Note: Descriptions are shown in the official language in which they were submitted.
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A method of manufacturing an article for use in an aerosol provision
system and an article for use in an aerosol provision system
Technical field
The present disclosure relates to a method of manufacturing an article for an
aerosol
provision device and to an article for an aerosol provision device. The
present
disclosure also relates to an assembly for use in manufacturing an aerosol
provision
device, a kit of parts comprising an article and an aerosol provision device,
and to a
package of articles.
Background
Aerosol-provision systems generate an inhalable aerosol or vapour during use
by
releasing compounds from an aerosol-generating-material. These may be referred
to as
non-combustible smoking articles, aerosol generating assemblies, or aerosol
provision
devices, for example.
Summary
In accordance with some embodiments described herein, there is provided a
method of
manufacturing an article for use in an aerosol provision system, the method
comprising: providing a first sheet material; providing a substrate comprising
a first
aerosol generating material, wherein the substrate is attached to the first
sheet
material; and, arranging the first sheet material with the substrate attached
thereto
such that the first sheet material surrounds the substrate.
In some embodiments, the substrate is adhered to the first sheet material.
In some embodiments, the substrate comprises a second sheet material and,
preferably, providing the substrate comprises attaching the second sheet
material to the
first sheet material.
In some embodiments, the substrate is cast on to the first sheet material. For
example,
a first sheet material may be provided, and a slurry comprising the first
aerosol
generating maLerial may be provided on the first. sheet. maLerial and allowed
Lo dry.
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In some embodiments, the second sheet material is a cast sheet. The method may
comprise casting the second sheet material, for example, casting the second
sheet
material from a slurry.
In some embodiments, the second sheet material comprises the first aerosol
generating
material.
In some embodiments, the second sheet material is formed from a slurry that
comprises the first aerosol generating material and, preferably, wherein the
slurry is
io cast to form the second sheet material.
In some embodiments, the second sheet material is a cast sheet.
In some embodiments, the first aerosol generating material is attached to a
surface of
the second sheet material and, preferably, is adhered to the surface of the
second sheet
material.
In some embodiments, the first aerosol generating material is attached to the
surface of
the second sheet material before or after attaching the second sheet material
to the first
sheet material.
In some embodiments, the second sheet material comprises one or more of:
paper, card
and/or aerosol generating material.
In some embodiments, providing the first sheet material comprises providing a
web of
first sheet material.
In some embodiments, the first sheet material comprises paper or card.
In some embodiments, the first sheet material comprises a metal.
In some embodiments, the first sheet material comprises an aluminium foil.
In some embodiments, the first sheet material comprises a co-laminated
material
comprising a paper layer and an aluminium layer.
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In some embodiments, attaching the substrate to the first sheet material
comprises
attaching the substrate to the aluminium layer.
In some embodiments, the method further comprises cutting ventilation
apertures into
the substrate and/or first sheet of material.
In some embodiments, providing the substrate comprises applying the substrate
to the
web of first sheet material.
In some embodiments, applying the substrate to the web of first sheet material
comprising applying a web of the second sheet material to the web of first
sheet
material.
In some embodiments, applying the substrate to the web of first sheet material
comprising applying a plurality of portions of second sheet material to the
web of first
sheet material.
In some embodiments, the plurality of portions of second sheet material are
spaced
from each other on the web of first sheet material.
In some embodiments, the portions of second sheet material are discrete. The
portions
of second sheet material may be spaced from each other in a direction along
the
conveyance path of the web of first sheet material.
In some embodiments, an edge of the substrate is spaced from an edge of the
first sheet
material such that a region of the first sheet material is not covered by the
substrate
and, preferably, the method comprises applying adhesive to said region.
In some embodiments, the first sheet material has a permeability of at most
loo
Coresta Units.
In some embodiments, the first sheet material has a thickness in the range of
20 to 100
microns.
In some embodiments, the first sheet material forms an exterior surface of the
article.
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In some embodiments, the first aerosol generating material comprises aerosol
generating material dust and/or aerosol generating material fibres.
In some embodiments, the first aerosol generating material comprises extruded
and/or
compressed aerosol generating material.
In some embodiments, the first aerosol generating material comprises beads.
In some embodiments, the beads have a diameter in the range of 0.5 to 3 mm
and,
preferably, in the range of 1 to 2 mm.
In some embodiments, the first aerosol generating material comprises, consists
of, or
essentially consists of tobacco material.
In some embodiments, the tobacco material of the first and/or second aerosol
generating material is derived only from tobacco lamina and no other types of
tobacco
material.
In some embodiments, the first and/or second aerosol generating material
comprises
tobacco lamina and reconstituted tobacco.
In some embodiment, the first and second aerosol generating material together
have an
average nicotine level in the range of 0.5% to 2.5% by weight of the first and
second
aerosol generating material and, preferably, in the range of 1% to 2.1%.
In some embodiments, the total weight of aerosol generating material in the
article is in
the range of 150 to 350 mg and, preferably, in the range of 200 to 300 mg, 220
to 280
mg, or 230 to 260 mg.
In some embodiments, the article comprises in the range of 7 mg per mm to 13
mg of
aerosol generating material per mm length of the article and, preferably, in
the range of
8 to 12, 9 to 11.5, 9 to 11, or 9.5 to 10.5 mg of aerosol generating material
per mm length
of the article.
In some embodiments, the first and/or second aerosol generating material is a
solid
material.
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In some embodiments, the article does not comprise plastic.
In some embodiments, the article does not comprise cellulose acetate.
In some embodiments, the first and second aerosol generating materials are
manufactured from the same aerosol generating starter materials that are
processed to
have different forms.
rrr In some embodiments, the article further comprises a second
aerosol generating
material.
In some embodiments, the density of one of the first and second aerosol-
generating
materials is at least about 25% higher than the density of the other one of
the first and
second aerosol generating materials. However, in other embodiments, the
density of
the first and second aerosol generating materials is the same.
In some embodiments, one of the first and second aerosol generating materials
has a
density of from about 0.1 g/cm3 to about 1 g/cm3.
In some embodiments, the other one of the first and second aerosol generating
materials has a density of from about 0.4 g/cm3 to about 2 g/cm3.
In some embodiments, the heating of the article provides a relatively constant
release
of volatile compounds into an inhalable medium.
In some embodiments, the first aerosol-generating material comprises extruded
tobacco.
In some embodiments, the first aerosol-generating material comprises beads.
In some embodiments, the second aerosol-generating material comprises one or
more
tobacco material selected from the group consisting of lamina and
reconstituted
tobacco material.
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In some embodiments, at least one of the first and second aerosol-generating
material
comprises a combination of lamina and reconstituted tobacco material. In some
embodiments, the lamina and reconstituted tobacco material are present in the
aerosol-
generating material in a ratio of from 1:4 to 4:1, by weight.
In some embodiments, the first and second aerosol-generating materials have
the same
levels of a volatile compound. In some embodiments, the volatile compound is
nicotine.
In some embodiments, the release of a volatile compound from the first and
second
aerosol-generating material is at the same rate when the materials reach a
given
temperature.
In some embodiments, the first and second aerosol-generating materials are
present in
the article in a ratio of from 1:10 to 10:1, by weight.
In some embodiments, the second aerosol generating material has a higher or
lower
density than the first aerosol generating material.
In some embodiments, the second aerosol generating material comprises,
consists of,
or essentially consists of tobacco material.
In some embodiments, the second aerosol generating material comprises shredded
tobacco and/or reconstituted tobacco.
In some embodiments, the substrate comprises the second aerosol generating
material.
In some embodiments, the second sheet material comprises the first and/or
second
aerosol generating materials. For example, the second sheet material may be
formed
from a slurry that comprises the first and/or second aerosol generating
materials.
In some embodiments, the first and/or second aerosol generating materials are
applied
to a surface of the second sheet material.
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In some embodiments, the second sheet material comprises one of the first and
second
aerosol generating materials and the other one of the first and second aerosol
generating materials is applied to a surface of the second sheet material.
In some embodiments, arranging the first sheet material with the substrate
attached
thereto comprises providing the first sheet material and substrate around at
least a
portion of a body of material and, preferably, comprises wrapping the first
sheet
material with substrate about the body of material.
In some embodiments, the first sheet material circumscribes the body of
material. In
some embodiments, the substrate circumscribes the body of material.
In some embodiments, the body of material comprises a third sheet material
that is
gathered to form the body of material.
In some embodiments, the third sheet material is crimped and/or cut into
strips.
In some embodiments, the substrate is in direct contact with the body of
material.
In some embodiments, the body of material comprises a tobacco rod. For
example, the
body of material may comprise shredded tobacco material that is formed into a
rod. In
some embodiments, the body of material comprises cut rag tobacco that is
formed into
a rod.
In some embodiments, the body of material comprises the second aerosol
generating
material.
According to the present disclosure, there is also provided an assembly for
use in a
method of manufacturing an article for use in an aerosol provision system, the
assembly comprising: a first sheet material; and, a patch comprising a first
aerosol
generating material, wherein the patch is attached to the first sheet
material.
In some embodiments, the patch is adhered to the first sheet material.
In some embodiments, the first sheet material is laid flat.
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According to the present disclosure, there is also provided an article for use
in an
aerosol provision system, the article comprising: a first sheet material; and,
a patch
comprising a first aerosol generating material, wherein the patch is attached
to the first
sheet material, wherein the sheet material and patch are arranged such that
the sheet
material surrounds the patch.
In some embodiments, the patch is adhered to the first sheet material.
In some embodiments, the first sheet material forms an exterior surface of the
article.
In some embodiments, the first sheet material comprises paper or card.
In some embodiments, the first sheet material comprises a metal.
In some embodiments, the first sheet material comprises an aluminium foil.
In some embodiments, the first sheet material comprises a co-laminated
material
comprising a paper layer and an aluminium layer.
In some embodiments, the patch is attached the aluminium layer.
In some embodiments, the article further comprises a second aerosol generating
material.
In some embodiments, the first and/or second aerosol generating material is
substantially tobacco free.
In some embodiments, the second aerosol generating material has a higher or
lower
density than the first aerosol generating material.
In some embodiments, the second aerosol generating material comprises,
consists of,
or essentially consists of tobacco material.
In some embodiments, the second aerosol generating material comprises shredded
tobacco and/or reconstituted tobacco.
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In some embodiments, the article further comprises a body of material, wherein
the
first sheet material and patch are disposed around at least a portion of the
body of
material.
In some embodiments, the first sheet material circumscribes the body of
material. In
some embodiments, the patch circumscribes the body of material.
In some embodiments, the body of material comprises a third sheet material
that is
gathered to form the body of material.
In some embodiments, the third sheet material is crimped and/or cut into
strips.
In some embodiments, the substrate is in direct contact with the body of
material.
In some embodiments, the body of material comprises a tobacco rod. For
example, the
body of material may comprise shredded tobacco material that is formed into a
rod. In
some embodiments, the body of material comprises cut rag tobacco that is
formed into
a rod.
In some embodiments, the body of material comprises the second aerosol
generating
material.
In some embodiments, the patch comprises a second sheet material and,
preferably, the
second sheet material is a cast sheet.
In some embodiments, the second sheet material is attached to the first sheet
material,
for example, by adhesive.
In some embodiments, the second sheet material comprises the first aerosol
generating
material.
In some embodiments, the second sheet material is formed from a slurry that
comprises the first aerosol generating material and, preferably, the slurry is
cast to
form the second sheet material.
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In some embodiments, the first aerosol generating material is attached to a
surface of
the second sheet material and, preferably, is adhered to the surface of the
second sheet
material.
In some embodiments, the second sheet material comprises one or more of:
impel, card
and/or aerosol generating material.
In some embodiments, the first and/or second aerosol-generating material
comprsies:
from about io to about 50 wt% aerosol-former material; from about 15 to about
60 wt%
gelling agent; and optionally filler; wherein the wt% values are calculated on
a dry
weight basis. In some embodimentsõ the first and/or second aerosol generating
material comprises a flavourant.
In some embodiments, the patch comprises a first end that is spaced from a
first end of
the first sheet material.
In some embodiments, the patch comprises a second end, opposite to the first
end,
wherein the second end is spaced from a second end of the first sheet
material.
In some embodiments, the patch extends over a portion of the length of the
article. In
some embodiments, the patch extends over the entire length of the article.
In some embodiments, an edge of the substrate is spaced from an edge of the
first sheet
material such that a region of the first sheet material is not covered by the
substrate
and, preferably, wherein said edges are longitudinal edges of the substrate
and first
sheet material.
In some embodiments, the first sheet material has a permeability of at most
100
Coresta Units.
In some embodiments, the first sheet material has a thickness in the range of
20 to 100
microns.
In some embodiments, the first aerosol generating material comprises aerosol
generating material dust and/or aerosol generating material fibres.
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In some embodiments, the first aerosol generating material comprises extruded
and/or
compressed aerosol generating material.
In some embodiments, the first aerosol generating material comprises beads.
In some embodiments, the beads have a diameter in the range of 0.5 to 3 mm
and,
preferably, in the range of 1 to 2 mm.
In some embodiments, the first aerosol generating material comprises, consists
of, or
_ro essentially consists of tobacco material.
In some embodiments, the tobacco material of the first and/or second aerosol
generating material is derived only from tobacco lamina and no other types of
tobacco
material.
In some embodiments, the first and/or second aerosol generating material
comprises
tobacco lamina and reconstituted tobacco.
In some embodiment, the first and second aerosol generating material together
have an
average nicotine level in the range of 0.5% to 2.5% by weight of the first and
second
aerosol generating material and, preferably, in the range of 1% to 2.1%.
In some embodiments, the first and/or second aerosol generating material is a
solid
material.
In some embodiments, the article does not comprise plastic. In some
embodiments, the
article does not comprise cellulose acetate.
In some embodiments, the first and second aerosol generating materials are
manufactured from the same aerosol generating starter materials that are
processed to
have different forms.
In some embodiments, the patch comprises the second aerosol generating
material.
In some embodiments, the patch comprises a second sheet material that
comprises the
first and/or second aerosol generating materials. For example, the second
sheet
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material may be formed from a slurry that comprises the first and/or second
aerosol
generating materials.
