WO2025219580A1

WO2025219580A1 - First and second aerosol-generating materials

Info

Publication number: WO2025219580A1
Application number: PCT/EP2025/060752
Authority: WO
Inventors: Walid Abi Aoun; Alina-Mariana CRAINIC; Arian FEJZULLA; Jack HUMPHREY; Benjamin Jenkins
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

An aerosol generating composition comprising a first and a second aerosol generating material, wherein the first and second aerosol generating materials are different and wherein at least a portion of the surface of the first material is bound to at least a portion of the surface of the second material is provided. Methods to make and use said aerosol generating composition are also provided.

Description

First and second aerosol-generating materials

Technical Field

The present application relates to aerosol-generating compositions, articles for use in non-combustible aerosol provision devices comprising the aerosol-generating compositions and to non-combustible 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

In a first aspect, an aerosol generating composition comprising a first and a second aerosol generating material is provided, wherein the first and second aerosol generating materials are different and wherein at least a portion of the surface of the first material is bound to at least a portion of the surface of the second material.

In some embodiments, each of the first and second aerosol generating materials is in the form of a sheet.

In some embodiments, the aerosol generating composition comprises a layer of the first and a layer of the second aerosol generating materials.

In some embodiments, the portion of the first material and the portion of the second material are bound together by being pressed together the portion of the first material and the portion of the second material in absence of an adhesive.

In some embodiments, at least portion of the surface of the first aerosol generating material is bound to at least a portion of the second aerosol generating material by coextruding the first aerosol generating material and second aerosol generating material.

In some embodiments, an adhesive is provided between the first and the second material, optionally wherein the adhesive is provided in a layer between the first and second material. In some embodiments, the adhesive is an aerosol former, optionally wherein the aerosol former is glycerol.

In some embodiments, wherein the first aerosol generating material, the second aerosol generating material and/or the aerosol generating composition is formed by extrusion.

In some embodiments, the aerosol generating composition comprises the first and second aerosol generating materials in an alternating stripe pattern.

In some embodiments, a longest dimension parallel to a length or a width of the aerosol generating composition of the stripes aligns with the length or the width of the aerosol generating composition.

In some embodiments, the aerosol generating composition is in the form of a sheet and an area of the portion of the first material and the portion of the second material bound together is up to 10% of the area of the sheet of aerosol generating composition.

In some embodiments, the first aerosol generating material and the second aerosol generating material are arranged in the aerosol generating composition such that the first and second aerosol generating materials are arranged in concentric rings around a centrally located cavity.

In some embodiments, a surface area to volume ratio of the first aerosol generating material is different to surface area to volume ratio of the second aerosol generating material.

In some embodiments, the first generating material comprises a first particle size and a second generating material comprises a second particle size.

In some embodiments, the first generating material and second aerosol generating materials comprise different or different amounts of active substances, flavour, botanical material, binder, water, and/or filler.

In another aspect, a process for preparing an aerosol generating composition is provided, the process comprising co-extruding a first and a second aerosol generating material.

In another aspect, a process for preparing an aerosol generating composition is provided, the process comprising: a) forming a first aerosol generating material in the form a first aerosolgenerating material, optionally via extrusion; b) forming a second aerosol generating material, optionally via extrusion; c) extruding the first and second aerosol-generating materials to form the aerosol generating composition.

In another aspect, a process for preparing the first and/or second aerosol generating materials is provided, comprising: a) forming a first composition comprising a first binder and an aerosol former; b) forming a second composition comprising a plant material, a filler and optionally a second binder; c) combining the first and second compositions and extruding the resultant mixture.

In another aspect, an aerosol generating composition produced by a process is provided.

In another aspect, a non-combustible aerosol-provision system comprising the aerosol generating composition is provided.

In another aspect, a consumable for use with a non-combustible aerosol-provision system comprising the aerosol generating composition is provided

In another aspect, a use of the aerosol generating composition for use in a non- combustible aerosol-provision system is provided.

Brief Description of the Drawings

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

Figure 1 shows exemplary embodiments of aerosol generating compositions in the form of a sheet;

Figure 2 is a simplified schematic view of an exemplary rolling press;

Figure 3a, 3b and 3c is a are views of cross sections of the aerosol generating composition; Figure 4a and b is a perspective view of the aerosol generating composition referred to in Figure 3a;

Figure 5 is a schematic view of extrusion apparatus for making the aerosol-generating materials described herein;

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.

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

Detailed Description

In a first aspect of the invention an aerosol generating composition comprising a first and a second aerosol generating material is provided, wherein the first and second aerosol generating materials are different and wherein at least a portion of the surface of the first material is bound to at least a portion of the surface of the second material.

The aerosol generating composition comprises the first and second aerosol generating materials. The aerosol generating composition may comprise further aerosol generating materials, for example a third and/or a fourth aerosol generating materials.

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

As used herein, the term "bound" as used herein means to attach together the surfaces in order to form in a single mass. The first and second aerosol generating materials (or at least a portion thereof) may be reversibly or irreversibly bound.

The aerosol generating composition may be heterogeneous or comprise a heterogenous mixture of the first and second aerosol generating materials. The aerosol generating composition may not comprise a homogeneous mixture of the first and second aerosol generating materials.

In some embodiments, the first and second aerosol generating compositions are distinct in the aerosol generating composition. That is to say that there is a clear distinction between the at least portions of the first and second aerosol generating materials.

On the other hand, in some embodiments, there may be blurring between the at least portions of the first and second aerosol generating materials in the aerosol generating composition. There may not be a clear distinction between the first and second material, and the materials may blend or "bleed" into one another when they are bound. This embodiment may be associated with processes in which at least a portion of the first and second aerosol generating materials are heated. Without wishing to be bound by a particular theory, this it thought to be because the heat may bring the temperature of the material to the glass transition temperature (Tg) of the binders in the aerosol generating materials if present. This changes the phase of said materials and may make them more capable of mixing. Advantageously, the blending of the first and second materials makes the binding irreversible and strong.

The aerosol generating composition and first and second aerosol generating materials may each be in the form of a sheet.

The area of the portion of the first aerosol generating material and the portion of the second aerosol generating material bound together is at most about 2, 5, 10, 20, 40, or 50% of the area of the sheet of aerosol generating composition. The area of the portion of the first material and the portion of the second material bound together is at least about 2, 5, 10, 20, 40, or 50% of the area of the sheet of aerosol generating composition.

At most about 2, 5, 10, 20, 40, or 50% of the surface area of the first aerosol generating material may be bound to the portion of the second aerosol generating material. At least about 2, 5, 10, 20, 40, or 50% of the surface area of the first aerosol generating material may be bound to the portion of the second aerosol generating material.

At most about 2, 5, 10, 20, 40, or 50% of the surface area of the second aerosol generating material may be bound to the portion of the first aerosol generating material. At least about 2, 5, 10, 20, 40, or 50% of the surface area of the second aerosol generating material may be bound to the portion of the first aerosol generating material.

The portion of the bound materials may be selected to provide a large enough surface area that the first and second materials remain bound together. Alternatively, or in addition, the portion of the materials that are bound together may be a consequence of the selected pattern or arrangement of the aerosol generating composition.

In some embodiments, one surface of the first and/or second aerosol generating materials are bound to each other. In some embodiments, more than one surface of the first and/or second aerosol generating materials are bound to each other.

In some embodiments, one or more than one surface of the first and/or second aerosol generating materials are not bound to each other.

In some embodiments, the first and/or second aerosol generating materials are in the form of a sheet. This is particularly advantageous because the first and second aerosol generating materials may be aligned to have overlapping portions which may then be bound to one another. In some embodiments, the sheet may be shredded or sliced to form a shredded sheet. The sheet has a first and a second surface, the second surface being on the opposing face of the sheet.

The aerosol generating composition may comprise a layer of the first and a layer of the second aerosol generating materials. At least a portion of the layers of the first and second aerosol generating materials may be bound to each other. The entirety of the layers of the first and second aerosol generating materials may be bound to each other.

In some embodiments, the aerosol generating composition has an arrangement or pattern formed by the first and second aerosol generating materials. The arrangement may vary depending on the process to form the aerosol generating composition, and the shape of the aerosol generating composition. For example, when the aerosol generating composition is in the form of a sheet, the first and second aerosol generating materials may alternate to provide a striped pattern. The arrangement may be selected to provide the aerosol generating composition to desired properties or flavour profile.

In some embodiments, arrangement may be selected to align with the aerosol generators. As described herein, the aerosol generator may be disposed in the noncombustible aerosol generating device. The aerosol generator may be disposed to provide a heating profile which heats the first or second aerosol generating material independently. For example, the non-combustible aerosol generating device may comprise two "zones", which may be heated to a first and a second temperature. The first zone may be arranged to heat the first aerosol generating material, which may comprise tobacco material for example. The second zone may be arranged to heat the second aerosol generating material, which may comprise non-tobacco material or cellulosic material for example. The second tobacco material may not comprise tobacco material. The first temperature may be a higher that the second temperature in this example.

In some embodiments, the longest dimension of the stripes aligns with a length or a width of the article. In some embodiments, a longest dimension parallel to a length or a width of the aerosol generating composition of the stripes aligns with the length or the width of the aerosol generating composition

Figure 1 shows exemplary embodiments of aerosol generating composition 1. The aerosol generating compositions 1 are in the form of a sheet. Figure la shows a first aerosol generating material 8 and a second aerosol generating material 9 with overlapping portions 10. Figure lb shows a first aerosol generating material 8 and a second aerosol generating material 9 entirely overlapping 10 such that the first and second aerosol generating materials are in the form of layers. Figure lc shows an embodiment in which the aerosol generating composition 1 comprises an alternating pattern of the first 8 and second 9 aerosol generating materials.

The first and second aerosol generating material, or a portion thereof, may be bound together via an adhesive. The adhesive may be incorporated into the first and/or second aerosol generating material and thus the materials adhere or stick to one another. Alternatively, the adhesive may be in the form of a layer between the first and second aerosol generating materials.

The adhesive may be a binder as described herein. This is advantageous because this can provide a suitable consistency or texture of the aerosol generating materials.

The adhesive may be an aerosol former as described herein, such as a polyol, or specifically glycerol. This is particularly suitable because the aerosol former contributes to the formation of an aerosol. Thus, an additional different adhesive is not required, which reduces costs. The first and second aerosol generating materials, or a portion thereof, may be bound together via being pressed together. In such embodiments, the portion of the first material and the portion of the second material are bound together by pressing together the portion of the first material and the portion of the second material in absence of an adhesive.

