Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
WO 2023/118845
PCT/GB2022/053317
AN ARTICLE FOR USE IN AN AEROSOL PROVISION SYSTEM AND A METHOD
OF MANUFACTURING AN ARTICLE
TEC I INIC AL HELD
The present disclosure relates to an article for use in an aerosol provision
system and a
method of manufacturing an article for use in an aerosol provision system. The
present
disclosure also relates to an aerosol provision system comprising an article
and to a package of
articles. The present disclosure also relates to a sheet material for forming
a receiving member
for an aerosol provision system article, a receiving member for an aerosol
provision device
system, and a method of manufacturing a sheet material.
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 an
article for
use in an aerosol provision system, the article comprising: an aerosol-
generating material; a
receiving member that comprises an end wall, an open end, and a peripheral
wall that surrounds
a storage area containing the aerosol-generating material; and, a blocking
member comprising
a body of material arranged to resist the aerosol-generating material from
moving out of the
storage area through the open end of the receiving member.
In some embodiments, the receiving member comprises a sheet material.
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In some embodiments, the sheet material comprises paper and/or foil.
In some embodiments, the sheet material is folded to form the end wall.
In some embodiments, the sheet material comprises a plurality of end portions
that
extend radially inwardly to form the end wall and, preferably, each end
portion comprises a
flap of the sheet material.
In some embodiments, the end portions are fixed together by adhesive.
In some embodiments, the end wall is gas permeable.
In some embodiments, the end wall comprises one or more apertures.
In some embodiments, the receiving member is generally cup-shaped.
In some embodiments, the article further comprises a wrapper that secures the
blocking
member relative to the receiving member and, preferably, wherein the wrapper
circumscribes
the receiving member and the blocking member.
In some embodiments, the wrapper is adhered to the receiving member and the
blocking
member.
In some embodiments, the blocking member is generally cylindrical.
In some embodiments, the blocking member comprises the end of a rod of aerosol
generating material and, preferably, said end of the rod has a higher density
than another
portion of the rod.
In some embodiments, said end of the rod has a density that is at least 10%
higher than
said another portion of the rod and, preferably, at least 20% higher than said
another portion of
the rod.
In some embodiments, the rod is a tobacco rod.
In some embodiments, the body of material comptises a plug of material.
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In some embodiments, the body of material is disposed adjacent to the open end
of the
receiving member.
In some embodiments, at least a portion of the body of material is received
within the
open end of the receiving member.
The article 1 may have an axial length 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.
The article 1 may have an axial length in the range of 10 to 36 mm and,
preferably, in
the range of 14 to 32 mm, in the range of 20 to 26 mm, or in the range of 22
to 24 mm.
In some embodiments, the body of material has an axial length in the range of
3 to 20
mm and, preferably in the range of 4 to 15 mm, 5 to 12 mm or 7 to 10 mm.
In some embodiments, the body of material has an axial length of at least 3 mm
and,
preferably, at least 4, 5, 6 or 7 mm.
In some embodiments, the body of material has an axial length of at most 20 mm
and,
preferably, at most 15, 12, 10 or 8 mm.
In some embodiments, the body of material comprises an aerosol-generating
material.
In some embodiments, the body of material comprises an aerosol-former
material.
In some embodiments, the blocking member comprises an aerosol-generating
material
comprising: from about 10 to about 50 wt% aerosol-former material; from about
15 to about
60 wt% gelling agent; and optionally filler; wherein the wt% values are
calculated on a dry
weight basis.
In some embodiments, the aerosol-generating material of the blocking member
comprises a flavourant.
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In some embodiments, the aerosol generating material in the storage area is a
first
aerosol generating material and the aerosol generating material of the
blocking member is 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 0.4 g/cm3 to about 2 g/cm3.
In some embodiments, the other 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 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 sonic embodiments, the second aerosol-generating material comprises one or
more
tobacco material selected from the group consisting of lamina and
reconstituted tobacco
material.
In some embodiments, at least one of the first and second aerosol-generating
material
comprises a combination of lamina and reconstituted tobacco material. In some
embodiments,
the lamina and reconstituted tobacco material are present in the aerosol-
generating material in
a ratio of from 1:4 to 4:1, by weight.
In sonic embodiments, the first and second aerosol-generating materials have
the same
levels of a volatile compound. In some embodiments, the volatile compound is
nicotine.
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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 blocking member comprises tobacco material.
In some embodiments, the blocking member comprises paper.
In some embodiments, the body of material comprises a sheet material that is
arranged
to form the body of material and, preferably, the sheet material is gathered
to form the body of
material.
In some embodiments, the sheet material is crimped.
In some embodiments, the sheet material of the body of material comprises one
or more
of: aerosol generating material and/or paper. The sheet material may comprise
tobacco.
In some embodiments, the blocking member comprises an end that contacts the
aerosol-
generating material.
In some embodiments, the aerosol-generating material is a loose material.
In some embodiments, the aerosol-generating material comprises, consists of,
or
essentially consists of, tobacco material.
In some embodiments, the article further comprises a cooling section and,
preferably,
wherein the cooling section is arranged such that, in use of the article with
an aerosol provision
device, the cooling section is downstream of the receiving member.
In some embodiments, the cooling section comprises an aerosol generating
material
and, preferably, comprises an aerosol generating material in the form of a
plug.
In some embodiments, the cooling section comprises a flavourant.
In some embodiments, the blocking member is upstream of the storage area. In
other
embodiments, the blocking member is downstream of the storage area.
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In some embodiments, the end wall is upstream of the storage area. In other
embodiments, the end wall is downstream of the storage area.
In some embodiments, the article further comprises a plug of material provided
on the
other side of the end wall to the storage area.
According to the present disclosure, there is also provided an aerosol
provision system
comprising the article as disclosed herein and an aerosol provision device.
According to the present disclosure, there is also provided a package
comprising a
plurality of articles as disclosed herein. Preferably, the plurality of
articles are hermetically
scaled.
According to the present disclosure, there is also provided a method of
manufacturing
an article for use in an aerosol provision system, the method comprising:
providing a receiving
member that comprises an end wall, an open end, and a peripheral wall that
surrounds a storage
area containing an aerosol-generating material; and, providing a blocking
member comprising
a body of material arranged to resist the aerosol-generating material from
moving out of the
storage area through the open end of the receiving member.
In some embodiments, providing the receiving member comprises forming the
receiving member and then providing the aerosol-generating material in the
storage area.
In some embodiments, providing the receiving member comprises forming the
receiving member around the aerosol-generating material.
In some embodiments, the receiving member comprises a sheet material and,
preferably, wherein the sheet material comprises paper and/or foil.
In some embodiments, providing the receiving member comprising arranging the
sheet
material to form the peripheral wall such that the peripheral wall is
generally cylindrical and,
preferably, comprising lolling the sheet material to form the peripheral wall.
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In some embodiments, providing the receiving member comprises folding the
sheet
material to form the end wall of the receiving member.