In some embodiments, the first and/or second aerosol generating materials are
applied
to a surface of the second sheet material.
In some embodiments, the second sheet material comprises one of the first and
second
aerosol generating materials and the other one of the first and second aerosol
generating materials is applied to a surface of the second sheet material.
According to the present disclosure, there is also provided an article
manufactured
according to the method disclosed herein.
According to the present disclosure, there is also provided a package
comprising a
plurality of articles disclosed herein. In some embodiments, the package is
hermetically
sealed.
According to the present disclosure, there is also provided a kit of parts
comprising the
article disclosed herein and an aerosol provision device.
In some embodiments, the aerosol provision device comprises a heating chamber
for
receiving the article to heat the first and second aerosol generating
materials.
Brief Description of the Drawings
Embodiments will now be described, by way of example only, with reference to
accompanying drawings, in which:
Fig. 1 is cross-sectional side view of an embodiment of an article for use in
an aerosol
provision system;
Fig. 2 is a top view of a first sheet material of the article of Fig. 1,
wherein the first sheet
material is laid flat;
Fig. 3 is a top view of a second sheet material of the article of Fig. 1,
wherein the second
sheet material is laid flat;
Fig. 4 is perspective view of an embodiment of the article of Fig. 1;
Fig. 5 is a top view of a substrate of the article of Fig. 1, wherein the
substrate is laid
fiat;
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Fig. 6 is a top view of an arrangement for use in the manufacture of the
article of Fig. 1,
wherein the arrangement comprises the first sheet material and the substrate;
Fig. 7 is a perspective view of a bead of aerosol-generating material of the
article of Fig.
1;
Fig. 8 is a cross-sectional side view of another embodiment of an article for
use in an
aerosol provision system;
Fig. 9 is a cross-sectional side view of another embodiment of an article for
use in an
aerosol provision system;
Fig. 10 is a cross sectional view of an embodiment of a non-combustible
aerosol
io provision device;
Fig. 11 is a simplified schematic of the components within the housing of the
aerosol
provision device shown in Fig. 10;
Fig. 12 is a cross sectional view of the non-combustible aerosol provision
device shown
in Fig. lo with the article shown in Fig. 1 inserted into the device;
Fig. 13 is a cross-sectional side view of another embodiment of an article for
use in an
aerosol provision system;
Fig. 14 is a block diagram illustrating a method of manufacturing an article
for use in an
aerosol provision system;
Fig. 15A is a top view of a first step of a method of manufacturing a
consumable for use
in an aerosol provision system;
Fig. 1513 is a top view of a second step of a method of manufacturing an
article for use in
an aerosol provision system;
Fig. 15C is a top view of a third step of a method of manufacturing an article
for use in
an aerosol provision system;
Fig. 15D is a top view of a fourth step of a method of manufacturing a
consumable for
use in an aerosol provision system;
Fig. 15E is a top view of a fifth step of a method of manufacturing an article
for use in
an aerosol provision system;
Fig. 15F is a cross-sectional side view of a sixth step of a method of
manufacturing an
article for use in an aerosol provision system;
Fig. 15G is a cross-sectional side view of a seventh step of a method of
manufacturing
an article for use in an aerosol provision system;
Fig. 16 is a schematic diagram of an apparatus for manufacturing an article
for use in
an aerosol provision system;
Fig. 17 is a cross-sectional side view of another embodiment of an article for
use in an
aerosol provision system; and,
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Fig. 18 is a cross-sectional side view of another embodiment of an article for
use in an
aerosol provision system.
Detailed description
As used herein, the term "delivery system" is intended to encompass systems
that
deliver at least one substance to a user, and includes:
combustible aerosol provision systems, such as cigarettes, cigarillos, cigars,
and
tobacco for pipes or for roll-your-own or for make-your-own cigarettes
(whether based
on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco,
tobacco
substitutes or other smokable material);
non-combustible aerosol provision systems that release compounds from an
aerosol-generating material without combusting the aerosol-generating
material, such
as electronic cigarettes, tobacco heating products, and hybrid systems to
generate
aerosol using a combination of aerosol-generating materials; and
aerosol-free delivery systems that deliver the at least one substance to a
user
orally, nasally, transdermally or in another way without forming an aerosol,
including
but not limited to, lozenges, gums, patches, articles comprising inhalable
powders, and
oral products such as oral tobacco which includes snus or moist snuff, wherein
the at
least one substance may or may not comprise nicotine.
According to the present disclosure, a "non-combustible" aerosol provision
system is
one where a constituent aerosol-generating material of the aerosol provision
system (or
component thereof) is not combusted or burned in order to facilitate delivery
of at least
one substance to a user.
In some embodiments, the delivery system is a non-combustible aerosol
provision
system, such as a powered non-combustible aerosol provision system.
In some embodiments, the non-combustible aerosol provision system is an
electronic
cigarette, also known as a vaping device or electronic nicotine delivery
system (END),
although it is noted that the presence of nicotine in the aerosol-generating
material is
not a requirement.
In some embodiments, the non-combustible aerosol provision system is an
aerosol-
generating material heating system, also known as a heat-not-burn system. An
example of such a system is a tobacco heating system.
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In some embodiments, the non-combustible aerosol provision system is a hybrid
system to generate aerosol using a combination of aerosol-generating
materials, one or
a plurality of which may be heated. Each of the aerosol-generating materials
may be,
for example, in the form of a solid, liquid or gel and may or may not contain
nicotine.
In some embodiments, the hybrid system comprises a liquid or gel aerosol-
generating
material and a solid aerosol-generating material. The solid aerosol-generating
material
may comprise a plant based material, for example, tobacco or a non-tobacco
product.
ro 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 aerosol-
generating material and configured to be used with non-combustible aerosol
provision
devices. These consumables are sometimes referred to as articles throughout
the
disclosure.
The terms 'upstream' and 'downstream' used herein are relative terms defined
in
relation to the direction of mainstream aerosol drawn through an article or
device in
use. Reference to the 'distal end' refers to an upstream end of the device,
whereas
'proximal end' refers to the downstream end of the device.
In some embodiments, the non-combustible aerosol provision system, such as a
non-
combustible aerosol provision device thereof, may comprise a power source and
a
controller. The power source may, for example, be an electric power source or
an
exothermic power source. In some embodiments, the exothermic power source
comprises a carbon substrate which may be energised so as to distribute power
in the
form of heat to an aerosol-generating material or to a heat transfer material
in
proximity to the exothermic power source.
In some embodiments, the non-combustible aerosol provision system comprises an
area for receiving the consumable, an aerosol generator, an aerosol generation
area, a
housing, a mouthpiece, a filter and/or an aerosol-modifying agent.
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In some embodiments, the consumable for use with the non-combustible aerosol
provision device may comprise aerosol-generating material, an aerosol-
generating
material storage area, an aerosol-generating material transfer component, an
aerosol
generator, an aerosol generation area, a housing, a wrapper, a filter, a
mouthpiece,
and/or an aerosol-modifying agent.
The consumable comprises a substance to be delivered. The substance to be
delivered
is an aerosol-generating material. As appropriate, the material may comprise
one or
more active constituents, one or more flavours, one or more aerosol-former
materials,
io and/or one or more other functional materials.
In some embodiments, the substance to be delivered comprises an active
substance.
The active substance as used herein may be a physiologically active material,
which is a
material intended to achieve or enhance a physiological response. The active
substance
may for example be selected from nutraceuticals, nootropics, psychoactives.
The active
substance may be naturally occurring or synthetically obtained. The active
substance
may comprise for example nicotine, caffeine, taurine, theine, vitamins such as
B6 or
B12 or C, melatonin, cannabinoids, or constituents, derivatives, or
combinations
thereof. The active substance may comprise one or more constituents,
derivatives or
extracts of tobacco, cannabis or another botanical. In some embodiments, the
active
substance comprises nicotine. In some embodiments, the active substance
comprises
caffeine, melatonin or vitamin B12.
As noted herein, the active substance may comprise or be derived from one or
more
botanicals or constituents, derivatives or extracts thereof. As used herein,
the term
"botanical" includes any material derived from plants including, but not
limited to,
extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen,
husk, shells or
the like. Alternatively, the material may comprise an active compound
naturally
existing in a botanical, obtained synthetically. The material may be in the
form of
liquid, gas, solid, powder, dust, crushed particles, granules, pellets,
shreds, strips,
sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise,
hemp, cocoa,
cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax,
ginger,
ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate,
orange skin,
papaya, rose, sage, tea such as green tea or black tea, thyme, clove,
cinnamon, coffee,
aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg,
oregano,
paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower,
vanilla,
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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 substance to be delivered comprises a flavour.
As used herein, the terms "flavour" and "flavourant" refer to materials which,
where
local regulations permit, may be used to create a desired taste, aroma or
other
somatosensorial sensation in a product for adult consumers. They may include
naturally occurring flavour materials, botanicals, extracts of botanicals,
synthetically
obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice
(liquorice), hydrangea, eugenolõTapanese 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,
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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
io 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 may comprise or be an "amorphous solid". In
some
embodiments, the aerosol-generating material comprises an aerosol-generating
film
that is an amorphous solid. The amorphous solid 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
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retain some fluid, such as liquid, within it. In some embodiments, the
amorphous solid
may, for example, comprise from about 50wt%, 6owt% or 70wt% of amorphous
solid,
to about 90wt%, 95wt% or movvt% of amorphous solid. An aerosol-generating
material may also be referred to as an aerosolisable material.
An aerosol-generating material is a material that is capable of generating
aerosol, for
example when heated, irradiated or energized in any other way. An aerosol-
generating
material may be in the form of a solid, liquid or gel which may or may not
contain an
active substance and/or flavourants. The aerosol-generating material is
incorporated
_to into an article for use in the aerosol-generating system.
As used herein, the term "tobacco material" refers to any material comprising
tobacco
or derivatives or substitutes thereof. The tobacco material may be in any
suitable form.
The term "tobacco material" may include one or more of tobacco, tobacco
derivatives,
expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco
material
may comprise one or more of ground tobacco, tobacco fibre, cut tobacco,
extruded
tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and/or tobacco
extract.
A consumable is an article comprising or consisting of aerosol-generating
material, part
or all of which is intended to be consumed during use by a user. A consumable
may
comprise one or more other components, such as an aerosol-generating material
storage area, an aerosol-generating material transfer component, an aerosol
generation
area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying
agent. A
consumable may also comprise an aerosol generator, in particular a heating
element,
that emits heat to cause the aerosol-generating material to generate aerosol
in use. The
heater may, comprise, a material heatable by electrical conduction, or a
susceptor.
The aerosol-generating material may comprise one or more active substances
and/or
flavours, one or more aerosol-former materials, and optionally one or more
other
functional material.
The aerosolisable material may be present on a substrate. The substrate may,
for
example, be or comprise paper, card, paperboard, cardboard, reconstituted
aerosolisable material, a plastics material, a ceramic material, a composite
material,
glass, a metal, or a metal alloy.
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The aerosol-former material may comprise one or more constituents capable of
forming
an aerosol. In some embodiments, the aerosol-former material may comprise one
or
more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene
glycol,
tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl
vanillate,
ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin
mixture, benzyl
benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid,
myristic acid, and
propylene carbonate.
The one or more other functional materials may comprise one or more of pH
regulators, colouring agents, preservatives, binders, fillers, stabilizers,
and/or
antioxidants.
A consumable is an article comprising or consisting of aerosol-generating
material, part
or all of which is intended to be consumed during use by a user. A consumable
may
comprise one or more other components, such as an aerosol-generating material
storage area, an aerosol-generating material transfer component, an aerosol
generation
area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying
agent. A
consumable may also comprise an aerosol generator, such as a heater, that
emits heat
to cause the aerosol-generating material to generate aerosol in use. The
heater may, for
example, comprise combustible material, a material heatable by electrical
conduction,
or a susceptor.
A susceptor is a material that is heatable by penetration with a varying
magnetic field,
such as an alternating magnetic field. The susceptor may be an electrically-
conductive
material, so that penetration thereof with a varying magnetic field causes
induction
heating of the heating material. The heating material may be magnetic
material, so that
penetration thereof with a varying magnetic field causes magnetic hysteresis
heating of
the heating material. The susceptor may be both electrically-conductive and
magnetic,
so that the susceptor is heatable by both heating mechanisms. The device that
is
configured to generate the varying magnetic field is referred to as a magnetic
field
generator, herein.
An aerosol-modifying agent is a substance, typically located downstream of the
aerosol
generation area, that is configured to modify the aerosol generated, for
example by
changing the taste, flavour, acidity or another characteristic of the aerosol.
The aerosol-
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modifying agent may be provided in an aerosol-modifying agent release
component,
that is operable to selectively release the aerosol-modifying agent.
The aerosol-modifying agent may, for example, be an additive or a sorbent. The
aerosol-modifying agent may, for example, comprise one or more of a
flavourant,
colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for
example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in
powder,
thread or granule form. The aerosol-modifying agent may be free from
filtration
material.
An aerosol generator is an apparatus configured to cause aerosol to be
generated from
the aerosol-generating material. In some embodiments, the aerosol generator is
a
heater configured to subject the aerosol-generating material to heat energy,
so as to
release one or more volatiles from the aerosol-generating material to form an
aerosol.
In some embodiments, the aerosol generator is configured to cause an aerosol
to be
generated from the aerosol-generating material without heating. For example,
the
aerosol generator may be configured to subject the aerosol-generating material
to one
or more of vibration, increased pressure, or electrostatic energy.
The filamentary tow material described herein can comprise cellulose acetate
fibre tow.
The filamentary tow can also be formed using other materials used to form
fibres, such
as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL),
poly(1-4
butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT),
starch
based materials, cotton, aliphatic polyester materials and polysaccharide
polymers or a
combination thereof. The filamentary tow may be plasticised with a suitable
plasticiser
for the tow, such as triacetin where the material is cellulose acetate tow, or
the tow may
be non-plasticised. The tow can have any suitable specification, such as
fibres having a
'Y' shaped or other cross section such as 'X' shaped, filamentary denier
values between
2.5 and 15 denier per filament, for example between 8.0 and 11.0 denier per
filament
and total denier values of 5,000 to 50,000, for example between 10,000 and
40,000.