A roller(s) or a rolling press may be used in order to press together the first and second aerosol generating materials. As used herein, a rolling press is a device including at least one roller. In embodiments in which the rolling press comprises one roller the material may be pressed between the roller and another substantially flat surface. Preferably, the rolling press comprises two or more rollers or sets of rollers, through which the material may be moved. This flattens the material and presses the surfaces together to bind them. The space between the rollers may define the thickness of the aerosol generating material. The use of sets of rollers provides a gradual and uniform/consistent flattening of the aerosol generating materials or aerosol generating composition, to control/reduce thickness and density of the aerosol generating materials.

Referring again to Figure lc, the first 8 and second 9 aerosol generating materials be feed into the rolling press through a dosing system, and alternated. This provides the striped arrangement of aerosol generating composition 1.

This provides the additional advantage that thickness of the produced aerosol composition can be easily controlled by varying the distance between the rollers. In addition, more than one rolling press may be used to incrementally reduce the thickness and provide tight control over the thickness and density of the sheet or shredded sheet. More than one rolling press may be used in order to firmly bind the first and second aerosol generating material together.

In embodiments wherein the aerosol generating composition is in the form of a sheet, the portions of the second material bound together may be thicker than the unbound sections. The use of rollers or a rolling press can provide a uniform thickness of the aerosol generating composition.

In some embodiments the thickness of the aerosol generating material(s) and/or aerosol generating composition in the form of a sheet is about 0.15 to about 0.35 mm. In some embodiments, the thickness of the aerosol-generating material(s)/composition is about 0.18 to about 0.32 mm, about 0.2 to about 0.3 mm, or about 0.24 to about 0.28. The thickness of the sheet can be determined using the Guobiao standards method outlined in "GB/T 451.3 Paper and board-Determination of thickness". In some embodiments, the thickness of the sheet or shredded sheet can be determined according to ISO 534 - Paper and board, which relates to the determination of thickness, density and specific volume. In some embodiments, the thickness of the sheet or shredded sheet can be determined according to ISO 3402- Tobacco and tobacco products, which relates to the atmosphere for conditioning and testing.

The area density of the aerosol generating material(s) and/or aerosol generating composition may be measured in GSM (grams per square metre or g/m²). For example, lower particle size distributions (D90) are associated with higher area densities. When the aerosol-generating material is incorporated into an article for use in a non-combustible aerosol provision system, this higher area density may decrease the fill-value of the botanical material.

In some embodiments, the aerosol generating material(s) and/or aerosol generating composition has an area density of from about 100 g/m² to about 300 g/m², or from about 150 to about 210 g/m². The aerosol generating material(s) and/or aerosol generating composition may have an area density of from about 110 g/m² to about 280 g/m², from about 120 g/m² to about 260 g/m², from about 130 g/m² to about 420 g/m² or from about 140 g/m² to about 220 g/m². In some embodiments, the sheet or shredded sheet has an area density of from about 130 g/m² to about 290 g/m², from about 140 g/m² to about 180 g/m², from about 160 g/m² to about 210 g/m².

The average volume density or grammage of the aerosol generating material(s) and/or aerosol generating composition may be calculated from the thickness and the area density of the aerosol generating material(s) and/or aerosol generating composition. In some embodiments, average volume density or grammage may be greater than about 0.4 g/cm³, about 0.6 g/cm³ or about 0.7 g/cm³. In some embodiments, the average volume density is from about 0.4 g/cm³ to about 1 g/cm³, from about 0.4 g/cm³ to about 0.9 g/cm³, from about 0.5 g/cm³ to about 0.8 g/cm³, from about 0.6 g/cm³ to about 0.8 g/cm³ or from about 0.7 g/cm³ to about 0.8 g/cm³. In some embodiments, the average volume density is from about 0.72 g/cm³ to about 0.80 g/cm³.

An exemplary rolling press is illustrated schematically in Figure 2. Rolling press 102 comprises two rollers 106. The rollers 106 have a space 103 through which the material 101 moves, flattening said material. The thickness of the material is therefore defined by the distance between the rollers in space 103. Space 103 may be adapted to produce a sheet with the required thickness. In embodiments in which more than one roller is used, space 103 may be increasingly small in each successive roller. This results in a process that slowly flattens and decreases the thickness of the material to the required thickness. This increases homogeneity of the sheet and reduces stress forced on the material as it moves through the rolling process.

The first and second aerosol generating material may be bound together via coextrusion. As described herein, extrusion uses heat and pressure to join the materials together.

The first and/or second aerosol generating materials may be extruded material. That is, the material(s) may be extruded prior to being bound together. The first and/or second aerosol generating materials may be extruded under a low pressure and/or extruded whilst transported along the transport sections as described herein.

The first and second composition may not be combined or mixed to form a homogenous mixture prior to being bound together or co-extrusion. The first aerosol generating material may not be in contact with the second aerosol generating material prior to extrusion or co-extrusion. The first aerosol generating material may not be mixed with the second aerosol generating material prior to extrusion or co-extrusion.

In some embodiments, the first and second aerosol generating materials may be extruded prior to being bound together. For example, the first and second aerosol generating materials may be extruded separately and then rolled to bind a portion of the first and second aerosol generating materials together, thus forming the aerosol generating composition. The first and second aerosol generating materials may be extruded and in the form of a sheet.

In some embodiments, the first and second aerosol generating materials are not extruded separately and then are bound together by co-extrusion.

Extrusion or co-extrusion may be performed using one of the main classes of extruders: screw, twin screw, sieve and basket, roll, and ram extruders. Such extruders move the material to an orifice or die.

During extrusion and co-extrusion the mixture is exposed to elevated pressure and is forced though the orifice or die to form an extruded material. In some embodiments, the extruded material has an elongated form and/or it may be cut into segments of a desired length as it exits the extruder. A rod-like extruded material may subsequently be cut into segments of desired length. The extrusion and co-extrusion process, which applies pressure to the material(s) combined with shear forces, may result in agglomerated structures, and/or may be substantially in the form of a sheet or a rod.

Other materials may also be added during the extrusion process, such as a base, diluent, solid aerosol forming agents, solid flavour modifiers, expansion agents and other additives known in the art. This has the advantage that the additive is evenly distributed throughout the agglomerated structures formed.

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 material may be heated prior to being supplied to the extrusion die or during extrusion. This may help improve the malleability of the material and thus facilitate its passage through the extrusion die. In addition, this may help also reach the glass transition temperature (Tg) of the components of the aerosol generating material(s). This provides the advantage that this helps retain the shape post extrusion and to reduces or prevents collapsing of the shape.

After the material exits the die of the extruder, it may be cooled, for example to room temperature, to provide the extruded-precursor material.

The materials may be exposed to pressures ranging from about 2 bar to about 200 bar, or from about 5 bar to about 60 bar, depending on the design of the die being used.

When two or more aerosol generating materials are co-extruded together, the pressure of the materials may be kept the same in order for them to bind together effectively.

Due to the relatively high density of the extruded material and the relatively open surface of the particles within it, the aerosol-generating material may exhibit good heat transfer and mass transfer.

In some embodiments, the first and second aerosol generating materials are bound together via co-extrusion. Co-extrusion is the process of pressing two or more materials through a die to produce a single co-extruded product. In particular, co- extrusion is the process of forming an extrudate composed of more than one aerosol generating materials which are bound together. Without wishing to be bound by a particular reason, it is thought that the pressure of the die binds the aerosol generating materials together. The surfaces of the first aerosol generating material which are in contact with the second aerosol generating material may be bound together during/after the co-extrusion process.

An advantage of co-extrusion process is that the aerosol generating composition that is produces is not homogenous. That is to say that the aerosol generating composition is heterogenous radially and has an uneven cross-section made up of more than one aerosol generating material.

In some embodiments, a third or fourth (or more) aerosol generating material may be added to the process.

In some embodiments, more than two aerosol generating materials enter the co- extrusion die, and more than two aerosol generating materials are bound together.

The die may be shaped to provide a selected cross section in the aerosol generating composition. The orifice or die may be shaped to provide an aerosol-generating material or composition with inner channels or an arrangement of the first or second aerosol generating materials. These inner channels provide further surface area and can enhance flavour release as described herein. The channel structure of the aerosol-generating material has enlarged inner surface area leading to improved heat and mass transfer. As a result, such compositions 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. In addition, the inner channels may also contribute to the pressure drop of the article as described herein. The inner channels also may provide a cavity for entry of the aerosol generator as described herein.

An die comprising one or more openings is selected to create the desired profile of the aerosol generating composition. The die may, for example, comprise a series of radially extending openings and a series of openings that bridge between or connect the series of radially extending openings to form a series of concentric substantially circular openings. When the aerosol generating material is forced through the openings of the die, the resulting extruded material comprises a series of concentric substantially circular walls connected by a series of radial walls. For example, one of the series of concentric substantially circular walls of the extruded material may form an outermost wall of the aerosol generating composition. The die may also comprise solid regions which form channels within the extruded material. In particular, the channels may be formed between the concentric substantially circular walls of the extruded material. The extruded material may be formed such that the aerosol generating composition comprises three or four concentric substantially circular walls, with one of the concentric substantially circular walls forming an outermost wall of the aerosol-generating material. The die may also comprise a central solid region which forms a cavity within the extruded material. The cavity may be defined by one or more cavity walls. As discussed previously, the cavity may not extend through the entire length of the aerosol-generating material. The central solid region of the die may have a circular, triangular, pentagonal, heptagonal or octagonal shaped cross section to form a cavity having the same cross-sectional shape.

The die may comprise opening in which the aerosol generating material enters. The die have more than one opening, so that the first and second aerosol generating material may enter the die simultaneously and not contact one another prior to entry or exit from the die. The die may comprise a plurality of such openings. The die may comprise a plurality of openings wherein the first, second, optional third and optional fourth aerosol generating material enters each opening. The die may be shaped to form the desired arrangement of the aerosol generating composition.

By means of various die designs and/or different process parameters within the extruder, including the temperature, pressure and shear forces, extruded aerosol generating materials and compositions 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. These properties may also be altered by providing different arrangements of the first and second aerosol generating materials.

For example, the die may have multiple entry points for the first and/or second aerosol generating materials, and this alters the way in which the materials come together. The first and/or second aerosol generating material may not be in contact prior to coextrusion.

