WO2025219583A1

WO2025219583A1 - Method of preparing an aerosol-generating material

Info

Publication number: WO2025219583A1
Application number: PCT/EP2025/060760
Authority: WO
Inventors: Walid Abi Aoun; Jordan RICKETT; Guilherme GONCALVES CARDOSO; Alina-Mariana CRAINIC; Peter Davis
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2024-04-19
Filing date: 2025-04-17
Publication date: 2025-10-23
Anticipated expiration: 2026-10-19

Abstract

A method of preparing an aerosol-generating material, the method comprising: providing a first composition comprising a binder, providing a second composition comprising a first substance to be delivered and an aerosol former and/or a solvent, combining the second composition with the first composition to form a third composition and extruding the third composition to form the aerosol-generating material.

Description

Method of Preparing an Aerosol-Generating Material

Technical Field

The present application relates to aerosol-generating compositions, methods for making aerosol-generating compositions, articles for use in non-combustible aerosol provision devices comprising the aerosol-generating compositions and to noncombustible aerosol provision systems comprising such articles and devices.

Background

Aerosol-generating systems produce an aerosol during use, which is inhaled by a user. For example, tobacco heating devices heat an aerosol-generating material such as tobacco to form an aerosol by heating, but not burning, the aerosol-generating material.

Summary

According to an aspect of the disclosure, there is provided a method of preparing an aerosol-generating material, the method comprising: providing a first composition comprising a binder, providing a second composition comprising a first substance to be delivered and an aerosol former and/or a solvent, combining the second composition with the first composition to form a third composition and extruding the third composition to form the aerosol-generating material.

The method may comprise providing a fourth composition comprising a second substance to be delivered and combining the fourth composition with the first composition and/or the second composition and/or the third composition.

The first composition or the second composition may comprise particulate material.

The first composition or the second composition may comprise plant material.

The first substance to be delivered may comprise a flavour or active.

The second substance to be delivered may comprise a flavour or active.

The first composition may be mixed prior to or during the combining with the second composition.

The third composition may be mixed prior to the extruding the third composition. The method may comprise transportation of the first composition before forming the third composition and/or transportation of the third composition to an extrusion die.

The method may comprise combining the second composition with the first composition prior to or during transportation of the first composition.

The method may comprise changing the temperature of the first composition and/or the third composition.

The method may comprise combining the second composition with the first composition when the first composition is at a temperature that is less than a maximum temperature attained by the first composition.

The method may comprise combining the second composition with the first composition when the first composition is at a temperature equal to or greater than a minimum temperature attained by the first composition.

The third composition may not exceed a maximum temperature attained by the first composition.

The temperature of the first composition when the second composition is combined with the first composition may be lower than the boiling point of the second composition or a component of the second composition.

The method may comprise mixing and/or transporting the first composition for a first period of time and mixing and/or transporting the third composition for a second period of time.

The second period time may be less than the first period of time.

The third composition may be extruded immediately after formation of the second composition.

The method may comprise mixing the substance to be delivered with aerosol former to form the second composition, optionally wherein the method comprises warming the aerosol former.

The substance to be delivered may be dissolved or suspended in the aerosol former. The method may comprise drying the aerosol-generating material.

The method may comprise cutting the aerosol-generating material.

According to an aspect there is provided an aerosol-generating material in the form of a body comprising a cavity for receiving an aerosol generator of an aerosol provision device, two or more channels extending through the body, each channel of the two or more channels being defined by a continuous perimeter wall and a flavour in an amount of at least about 0.5 wt%.

According to an aspect there is provided an aerosol-generating material in the form of a body formed from a non-tobacco botanical material comprising two or more channels extending through the body, each channel of the two or more channels being defined by a continuous perimeter wall and a flavour in an amount of at least about 0.5 wt%.

The aerosol-generating material may comprise the flavour in an amount of up to about 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 wt%.

According to an aspect there is provided an aerosol-generating material produced according to the method described above, optionally wherein the aerosol-generating material produced according to the method is the aerosol-generating material as described above.

According to an aspect there is provided an article for use with or as a noncombustible aerosol provision device, the article comprising the aerosol-generating material as described above.

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:

Figures 1 is a flow chart showing the key steps in methods for preparing the aerosolgenerating materials described herein;

Figure 2 is a schematic view of extrusion apparatus for making the aerosol-generating materials described herein;

Figures 3 and 4 are perspective views of a bodies of aerosol-generating material produced using the methods described herein; Figure 5 is an end-on view of the upstream ends of different bodies of aerosolgenerating material;

Figure 6 is a cross-sectional view of a consumable comprising aerosol-generating material as described herein;

Figure 7 is a cross-sectional view of an aerosol provision system comprising the consumable shown in Figure 6;

Figure 8 is a schematic view of a non-combustible aerosol provision device; and Figure 9 is a flow chart showing the steps in manufacturing a consumable comprising aerosol-generating material as described herein.

Detailed Description

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

As used herein, the term "aerosol-generating material" describes 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 substances to be delivered, such as one or more active substances (sometimes referred to as "actives" herein) and/or flavours, one or more aerosol-former materials, filler and optionally one or more other functional material. The substance to be delivered is for delivery to a user. The aerosol-generating material may be an extruded aerosol-generating material.

Figure 1 is a flow chart showing the key steps in a process for preparing the aerosolgenerating material. At step la, a first composition is provided. The first composition comprises a binder and optionally other materials, such as a particulate plant material. At step lb, a second composition comprising a substance to be delivered and an aerosol former and/or a solvent is applied to the first composition to form a third composition. At step lc, the third composition is extruded to form an aerosolgenerating material.

The binder may be, for example, a gelling agent. The binder may be selected from one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), amylose, amylopectin, celluloses (and derivatives), such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, and carboxymethylcellulose (CMC), gums, silica or silicones compounds, clays, polyvinyl alcohol, a polysaccharide such galactomannan or glucomannan, a gum such as acacia gum, curdlan gum, xanthan gum, pullulan, gellan gum, tragacanth gum, gum karaya, and combinations thereof.

The first composition may comprise particulate material. The binder may bind the particles of the particulate material. The particulate material may be an organic or inorganic material. For example, the particulate material may be an organic material, such as a cellulose or cellulose based material, or an inorganic material, such as calcium carbonate.

The first composition may comprise plant material. The first composition may comprise particulate plant material, for example.

The term "plant material" 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. A plant material may be or 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, Aspalathus linearis (rooibos), chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, Wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens comprise, consist and/or be formed from a botanical material.

In particular, the botanical material may selected from tobacco, eucalyptus, star anise, cocoa and hemp, Aspalathus linearis and fennel.

The first composition and/or the aerosol generating material may not comprise tobacco and/or may not comprise tobacco-derived material. The first composition and/or the aerosol generating material may be substantially free from tobacco or tobacco derived material.

The first composition and/or the aerosol generating material may comprise particulate plant material, such as tobacco or Aspalathus linearis, a filler (e.g. microcrystalline cellulose or wood pulp), a binder (e.g. a cellulosic binder, such as carboxymethyl cellulose or ethyl cellulose or a polysaccharide, such as glucomannan or amylopectin, or alginate) and aerosol former (e.g. glycerol and/or propylene glycol).

The first composition and/or the aerosol generating material may comprise powdered cellulosic material (e.g. microcrystalline cellulose) in an amount of about 1 to 7 wt%, binder (e.g. carboxymethyl cellulose) in an amount of about 1 to 20 wt%, botanical material (e.g. Aspalathus linearis or tobacco) in an amount of 50 to 90% and aerosol former in an amount of about 5 to 30 wt%.

The aerosol-generating material produced using the method may comprise a substance to be delivered.

The substance to be delivered may be an active. An active as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active may for example be selected from nutraceuticals, nootropics, psychoactives. The active may be naturally occurring or synthetically obtained. The active 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 may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical. The active may be a legally permissible recreational drug.

The active may comprise nicotine. In some embodiments, the active comprises caffeine, melatonin or vitamin B12.

As noted, the active may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

The active may be CBD or a derivative thereof.

The substance to be delivered may be derived from one of more botanicals, such as one or more of the botanicals described herein. The substance to be delivered may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof.

The substance to be delivered may comprise 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, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-2 or WS-3.

The flavour may be in the form of a flavour composition which comprises or consists of the flavour. The flavour composition may comprise the flavour and one or more other components, such as a flavour, or a solvent, such as water, ethanol, isopropanol, n- butanol, ethyl acetate, isopropyl acetate, butyl acetate, anisole, glycerol or propylene glycol. The inclusion of a solvent in the flavour composition may improve the homogeneity of the flavour in the aerosol-generating material and improve the absorption or adsorption of the flavour into the aerosol-generating material.

The substance to be delivered may be present in in an amount of at least about 0.5 wt%. For example, the substance to be delivered may be present in in an amount of at least about 0.5, 1, 2, 3, 4, 5, 6, 7, 8 or 9 wt%.

The substance to be delivered may be present in in an amount of up to about 10 wt%. For example, the substance to be delivered may be present in in an amount of up to about 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 wt%. The first composition may comprise a filler. The filler may include one or more organic fillers, such as wood pulp, cellulose, cellulose derivatives (e.g. microcrystalline cellulose, methylcellulose, hydroxypropyl cellulose, and carboxymethylcellulose (CMC)) and a metal carbonate, such as calcium carbonate. In certain instances, the amorphous solid does not contain calcium carbonate, such as chalk.

The first composition may comprise aerosol former material. An aerosol-former material is a material that is 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 first composition may be formed by mixing the components of the first composition using any suitable mixing method. For example, the first composition may be formed by mixing the components in a mixing vessel and/or in an extruder.

