cross-sectional view of an alternative article including a distal plug, wherein tipping paper with a partial coating to reduce lip adhesion extends the entire length of the article;

Figure 7 is a perspective illustration of a non-combustible aerosol provision device for generating aerosol from an article according to the present disclosure.

Detailed Description

The invention relates to the provision of a coating on the surface of an aerosolgenerating article to reduce or prevent adhesion of a user's lips to the article on use. Such coatings are well known and have been used for decades in combustible smoking articles such as cigarettes.

The problem of adhesion of the user's lips to a paper-wrapped article is associated with the tendency of the paper to absorb moisture from the user's lips. This can cause discomfort as a result of adhesion of the lips to the paper and can even result in some of the skin of the lips becoming detached when the lips are removed from contact with the article. Conventionally, the lip adhesion-reducing coating is a hydrophobic material that prevents the paper absorbing the moisture present on the lips of the user. Suitable hydrophobic coatings include nitrocellulose, which is probably the most widely used coating to prevent lip adhesion. Other suitable coatings that are used include waxes, silicone compounds and polyvinyl acetate/butylacrylate copolymers, diatomite, sodium oleate or hydroxyl polysiloxane copolymers. The lip adhesion-reducing coating is traditionally provided over the entire surface of the tipping paper.

Tipping paper has a structural role to play in aerosol generating articles. The tipping paper circumscribes the mouth end section of the article, also referred to herein as the mouthpiece. In addition to circumscribing the mouth end section, it also extends beyond the mouth end section where that section abuts a section comprising aerosolgenerating material, so that the tipping paper also circumscribes a portion at the end of the adjacent rod of aerosol-generating material. Accordingly, the tipping paper can hold together the two separate parts of the aerosol-generating article, namely the mouth end section and the aerosol-generating portion.

In a combustible cigarette, the tipping paper is generally not combusted, as the cigarette tends to be extinguished or discarded by the user before the burning end reaches the tipping paper (which, as mentioned above, is often visibly distinct from the other wrapper of a cigarette.

However, in tobacco heating products, it is usual for the entirety of the aerosolgenerating portion to be heated during use. This means that the portion of the tipping paper that overlies the aerosol-generating portion of the article will be directly heated. For example, where the aerosol-generating article is inserted into a heating device, the tipping paper will, during use, generally be positioned so that it is also inserted into the device, will be exposed to the heater and heated to at or around the temperature that the aerosol-generating material is heated to. Where the heat source surrounds the aerosol-generating article during use, the tipping paper on the outside of the article may be directly heated to an even greater extent.

The inventors have surprisingly discovered that there are several undesirable effects seen when the tipping paper comprising a lip adhesion-reducing coating is directly heated and particularly where the coating reaches temperatures exceeding about 100°C, or within the range of from about 150 to 200°C or higher. One of these undesirable effects is the discolouration or staining of the article which is caused by the heating the lip adhesion-reducing coating on the tipping paper. It has been found that the coating turns an unsightly brown colour as a result of heating. This means that the used aerosol-generating article has an unsightly appearance after use. This staining is present close to the mouth end of the article, and therefore close to where the user's lips were in contact with the article, when viewed by the user after use. This makes the staining particularly worrying and unpleasant for the user.

A further undesirable effect of heating the lip adhesion-reducing coating on the tipping paper may be contamination of the device, for example including contamination of the heater, surrounding the article during use. This may be as a result of the heating of the coating to high temperatures resulting in degradation and/or vaporisation of the coating composition, that then becomes deposited on the device and potentially the heater in devices comprising a heater positioned to surround the inserted aerosol generating article.

In addition, where the lip-release coating degrades or vaporises as a result of heating, this can lead to compounds being released that could be inhaled by the user.

The inventors have devised improvement to the inclusion of the lip adhesion-reducing coating to reduce or avoid these undesirable effects. In summary, the lip adhesionreducing coating does not extend the entire length of the tipping paper, so that lip- adhesion-reducing coating does not overlap with the aerosol-generating portion of the article.

According to the invention, an article for use in an aerosol provision system comprises an aerosol-generating portion comprising a rod of aerosol-generating material and a mouthpiece, wherein the aerosol-generating portion is heated during use to generate an aerosol. The mouthpiece and aerosol-generating portion are joined by tipping paper that circumscribes at least a portion of both of these parts of the article. The mouthpiece is provided with a surface to reduce adhesion of the lips of the user to the article, wherein the lip adhesion-reducing surface is distanced from the rod of aerosolgenerating material by at least about 5 mm.

In some embodiments, the lip adhesion-reducing surface does not extend beyond about 25 mm from the mouth end of the article. In some embodiments, the lip adhesion-reducing surface is distanced from the mouth end of the article by no more than about 5 mm. In some embodiments, the lip adhesion-reducing surface extends from the mouth end of the article.