In the figures described herein, like reference numerals are used to
illustrate equivalent
features, articles or components.
Fig. 1 is a cross-sectional side view of an article 1 for use in an aerosol
delivery system
that includes an aerosol delivery device 200 (see Figs. 10 to 12).
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The article 1 has an upstream or distal end 'D' and a downstream or proximal
end 'P'. In
some embodiments, the proximal end P is located relatively closer to a
mouthpiece 207
of the aerosol delivery device 200 in use than the distal end D. In another
embodiment
(not shown), the proximal end P of the article 1 comprises a mouthpiece. In
some
embodiments (not shown), the proximal end P of the article 1 forms the
mouthpiece.
It should be recognised that in some embodiments, the article 1 can be used
with the
aerosol delivery device 200 in either orientation, such that it does not
matter which end
_ro of the article 1 is upstream and which is downstream.
The article 1 comprises a substrate 2 and a body of material 3. The substrate
2 at least
partially circumscribes the body of material 3.
In the present example, the substrate 2 is in the form of a patch 2.
The patch 2 comprises a first aerosol generating material 4. The body of
material 3
comprises a second aerosol generating material 5.
In the present example, the first sheet material 6 and patch 2 are arranged
such that the
patch 2 is provided on an inside surface of the first sheet material 6. That
is, the patch 2
is located radially inwardly of the first sheet material 6. In some
embodiments, the first
sheet material 6 surrounds, or at least partially surrounds, the patch 2.
However, it
should be recognised that in alternative embodiments (not shown), the patch 2
may be
provided on an exterior surface of the first sheet material 6 such that the
first sheet
material 6 is located radially inwardly of the patch 2.
In some embodiments, the first sheet material 6 forms an exterior surface IA
of the
article 1. In the present example, the first sheet material 6 forms a
generally cylindrical
peripheral surface IA of the article 1.
The first sheet material 6 may comprise paper or card of suitable grammage and
thickness. The grammage and thickness of the first sheet material 6 may be
selected
according to the desired stiffness of the first sheet material 6.
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In some embodiments, the first sheet material 6 may comprises a metal. For
example,
the first sheet material 6 may be a co-laminated material comprising a paper
layer and
metal layer. In some embodiments the metal layer may comprise or consist of
aluminium. The thickness of the aluminium layer may be selected to provide the
first
sheet material with the requisite structural propeities and/or act as a
susceptor to heat
the aerosol generating material 4 in use.
The patch 2 comprises a second sheet material 7. In the present example, the
second
sheet material 7 is a cast sheet. For example, the second sheet material 7 may
be formed
_ro from a slurry that is cast and then set (e.g. by heating) to form the
second sheet
material 7.
In some embodiments, the slurry is cast and dried to form the second sheet
material 7,
which is subsequently attached to the first sheet material 6.
In other embodiments, the slurry may be cast in place on the first sheet
material 6 such
that when the slurry dries it forms a second sheet material 7 (e.g. a patch 2)
that is
adhered to the first sheet material 6. The first aerosol generating material 4
may be
provided in the slurry before it is applied to the first sheet material 6, or
applied to or
mixed with the slurry after the slurry has been applied to the first sheet
material 6.
In the embodiment of Figs. 1 to 6, the first aerosol generating material 4 is
attached to a
first surface of the second sheet material 7. In the present example, the
first aerosol
generating material 4 is adhered to the first surface of the second sheet
material 7. For
example, adhesive (not shown) may be applied to one or both of the first
aerosol
generating material 4 or second sheet material 7.
The first aerosol generating material 4 may be a loose aerosol generating
material (for
example, dust, fibres or beads/pellets/granules) that are adhered to the
second sheet
material 7.
In some embodiments, the second sheet material 7 comprises one or more of:
paper,
card or an aerosol generating material. The second sheet material 7 may
comprise
reconstituted tobacco.
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In the present example, the body of material 3 is a rod 3 comprising the
second aerosol
generating material 5. The body of material 3 may be a tobacco rod 3. For
example, the
body of material 3 may be a rod comprising shredded lamina tobacco and/or
shredded
reconstituted tobacco (for example, shredded reconstituted tobacco sheet).
In another embodiment (not shown), the body of material 3 comprises a third
sheet
material that is gathered to form the body of material 3. The third sheet
material may
comprise the second aerosol generating material 5, which optionally may
comprise,
consist of, or essentially consist of, a tobacco material. For example, the
third sheet
io material may be reconstituted tobacco that is gathered to form
the body of material 3.
In some embodiments, the third sheet material is crimped to promote gathering
of the
third sheet material to form the body of material 3.
In some embodiments, the third sheet material is cut into strips and then the
strips are
formed into the body of material 3.
In some embodiments, the patch 2 is in direct contact with the body of
material 3. This
helps to encourage heat transfer between the patch 2 and the body of material
3.
The patch 2 comprises opposite first and second edges 2A, 2B. In the present
example,
the first edge 2A of the patch 2 is spaced from a first end 3A of the body of
material 3
and the second edge 2B of the patch 2 is spaced from a second end 3B of the
body of
material 3.
In the present example, the first sheet of material 6 comprises opposite first
and second
edges 6A, 6B. The patch 2 may be located on the first sheet of material 6 such
that the
first edge 2A of the patch 2 is proximate to, but spaced from, the first edge
6A of the
first sheet of material 6 and such that the second edge 2B of the patch 2 is
proximate to,
but spaced from, the second edge 6B of the first sheet of material 6. In an
alternative
embodiment, the first edge 2A of the patch 2 is aligned with the first edge 6A
of the first
sheet of material 6 and/or the second edge 2B of the patch 2 is aligned with
the second
edge 6B of the second sheet of material 6.
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In the present example, the patch 2 extends over a portion of the axial length
of the
body of material 3. However, it should be recognised that in other embodiments
the
patch 2 extends over the entire axial length of the body of material 3.
In the present example, the body of material 3 extends over a portion of the
length of
the article 1 (shown by arrow 'X' in Fig. 1). In an alternative embodiment,
the body of
material 3 extends over the entire length X of the article 1.
In some embodiments, the patch 2 comprises opposite third and fourth edges 2C,
2D
io and the first sheet material 6 comprises opposite third and fourth edges
6C, 6D. The
third edge 2C of the patch 2 may be spaced from the third edge 6C of the first
sheet
material 6 such that the first sheet material 6 comprises a region 8 that is
not covered
by the patch 2. The region 8 may be arranged to overlap the fourth edge 6D of
the first
sheet material 6 and may be adhered to an outer surface of the first sheet
material 6.
The region 8 not being covered by the patch 2 facilitates adhesion of the
inside surface
of the region 8 of the first sheet material 6 to the outer surface of the
first sheet material
6.
The article 1 is configured to heated by an aerosol provision device 200 such
that the
first and second aerosol generating materials 4, 5 are heated to generate an
aerosol.
In some embodiments, the first sheet material 6 has a permeability of at most
loo
Coresta Units and, preferably, at most 90, 8o, 70, 6o or 50 Coresta Units. In
some
embodiments, the first sheet material 6 is a porous material and may have a
permeability of greater than 100 Coresta Units. Alternatively, or
additionally, the first
sheet material 6 may comprise one or more slits or apertures to increase the
permeability of the first sheet material 6.
In some embodiments, the first sheet material 6 has a thickness in the range
of 20 to
100 microns. It has been found that reducing the thickness of the first sheet
material 6
helps to facilitate heat transfer to the first and second aerosol generating
materials 4, 5.
In some embodiments, the first sheet material 6 is a porous material.
Increasing the heat transfer through the sheet material 6 advantageously
improves the
efficiency of the heating of the first and second aerosol generating materials
4, 5.
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In some embodiments, the first sheet material 6 has a basis weight in the
range of 20 to
50 gsm.
In some embodiments, the first and/or second aerosol generating material 4, 5
is a
loose material.
In the present example, the first aerosol generating material 4 comprises
extruded
and/or compressed aerosol generating material, as explained in more detail
below.
However, it should be recognised that in other embodiments, the first aerosol
K.) generating material 4 may have a different form.
In some embodiments, the first and/or second aerosol generating material 4, 5
comprises beads. The beads may be cylindrical, or may have an alternative
shape, for
example, spherical, pyramid or cuboid shaped.
In the present example, the first aerosol generating material 4 comprises
beads 4.
In some embodiments, the beads 4 have a diameter (shown by arrow `1Y in Fig.
7) in the
range of 0.5 to 3 mm and, preferably, in the range of 1 to 2 MM.
In some embodiments, the beads 4 have an axial length (shown by arrow L' in
Fig. 7) in
the range of 0.5 to 3 mm and, preferably, in the range of 1 to 2 mm.
In some embodiments, the beads 4 have a particle size in the range of 0.5 to 3
mm and,
preferably, in the range of 1 to 2 mm.
In some embodiments, the first and/or second aerosol generating material 4, 5
comprises, consists of, or essentially consists of tobacco material.
In some embodiments, the tobacco material of the first and/or second aerosol
generating material 4, 5 is derived only from tobacco lamina and no other
types of
tobacco material.
In some embodiments, the first and/or second aerosol generating material 4, 5
comprises tobacco lamina and reconstituted tobacco.
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In some embodiments, the first and second aerosol generating material 4, 5
together
have an average nicotine level in the range of 0.5% to 2.5% by weight of the
first and
second aerosol generating materials 4, 5 and, preferably, in the range of 1%
to 2.1%.
In some embodiments, the first aerosol generating material 4 has a nicotine
level in the
range of 0.5% to 2.5% by weight of the first aerosol generating material 4
and,
preferably, in the range of 1% to 2.1%.
In some embodiments, the second aerosol generating material 5 has a nicotine
level in
io the range of 0.5% to 2.5% by weight of the second aerosol generating
material 5 and,
preferably, in the range of 1% to 2.1%.
In some embodiments, the aerosol generating material in the article 1
comprises
approximately 50% of the first aerosol-generating material 4 and about 50% of
the
second aerosol-generating material 5, by weight. Thus, for example, an article
comprising 26o mg of aerosol-generating material may comprise 13o mg of the
first
aerosol-generating material 4 and 130 mg of the second aerosol-generating
material 5.
In some embodiments, the article 1 comprises from about 20 to about 330 mg of
the
first aerosol generating material 4 and, preferably, from about 50 to about
300 mg, or
from about 40 to about 125 mg of the first aerosol generating material 4.
In some embodiments, the article 2 comprises from about 20 to about 330 mg of
the
second aerosol generating material 5 and, preferably, from about 50 to about
300 mg,
or from about 40 to about 125 mg of the second aerosol generating material
5.In some
embodiments, the total mass of aerosol generating material 4, 5 of the article
1 is in the
range of about 8o to 350 mg and, preferably, is in the range of about 120 to
330 mg, or
about 150 to 300 mg.
In some embodiments, the total mass of tobacco of the article 1 is in the
range of about
8o to 350 mg and, preferably, is in the range of about 120 to 330 mg, or about
150 to
300 mg.
In some embodiments, the first and/or second aerosol generating material 4, 5
is a
solid material.
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In some embodiments, the first and second aerosol generating materials are
different
materials and/or have one or more different properties.
The article 1 may have an axial length (shown by arrow 'X' in Fig. 1) of at
least 10 mm
and, preferably, at least 12, 14, 16, 18, 20, 22 Or 23 mm.
The article 1 may have an axial length of at most 36 mm and, preferably, at
most 34, 32,
30, 28, 26, 24 or 23 mm.
ro The article 1 may have an axial length in the range of ro to 36 mm and,
preferably, in
the range of 14 to 32 mm, in the range of 20 to 26 mm, or in the range of 22
to 24 mm.
In some embodiments, one or more of the first sheet material 6, second sheet
material
7, the substrate 2, and/or the body of material 3 do not comprise plastic.
This makes
the article 1 more environmentally friendly, and is also advantageous in
embodiments
wherein the entire article 1 is heated by the aerosol delivery device 200 (as
described
below).
In some embodiments, the entire article 1 does not comprise plastic. In some
embodiments, the body of material 3 or the entire article 1 does not comprise
cellulose
acetate.
In some embodiments, the article 1 does not comprise cellulose acetate.
In some embodiments, the first and/or second aerosol-generating material 4, 5
may
comprise, consist of, or essentially consist of, botanical material. The
botanical material
may be tobacco material. The term "tobacco material" refers to any material
comprising
tobacco or derivatives or substitutes thereof. The tobacco material may be in
any
suitable form. The term "tobacco material" may include one or more of tobacco,
tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco
substitutes.
The tobacco material may comprise one or more of ground tobacco, tobacco
fibre, cut
tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco
and/or
tobacco extract.
In some embodiments, the first and/or second aerosol generating material 4, 5
or
another material (not shown) of the article 1, for example, another material
of the body
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of material 3, may comprise one or more aerosol-former materials. For example,
the
first and/or second aerosol generating material 4, 5 or said another material
may
comprise one or more constituents capable of forming an aerosol. The aerosol-
former
material comprises one or more of glycerine, glycerol, propylene glycol,
diethylene
glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol,
erythritol, meso-
Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl
citrate, triacetin, a
diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl
acetate,
lauric acid, myristic acid, and propylene carbonate. The aerosol-former
material can be
glycerol or propylene glycol.
The first and/or second aerosol generating material 4, 5 may be provided as a
loose
material. For instance, the first aerosol generating material 4 may be a loose
material
that is held in place in the substrate 2 by adhesive or by being formed with
the second
sheet material 7. The first and/or second aerosol generating material 4, 5
may, for
example, be discrete strands or particles of aerosol generating material.
Another
example of loose aerosol generating material is beads/pellets of aerosol
generating
material, including aerosol generating material that has been extruded and
then cut
into beads/pellets. Yet another example of aerosol generating material is a
sheet of
aerosol generating material that has been cut into individual pieces, for
example, cut
into individual strips of aerosol generating material. The sheet of aerosol
generating
material may be a sheet of reconstituted tobacco.
For example, the body of material 3 may comprise a sheet of the second aerosol
generating material that is gathered to form the body of material 3.