The second composition comprises a substance to be delivered, as described herein, and an aerosol former, as described herein, and/or a solvent, as described herein. The second composition is applied to the first composition. It has been found that the homogeneity of the aerosol-generating material that is produced is higher where the substance to be delivered is pre-mixed with the aerosol former and/or solvent compared with where the substance to be delivered is mixed neat with the first composition. In particular, where the substance to be delivered is pre-mixed with the aerosol former and/or solvent prior to its application to the first composition, it may be more evenly distributed throughout the aerosol-generating material. As a consequence, aerosol generating by the aerosol-generating material may comprise more consistent levels of the substance to be delivered and thus a more consistent sensory experience for the user.

The second composition may be formed by mixing the substance to be delivered with aerosol former and/or a solvent to form the second composition. For example, the substance to be delivered may be a solid that is first dispersed, dissolved or suspended in the aerosol former material and/or solvent. The substance to be delivered may be dissolved or suspended in the aerosol former. The substance to be delivered may be melted before combining it with the aerosol former and/or solvent. The substance to be delivered may be molten when it is combined with the aerosol former and/or solvent. This may improve the homogeneity of the substance to be delivered in the final product.

The substance to be delivered may be an active or a flavour. For example, the substance to be delivered may be any of the actives or flavours described herein. Preferred flavours are, for example, menthol, spearmint and/or peppermint.

The solvent can be, for example, water. One or more other components of the first composition and/or the second composition may or may not be soluble in the solvent.

The amount of aerosol former material in the first composition, the second composition and/or the aerosol-generating material may be at least about 3% by weight, at least about 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19% by weight, or at least about 20% by weight. The amount of aerosol former material incorporated in the first composition, the second composition and/or the aerosol-generating material may be up to about 15%, up to about 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29% by weight or up to about 30% by weight.

The aerosol former material may be included in an amount of from about 3% to about 30% by weight of the first composition, the second composition and/or the aerosolgenerating material, preferably in an amount of from about 10% to about 30% or from about 10% to about 20% by weight of the component.

The first and/or the second composition may comprise one or more other materials. For example, the aerosol-generating material may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

The second composition is applied to the first composition to form the third composition.

Water may be added to the first, second or third compositions as a processing aid. For example, the presence of water may help to dissolve components of the first composition, and/or it may assist with binding or improve agglomeration.

The first composition may be transported before formation of the second composition. For example, the first composition may be transported within extrusion machinery from a first location to a second location. Transportation of the first composition allows for a period during which the first composition may be further mixed to achieve greater homogeneity.

The second composition may be applied during transportation of the first composition. The second composition may be mixed into the first composition, optionally during transportation of the first composition, to form the third composition.

In order to achieve efficient mixing and homogeneity the first composition may be heated and/or cooled. The heating and/or cooling of the first composition may be performed during transportation of the first composition. Heating of the first composition may improve mixing of the material and help to achieve greater homogeneity.

For example, the temperature of the first composition may be elevated to up to about 200 °C, 180 °C, 160 °C, 140 °C, 120 °C, 100 °C, 80 °C, 60 °C, 40°C or about 30 °C.

The temperature of the first composition may be altered numerous times prior to addition of the second composition. For example, the temperature of the first composition may be raised and lowered. The temperature may be altered during transportation of the first composition.

The temperature of the first composition may be raised to a first temperature and then subsequently cooled in stages. For example, the first composition may be raised to up to about 200 °C, cooled to up to about 160 °C, cooled to up to about 120 °C and cooled to ambient temperature.

Elevating temperature of the first composition helps to ensure that the first composition is thoroughly mixed prior to addition of the second composition. However, the second composition, the substance to be delivered, or another component of the liquid, may be relatively volatile and so it may be beneficial to apply the second composition when the first composition is at a relatively low temperature. Accordingly, the temperature of the first composition may be elevated to achieve thorough mixing and then cooled prior to addition of the second composition to reduce volatile loses.

The temperature of the first composition when the second composition is applied may be lower than the boiling point of the second composition. The second composition may be applied to the first composition when the first composition is at a temperature that is less than a maximum temperature attained by the first composition.

The second composition may be at temperature equal to or greater than a minimum temperature attained by the first composition. Applying the second composition at a temperature that is lower than the maximum temperature attained by the first composition but higher than the minimum temperature may help to achieve efficient mixing of the second composition with the first composition whilst at the same time avoiding unwanted volatilisation of the liquid or components thereof.

In order to avoid unwanted volatilisation of components from the second composition, the temperature of the second composition may not exceed a maximum temperature attained by the first composition. The second composition may be cooled to a temperature that is lower than the minimum temperature attained by the first composition to further reduce volatile loss.

Addition of the second composition to the first composition results in the formation of the third composition. Therefore, the concentration of substance to be delivered in the third composition may be higher than the concentration of the substance to be delivered in the first composition.

The third composition may be subjected to further mixing prior to being extruded in order to improve the homogeneity of the second composition. In particular, the mixing may be performed in order to thoroughly mix the third composition with the other components of the third composition. The temperature of the third composition may be elevated in order to assist with mixing.

The first composition can be mixed and/or transported for a first period of time and the third composition can be mixed and/or transported for a second period of time. In order to reduce the opportunity for loss of volatile components from the third composition, the second period of time may be shorter than the first period of time. The first period of time may be up to about 60 minutes. The second period of time may be less than about 60 minutes. For example, the first period of time may be up to about 30 minute sand the second period of time may be up to about 29 minutes. The first period of time may be up to about 30 minute sand the second period of time may be up to about 28, 27, 26, 25, 24, 23, 22, 21, 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3 or minutes or up to about 1 minute. The first period of time may be up to about 5 minutes. A shorter first period of time improves the efficiency of the method. In order to further reduce the opportunity for loss of volatile components from the third composition, the third composition may be extruded immediately after its formation. For example, the third composition may be extruded as soon as the components of the third composition are homogeneously mixed.

The third composition is extruded through an extrusion die to form an extruded material. The third composition may be heated prior to being supplied to the extrusion die or during extrusion. This may help improve the malleability of the third composition and thus facilitate its passage through the extrusion die.

The extrusion die comprises at least one orifice. The second composition is forced though the orifice(s) to form the extruded material. The aerosol-generating material can have an elongated form and/or it may be cut into segments of a desired length as it exits the extruder. A rod-like aerosol-generating material may subsequently be cut into aerosol-generating material sections of desired length. These aerosol-generating material sections may be used directly in the aerosol-generating section of an article for use with a non-combustible aerosol provision system.

The method described herein may be an extrusion method and be carried out in an extruder. The extrusion may be performed using one of the main classes of extruders: screw, twin screw, sieve and basket, roll, and ram extruders. Forming the extruded material by extrusion has the advantage that this processing combines mixing, conditioning, homogenizing and moulding of the precursor composition.

Referring to Figure 2, an extruder 2 comprises hopper 3, transport section 4, dosing apparatus 5 and extrusion die 6. In use, the first composition 7 as described herein is supplied to the hopper 3 and transported along the transport section in a transport direction D. The transport section 4 comprises first, second and third transport zones, Tl, T2 and T3, respectively, and first and second mixing zones, Ml and M2, respectively. The transport zones are configured to transport the first composition 7 and the third composition 8 in the transport direction D. Some mixing of the respective compositions occurs in the transport sections Tl, T2 and T3. The mixing zones are configured to transport the first composition 7 and the third composition 8 in the transport direction D and at the same time vigorously mix the respective compositions.

The first composition 7 is supplied to the first transport zone Tl and is moved in the transport direction D to the first mixing zone Ml where it is vigorously mixed. The first composition 7 is then transported to the second mixing zone M2 via the second transport zone T2. At mixing zone M2, the second composition 8, as described herein, is supplied from the dosing apparatus 5 and mixed with the first composition 7 to form the third composition (not shown). The third composition is then transported to the die 6 via the third transport zone T3 and extruded through the die to form extruded aerosol-generating material 9.

In other embodiments, instead of, or in addition to, the second composition being added to at the second mixing zone M2, it may be added at another location and/or at more than one location. For example, it may be added to the first composition 7 at the hopper 3 instead of, or in addition to, being added at the second mixing zone M2.

Any number of transport zones, mixing zones and dosing apparatus can be used depending on the desired composition of the aerosol-generating material. For example, where it is desired to incorporate multiple substances to be delivered into the first composition, a plurality of separate dosing apparatuses can be used to achieve this.

The total time that the first and second compositions spend in the transport section 4 can be up to about 60 minutes. The total time that the first and second compositions spend in the transport section 4 can be up to about 28, 27, 26, 25, 24, 23, 22, 21, 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3 or minutes or up to about 1 minute. The total period of time may be up to about 5 minutes. A shorter period of time improves the efficiency of the method.

The extruder may be operated without applying heat to the system (for example, at room/ambient temperature) or at an elevated temperature. Where the extruder is operated at an elevated temperature, the extruder may be operated at a temperatures of up to about 200 °C. The first, second and/or third compositions may be heated to the same or different temperatures. After the extrudate exits the die of the extruder, it may be cooled, for example to room temperature.

The third composition may be exposed to pressures 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 being used.

Due to the relatively high density of the extrudate and the relatively open surface of the particles within it, the aerosol-generating material may exhibit good heat transfer and mass transfer, which has a positive impact on the release of constituents, such as the substance to be delivered once applied.