In some embodiments, the lip adhesion-reducing surface does not extend beyond about 25 mm from the mouth end of the article. In some embodiments, the distance is no more than about 24.5 mm, about 24 mm, about 23.5 mm, about 23 mm, about 22.5 mm, about 22 mm, about 21.5 mm, about 21 mm, about 20.5 mm, no more than about 20 mm, no more than about 19 mm, no more than about 18 mm, no more than about 17 mm, no more than about 16 mm, no more than about 15 mm, no more than about 14 mm or no more than about 13 mm from the mouth end of the article.

In some embodiments, the lip adhesion-reducing surface is distanced from the rod of aerosol-generating material by at least about 5 mm. In some embodiments, the distance is at least about 5.1 mm, about 5.2 mm, about 5.3 mm, about 5.4 mm, about 5.5 mm, about 5.6 mm, about 5.7 mm, about 5.8 mm, about 5.9 mm, about 6 mm, about 6.1 mm, about 6.2 mm, about 6.3 mm, about 6.4 mm, about 6.5 mm, about 6.6 mm, about 6.7 mm, about 6.8 mm, about 6.9 mm, about 7 mm, about 7.1 mm, about 7.2 mm, about 7.3 mm, about 7.4 mm, about 7.5 mm, about 7.6 mm, about 7.7 mm, about 7.8 mm, about 7.9 mm, about 8 mm, about 8.1 mm, about 8.2 mm, about 8.3 mm, about 8.4 mm, about 8.5 mm, about 8.6 mm, about 8.7 mm, about 8.8 mm, about 8.9 mm, about 9 mm, about 9.1 mm, about 9.2 mm, about 9.3 mm, about 9.4 mm, about 9.5 mm, about 9.6 mm, about 9.7 mm, about 9.8 mm, about 9.9 mm, about 10 mm, about 10.1 mm, about 10.2 mm, about 10.3 mm, about 10.4 mm, about 10.5 mm, about 10.6 mm, about 10.7 mm, about 10.8 mm, about 10.9 mm, about 11 mm, about 11.1 mm, about 11.2 mm, about 11.3 mm, about 11.4 mm, about 11.5 mm, about 11.6 mm, about 11.7 mm, about 11.8 mm, about 11.9 mm, about 12 mm, about 12.1 mm, about 12.2 mm, about 12.3 mm, about 12.4 mm, about 12.5 mm, about 12.6 mm, about 12.7 mm, about 12.8 mm, about 12.9 mm, about 13 mm, about 13.1 mm, about 13.2 mm, about 13.3 mm, about 13.4 mm, about 13.5 mm, about 13.6 mm, about 13.7 mm, about 13.8 mm, about 13.9 mm, about 14 mm, about 14.1 mm, about 14.2 mm, about 14.3 mm, about 14.4 mm, about 14.5 mm, about 14.6 mm, about 14.7 mm, about 14.8 mm, about 14.9 mm, or at least about 15 mm.

In some embodiments, the minimum distance between the lip adhesion-reducing surface and the mouth end of the mouthpiece along the surface of the article is from 0 to about 5 mm. In some embodiments, the distance is at least about 0.1 mm, about 0.2 mm, about 0.3 mm, about 0.4 mm, about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, about 3 mm, about 3.1 mm, about 3.2 mm, about 3.3 mm, about 3.4 mm, about 3.5 mm, about 3.6 mm, about 3.7 mm, about 3.8 mm, about 3.9 mm, about 4 mm, about 4.1 mm, about 4.2 mm, about 4.3 mm, about 4.4 mm, about 4.5 mm, about 4.6 mm, about 4.7 mm, about 4.8 mm, about 4.9 mm, or at least about 5 mm.

In some embodiments that may be preferred, the aerosol-generating article is to be inserted into a device comprising a heater upon use. The device comprises an opening into which the aerosol-generating article is partially inserted, leaving a portion of the mouthpiece protruding from the device. In some embodiments, the lip adhesion-reducing surface does not cover any part of the mouthpiece of the article that is positioned inside the device when inserted into a heating device.

In some embodiments, upon insertion of the aerosol generating article into a device, the lip adhesion-reducing surface is distanced from the opening of the device into which the article is inserted upon use by at least about 1 mm. In some embodiments, the distance is at least about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, about 3 mm, about 3.1 mm, about 3.2 mm, about 3.3 mm, about 3.4 mm, about 3.5 mm, about 3.6 mm, about 3.7 mm, about 3.8 mm, about 3.9 mm, about 4 mm, about 4.1 mm, about 4.2 mm, about 4.3 mm, about 4.4 mm, about 4.5 mm, about 4.6 mm, about 4.7 mm, about 4.8 mm, about 4.9 mm, or at least about 5 mm.