In some embodiments, the article 1 further comprises a third aerosol
generating
material. In one such embodiment, the body of material 3 comprises the second
and
third aerosol generating materials. For example, the body of material 3 may be
formed
from a sheet/strips of one of the second or third aerosol generating material
and
beads/dust/fibres of the other one of the second or third aerosol generating
materials
may be applied to the sheet/strips.
In another embodiment, the substrate 2 comprises the first and third aerosol
generating materials. For example, the second sheet material 7 of the
substrate 2 may
be formed from one of the first and third aerosol generating materials and
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beads/dust/fibres of the other one of the first and third aerosol generating
materials
may be applied to the second sheet material 7 (for example, being adhered
thereto).
In the present example, the second aerosol generating material 4 comprises
shredded
tobacco material (for example, shredded lamina and/or shredded reconstituted
tobacco). The shredded tobacco material is formed into a tobacco rod 3. The
patch 2 at
least partially circumscribes the rod 3.
In the present example, the first aerosol generating material 4 comprises
extruded
_ro and/or compressed tobacco. In such embodiments, the first aerosol
generating material
4 may comprise a single body of aerosol generating material. However, in the
present
example, the first aerosol generating material 4 comprises a plurality of
bodies of
aerosol generating material.
In the present example, the first aerosol generating material 4 comprises
beads/pellets/granules of aerosol generating material (hereinafter referred to
as 'beads'
of aerosol generating material). The beads 4 may be extruded and/or compressed
beads
4.
Optionally, one of the first and second aerosol generating materials 4, 5 has
a higher
density than the other one of the first and second aerosol generating
materials 4, 5. It
has been found that this causes the denser aerosol generating material to heat
up
slower when subjected to a given heating power. This means that the less dense
material (for example, the second aerosol generating material 5) will
initially release
one or more volatile compounds (e.g. nicotine) at a higher rate than the more
dense
material (for example, the first aerosol generating material 4). This also
means that the
less dense material (for example, the second aerosol generating material 5)
will become
relatively depleted of said volatile compound(s) more quickly than the more
dense
material (for example, the first aerosol generating material 4). However, as
the less
dense material (for example, the second aerosol generating material 5) starts
to become
relatively depleted of said volatile compound(s), the more dense material (for
example,
the first aerosol generating material 4) will begin to reach a temperature
wherein it
begins to release volatile compound(s) at a higher rate. The effect of this is
a more
consistent release of the volatile compound(s) over the period of consumption
of the
article 1, with the less dense material (for example, the second aerosol
generating
material 5) releasing a greater proportion of volatile compound(s) towards the
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beginning of the consumption of the article 1 and the more dense material (for
example,
the first aerosol generating material 4) releasing a greater proportion of
volatile
compound(s) towards the end of the consumption of the article 1. This is
particularly
advantageous because the article 1 can be made relatively small whilst still
achieving a
relatively consistent and/or sufficient release of volatile compound(s) over
the period of
consumption.
In some embodiments, said one or more volatile compound(s) released by the
first
aerosol generating material 4 are the same as the volatile compound(s)
released by the
io second aerosol generating material 5.
In some embodiments, the first aerosol generating material 4 comprises aerosol
generating material that has been compressed or extruded (without subsequent
expansion or with a relatively low/minimal expansion) such that the density of
the first
aerosol generating material 4 is higher than the density of the second aerosol
generating material 5.
In some embodiments, the second aerosol generating material 5 comprises one or
more
of: tobacco lamina; tobacco stems or reconstituted tobacco. In one such
embodiment,
the second aerosol generating material 5 comprises a mixture of tobacco lamina
and
reconstituted tobacco. The second aerosol generating material 5 may comprise
shredded or cut material. However, it should be recognised that in other
embodiments,
the second aerosol generating material 5 comprises a compressed or extruded
aerosol
generating material that has a lower density than the first aerosol generating
material 4
(for example, having a lower compression than the first aerosol generating
material 4,
which optionally may also be extruded or compressed). For instance, the body
of
material 3 may comprise an extruded/compressed body of the second aerosol
generating material 5.
In some embodiments, the first and second aerosol-generating material 4, 5 may
comprise the same material, for example, tobacco, but are processed to have
different
densities. In one such embodiment, the first and second aerosol generating
materials 4,
5 may be in different forms. For example, the second aerosol generating
material 5 may
be a shredded material (for example, shredded lamina tobacco and/or shredded
reconstituted tobacco) that is formed into a body 3, whereas the first aerosol
generating
material 4 may be compressed or extruded (without or with minimal expansion)
such
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that the first aerosol generating material 4 has a higher density than the
second aerosol
generating material 5.
For example, the first aerosol generating material 4 may be in the form of
extruded/compressed beads of aerosol generating material (for example, tobacco
or
another material) and the second aerosol generating material 5 may be in the
form of,
for example: strands or strips of aerosol generating material (for example,
tobacco or
another material); a sheet of aerosol generating material that is gathered
into a plug or
is cut into strips; a rod of aerosol generating material (e.g. a rod formed
from cut rag
io tobacco); or, tobacco lamina and/or stem material that has been formed
into a plug.
However, it should be recognised that the first second, and/or third aerosol
generating
material 4, 5 may alternatively have the same form (e.g. both being cut rag
tobacco).
It should be recognised that in alternative embodiments, the density of the
first aerosol
generating material 4 is lower than the density of the second aerosol
generating
material 5. In yet another embodiment, the densities of the first and second
aerosol
generating materials 4, 5 are the same.
In some embodiments, the first aerosol-generating material 4 has at least one
further
different characteristic to the second aerosol generating material 5. The
different
characteristic may be one or more of form, sizeõ water content, amount (by
weight),
material or materials, or proportion of materials that make the first and
second aerosol-
generating materials 4, 5 (including the recipe of the aerosol generating
materials 4, 5
when each is manufactured more than one material). In some embodiments, the
first
and second aerosol-generating materials 4, 5 do not have a different
characteristic,
other than being in a different form.
The first and/or second aerosol-generating material 4, 5 may comprise a
plurality of
strands or strips of aerosol-generating material. For example, the first
and/or second
aerosol-generating material 4, 5 may comprise a plurality of strands or strips
of an
aerosolisable material and/or a plurality of strands or strips of an amorphous
solid.
The first and/or second aerosol-generating material 4, 5 may comprise a plant
based
material, such as a tobacco material. The first and/or second aerosol-
generating
material 4, 5 may be a sheet or shredded sheet of aerosolisable material
comprising a
plant based material, such as a tobacco material. The sheet material may be
processed
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such that the second aerosol generating material 5 has a higher density than
the first
aerosol generating material 4.
The plant based material may be a particulate or granular material. In some
embodiments, the plant based material is a powder. Alternatively, or in
addition, the
plant based material may comprise may comprise strips, strands or fibres of
tobacco.
For example, where tobacco material is provided, the tobacco material may
comprise
particles, granules, fibres, strips and/or strands of tobacco. In some
embodiments, the
tobacco material consists of particles or granules of tobacco material.
The tobacco material of the first and/or second aerosol-generating material 4,
5 may
comprise tobacco obtained from any part of the tobacco plant. In some
embodiments,
the tobacco material comprises tobacco leaf.
The sheet or shredded sheet can comprise from 5% to about 90% by weight
tobacco
leaf.
In some embodiments, both of the first and/or second aerosol-generating
material 4, 5
comprise, consist of, or essentially consist of tobacco material.
In some embodiments, the first and/or second aerosol-generating material 4, 5
comprises a sheet or shredded sheet of aerosolisable material that comprises
an
aerosol-former material. The aerosol-former material is provided in an amount
of up to
about 50% on a dry weight base by weight of the sheet or shredded sheet. In
some
embodiments, the aerosol-former material is provided in an amount of from
about 5%
to about 40% on a dry weight base by weight of the sheet or shredded sheet,
from about
10% to about 30% on a dry weight base by weight of the sheet or shredded sheet
or
from about 10% to about 20% on a dry weight base by weight of the sheet or
shredded
sheet.
The first and/or second aerosol-generating material 4, 5 may comprise a
filler. The
filler is generally a non-tobacco component, that is, a component that does
not include
ingredients originating from tobacco. The filler may comprise one or more
inorganic
filler materials, such as calcium carbonate, perlite, vermiculite,
diatomaceous earth,
colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate,
and
suitable inorganic sorbents, such as molecular sieves. The filler may be a non-
tobacco
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fibre such as wood fibre or pulp or wheat fibre. The filler can be a material
comprising
cellulose or a material comprises a derivate of cellulose. The filler
component may also
be a non-tobacco cast material or a non-tobacco extruded material. In some
embodiments, first and/or second aerosol generating materials 4, 5 are in the
form of a
sheet or shredded sheet that comprises the filler.
The first and/or second aerosol generating materials 4, 5 can comprise an
aerosol
modifying agent, such as any of the flavours described herein. In one
embodiment, the
first and/or second aerosol generating materials 4, 5c0mprise5 menthol. When
the first
ro and/or second aerosol generating materials 4, 5 is incorporated into an
article 1 for use
in an aerosol-provision system, the article may be referred to as a
mentholated
consumable or article 1. The first and/or second aerosol generating materials
4, 5 can
comprise from o.5mg to 2 omg of menthol, from 0.7 mg to 20 mg of menthol,
between
irrig and 18mg or between 8mg and 16mg of menthol.
In some embodiments, the article 1 comprises an aerosol-generating composition
comprising aerosol-generating material. The aerosol-generating material may
comprise
the first and/or second aerosol-generating material 4, 5 (and/or the third
aerosol
generating material).
An aerosol-generating material is a material that is capable of generating
aerosol, for
example when heated, irradiated or energized in any other way. Aerosol-
generating
material (for example, the first and/or second aerosol generating material 4,
5) may, for
example, be in the form of a solid, liquid or semi-solid (such as a gel) which
may or may
not contain an active substance and/or flavourants.
The aerosol-generating material (for example, the first and/or second aerosol
generating material 4, 5) may comprise a binder and an aerosol former.
Optionally, an
active and/or filler may also be present. Optionally, a solvent, such as
water, is also
present and one or more other components of the aerosol-generating material
may or
may not be soluble in the solvent. In some embodiments, the aerosol-generating
material (for example, the first and/or second aerosol generating material 4,
5) is
substantially free from botanical material. In particular, in some
embodiments, the
aerosol-generating material (for example, the first and/or second aerosol
generating
material 4, 5) is substantially tobacco free.
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In some embodiments, the composition of the first and/or second aerosol
generating
materials 4, 5 comprises an aerosol-forming "amorphous solid". The amorphous
solid
may be a "monolithic solid". 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 aerosol-generating material may,
for
example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to
about
90wt%, 95wt% or wowt% of amorphous solid. The amorphous solid may be
substantially non-fibrous.
ro In some examples, the amorphous solid comprises:
- 1-60 wt% of a gelling agent;
- 0.1-50 wt% of an aerosol-former material; and
- o.1-8o wt% of a flavour;
wherein these weights are calculated on a dry weight basis.
In some further embodiments, the amorphous solid comprises:
- 1-50 wt% of a gelling agent;
- 0.1-50 wt% of an aerosol-former material; and
- 30-60 wt% of a flavour;
wherein these weights are calculated on a dry weight basis.
The aerosol-generating material (for example, the first and/or second aerosol
generating material 4, 5) may comprise or be an aerosol-generating film. The
aerosol-
generating film may be formed by combining a binder, such as a gelling agent,
with a
solvent, such as water, an aerosol-former and one or more other components,
such as
active substances, to form a slurry and then heating the slurry to volatilise
at least some
of the solvent to form the aerosol-generating film. The 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 film may be a continuous film or a discontinuous film, such
an
arrangement of discrete portions of film on a support. The aerosol-generating
film may
be substantially tobacco free.
The aerosol-generating film may comprise or be a sheet, which may optionally
be
shredded to form a shredded sheet.
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The aerosol-generating material may comprise one or more active substances
and/or
flavours, one or more aerosol-former materials, and optionally one or more
other
functional material.
In each of the embodiments of aiticle 1 described herein, the article may
comprise such
a first and/or second aerosol generating material 4, 5 (and/or third aerosol
generating
material), and may comprise such an aerosol-generating composition.
The amorphous solid material may be provided in sheet or in shredded sheet
form. The
amorphous solid material may take the same form as the sheet or shredded sheet
of
aerosolisable material.
In some embodiments, the aerosol generating material, for example, the first
or second
aerosol generating material 4, 5 comprises: from about 10 to about 50 wt%
aerosol-
former material; from about 15 to about 6o wt% gelling agent; and optionally
filler;
wherein the wt% values are calculated on a dry weight basis.
The first and/or second aerosol generating materials 4, 5 can comprise a paper
reconstituted tobacco material. The composition can alternatively or
additionally
comprise any of the forms of tobacco described herein. The first and/or second
aerosol
generating materials 4, 5 can comprise a sheet or shredded sheet comprising
tobacco
material comprising between 10% and 90% by weight tobacco leaf, wherein an
aerosol-
former material is provided in an amount of up to about 20% by weight of the
sheet or
shredded sheet, and the remainder of the tobacco material comprises paper
reconstituted tobacco.
Where the first and/or second aerosol generating material 4, 5 comprises an
amorphous solid material, the amorphous solid material may be a dried gel
comprising
menthol.
In some embodiments, the first and/or second aerosol generating material 4, 5
comprises an extruded aerosol generating material that is then cut into beads
of pellets.
Referring now to Fig. 8, an alternative article 1 for an aerosol provision
device 200 is
shown. The article 1 has similar features to the article 1 described above in
relation to
Figs. 1 to 7, with like features retaining the same reference numerals, and
may have any
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of the variations of features described herein. The difference is that, the
substrate 2
comprises the first aerosol generating material 4, instead of the first
aerosol generating
material 4 being applied to a surface of the second sheet material 7. In one
embodiment, the substrate 2 comprises a second sheet material 7 that comprises
the
first aerosol generating material 4. For example, the second sheet material 7
may be
formed with the first aerosol generating material 4. The first aerosol
generating
material 4 may be integral to the second sheet material 7.