In some embodiments, the method comprises forming a plurality of end portions
in the
sheet material and, preferably, forming the end portions comprising providing
one or more cuts
into the sheet material.
In some embodiments, the method comprises adhering the end portions together
using
an adhesive.
In some embodiments, the method comprises forming one or more apertures in the
portion of the sheet material that comprises the end wall.
In some embodiments, the or each aperture is formed in the sheet material
before the
sheet material is formed into the receiving member. In other embodiments, the
or each aperture
is formed in the sheet material after the sheet material is formed into the
receiving member.
In some embodiments, the receiving member is generally cup-shaped.
In some embodiments, the method comprises securing the blocking member
relative to
the receiving member using a wrapper and, preferably, wherein securing the
blocking member
relative to the receiving member using the wrapper comprises circumscribing
the blocking
member and receiving member with the wrapper.
In some embodiments, the wrapper is adhered to the receiving member and the
blocking
member.
In some embodiments, the blocking member is generally cylindrical.
In some embodiments, the blocking member comprises the end of a rod of aerosol
generating material and, preferably, said end of the rod has a higher density
than another
portion of the rod and, preferably, said rod is a tobacco rod.
In some embodiments, the blocking member comprises a plug of material.
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In some embodiments, the body of material is disposed adjacent to the open end
of the
receiving member.
In some embodiments, at least a portion of the body of material is received
within the
open end of the receiving member.
In some embodiments, the body of material has an axial length in the range of
3 to 20
mm and, preferably in the range of 4 to 15 mm, 5 to 12 mm or 7 to 10 mm.
In some embodiments, the body of material comprises an aerosol-generating
material.
In some embodiments, the body of material comprises an aerosol-former
material.
In some embodiments, the blocking member comprises an aerosol generating
material.
In some embodiments, the blocking member comprises tobacco material.
In some embodiments, the blocking member comprises a sheet material and,
preferably,
wherein the method comprises arranging the sheet material to form the body of
material and,
preferably, comprises gathering the sheet material to form the body of
material.
In some embodiments, the sheet material is crimped and, preferably, the method
comprises crimping the sheet material.
In some embodiments, the sheet material of the body of material comprises one
or more
of: aerosol generating material and/or paper. The sheet material may comprise
tobacco
In some embodiments, the blocking member comprises an end that contacts the
aerosol-
generating material.
In some embodiments, the aerosol-generating material in the storage area is a
loose
material.
In some embodiments, the aerosol-generating material in the storage area
comprises,
consists of, or essentially consists of, tobacco material.
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In some embodiments, the tobacco material comprises tobacco beads and,
preferably,
wherein the tobacco material further comprises another tobacco material other
than tobacco
beads.
In some embodiments, the method comprises providing a cooling section and
incorporating the cooling section into the article and, preferably, wherein
the cooling section
is disposed such that, in use of the article, the cooling section is
downstream of the receiving
member.
In some embodiments, the cooling section comprises an aerosol generating
material
and, preferably, comprises an aerosol generating material in the form of a
plug.
In some embodiments, the cooling section comprises a flavourant.
In some embodiments, the blocking member is upstream of the storage area. In
other
embodiments, the blocking member is downstream of the storage area.
In some embodiments, the end wall is upstream of the storage area. In other
embodiments, the end wall is downstream of the storage area.
In some embodiments, the method comprises providing a plug of material on the
other
side of the end wall to the storage area.
According to the present disclosure, there is also provided a sheet material
for forming
a receiving member for an aerosol provision system article, wherein the sheet
material
comprises one or more regions of strength discontinuity configured to promote
folding of the
sheet material in a predetermined manner to form an end wall of the receiving
member.
In some embodiments, the one or more regions of strength discontinuity are
arranged
such that the sheet material can be folded along the one or more regions of
strength
discontinuity to form the end wall.
In some embodiments, the one or more regions of strength discontinuity
comprise one
or more of: embossing; cuts (including cuts partially through the thickness of
the sheet material
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or cuts through the entire thickness of the sheet material): pin holes; crease-
lines; score lines;
and/or, regions of reduced thickness of the sheet material.
In some embodiments, the one or more regions of strength discontinuity are
regions of
weakening.
In some embodiments, the one or more lines of strength discontinuity comprises
regions
of increased strength.
In some embodiments, the regions of strength discontinuity are continuous. In
other
embodiments, the regions of strength discontinuity are discontinuous.
In some embodiments, the one or more regions of strength discontinuity are
lines of
strength discontinuity.
In some embodiments, the sheet material has first and second edges and
wherein,
wherein at least one line of strength discontinuity extends substantially
perpendicular to the
first and second edges.
In some embodiments, the first and second edges are configured to overlap when
the
sheet material is formed into a receiving member.
In some embodiments, the sheet material has basis weight of at least 35 GSM
and,
preferably, at least 100, 150 or 200 GSM.
In some embodiments, the sheet material has basis weight of at most 300 GSM
and,
preferably, at most 250, 200 or 150 GSM.
In some embodiments, sheet material comprises one or more flaps that are
configured
to be folded to form the end wall.
In some embodiments, the one or more flaps are generally triangular.
In some embodiments, at least one of the regions of strength discontinuity are
arranged
to promote folding of the one or more flaps to form the end wall.
In some embodiments, the sheet material comprises paper and/or foil.
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According to the present disclosure, there is also provided a receiving member
for an
aerosol provision system article, wherein the receiving member comprises an
end wall, an open
end, and a peripheral wall that surrounds a storage area for containing an
aerosol-generating
material, wherein the receiving member comprises the sheet material as
disclosed herein,
wherein the sheet material is arranged to form the peripheral wall and end
wall.
According to the present disclosure there is also provided an article for use
in an aerosol
provision system comprising: the receiving member as disclosed herein; an
aerosol-generating
material provided in the storage area of the receiving member; and, a blocking
member
comprising a body of material arranged to resist the aerosol-generating
material from moving
out of the storage area through the open end of the receiving member.
In some embodiments, the article has one or more of the features of the
article as
disclosed herein.
According to the present disclosure, there is also provided a method of
manufacturing
a sheet material for an article for use in an aerosol provision system, the
method comprising
providing a sheet material and forming one or more regions of strength
discontinuity in the
sheet material arranged such that the regions of strength discontinuity
promote folding of the
sheet material in a predetermined manner to form an end wall of the receiving
member.
In some embodiments, the sheet material has any of the features of the sheet
material
disclosed herein.