In some embodiments, the lip adhesion-reducing surface is a coating provided in the form of a coating on the surface of a wrapper forming the outer surface of the mouthpiece of the article. In some embodiments, the coating comprises a hydrophobic material. In some embodiments, the hydrophobic material is one or more selected from the group consisting of: nitrocellulose, silicone compounds and polyvinyl acetate/butylacrylate copolymers. In some embodiments, the lip adhesionreducing coating is a gloss or lacquer with a surface smoothness that reduces the tendency of the lips of a user to adhere to the coating. In some of the embodiments, the lip adhesion-reducing surface is a textured surface of a wrapper or a textured surface applied to a wrapper forming the outer surface of the mouthpiece of the article. The textured surface provides a reduced area of direct contact between the lips and the wrapper and therefore reduces the tendency of the lips to adhere to the wrapper. In some embodiments, the textured surface has a regular texture or an irregular texture. In some embodiments, the textured surface is formed by embossing, debossing, moulding, cutting or roughening the wrapper. In some embodiments, the textured surface is formed by providing a discontinuous layer on the surface to provide a raised profile where the layer is present.

In some embodiments, the wrapper forming the outer surface of the mouthpiece of the article is the tipping paper that joins the mouthpiece and the aerosol-generating portion of the article. The tipping paper circumscribes the mouthpiece and at least a portion of the adjacent aerosol-generating portion. The lip adhesion-reducing surface is provided on the tipping paper but covering only a portion of the surface of the tipping paper. The lip adhesion-reducing surface is located on the tipping paper so that the surface does not extend beyond about 25 mm, beyond about 20 mm or beyond about 18 mm from the mouth end of the article, and/or so that the surface is distanced from the aerosol-generating portion by at least about 5 mm or by at least about 10 mm.

The tipping paper may, in some embodiments, extend the entire length of the aerosolgenerating portion. In some embodiments, the tipping paper extends the entire length of the aerosol-generating article. In all of these embodiments, the lip adhesion-reducing surface is located on the tipping paper so that the lip adhesionreducing surface does not extend beyond about 25 mm, beyond about 20 mm or beyond about 18 mm from the mouth end of the article, and/or so that the coating is distanced from the aerosol-generating portion by at least about 5 mm or by at least about 10 mm.

In other embodiments, the lip adhesion-reducing surface is provided on a further wrapper that only circumscribes the mouthpiece. In such embodiments, the tipping paper does not comprise a lip adhesion-reducing surface. Instead, at least a portion of the tipping paper is surrounded by the further wrapper which therefore forms the outer surface of the article in the area in the region of the article that is expected to be contacted by the user's lips. The further wrapper with the lip adhesion-reducing surface is positioned so that the coating does not extend beyond about 25 mm, beyond about 20 mm or beyond about 18 mm from the mouth end of the article, and/or so that the coating is distanced from the aerosol-generating portion by at least about 5 mm or by at least about 10 mm. The further wrapper with the lip adhesion-reducing surface may be glued in place around the mouthpiece of the article, optionally being glued to a portion of the tipping paper.

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

Figure 1 is a side-on cross-sectional view of an article 1 for use in an aerosol provision system. In the present case, the article comprises a consumable for a noncombustible aerosol provision system.

The article comprises an aerosol generating portion, in the present case a cylindrical rod of aerosol generating material 2, and a mouthpiece 3 downstream from and connected to the rod of aerosol generating material 2.

The rod of aerosol-generating material is wrapped in a rod wrapper 10.

The mouthpiece 3 has a mouth end 3b and a distal end 3a that abuts the rod of aerosol-generating material 2.

The mouthpiece 3 illustrated in Figure 1 is located at the mouth end of the article 1 and comprises three elements, a mouthpiece body 14 downstream of a cooling section 13, and a hollow tubular element 15 downstream of the mouthpiece body 14. In other embodiments, one or two of these different mouthpiece elements may be omitted or duplicated, and/or the elements may be provided in a different sequence. For example, the hollow tubular element 15 may be omitted, and the mouthpiece body 14 may form the mouth end of the article. In some examples where the hollow tubular element 15 is omitted, the length of the mouthpiece body 14 may be increased, or a further body of material may be provided at the mouth end.

In an alternative arrangement that is not illustrated, the mouthpiece comprises a mouthpiece body at the mouth end of the mouthpiece, optionally comprising a plug of cellulose acetate tow or paper, and optionally including capsule. Adjacent to this mouthpiece body is a first tube, optionally formed from paper, which abuts at its other end a further tubular section, optionally comprising cellulose acetate.

In the mouthpiece shown in Figure 1, the cooling section 13, mouthpiece body 14 and hollow tubular element 15 are connected by a combining wrapping material 11.

As shown in Figure 1, tipping paper 9 is wrapped around the full length of the mouthpiece 3 and over part of the rod of aerosol generating material 2. The tipping paper 9 has an adhesive on its inner surface (not shown) to connect the mouthpiece 3 and rod 2. In the illustrated embodiment, the tipping paper 9 extends 5 mm over the rod of aerosol generating material 2 but it can alternatively extend between 3 mm and 15 mm over the rod 2, or between 4 mm and 6 mm, to provide a secure attachment between the mouthpiece 3 and rod 2.

The tipping paper 9 shown in Figure 1 has a lip adhesion-reducing coating 8 on its outer surface that covers only part of the length of the tipping paper 9, extending from the mouth end 3b of the mouthpiece, but not extending as far as the distal end 3a of the mouthpiece 3.