In one such embodiment, the substrate 2 comprising the first aerosol
generating
io material 4 is printed on to the first sheet material 6. By 'printing' it
is meant that the
first aerosol generating material 4 is applied in a fluid form to the first
sheet material 6
and allowed to dry or is cured.
In one such embodiment, the second sheet material 7 is formed from a slurry,
wherein
the first aerosol generating material 4 is provided in the slurry and then the
second
sheet material 7 is formed from the slurry. For example, the second sheet
material 7
may be cast from a slurry comprising the first aerosol generating material 4..
In another embodiment (not shown), the second sheet material 7 comprises the
first
aerosol generating material 4 (for example, being formed from a slurry
comprising the
first aerosol generating material 4) and wherein a third aerosol generating
material is
applied to a surface of the second sheet material 7 (for example, being
retained in
position by an adhesive).
Referring now to Fig. 9, another article 1 for an aerosol provision device 200
is shown.
The article 1 has similar features to the article 1 described above in
relation to Figs. 1 to
7, with like features retaining the same reference numerals, and may have any
of the
variations of features described herein. The difference is that the substrate
2 of the
embodiment of Fig. 9 extends over the entire axial length (shown by arrow 'X')
of the
article 1. In the present embodiment, the second sheet material 7 and first
aerosol
generating material 4 both extend over substantially the entire axial length X
of the
article 1. However, it should be recognised that in alternative embodiments,
the second
sheet material 7 may extend over substantially the entire axial length X of
the article 1
whereas the first aerosol generating material 4 may extend over only a portion
of the
axial length of the article 1.
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Embodiments wherein the first aerosol generating material 4 extends over the
entire
axial length X of the article 1 (or the entire axial length of the body of
material 3)
provide the advantage of increasing the amount of first aerosol generating
material 4 in
the article 1 and thus the amount of aerosol that can be generated for a given
axial
length X of the article 1.
Embodiments wherein the first aerosol generating material 4 over only a
portion of the
entire axial length X of the article 1 provide the advantage that the first
aerosol
generating material 4 is not visible from the ends P. D of the article 1 and
also helps to
ro reduce the possibility of the first aerosol generating material 4 from
falling out of the
ends P. D of the article 1.
In some embodiments, the apertures (not shown) are cut into the substrate 2
and/or
the first sheet material 6. The apertures may be formed in the first sheet
material 6.
Specifically, the apertures may be formed in a region underlying the substrate
2. The
apertures are formed all the way through the first sheet material and,
optionally,
through the substrate 2. The apertures may prevent the substrate from
separating from
the first sheet material 6 when the article 1 is heated in use.
Referring now to Figs. 10 to 12, an embodiment of an aerosol provision device
200 is
shown.
The article 1 is configured for use in an aerosol provision device 200 (see
Fig. 10)
comprising an aerosol generator in the form of a heating element 203 for
heating the
article 1. In the present example, the heating element 203 at least partially
surrounds a
heating area 202, for example, a heating chamber 202. The heating element 203
may
be resistively and/or inductively heated.
In other embodiments (not shown), the heating element 203 instead comprises a
blade
or pin, for insertion into the article 1, for example, the blade or pin may be
inserted
through the body of material 3. In other embodiments (not shown), the
consumable 1
may comprise the heating element which, for example, may be embedded in the
body of
material 3.
In Fig. 10, the components of an embodiment of an aerosol provision device 200
are
shown in a simplified manner. Particularly, the elements of the aerosol
provision device
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200 are not drawn to scale in Fig. 10. Elements that are not relevant for the
understanding of this embodiment have been omitted to simplify Fig. 10.
In the example of Fig. 10, the aerosol provision device 200 is a non-
combustible aerosol
provision device 200. The non-combustible aerosol provision device 200
comprises a
housing 201 comprising an area 202 for receiving an article 1.
When the article 1 is received into the heating area 202, at least a portion
of the article 1
comes into thermal proximity with the heater 203. Thus, at least a portion of
the
ro aerosol generating material 4, 5 is in thermal proximity with the heater
203. In some
embodiments, the heater 203 is spaced from the article 1, for example,
circumscribing
the article 1 but having a larger diameter and being spaced therefrom. In
other
embodiments, the heater 203 is in direct contact with the article 1, for
example,
contacting an outer surface of the first sheet material 6 of the article. In
another
embodiment, the heater 203 comprises a blade or pin that contacts the inside
of the
article 1, for example, contacting the body of material 3 and/or the substrate
2.
When the article 1 is heated, the first and/or second aerosol generating
material 4, 5
will release one or more volatile compounds and may release a range of
volatile
compounds at different temperatures. By controlling the maximum operation
temperature of the electrically heated aerosol generating system 200, the
selective
release of undesirable compounds may be controlled by preventing the release
of select
volatile compounds.
As shown in Fig. 11, within the housing 201 there is an electrical energy
supply 204, for
example a rechargeable lithium ion battery. A controller 205 is connected to
the heater
203, the electrical energy supply 204, and a user interface 206, for example a
button or
display. The controller 205 controls the power supplied to the heater 203 in
order to
regulate its temperature. Typically, the aerosol-forming substrate is heated
to a
temperature of between 250 and 450 degrees centigrade.
Fig. 12 is a schematic cross-section of a non-combustible aerosol-provision
device 200
of the type shown in Fig. 10, with the article 1 received in the heating area
202 of the
device 200 for heating by the heater 203. The non-combustible aerosol
provision
device 200 is illustrated receiving the aerosol-generating article 1 for
consumption of
the aerosol-generating article 1 by a user.
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The housing 201 of non-combustible aerosol provision device 200 defines an
area 202
in the form of a cavity, open at the proximal end (or mouth end), for
receiving an
aerosol-generating article 1 for consumption by a user.
In the present example, the aerosol-provision device 200 comprises a
mouthpiece 207
that is detachable from the remainder of the device 200 to allow access to the
area 202
such that an article 1 can be interested into and removed from the area 202.
Once a
article 1 has been provided in the area 202, the mouthpiece 207 can be
reattached. In
io some embodiments, the mouthpiece 207 is removably attached to
the housing 201 of
the device 200, for example, by a screw thread or bayonet connection.
As a user draws on the mouthpiece 207, air is drawn into the article 1 and the
volatile
substances condense to form an inhalable aerosol. This aerosol passes through
the
mouthpiece 207 of the device 200 and into the user's mouth.
It should be recognised that in other embodiments the mouthpiece 207 of the
device
200 may be omitted. In some embodiments, the article 1 may form a mouthpiece
and
may come into contact with a user's mouth.
In the above described embodiments, the body of material 3 extends between the
ends
P, D of the article 1. However, it should be recognised that in alternative
embodiments
(not shown), the article 1 may comprise one or more further segments, for
example, a
further segment upstream or downstream of the body of material 3.
For example, an alternative embodiment of an article 1 is shown in Fig. 13
which
further comprises a cooling section 25, also referred to as a cooling element,
positioned
immediately downstream of the body of material 3. In the present example, the
cooling
element 25 is immediately downstream of and adjacent to the body of material
3. In
some such embodiments, the cooling element 25 is in an abutting relationship
with the
body of material 3. The article 1 may additionally or alternatively include a
further body
of material 26 downstream of the cooling element 25. The further body of
material 26
may comprise flavouring and/or filtering material and/or may be provided to
obscure
the view of the cooling element 25.
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The cooling element 25 comprises a hollow channel, having an internal diameter
of
between about 1 mm and about 4 mm, for example between about 2 mm and about 4
mm. The hollow channel may have an internal diameter of about 3 mm. The hollow
channel extends along the full length of the cooling element 25. The cooling
element 25
may comprise a single hollow channel. In alternative embodiments, the cooling
element
25 can comprise multiple channels, for example, 2, 3 or 4 channels. The single
hollow
channel may be substantially cylindrical, although in alternative embodiments,
other
channel geometries/cross-sections may be used. The hollow channel can provide
a
space into which aerosol drawn into the cooling element 25 can expand and cool
down.
io The cooling element 25 may be configured to limit the cross-sectional
area of the
hollow channel/s, to limit tobacco displacement into the cooling element 25,
in use.
The cooling element 25 may have a wall thickness in a radial direction. The
wall
thickness of the cooling element 25, for a given outer diameter of cooling
element 25,
defines the internal diameter for the chamber surrounded by the walls of the
cooling
element 25. The cooling element 25 can have a wall thickness of at least about
1.5 mm
and up to about 2 mm. In the present example, the cooling element 25 has a
wall
thickness of about 2 MM.
The cooling element 25 may be formed from filamentary tow. Other constructions
can
be used, such as a plurality of layers of paper which are parallel wound, with
butted
seams, to form the cooling element 25; or spirally wound layers of paper,
cardboard
tubes, tubes formed using a papier-mâché type process, moulded or extruded
plastic
tubes or similar. The cooling element 25 is manufactured to have a rigidity
that is
sufficient to withstand the axial compressive forces and bending moments that
might
arise during manufacture and whilst the article 1 is in use.
The wall material of the cooling element 25 can be relatively non-porous, such
that at
least 90% of the aerosol generated by the aerosol generating material 3 passes
longitudinally through the one or more hollow channels rather than through the
wall
material of the cooling element 25. For instance, at least 92% or at least 95%
of the
aerosol generated by the first and/or second aerosol generating material 4, 5
can pass
longitudinally through the one or more hollow channels.
The cooling element 25 can be configured to provide a temperature differential
of at
least 40 degrees Celsius between a heated volatilised component entering a
first,
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upstream end of the cooling element 25 and a heated volatilised component
exiting a
second, downstream end of the cooling element 25. The cooling element 25 can
be
configured to provide a temperature differential of at least 6o degrees
Celsius, or at
least 80 degrees Celsius, or at least 100 degrees Celsius between a heated
volatilised
component entering a first, upstream end of the cooling element 25 and a
heated
volatilised component exiting a second, downstream end of the cooling element
25.
This temperature differential across the length of the cooling element 25
protects the
temperature sensitive body of material 26 from the higher temperatures of the
aerosol-
generating material 4, 5 when it is heated.
The body of material 26 defines a substantially cylindrical overall outer
shape and is
wrapped in a plug wrap 28. The plug wrap 28 can have a basis weight of less
than 50
gsm, or between about 20 gsm and 40 gsm. The plug wrap 28 can have a thickness
of
between 30 pm and 6o itm, or between 35 vim and 45 vim. The plug wrap 28 may
be a
non-porous plug wrap, for instance having a permeability of less than loo
Coresta
units, for instance less than 50 Coresta units. However, in other embodiments,
the plug
wrap 28 can be a porous plug wrap, for instance having a permeability of
greater than
100 Coresta Units or 200 Coresta Units.
The cooling element 25 and/or body of material 26 may form a mouthpiece of the
article 1 that is configured to be received within the mouth of the user. In
some
embodiments, the mouthpiece 207 of the device 200 may be omitted.
In some embodiments, a tipping paper (not shown) is wrapped around the cooling
element 25 and body of material 26 and also circumscribes the first sheet of
material 6
that circumscribes the substrate 2 and body of material 3, and may be
connected to
these components by adhesive. Thus, the tipping paper connects the cooling
element 25
and body of material 26 to the body of material 3. In other embodiments, the
tipping
paper is omitted and instead the first sheet material 6 extends to
circumscribe the
cooling element 25 and body of material 26 to connect these components to the
body of
material 3 and substrate 2.
Referring now to Fig. 15, a block diagram depicting an exemplary embodiment of
a
method loo of manufacturing an article 1 for an aerosol provision device is
shown.
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The method loo comprises the step (Si) of providing a first sheet material 6.
The
method loci also comprises the step (S2) of providing a substrate 2 comprising
a first
aerosol generating material 4, wherein the substrate 2 is adhered to the first
sheet
material 6. The method ioo further comprises the step (S3) of arranging the
first sheet
material 6 with the substrate adhered thereto such that the first sheet
material 6
surrounds the substrate 2. In the present example, the substrate 2 is a patch
2.
In some embodiments, the substrate 2 comprises a second sheet material 7 and
providing the substrate 2 comprises attaching the second sheet material 7 to
the first
io sheet material 6.
The second sheet material 7 may be a cast sheet.
In some embodiments, the second sheet material 7 comprises the first aerosol
generating material 4. For example, the second sheet material 7 may be formed
with
the first aerosol generating material 4. The first aerosol generating material
4 may be
integral to the second sheet material 7. In one such embodiment, the second
sheet
material 7 is formed from a slurry, wherein the first aerosol generating
material 4 is
provided in the slurry and then the second sheet material 7 is formed from the
slurry.
For example, the second sheet material 7 may be cast from a slurry comprising
the first
aerosol generating material 4.
In some embodiments, the first aerosol generating material 4 is attached to a
surface of
the second sheet material 7 and, preferably, is adhered to the surface of the
second
sheet material 7.
The first aerosol generating material 4 may be attached to the surface of the
second
sheet material 7 before or after attaching the second sheet material 7 to the
first sheet
material 6.
The first aerosol generating material 4 may be applied to the first sheet
material 6 as or
in slurry that is then dried to form a layer on the first sheet material 6.
In some embodiments, the second sheet material 7 comprises one or more of:
paper,
card and/or aerosol generating material.
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In some embodiments, providing the first sheet material 6 comprises providing
a web
of first sheet material.
In some embodiments, providing the substrate 2 comprises applying the
substrate 2 to
the web of first sheet material 6.
In some embodiments, applying the substrate 2 to the web of first sheet
material 6
comprises applying a web of the second sheet material 7 to the web of first
sheet
material 6. For example, continuous webs of the first and second sheet
materials 6, 7
io may be brought together and adhered together.
In some embodiments, applying the substrate 2 to the web of first sheet
material 6
comprising applying a plurality of portions of second sheet material 7 to the
web of first
sheet material 6.
In some embodiments, the plurality of portions of second sheet material 7 are
spaced
from each other on the web of first sheet material 6.
In some embodiments, the portions of second sheet material 7 are discrete. The
portions of second sheet material 7 may be spaced from each other in a
direction along
the conveyance path of the web of first sheet material 6.
In some embodiments, an edge of the substrate 2 is spaced from an edge 6C of
the first
sheet material 6 such that a region 8 of the first sheet material 6 is not
covered by the
substrate 2 and, preferably, the method comprises applying adhesive to said
region 8.