Exemplary aerosol generating compositions 1 are shown in Figure 3. In a particular example, according to Figure 3a, the cross-section of an aerosol generating composition 1 is shown, comprising radial axis (Y-Y'). A first aerosol generating material 8 is provided on the exterior circumference of the aerosol generating composition 1. The second aerosol generating material 9 is on the inside of the aerosol generating composition 1. Thus, the first and second aerosol generating materials are arranged in concentric rings around the central cavity. The first or second aerosol generating material may be a "core" and the second or first aerosol generating material may be a "shell" around it.

As with all the examples and embodiments described herein, the second aerosol generating material and the first aerosol generating material may be interchangeable. That is to say, the first aerosol generating material may be in the place of the second aerosol generating material and vice versa.

In this embodiment, the aerosol generating composition 1 is rod-shaped, and 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 aerosol generating composition has a non-circular cross-section, the cavity may be in the geometric centre, or centroid, of cross-section of the aerosol generating composition. This may ensure that heat is distributed as evenly as possible throughout the aerosolgenerating material when the aerosol generator is activated.

The aerosol generating composition may be substantially in the form of a rod, body, cylinder. The aerosol generating composition may be monolithic. This provides the advantage that the aerosol generating composition may fit the aerosol generating device.

The cavity 3a 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 3a 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 aerosolgenerated in use by the aerosol-generating material.

In some embodiments the cavity has a width/diameter of about 7 mm and a length of about 12 mm.

Figure 4a and b is a perspective view of the aerosol generating composition 1 referred to in Figure 3a in the form of a body 2. The body 2 comprises a cavity 3a for receiving an aerosol generator of an aerosol provision device, two channels 4a, 4b extending through the body 2, each channel 4a, 4b being defined by a continuous perimeter wall 5a, 5b.

The channels 4a, 4b extend from inlets 6a, 6b at an upstream end of the body 2, through the body 2 and terminate in outlets 7a, 7b at a downstream end of the body 2. The channels 6a, 6b are configured to allow fluid, such as air and/or aerosol, to pass between the upstream end and the downstream end via channels 16 through the body 2. Although in this embodiment the body 2 comprises two channels 4a, 4b, 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 2 of aerosol-generating composition 1 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 2 is in the form a rod, the width is equivalent to the diameter of the upstream end of the rod.

The width/diameter of the body of aerosol-generating composition 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 composition 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 composition 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 composition to the desired length.

In some embodiments the body of aerosol-generating composition has a width/diameter of from about 5 mm to about 8 mm and/or a length of from about 5 mm to about 15 mm.

In the present example, the continuous perimeter wall 5a, 5b of the channels 4a, 4b is configured to fluidly isolate the channels 6a, 6b 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 exiting the body (e.g. through the outlets).

The cavity 3a for receiving an aerosol generator of an aerosol provision device comprises an opening 3b at the upstream end of the body 2 to allow for the aerosol generator to be inserted into the cavity 3a and is defined by a wall 3c extending from the perimeter edge of the opening 3b into the body 2. In the present example, the wall 3c of the cavity 3a extends along the full length of the body 2. In some embodiments, the wall 3c of the cavity 3a does not extend along the full length of the body 2, but terminates within the body 2 and so may be referred to as a blind cavity. The cavity 3a 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 2. The depth of the cavity and the width of the cavity may be adapted during manufacturing of the body 2 to suit the width and length of the aerosol-generator to be inserted into the cavity.

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.

In some embodiments, an aerosol generator is located on the exterior or side of the aerosol generating composition.

When the aerosol generator is inserted into the cavity 3a, the aerosol generator can rapidly heat up the body 2 of aerosol generating material 1. The walls 5a, 5b of the channels 4a, 4b are relatively close to the aerosol generator and have a relatively large surface area. The heat generated by the aerosol generator causes the aerosolgenerating material 1 to release aerosol, which subsequently travels downstream through the channels 4a, 4b to the downstream end of the body.

The channels 4a, 4b are configured to convey a fluid from the upstream end to the downstream end the body 2. The fluid may be an aerosol. The aerosol-generating material generates an aerosol that flows from the upstream end of the body 2 to the downstream end of the body through the channels 4a, 4b.

The channels 4a, 4b are defined by the perimeter walls 5a, 5b, which extend from the upstream end to the downstream end of the body 1. The upstream end of the perimeter walls 5a, 5b also define, respectively, the inlets 6a, 6b. The downstream end of the perimeter walls 5a, 5b also define, respectively, the outlets 7a, 7b. The perimeter walls 5a, 5b produce aerosol when the aerosol-generating composition is heated to a temperature that is sufficient to generate the aerosol.

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 composition when the aerosol generator is activated.

The aerosol-generating composition 1 may also be used with an aerosol provision device that heats the aerosol-generating composition from the "outside in" (i.e. by heating the outer surface of the body 2). When used with such an aerosol generating device, the aerosol generator heats the outer surface of the body 2. As the heat does not need to conduct through the complete volume of the body 2 in order for the aerosol to be released, aerosol may be more efficiently generated compared with a body that does not comprise channels.

First aerosol generating material 8 is provided on the exterior circumference of the aerosol generating composition 1. The second aerosol generating material 9 is on the inside of the aerosol generating composition 1. First aerosol generating material 8 may wrap around the whole of the exterior surface of the second aerosol generating material 9.

The thickness, that is the radial distance of the outermost surface to the inner most surface, of the first aerosol generating material may be at most about 0.2, 0.4, 0.6, 1, 2, 3 mm. The thickness, that is the radial distance of the outermost surface to the inner most surface, of the first aerosol generating material may be at least about 0.01, 0.2, 0.4, 0.6, 1, 2, 3 mm.

In some embodiments, the taste and organoleptic properties of the aerosol generated from the aerosol generating composition may be tailored by selecting the pattern or arrangement of the first and second aerosol generating materials (or more if included in the aerosol generating composition). In particular, the composition of the first and/or second aerosol generating materials may also be selected on this basis.

The first and second aerosol generating materials may be located in the aerosol generating composition and/or consumable to alter their proximity to the aerosol generator, cavities, exterior/exposed surfaces and the mouth end (from which air is drawn).

The composition of the first and second aerosol generating materials may also be adjusted depending on their proximity to the aerosol generator, cavities, exterior/exposed surfaces and the mouth end (from which air is drawn). The proximity to an aerosol generator, cavities, exterior/exposed surfaces and the mouth end (from which air is drawn) may affect the taste and organoleptic properties of the aerosol generated from the aerosol generating composition depending on the arrangement of the first and second aerosol generating materials. The aerosol generator may be particularly warm in the first 10 seconds of use. This is to provide an immediate flavour to the consumer.

The aerosol generating composition may be adjusted to alter the flavour profile. For example, first and second aerosol generating materials may comprise different flavours or substances to be delivered to the user or different concentrations thereof because they have different compositions. In another example, the first and second aerosol generating materials may comprise tobacco and non-tobacco materials respectively.

In some embodiments, a first aerosol generating material is provided at a greater distance to the aerosol generator than a second aerosol generating material. This results in the second aerosol generating material being heated more quickly than the first aerosol generating material.

In some embodiments the substance to be delivered to the user or volatile substance may be aerosolised earlier in the first aerosol generating material compared to the second aerosol generating material, or vice versa.

The volatility of the of substances to be delivered to the user in the first and second aerosol generating material may be tailored to select a particular flavour profile. For example, more volatile substances or flavours may be included in the first aerosol generating material so that the material is exposed to lower temperatures and the flavour is aerosolised earlier. On the other hand, a less volatile substance or flavour will have the opposite profile.

In some embodiments, the aerosol generating material(s) comprise one or more additives for scavenging carbonyls. As used herein, the term carbonyl is intended to encompass reactive carbonyl species which may be found in an aerosol generated from an aerosol generating material. Reactive carbonyl species include aldehydes and ketones such as formaldehyde, acetaldehyde, 2,3-butanedione, 2,3-pentanedione, acetoin, acetone, acrolein, butyraldehyde, crotonaldehyde, glyoxal, isobutyraldehyde, methyl ethyl ketone, methylglyoxal, and propionaldehyde.

It is noted that different aerosol generating materials may produce differing levels of carbonyls when heated, for example in an aerosol provision system. It is also thought that carbonyl generation may be influenced by temperature, specifically the temperature to which the aerosol generating material is heated. Many aerosol provision systems are configured to heat an aerosol generating material to approximately 250-300 °C. However, such systems typically take 15-20+ seconds in order to reach optimum temperature. This initial heating profile may be referred to as the ramp up time and illustrates the amount of time that a user must wait before taking their first puff. The ramp up time may be less than 10 seconds or less than 5 seconds. This would be advantageous because the user has less time to wait before their first puff of a session. However, in order to achieve such a fast ramp up time, it will likely be necessary for the aerosol provision system to reach higher temperatures, such as about 500 °C, about 600 °C, or even above 600 °C. It is hypothesised that when exposed to higher temperatures, aerosol generating materials will produce higher levels of carbonyls.

Thus, the inclusion of an additive for scavenging carbonyls would heating of an aerosol generating material to a higher temperature, while minimising the exposure of the consumer to an increased level of carbonyls.

The aerosol generating material that is closest or in closest proximity to the aerosol generator will be heated the fastest, and thus generate more carbonyls faster. To mitigate this, an aerosol generating material comprising one or additive for scavenging carbonyls as described herein may be provided in proximity to the aerosol generator. This advantageously provides the additive for scavenging carbonyls where they are most required. An aerosol generating material comprising no or lower concentrations of the one or more additive for scavenging carbonyls as described herein may be provided in remotely from the aerosol generator.

For example, referring again to Figure 3a, first aerosol generating material 8 may not comprise an additive for scavenging carbonyls and second aerosol generating material 9 may comprise one or more additive for scavenging carbonyls as described herein.

In some embodiments, the additive is selected from the list consisting of: ammonium- based scavengers, anti-oxidant-based scavengers, organic acid-based scavengers, polyphenol-based scavengers, flavonoid and (ester) derivative -based scavengers, amine-based scavengers, phenolic-based scavengers, amino acid-based scavengers and combinations/mixtures thereof. Ammonium-based scavengers may be selected from: diammonium phosphate, ammonium dihydrogen phosphate, ammonium magnesium phosphate, and combinations/mixtures thereof. Polyphenol-based scavengers may be selected from: chlorogenic acid, gallic acid, and combinations/mixtures thereof.