In the illustrated embodiment, the article 1 is provided with first and second parallel rows of perforations 12 through the tipping material 9, combining wrapping material 11 and cooling section 13, providing ventilation into the mouthpiece 3 at the cooling section 13. The perforations 12 shown are formed as laser perforations, at positions about 18 mm and about 19 mm respectively from the downstream, mouth-end 3b of the mouthpiece 3. In other examples, the ventilation can be provided into the mouthpiece 3 at other locations.

Figure 2 is a side-on cross-sectional view of an article very similar to the article shown in Figure 1, except that the lip adhesion-reducing coating 8 on the outer surface of the tipping paper does not extend all the way to the mouth end 3b of the mouthpiece 3.

Figure 3 is a side-on cross-sectional view of an alternative article comprising an aerosol generating portion and a mouthpiece.

The construction of the article shown in Figure 3 is basically the same as that shown in Figure 1. However, the tipping paper 9 extends the entire length of the article. Once again, the tipping paper 9 has a lip adhesion-reducing coating 8 on its outer surface that covers only part of the length of the tipping paper 9, extending from the mouth end 3b of the mouthpiece, but not extending as far as the distal end 3a of the mouthpiece 3.

Figure 4 is a side-on cross-sectional view of another article, the construction of the article shown being basically the same as that shown in Figure 3. In the article of Figure 4, the tipping paper extends the entire length of the article, but the lip adhesion-reducing surface is provided by a further wrapper 18. The further wrapper 18 circumscribes a portion, but not the entire length, of the mouthpiece 3. The further wrapper is affixed to the tipping paper 9 with an adhesive.

Figure 5 is a side-on cross-sectional view of a further article comprising a rod of aerosol generating material 2, a mouthpiece 3. In addition, the article comprises a component 4 at the upstream or distal end of the article 1. The component 4 includes a body of material 5 wrapped in a component wrapper 6. The component 4 is attached to the rod of aerosol-generating material 2 by a connecting wrapper 7.

The mouthpiece end of the article shown in Figure 5 includes a tipping paper 9 with a lip adhesion-reducing coating 8 as shown in Figure 1.

Figure 6 is a side-on cross-sectional view of an alternative article including a distal plug, component 4 as shown in Figure 5. However, the tipping paper 9 extends the entire length of the article. Once again, the illustrated tipping paper 9 has a lip adhesion-reducing coating 8 on its outer surface that covers only part of the length of the tipping paper 9, extending from the mouth end 3b of the mouthpiece, but not extending as far as the distal end 3a of the mouthpiece 3.

Aerosol generating section

The articles for use with the non-combustible aerosol provision device comprise aerosol-generating material in the portion of the article that is heated upon use.

Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants.

The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material. In some embodiments, the substance to be delivered comprises an active substance, also referred to as an active material.

The active substance or material 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 one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

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

Mentha spicata c.v. and Mentha suaveolens

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

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

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

In some embodiments, the substance to be delivered comprises a flavour.

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

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

In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, van illyl ethyl ether and a suitable cooling agent may be, but not limited to eucalyptol, WS-3.

In some embodiments, the aerosol-generating material comprises one or more aerosol-former material. The aerosol-former material may comprise one or more selected from the group consisting 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.

In some embodiments, the aerosol former comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1 ,3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and/or aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. In some embodiments, the aerosol-former material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, vegetable glycerine (VG), triacetin, sorbitol and xylitol. In some embodiments, the aerosol-former material comprises, consists essentially of or consists of glycerol. Glycerol provides a visible aerosol when the aerosolgeneration device is used. It is common that consumers like the aerosol generating device to provide a visible aerosol, as this enables the consumer to visualise the product and what they are consuming. This makes glycerol a desirable choice for aerosol former material. Propylene glycol has the benefit that it is a better flavour carrier than glycerol.

A combination of two or more aerosol forming agents may be used, in equal or differing proportions.

The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

The aerosol-generating material may comprise or be in the form of an aerosolgenerating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

The aerosol-generating material may comprise more than one film, and the thickness described herein may refer to the aggregate thickness of those films.

The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, it may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosolgenerating material.

The aerosol-generating film may be discontinuous. For example, the aerosolgenerating film may comprise one or more discrete portions or regions of aerosolgenerating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.

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 one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosolgenerating film.

The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.

The aerosol-generating material may comprise or be an "amorphous solid". In some embodiments, the aerosol-generating materiel comprises an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid". The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.

The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free.

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 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 a pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.

In some embodiments, the rod of aerosol generating material is wrapped in a rod wrapper. The rod wrapper can, for instance, be a paper or paper-backed foil wrapper.

In some embodiments, the tipping paper circumscribes substantially the entire length of the rod of aerosol generating material, such that the rod of aerosol generating material is circumscribed by two wrappers along substantially its entire length. Such a double wrapped rod of aerosol generating material may have improved stiffness and/or rigidity. Advantageously, this can allow a lower density rod of aerosol generating material to be provided, whilst maintaining the desired level of stiffness.