In some embodiments, the substrate 2 comprises opposite third and fourth edges
2C,
2D and the first sheet material 6 comprises opposite third and fourth edges
6C, 6D. The
third edge 2C of the patch 2 may be spaced from the third edge 6C of the first
sheet
material 6 such that the first sheet material 6 comprises the region 8 that is
not covered
by the patch 2. The region 8 may be arranged to overlap the fourth edge 6D of
the first
sheet material 6 and may be adhered to an outer surface of the first sheet
material 6.
The region 8 not being covered by the patch 2 facilitates adhesion of the
inside surface
of the region 8 of the first sheet material 6 to the outer surface of the
first sheet material
6. The method roo may comprise applying adhesive to the region 8.
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In some embodiments, the first sheet material 6 has a permeability in the
range of at
most wo Coresta Units and, preferably, at most 90, 8o, 70, 6o or 50 Coresta
Units.
In some embodiments, the first sheet material 6 has a thickness in the range
of 20 to
100 microns.
In some embodiments, the first sheet material 6 forms an exterior surface IA
of the
article 1.
In some embodiments, the method loo comprises providing a continuous web of
first
sheet material 6. The web may be fed along a conveyance path. The web of the
first
sheet material 6 may be supplied from a reel.
In some embodiments, the first aerosol generating material 4 comprises aerosol
generating material dust and/or aerosol generating material fibres.
In some embodiments, the first aerosol generating material 4 comprises
extruded
and/or compressed aerosol generating material.
In some embodiments, the first aerosol generating material 4 comprises beads
4.
In some embodiments, the beads 4 have a diameter in the range of 0.5 to 3 mm
and,
preferably, in the range of 1 to 2 min.
In some embodiments, the beads 4 have a particle size (measured by sieving) in
the
range of 0.5 to 3 mm, and preferably, in the range of 1 to 2 mm.
In some embodiments, the first aerosol generating material 4 comprises,
consists of, or
essentially consists of tobacco material.
In some embodiments, the tobacco material of the first and/or second aerosol
generating material 4, 5 is derived only from tobacco lamina and no other
types of
tobacco material.
In some embodiments, the first and/or second aerosol generating material 4, 5
comprises tobacco lamina and reconstituted tobacco.
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In some embodiment, the first and second aerosol generating materials 4, 5
together
have an average nicotine level in the range of 0.5% to 2.5% by weight of the
first and
second aerosol generating materials 4, 5 and, preferably, in the range of 1%
to 2.1%.
In some embodiments, the first and/or second aerosol generating material 4, 5
is a
solid material.
In some embodiments, the article 1 does not comprise plastic.
In some embodiments, the article 1 does not comprise cellulose acetate.
In some embodiments, the first and second aerosol generating materials 4, 5
are
manufactured from the same aerosol generating starter materials that are
processed to
have different forms.
In some embodiments, the article 1 further comprises a second aerosol
generating
material 5.
In some embodiments, the second aerosol generating material 5 has a higher or
lower
density than the first aerosol generating material 4.
In some embodiments, the second aerosol generating material 5 comprises,
consists of,
or essentially consists of tobacco material.
In some embodiments, the second aerosol generating material 5 comprises
shredded
tobacco and/or reconstituted tobacco.
In some embodiments, the substrate 2 comprises the second aerosol generating
material 5.
In some embodiments, the second sheet material 7 comprises the first and/or
second
aerosol generating materials 4, 5. For example, the second sheet material 7
may be
formed from a slurry that comprises the first and/or second aerosol generating
materials 4, 5.
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In some embodiments, the first sheet material 6 and substrate 2 are arranged
such that
the substrate 2 is provided on an inside surface of the first sheet material 6
once formed
into an article 1. In some embodiments, the first sheet material 6
circumscribes, or at
least partially circumscribes, the substrate 2.
In some embodiments, the first and/or second aerosol generating materials 4, 5
are
applied to a surface of the second sheet material 7.
In some embodiments, the second sheet material 7 comprises one of the first
and
io second aerosol generating materials 4, 5 and the other one of
the first and second
aerosol generating materials 4, 5 is applied to a surface of the second sheet
material 7.
In some embodiments, arranging the first sheet material 6 with the substrate 2
adhered
thereto comprises providing the first sheet material 6 and substrate 2 around
at least a
portion of a body of material 3 and, preferably, comprises wrapping the first
sheet
material 6 with substrate 2 about the body of material 2.
The method loo may comprise forming the body of material 3 and then wrapping
the
first sheet material 6 and substrate 2 about the body of material 3. In
another
embodiment, the body of material 3 is formed at the same time as wrapping the
first
sheet material 6 and substrate 2 about the body of material 3, for example, by
feeding
the first sheet material 6 and substrate through a garniture together with the
material
that is formed into the body of material 3.
In some embodiments, the substrate 2 circumscribes the entire circumference of
the
body of material 3. In some embodiments, the first sheet material 6
circumscribes the
body of material 3. In some embodiments, the substrate 2 circumscribes the
body of
material 3.
In some embodiments, the body of material 3 comprises a third sheet material
that is
gathered to form the body of material 3. In some embodiments, the third sheet
material
is crimped and/or cut into strips.
In some embodiments, the substrate 2 is in direct contact with the body of
material 3.
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In some embodiments, the body of material 3 comprises a tobacco rod. For
example,
the body of material 3 may comprise shredded tobacco material that is formed
into a
rod. In some embodiments, the body of material 3 comprises cut rag tobacco
that is
formed into a rod.
In some embodiments, the body of material 3 comprises the second aerosol
generating
material 5.
In some embodiments, the body of material 3 comprises a third sheet material
(not
io shown) and, preferably, the method 100 comprises gathering the
third sheet material to
form the body of material 3. The third sheet material may optionally be
crimped and/or
cut into strips.
In some embodiments, the body of material 3 comprises a tobacco rod. For
example,
the body of material 3 may comprise shredded tobacco material that is formed
into a
rod. In some embodiments, the body of material 3 comprises cut rag tobacco
that is
formed into a rod.
In some embodiments, the article 1 comprises a third aerosol generating
material. For
example, the substrate 2 or body of material 3 may comprise the third aerosol
generating material. In some embodiments, the substrate 2 comprises a second
sheet
material 7 that comprises the first and/or third aerosol generating materials.
For
example, the second sheet material 7 may be formed from a slurry that
comprises the
first and/or third aerosol generating materials. In some embodiments, the
first and/or
third aerosol generating materials are applied to a surface of the second
sheet material
7. In some embodiments, the second sheet material 7 comprises one of the first
and
third aerosol generating materials and the other one of the first and third
aerosol
generating materials is applied to a surface of the second sheet material 7.
In another embodiment, the substrate 2 is provided axially upstream or
downstream of
the body of material 3. In another embodiments the article 1 does not comprise
a body
of material 3. For example, the substrate 2 may be arranged to define a tube
that
surrounds an empty space. The empty space may form a passage for the flow of
gas
therethrough. In another example, the substrate 2 extends about a component
other
than a body of material 3.
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It should be recognised that the first and second aerosol generating materials
4, 5 and
the body of material 3 may have a variety of features and/or forms, including
any of the
features described above, including described above in relation to Figs. 1 to
14.
Referring now to Figs. 15A to 15G, an embodiment of a method of manufacturing
an
article 1 for an aerosol provision device 200 is shown. An example of an
apparatus 300
for carrying out the method is shown in Fig. 16.
In a first step (shown in Fig. 15A), a continuous web Wi of a second sheet
material 7 is
provided. In the present example, the second sheet material 7 comprises a
strip of
paper. The continuous web Wi may be supplied from a first reel Si.
In a second step (shown in Fig. 15B), a first aerosol generating material 4 is
applied to a
surface of the web Wi of the second sheet material 7. For example, an adhesive
may be
applied to the web Wi and/or to the first aerosol generating material 4 such
that the
first aerosol generating material 4 is adhered to the web Wi. In the present
example,
the apparatus 300 comprises an applicator 301 that sprays the adhesive onto
the web
Wi and then supplies the first aerosol generating material 4 under the effect
of gravity,
for example, using a hopper. In another embodiment, the first aerosol
generating
material 4 is supplied pneumatically, and optionally may be sprayed on to the
web
The first aerosol generating material 4 may be supplied as loose aerosol
generating
material 4, for example, loose beads/fibres/dust of the first aerosol
generating material
4.
The second sheet material 7 and first aerosol generating material 4 may
together form a
substrate 2.
It should be recognised that in an alternative embodiment, the second sheet
material 7
comprises the first aerosol generating material 4. For example, the second
sheet
material 7 may be cast from a slurry that comprises the first aerosol
generating material
4.
In a third step (shown in Fig. 15C), a plurality of successive cuts are
provided in the web
Wi to form a plurality of individual portions of the substrate 2. In the
present example,
the web Wi is cut along successive cut lines
(shown in Fig. 15C). The cuts may be
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formed using a cutting device 302. For example, the cutting device 302 may
comprise a
cutting drum, one or more cutting knives or one or more lasers. In some
embodiments,
each individual portion forms a respective patch 2.
In a fourth step (shown in Fig. 15D), the plurality of individual portions of
the substrate
2 are spaced apart from each other. In the present example, the apparatus 300
comprises a first belt conveyor 303 and a second belt conveyor 304 that
operates at a
faster speed than the first belt conveyor 303. The individual portions of the
substrate 2
are conveyed from the first belt conveyor 303 to the second belt conveyor 304,
wherein
_ro each individual portion of the substrate 2 is accelerated and becomes
spaced from the
upstream portions of substrate 2. In an alternative embodiment (not shown),
the
individual portions of substrate 2 are spaced apart using a spacing drum. In
yet another
embodiment, the individual portions of substrate 2 are not spaced apart from
each
other.
In a fifth step (shown in Fig. 15E), the individual portions of substrate 2
are adhered to
a web W2 of a first sheet material 6. The individual portions of substrate 2
are fed from
the second belt conveyor 304 and onto the web W2 of first sheet material 6 as
the web
W2 passes along a conveyance path. The web W2 may be supplied from a second
reel
S2.
The adhesive may be applied to the web W2 of the first sheet material 6 and/or
to the
substrate 2 (for example, being applied to the second sheet material 7 of the
substrate
2).
In the present example, the adhesive is applied by an adhesive applicator 305.
The
adhesive applicator 305 may be configured to spray the adhesive on to the
first sheet
material 6 and/or substrate 2 as it is fed along a conveyance path and passes
the
adhesive applicator 305, or may apply the adhesive using one or more brushes
or
rollers. In another embodiment, the adhesive is pre-applied to the web W2 or
substrate
2 as a hot melt adhesive, and wherein the fifth step comprises heating the
adhesive to
activate the adhesive.
In a sixth step (shown in Fig. 15F), the web W2 of the first sheet material 6
with the
individual portions of substrate 2 thereon are combined with a second aerosol
generating material 5 to form a continuous rod R.
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In the present example, the second aerosol generating material 5 is tobacco
material
that is fed from a tobacco supply S3. The tobacco may comprise, for example,
shredded
tobacco. In other embodiments, the tobacco material may comprise a sheet of
tobacco
(for example, reconstituted tobacco) that is gathered to form the body of
material 3.
In the present example, the web W2 of the first sheet material 6 with the
individual
portions of substrate 2 thereon are combined with the second aerosol
generating
material 5 in a wrapping apparatus 306.
In one embodiment, the wrapping apparatus 306 may comprise, for example, a
garniture tongue 307, a garniture belt (not shown) and a belt drive (not
shown) that
drives the garniture belt (not shown). The belt drive may comprise, for
example, one or
more pulleys or wheels that are driven by an electric motor to drive the
garniture belt.
The garniture belt extends through the garniture tongue 307. The web W2 of
first sheet
material 6 with the individual portions of substrate 2 thereon (hereinafter
`the
arrangement') overlies the garniture belt such that operation of the belt
drive feeds the
arrangement through the garniture tongue 307. The garniture tongue 307
comprises a
first portion (not shown) that is shaped to form the arrangement into a U-
shape as it
passes through the garniture tongue 307. The second aerosol generating
material 5 is
fed into the garniture tongue 307 to be received in the U-shaped portion of
the
arrangement of the web W2 and substrate 2.
The U-shaped arrangement then passes through a second portion (not shown) of
the
garniture tongue 307 that is shaped to fold a first longitudinal edge (not
shown) of the
web W2 over an opposite second longitudinal edge (not shown) such that the
arrangement exiting the garniture tongue 307 is formed into a cylinder. In the
present
example, said first longitudinal edge of the web W2 is proximate the uncovered
region
8 of the web W2 such that the uncovered region 8 of the web W2 is adhered to
an outer
surface of the web W2 to form a cylinder. In some embodiments, the first
portion of the
garniture tongue 307 is generally U-shaped in cross-section and the second
portion of
the garniture tongue 307 is generally 0-shaped in cross-section.
As the second aerosol generating material 5 passes through the garniture
tongue 307, it
is formed into a body of material 3. In the present example, the second
aerosol
generating material 5 is formed into a cylinder. However, it should be
recognised that
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in alternative embodiments the body of material 3 may have a different shape,
for
example, having a square, rectangular, oval or triangular cross-section.
In some embodiments, the wrapping apparatus 306 further comprises an adhesive
applicator (not shown) configured to apply a line of adhesive to the web W2
(for
example, to the uncovered region 8) such that when the web W2 passes through
the
second portion (not shown) of the garniture tongue 307, the first longitudinal
edge is
folded over the opposite second longitudinal edge of the web W2 and is glued
in
position by the line of adhesive. Thus, a continuous rod R is formed
comprising the
io body of material 3 that is intermittently circumscribed by the
individual portions of the
substrate 2 and is continuously circumscribed by the first wrapping material
6.
In alternative embodiments (not shown), the wrapping apparatus 306 has a
different
arrangement, for example, comprising one or more drums or conveyor belts that
are
configured to convey portions of the first wrapping material 6, substrate 2
and second
aerosol generating material 5 such that the components are combined into a
rod.