The temperature of the first composition may be raised by heating it using any suitable means. The temperature of the first composition may be raised in mixing zone M2 or prior to it reaching the mixing zone M2. Convection heating, microwave heating, infrared (IR) heating or conductive heating are some examples of technologies that may be used to heat the first and/or second compositions.

Applying the substance to be delivered to the first composition when the first composition is at an elevated temperate may improve the take up (e.g. by absorption or adsorption) of the substance to be delivered into the body of the first composition compared with applying the flavour at ambient temperature. Without wishing to be bound by theory, it is postulated that the first composition is porous and that when the temperature of the first composition is elevated, it becomes more porous and so can absorb or adsorb higher quantities of the substance to be delivered. This is particularly beneficial for flavours that are volatile.

The temperature of the first composition when the substance to be delivered is applied may be from about 5 °C, 10 °C, 20 °C, 30 °C, 40 °C, 50 °C, 60 °C, 70 °C, 80 °C, 90 °C, 100 °C, 110 °C, 120 °C, 130 °C, 140 °C, 150 °C, 160 °C, 170 °C, 180 °C or 190 °C and/or up to about 10 °C, 20 °C, 30 °C, 40 °C, 50 °C, 60 °C, 70 °C, 80 °C, 90 °C, 100 °C, 110 °C, 120 °C, 130 °C, 140 °C, 150 °C, 160 °C, 170°C, 180 °C, 190 °C or 200 °C.

The temperature of the first composition when the substance to be delivered is applied may be from 10 °C to 200 °C, from 10 °C to 190 °C, from 10 °C to 180 °C, from 10 °C to 170 °C, from 10 °C to 160 °C, from 10 °C to 160 °C, from 10 °C to 150 °C, from 10 °C to 140 °C, from 10 °C to 130 °C or from 10 °C to 120 °C, in particular from 20 °C to 120 °C, from 30 °C to 120 °C, from 40 °C to 120 °C, from 50 °C to 120 °C, from 60 °C to 120 °C, from 70 °C to 120 °C, from 80 °C to 120 °C or from 90 °C to 120 °C.

The extrusion may be a generally dry process, with the second composition being extruded being added to a substantially dry first composition. The liquid content of the first composition may be relatively low. The first composition may comprise less than about 30% liquid, for example. This may reduce the requirement to dry the extruded material and, as a consequence, further reduce volatile loss. Liquids other than the second composition may be added to the mixture during the extrusion process. For example, water may be added to the first and/or the third composition, for example as a processing aid to assist dissolution or solubilisation of components of the composition, or to aid binding or agglomeration.

The liquid may be an aerosol former material such as glycerol or others discussed herein. When liquid is added to the mixture 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 extruded material 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 extruded material to enhance evaporation of flavour components and other components of the final aerosol-forming material.

The extruded material may be shaped by the orifice or die through which it is forced. In some embodiments, the extruded material is cut into pieces of desired length. The pieces formed in this way may be used as tobacco constituent releasing components or they may undergo further processing.

The orifice or die may be shaped to provide a strand of extruded material. For example, the extruded material may have the form of a cylindrical rod. Alternatively, the extruded material may have different cross-sectional shapes, including oval, polygonal (such as triangular, square, etc.), and stars.

In some embodiments, the extruded material is formed into a desired shape selected to enhance or promote the release of a substance to be delivered, for example by providing a form having a large surface area per unit volume. This large surface area may be provided on the outer surface of the extruded material, for example by selecting cross-sectional shapes with large perimeter.

The orifice or die may be shaped to provide an aerosol-generating material with inner channels. These inner channels provide further surface area and can enhance flavour release. The channel structure of the aerosol-generating material has enlarged inner surface area leading to improved heat and mass transfer. As a result, such components exhibit better, more uniform aerosol delivery. Furthermore, the structure with channels exhibits significantly improved strength in both the radial and axial directions, which is beneficial for the further processing of the aerosol-generating material, for example when it is cut into segments. By means of various die designs and/or different process parameters within the extruder, including the temperature, pressure and shear forces, extruded materials with different physical properties may be prepared, including different heat transfer properties, draft resistance, and capable of producing different aerosols and/or of modifying aerosols being drawn through the extruded material.

In some embodiments, the aerosol-generating material is shaped upon discharge from the extruder. In some embodiments, the aerosol-generating material is cut to an initial length, for example, 1 metre, and allowed to cool before then being cut into sections of the desired length to provide an aerosol-generating material of the desired dimensions.

As noted previously, the aerosol-generating material may be cooled after it is formed. In some embodiments, the cooling is intensive and involves exposing the aerosolgenerating material, which may be at an elevated temperature, for example from about 30°C to about 100°C, or from about 40°C to about 70°C, to a cooling means that will reduce the temperature to within a range of from about 0°C to about 25°C, or from 5°C to about 15°C. This rapid cooling of the aerosol-generating material may enhance the internal and external stability of the extruded material. In some embodiments, it is the die that is cooled to achieve this effect.

In some embodiments, it may be desirable to control the temperature of the third composition during extrusion, including before feeding the mixture through the die. This is especially the case where the extruded composition includes temperature sensitive components, such as aerosol former materials such as glycerol. Thus, in some embodiments, extrusion of the second composition includes reducing the temperature of the third composition before it reaches the die. Such cooling of the third composition may result in the formation of an aerosol-generating material with beneficial properties, or may improve the shaping process.

Figure 3 is a perspective view of an aerosol-generating material 10 formed according to the methods described herein. Aerosol-generating material 10 is in the form of a body 11. The body 11 comprises a cavity lib for receiving an aerosol generator of an aerosol provision device, two channels 12a, 12b extending through the body 11, each channel 12a, 12b being defined by a continuous perimeter wall 13a, 13b. The aerosol-generating material comprises a substance to be delivered, such as a flavour. The channels 12a, 12b extend from inlets 14a, 14b at an upstream end of the body 11, through the body 11 and terminate in outlets 15a, 15b at a downstream end of the body 11. The channels 12a, 12b are configured to allow fluid, such as air and/or aerosol, to pass between the upstream end and the downstream through the body 11. Although in this embodiment the body 11 comprises two channels 12a, 12b, additional channels may be provided in other embodiments. Increasing the number of channels increases the total surface area of the aerosol-generating material and therefore improves the efficiency of aerosol generation.

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

The body 11 of aerosol-generating material 10 has a width, which is the longest straight line distance between a first point on the peripheral edge of the upstream end to a second point on the peripheral edge of the upstream end. Where the body 11 is in the form a rod, the width is equivalent to the diameter of the upstream end of the rod.

In the present example, the body 11 of aerosol-generating material 10 is in the form of a rod which has a diameter of about 7 mm and a length of about 12 mm.

The width/diameter of the body of aerosol-generating material may be from about 2 mm to about 20 mm, about 3 mm to about 16 mm, about 4 mm to about 14 mm, about 5 mm to about 12 mm or about 6 to about 10 mm.

The body of aerosol-generating material can have a length of from about 1 mm to about 30 mm, from about 2 mm to about 25 mm or from about 3 mm to about 20 mm. The body of aerosol-generating material can have a length of about 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm or 20 mm. The body of aerosol-generating material can be formed by cutting a longer body of aerosolgenerating material to the desired length.

In some embodiments the body of aerosol-generating material has a width/diameter of from about 5 mm to about 8 mm and a length of from about 5 mm to about 15 mm. In the present example, the continuous perimeter wall 13a, 13b of the channels 12a, 12b is configured to fluidly isolate the channels 12a, 12b from each other. In embodiments comprising more than two channels, the continuous perimeter wall may be configured to fluidly isolate some or all of the channels from each other. Thus, some or all of the channels may be fluidly isolated from some or all of the other channels. For example, some or all of the channels may be configured such that fluid contained in one channel may not be able to pass into another channel without the fluid first existing the body (e.g. through the outlets).

The cavity 11a for receiving an aerosol generator of an aerosol provision device comprises an opening lib at the upstream end of the body 11 to allow for the aerosol generator to be inserted into the cavity 11a and is defined by a wall 11c extending from the perimeter edge of the opening lib into the body 11. In the present example, the wall 11c of the cavity 11a extends along the full length of the body 11. In some embodiments, the wall 11c of the cavity 11a does not extend along the full length of the body 11, but terminates within the body 11 and so may be referred to as a blind cavity. The cavity 11a may extend into the body by a length that is equal to or about 5% to about 90%, 80%, 70%, 60%, 50%, 40%, 30% 20% or 10% of the total length of the body 11. The depth of the cavity and the width of the cavity may be adapted during manufacturing of the body 11 to suit the width and length of the aerosol-generator to be inserted into the cavity.

The cavity 11a is configured (e.g. it has a suitable cross-sectional area and volume) to receive an aerosol generator, such as a heating pin or blade, of an aerosol provision device.

The cavity 11a may have a width/diameter of from about 1 mm to about 10 mm, about 1.5 mm to about 8 mm or from about 2 mm to about 6 mm. In some embodiments, the cavity has a width/diameter of from about 1.5 mm to about 5 mm or about 2 mm to about 4 mm. A cavity width of around 2 to about 4 mm may be a good compromise between the amount of volume occupied by the cavity and the aerosol-generated in use by the aerosol-generating material.

In some embodiments the body 11 of aerosol-generating material has a width/diameter of about 7 mm and a length of about 12 mm.

As set out previously, the cavity is suitable for receiving an aerosol generator of an aerosol provision device. An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. The aerosol generator can be 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. The aerosol generator may be configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

When the aerosol generator is inserted into the cavity 11a, the aerosol generator can rapidly heat up the body 11 of aerosol generating material 10. The walls 13a, 13b of the channels 12a, 12b are relatively close to the aerosol generator and have a relatively large surface area. The heat generated by the aerosol generator causes the aerosol-generating material 10 to release aerosol, which subsequently travels downstream through the channels 12a, 12b to the downstream end of the body.