In some embodiments, the rod wrapper may comprise one or more of: a flavourant, an aerosol modifying additive, an aerosol former, or an aerosol generating material.

In some embodiments, the mouthpiece comprises a mouthpiece body which is a filter. However, it should be recognised that in other embodiments the mouthpiece body may be provided without substantially filtering the aerosol generated by the article.

In some embodiments, the mouthpiece body is formed from a plug of fibrous material, such as a fibrous tow. This fibrous material may, for example, comprise cellulose acetate tow.

In some embodiments, the mouthpiece body is formed from a sheet material, such as paper. The sheet material may be folded to form the mouthpiece body. The mouthpiece body may be formed from a continuous web of sheet material. In the present example, the sheet material is gathered to form the mouthpiece body in a similar manner to a 'crepe filter'. The entire mouthpiece may be formed from the mouthpiece body. Alternatively, the mouthpiece may comprise two or more segments. These segments of the mouthpiece may be different in form and/or the materials that they are formed from.

In some embodiments, the mouthpiece comprises a cooling section, positioned downstream of the rod of aerosol-generating material. In some embodiments, the cooling section is in an abutting relationship with the rod of aerosol-generating material. In other embodiments, additional components may be provided between the rod of aerosol generating material and the cooling section.

The cooling section may define an air gap within the mouthpiece. The air gap provides a chamber through which heated volatilised components generated by the rod of aerosol generating material flow. The cooling section is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article is in use. The cooling section provides a physical displacement between the rod of aerosol generating material and downstream portions of the mouthpiece.

Preferably, the internal volume of the cooling section is greater than 130 mm³.

Providing a cavity of at least this volume has been found to enable the formation of an improved aerosol. Such a cavity size provides sufficient space within the mouthpiece to allow heated volatilised components to cool, therefore allowing the exposure of the aerosol generating material to higher temperatures than would otherwise be possible, since they may result in an aerosol which is too warm. More preferably, the mouthpiece comprises a cavity having an internal volume greater than 170 mm³, and still more preferably greater than 200 mm³, allowing further improvement of the aerosol. In some examples, the internal cavity comprises a volume of between about 130 mm³ and about 700 mm³ and, preferably, between about 160 mm³ and about 700 mm³. For example, the internal cavity may have a volume between about 170 mm³ and about 300 mm³.

The cavity can be configured to provide a temperature differential of at least 40 degrees Celsius between a heated volatilised component entering a first, upstream end of the cavity and a heated volatilised component exiting a second, downstream end of the cavity. The cavity is preferably configured to provide a temperature differential of at least 60 degrees Celsius, preferably at least 80 degrees Celsius and more preferably at least 100 degrees Celsius between a heated volatilised component entering a first, upstream end of the cavity and a heated volatilised component exiting a second, downstream end of the cavity. This temperature differential across the length of the cavity can protect temperature sensitive elements of the mouthpiece downstream of the cavity from the high temperatures of the aerosol generating material when it is heated.

Preferably, the length of the cooling section is less than about 50 mm. More preferably, the length of the cooling section is less than about 40 mm. Still more preferably, the length of the cooling section is less than about 35 mm. In addition, or as an alternative, the length of the cooling section is preferably at least about 10 mm.

Preferably, the length of the cooling section is at least about 15 mm.

In some preferred embodiments, the length of the cooling section is from about 15 mm to about 35 mm, more preferably from about 20 mm to about 30 mm, even more preferably from about 23 to about 27 mm, most preferably about 25 mm. In the present example, the length of the cooling section is 25 mm.

In some embodiments, the cooling section is formed from a plurality of layers of paper which are parallel wound, with butted seams, to form a hollow tube. In the present example, first and second paper layers are provided in a two-ply tube, although in other examples 3, 4 or more paper layers can be used forming 3, 4 or more ply tubes. Other constructions can be used, such as spirally wound layers of paper, cardboard tubes, tubes formed using a papier-mache type process, moulded or extruded plastic tubes or similar.

In some embodiments, the cooling section preferably has a wall thickness of at least about 50 pm and up to about 1 mm, preferably between 100 pm and 500 pm and more preferably between 100 pm and 150 pm. In some embodiments , the cooling section has a wall thickness of about 150 pm. The "wall thickness" of the cooling section corresponds to the thickness of the wall of the hollow tube in a radial direction, not including any surrounding material in which the hollow tube may be embedded. The wall thickness of the cooling section may be measured, for example, using a calliper.

In some embodiments, the thickness of the wall of the cooling section is at least 50 microns and, preferably, at least 75, 80, 85, 90, 95, 100, or 105 pm. In some embodiments, the thickness of the wall of the cooling section is at least 100 or 110 pm. In some embodiments, the thickness of the wall of the cooling section is less than 1000 pm and, preferably, less than 500 pm.

In some embodiments, the mouthpiece comprises a hollow tubular element positioned at the mouth end of the article. The hollow tubular element may be formed from a plurality of layers of paper which are parallel wound, with butted seams, to form a hollow tube, as described in relation to the cooling section. The hollow tubular element may be formed according to any of the means described for the cooling section and may have any wall thickness as described in relation to the cooling section.