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 a side-on cross sectional view of an embodiment of an article for
use with an
aerosol provision device;
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Fig. 2 is an end view of a receiving member of the article of Fig. 1;
Fig. 3 is a perspective view of the receiving member of the article of Fig. 1;
Fig. 4 is a top view of a sheet material that is used to form the receiving
member of the
article of Fig. 1, wherein the sheet material is laid flat prior to forming
the receiving member;
Fig. 5 is a side-on cross-sectional view of the sheet material rolled into a
tube;
Fig. 6 is a side-on cross-sectional view of the sheet material rolled into a
tube, with an
end folded to form an end wall;
Fig. 7 is a perspective view of a blocking member of the article of Fig. 1;
Fig. 8 is a block diagram depicting a method of manufacturing an article for
use with
an aerosol provision device;
Fig. 9 is an alternative embodiment of a sheet material that is used to form a
receiving
member of an article for use with an aerosol provision device, wherein the
sheet material is
laid flat prior to forming the receiving member;
Fig. 10 is another alternative embodiment of a sheet material that is used to
form a
receiving member of an article for use with an aerosol provision device,
wherein the sheet
material is laid flat prior to forming the receiving member;
Fig. 11 is cross-sectional side view of an alternative blocking member;
Fig. 12 is a cross-sectional side view of another alternative blocking member;
Fig. 13 is a cross sectional view of an embodiment of a non-combustible
aerosol
provision device;
Fig. 14 is a simplified schematic of the components within the housing of the
aerosol
provision device shown in Fig. 13;
Fig. 15 is a cross sectional view of the non-combustible aerosol provision
device shown
in Fig. 13 with the article shown in Fig. 1 inserted into the device; and,
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Fig. 16 is a side-on cross sectional view of another embodiment of an article
for use
with an aerosol provision device.
DETAILED DESCRIPTION
As used herein, the term "delivery system" is intended to encompass systems
that
deliver at least one substance to a user, and includes: combustible aerosol
provision systems,
such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-
own or for make-
your-own cigarettes (whether based 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.
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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.
In some embodiments, the non-combustible aerosol provision system is a hybrid
system
to generate aerosol using a combination of aerosol-generating materials, one
or a plurality of
which may be heated. Each of the aerosol-generating materials may be, for
example, in the
form of a solid, liquid or gel and may or may not contain nicotine. In some
embodiments, the
hybrid system comprises a liquid or gel aerosol-generating material and a
solid aerosol-
generating material. The solid aerosol-generating material may comprise a
plant based
material, for example, tobacco or a non-tobacco product.
Typically, the non-combustible aerosol provision system may comprise a 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.
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The power source may, for example, be an electric power source or an
exothermic power
source. In some embodiments, the exothermic power source comprises a carbon
substrate
which may be energised so as to distribute power in the form of heat to an
aerosol-generating
material or to a heat transfer material in proximity to the exothermic power
source.
In some embodiments, the non-combustible aerosol provision system comprises an
area
for receiving the consumable, an aerosol generator, an aerosol generation
area, a housing, a
mouthpiece, a filter and/or an aerosol-modifying agent.
In some embodiments, the consumable for use with the non-combustible aerosol
provision device may comprise aerosol-generating material, an aerosol-
generating material
storage area, an aerosol-generating material transfer component, an aerosol
generator, an
aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or
an aerosol-
modifying agent.
The consumable comprises a substance to be delivered. The substance to be
delivered
is an aerosol-generating material. As appropriate, the material may comprise
one or more
active constituents, one or more flavours, one or more aerosol-former
materials, and/or one or
more other functional materials.
In some embodiments, the substance to be delivered comprises an active
substance. The
active substance as used herein may be a physiologically active material,
which is a material
intended to achieve or enhance a physiological response. The active substance
may for example
be selected from nutraceuticals, nootropics, psychoactives. The active
substance may be
naturally occurring or synthetically obtained. The active substance may
comprise for example
nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C,
melatonin, cannabinoids,
or constituents, derivatives, or combinations thereof. The active substance
may comprise one
Or more constituents, derivatives or extracts of tobacco, cannabis Or another
botanical. In some
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embodiments, the active substance comprises nicotine. In some embodiments, the
active
substance comprises caffeine, melatonin or vitamin B12.
As noted herein, the active substance may comprise or be derived from one or
more
botanicals or constituents, derivatives or extracts thereof. As used herein,
the term "botanical"
includes any material derived from plants including, but not limited to,
extracts, leaves, bark,
fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the
like. Alternatively, the
material may comprise an active compound naturally existing in a botanical,
obtained
synthetically. The material may be in the form of liquid, gas, solid, powder,
dust, crushed
particles, granules, pellets, shreds, strips, sheets, or the like. Example
botanicals are tobacco,
eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint,
spearmint,
rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel,
licorice (liquorice),
matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black
tea, thyme, clove,
cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander,
cumin, nutmeg,
oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper,
elderflower, vanilla,
wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro,
bergamot, orange
blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive,
lemon balm, lemon
basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine,
theacrine, maca,
ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof.
The mint
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 Of constituents, derivatives Or extracts thereof and the botanical
is tobacco.
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In some embodiments, the active substance comprises or derived from one or
more
botanicals or constituents, derivatives or extracts thereof and the botanical
is selected from
eucalyptus, star anise, cocoa and hemp.
In some embodiments, the active substance comprises or derived from one or
more
botanicals or constituents, derivatives or extracts thereof and the botanical
is selected from
rooibos and fennel.
In some embodiments, the substance to be delivered comprises a flavour.
As used herein, the terms "flavour" and "flavourant" refer to materials which,
where
local regulations permit, may be used to create a desired taste, aroma or
other somatosensorial
sensation in a product for adult consumers. They may include naturally
occurring flavour
materials, botanicals, extracts of botanicals, synthetically obtained
materials, or combinations
thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol,
Japanese white bark
magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese
mint, aniseed
(anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen,
cherry, berry, red
berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime,
tropical fruit, papaya,
rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus
fruits, Drambuie,
bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender,
aloe vera,
cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat,
naswar, betel,
shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange
blossom, cherry
blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi,
piment, ginger,
coriander, coffee, hemp, a mint oil from any species of the genus Mentha,
eucalyptus, star
anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus,
laurel, mate, orange
skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower,
basil, bay leaves,
cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant.
curcuma,
cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive,
lemon balm, lemon
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basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour
enhancers,
bitterness receptor site blockers, sensorial receptor site activators or
stimulators, sugars and/or
sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame,
saccharine, cyclamates,
lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other
additives such as charcoal,
chlorophyll, minerals. botanicals, or breath freshening agents. They may be
imitation, synthetic
or natural ingredients or blends thereof. They may be in any suitable form,
for example, liquid
such as an oil, solid such as a powder, or gas.
In some embodiments, the flavour comprises menthol, spearmint and/or
peppermint.
In some embodiments, the flavour comprises flavour components of cucumber,
blueberry,
citrus fruits and/or redben-y. 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 retain some fluid, such
as liquid, within
it. In some embodiments, the amorphous solid may, for example, comprise from
about 50wt%,
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60wt% or 70wt% of amorphous solid, to about 90wt%. 95wt% or 100wt% of
amorphous solid.
An aerosol-generating material may also be referred to as an aerosolisable
material.
An aerosol-generating material is a material that is capable of generating
aerosol, for
example when heated, irradiated or energized in any other way. An aerosol-
generating material
may be in the form of a solid, liquid or gel which may or may not contain an
active substance
and/or flavourants. The aerosol-generating material is incorporated into an
article for use in
the aerosol-generating system.