An example of an antioxidant-based scavenger is ferulic acid. An example of an organic acid-based scavenger is fumaric acid. Flavonoid and (ester) derivative -based scavengers may be selected from: (+) -catechin hydrate, (-)-epicatechin, (-)- epigallocatechin gallate, and combinations/mixtures thereof. Examples of phenolic- based scavengers include: hydroxytyrosol, and phloroglucinol dihydrate, and combinations thereof. Amine-based scavengers may be selected from : ethylenediamine hydrochloride, polyallylamine hydrochloride, ethylenediamine diacetate, 4-aminobenzoic acid, 3-aminobenzoic acid, and combinations/mixtures thereof. Amino acid-based scavengers may be selected from : lysine, arginine, proline, methionine, L-cystine, and combinations thereof. In some embodiments, the additive is selected from sugar alcohols such as: ethylene glycol, glycerol, erythritol, threitol, arabitol, xylitol, ribitol, mannitol, sorbitol, galactitol, fucitol, iditol, inositol, volemitol, isomalt, maltitol, lactitol, maltotriitol, maltotetraitol, polyglycitol, and combinations/mixtures thereof. In some embodiments, the additive is selected from diammonium phosphate, gallic acid, fumaric acid, chlorogenic acid, and ferulic acid. In some embodiments, the additive is diammonium phosphate. In some embodiments, the additive is lysine. In some embodiments, the additive is arginine. In some embodiments, the additive is ammonium dihydrogen phosphate. In some embodiments, the additive is 4-aminobenzoic acid.

In some embodiments, the additive is selected from glycine, homocysteine; a tripeptide, such as glutathione; urea or a urea derivative such as N-hydroxy urea, N- alkyl urea or N-aryl urea; a nitrogen-containing saccharide and polysaccharide, such as glucosamine, galactosamine, and chitosan; additional inorganic ammonium compounds, such as tri-ammonium phosphate, ammonium hydrogen phosphate, and ammonium alkaline earth metal phosphates; an nitrogen-containing plastic compounds, such as polyethylene-imine, poly styrene- acrylonitrile, and polyacrylonitrilebutadiene-styrene.

In some embodiments, the additive is selected from lysine, urea, chitosan, polyethylene-imine, and diammonium phosphate, and combinations thereof.

In some embodiments, the additive is included in an amount of from about 0.01 wt% to about 5 wt%, based on the total weight of the aerosol generating material. For example, the additive may be included in an amount of from about 0.1 wt% to about 5 wt%, from about 0.2 wt% to about 5 wt% from about 0.5 wt% to about 5 wt%, from about 0.5 wt% to about 4.5 wt%, from about 0.5 wt% to about 4 wt%, from about 0.5 wt% to about 3.5 wt%, from about 0.5 wt% to about 3 wt%, from about 0.5 wt% to about 2.5 wt%, from about 0.5 wt% to about 2 wt%, based on the total weight of the aerosol generating material.

In another example, according to Figure 3b, aerosol generating composition 1 comprises a major segment consisting of a first aerosol generating material 9 and a minor segment consisting of a second aerosol generating material 8. The aerosol generating composition further comprises cavity 3a centrally.

In yet another example, according to Figure 3c, aerosol generating composition 1 comprises a first aerosol generating material 8, a segment consisting of a second aerosol generating material 9 and third aerosol generating material 14. The aerosol generating composition further comprises cavities 3a, 4a, 4b.

Such segments may be located anywhere in the aerosol composition, and may be of any size. In embodiments with more than one segment, the segments may be symmetrically or asymmetrically arranged.

The ratio of the first to the second aerosol generating material in the aerosol generating composition may be at most about 2, 4, 5, 10, 15, 20, 25, 30, 40, or 50%.

The ratio of the first to the second aerosol generating material in the aerosol generating composition may be at least about 2, 4, 5, 10, 15, 20, 25, 30, 40, or 50%.

During the extrusion process, the material may be exposed to elevated temperatures. The process may be adjusted according to the temperature sensitivity of the first and/or second aerosol generating material. For example, the first aerosol generating material may be heated to a different temperature to the second aerosol generating material during the extrusion process.

Heating the material(s) during extrusion may bring the temperature of the material to the glass transition temperature (Tg) of the binders in the aerosol generating materials if present. The binders may change phase and become more malleable. Binders that are particularly suitable for this may be selected from : Glucomannan, Curdlan, xanthan gum, Acacia Gum, gelatin, agar, sugar, starch, ethyl cellulose, carboxymethyl cellulose, and/or hydroxy propyl methyl cellulose (HPMC). A co-extruder comprises at least two hoppers, transport section(s), and die(s). The co-extrusion steps may be performed in a single die.

Figure 5 shows a simplified schematic representation of co-extrusion of a first aerosol generating material 8 and a second aerosol generating material 9 (both as described herein). In use, first aerosol generating material 8 and a second aerosol generating material 9 are supplied to the hoppers 11a and lib respectively, transported along the transport sections 12a and 12b in a transport direction D, and co-extruded through the die 13 to form extruded aerosol-generating composition 1.

Any number of hoppers, transport sections, and dies can be used depending on the desired arrangement of the aerosol-generating composition. For example, where it is desired to bind a first, second and third aerosol generating material, a plurality of hoppers, and transport sections can be used to achieve this. In some embodiments, the two transport sections are provided in the extrusion process. In some embodiments, the number transport sections provided in the extrusion process is the same as the number of aerosol generating materials in the aerosol generating composition. Each different aerosol generating material may travel to the die via a different transport section. This prevents the aerosol generating materials from contacting one another until reaching the die.

The transport section may comprise or consist of an extruder or conveyor that moves material a transport direction D, for example a twin-screw extruder. A twin-screw extruder may comprise screws that counter rotate and intermesh so that the aerosol generating material is conveyed. The transport section may move material to the die. The transport section may be heated as described herein. This prevents cooling down or reduction the pressure of the material, which could change the rheological properties of the extrudate.

The transport sections/extruders may be positioned in any suitable arrangement. For example, the transport sections/extruders may be positioned to be perpendicular to each other.

The total time that the first and second materials spend in any one of the transport sections can be up to about 60 minutes. The total time that the first and second aerosol generating materials spend in the transport section 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 first and second aerosol generating materials may spend different amounts of time in the transport section.

The total time that the first and second materials spend the die can be up to about 10 minutes. The total time that the first and second materials spend in the die can be up to about 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 reduces the length of time that the aerosol generating material is exposed to elevated temperatures of the die, and thus reduces loss of volatile substances to be delivered to the user. This improves the flavour delivered to the user.

The extruder may be operated without applying heat to the system (for example, at room/ambient temperature) or at an elevated temperature. The transport sections and/or dies may be operated at elevated temperatures. The temperatures of transport sections and/or dies may the be same or different. The first, second, optional third and/or optional fourth aerosol generating materials may be heated to the same or different temperatures prior to co-extrusion. The temperature of the die may be same as the highest temperature in the transport sections.

The temperatures, time and other properties of the transport sections and/or dies has an effect on the properties of the aerosol generating composition because this affects the aerosolization and loss of the volatile substances to be delivered to the user during the process and the amount remaining in the aerosol generating composition.

The temperature of the die and/or a transport section during an extrusion step 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 die and/or a transport section during an extrusion step may be from about 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 pressure of the process during extrusion may be from about 1 to about 200 bar. The pressure may be about 30 to about 120, about 50 to 100 or about 70 to 90 bar. The pressure may be about 120 to about 180 bar, about 130 to about 170 bar or about 150 to about 165 bar. A higher pressure may compensate for a lower temperature and vice versa.

Heating the material(s) during extrusion may bring the temperature of the aerosol generating material to the boiling point of the volatile substances in the aerosol generating material. The volatile substances may vaporise and therefore be lost, for example either inside the extruder or as the material exits the die. Thus, it is advantageous to keep the materials at a low temperature to reduce loss of volatile substances. The volatile substance may refer to an aerosol former, flavour, active or other substance as described herein. As used herein, the volatile substance may be referred to interchangeably with the substance to be delivered to the user.

The hopper, transport section and die may be kept at a temperature lower than the boiling point of the optional volatile substances in the aerosol generating material. This reduces or prevents loss of volatile substances.

The hopper, transport section and die may be kept at a temperature higher than the glass transition temperature (Tg) of the optional binders in the aerosol generating material. This changes the phase of said materials and makes them more malleable. The temperature may be selected to provide a suitable malleability of the aerosol generating material, for example so that the materials may bind together but not completely blend together.

Referring to Figure 5, for example, first aerosol generating material 8 may be desired to maintain at a first temperature T1 such as below 70 °C to reduce or prevent loss of volatile substances. First aerosol generating material 8 can be transported via transporting section 12a which is maintained at a temperature of about 50 to about 60 °C. Thus, the volatile boiling point of the compound is not lost. Second aerosol generating material 9 may be desired to maintain at a second temperature T2 such as above 110 °C as this is a suitable temperature to reach the Tg of the binders in second aerosol generating material 9. Thus, the materials may be maintained at different suitable temperatures prior to co-extrusion. Referring to Figure 5 in another example, first aerosol generating materials 8 may be maintained as an elevated temperature (Tl) in transport section 5a. The second aerosol generating material 9 may be maintained at a temperature (T2), wherein Tl is higher than T2. The transport section lib may be maintained at the lower temperature T2.

Where the die is operated at an elevated temperature, the die may be operated at a temperature of up to about 200 °C. After the extrudate exits the die, it may be cooled, for example to room temperature.

The temperature may be raised by heating it using any suitable means. 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 materials.

The aerosol generating composition may comprise first and second generating materials which comprise volatile substances with different boiling points. Said first and second generating materials may be arranged to alter their proximity to sources of heat or air flow as described herein to tailor the flavour delivery profile to the user.

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 may be added during the extrusion process. For example, water may be added to the first and/or second aerosol generating material or at any point in the extrusion process.

Water may be added in the extrusion process in order to reduce the density of the first and/or second aerosol generating material. Without wishing to be bound by a particular theory, it is thought that when the water is added to a material at an elevated temperature, it generates gas bubbles of steam which generate pores within the aerosol-generating material. This reduces the density and increases the porosity of the material. Water may be added to the transport section, and may be added to a transport section for the first and/or second aerosol generating material. A lower density of the aerosol generating material is associated with a higher porosity and results in more air flow. This can increase the release of the volatile substances.

The aerosol generating composition may comprise first and second generating materials which comprise volatile substances with different porosities. Said first and second generating materials may be arranged to alter their proximity to air flow. As the surface area that is exposed to air flow alters the release of the substances to be delivered to the used as described herein, this may be selected to tailor the flavour delivery profile to the user.