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

Aerosol-modifying agent

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

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

Heater In some embodiments, the aerosol-generating article further comprises 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.

The heater may be provided as an integral part of the aerosol-generating article. Alternatively, the heater may form part of the device with which the article is to be used. For example, the heater may in the form of a pin or blade that is inserted into the article, and specifically into the aerosol-generating segment of the article, as the aerosol-generating article is inserted into the device. In such embodiments, the aerosol-generating article will comprise the heater (only) when the article is inserted in the device.

Dimensions of the aerosol-generating article

Articles, for instance those in the shape of rods, are often named according to the product length: "regular" (typically in the range 68 - 75 mm, e.g. from about 68 mm to about 72 mm), "short" or "mini" (68 mm or less), "king size" (typically in the range 75 - 91 mm, e.g. from about 79 mm to about 88 mm), "long" or "super-king" (typically in the range 91 - 105 mm, e.g. from about 94 mm to about 101 mm) and "ultra-long" (typically in the range from about 110 mm to about 121 mm).

They are also named according to the product circumference: "regular" (about 23 - 25 mm), "wide" (greater than 25 mm), "slim" (about 22 - 23 mm), "demi-slim" (about 19 - 22 mm), "super-slim" (about 16 - 19 mm), and "micro-slim" (less than about 16 mm).

Accordingly, an article in a king-size, super-slim format will, for example, have a length of about 83 mm and a circumference of about 17 mm.

Each format may be produced with mouthpieces of different lengths. The mouthpiece length will be from about 10 mm to 50 mm, for instance from 15 mm to 35 mm. A tipping paper connects the mouthpiece to the aerosol generating material and will usually have a greater length than the mouthpiece, for example from 3 mm to 15 mm longer or 3 mm to 12 mm longer, such that the tipping paper covers the mouthpiece and overlaps the aerosol generating material, for instance in the form of a rod of aerosol generating material, to connect the mouthpiece to the rod. Articles and their aerosol generating materials and components described herein can be made in, but are not limited to, any of the above formats.

In some embodiments, the aerosol-generating article has an outer circumference of about 21 mm (i.e. the article is in the demi-slim format). Preferably, the article has a rod of aerosol generating material having a circumference greater than 19 mm. This has been found to provide a sufficient circumference to generate an improved and sustained aerosol over a usual aerosol generation session preferred by consumers. As the article is heated, heat transfers through the rod of aerosol generating material to volatise components of the aerosol generating material, and circumferences greater than 19 mm have been found to be particularly effective at producing an aerosol in this way. Since the article is to be heated to release an aerosol, improved heating efficiency can be achieved using articles having circumferences of less than about 23 mm. To achieve improved aerosol via heating, while maintaining a suitable product length, rod circumferences of greater than 19 mm and less than 23 mm are preferable. In some examples, the rod circumference can be between 20 mm and 22 mm, which has been found to provide a good balance between providing effective aerosol delivery while allowing for efficient heating.

The outer circumference of the mouthpiece is substantially the same as the outer circumference of the rod of aerosol generating material, such that there is a smooth transition between these components. In the present example, the outer circumference of the mouthpiece is about 20.8 mm.

Distal end plug

Where the aerosol-generating article comprises a component or distal end plug at the upstream end of the article, this can provide several advantages. For instance, the stability of the article, in use, may be improved, by preventing fall-out of aerosolgenerating material from the upstream end of the article. Where the component comprises a body of material having a resistance to draw between about 5% and 25% of the resistance to draw of the article, this can also result in greater consistency of resistance to draw between articles, since the contribution of the rod of aerosol generating material to the overall resistance to draw of the article is relatively less. Advantageously, the relatively high resistance to draw of the component can make the overall resistance to draw of the article less sensitive to variations in the resistance to draw of the rod of aerosol-generating material. The component or distal end plug is connected to the rod of aerosol generating material by a connecting wrapper. This connecting wrapper may be a paper wrapper. In some embodiments, the connecting wrapper may have combustion-retarding properties (for example, to prevent the aerosol-generating article being lit like a conventional combustible cigarette). The combustion-retarding wrapper may, for example, comprise a paper backed foil wrapper, a metal foil, or a paper wrapper comprising a combustion-retarding additive in the paper or in a coating applied to the paper.

In some embodiments, the component or distal end plug is connected to the rod of aerosol generating material with a connecting wrapper which extends over substantially the entire length of the rod of aerosol generating material. This can advantageously provide additional strength and rigidity to the rod of aerosol generating material. This can be particularly advantageous where the aerosol generating material is less densely packed, or is provided in a form having an inherently lower level of structural stability, such as granular tobacco.