In a seventh step (shown in Fig. 15G), the continuous rod R is cut to form
individual
articles 1 or to form multiple-length articles 1 that may then subsequently
cut to form
individual articles 1 (before or after optionally being combined with further
components). In the present example, the continuous rod R is cut along dashed
line Zz-
Z2 (shown in Fig. 15F) by a cutting device 308, for example, a cutting drum,
reciprocating blade/knife or laser.
The method described above is thus a continuous process wherein a continuous
rod R
is formed and then the end of the continuous rod R is repeatedly cut to form a
plurality
of articles 1.
It has been found that providing the first aerosol generating material 4 on a
substrate 2
allows for a more accurate positioning of the first aerosol generating
material 4 and
thus for a more consistent manufacturing of the articles 1.
It should be recognised that various steps of the method described above may
be
modified, performed in a different order, or omitted entirely. For example, in
one
alternative embodiment the steps of cutting and spacing individual potions of
the
substrate 2 may be omitted. Instead, the first aerosol generating material 4
is applied to
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the web Wi of the second sheet material 7 which is then combined with the web
W2 of
the first sheet material 6, and subsequently fed through a wrapping apparatus
306 to
form an article 1 wherein the substrate 2 extends between the first and second
ends of
the body of material 3 (for example, to produce an article 1 of the
configuration shown
in Fig. 9).
In another alternative, the body of material 3 is pre-formed and then the
arrangement
of the substrate 2 and first sheet material 6 are wrapped about the body of
material 3.
In some embodiments (not shown), individual portions of first sheet material 6
are
io formed that each has an individual portion of substrate 2 adhered
thereto, wherein the
individual portions of first sheet material 6 and respective individual
portions of
substrate 2 are each wrapped about a respective body of material 3.
Referring now to Fig. 17, an alternative article 1 for an aerosol provision
device 200 is
shown. The article 1 has similar features to the article 1 described above in
relation to
Figs. 1 to 7, with like features retaining the same reference numerals, and
may have any
of the variations of features described herein. The difference is that the
article 1 does
not comprise a body of material 3. Instead, the first sheet material 6 with
substrate 2
thereon are formed into a cylinder such that the substrate 2 surrounds an
empty space
10. The space lo forms a passage 10 that allows gas to pass through the
article 1.
Referring now to Fig. 18, an alternative article 1 for an aerosol provision
device 200 is
shown. The article 1 has similar features to the article 1 described above in
relation to
Figs. 1 to 7, with like features retaining the same reference numerals, and
may have any
of the variations of features described herein. The difference is that the
substrate 2 does
not circumscribe the body of material 3. Instead, the body of material 3 is
provided
axially upstream of the substrate 2.
In an alternative embodiment (not shown), the body of material 3 may be
provided
downstream of the substrate 2. In yet another embodiment (not shown), a first
body of
material may be provided upstream of the substrate 2 and a second body of
material
may be provided downstream of the substrate 2.
The body of material 3 being provided upstream and/or downstream of the
substrate 2
facilitates the body of material 3 being heated separately to the substrate.
For instance,
a first heater may be arranged to heat the body of material 3 and a second
heater may
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be arranged to heat the substrate 2. Thus, the substrate 2 and body of
material 3 may be
heated at different times and/or heated to different temperatures.
In each of the above embodiments that are described as having a body of
material 3, the
body of material is described as comprising, consisting of, or essentially
consisting of a
second aerosol generating material 5. However, it should be recognised that in
other
embodiments the body of material 3 does not comprise, consist of, or
essentially consist
of any aerosol generating material. For instance, the body of material 3 may
be formed
from a paper sheet that is gathered to form a body of material 3, without any
aerosol
io generating material. In another embodiment, the body of material 3 may
be formed
from a sheet that does not comprise any aerosol generating material.
In the articles 1 shown in Figs. 1, 8, 9, 13, and 15G, the body of material 3
is shown
being compressed radially inwardly in the region of the substrate 2. That is,
when the
substrate 2 and first sheet material 6 are wrapped about the body of material
3, the
substrate 2 deforms the body of material 3 radially inwardly to compress the
body of
material 3. However, in other embodiments, less material is provided in the
portion of
the body of material 3 that is wrapped in the substrate 2 in order to
accommodate the
substrate 2 without the body of material 3 being compressed. In one such
embodiment,
a circumferential groove may be provided in the body of material 3 that
accommodates
the substrate 2. In other embodiments, the body of material 3 is a cylindrical
rod and
the substrate 2 and first sheet material 6 are wrapped about the body of
material 3 such
that the cylindrical rod is not compressed or is substantially not compressed
by the
substrate 2.
In all of the above examples, the first and/or second aerosol generating
material 4, 5
may comprise, consist of, or essentially consist of extruded or compressed
bodies of
tobacco material and, preferably, the extruded or compressed bodies of tobacco
material comprise beads of tobacco material.
In each of the above examples, the first and/or second aerosol generating
material 4, 5
may comprise, consist of, or essentially consist of reconstituted tobacco and,
preferably,
comprises a shredded sheet of reconstituted tobacco.
In all of the above examples, the first and/or second aerosol generating
material 4, 5
may comprise, consist of, or essentially consist of lamina tobacco.
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In all of the above examples, the first and/or second aerosol generating
material 4, 5
may comprise, consist of, or essentially consist of reconstituted tobacco and
lamina
tobacco and, preferably, the reconstituted tobacco and lamina tobacco are
mixed
together.
In all of the above examples, the body of material 3 may comprise, consist of,
or
essentially consist of a sheet of aerosol generating material that is gathered
to form the
body of material 3 and, preferably, the sheet material is crimped. Preferably,
the sheet
io is a sheet of reconstituted tobacco.
In all of the above examples, the first and/or second aerosol generating
material 4, 5
may comprise, consist of, or essentially consist of a sheet of aerosol
generating material
that is cut into strips. Preferably, the sheet is a sheet of reconstituted
tobacco. For
example, the second aerosol generating material 5 may be cut into strips that
are then
arranged to form the body of material 3.
In all of the above examples, the first and/or second aerosol generating
material 4, 5
may comprise tobacco material, and wherein the tobacco material is
manufactured only
from tobacco lamina and no other types of tobacco material.
In all of the above examples, the first and second aerosol generating
materials 4, 5 are
manufactured from the same aerosol generating starter materials that are
processed to
have different forms.
In each of the examples of article described above (including each of the
articles shown
in Figs. 1 to 9, 12, 13, 15G, 17 and 18), the first and second aerosol-
generating materials
4, 5 may have different densities. Otherwise, the aerosol-generating materials
of the
article may be the same or different. In other embodiments, the densities of
the first
and second aerosol-generating materials 4, 5 may be the same.
In some embodiments, the article further comprises a third aerosol generating
material, which may a different density to the first and/or second aerosol
generating
material.
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It has been found that providing different densities of first and second
aerosol
generating materials 4, 5 means that the higher density material heats up
slower when
both materials are exposed to the same heating and thus the higher density
material
will release its volatile compounds (e.g. nicotine) at a slower rate than the
lower density
material. In some embodiments, the first aerosol-generating material 4 has a
greater
density than the second aerosol-generating material 5 so that the first
aerosol
generating material 4 heats up slower than the second aerosol generating
material 5
when exposed to the same heating and will release its volatile compounds (e.g.
nicotine) at a slower rate than the second aerosol-generating material 5
(however, in
_ro other embodiments the reverse may be true such that the second aerosol
generating
material 5 has a higher density than the first aerosol generating material 4).
Thus,
combining aerosol-generating materials with different densities provides a
more
consistent and longer-lasting release of volatile compound(s). In some
embodiments,
the aerosol-generating materials of different densities are combined with
separate
heating of these materials at optionally different times and/or different
temperatures,
thereby allowing the provision of a more tailored release of the volatile
compound(s)
over the period of consumption of the article, for example. Alternatively, it
may be
desirable to have a more rapid or greater release of volatiles towards the
beginning of
the consumption of the article, to provide the user with a greater initial
impact from
use. The capacity to control the aerosol generation and volatile compound
release may
be particularly advantageous because the article can be made relatively small
whilst still
achieving a particular desired release of volatile compound(s) over the period
of
consumption.
In some embodiments, one of the first and second aerosol generating materials
4, 5 has
a density that is at least about 25% higher than the density of the other one
of the first
and second aerosol generating materials 4, 5 and, optionally, at least about
30%, 35%,
40%, 45%, 50%, 55%, 60%, 65%, 70% or 75% higher. The said one of the first and
second aerosol generating materials 4, 5 may have a density that is no more
than about
200% higher than the density of the other one of the first and second aerosol
generating materials 4, 5 and, optionally, no more than about 150%, 125%, mo%
or
75% higher. In some embodiments, the one of the first and second aerosol
generating
materials 4, 5 has a density that is from about 25% to about 75% higher than
the density
of the other one of the first and second aerosol generating materials 4, 5.
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In some embodiments, said one of the first and second aerosol generating
materials 4,
has a density of from at least about 0.4 g/cm3 and optionally from at least
about 0.5,
o.6, 0.7, o.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3.
The said one of the
first and second aerosol generating materials 4, 5 may have a density of no
more than
5 about 2 g/cm3 and, optionally no more than about 1.9, 1.8, 1.7, 1.6, 1.5,
1.4, 1.3, 1.2, 1.1,
1, 0.9, 0.8, 0.7, 0.6 or 0.5 g/cm3. In some embodiments, the density of said
one of the
first and second aerosol generating materials 4, 5 is from about 0.4 to 1.99
g/cm3.
In some embodiments, the said other one of the first and second aerosol
generating
io materials 4, 5 has a density of from at least about 0.1 g/cm3 and
optionally from at least
about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, o.8 or 0.9 g/cm3. The said other one of
the first and
second aerosol generating materials 4, 5 may have a density of no more than
about 1
g/cm3 and, optionally no more than about 0.9, o.8, 0.7, o.6, 0.5, 0.4, 0.3 or
0.2 g/cm3.
In some embodiments, the density of the said other one of the first and second
aerosol-
1,5 generating materials 4, 5 is from about 0.1 to 0.9 g/cm3.
In some embodiments, the first and second aerosol-generating materials 4, 5
comprise
the same components. Upon heating, they will therefore release very similar
aerosols,
potentially having the same content of active substance and/or flavour, etc.
Their
20 different densities allow the aerosol to be generated from the two
materials at different
speeds and/or different times during heating.
In other embodiments, the first and second aerosol-generating materials 4, 5
comprise
different components (and may have the same or different densities). Upon
heating,
25 they will therefore release different aerosols, potentially having
different make-up of
active substance and/or flavour, etc. Their different densities allow the
different
aerosols to be generated from the two materials at different speeds and/or
different
times during heating, potentially providing an aerosol that changes over the
period of
use.
In some embodiments, the first aerosol-generating material 4 and the second
aerosol-
generating material 5 each comprise a botanical material, for example,
tobacco. The
tobacco will contain volatile components including nicotine, aromas and
flavours. The
tobacco may be any type of tobacco and any part of the tobacco plant,
including tobacco
leaf, lamina, stem, stalk, ribs, scraps and shorts or mixtures of two or more
thereof.
Suitable tobacco materials include the following types: Virginia or flue-cured
tobacco,
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Burley tobacco, Oriental tobacco, or blends of tobacco materials, optionally
including
those listed here. The tobacco may be expanded, such as dry-ice expanded
tobacco
(DIET), or processed by any other means. In some embodiments, the tobacco
material
may be reconstituted tobacco material. The tobacco may be pre-processed or
unprocessed, and may be, for instance, solid stems (SS); shredded dried stems
(SDS);
steam treated stems (STS); or any combination thereof. The tobacco material
may be
fermented, cured, uncured, toasted, or otherwise pre-treated.
The first and second aerosol-generating materials 4, 5 may comprise different
tobacco.
Alternatively, the tobacco may be the same, but is provided in a different
form, so that
one of the first and second aerosol-generating materials 4, 5 has a greater
density than
the other one of the first and second aerosol-generating materials 4, 5.
In some embodiments, the first aerosol-generating material 4 has at least one
(further)
different characteristic to the second aerosol generating material 5. The
different
characteristic may be one or more of form, size, ,water content, amount (by
weight),
material or materials, or proportion of materials that make the first and
second aerosol-
generating materials 4, 5 (including the recipe of the aerosol generating
materials when
each is manufactured from more than one material). In some embodiments, the
first
and second aerosol-generating materials 4, 5 do not have a different
characteristic,
other than their different densities. In other embodiments, the densities of
the first and
second aerosol generating materials is the same.
In some embodiments, the second aerosol-generating material 5 comprises one or
more
tobacco in the form of cut rag. This tobacco material may lamina or
reconstituted
tobacco material. In some embodiments, the second aerosol-generating material
5 is a
blend comprising both lamina and reconstituted tobacco. For example, the ratio
of
lamina and reconstituted tobacco may from about to about 4:1.
In some embodiments, the first aerosol-generating material 4 has a greater
density
than the second aerosol-generating material 5. In some embodiments, this more
dense,
first aerosol-generating material 4 comprises particles or may be in the form
of beads
or one or more sheets. Each bead or sheet may be formed from smaller particles
that
have been agglomerated. However, it should be recognised that in other
embodiments,
the second aerosol-generating material 5 may be denser than the first aerosol
generating material 4 and, for example, may be in the form of beads or one or
more
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sheets. In some embodiments, the both of the first and second aerosol
generating
materials 4, 5 may be in the form of beads or one or more sheets and,
optionally, may
be processed such that one of the first and second aerosol generating
materials 4, 5 has
a higher density than the other one of the first and second aerosol generating
materials
4, 5. In some embodiments, the beads 4, 5 may be cast in a sheet material.
As used herein, the term "beads" is meant to include beads, pellets, or other
discrete
small units that have been shaped, moulded, compressed or otherwise fashioned
into a
desired shape. The beads may have smooth, regular outer shapes (e.g., spheres,
cylinders, ovoids, etc.) and/or they may have irregular outer shapes.
In some embodiments, the beads have a diameter (for example, as measured by
sieving) of at least about 0.5 mm and, optionally at least about 1, 1.5, 2.
2.5 or 3 mm.