Referring to Fig 3a for example, a first aerosol generating material 9 with higher porosity may be located more centrally in the body or rod of the aerosol composition than a second aerosol generating material 8 with lower porosity. First aerosol generating material 8 has a higher external surface area and second generating material 9 has a higher porosity and so a higher "internal" surface area. Thus the

The aerosol generating material may comprise pores of a size that allow release of the aerosol from the aerosol-generating material. The greater number of these pores is referred to as higher porosity. For example, the pores may have an average pore size of less than about 0.5mm, for example less than about 0.3mm, or less than about 0.1mm, or less than or equal to about 0.08mm, or less than or equal to about 0.06mm, or less than or equal to about 0.04mm, or less than or equal to about 0.02mm, or less than or equal to about 10pm, or less than or equal to about 5pm. The term 'average pore size' used herein relates to the smallest dimension within a given pore shape, that is, the diameter for a cylindrical pore and the width between two opposite walls for a slit-shaped pore. The term 'pore' used herein relates to regions of the material that are devoid of material. For example, the aerosol generating material comprises portions of aerosol-generating material and portions that are voids between the portions of the aerosol-generating material. The pore sizes may vary along the length and I or width of the body. Alternatively, the pore sizes may be substantially consistent along the length and I or width of the body.

The surface area to volume ratio is greater for a higher porosity aerosol generating material compared to lower porosity material, or a non-porous material. Thus, air that is drawn into the aerosol generating material may be heated quicker than in a non- porous body, which leads to improved aerosol generation.

The surface area to volume ratio of the first aerosol generating material may be different to surface area to volume ratio of the second aerosol generating material. The surface area to volume ratio of the material(s) may be at least 10 to 1. For example, the surface area to volume ratio of the material(s) may be about 50 to 1, about 100 to 1, about 150 to 1, about 200 to 1, about 250 to 1, about 300 to 1, about 350 to 1, about 400 to 1, about 450 to 1, about 500 to 1, about 550 to 1, about 600 to 1, about 650 to 1, about 700 to 1.

The pores within the porous aerosol generating material may create a tortuous path through the material. This arrangement may allow fluid to meander through the material. The pores may connect with one or more channels. In some cases, the pores may allow two or more channels to interconnect. Thus, the material may provide both direct fluid paths through the channels, and indirect fluid paths through the pores.

The porous aerosol generating material may be less dense than a non-porous material. For example, the porous body may be from about 10 to about 50% less dense than a non-porous material. The body may be about 25% less dense than a non-porous material. The porous body may also be lighter than a non-porous material. For example, the porous material may be from about 5% to about 20% lighter than a non-porous material. The material may be about 10% lighter than a non-porous material. Whilst the porous material may advantageously have a lower density and weight compared to a non-porous material, the porous material maintains or increases the release of aerosol compared to the non-porous material, and thus the user experience is maintained or improved.

The aerosol generating composition may comprise first and second generating materials which comprise a botanical material as described herein. The botanical material may comprise particles, granules, fibres, strips and/or strands of plant or botanical material. In some embodiments, the botanical material consists of particles or granules of botanical material.

The aerosol generating composition may comprise a first generating material comprising a first particle size and a second generating material comprising a second particle size. The first and second particle size may be different, and may be selected as described herein. The botanical material particles provide the benefit that the particle size distribution and the resulting characteristics as described herein may be more easily controlled, and therefore may differ between the first and second aerosol generating material. In embodiments in which the botanical material is a particulate botanical material, each particle of the particulate botanical material may have a maximum dimension. As used herein, the term "maximum dimension" refers to the longest straight line distance from any point on the surface of a particle of botanical material, or on a particle surface, to any other surface point on the same particle of botanical material, or particle surface. The maximum dimension of a particle of particulate botanical material may be measured using scanning electron microscopy (SEM).

In some embodiments, the maximum dimension of each particle of botanical material is up to about 800 pm. In some embodiments, the maximum dimension of each particle of botanical material is up to about 2000 pm, up to about 1000 pm, up to about 500 pm, up to about 350 pm, up to about 320 pm, or up to about 300 pm. In some embodiments, the maximum dimension of each particle of botanical material is about 200 pm to about 800 pm.

In some embodiments, a population of particles of the botanical material has a particle size distribution (D90) of at least about 50 pm, of at least about 60, of at least about 70 pm, of at least about 80 pm, of at least about 90, of at least about 100 pm, of at least about 110 pm, of at least about 120 pm, of at least about 130 pm. In some embodiments, a population of particles of the botanical material has a particle size distribution (D90) of at most about 360, of at most about 400 pm, of at most about 500 pm, of at most about 600 pm, of at most about 700 pm, of at most about 800 pm, or of at most about 860 pm. In some embodiments, a population of particles of the botanical material has a particle size distribution (D90) of about 600 pm. In some embodiments, a population of particles of the botanical material has a particle size distribution (D90) of about 70 pm. In some embodiments, a population of particles of the botanical material has a particle size distribution (D90) of about 70 pm to about 600 pm, or about 70 to about 360 pm. A particle size and shape analyser, such as a Camsizer may be used to measure the particle size distribution, and sieve analysis may be used to determine the particle size distribution of the particles of botanical material.

The particle size may be selected to be small enough to prevent blocking the die. The die may be of a complex shape and have a propensity to be blocked by the aerosol generating material(s). On the other hand, larger particle sizes require less grinding and processing to be produced, and thus require less energy. The inventors have found that the botanical material particle size affects the tensile strength. A small particle size distribution is associated with a higher tensile strength and higher and density of the aerosol generating material. The aerosol generating composition may be optimised for this, wherein the particle size is selected to provide a suitable tensile strength.

The inventors have found that the particle size distribution (D90) may be controlled to achieve the desired area density of the aerosol-generating material. The area density of the material may be measured in GSM (grams per square metre or g/m²). For example, lower particle size distributions (D90) are associated with higher area densities. When the aerosol-generating material is incorporated into an article for use in a non-combustible aerosol provision system, this higher area density may decrease the fill-value of the botanical material. A particular example of this is that a particle size distribution (D90) of 300 is predicted to provide an area density of 246.6 g/m2.

In some embodiments, the aerosol-generating material has an area density of from about 100 g/m² to about 300 g/m², from about 110 g/m² to about 280 g/m², from about 120 g/m² to about 260 g/m², f from about 150 to about 210 g/m², from about 180 to about 205 g/m² or from about 185 to about 195 g/m². In some embodiments, the aerosol-generating material has an area density of about 180 to about 200 g/m².

The average volume density or grammage of the aerosol-generating material may be calculated from the thickness of the aerosol-generating material and the area density of the aerosol-generating material. In some embodiments, average volume density or grammage may be from about 0.5 g/cm³ to about 1 g/cm³. In some embodiments, the average volume density is from about 0.6 g/cm³ to about 0.9 g/cm³, from about 0.7 g/cm³ to about 0.86 g/cm³. In some embodiments, the average volume density is about 0.8 g/cm³.

The aerosol generating material may have a lower density compared to other aerosol generating materials. As a result of this lower density, the aerosol generating composition is lighter, and therefore easier to handle and stored. A lower density is desirable as this reduces the amount of material required to produce the aerosol generating composition.

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.

The aerosol-generating material may be cooled after it is formed. In some embodiments, the cooling is intensive and involves exposing the aerosol-generating 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, the aerosol generating composition comprises different aerosol generating materials such as the first and the second aerosol generating material. The first and/or second aerosol generating material herein may comprise or consist of the components as described herein. The first and/or second aerosol generating material may be in the form selected from a slurry, dough, mixture, paste, solid, gel and/or suspension.

The first and second aerosol generating materials may independently comprise different and/or different amounts of substance(s) to be delivered to the user, active substances, flavour, aerosol former botanical material, binder, water, and/or filler as described herein.

Advantageously, the different aerosol generating materials (or at least a portion thereof) may be bound together in the aerosol generating composition in particular arrangements as described herein. The mixed proportions may be easily controlled, either by differing the concentration in the first and/or second aerosol generating materials, changing the size/shape of the first and/or second aerosol generating materials, the location of the first and/or second aerosol generating materials in the aerosol generating composition. This means that the aerosol generated may be finely tuned and controlled, for example to provide a specific flavour profile over time.

In some embodiments, water may be added to the aerosol generating materials as a processing aid. For example, the presence of water may help to dissolve components of the precursor composition, and/or it may assist with binding or improve agglomeration. Water may be added in an amount of up to about 12 wt %, for example, about 11 wt%, about 10 wt%, about 9 wt%, about 8 wt%, about 7 wt%, about 6 wt%, about 5 wt%, about 4 wt% about 3 wt%, about 2 wt% or about 1 wt%.

The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

A polyol, and in particular glycerol, provides emollient properties. This therefore also improves the viscosity of the aerosol generating material(s) and aerosol generating composition.

In some embodiments, the amount of aerosol former material incorporated into the aerosol generating material(s) and/or aerosol-generating composition may be at least about 5% by weight, at least about 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19% by weight, or at least about 20% by weight. In some embodiments, the amount of aerosol former material incorporated into the aerosol generating material(s) and/or aerosol-generating composition 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.

In some embodiments, aerosol former material is included in an amount of from about 5% to about 30% by weight of aerosol generating material(s) and/or aerosolgenerating composition, for example, in an amount of from about 10% to about 30% by weight of the component.

In some embodiments, the substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolised. As appropriate, either material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials. The one or more other functional materials may comprise one or more of a pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

In some embodiments, the substance to be delivered comprises an active substance.

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

In one embodiment the active substance is a legally permissible recreational drug.

In some embodiments, the active substance comprises nicotine. For example, the active may comprise nicotine in an amount of less than about 5 wt% or less than about 3 wt%. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

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

The active substance may be CBD or a derivative thereof.

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

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

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

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

In some embodiments, the first and/or second aerosol generating material does not comprise tobacco. In some embodiments, the first and/or second aerosol generating material comprise rooibos.

In some embodiments, the botanical material comprises tobacco in an amount of about 50 to about 90 wt%. For example, the botanical material may comprise tobacco in an amount of about 60 wt% to 80 wt%.