The channels 12a, 12b are configured to convey a fluid from the upstream end to the downstream end the body 11. The fluid may be an aerosol. The aerosol-generating material generates an aerosol that flows from the upstream end of the body 11 to the downstream end of the body through the channels 12a, 12b.

The channels 12a, 12b are defined by the perimeter walls 13a, 13b, which extend from the upstream end to the downstream end of the body 11. The upstream end of the perimeter walls 13a, 13b also define, respectively, the inlets 14a, 14b. The downstream end of the perimeter walls 13a, 13b also define, respectively, the outlets 15a, 15b. The perimeter walls 13a, 13b produce aerosol when the aerosol-generating material is heated to a temperature that is sufficient to generate the aerosol.

As noted above, in the present example, the body 11 of aerosol-generating material 10 has a length of around 12 mm. The total surface area of the walls 13a, 13b can be calculated by adding the area of the walls 13a, 13b. The total surface area of walls 13a, 13b can be from about 50 mm² to around 10000 mm², from around 100 mm² to around 5000 mm² or from around 500 mm² to about 3000 mm². Increasing the number of channels may increase the total surface area of the walls and thus increase aerosol generation efficiency. A total surface area of around 1200 mm² to around 1400 mm² provided by 36 channels (and thus 36 continuous peripheral walls) and a body 12 mm long has been found to be particularly effective at generating aerosol without compromising the structural integrity of the body. The total surface area of the walls of the channels per mm length of the body can be from about 20 mm² to about 5000 mm² per mm length of body, from about 30 mm² to about 2000 mm² per mm length of body, from about 40 mm² to about 1000 mm² per mm length of body, from about 50 mm² to about 500 mm² per mm length of body, from about 60 mm² to about 250 mm² per mm length of body, or from about 80 mm² to 120 mm².

Compared to a body without channels (i.e. a body that only has a cavity for receiving the aerosol generator), the aerosol-generating material 10 produces aerosol more efficiently because aerosol can rapidly enter the channels 12a, 12b and move through the body towards the downstream end. Furthermore, as the aerosol generator heats the body 11 radially and the channels 12a, 12b are relatively close to the aerosol generator when it is inserted in the cavity 11a, the heat does not need to conduct through the complete volume of the body 11 in order for the aerosol to be released. Thus, the rate of aerosolisation may be improved.

The cavity 11a may be shaped to receive the aerosol-generator such that when the aerosol-generator is received by the cavity 11a, the aerosol-generator is in contact with the wall 11c of the cavity 11a. This may improve the efficiency of heating of the aerosol-generating material when the aerosol-generator is activated (e.g. when the aerosol-generator is emitting heat). The cavity 11a and/or cavity opening lib may be shaped to receive the aerosol-generator without deforming or damaging the body.

Where the body is rod-shaped, it may have a circular cross-section and the centre of the cavity may be approximately equidistant from an outer surface of the rod. Where the body has a non-circular cross-section, the cavity may be in the geometric centre, or centroid, of cross-section of the body. This may ensure that heat is distributed as evenly as possible throughout the aerosol-generating material when the aerosol generator is activated.

Figure 4 is a perspective view of an aerosol-generating material 10 of a further embodiment. The aerosol-generating material is in the form of a body 11. As with the embodiment shown in Figure 3, the body 11 comprises two or more channels 12a, 12b, as previously described. In the present embodiment, the body 11 is formed from a non-tobacco botanical material. Unlike the embodiment shown in Figure 3, in the embodiment shown in Figure 4, the body 11 does not comprise a cavity for receiving an aerosol generator of an aerosol provision device. The aerosol-generating material 10 may still be used with an aerosol provision device comprising an aerosol-generator in the form of a blade or pin, but rather than inserting the blade or pin into a cavity, the blade or pin can be inserted into the body 11 by deforming the aerosol-generating material. The channels 12a, 12b may facilitate the deformation of the body 11 during insertion of the blade or pin. Increasing the number of channels 12a, 12b may decrease the structural rigidity of the body 11 but improve the ease by which an aerosol generator may be inserted into the body 11 and yet still facilitate aerosol generation and delivery of the aerosol through the body 11.

The aerosol-generating material 10 may also be used with an aerosol provision device that heats the aerosol-generating material from the "outside in" (i.e. by heating the outer surface of the body 11). When used with such an aerosol generating device, the aerosol generator heats the outer surface of the body 11. As the heat does not need to conduct through the complete volume of the body Il in order for the aerosol to be released, aerosol may be more efficiently generated compared with a body that does not comprise channels.

In the embodiments described above, the aerosol-generating material is in the form of a rod. In embodiments, the body may, for example, be in the form of a disc, a cube or a cuboid. The channels may confer the body with honeycomb or honeycomb-like structure (e.g. the upstream end of the body 11 may have a honeycomb appearance when viewed from the upstream end of the body 11). The channels may have a regular cross-sectional shape or an irregular cross-sectional shape. The cross- sectional shape of the channels may be circular, square, hexagonal, pentagonal, heptagonal, octagonal or oblong. Decreasing the cross-sectional area of the channels 12a, 12b may reduce the volume of the channels 12a, 12b to allow for the body 11 to comprise more channels. Increasing the number of channels may increase the surface area of the body 11 and thus increase the efficiency of aerosol generation.

The channels may have a cross-sectional area of at least about 0.01 mm² to about 1 mm², from about 0.05 mm² to about 0.5 mm², from about 0.1 mm² to about 0.4 mm² or from about 0.1 mm² to about 0.3 mm². One or more of the channels may have a different cross-sectional area from the other channels or each channel may have or the same cross-sectional area.

Figure 5 shows the upstream end of various different bodies 11 of aerosol-generating material having different numbers and shapes of channels 12a and channel inlets 14a. The cavity 11a may have any suitable cross-sectional area, but is typically larger in cross-sectional area than the cross-section area of each of the channels 12a, 12b in order to accommodate the aerosol generator. As shown, in these embodiments, the cavity 11a may be circular or have a hexagonal cross-section. The cross-sectional shape of the cavity may be, for example, circular, square, triangular, hexagonal, pentagonal, heptagonal, octagonal or oblong. These shapes may improve the structural rigidity of the body 11.

The aerosol-generating material may be the form of a body comprising a cavity for receiving an aerosol generator of an aerosol provision device, two or more channels extending through the body, each channel of the two or more channels being defined by a continuous perimeter wall and a flavour in an amount of at least about 0.5 wt%. The flavour may be, for example, menthol. The aerosol-generating material may be formed using the methods described herein.

The aerosol-generating material may be in the form of a body formed from a nontobacco botanical material comprising two or more channels extending through the body, each channel of the two or more channels being defined by a continuous perimeter wall and a flavour in an amount of at least about 0.5 wt%. The flavour may be, for example, menthol. The aerosol-generating material may be formed using the methods described herein.

The aerosol-generating material may comprise the menthol in an amount of up to about 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 wt%. The methods described herein provide an aerosol-generating material having a relatively content of the substance to be delivered (e.g. menthol).

The aerosol-generating material may be incorporated into an article for use with a delivery system. An article is sometimes referred to as consumable throughout this disclosure.

As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user, and includes 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.

The article is for use in a non-combustible aerosol provision system. 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.

The non-combustible aerosol provision system can be 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.

The non-combustible aerosol provision system may be an aerosol-generating 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 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 comprises an area for receiving the article for use in the non-combustible aerosol-provision system, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

Referring to Figure 6, an article 16 includes aerosol-generating section 18 comprising an aerosol-generating material 10, as described herein. The aerosol-generating material 10 comprises cavity 11a and channels 12a, 12b. The cavity 11a is located substantially centrally within the cross section of the aerosol-generating section. The cavity 11a is suitable for receiving an aerosol-generator of a non-combustible aerosol provision device. Where cross-sections are referred to herein, these mean a crosssection taken in a plane perpendicular to the longitudinal direction through the article or component.

A first tubular element 17a defines a first portion of the hollow cavity 17c such that this overlaps with a portion of the cavity 11a and/or one or more channels 12a, 12b. For example, cavity 11a may entirely overlap with the first portion of the hollow cavity 17c defined by the first tubular element 17a, and channel 12b may overlap with the first portion of the hollow cavity 17c.

The cross-sectional area of overlap of the hollow cavity 17c of the tubular portion 17a, 17b and of the cavity 11a and the channels 12a, 12b is at least about 5mm², at least about 6mm², at least about 7mm², or at least about 8mm², optionally wherein the cross-sectional area of overlap is between 20% and 50% or between 30% and 45% of the total cross-sectional area of the cavity 11a and the channels 12a, 12b.

The article 16 comprises the aerosol-generating section 18 and a downstream section 19 downstream of the aerosol-generating section 18. The downstream section 19 can be or include a mouthpiece designed to be inserted into a user's mouth in use, or alternatively may be arranged to work with a separate mouthpiece such as one provided as a separate attachment to the downstream section 19 or as part of a non- combustible aerosol provision device. The downstream section 19 has an upstream end 19a and a downstream end 19b. In the present examples, the aerosol-generating section 18 comprises a source of aerosol-generating material in the form of a cylindrical rod of aerosol-generating material as described herein. The aerosolgenerating material can include at least 5% aerosol-former material by weight of the aerosol-generating material, calculated on a dry weight basis, the aerosol-former material being, for instance, one of the aerosol-former materials described herein. Figure 7 is a cross-sectional illustration of the aerosol-generating material section 18 of Figure 6 respectively with the article in which it is provided inserted into a noncombustible aerosol provision device 21, illustrating the location of the pin heater 21a within the cavity 11a of section 18.