As used herein, the term "tobacco material" refers to any material comprising
tobacco
or derivatives or substitutes thereof. The tobacco material may be in any
suitable form. The
term "tobacco material" may include one or more of tobacco, tobacco
derivatives, expanded
tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material
may comprise one
or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco,
tobacco stem, tobacco
lamina, reconstituted tobacco and/or tobacco extract.
A consumable is an article comprising or consisting of aerosol-generating
material, part
or all of which is intended to be consumed during use by a user. A consumable
may comprise
one or more other components, such as an aerosol-generating material storage
area, an aerosol-
generating material transfer component, an aerosol generation area, a housing,
a wrapper, a
mouthpiece, a filter and/or an aerosol-modifying agent. A consumable may also
comprise an
aerosol generator, in particular a heating element, that emits heat to cause
the aerosol-
generating material to generate aerosol in use. The heater may, comprise, a
material heatable
by electrical conduction, or a susceptor.
The aerosol-generating material may comprise one or more active substances
and/or
flavours, one or more aerosol-former materials, and optionally one or more
other functional
material.
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The aerosolisable material may be present on a substrate. The substrate may,
for
example, be or comprise paper, card, paperboard, cardboard, reconstituted
aerosolisable
material, a plastics material, a ceramic material, a composite material,
glass, a metal, or a metal
alloy.
The aerosol-former material may comprise one or more constituents capable of
forming
an aerosol. In some embodiments, the aerosol-former material may comprise one
or more of
glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol,
tetraethylene
glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate,
ethyl laurate, a diethyl
suberate, triethyl citrate, triacetin, a diacctin 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
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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-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 flay
ourant, a colourant,
water, and a carbon adsorbent. The aerosol-modifying agent may, for example,
be a solid, a
liquid, or a gel. The aerosol-modifying agent may be in powder, thread or
granule form. The
aerosol-modifying agent may be free from filtration material.
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
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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
tri aceti n where the material is cellulose acetate tow, or the tow may be no
n -pl as ti ci sed. 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 side-on cross-sectional view of an article 1 for use in an aerosol
delivery
system that includes an aerosol delivery device 200 (see Figs. 13 to 15).
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.
The article 1 comprises a receiving member 2, an aerosol-generating material
3, and a
blocking member 4.
The receiving member 2 comprises a peripheral wall 5 that surrounds a space 6
that
contains the aerosol-generating material 3. The space 6 forms a storage area 6
for the aerosol-
generating material 3.
The receiving member 2 has a first open end 7. The receiving member 2
comprises an
end wall 8 at a second end of the receiving member 2, opposite to the first
open end 7.
In some embodiments, the peripheral wall 5 and end wall 8 of the receiving
member 2
are integrally formed.
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In the present example, the receiving member 2 comprises a sheet material 9.
In some
embodiments, the sheet material 9 comprises paper and/or foil, for example, a
metallic foil
such as aluminium foil. The sheet material 9 may optionally comprise a
plurality of layers of
materials, for example, a layer of paper with a layer of foil. In some
embodiments, the sheet
material 9 does not comprise any foil.
The sheet material 9 is rolled into a tube to form the peripheral wall 5 of
the receiving
member 2 (as shown in Fig. 5). In some embodiments, adhesive is applied to the
sheet material
9 to retain the sheet material 9 as a tube. In other embodiments (not shown),
the sheet material
9 is alternatively or additionally held in a tube shape by a wrapper that
circumscribes the sheet
material 9.
An end of the sheet material 9 is folded radially inwardly to form the end
wall 8 (as
shown in Fig. 6). Thus, the end wall 8 is located at an end of the peripheral
wall 5. The end
wall 8 at least partially forms a boundary of the space 6. The end wall 8 may
close, or at least
partially close, an end of the receiving member 2.
In the present example, the sheet material 9 comprises a plurality of end
portions 10
that are each folded radially inwardly once the peripheral wall 5 has been
formed such that the
end portions 10 form the end wall 8. Alternatively, each end portion 10 is
folded and then the
sheet material 9 is rolled/wrapped to form the peripheral wall 5, wherein said
rolling of the
sheet material 9 causes the end portions 10 to come together, or towards each
other, to form
the end wall 8.
In some embodiments, each end portion 10 comprises a flap 10 of the sheet
material 9.
Each flap 10 may be generally triangular. However, the skilled person will
recognise that other
shapes of flap 10 are possible, for example, semi-circular or rectangular
flaps.
The end portions 10 may be retained in a folded position forming the end wall
8 using
adhesive. In alternative embodiments, the end portions 10 may be retained in
position by the
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stiffness and/or ductility of the sheet material 9 or due to a further
component (for example, a
plug of material now shown) that is provided on the opposite side of the end
portions 10 to the
aerosol-generating material 3 and, for example, the further component may abut
the end
portions 10.
In the present example, the receiving member 2 is generally cup-shaped, having
a
generally cylindrical peripheral wall 5 that is closed, or at least partially
closed, at one end by
the end wall 8 and has an open end 7 at the opposite end of the receiving
member 2 to the end
wall 8.
The cnd wall 8 helps to retain the aerosol-generating material 3, which may
optionally
be a loose material, in the space 6 such that the aerosol-generating material
3 is resisted from
falling out of an end of the space 6 by the end wall 8.
The end wall 8 is configured to be gas permeable. Therefore, in embodiments
wherein
the open end 7 is upstream of the end wall 8 during use of the article 1 in
the device 200, gas
can enter the open end 7 of the receiving member 2, pass through the aerosol-
generating
material 3, and pass through the end wall 8 to exit the receiving member 2 for
inhalation by the
user. Alternatively, in embodiments, wherein the end wall 8 is upstream of the
open end 7, gas
can pass through the end wall 8 to enter the space 6 wherein the gas passes
through the aerosol-
generating material 3, and then flow out of the open end 7 of the receiving
member 2 for
inhalation by the user.
In some embodiments, the end wall 8 comprises one or more apertures 11 to
permit the
flow of gas through the end wall S. The or each aperture 11 may be holes or
slits through the
sheet material 9. For example, one or more holes and/or slits may be provided
in one or more
of the end portions 10. In another embodiment (not shown), the or each
aperture 11 may
comprise one or more gaps between adjacent end portions 10 of the end wall 8.
In yet another
embodiment (not shown), the end portions 10 may be sized such that they do not
meet in the
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axial centre of the article 1 when folded to form the end wall 8, such that an
aperture is provided
for the flow of gas therethrough.
The or each aperture 11 may be of sufficient size to permit the flow of gas
through the
end wall 8 whilst being small enough to resist aerosol-generating material 3
from flowing out
of the end wall 8 via the or each aperture 11. In some embodiments, the or
each aperture 11
has a diameter in the range of 0.1 to 1 mm and, preferably, in the range of
0.2 to 0. 8 mm.