In some embodiments, the substance to be delivered comprises a flavour. In some embodiments, a flavour may be added to the aerosol generating material(s). The flavour may be added in an amount of up to about 10 wt%, for example, about 9 wt%, about 8 wt%, about 7 wt%, about 6 wt%, about 5 wt%, about 4 wt%, about 3 wt%, about 2 wt% or about 1%. The aerosol generating composition may comprise up to about 10 wt%, for example, about 9 wt%, about 8 wt%, about 7 wt%, about 6 wt%, about 5 wt%, about 4 wt%, about 3 wt%, about 2 wt% or about 1% of 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-3.

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

In some embodiments, the aerosol generating material(s) comprises a filler. The filler is generally a non-tobacco component, that is, a component that does not include ingredients or components originating from tobacco. The filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may be a non-tobacco fibre such as wood fibre or pulp or wheat fibre. The filler can be a material comprising cellulose or a material comprises a derivate of cellulose. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material. In some embodiments, the filler is cellulosic material, cellulose or CMC. In some embodiments, the filler is essentially composed or consists of cellulose.

In some embodiments, the filler is inert and unreactive. In some embodiments the filled is tasteless, and does not contribute to the flavour or organoleptic properties of the aerosol generated. This provides the advantage that the amount and type of filler may be selected to alter the physical properties of the aerosol generating material, but not to affect the taste profile of the aerosol or the user experience.

In particular embodiments which include filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood, wood pulp, hemp fibre, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is believed that including fibrous filler may increase the tensile strength of the aerosol-generating material that is formed. The use of cellulose as a filler has been found to have a particularly favourable impact on the burst strength of the aerosol-generating material.

The filler may also contribute to the texture of the aerosol-generating material. For example, a fibrous filler, such as cellulose, may provide an aerosol-generating material having relatively rough first and second surfaces. Conversely, a non-fibrous, particulate filler, such as powdered chalk, may provide an aerosol-generating material having relatively smooth first and second surfaces. In some embodiments, the aerosol-generating material comprises a combination of different filler materials. The filler may help to improve the general structural properties of the aerosol-generating material, such as its tensile strength and burst strength.

The aerosol generating material(s) and/or aerosol-generating composition may comprise the filler in an amount of less than 5 wt%.

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

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

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

The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosolgenerating film.

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

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

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), gums, silica or silicones compounds, clays, polyvinyl alcohol, a polysaccharide such as galactomannan or glucomannan, a gum such as acacia gum, xanthan gum, pullulan, gellan gum, tragacanth gum, gum karaya, and combinations thereof. For example, in some embodiments, the binder comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the binder comprises alginate and/or pectin or carrageenan. In some embodiments, the binder comprises CMC.

In some embodiments, the aerosol generating material(s) and/or aerosol-generating composition comprises modified starch. For example, the aerosol generating material(s) and/or aerosol-generating composition comprises modified starch in an amount of less than about 10 wt%, or less than about 8 wt%, or less than or equal to about 6 wt%.

In some embodiments, the binder is selected to have a suitable glass transition temperature as described herein. Such binders may be selected from the group including: Glucomanna, Curdlan, xanthan gum, Acacia Gum, gelatin, agar, sugar, starch, ethyl cellulose, carboxymethyl cellulose, hydroxy propyl methyl (HPMC) and/or cellulose.

In some embodiments, the aerosol generating material(s) and/or aerosol-generating composition comprises one or more binders. For example, the aerosol generating material(s) and/or aerosol-generating composition may comprise one or more binders in an amount of less than about 20 wt% or less than about 15 wt%. The one or more binders may be in an amount of about 10 wt%. The one or more binders may be in an amount of less than about 10 wt%. The one or more binders may comprise amylopectin, and a gum, such as Curdlan gum, for example. Optionally, the one or more binders may not comprise glucomannan.

In some embodiments, the aerosol generating material(s) and/or aerosol-generating composition comprises a botanical material in an amount of 20 to 90% wt%, one or more binders in an amount of about 5 to 20 wt%, and one or more aerosol formers in an amount of about 5 to 30 wt%.

Where present, the filler may include one or more organic fillers, such as wood pulp, cellulose, cellulose derivatives (e.g. microcrystalline cellulose) and a metal carbonate, such as calcium carbonate. In certain instances, the amorphous solid does not contain calcium carbonate, such as chalk.

The aerosol generating material(s) and/or aerosol-generating composition may comprise the filler in an amount of less than 10 wt%. For example, the aerosol generating material(s) and/or aerosol-generating composition may comprise the filler in an amount of less than 5 wt%, or less than or equal to about 3 wt%.

In some embodiments, the aerosol generating material(s) and/or aerosol-generating composition comprises calcium carbonate. For example, the calcium carbonate is in the form of chalk. The aerosol generating material(s) and/or aerosol-generating composition may comprise chalk in an amount of less than about 10 wt %, or less than or equal to about 5 wt%.

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.

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

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

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

In some embodiments, the non-combustible aerosol provision system is an aerosolgenerating material(s) and/or composition 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(s) and/or aerosol-generating composition, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material(s) and/or aerosolgenerating composition and a solid aerosol-generating material(s) and/or aerosolgenerating composition. The solid aerosol-generating material(s) and/or aerosolgenerating composition 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 disclosure relates to consumables comprising aerosolgenerating material(s) and/or composition and configured to be used with non- combustible aerosol provision devices. Consumables may be referred to as articles herein.

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

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

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

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

In some embodiments, a non-combustible aerosol-provision system comprising the article is provided. The non-combustible aerosol-provision system may be as described herein.

In some embodiments, the pressure drop across the article is about 20 to about 120 mmWg, about 30 to about 80 mmWg, or about 30 to about 60 mmWg. The pressure drop may be measured between an upstream end and a downstream end of the article. The pressure drop may a result of the properties of the first and second aerosol generating materials, for example their porosity or density. 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. As used herein, the term article and consumable may be used interchangeably.

Referring to Figure 6, an article 216 includes aerosol-generating material(s) and/or aerosol-generating composition as described herein. The aerosol-generating material(s) and/or aerosol-generating composition 210 comprises cavity 211a and channels 212a, 212b. The cavity 211a is located substantially centrally within the cross section of the aerosol-generating material(s) and/or aerosol-generating composition section 24. The cavity 211a is suitable for receiving an aerosol-generator of a non-combustible aerosol provision device. Where cross-sections are referred to herein, these mean a cross-section taken in a plane perpendicular to the longitudinal direction through the article or component.

The first tubular element 217a defines the first portion of the hollow cavity 217c such that this overlaps with a portion of the cavity 211a and/or one or more channels 212a, 212b. For example, cavity 212a may entirely overlap with the first portion of the hollow cavity 217c defined by the first tubular element 217a, and channel 212b may overlap with the first portion of the hollow cavity 217c.

The cross-sectional area of overlap of the hollow cavity 217c of the tubular portion 217a, 217b and of the cavity 211a and the channels 212a, 212b 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 211a and the channels 212a, 212b.

The article 216 comprises the aerosol-generating section 218 and a downstream section 219 downstream of the aerosol-generating section 218. The downstream section 219 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 219 or as part of a non-combustible aerosol provision device. The downstream section 219 has an upstream end 219a and a downstream end 219b. In the present examples, the aerosol-generating section 218 comprises a source of aerosol-generating material(s) and/or composition in the form of a cylindrical rod of aerosol-generating material(s) and/or composition as described herein. The aerosol-generating material(s) and/or composition can include at least 5% aerosol-former material by weight of the aerosolgenerating material(s) and/or composition, calculated on a dry weight basis, the aerosol-former material being, for instance, one of the aerosol-former materials and/or compositions described herein.

Figure 7 is a cross-sectional illustration of the aerosol-generating material section 218 of Figure 6 respectively with the article in which it is provided inserted into a noncombustible aerosol provision device 221, illustrating the location of the pin heater 221a within the cavity 211a of section 218.

Referring to Figures 6 and 7, in the present examples, the receiving portion 220 is a recess in the device 221 including a pin-shaped heater 221a which penetrates the aerosol generating section 218. The pin-shaped heater 221a 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 21 mm shorter than the combined length of the upstream body of material 222 and aerosol-generating material section 218. In other examples, the aerosol generating section 218 of the article 216 can include a heating material, for instance one which can be inductively heated, such as a susceptor.

The mouthpiece or downstream portion 219 includes the first tubular element 217a immediately downstream of the aerosol-generating material section 218, the first tubular element 217a defining a first portion of the hollow cavity 217c. In the present example, the first tubular element 217a is in an abutting relationship with the aerosolgenerating material. The first tubular element 217a has a first tubular wall. The mouthpiece or downstream portion 222 also includes a second tubular element 217b immediately downstream of the first tubular element 217a. In the present example, the second tubular element 217b is in an abutting relationship with the first tubular element 217a. The second tubular element 217b has a second tubular wall having a wall thickness of less than about 320 pm. The second tubular element 217b 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 223 is provided at the downstream end 219b of the downstream section 219. The first and second tubular elements 217a, 217b, and the downstream body of material 223, 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 217a, 217b, aerosolgenerating material section 218 and body of material 223 have approximately the same outer diameter.

The upstream body of material 222 can be provided upstream of the aerosolgenerating material section 218.

The first and second tubular elements 217a, 217b together define a chamber 217c 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 217a, 217b enables these components to be designed to achieve different functional effects. For instance, the first tubular element 217a can be arranged to provide functions such as helping to reduce movement of the aerosol-generating material(s) and/or composition in use, as the article 216 is inserted into the recess 220 and the pin heater 221a penetrates the aerosol-generating material section 218. For this purpose, the first tubular element 217a 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 217a can be arranged to help with providing rigidity to the article 216. Alternatively or additionally, the first tubular element 217a can be arranged to encourage aerosol to flow predominantly through an axial region of the second tubular element 217b, for instance to assist with aerosol formation. The second tubular element 217b can be designed to define a relatively large chamber as compared to the first tubular element 217a, providing greater space into which the aerosol formed in the aerosol-generating section 218 can be drawn to expand and cool. In addition, for a given weight of the second tubular element 217b, 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 217b, 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 6 and 7 have the specific features set out in table 1.0 below.

Although in the present case, the downstream body of material 223 is provided at the mouth or downstream end 216b of the article 216, in other examples a further component can be provided downstream of the downstream body of material 223. For instance, a further body of material and/or composition can be provided.