Referring to Figures 6 and 7, in the present examples, the receiving portion 20 is a recess in the device 21 including a pin-shaped heater 21a which penetrates the aerosol generating section 18. The pin-shaped heater 21a is resistively heated in the present example, although may alternatively be formed of a heating material as described herein which can be inductively heated, such as a susceptor, or make use of a pin-shaped heater which is heated in other ways. The pin-shaped heaters described herein can be in the general form of a cylinder which and has a diameter of between 1.8 mm and 3 mm, or between 2.2 mm and 2.6 mm. The length of the pin-shaped heater can be between 11 mm and 20 mm, for instance between 15 mm and 18 mm. The length of the pin-shaped heater can be approximately 1 mm shorter than the combined length of the upstream body of material 22 and aerosol-generating material section 18. In other examples, the aerosol generating section 18 of the article 16 can include a heating material, for instance one which can be inductively heated, such as a susceptor.

The mouthpiece or downstream portion 19 includes the first tubular element 17a immediately downstream of the aerosol-generating material section 18, the first tubular element 17a defining a first portion of the hollow cavity 17c. In the present example, the first tubular element 17a is in an abutting relationship with the aerosolgenerating material. The first tubular element 17a has a first tubular wall. The mouthpiece or downstream portion 19 also includes a second tubular element 17b immediately downstream of the first tubular element 17a. In the present example, the second tubular element 17b is in an abutting relationship with the first tubular element 17a. The second tubular element 17b has a second tubular wall having a wall thickness of less than about 320 pm. The second tubular element 17b has an axial length of greater than about 15 mm, for instance between about 15 mm and about 25 mm. In the present example, a downstream body of material 23 is provided at the downstream end 19b of the downstream section 19. The first and second tubular elements 17a, 17b, and the downstream body of material 23, in the present example, each define a cylindrical outer shape and are arranged end-to-end on a common axis. The first and second tubular elements 17a, 17b, aerosol-generating material section 18 and body of material 23 have approximately the same outer diameter. The upstream body of material 22 can be provided upstream of the aerosol-generating material section 18.

The first and second tubular elements 17a, 17b together define a chamber 17c into which aerosol formed in the aerosol-generating section 18 is drawn and expands and cools. The provision of discrete first and second tubular elements 17a, 17b enables these components to be designed to achieve different functional effects. For instance, the first tubular element 17a can be arranged to provide functions such as helping to reduce movement of the aerosol-generating material in use, as the article 16 is inserted into the recess 20 and the pin heater 21a penetrates the aerosol-generating material section 18. For this purpose, the first tubular element 17a can have a wall thickness of, for instance, between 1mm and 3.5mm, or between 1.5mm and 2.5mm. Alternatively or additionally, the first tubular element 17a can be arranged to help with providing rigidity to the article 16. Alternatively or additionally, the first tubular element 17a can be arranged to encourage aerosol to flow predominantly through an axial region of the second tubular element 17b, for instance to assist with aerosol formation. The second tubular element 17b can be designed to define a relatively large chamber as compared to the first tubular element 17a, providing greater space into which the aerosol formed in the aerosol-generating section 18 can be drawn to expand and cool. In addition, for a given weight of the second tubular element 17b, providing a relatively thin wall thickness of less than 320 pm enables material to be concentrated in the outer region of the second tubular element 17b, which can provide a higher bending stiffness as compared to components with thicker walls and the same weight.

In some examples, articles as described with reference to Figures 1 and 2 have the specific features set out in table 1.0 below.

Table 1.0

Although in the present case, the downstream body of material 23 is provided at the mouth or downstream end 16b of the article 16, in other examples a further component can be provided downstream of the downstream body of material 23. For instance, a further body of material can be provided.

In the present examples, the first tubular element 17a has an axial length of about 7mm, but in other examples the first tubular element 17a can have an axial length between about 5mm and about 14mm. In the present examples, the first tubular element 17a has a wall thickness of about 1.6mm and an inner radius of the hollow cavity defined by the first tubular element 17a is about 1.95 mm. This results in a ratio between the thickness of the first tubular wall to the internal radius of the first hollow cavity of about 0.82. In other examples, the ratio of the thickness of the first tubular wall to the internal radius of the first hollow cavity can be between about 0.6 and about 1.1, or between about 0.7 and about 0.9. In the present examples, the volume of the second portion of the hollow cavity 17c defined by the second tubular element 17b is about 588 mm³. The volume of the first portion of the hollow cavity 17c defined by the first tubular element 17a is about 84 mm³. The ratio of the volume of the second portion to the volume of the first portion is therefore about 7 times. The ratio of the volume of the second portion to the volume of the first portion can alternatively be between about 6.5 and about 8. This provides an arrangement in which aerosol can expand from a relatively small cavity within the first tubular element 17a into the much larger cavity of the second tubular element 17b. The second tubular element 17b can define a second portion of the hollow cavity 17c having a volume of at least about 520 mm³. The combined volumes of the first and second portions of the hollow cavity 17c can, for instance, be at least about 580 mm³, or at least about 620 mm³ or at least about 650 mm³.

The second tubular wall can comprise at least first and second overlapping paper layers each extending around substantially the whole circumference of the second tubular element 17b. The at least first and second overlapping paper layers can each have a thickness of between 30 and 150 pm. Alternatively or in addition, the at least first and second overlapping paper layers can each have a basis weight of between 25 and 130 gsm. The at least first and second overlapping paper layers can be connected to each other by a layer of adhesive. The first and second overlapping paper layers can each be non-porous.

The aerosol-generating material section 18 can be in the form of a rod having an axial length which is less than or equal to the axial length of the second tubular element 17b. For instance, the aerosol-generating material section 18 can be in the form of a rod having an axial length which is between 50% and 80% of the axial length of the second tubular element 17b. These arrangements result in an article with a relatively large cavity size defined by the second tubular element 17b as compared to the volume occupied by the aerosol-generating material. Such a cavity can allow for improved expansion of the volume of aerosol passing though the article 16 and better aerosol formation. Preferably, ventilation apertures are provided into the wall of the second tubular element 17b such that cool air enters the cavity defined by the second tubular element 17b in use, further enhancing aerosol formation via condensation of aerosol components within the cavity 17c. The second tubular element 17b can have an axial length of greater than about 16mm or greater than about 16.5mm. For instance, in some examples, the second tubular element 17b can have an axial length which is at least 1.5 or at least 2 times greater than the axial length of the first tubular element 17a. Use of a second tubular element 17b immediately downstream of the first tubular element 17a, which has a wall thickness of less than about 320 pm and an axial length of greater than about 15mm, can result in an article which has an overall weight which is lower than previous designs. In the present examples, the aerosol-generating material section 18 has a weight of between about 200 mg and about 280 mg and the non-aerosol-generating material components of the article 16 have a combined weight of about 320 mg. The total weight is therefore between about 520 grams and about 600 mg for an article 16 with an overall length of 54mm, resulting in an average weight of between 9.6 and 11.1 mg/mm. In some examples, the average weight per mm of axial length of the article can be less than about 12.5 mg/mm or less than about 12 mg/mm or less than about 11.5 mg/mm. In some examples, the average weight per mm of axial length of the article can be between 8.0 and 12.5 mg/mm, or between 9.0 and 11.5 mg/mm. The non-aerosol-generating material weight of the article can be between 45% and 55% of the overall article weight, for instance between 46% and 53%.

The tubular wall of the second tubular element 17b, in the present example, is formed from first and second overlapping paper sheets, resulting in an overall thickness of about 200pm. In alternative examples, the second tubular wall can have a thickness of between about 160pm and about 250 pm. The second hollow cavity defined by the second tubular element has a diameter of about 6.6mm and a radius 'r' of about 3.3mm. The second tubular wall can, for instance, have a thickness which is less than about 15% or less than about 10% of the internal radius 'r' of the second hollow cavity.

As shown in Figure 7, the non-combustible aerosol provision device 21 and the article 16 together form a non-combustible aerosol provision system. The non-combustible aerosol provision device 21 includes a heating element 21a configured for insertion into the aerosol-generating material of the article 16. In the present example, the heating element 21a is a pin-shaped heater 21a which is insertable into the cavity 11a. The non-combustible aerosol provision device comprises a battery 21b, a processor 21c and a user interface 21d, such as a button, configured to operate the device 21. The device may comprise other components.

The non-combustible aerosol provision device 21 includes a housing 24 and an aperture 25 in the housing 24 into which the article 16 is inserted in use. The system is configured such that the second tubular element 17b extends partially within and partially outside the housing 24 when the article 16 is fully inserted into the noncombustible aerosol provision device 21, as shown in Figure 7. The system can be configured such that the second tubular element 17b extends at least about 5mm within and at least about 8mm outside the housing 24 when the article 16 is fully inserted into the non-combustible aerosol provision device 21. In the present example, the article 16 comprises aerosol-generating material section 18 having a length of about 12mm, a first tubular element 17a having a length of about 7mm and a second tubular element 17b having a length of about 17mm. The article 16 is inserted into the device 21 to an insertion depth of about 31mm, as shown by arrow 'B' in Figure 7. In the present case, about 6mm of the second tubular element 17b, between the upstream end 17b' of the second tubular element and the location 'B' on the article 16 aligned with the entrance to the recess 25 in the device 21, extends within the device. About 11mm of the second tubular element 17b, between the location 'B' on the article 16 aligned with the entrance to the recess 25 in the device 16 and the downstream end 17b" of the second tubular element 17b, extends outside the device 24 when the article 16 is fully inserted into the device 21.