In some embodiments, each aperture 11 has a diameter of at least 0.1 nun and,
preferably, at least 0.2 mm.
In some embodiments, each aperture 11 has a diameter of at most 1 mm and,
preferably,
at most 0.8 mm.
In another embodiment, sheet material 9 at the end wall 8 comprises a gas
permeable
material to permit the flow of gas through the end wall 8. The permeable
material may be, for
example, paper and may have a porosity of at least 100 Coresta Units and,
preferably, at least
200, 300, 400, 500, 1000, 2000, 3000, 5000 , 7000, 10000 or 20000 Coresta
Units. In some
embodiments, the entire sheet material 9 is manufactured from said gas
permeable material. In
other embodiments, only the sheet material 9 in the region of the end portions
10 is
manufactured from said gas permeable material. In some embodiments, the
permeability of the
sheet material 9 is selected based on the desired resistance to draw of the
article 1 (with a higher
permeability resulting in a lower resistance to draw).
The blocking member 4 comprises a body of material 12 arranged to resist the
aerosol-
generating material 3 from falling out of the open end 7 of the receiving
member 2.
In the present example, the body of material 12 of the blocking member 4 is
generally
cylindrical. However, it should be recognised that the body of material 12 may
have a different
shape.
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The article 1 further comprises a wrapper 13 that secures the blocking member
4
relative to the receiving member 2. In the present example, the wrapper 13
circumscribes both
of the receiving member 2 and blocking member 4. The wrapper 13 may be wrapped
around
the entire axial length of the receiving member 2 and/or blocking member 4. In
other
embodiments, the wrapper 13 may be wrapped around only a portion of the axial
length of the
receiving member 2 and/or blocking member 4 and, for example, may be provided
as a strip of
material that overlaps the joint between the receiving member 2 and blocking
member 4
without extending to the other ends of the receiving member 2 and/or blocking
member 4.
In some embodiments, the wrapper 13 is adhered to the receiving member 2
and/or
blocking member 4. However, the skilled person will recognise that in other
embodiments the
wrapper 13 may not be adhered to the receiving member 2 and/or blocking member
4 and may
be held in place, for example, by friction.
In the present embodiment, the body of material 12 is a plug of material. In
the present
embodiment, the plug of material comprises aerosol-generating material 14. For
example, the
aerosol-generating material 14 may comprise, consist of, or essentially
consist of, tobacco
material. As explained previously, 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 body of material 12 additionally, or alternatively,
comprises
one or more aerosol-former materials. For example, the body of material 12 may
additionally
Of alternatively comprise one or more constituents capable of forming an
aerosol. The aerosol-
former material comprises one or more of glycerine, glycerol, propylene
glycol, diethylene
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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.
In some embodiments, the body of material 12 has an axial length in the range
of 3 to
20 mm and, preferably in the range of 4 to 15 mm, 5 to 12 mm or 7 to 10 mm.
In some embodiments, the receiving member 2 has an axial length in the range
of 5 to
25 mm and, preferably, in the range of 11 to 18 mm or 13 to 16 mm.
In some embodiments, the total weight of aerosol generating material 3, 14 in
the article
1 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 blocking member 4 comprises in the range of 7 mg per
mm
to 13 mg of aerosol generating material per mm length of the blocking member 4
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 blocking member 4.
In some embodiments, the space 6 contains in the range of 7 mg per mm to 13 mg
of
aerosol generating material per mm length of the space 6 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
space 6.
In some embodiments, the article 1 contains in the range of 7 mg per liana to
13 mg of
aerosol generating material per mm length of the article 1 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 1.
The blocking member 4 is disposed in proximity to the open end 7 of the
receiving
member 2. The blocking member 4 may be disposed adjacent to the open end 7 of
the receiving
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member 2, and optionally may abut the open end 7 of the receiving member 2.
Alternatively,
at least a portion of the blocking member 4 may be received within the open
end 7 of the
receiving member 2 such that the peripheral wall 5 of the receiving member 2
circumscribes
the blocking member 4.
In some embodiments, the body of material 12 comprises an end that contacts
the
aerosol-generating material 3 that is received in the space 6 of the receiving
member 2.
In some embodiments, the body of material 12 is wrapped in a plug wrap 15. The
plug
wrap 15 may comprise paper or another sheet material, for example, a foil,
including a metal
foil such as aluminium foil.
The aerosol generating material 3 may be provided in the space 6 of the
receiving
member 2 as a loose material, that is retained in the space 6 by the end wall
8 of the receiving
member 2 and by the blocking member 4. The aerosol generating material 3 may,
for example,
be discrete strands or particles of aerosol generating material 3. Another
example of loose
aerosol generating material 3 is beads/pellets of aerosol generating material
3, including aerosol
generating material that has been extruded and then cut into beads/pellets.
Yet another example
of aerosol generating material 3 is a sheet of aerosol generating material
that has been cut into
individual pieces, for example, cut into individual strips of aerosol
generating material 3. The
sheet of aerosol generating material may be a sheet of reconstituted tobacco.
In some embodiments, the aerosol generating material 3 in the space 6 of the
receiving
member 2 is a first aerosol generating material 3. In embodiments wherein the
body of material
12 of the blocking member 4 comprises an aerosol generating material 14, this
is a second
aerosol generating material 14. Thus, the article 1 may comprise first and
second regions 3A,
14A of aerosol generating material 3, 14. The first and second regions 3A, 14A
may be discrete
regions.
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In some embodiments, the first aerosol generating material 3 has at least one
different
characteristic to the second aerosol generating material 14. The different
characteristic may be
one or more of form, size, density, water content, amount (by weight),
material or materials, or
proportion of materials that make each aerosol generating material 3, 14
(including the recipe
of each aerosol generating material 3, 14 when each is manufactured more than
one material).
In other embodiments, the first and second aerosol generating material 3, 14
do not have a
different characteristic and instead are the same.
In some embodiments, the first and second aerosol generating material 3, 14
may
comprise the same material, for example, tobacco, that has a different
characteristic. In one
such embodiment, the first and second aerosol generating material 3, 14 may be
in different
forms. For example, the first aerosol generating material 3 may be in the form
of beads or
pellets of aerosol generating material (for example, tobacco or another
material) and the second
aerosol generating material 14 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; loose material
(e.g. cut rag tobacco); a
dense end of a rod of aerosol generating material (e.g. tobacco); or, tobacco
lamina and/or stem
material that has been formed into a plug. However, it should he recognised
that the first and
second aerosol generating material 3, 14 may alternatively have the same form
(e.g. both being
cut rag tobacco) and have some other differing characteristic (e.g. different
densities of
material).