The beads may have a diameter (for example, as measured by sieving) of no more
than
about 5 mm and, optionally no more than about 4.5, 4, 3.5, 3, 2.5, 2 or 1.5
mm. In some
embodiments, the diameter of each bead may range from about 0.5 mm to about 3
mm,
or from about 1 mm to about 2 mm. The size of the beads may refer to their
average
size, such as the number or volume mean size.
In some embodiments, the desired density of the aerosol-generating material 4,
5 is
achieved or controlled through the formulation of the material and/or the
method(s) by
which the material is processed. Processes involving agglomeration, and
especially
agglomeration with the application of some of compressive forces will tend to
increase
the density of the material.
Thus, in some embodiments, the first and/or second aerosol-generating material
4, 5
comprises particles of material that are agglomerated.
In the case of a sheet material, the sheet may be formed from particles of
material that
are bound and optionally compressed to form a sheet with the desired
dimensions and
density.
In some embodiments, beads or pellets can be formed using a so called
marumarising
process.
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In some embodiments, the agglomeration is by pelletisation. Pelletisation is
an
agglomeration process that converts fine particles of material, optionally
together with
excipient, into free-flowing units, referred to as pellets. Depending on the
type of
equipment and processes selected, pellet formation and growth may occur in a
number
of ways. These pellets may be formed by agitation and as the particles are
rolled and
tumbled in the presence of appropriate quantities of a liquid, agglomerates
are formed.
Balling may involve the use of apparatus such as pans, discs, drums or mixers
to
produce pellets. Compaction pelletisation is a form of pressure agglomeration,
in
which the particles are forced together by a mechanical force, optionally with
rcr formulation aids. The compressive forces mean that the pellets formed
have increased
density compared to the starting material.
In some embodiments, the agglomeration is by extrusion. In some embodiments,
pellets formed by pelletisation may be extruded to form higher density
extrudates.
The particles to be extruded may have a size selected to produce a more dense
aerosol-
generating material (e.g. a more dense first or second aerosol generating
material 4, 5),
which will have an impact on the heat transfer within the material and the
release of the
volatile components.
Extrusion involves feeding a composition (also referred to as a precursor
composition)
through a die to produce an extruded product. The process applies pressure to
the
composition combined with shear forces.
Extrusion may be performed using one of the main classes of extruders: screw,
sieve
and basket, roll, ram and pin barrel extruders. A single screw or twin screw
extruder
may be used. Forming the tobacco beads by extrusion has the advantage that
this
processing combines compression, mixing, conditioning, homogenizing and
moulding
of the composition.
In some embodiments, during extrusion the free-flowing composition comprising
particles, such as tobacco particles, is exposed to elevated pressure and
temperature
and is forced though an orifice, such as a shaping nozzle or die, to form an
extrudate.
In some embodiments, the extrudate has a rod-like form and it may be cut into
segments of a desired length.
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In some embodiments, the composition is exposed to temperatures from about 40
C to
about 150 C, or from about 8o C to about 130 C, or from about 6o C to about 95
C
within the extruder. In some embodiments, including those using double
extrusion, the
precursor composition is exposed to temperatures from about 70 C to about 95 C
within the extruder. In some embodiments, including those using single
extrusion, the
precursor composition is exposed to temperatures from about 60 C to about 80 C
within the extruder.
The composition may be exposed to pressures (immediately before the die or
nozzle)
_ro ranging from about 2 bar to about 100 bar, or from about 5 bar to about
6o bar,
depending on the design of the die or nozzle being used. The higher the
pressure, the
greater the density of the extrudate is likely to be. Thus, the extrusion
process may be
adjusted to provide extruded aerosol-generating material with the desired
density.
In some embodiments where tobacco particles are extruded, due to the
relatively high
density of the extrudate and the relatively open surface of the tobacco
particles within
it, the tobacco beads formed from the extrudate exhibit good heat transfer and
mass
transfer, which has a positive impact on the release of tobacco constituents,
such as
flavours and nicotine.
In some embodiments, the extrusion may be a generally dry process, with the
composition including aerosol generating particles that are dry or
substantially dry.
The composition may optionally include other particulate materials including,
for
example, base, diluent, solid aerosol forming agents, solid flavour modifiers,
etc.
In some embodiments, liquids may be added to the composition prior to or
during the
extrusion process. For example, water may be added, for example as a
processing aid
to assist dissolution or solubilisation of components of the composition, or
to aid
binding or agglomeration. Alternatively or additionally, a wetting agent may
be added
to the composition.
In some embodiments, the liquid may be an aerosol former material such as
glycerol or
others discussed herein. When liquid is added to the composition in this
manner, the
liquid is applied not only on the surface, but, as a result of the extruder
pressure
combined with the intensive mixing by high shear forces, the extrudate becomes
impregnated with the liquid. Where the liquid is an aerosol former material,
this can
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result in a high availability of the aerosol former material in the resultant
beads to
enhance evaporation of volatile components.
In some embodiments, the amount of aerosol former material incorporated into
the
extruded beads may be up to about 30% by weight and even up to about 40% by
weight.
Ordinarily, such high amounts of aerosol former material could render the
composition
difficult to handle. However, this is less of an issue where extrusion results
in the
particles being impregnated with the aerosol former material. It may be
desirable to
include an aerosol former material in an amount such as at least about 10% or
at least
about 20% by weight where the beads are to generate an aerosol in addition to
releasing
the volatile components. Smaller amounts of aerosol former material, such as
up to
about 5% by weight, may be sufficient where the beads' primary function is to
release
volatile constituents carried by the beads into an existing aerosol or air
flow.
In some embodiments, the agglomerates do not include a binder or binding
additive.
For example, extruded beads may not require a binder to maintain their
structural
integrity. In other embodiments, the agglomerates comprise a binder or binding
additive. The binding additive may be selected to assist in the formation of
an
agglomerated structure by helping to adhere the particles to each other and to
other
components in the composition. Suitable binding additives include, for
example,
thermoreversible gelling agents such as gelatin, starches, polysaccharides,
pectins,
alginates, wood pulp, celluloses, and cellulose derivatives such as
carboxymethylcellulose.
In some embodiments, processing by extrusion is sufficient to provide the
higher
density of the first or second aerosol-generating material 4, 5, where
desired. However,
in other embodiments, the extrudate may be further treated to increase the
density of
the first or second aerosol-generating material 4, 5.
For example, in some embodiments, the extruded aerosol-generating material
undergoes spheronisation. In spheronisation, the extruded, cylindrically
shaped
particles are broken into uniform lengths and are gradually transformed into
spherical
shapes due to plastic deformation. Where the extrudate is first broken into
uniform
lengths, spheres with a uniform diameter will be produced by the
spheronisation step.
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According to one specific example of the embodiments discussed herein, samples
of the
first aerosol-generating material 4 were produced as follows (but note that in
some
embodiments samples may be produced according to the below, which are instead
used
for the second aerosol generating material5 and/or a third aerosol generating
material).
Three sample formulations with and without binders are shown in Table 1, with
the
amounts indicated as percent wet weight basis (WWB).
Table 1
Formulation 1 Formulation 2 Formulation
3
(with binders) (without binders) (without
binders)
Tobacco 29% 75%
75%
Calcium Carbonate 29%
Water 26% 4% 9%
Glycerol 14% 20%
15%
CMC 1%
Flavour 1% 1%
The tobacco was ground to produce a fine powder, taking care not to overheat
the
tobacco. The ground tobacco particles were sieved to select those with a
desired size,
for example a particle size of less than 250 pm, of less than 100 pm or less
than 6o pm.
Next, all of the dry (non-liquid) components of the formulation were combined
and
mixed or blended in a mixer. In this particular instance, the mixture was
mixed for 1
minute at a speed to 75 RPM. This was to ensure that the dry components are
homogenou sly distributed within the mixture.
Next, half of the glycerol and half of the water were added to the dry mixture
and
mixed. Specifically, the mixture was mixed for a further minute at 75 RPM. The
remaining glycerol and water was then added and mixed, again for 1 minute at
75 RPM.
Then, to ensure that a homogenous mixture was achieved, mixing was continued
until
the mixture had a crumbly consistency that could be squeezed into a mass. In
this
specific instance, the additional mixing lasted 3 minutes.
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The mixture was then extruded using a Caleva Multilab. The extruder was
operated at
approximately 1500 rpm to produce lengths of extrudate resembling spaghetti.
The extrudate was broken into pieces of varying length as it came out of the
extruder.
These pieces were then spheronised. Spheronisation was carried out until
spherical
beads were formed. In this instance, the extrudate was initially spheronised
in a Caleva
Multilab operating at 2,500 RPM for 1 minute and then the beads were checked
for any
defects. Then, spheronisation continued for a further 1 to 2 minutes. This
spheronisation step broke the extruded tobacco into the individual pieces and
formed
io the dense, spherical beads.
In a final step, the spheronised beads were dried in an oven at 65 C for 30
minute
periods. After each drying period, the beads were weighed and drying was
halted when
the desired moisture weight loss was achieved. Generally, such drying will
take about 1
hour.
In some embodiments, the other one of the first and/or second aerosol-
generating
material 4, 5 is in the form of discrete particles, or in the form of an
agglomerated body
of particles. These particles may share various characteristics with the
(denser) one of
the first and second aerosol-generating material 4, 5, such as particle size,
but will have
a lower density. As described above, there are various ways to adjust the
density of the
aerosol-generating material 4, 5, such as the formulation and/or the
processing of the
material into particles, beads or pellets.
In some embodiments, said other one of the first and second aerosol-generating
materials 4, 5 comprises a combination of 6o% reconstituted tobacco and 40%
lamina
tobacco, with the density of this material being in the range of from about
0.1 to about
0.9 g/cm3. The other (denser) aerosol-generating materials 4, 5 comprises from
about
to about 90% tobacco, with a density in the range of from about 0.4 to about
1.99
30 g/cm3. The amount of aerosol forming material included in the first
and/or second
aerosol-generating materials 4, 5 may be from about 8 to about 15%. The
(denser) one
of the first and second aerosol-generating materials 4, 5 may comprise largely
spherical
beads with a particle size between about 0.5 and about 3 mm. In some
embodiments,
the aerosol generating material in an article comprises approximately 50% of
the first
aerosol-generating material 4 and about 50% of the second aerosol-generating
material
5, by weight. Thus, for example, an article comprising 260 mg of aerosol-
generating
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material may comprise 130 mg of the first aerosol-generating material 4 and
130 mg of
the second aerosol-generating material 5.
In some embodiments where the aerosol-generating material comprises tobacco,
the
tobacco is present in an amount of between about 10% and about 90% by weight
of the
aerosol generating material.
In some embodiments, the tobacco may be present in an amount of at least about
10%,
11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%,
26%,
27%, 28%, 29%, 30%, 31% 32% 33%, 34%, or at last about 35% tobacco based on
the
weight of the aerosol generating material.
In some embodiments, the tobacco may be present in an amount of no more than
about
90%, 89%, 88%, 87%, 86%, 85%, 84%, 83%, 82%, 81%, 80%, 75%, 70%, 65%, 60%,
55%, 50%, 45%, or no more than about 40% tobacco based on the weight of the
aerosol
generating material.
The tobacco described herein may contain nicotine. In some embodiments, the
nicotine content is from 0.5 to 2% by weight of the tobacco, and may be, for
example,
from 0.5 to 1.75% by weight of the tobacco, from o.8 to 1.2% by weight of the
tobacco or
from about o.8 to about 1.75% by weight of the tobacco. In some embodiments,
the
nicotine content may be from 0.8 to 1% by weight of the tobacco.
In some embodiments, the first and second aerosol-generating materials 4, 5
have the
same nicotine content.
In some embodiments, the first and second aerosol-generating materials 4, 5
comprise
one or more volatile components. In some embodiments, the first and second
aerosol-
generating materials 4, 5 have the same volatile component content.
In some embodiments, the first and/or second aerosol-generating materials 4, 5
comprise tobacco. For example, the first and/or second aerosol-generating
materials 4,
5 may comprise from about 8o to about 350 mg of tobacco. In some specific
embodiments, the aerosol-generating material in an article or consumable has a
weight
of 260 mg, comprising a combination of 130 mg of a second aerosol-generating
material 5, for example comprising a blend of lamina and reconstituted
tobacco, and
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130 mg of a first aerosol-generating material 4, for example comprising higher
density
tobacco beads.
In some embodiments, the article comprises regions of aerosol-generating
material,
wherein each region comprises aerosol-generating material contain an equal
amount of
tobacco. In alternative embodiments, the regions may contain different amounts
of
tobacco. Where the total amount of tobacco is from about 80 to about 350 mg,
one
region of aerosol-generating material comprises from about 20 to about 330 mg,
or
from about 50 to about 300 mg, or from about 40 to about 125 mg of tobacco and
the
_ro other region of aerosol-generating material comprises from about 20 to
about 330 mg,
or from about 30 to about 300 mg or from about 40 to about 125 mg of tobacco.
According to the present disclosure, there is also provided a kit of parts
comprising a
article 1 according to any of the examples described herein and an aerosol
provision
device 200.
According to the present disclosure, there is also provided a package (not
shown)
comprising a plurality of articles according to any of the examples described
herein. In
some embodiments, the package is hermetically sealed. The package may comprise
a
container comprising a body and a lid, wherein a space is provided within the
container
body to receive the plurality of articles. The lid may, for example, be a
hinged lid, a
snap-fit lid or lid that is connected by a screw thread.
The various embodiments described herein are presented only to assist in
understanding and teaching the claimed features. These embodiments are
provided as
a representative sample of embodiments only, and are not exhaustive and/or
exclusive.
It is to be understood that advantages, embodiments, examples, functions,
features,
structures, and/or other aspects described herein are not to be considered
limitations
on the scope of the invention as defined by the claims or limitations on
equivalents to
the claims, and that other embodiments may be utilised and modifications may
be
made without departing from the scope of the claimed invention. Various
embodiments
of the invention may suitably comprise, consist of, or consist essentially of,
appropriate
combinations of the disclosed elements, components, features, parts, steps,
means, etc,
other than those specifically described herein. In addition, this disclosure
may include
other inventions not presently claimed, but which may be claimed in future.
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