The article 16 includes one or more ventilation apertures 16c extending through the second tubular element 17b at a location in the second tubular element 17b which is outside the housing 24 when the article 16 is fully inserted into the non-combustible aerosol provision device 24. The one or more ventilation apertures 16c can be provided as one or more rows of apertures, such as laser or mechanically formed perforations, circumscribing the article 16. In some examples, the level of ventilation is between about 10% and about 60%, for instance between about 20% and about 55% of the mainstream aerosol.

In some examples, the body of aerosol-generating material 11 is a rod of aerosolgenerating material and is circumscribed by a wrapper 26. The wrapper 26 may be a moisture impermeable wrapper.

In the present example, the rod of aerosol-generating material has a circumference of about 22.7 mm. In alternative embodiments, the rod of aerosol-generating material may have any suitable circumference, for example between about 20 mm and about 26 mm.

The first tubular element 17a can be formed from filamentary tow, in the present example plasticised cellulose acetate tow. Other constructions can be used, such as a tubular element 17a formed having inner and outer paper tubes sandwiching a crimped paper sheet material. The wall of the first tubular element can be relatively non-porous, such that at least 80% of the aerosol generated by the aerosol generating material passes longitudinally through the hollow channels through the tube rather than through the wall material itself. For instance, at least 92% or at least 95% of the aerosol generated by the aerosol generating material can pass longitudinally through the first hollow cavity.

The filamentary tow forming the first tubular element 17a preferably has a total denier of between 25,000 and 45,000, preferably between 35,000 and 45,000. Preferably the cross-sectional shape of the filaments of tow are 'Y' shaped, although in other embodiments other shapes such as 'X' shaped filaments can be used.

The filamentary tow forming the first tubular element 17a preferably has a denier per filament between 4 and 10, more preferably between 4 and 9. In one example, the filamentary tow forming the first tubular element 17a has an 8Y40,000 tow formed from cellulose acetate and comprising 18% plasticiser, for instance triacetin.

Preferably, the density of the material forming the first tubular element 17a is at least about 0.20 grams per cubic centimetre (g/cc), more preferably at least about 0.25 g/cc. Preferably, the density of the material forming the first tubular element 17a is less than about 0.80 grams per cubic centimetre (g/cc), more preferably less than 0.6 g/cc. In some embodiments, the density of the material forming the first tubular element 17a is between 0.20 and 0.8 g/cc, more preferably between 0.3 and 0.6 g/cc, or between 0.4 g/cc and 0.6 g/cc or about 0.5 g/cc. These densities have been found to provide a good balance between improved firmness afforded by denser material and minimising the overall weight of the article. For the purposes of the present invention, the "density" of the material forming the first tubular element 17a refers to the density of any filamentary tow or other material forming the element with any plasticiser incorporated. The density may be determined by dividing the total weight of the material forming the first tubular element 17a by the total volume of the material forming the first tubular element 17a, wherein the total volume can be calculated using appropriate measurements of the material forming the first tubular element 17a taken, for example, using callipers. Where necessary, the appropriate dimensions may be measured using a microscope.

The first and second tubular elements 17a, 17b 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 first and second tubular elements 17a, 17b and a heated volatilised component exiting a second, downstream end of the first and second tubular elements 17a, 17b. The first and second tubular elements 17a, 17b are 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 first and second tubular elements 17a, 17b and a heated volatilised component exiting a second, downstream end of the first and second tubular elements 17a, 17b. This temperature differential across the length of the first and second tubular elements 17a, 17b protects the temperature sensitive downstream body of material 23 from the high temperatures of the aerosol-generating material when it is heated.

The aerosol-generating section 18 may exhibit a pressure drop of less than about 20 mm H2O. In some embodiments, the aerosol-generating section 18 exhibits a pressure drop across the aerosol-generating section 18 of from about 1 to about 15 mm H2O.

The resistance to draw or pressure drop through the length of a section, component or article as defined herein is determined according to the ISO standard method (ISO6565:2015). The resistance to draw or pressure drop refers to the 'closed pressure drop', in which any ventilation zones into the section, component or article under measurement are closed, unless otherwise stated.

The aerosol-generating material may have a packing density or bulk density of between about 400 mg/cm³ and about 600 mg/cm³ within the aerosol-generating section. A packing density higher than this may make it difficult to insert the aerosolgenerator of the aerosol provision device into the aerosol-generating material and increase the pressure drop. A packing density lower than 400 mg/cm³ may reduce the rigidity of the article. Furthermore, if the packing density is too low, the aerosolgenerating material may not effectively grip the aerosol-generator of the aerosol provision device.

Between about 30% and about 50% of a volume of the aerosol-generating section 18 is composed of the aerosol-generating material. In some embodiments, from about 35% to about 45% of the volume of the aerosol-generating section 18 is filled with the aerosol-generating material, and the remainder is the cavity 11a and the channels 12, 12b. In the present embodiment, the moisture impermeable wrapper 26 which circumscribes the rod of aerosol-generating material comprises aluminium foil. In other embodiments, the wrapper 26 comprises a paper wrapper, optionally comprising a barrier coating to make the material of the wrapper substantially moisture impermeable. Where the wrapper comprises paper or a paper backing, i.e. a cellulose based material, the wrapper can have a basis weight greater than about 30 gsm. For example, the wrapper can have a basis weight in the range from about 40 gsm to about 70 gsm.

In the present example, the moisture impermeable wrapper 26 is also substantially impermeable to air. The wrapper 26 preferably has a permeability of less than 100 Coresta Units, more preferably less than 60 Coresta Units. It has been found that low permeability wrappers, for instance having a permeability of less than 100 Coresta Units, more preferably less than 60 Coresta Units, result in an improvement in the aerosol formation in the aerosol-generating material. The permeability of the wrapper 26 can be measured in accordance with ISO 2965:2009 concerning the determination of air permeability for materials used as cigarette papers, filter plug wrap and filter joining paper.

The downstream body of material 23 is wrapped in a first plug wrap 27. A second plug wrap 28 is provided to connect the downstream body of material 23 and second tubular element 17b. The upstream body of material 22 is wrapped in a third plug wrap 29. Preferably, the first, second and third plug wraps 27, 28, 29 each have a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. Preferably, the first, second and third plug wraps 27, 28, 29 each have a thickness of between 30 pm and 60 pm, more preferably between 35 pm and 45 pm. Preferably, the first, second and third plug wraps 27, 28, 29 are non-porous plug wraps, for instance having a permeability of less than 100 Coresta units, for instance less than 50 Coresta units. However, in other embodiments, the first, second and/or third plug wrap 27, 28, 29 can be a porous plug wrap, for instance having a permeability of greater than 200 Coresta Units.

A combining wrapper 30 is provided to connect the upstream body of material 22, aerosol generating material section 18 and first tubular element 17a. The combining wrapper 30 can have a basis weight of between about 30 gsm and about 70 gsm. Preferably, the combining wrapper 30 has a thickness of between 35 pm and 70 pm, more preferably between 40 pm and 60 pm. Preferably, the combining wrapper 30 is non-porous, for instance having a permeability of less than 100 Coresta units, for instance less than 50 Coresta units. However, in other embodiments, the combining wrapper 30 can be a porous wrapper, for instance having a permeability of greater than 200 Coresta Units.

The aerosol-generating material section 18 as described herein can be in the form of a cylinder comprising the aerosol-generating material. A first cylindrical element can be provided upstream of the aerosol-generating material section 18, for instance in the form of the upstream body of material 22. A second cylindrical element can be provided downstream of the aerosol-generating material section 18, for instance in the form of the first tubular element 17a. Advantageously, the first and second cylindrical elements can each have a diameter which is equal to or greater than the diameter of the aerosol-generating material section 18, thereby acting to protect the aerosolgenerating material section 18. For instance, the first and second cylindrical elements 17, 17a can act to support and/or protect the aerosol-generating material section 18 while it is wrapped in the combining wrapper 26. Furthermore, the first and second cylindrical elements 17, 17a can act to support and/or protect the aerosol-generating material section 18 while in use in the device 21, for instance reducing lateral forces on the aerosol-generating material section 18. For instance, the aerosol-generating material section 18 can be relatively fragile when formed from reconstituted botanical material or as a moulded component.

In some examples, the hardness of each of the first and second cylindrical elements 17, 17a is at least 78%, at least 80% or at least 82%. In some examples, the hardness of at least one of the first and second cylindrical elements 17, 17a is at least 86%, at least 90% or at least 92%. Such hardness levels can assist the first and second cylindrical elements 17, 17a in supporting and/or protecting the aerosolgenerating material section 18. Alternatively or in addition, the first and second cylindrical elements 17, 17a can each have a diameter which is greater than the diameter of the aerosol-generating material section 18, again helping to protect and/or support the section 18. For instance, the first and second cylindrical elements 17, 17a can each have a diameter which is at least 0.2 mm or 0.3 mm greater than the diameter of the aerosol-generating material section 18.