In some embodiments, the first and second aerosol generating materials 3, 14
may
release one or more volatile compounds at different rates when heated. This
allows for a more
consistent delivery of said compounds over the duration of the consumption
session of the
article 1. For example, the second aerosol generating material 14 may reach a
given
temperature more quickly than the first aerosol generating material 3 when
heated by a
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particular power of heater. This may cause the second aerosol generating
material to initially
release volatile compounds at a greater rate than the first aerosol generating
material 3. In one
such embodiment, the second aerosol generating material 14 may provide the
release of volatile
compounds during a first period of the consumption session and the first
aerosol generating
material 3 may provide the release of volatile compounds during a later second
period of the
consumption session. In one such embodiment, the second aerosol generating
material 14 is
heated during the first period and the first aerosol generating material 3 is
heated during the
second period of the consumption session.
In some embodiments, the first aerosol generating material 3 initially
releases one or
more volatile compounds at a faster rate than the second aerosol generating
material 14 when
subjected to a given heating power. In other embodiments, the first aerosol
generating material
3 releases one or more volatile compounds at a slower rate than the second
aerosol generating
material 14 when subjected to a given heating power.
In some embodiments, one of the first and second aerosol generating materials
3, 14 is
denser than the other one of the first and second aerosol generating materials
3, 14. Therefore,
the denser material may have a greater thermal mass so that it heats up more
slowly (and thus
initially releases the volatile compound(s) more slowly) when subjected to a
given heating
power.
In one embodiment, the first or second aerosol generating material 3, 14 may
comprises
beads/pellets of aerosol generating material, which have been found to release
volatile
compounds at a relatively slow rate. In some such embodiments, the other one
of the first and
second aerosol generating materials 3, 14 comprises one or more of: tobacco
lamina; tobacco
stems or reconstituted tobacco. In one such embodiment, said other one of the
first and second
aerosol generating material 3, 14 comprises a mixture of tobacco lamina and
reconstituted
tobacco.
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In other embodiments, the first and second aerosol generating materials 3, 14
are the
same.
Advantageously, the body of material 12 is arranged to resist the aerosol
generating
material 3 from falling out of the open end 7 of the receiving member 2. This
reduces the size
and weight of the article 1 and the amount of materials required to
manufacture the article 1,
because the article 1 does not require a further component to retain the
aerosol generating
material 3 in the receiving member 2. For example, arranging the body of
material 12 to retain
the aerosol generating material 3 in the receiving member 2 means that the
receiving member
2 can have an open end 7, rather than comprising a second end wall (on the
opposite side of
the space 6 to the end wall 8) to enclose the space 6, and thus requires less
material.
In addition, the body of material 12 can perform a further function of the
article 1 in
addition to retaining the aerosol generating material 3 in the space 6. In the
present example,
the body of material 12 comprises an aerosol generating material 14 and thus
the body of
material 12 performs both the function of retaining the aerosol generating
material 3 in the
space 6 and also the function of releasing one or more volatile compounds when
heated.
Similarly, the body of material 12 may alternatively or additionally comprise
an aerosol former
material and thus also performs the function of forming an aerosol. In other
embodi meats, the
body of material 12 may comprise a filter (for example, paper gathered into a
plug) that also
performs the function of filtering the flow of gas as it passes through the
article 1.
The first and/or second aerosol-generating material 3, 14 may comprise a
plurality of
strands or strips of aerosol-generating material. For example, the first
and/or second aerosol-
generating material 3, 14 may comprise a plurality of strands or strips of an
aerosolisable
material and/or a plurality of strands or strips of an amorphous solid.
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The first and/or second aerosol-generating material 3, 14 may comprise a plant
based
material, such as a tobacco material. The first and/or second aerosol-
generating material 3, 14
may be a sheet or shredded sheet of aerosoli sable material comprising a plant
based material,
such as a tobacco material.
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 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 second aerosol generating
materials 3, 14
comprise, consist of, or essentially consist of tobacco material.
The first and/or second aerosol-generating material 3, 14 may comprise an
aerosol-
former material. The aerosol-former material comprises 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.
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In some embodiments, the first and/or second aerosol-generating material 3, 14
comprises a sheet or shredded sheet of aerosolisable material that comprises
an aerosol-former
material. Optionally, the aerosol-former material is provided in an amount of
up to about 50%
on a dry weight base by weight of the sheet or shredded sheet. In some
embodiments, the
aerosol-former material is provided in an amount of from about 5% to about 40%
on a dry
weight base by weight of the sheet or shredded sheet, from about 10% to about
30% on a dry
weight base by weight of the sheet or shredded sheet or from about 10% to
about 20% on a dry
weight base by weight of the sheet or shredded sheet.
The first and/or second aerosol-generating material 3, 14 may comprise a
filler. In some
embodiments, the sheet or shredded sheet comprises the filler. The filler is
generally a non-
tobacco component, that is, a component that does not include ingredients
originating from
tobacco. The filler may comprise one or more inorganic filler materials, such
as calcium
carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica,
magnesium oxide,
magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such
as molecular
sieves. The filler may be a non-tobacco fibre such as wood fibre or pulp or
wheat fibre. The
filler can be a material comprising cellulose or a material comprises a
derivate of cellulose.
The filler component may also be a non-tobacco cast material or a non-tobacco
extruded
material.
The first and/or second aerosol-generating material 3, 14 herein can comprise
an aerosol
modifying agent, such as any of the flavours described herein. In one
embodiment, the first
and/or second aerosol-generating material 3, 14 comprises menthol. When the
first and/or
second aerosol-generating material 3, 14 is incorporated into an article 1 for
use in an aerosol-
provision system, the article may be referred to as a mentholated article 1.
The first and/or
second aerosol-generating material 3, 14 can comprise from 0.5mg to 20mg of
menthol, from
0.7 mg to 20 mg of menthol, between lmg and 18mg or between 8mg and 16mg of
menthol.
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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 3, 14.
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 3, 14) 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 3, 14) 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 3, 14) 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 3, 14) is substantially tobacco free.
The aerosol-generating material (for example, the first and/or second aerosol
generating
material 3. 14) may comprise or be an "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%,
60w1% or 70w1% of amorphous solid, to about 90w1%. 95wt% or 100wt% of
amorphous solid.
The amorphous solid may be substantially non-fibrous.
The aerosol-generating material (for example, the first and/or second aerosol
generating
material 3, 14) may comprise or be an aerosol-generating film. The aerosol-
generating film
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may be formed by combining a binder, such as a gelling agent, with a solvent,
such as water,
an aerosol-former and one or more other components, such as active substances,
to form a
slurry and then heating the slurry to volatilise at least some of the solvent
to form the aerosol-
generating film. The slurry may be heated to remove at least about 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.
The aerosol-generating material (for example, the first and/or second aerosol
generating
material 3. 14) may comprise one or more active substances and/or flavours,
one or more
aerosol-former materials, and optionally one or more other functional
material.
In each of the embodiments of article 1 described herein, the article may
comprise such
a first and/or second aerosol generating material 3, 14, and may comprise such
an aerosol-
generating composition.
The first and/or second aerosol-generating material 3, 14 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 material
3, 14 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.
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Where the first and/or second aerosol-generating material 3, 14 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 3, 14
comprises an extruded aerosol generating material that is then cut into beads
of pellets.