The connecting wrapper is adhered to both the component and the rod of aerosolgenerating material. At least part of the inner surface of the connecting wrapper is covered by a layer of adhesive. It has been surprisingly found that applying a reduced amount of adhesive to the connecting wrapper can result in the formation of an improved aerosol. This may be achieved by reducing the thickness of the layer of adhesive, or preferably by providing gaps in the layer of adhesive. Preferably, the layer of adhesive is discontinuous. For example, prior to combining the component or distal plug and the tobacco rod, adhesive may be applied to the connecting wrapper in bands, such that the remaining portions of the connecting wrapper are entirely free of adhesive. When the connecting wrapper with bands of adhesive is wound around the component and the rod of aerosol-generating material, portions of the component and the rod of aerosol-generating material may be free of adhesive. The bands of adhesive may extend in the same direction as the longitudinal axis of the article, perpendicular to the longitudinal axis of the article, or at another angle, such as diagonal to the longitudinal axis. Providing a discontinuous layer of adhesive on the inner surface of the connecting wrapper may advantageously improve the ease of manufacture of the article, since less of the connecting wrapper is wetted by the adhesive which can result in a higher tensile strength of the connecting wrapper during manufacture. Other means of varying or reducing the amount of adhesive applied to the connecting wrapper may be employed. For instance, the adhesive layer may be applied in a different pattern, for instance a dot matrix.

In some embodiments, at least a portion of the area of the inner surface of the connecting wrapper is free of adhesive. Suitably, at least 30%, at least 40%, or at least 50% of the area of the inner surface of the connecting wrapper is free of adhesive.

Suitably, the connecting wrapper has a tensile strength of at least 2.5 kgf/15mm, for instance at least 3 kgf/15mm, or at least 3.5 kgf/15mm. The tensile strength of the connecting wrapper may be determined in accordance with the test method T 494.

In some examples, the connecting wrapper has a permeability of at least 3 Coresta Units. In some examples, the connecting wrapper has a permeability of at least 5 Coresta Units, at least 10 Coresta Units, or at least 20 Coresta Units. In some examples, this permeability is an inherent property of the connecting wrapper. In other examples, the connecting wrapper may be provided with perforations to increase the material permeability. In some examples, the combined permeability of the rod wrapper and the connecting wrapper, together with any intermediate layer of adhesive, is at least 25 Coresta Units, or at least 30 Coresta Units, or at least 50 Coresta Units. The combined permeability of the rod wrapper and the connecting wrapper together with any intermediate layer of adhesive may be determined by breaking down the article to separate the wrapping materials from the rod of aerosolgenerating material, and measuring the total permeability through the wrapping materials surrounding the rod of aerosol-generating material, i.e., the rod wrapper, the connecting wrapper, and any intermediate layer of adhesive, in accordance with ISO 2965:2019.

In some embodiments, one or more of an aerosol-modifying agent and an aerosol former may be added to the material forming the distal end plug. For example, a flavour carrier or glycerol may be applied to the sheet material before forming the body of material forming the plug. In some embodiments, the body of material includes an aerosol-generating film comprising lactic acid, for instance as described in WO 2021/105449.

In some examples, the distal end plug comprises aerosol-former in an amount from 10% to 30% by weight on a dry weight basis. In other embodiments, the distal end plug comprises aerosol former in an amount less than 5% by weight on a dry weight basis.

In other embodiments, the body of material forming the distal end plug comprises a combustion retarding material, for instance a combustion retarding salt and an aerosol-generating film, as described in WO 2020/183163 Al.

In some embodiments, the component or distal end plug has a length of about 6 mm. In other embodiments, the component may have any length in the range of about 3 mm to about 15 mm, preferably about 4 mm to about 6 mm.

The outer circumference of the component is substantially the same as the outer circumference of the rod of aerosol generating material, such that there is a smooth transition between these components.

Aerosol-generating systems

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

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

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

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

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

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

In some embodiments, the non-combustible aerosol provision system, such as a non- combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which 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 may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

The aerosol generating articles described herein may be used within a non- combustible aerosol provision device to form a non-combustible aerosol provision system. In other examples, the article can include its own heat source, forming an aerosol provision system without requiring a separate aerosol provision device.

Figure 7 shows an example of a non-combustible aerosol provision device 100 for generating aerosol from an aerosol-generating material of an article or consumable 110, as described herein. For example, the article 110 may be any one of the articles 1 shown in Figures 1 to 6.

In broad outline, the device 100 may be used to heat a replaceable article 110 comprising the aerosol-generating material, for instance an article as described elsewhere herein, to generate an aerosol or other inhalable medium which is inhaled by a user of the device 100. The device 100 and replaceable article 110 together form a system.

The device 100 comprises a housing 102 (in the form of an outer cover) which surrounds and houses various components of the device 100. The device 100 has an opening 104 in one end, through which the article 110 may be inserted for heating by a heating assembly. In use, the article 110 may be fully or partially inserted into the heating assembly where it may be heated by one or more components of the heater assembly. The article 110 is illustrated having a rod-shape, like the articles 1 illustrated in Figures 1 to 6. The shaded area 107 represents the lip adhesionreducing surface of the articles according to the present invention.