Figure 9 is a flow diagram illustrating a method of manufacturing an article for insertion into a non-combustible aerosol provision device to generate an aerosol. At step 100 an aerosol-generating material section 18 is provided in the form of a cylinder comprising aerosol-generating material, as well as first and second cylindrical elements each having a diameter equal to or greater than the diameter of the aerosol- generating material section. At step 101, the aerosol-generating material section is arranged between the first and second cylindrical elements, for instance such that the first cylindrical element is upstream of the aerosol-generating material section and the second cylindrical element is downstream of the aerosol-generating material section. The first and second cylindrical elements can each have a diameter which is equal to or greater than the diameter of the aerosol-generating material section. At step 102, the aerosol-generating material section and the first and second cylindrical elements are wrapped in a combining wrapper. In further steps (not illustrated), the resulting combined rod can be aligned in an end-to-end configuration with a downstream portion 19, such as that described herein, and the combined rod and the downstream portion 19 connected using a further wrapper such as tipping paper 31.

Preferably, the length of the downstream body of material 23 is less than about 15 mm. More preferably, the length of the downstream body of material 23 is less than about 14 mm. In addition, or as an alternative, the length of the downstream body of material 23 is at least about 5 mm. Preferably, the length of the downstream body of material 23 is at least about 8 mm. In some preferred embodiments, the length of the downstream body of material 23 is from about 5 mm to about 15 mm, more preferably from about 8 mm to about 14 mm, even more preferably from about 10 mm to about 14 mm, most preferably about 10 mm, 11 mm or 12 mm. In the present example, the length of the downstream body of material 23 is 12 mm.

Preferably, the length of the upstream body of material 22 is less than about 10 mm. More preferably, the length of the upstream body of material 22 is less than about 8 mm. In addition, or as an alternative, the length of the upstream body of material 22 is at least about 5 mm. Preferably, the length of the upstream body of material 22 is at least about 6 mm. In some preferred embodiments, the length of the upstream body of material 22 is from about 5 mm to about 10 mm, more preferably from about 6 mm to about 8 mm. In the present example, the length of the upstream body of material 22 is 6 mm.

In the present example, the downstream body of material 23 is formed from filamentary tow. In the present example, the tow used in the downstream body of material 23 has a denier per filament (d.p.f.) of 3.5 and a total denier of 30,000. In the present example, the tow comprises plasticised cellulose acetate tow. The plasticiser used in the tow comprises about 8% by weight of the tow. In the present example, the plasticiser is triacetin. In other examples, different materials can be used to form the downstream body of material 23. For instance, rather than tow, the downstream body 23 can be formed from paper, for instance in a similar way to paper filters known for use in cigarettes. For instance, the paper, or other cellulose-based material, can be provided as one or more portions of sheet material which is folded and/or crimped to form the downstream body of material 23. The sheet material can have a basis weight of from 15gsm to 60gsm, for instance between 20 and 50 gsm. The sheet material can, for instance, have a basis weight in any of the ranges between 15 and 25 gsm, between 25 and 30 gsm, between 30 and 40 gsm, between 40 and 45 gsm and between 45 and 50 gsm. Additionally or alternatively, the sheet material can have a width of between 50mm and 200mm, for instance between 60mm and 170mm, or between 80mm and 150mm. For instance, the sheet material can have a basis weight of between 20 and 50 gsm and a width between 80mm and 180mm. This can, for instance, enable the cellulose-based bodies to have appropriate pressure drops for an article having dimensions as described herein.

Alternatively, the downstream body 23 can be formed from tows other than cellulose acetate, for instance polylactic acid (PLA), other materials described herein for filamentary tow or similar materials. The tow is preferably formed from cellulose acetate. The tow, whether formed from cellulose acetate or other materials, preferably has a d.p.f. of at least 5. Preferably, to achieve a sufficiently uniform downstream body of material 23, the tow has a denier per filament of no more than 12 d.p.f., preferably no more than 11 d.p.f. and still more preferably no more than 10 d.p.f.

The total denier of the tow forming the downstream body of material 23 is preferably at most 35,000, more preferably at most 32,000 and still more preferably at most 30,000. These values of total denier provide a tow which takes up a reduced proportion of the cross-sectional area of the mouthpiece 19 which results in a lower pressure drop across the mouthpiece 19 than tows having higher total denier values. For appropriate firmness of the downstream body of material 23, the tow preferably has a total denier of at least 8,000 and more preferably at least 10,000. Preferably, the denier per filament is between 3 and 10 while the total denier is between 10,000 and 35,000. Preferably the cross-sectional shape of the filaments of tow are 'Y' shaped, although in other embodiments other shapes such as 'X' shaped filaments can be used, with the same d.p.f. and total denier values as provided herein.

Irrespective of the material used to form the downstream body 23, the pressure drop through the length of the downstream body 23, can, for instance, be between 0.3 and 5mmWG per mm of length of the downstream body 23, for instance between 0.5mmWG and 2.5mmWG per mm of length of the downstream body 23. The pressure drop can, for instance, be between 1.5 and 2.5mmWG/mm of length, on average. The total pressure drop across the downstream body 23 can, for instance, be between 12mmWG and 30mWG, or between 15mmWG and 25mmWG. Where the downstream body 23 includes an additive release component, the pressure drop refers to the average or total pressure drop prior to any rupture of that component.

The upstream body 22 can be formed from paper or other sheet material. For instance, the paper, or other cellulose-based material sheet, can be provided as one or more portions of sheet material which is folded and/or crimped to form the upstream body 22. The sheet material can have a basis weight of from 15gsm to 60gsm, for instance between 20 and 50 gsm, such as 36 gsm. The sheet material can, for instance, have a basis weight in any of the ranges between 15 and 25 gsm, between 25 and 30 gsm, between 30 and 40 gsm, between 40 and 45 gsm and between 45 and 50 gsm. Additionally or alternatively, the sheet material can have a width of between 50mm and 200mm, for instance between 80mm and 190mm, or between 100mm and 180mm. For instance, the sheet material can have a basis weight of between 20 and 50 gsm and a width between 120mm and 200mm. This can, for instance, enable the cellulose-based bodies to have appropriate pressure drops for an article having dimensions as described herein.

Irrespective of the material used to form the upstream body 22, the pressure drop through the length of the upstream body 22, can, for instance, be between 0.3 and 5mmWG per mm of length of the upstream body 22, for instance between 0.5mmWG and 2.5mmWG per mm of length of the upstream body 22. The pressure drop can, for instance, be between 1.0 and 2.0mmWG/mm of length, on average. The total pressure drop through the length of the upstream body 22 can, for instance, be between 6 mmH20 and 30 mmH20, or between 8 mmH20 and 20 mmH20, or between 6mmH2O and 12mmH2O. In some examples, the upstream body of material 22 has a resistance to draw through its length which is at least 15% or at least 20% of the resistance to draw through the length of the article 16. The resistance to draw and pressure drop of the upstream body of material 22 and of the aerosol-generating material section 18 as described herein are measured prior to the insertion of the article 16 into the non-combustible aerosol provision device 21.

The bulk density of the upstream body of material 22 can be between 0.1 and 0.3g/cm³, or between 0.15 and 0.25g/cm³. The upstream body of material 22 can be made from a sheet of material, such as paper or other fibrous material, having a width of between 100 mm and 240 mm, or between 150 mm and 200 mm.

The downstream body of material 23 downstream of the tubular portion 17a, 17b can define the downstream end 16b of the article 16. The upstream body of material 22 can define the upstream end 16a of the article 16. The resistance to draw through the length of the downstream body of material 23 can be higher than the resistance to draw through the length of the upstream body of material 22.

As illustrated in Figure 7, the device 21 can include a heating element 21a for insertion into the aerosol-generating material section 18 of the article 16 when the article 16 is inserted into the non-combustible aerosol provision device 21. The heating element 21a can be arranged for insertion into the aerosol-generating material section 18 of the article 16 when the article 16 is fully inserted into the noncombustible aerosol provision device 21. When this happens, the heating element 21a passes through the upstream body of material 22 and into the aerosol-generating material section 18. Advantageously, the resistance to draw through the length of the upstream body of material 22 can increase by at least 30%, at least 40% or at least 50% when the article 16 is fully inserted into the non-combustible aerosol provision device 21. This means that greater relative changes in pressure drop can be observed in the upstream body of material 22 than in the remainder of the article 16, making the change in pressure drop more predictable than that which may occur in the aerosol-generating material section 18. For instance, the percentage increase in the resistance to draw through the length of the upstream body of material 22 when the article 16 is fully inserted into the non-combustible aerosol provision device 21 can be greater than the overall percentage increase in the resistance to draw of the article 16 when fully inserted into the non-combustible aerosol provision device 21.

In some examples, when the article 16 is fully inserted into the non-combustible aerosol provision device 21 the article 16 has an insertion depth of at least 10 mm, for instance approximately 31 mm. Advantageously, the force required to insert the article 16 into the device 21 for the first time for each millimetre of the last 10 mm of the insertion depth changes by less than 300 grams force. By providing a stable insertion force in the final portion of the insertion depth, the consumer is provided with a clear tactile indication that the article can still be inserted further, up until the point at which the article is fully inserted. The insertion force can be measured using a texture analyser. The force measurements can be made using a TA.XTPIusC Texture Analyser from Stable Micro Systems. The machine is set to Compression Mode with a pre-test speed of 1 mm/sec, a test speed of 2 mm/sec and a post-test speed of 5mm/sec and a Target Mode of 'Distance'

The heating element 21a can have a width at its widest point of between about 1.5 mm and about 4 mm, or between about 2 mm and about 3 mm. The heating element 21a can have an insertion length of between about 10 mm and about 25 mm, or between about 15 mm and about 20 mm, for instance the portion of the heating element 21a which is within the article 16 when the article 16 is fully inserted into the device 21. The heating element 21a can, for instance, have an insertion length of at least 4 mm greater than the axial length of the aerosol-generating material section 18 of the article 16.