In the above described embodiments, the body of material 12 of the blocking
member
4 comprises a plug of aerosol generating material 14, for example, a plug of
tobacco fibres, or
strips of reconstituted tobacco, or a sheet of reconstituted tobacco that is
gathered into a plug.
In one embodiment, the body of material 12 is formed from a crimped sheet of
aerosol
generating material (for example, reconstituted tobacco). Apparatus and
methods for
manufacturing a crimped web for use in an aerosol- generating article 1 are
known in the art
and generally involve feeding the web or sheets between a pair of interleaved
rollers that apply
a plurality of parallel, equidistant longitudinally extending crimp
corrugations to the web or
sheet. Once crimped, the sheet or web is gathered to form a continuous rod.
In some embodiments, the body of material 12 of the blocking member 4 is
formed
from a sheet of material that has aerosol generating material added during
casting of the sheet.
For example, the sheet material may be cast from a slurry, wherein aerosol
generating material
(e.g. fibres, granules, pellets, beads or dust, including tobacco fibres,
granules, pellets, beads
or dust and/or other plant materials) is added to the slurry during casting.
In other embodiments,
the aerosol generating material is added to the sheet material once the sheet
material has been
formed. For example, aerosol generating material (e.g. fibres, granules,
pellets, beads or dust,
including tobacco fibres, granules, pellets, beads or dust and/or other plant
materials) is adhered
to the sheet material using an adhesive or is applied to the sheet material
and then held within
the sheet material when it is gathered into a plug. In some embodiments, the
sheet material
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comprises a paper or gel sheet and the aerosol generating material is
incorporated within or
applied to the sheet.
It should be recognised that in other embodiments the body of material 12 does
not
comprise an aerosol generating material. For example, in one alternative
embodiment the body
of material 12 comprises paper formed into a plug (for example, being crimped
or cut into
strips and formed into the plug), without any aerosol generating material
applied to or
incorporated within the sheet material of the plug.
An example of a blocking member 4 that comprises a sheet material is shown in
Fig.
11. In this embodiment, the body of material 12 of the blocking member 4
comprises a sheet
material 14B that has been gathered to form the body of material 12. The
blocking member 4
may have any of the features previously described. For example, the sheet
material may
comprise an aerosol generating material and/or aerosol-former material (either
being formed
with the sheet material during manufacture of the sheet material or
subsequently applied to the
sheet material). In one embodiment, the sheet material comprises tobacco
material and/or a gel.
In one embodiment, the sheet material comprises paper. The sheet material may
be crimped
and gathered to form a plug. In other embodiments, the sheet material may be
rolled-up (e.g.
in a spiral) to form a body of material. In yet further embodiments, the sheet
material may be
cut into strips and/or strands which are then formed into a body of material.
In some
embodiments, the blocking member 4 further comprises a plug wrap 15 that
circumscribes the
body of material 12.
Another example of a blocking member 4 is shown in Fig. 12. The blocking
member 4
comprises the end portion 17 of a body of material 12 that is in the form of a
rod 16 of aerosol
generating material 14. Optionally, said end portion 17 of the rod 16 has a
higher density than
another portion 18 of the rod. For example, the end portion 17 may be at least
10% and,
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preferably, at least 20%, denser than said another portion 18 of the rod 16
(and said another
portion 18 may be adjacent to said end portion 17).
In some embodiments, the rod 16 is a tobacco rod. In some embodiments, said
another
portion 18 of the rod 16 is the remaining length of the rod 16. The end
portion 17 may extend
a first region along the length of the rod 16 and the another portion 18 may
extend a second
region along the length of the rod 16, which may be the remaining axial length
of the rod 16.
In some embodiments, the rod 16 comprises a plug warp 15 that circumscribes
the body
of material 12 of the rod 16.
The end portion 17 of the rod 16 having an increased density helps to prevent
the
aerosol-generating material 3 from falling out of the space 6 in the receiving
member 2.
Furthermore, the end portion 17 of the rod 16 having an increased density
helps to prevent
material of the end portion 17 from falling out of the end portion 17 and
mixing with the aerosol
generating material 3 in the space 6 of the receiving member 2.
In some embodiments, the end portion 17 of the rod 16 comprises a greater
amount of
material per unit axial length (e.g. per mm) of the rod 16 than said another
portion 18. For
example, the end portion 17 comprises a greater amount of aerosol generating
material 14,
aerosol-former material, filler material and/or other material. Thus, when the
aerosol
generating material 14 is formed into the rod 16 (for example, using a rod
forming apparatus
as will be known to a person skilled in the art), the increased amount of
material at the end
portion 17 causes the rod 16 to have an increased density at the end portion
17 compared to
said another portion 18 of the rod 16. In some embodiments, the end portion 17
of the rod 16
comprises at least 10% (by weight) and, preferably, at least 20 % (by weight)
of material per
mm of length of the rod 16 than said another portion 18 of the rod 16.
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Referring now to Fig. 8, block diagram depicting an embodiment of a method 100
of
manufacturing an article 1 for an aerosol provision device is shown.
The method 100 comprises the step (Si) of providing a receiving member 2 that
comprises a peripheral wall 5 that surrounds a space 6 containing an aerosol-
generating
material 3, an end wall 8, and an open end 7. The method 100 further comprises
the step (S2)
of providing a blocking member 4 comprising a body of material 12 arranged to
resist the
aerosol-generating material 3 from falling out of the open end 7 of the
receiving member 2.
In some embodiments, the step S1 of providing the receiving member 2 comprises
forming the receiving member 2 and then providing the aerosol-generating
material 3 in the
space 6. For example, the aerosol-generating material 3 may be poured into the
open end 7 of
the receiving member 2. In one such embodiment, the receiving member 2 is
orientated such
that the central axis of the receiving member 2 is substantially vertical with
the open end 7
facing upwardly, and then the space 6 of the receiving member 2 is filled, or
at least partially
filled, with the aerosol generating material 3. In some embodiments, a
plurality of receiving
members 2 are moved along a conveyance path to pass a filling machine (not
shown), wherein
the filling machine is configured to deposit an aerosol generating material 3
in each receiving
member 2 as it passes the filling machine. Optionally, the filling machine may
deposit a
metered amount of aerosol generating material 3 in each receiving member 2.
The filling
machine may comprise, for example, a dosage wheel configured to deposit
aerosol generating
material 3 in the receiving members 2. Alternatively, the filling machine may
supply a
continuous stream of aerosol generating material 3 (for example, using one or
more hoppers),
and aerosol generating material 3 that does not enter the space 6 of one of
the receiving
members 2 is collected and disposed of or recycled.
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In other embodiments, the step S1 of providing the receiving member 2
comprises
forming the receiving member 2 around the aerosol-generating material 3. For
example, a
aerosol generating material 3 may be deposited on the sheet material 9, and
then the sheet
material 9 is wrapped around the aerosol generating material 3 and formed into
the receiving
member 2. In some embodiments, a metered amount of aerosol generating material
3 may be
deposited on the sheet material 9, for example, using a dosage wheel (not
shown) or any other
suitable apparatus.