In the present examples, the first tubular element 217a has an axial length of about 7mm, but in other examples the first tubular element 217a can have an axial length between about 5mm and about 14mm. In the present examples, the first tubular element 217a has a wall thickness of about 1.6mm and an inner radius of the hollow cavity defined by the first tubular element 217a 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 217c defined by the second tubular element 217b is about 588 mm³. The volume of the first portion of the hollow cavity 217c defined by the first tubular element 217a 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 217a into the much larger cavity of the second tubular element 217b. The second tubular element 217b can define a second portion of the hollow cavity 217c having a volume of at least about 520 mm³. The combined volumes of the first and second portions of the hollow cavity 217c 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 217b. 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 218 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 217b. For instance, the aerosol-generating material section 218 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 217b. These arrangements result in an article with a relatively large cavity size defined by the second tubular element 217b 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 216 and better aerosol formation. Preferably, ventilation apertures are provided into the wall of the second tubular element 217b such that cool air enters the cavity defined by the second tubular element 217b in use, further enhancing aerosol formation via condensation of aerosol components within the cavity 217c. The second tubular element 217b 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 217b 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 217a. Use of a second tubular element 217b immediately downstream of the first tubular element 217a, 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 aerosolgenerating material section 218 has a weight of between about 200 mg and about 280 mg and the non-aerosol-generating material components of the article 216 have a combined weight of about 320 mg. The total weight is therefore between about 520 grams and about 600 mg for an article 216 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 217b, 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 221 and the article 216 together form a non-combustible aerosol provision system. The non-combustible aerosol provision device 221 includes a heating element 221a configured for insertion into the aerosol-generating material(s) and/or composition of the article 216. In the present example, the heating element 221a is a pin-shaped heater 221a which is insertable into the cavity 211a. The non-combustible aerosol provision device comprises a battery 221b, a processor 221c and a user interface 221d, such as a button, configured to operate the device 221. The device may comprise other components.

The non-combustible aerosol provision device 221 includes a housing 224 and an aperture 225 in the housing 224 into which the article 216 is inserted in use. The system is configured such that the second tubular element 217b extends partially within and partially outside the housing 224 when the article 216 is fully inserted into the non-combustible aerosol provision device 221, as shown in Figure 7. The system can be configured such that the second tubular element 217b extends at least about 5mm within and at least about 8mm outside the housing 224 when the article 216 is fully inserted into the non-combustible aerosol provision device 221. In the present example, the article 216 comprises aerosol-generating material section 218 having a length of about 12mm, a first tubular element 217a having a length of about 7mm and a second tubular element 217b having a length of about 17mm. The article 216 is inserted into the device 221 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 217b, between the upstream end 217b' of the second tubular element and the location 'B' on the article 216 aligned with the entrance to the recess 225 in the device 221, extends within the device 23. About 11mm of the second tubular element 217b, between the location 'B' on the article 216 aligned with the entrance to the recess2 25 in the device 216 and the downstream end 217b" of the second tubular element 217b, extends outside the device 224 when the article 216 is fully inserted into the device 221.

The article 216 includes one or more ventilation apertures 216c extending through the second tubular element 217b at a location in the second tubular element 217b which is outside the housing 224 when the article 216 is fully inserted into the non- combustible aerosol provision device 224. The one or more ventilation apertures 216c can be provided as one or more rows of apertures, such as laser or mechanically formed perforations, circumscribing the article 216. 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(s) and/or composition 211 is a rod of aerosol-generating material(s) and/or composition and is circumscribed by a wrapper 226. The wrapper 226 may be a moisture impermeable wrapper.

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

The first tubular element 217a can be formed from filamentary tow, in the present example plasticised cellulose acetate tow. Other constructions can be used, such as a tubular element 217a 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(s) and/or composition 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(s) and/or composition can pass longitudinally through the first hollow cavity.

The filamentary tow forming the first tubular element 217a 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 217a 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 217a 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 217a 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 217a 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 217a 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 217a 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 217a by the total volume of the material forming the first tubular element 217a, wherein the total volume can be calculated using appropriate measurements of the material forming the first tubular element 217a taken, for example, using callipers. Where necessary, the appropriate dimensions may be measured using a microscope.

The first and second tubular elements 217a, 217b 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 217a, 217b and a heated volatilised component exiting a second, downstream end of the first and second tubular elements 217a, 217b. The first and second tubular elements 217a, 217b 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 217a, 217b and a heated volatilised component exiting a second, downstream end of the first and second tubular elements 217a, 217b. This temperature differential across the length of the first and second tubular elements 217a, 217b protects the temperature sensitive downstream body of material 223 from the high temperatures of the aerosolgenerating material when it is heated.

The aerosol-generating section 218 may exhibit a pressure drop of less than about 20 mm H2O. In some embodiments, the aerosol-generating section 218 exhibits a pressure drop across the aerosol-generating section 218 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(s) and/or composition may have a packing density or bulk density of between about 400 mg/cm³ and about 600 mg/cm³ within the aerosolgenerating section. A packing density higher than this may make it difficult to insert the aerosol-generator of the aerosol provision device into the aerosol-generating material(s) and/or composition 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 aerosol-generating material(s) and/or composition 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 218 is composed of the aerosol-generating material(s) and/or composition. In some embodiments, from about 35% to about 45% of the volume of the aerosol-generating section 218 is filled with the aerosol-generating material, and the remainder is the cavity 211a and the channels 212, 212b. In the present embodiment, the moisture impermeable wrapper 226 which circumscribes the rod of aerosol-generating material(s) and/or composition comprises aluminium foil. In other embodiments, the wrapper 226 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 226 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(s) and/or composition. The permeability of the wrapper 226 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 223 is wrapped in a first plug wrap 227. A second plug wrap 228 is provided to connect the downstream body of material 223 and second tubular element 217b. The upstream body of material 222 is wrapped in a third plug wrap 229. Preferably, the first, second and third plug wraps 227, 228, 229 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 227, 228, 229 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 227, 228, 229 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 227, 228, 229 can be a porous plug wrap, for instance having a permeability of greater than 200 Coresta Units.

A combining wrapper 230 is provided to connect the upstream body of material 222, aerosol generating material section 218 and first tubular element 217a. The combining wrapper 230 can have a basis weight of between about 30 gsm and about 70 gsm. Preferably, the combining wrapper 230 has a thickness of between 35 pm and 70 pm, more preferably between 40 pm and 60 pm. Preferably, the combining wrapper 230 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 230 can be a porous wrapper, for instance having a permeability of greater than 200 Coresta Units.

The aerosol-generating material section 218 as described herein can be in the form of a cylinder comprising the aerosol-generating material(s) and/or composition. A first cylindrical element can be provided upstream of the aerosol-generating material section 218, for instance in the form of the upstream body of material 222. A second cylindrical element can be provided downstream of the aerosol-generating material section 218, for instance in the form of the first tubular element 217a. 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 218, thereby acting to protect the aerosol-generating material section 218. For instance, the first and second cylindrical elements 217, 217a can act to support and/or protect the aerosol-generating material section 218 while it is wrapped in the combining wrapper 226. Furthermore, the first and second cylindrical elements 217, 217a can act to support and/or protect the aerosol-generating material section 18 while in use in the device 221, for instance reducing lateral forces on the aerosolgenerating material section 218. For instance, the aerosol-generating material section 218 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 217, 217a 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 217, 217a is at least 86%, at least 90% or at least 92%. Such hardness levels can assist the first and second cylindrical elements 217, 217a in supporting and/or protecting the aerosolgenerating material section 218. Alternatively or in addition, the first and second cylindrical elements 217, 217a can each have a diameter which is greater than the diameter of the aerosol-generating material section 218, again helping to protect and/or support the section 218. For instance, the first and second cylindrical elements 217, 217a 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 218.

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 300 an aerosol-generating material section 318 is provided in the form of a cylinder comprising aerosol-generating material(s) and/or composition, 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 301, the aerosolgenerating 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 302, 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 219, such as that described herein, and the combined rod and the downstream portion 219 connected using a further wrapper such as tipping paper 231.

Preferably, the length of the downstream body of material 223 is less than about 15 mm. More preferably, the length of the downstream body of material 223 is less than about 14 mm. In addition, or as an alternative, the length of the downstream body of material 223 is at least about 5 mm. Preferably, the length of the downstream body of material 223 is at least about 8 mm. In some preferred embodiments, the length of the downstream body of material 223 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 223 is 12 mm.

Preferably, the length of the upstream body of material 222 is less than about 10 mm. More preferably, the length of the upstream body of material 222 is less than about 8 mm. In addition, or as an alternative, the length of the upstream body of material 222 is at least about 5 mm. Preferably, the length of the upstream body of material 222 is at least about 6 mm. In some preferred embodiments, the length of the upstream body of material 222 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 222 is 6 mm.

In the present example, the downstream body of material 223 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 223. For instance, rather than tow, the downstream body 223 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 body 223. 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 223 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 223, 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 223 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 219 which results in a lower pressure drop across the mouthpiece 219 than tows having higher total denier values. For appropriate firmness of the downstream body of material 223, 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 23 and 210 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 223, the pressure drop through the length of the downstream body 223, can, for instance, be between 0.3 and 5mmWG per mm of length of the downstream body 223, for instance between 0.5mmWG and 2.5mmWG per mm of length of the downstream body 223. The pressure drop can, for instance, be between 1.5 and 2.5mmWG/mm of length, on average. The total pressure drop across body 26 can, for instance, be between 12mmWG and 30mWG, or between 15mmWG and 25mmWG. Where the downstream body 223 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 222 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 222. 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 222, the pressure drop through the length of the upstream body 222, can, for instance, be between 0.3 and 5mmWG per mm of length of the upstream body 222, for instance between 0.5mmWG and 2.5mmWG per mm of length of the upstream body 222. 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 222 can, for instance, be between 6 mmHzO and 30 mmH20, or between 8 mmHzO and 20 mmHzO, or between 6mmH2O and 12mmH2O. In some examples, the upstream body of material 222 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 216. The resistance to draw and pressure drop of the upstream body of material 222 and of the aerosol-generating material section 218 as described herein are measured prior to the insertion of the article 216 into the non-combustible aerosol provision device 221. The bulk density of the upstream body of material 222 can be between 0.1 and 0.3g/cm³, or between 0.15 and 0.25g/cm³. The upstream body of material 222 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 223 downstream of the tubular portion 217a, 217b can define the downstream end 216b of the article 216. The upstream body of material 222 can define the upstream end 216a of the article 216. The resistance to draw through the length of the downstream body of material 223 can be higher than the resistance to draw through the length of the upstream body of material 222.