The average force required to insert the heating element 21a into each millimetre of length of the upstream body of material 22 can be less than 600 grams force, or less than 400 grams force or less than 300 grams force.

Having a relatively low insertion force means that the consumer is provided with a clearer tactile indication when the article 16 reaches the full insertion depth within the device 21 and the force required for further insertion is at that stage compressing the article 16. The relatively large increases in force from the low insertion forces to the relatively high compression force applied to the article once it is fully inserted, provide a clear indication to a consumer that they should stop applying force to the article.

The force to compress the article axially by 2mm is advantageously at least 1500 grams force or at least 1800 grams force.

A tipping paper 31 is wrapped around part of the downstream portion 19 and over part of the rod of aerosol-generating material and has an adhesive on its inner surface to connect the pre-combined downstream body 23 and second tubular element 17b, with the pre-combined first tubular element 17a, aerosol-generating material section 18 and upstream body of material 22. In the present example, the rod of aerosolgenerating material is wrapped in wrapper 26, which forms a first wrapping material, and the combining wrapper 30 forms an outer wrapper. In some examples, the tipping paper 31 can extend fully over the aerosol-generating material section 18.

In the present example, the tipping paper 31 extends 5 mm over the pre-combined first tubular element 17a, aerosol-generating material section 18 and upstream body of material 22, but it can alternatively extend between 3 mm and 10 mm over the rod, or more preferably between 4 mm and 6 mm, to provide a secure attachment. The tipping paper 31 can have a basis weight greater than 20 gsm, for instance greater than 25 gsm, or preferably greater than 30 gsm, for example 36 or 37 gsm. These ranges of basis weights have been found to result in tipping papers having acceptable tensile strength while being flexible enough to wrap around the article 16 and adhere to itself along a longitudinal lap seam on the paper.

The article 16 can have a ventilation level of about 20% of the total aerosol and ventilation drawn through the article 16. The article 16 preferably includes ventilation apertures provided into the second tubular element 17b. In alternative embodiments, the article 16 can have a ventilation level of between 10% and 60% of the total aerosol and ventilation drawn through the article 16, for instance between 20% and 50%.

An aerosol modifying agent is provided within the downstream body of material 23, in the present example in the form of an additive release component, in the present case a capsule 32. However, the capsule 32 can be omitted in other embodiments. In the case that the capsule 32 is provided, the first plug wrap 27 can be an oil-resistant first plug wrap 27. In other examples, the aerosol modifying agent can be provided in other forms, such as material injected into the downstream body of material 23 or provided on a thread, for instance the thread carrying a flavourant or other aerosol modifying agent, which may also be disposed within the downstream body of material 23.

The capsule 32 can comprise a breakable capsule, for instance a capsule which has a solid, frangible shell surrounding a liquid payload. In the present example, a single capsule 32 is used. The capsule 32 is entirely embedded within the body of material 23. In other words, the capsule 32 is completely surrounded by the material forming the body 23. In other examples, a plurality of breakable capsules may be disposed within the body of material 23, for instance 2, 3 or more breakable capsules. The length of the body of material 23 can be increased to accommodate the number of capsules required. In examples where a plurality of capsules is used, the individual capsules may be the same as each other, or may differ from one another in terms of size and/or capsule payload. In other examples, multiple bodies of material 23 may be provided, with each body containing one or more capsules.

The capsule 32 has a core-shell structure. In other words, the capsule 32 comprises a shell encapsulating a liquid agent, for instance a flavourant or other agent, which can be any one of the flavourants or aerosol modifying agents described herein. The shell of the capsule can be ruptured by a user to release the flavourant or other agent into the body of material 23.

In the present example, the capsule 32 is spherical and has a diameter of about 3 mm. In other examples, other shapes and sizes of capsule can be used. For example, the capsule may have a diameter less than 4 mm, or less than 3.5 mm, or less than 3.25 mm. In alternative embodiments, the capsule may have a diameter greater than about 3.25 mm, for example greater than 3.5 mm, or greater than 4 mm. The total weight of the capsule 32 may be in the range about 10 mg to about 50 mg.

In the present example, the capsule 32 is located at a non-longitudinally central position within the downstream body of material 23. In the present example, the capsule 32 is located closer to the upstream end of the body of material 23 than to the downstream end. That is, the capsule 32 is positioned so that its centre is 5 mm from the upstream end of the downstream body of material 23 and 7mm from the downstream end, which can assist with ensuring that the capsule cannot be seen from the downstream end of the article 16.

Examples

Comparative Example

A composition in a hopper of a twin screw extruder was formed comprising particulate Aspalathus linearis, binder, aerosol former and molten menthol. The composition was fed from the hopper and transported via the twin screws of the twin screw extruder to an extrusion die of the twin screw extruder to form a continuous rod of extruded material. The extruded material was dried and was cut into shorter rod sections.

Upon visual examination, the rod sections exhibited discrete lumps of material distributed non-homogenously throughout their structure, which it is believed were lumps of menthol.

Example 1

A composition in a hopper of a twin screw extruder was formed comprising particulate Aspalathus linearis, binder and aerosol former. Separately, solid menthol was mixed with aerosol former with heating to form a liquid comprising the menthol until most of the menthol had dissolved in the aerosol former. The liquid comprising the menthol was added to the first composition and the resultant composition was fed from the hopper and transported via the twin screws of the twin screw extruder to an extrusion die of the twin screw extruder to form a continuous rod of extruded material. The extruded material was dried and was cut into shorter rod sections. Upon visual examination, the rod sections appeared to be relatively homogenous. In contrast with the comparative example, the rod sections did not appear to comprise discrete lumps of material distributed non-homogenously throughout their structure. 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. A method of preparing an aerosol-generating material, the method comprising: providing a first composition comprising a binder; providing a second composition comprising a first substance to be delivered and an aerosol former and/or a solvent; combining the second composition with the first composition to form a third composition; and extruding the third composition to form the aerosol-generating material.

2. A method as claimed in claim 1, wherein the method comprises: providing a fourth composition comprising a second substance to be delivered; combining the fourth composition with the first composition and/or the second composition and/or the third composition.

3. A method as claimed in either claim 1 or claim 2, wherein the first composition or the second composition comprises particulate material.

4. A method as claimed in either claim 1 or claim 2, wherein the first composition or the second composition comprises plant material.

5. A method as claimed in any one of claims 1 to 4, wherein the first substance to be delivered comprises a flavour or active.

6. A method as claimed in any one of claims 2 to 5, wherein the second substance to be delivered comprises a flavour or active.

7. A method as claimed in any one of claims 1 to 6, wherein the first composition is mixed prior to or during the combining with the second composition.

8. A method as claimed in any one of claims 1 to 7, wherein the third composition is mixed prior to the extruding the third composition.

9. A method as claimed in any one of claims 1 to 8, wherein the method comprises transportation of the first composition before forming the third composition and/or transportation of the third composition to an extrusion die.

10. A method as claimed in any one of claims 1 to 9, wherein the method comprises combining the second composition with the first composition prior to or during transportation of the first composition.

11. A method as claimed in any one of claims 1 to 10, wherein the method comprises changing the temperature of the first composition and/or the third composition.

12. A method as claimed in any one of claims 1 to 11, wherein the method comprises combining the second composition with the first composition when the first composition is at a temperature that is less than a maximum temperature attained by the first composition.

13. A method as claimed in any one of claims 1 to 12, wherein the method comprises combining the second composition with the first composition when the first composition is at a temperature equal to or greater than a minimum temperature attained by the first composition.

14. A method as claimed in any one of claims 1 to 13, wherein the third composition does not exceed a maximum temperature attained by the first composition.

15. A method as claimed in any one of claims 1 to 14, wherein the temperature of the first composition when the second composition is combined with the first composition is lower than the boiling point of the second composition or a component of the second composition.

16. A method as claimed in any one of claims 1 to 15, wherein the method comprises mixing and/or transporting the first composition for a first period of time and mixing and/or transporting the third composition for a second period of time.

17. A method as claimed in claim 16, wherein the second period time is less than the first period of time.

18. A method as claimed in any one of claims 1 to 17, wherein the third composition is extruded immediately after formation of the second composition.

19. A method as claimed in claim 18, wherein the method comprises mixing the substance to be delivered with aerosol former to form the second composition, optionally wherein the method comprises warming the aerosol former, optionally wherein the substance to be delivered is dissolved or suspended in the aerosol former.

20. A method as claimed in any one of claims 1 to 19, wherein the method comprises drying the aerosol-generating material, optionally wherein the method comprises cutting the aerosol-generating material.

21. An aerosol-generating material in the form of a body comprising: a cavity for receiving an aerosol generator of an aerosol provision device; two or more channels extending through the body, each channel of the two or more channels being defined by a continuous perimeter wall; and a flavour in an amount of at least about 0.5 wt%.

22. An aerosol-generating material in the form of a body formed from a nontobacco botanical material comprising: two or more channels extending through the body, each channel of the two or more channels being defined by a continuous perimeter wall; and a flavour in an amount of at least about 0.5 wt%.

23. An aerosol-generating material as claimed in either claim 21 or 22 comprising the flavour in an amount of up to about 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 wt%.

24. An aerosol-generating material produced according to the method as claimed in any one of claims 1 to 20, optionally wherein the aerosol-generating material produced according to the method as claimed in any one of claims 1 to 20 is the aerosol-generating material as claimed in any one of claims 21 to 23.

25. An article for use with or as a non-combustible aerosol provision device, the article comprising the aerosol-generating material as claimed in any one of claims 21