The device 100 of this example comprises a first end member 106 which comprises a lid 108 which is moveable relative to the first end member 106 to close the opening 104 when no article 110 is in place. In Figure 7, the lid 108 is shown in an open configuration, however the lid 108 may move into a closed configuration. For example, a user may cause the lid 108 to slide in the direction of arrow "B".

The device 100 may also include a user-operable control element 112, such as a button or switch, which operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the switch 112. This switch may also actuate the means for opening the container inserted into the device, in readiness for its use.

The device 100 may also comprise an electrical component, such as a socket/ port 114, which can receive a cable to charge a battery of the device 100. For example, the socket 114 may be a charging port, such as a USB charging port. In use, the user's lips will contact the lip adhesion-reducing surface 107 of the aerosol-generating article.

The terms 'upstream' and 'downstream' used herein are relative terms defined in relation to the direction of mainstream aerosol drawn though an article or device in use.

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

Claims

1. An article for use in an aerosol provision system, comprising an aerosolgenerating portion comprising a rod of aerosol-generating material and a mouthpiece, wherein the mouthpiece is provided with a surface to reduce adhesion of the lips of the user to the article and the lip adhesion-reducing surface is distanced from the rod of aerosol-generating material by at least about 5 mm.

2. An article as claimed in claim 1, wherein the lip adhesion-reducing surface is distanced from the mouth end of the article by no more than about 5 mm.

3. An article as claimed in either claim 1 or claim 2, wherein the mouthpiece and aerosol-generating portion are joined by tipping paper that circumscribes at least a portion of both of these parts of the article, optionally wherein the lip adhesionreducing surface is provided on the tipping paper.

4. An article as claimed in any one of claims 1 to 3, wherein the lip adhesionreducing surface is provided by a mouthpiece wrapper that circumscribes only a portion of the length of the mouthpiece, optionally wherein the lip adhesion-reducing surface is provided over an entire surface of the mouthpiece wrapper

5. An article as claimed in any one of claims 1 to 4, wherein the lip adhesionreducing surface comprises a coating, optionally wherein the coating comprises a hydrophobic material or wherein the coating comprises a gloss or lacquer.

6. An article as claimed in claim 5, wherein the coating comprises one or more selected from the group consisting of: nitrocellulose, waxes, silicone compounds and polyvinyl acetate/butylacrylate copolymers, diatomite, sodium oleate or hydroxyl polysiloxane copolymers.

7. An article as claimed in any one of claims 1 to 6, wherein the lip adhesionreducing surface comprises a textured surface reducing the area of contact between the article and the lips of the user, optionally wherein the textured surface is embossed, moulded, cut or roughened.

8. An article as claimed in claim 7, wherein the textured surface comprises a discontinuous layer providing a raised profile where the layer is present.

9. An article as claimed in any one of claims 1 to 8, wherein the mouthpiece comprises one or more sections selected from : a mouthpiece body, a cooling section and a hollow tubular element, optionally wherein the one or more sections of the mouthpiece are circumscribed by a combining wrapping material.

10. An article as claimed in any one of claims 1 to 9, wherein the rod of aerosolgenerating material is circumscribed by a rod wrapper.

11. An article as claimed in any of claims 1 to 10, wherein a tipping paper extends the entire length of the article.

12. An article as claimed in any one of claims 1 to 11, comprising a distal end plug, optionally wherein the distal end plug comprises one or more selected from the group consisting of: a flavour carrier, glycerol, a salt gel, and lactic acid.

13. An article according to claim 12, wherein the distal end plug comprises aerosol former in an amount less than 5% by weight or in an amount between 5% and 25% by weight on a dry weight basis.

14. An article according to any one of claims 1 to 13, wherein ventilation is provided into the article, and the level of ventilation is between 40% and 75%.

15. An article according to any one of claims 1 to 14, wherein the aerosolgenerating portion comprises aerosol former in an amount from about 8% to about 25%, or from about 12% to about 20% by weight on a dry weight basis.

16. An article according to any one of claims 1 to 15, wherein the aerosolgenerating portion comprises tobacco material or non-tobacco botanical material.

17. A system comprising: an article according to any one of claims 1 to 16, and a heating device configured to receive the aerosol-generating portion, wherein the heating device is configured to externally heat the aerosol-generating portion, and/or inductively heat the aerosol-generating portion, and/or resistively heat the aerosol-generating portion.

18. A method for forming an article according to any one of claims 1 to 16, comprising the steps: providing an aerosol generating portion, a mouthpiece, and a wrapping material; combining the aerosol generating portion and mouthpiece with the wrapping material to form a component; wherein the wrapping material comprises a lip adhesion-reducing surface on a portion of a surface so that, when the wrapper is included in the article, the lip adhesion-reducing surface is distanced from the rod of aerosol-generating material by at least about 5 mm.

19. A method for forming an article according to any one of claims 1 to 16, comprising the steps: providing an aerosol generating portion, a mouthpiece, and a wrapping material; combining the aerosol generating portion and mouthpiece with the wrapping material to form a component;