As illustrated in Figure 7, the device 221 can include a heating element 221a for insertion into the aerosol-generating material section 218 of the article 216 when the article 216 is inserted into the non-combustible aerosol provision device 221. The heating element 221a can be arranged for insertion into the aerosol-generating material section 218 of the article 2216 when the article 216 is fully inserted into the non-combustible aerosol provision device 221. When this happens, the heating element 221a passes through the upstream body of material 222 and into the aerosolgenerating material section 218. Advantageously, the resistance to draw through the length of the upstream body of material 222 can increase by at least 30%, at least 40% or at least 50% when the article 216 is fully inserted into the non-combustible aerosol provision device 221. This means that greater relative changes in pressure drop can be observed in the upstream body of material 222 than in the remainder of the article 216, making the change in pressure drop more predictable than that which may occur in the aerosol-generating material section 218. For instance, the percentage increase in the resistance to draw through the length of the upstream body of material 222 when the article 216 is fully inserted into the non-combustible aerosol provision device 221 can be greater than the overall percentage increase in the resistance to draw of the article 216 when fully inserted into the non-combustible aerosol provision device 221.

In some examples, when the article 216 is fully inserted into the non-combustible aerosol provision device 221 the article 216 has an insertion depth of at least 10 mm, for instance approximately 31 mm. Advantageously, the force required to insert the article 216 into the device 221 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 heating element 221a 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 221a 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 221a which is within the article 216 when the article 216 is fully inserted into the device2 21. The heating element 221a can, for instance, have an insertion length of at least 4 mm greater than the axial length of the aerosol-generating material section 218 of the article 216.

The average force required to insert the heating element 221a into each millimetre of length of the upstream body of material 222 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 216 reaches the full insertion depth within the device 221 and the force required for further insertion is at that stage compressing the article 216. 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 231 is wrapped around part of the downstream portion 219 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 223 and second tubular element 217b, with the pre-combined first tubular element 217a, aerosol-generating material section 218 and upstream body of material 222. In the present example, the rod of aerosolgenerating material is wrapped in wrapper 226, which forms a first wrapping material, and the combining wrapper 230 forms an outer wrapper. In some examples, the tipping paper 231 can extend fully over the aerosol-generating material section 29.

In the present example, the tipping paper 231 extends 5 mm over the pre-combined first tubular element 217a, aerosol-generating material section 9 and upstream body of material 222, 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 231 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 216 and adhere to itself along a longitudinal lap seam on the paper.

The article 216 can have a ventilation level of about 20% of the total aerosol and ventilation drawn through the article 216. The article 216 preferably includes ventilation apertures provided into the second tubular element 217b. In alternative embodiments, the article 216 can have a ventilation level of between 10% and 60% of the total aerosol and ventilation drawn through the article 216, for instance between 20% and 50%.

An aerosol modifying agent is provided within the downstream body of material 223, in the present example in the form of an additive release component, in the present case a capsule 232. However, the capsule 232 can be omitted in other embodiments. In the case that the capsule 232 is provided, the first plug wrap 227 can be an oilresistant first plug wrap 227. In other examples, the aerosol modifying agent can be provided in other forms, such as material injected into the downstream body of material 223 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 223.

The capsule 232 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 232 is used. The capsule 232 is entirely embedded within the body of material 223. In other words, the capsule 232 is completely surrounded by the material forming the body 223. In other examples, a plurality of breakable capsules may be disposed within the body of material 223, for instance 2, 3 or more breakable capsules. The length of the body of material 223 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 223 may be provided, with each body containing one or more capsules.

The capsule 232 has a core-shell structure. In other words, the capsule 232 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 223.

In the present example, the capsule 232 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 232 may be in the range about 10 mg to about 50 mg.

In the present example, the capsule 232 is located at a non-longitudinally central position within the downstream body of material 223. In the present example, the capsule 232 is located closer to the upstream end of the body of material 223 than to the downstream end. That is, the capsule 232 is positioned so that its centre is 5 mm from the upstream end of the downstream body of material 223 and 7mm from the downstream end, which can assist with ensuring that the capsule cannot be seen from the downstream end of the article 216.

In another aspect, a use of the aerosol generating composition as described herein for use in a non-combustible aerosol-provision system is provided.

In another aspect, a process for preparing an aerosol generating composition is provided, wherein the aerosol generating composition comprises a first and a second aerosol generating material, wherein the first and second aerosol generating materials are different and wherein at least a portion of the surface of the first material is bound to at least a portion of the surface of the second material, comprising co-extruding the first and second aerosol generating materials as described herein.

In another aspect, a process for preparing an aerosol generating composition is provided, wherein the aerosol generating composition comprises a first and a second aerosol generating material, wherein the first and second aerosol generating materials are different and wherein at least a portion of the surface of the first material is bound to at least a portion of the surface of the second material, comprising: a) forming a first aerosol generating material in the form a first sheet optionally via extrusion; b) forming a second aerosol generating material in the form a second sheet optionally via extrusion; c) extruding the first and second sheets to form the aerosol generating composition. Step (c) may involve any extrusion or co-extrusion process or step as described herein.

In some embodiments, the first composition, also known as the "wet mixture", comprises an aerosol former or humectant and a binder. The first composition may also comprise other liquids or suspensions disclosed herein.

In some embodiments, the first composition may comprise an aerosol former. The aerosol former comprises one or more constituents capable of forming an aerosol. The aerosol former comprises one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some embodiments, the aerosol former is glycerine, glycerol or propylene glycol.

In some embodiments, the first composition may comprise a first binder. The binder is arranged to bind the components of the first composition. Once combined with the second composition, the binder binds the components of the first and second compositions to form the aerosol-generating material. The first composition can comprise more than one binder. In such embodiments, the binders in the first composition can be the same or different.

In some embodiments, the first composition may comprise a nicotine component.

In some embodiments, water is added to the first composition to form a suitable consistency. The first composition may be in a liquid, gel, slurry or suspension phase. Water is added to provide a suitable consistency for mixing, extrusion and rolling processes. The second composition, also known as the "dry mixture", comprises a botanical material, a filler and optionally a second binder. The second composition may also comprise other solids or gels disclosed herein. The second composition may be in the solid phase.

In some embodiments, the second composition comprises a filler.

The first and the second compositions described herein may be mixed to provide a mixture of the first composition and the second composition. The mixture of the first composition and the second composition may be formed by homogenising the first composition and the second composition. The mixture of the first composition and the second composition may be in the form of a "dough". Advantageously, minimal addition water, or no water at all, is required to be added to the mixture to provide a homogenous dough that is suitable for subsequent processing steps. For example, the dough may then be extruded via a die, through which a homogenous dough may suitably pass without the further addition of water or the addition of a small amount of water.

The mixture of the first composition and the second composition, once formed and mixed, may be extruded using any extrusion technique or apparatus known in the art to from the aerosol-generating material or aerosol-generating composition.

The first and/or second aerosol generating material as described herein may comprise or consist of the mixture of the first composition and the second composition, once formed and mixed.

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

Claims

1. An aerosol generating composition comprising a first and a second aerosol generating material, wherein the first and second aerosol generating materials are different and wherein at least a portion of the surface of the first material is bound to at least a portion of the surface of the second material.

2. The aerosol generating composition according to claim 1, wherein each of the first and second aerosol generating materials is in the form of a sheet.

3. The aerosol generating composition according to claim 1 or 2, wherein the aerosol generating composition comprises a layer of the first and a layer of the second aerosol generating materials.

4. The aerosol generating composition according to any one of claims 1 to 3, wherein the portion of the first material and the portion of the second material are bound together by being pressed together the portion of the first material and the portion of the second material in absence of an adhesive.

5. The aerosol generating composition according to any one of claims 1 to 3, wherein at least portion of the surface of the first aerosol generating material is bound to at least a portion of the second aerosol generating material by co-extruding the first aerosol generating material and second aerosol generating material.

6. The aerosol generating composition according to any one of claims 1 to 3, wherein an adhesive is provided between the first and the second material, optionally wherein the adhesive is provided in a layer between the first and second material.

7. The aerosol generating composition according to claim 6, wherein the adhesive is an aerosol former, optionally wherein the aerosol former is glycerol.

8. The aerosol generating composition according to any preceding claim, wherein the first aerosol generating material, the second aerosol generating material and/or the aerosol generating composition is formed by extrusion.

9. The aerosol generating composition according to any preceding claim, wherein the aerosol generating composition comprises the first and second aerosol generating materials in an alternating stripe pattern.

10. The aerosol generating composition according to claim 9, wherein a longest dimension parallel to a length or a width of the aerosol generating composition of the stripes aligns with the length or the width of the aerosol generating composition.

11. The aerosol generating composition according to any one of claims 9 or 10, wherein the aerosol generating composition is in the form of a sheet and an area of the portion of the first material and the portion of the second material bound together is up to 10% of the area of the sheet of aerosol generating composition.

12. The aerosol generating composition according to any one of the preceding claims, wherein the first aerosol generating material and the second aerosol generating material are arranged in the aerosol generating composition such that the first and second aerosol generating materials are arranged in concentric rings around a centrally located cavity.

13. The aerosol generating composition according to any one of the preceding claims, wherein a surface area to volume ratio of the first aerosol generating material is different to surface area to volume ratio of the second aerosol generating material.

14. The aerosol generating composition according to any one of the preceding claims, wherein the first generating material comprises a first particle size and a second generating material comprises a second particle size.

15. The aerosol generating composition according to any one of the preceding claims, wherein the first generating material and second aerosol generating materials comprise different or different amounts of active substances, flavour, botanical material, binder, water, and/or filler.

16. A process for preparing an aerosol generating composition, the process comprising co-extruding a first and a second aerosol generating material.

17. A process for preparing an aerosol generating composition, the process comprising: a) forming a first aerosol generating material in the form a first aerosolgenerating material, optionally via extrusion; b) forming a second aerosol generating material, optionally via extrusion; c) extruding the first and second aerosol-generating materials to form the aerosol generating composition.

18. A process for preparing the first and/or second aerosol generating materials according to claims 16 to 18, comprising: a) forming a first composition comprising a first binder and an aerosol former; b) forming a second composition comprising a plant material, a filler and optionally a second binder; c) combining the first and second compositions and extruding the resultant mixture.

19. An aerosol generating composition produced by a process according to any one of claims 16 to 18.

20. A non-combustible aerosol-provision system comprising the aerosol generating composition according to any one of claims 1 to 15.

21. A consumable for use with a non-combustible aerosol-provision system comprising the aerosol generating composition according to any one of claims 1 to 15.

22. Use of the aerosol generating composition according to any one of claims 1 to 15 for use in a non-combustible aerosol-provision system.