In embodiments wherein the receiving member 2 is formed from a sheet material
9, the
sheet material 9 may have the features previously discussed, for example,
comprising paper
and/or foil. Optionally, the sheet material 9 may have one or all of the
features of any of the
sheet materials described herein, including those shown in Figs. 4, 9 and/or
10.
In some embodiments, the step S1 of providing the receiving member 2 comprises
rolling/wrapping the sheet material 9 to form the peripheral wall 5 of the
receiving member 2.
An example of rolling of the sheet material 9 is depicted in Fig. 5. In some
embodiments, the
sheet material 9 is rolled to form an open ended tube.
In some embodiments (not shown), a web of sheet material 9 is formed into a
continuous tube, an end of the continuous tube is folded to form an end wall
8, and then a
portion of the sheet material 9 comprising the end wall 8 and peripheral wall
5 is cut from the
remainder of the continuous tube such that a receiving member 2 is formed. The
process can
then be repeated with the remainder of the continuous tube to form further
receiving members
2. That is, the new end of the continuous tube is folded to form an end wall
8, and then a portion
of the sheet material 9 comprising the end wall 8 and peripheral wall 5 is cut
from the remainder
of the continuous tube such that a further receiving member 2 is formed, and
again the process
can be repeated to form further receiving members 2.
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In some embodiments, the step S1 of providing the receiving member 2 comprises
folding the sheet material 9 to form the end wall 8 of the receiving member 2.
The folding of
the sheet material 9 to form the end wall 8 of the receiving member 2 may take
place before or
after said rolling of the sheet material 9.
An example of folding of the sheet material 9 to form the end wall 8 is
depicted in Fig.
6. An end of the sheet material 9 is folded along a fold line (depicted by
dashed line `X-X' in
Fig. 6) in a radially inwards direction (in the direction of arrows 'Y' in
Fig. 6) to form the end
wall 8 of the receiving member 2. In some embodiments, the end portion 10 of
the sheet
material 9 partially overlap when folded to form the end wall 8. In other
embodiments, the end
portions 10 do not overlap and, in some embodiments, one or more gaps (not
shown) may be
formed between the end portions 10 to form apertures to permit the flow of gas
through the end
wall 8.
In some embodiments, the step Si of providing the receiving member 2 comprises
forming a plurality of end portions 10 in the sheet material 9 and folding the
end portions 10
to form the end wall 8 of the receiving member 2. Preferably, forming the end
portions 10
comprising providing one or more cuts into the sheet material 9. In one such
example, a
generally zig-zag arrangement of cuts is provided in the sheet material 9,
which form cut edges
10A, in order to form the end potions 10.
In some embodiments, the sheet material 9 comprises first and second edges 9A,
9B.
In some embodiments, the edges 9A, 9B overlap when the sheet material 9 is
formed into the
receiving member 2.
In some embodiments, a first plurality of the cut edges 10A extend at an angle
to the
first and second edges 9A, 9B in a first direction. In some embodiments, a
second plurality of
the cut edges 10A extend at an angle to the first and second edges 9A, 9B in a
second direction.
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The first and second plurality of cut edges 10A may be arranged alternately
between the first
and second edges 9A, 9B.
In some embodiments, the step S1 of providing the receiving member 2 comprises
securing the end portions 10 together using an adhesive. The adhesive may be
provided on one
or more of the end portions 10 prior to folding the end portions 10.
Alternatively, the adhesive
may be provided on one or more of the end portions 10 after folding the end
portions 10. In
other examples, the end portions 10 may be welded together or held in positon
by one or more
securing member(s), for example, a staple, sticker or label.
In some embodiments, the step S1 of providing the receiving member 2 comprises
forming one or more apertures 11 into the portion of the sheet material 9 that
comprises the
end wall 8.
In some embodiments, the or each aperture 11 is formed in the sheet material 9
before
the sheet material 9 is formed into the receiving member 2. In other
embodiments, the or each
aperture 11 is formed in the sheet material 9 after the sheet material 9 is
formed into the
receiving member 2.
In some embodiments, the or each aperture 11 is formed into one or more of the
end
portions 10 of the sheet material 9.
In some embodiments, the or each aperture 11 is formed by cutting, tearing,
punching
or burning the sheet material, and/or by forming gaps between end portions 10
of the sheet
material 9. For example, the or each aperture 11 may be formed by cutting
using a knife or
laser. In some embodiments, the or each aperture 11 comprises a hole, for
example, a round
hole, in the sheet material 9. In other embodiments, the or each aperture 11
comprises a slit in
the sheet material 9.
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In some embodiments, the method further comprises forming one or more regions
of
strength discontinuity of the sheet material 9 arranged such that the sheet
material 9 can be
folded along the one or more regions of strength discontinuity to form said
end wall 8, as is
described in more detail in reference to Figs. 9 and 10. However, in other
embodiments, the
method does not comprise forming such regions of strength discontinuity.
In some embodiments, the sheet material 9 is provided from a continuous web of
sheet
material that is cut into pieces to form the sheet material 9 of each
receiving member 2.
In some embodiments, the receiving member 2 is generally cup-shaped.
In some embodiments, the step S2 of providing a blocking member 4 comprises
securing the blocking member 4 relative to the receiving member 2 using a
wrapper 13. In one
such embodiment, securing the blocking member 4 relative to the receiving
member 2 using
the wrapper 13 comprises circumscribing the blocking member 4 and receiving
member 2 with
the wrapper 13.
In some embodiments, the wrapper 13 is adhered to the receiving member 2
and/or the
blocking member 4. However, in other embodiments the wrapper 13 may hold the
receiving
member 2 and/or blocking member 4 in position using friction.
In some embodiments, the blocking member 4 is generally cylindrical. In some
embodiments, the body of material 12 is generally cylindrical.
In some embodiment, the peripheral wall 5 of the receiving member 2 is
generally
cylindrical.
In some embodiments, the blocking member 4 comprises the end portion 17 of a
rod
16 of aerosol generating material 14 and, preferably, said end portion 17 of
the rod 16 has a
higher density than another portion 18 of the rod 16, as discussed above. In
some embodiments,
said rod 16 is a tobacco rod.
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In one such embodiment, the step S2 of providing the blocking member 4
comprises
forming a rod 16 of aerosol generating material 14 such that an end portion 17
of the rod 16
has a higher density than another portion 18 of the rod 16. In one such
example, the step S2
comprises providing aerosol generating material 14 and forming the aerosol
generating
material 14 into a rod 16, wherein a greater amount of material (e.g. aerosol
generating material
14, aerosol-former material, filler material, or other material) is provided
at the end portion 17
of the rod 16 than at said another portion 18 of the rod 16 such that when the
rod 16 is formed
said end portion 17 has a higher density of material than said another portion
18 of the rod 16.
The end portion 17 of the rod 16 may have a higher density of material per mm
axial
length of the rod 16 than said another portion 18.
In some embodiments, the end portion 17 of the rod 16 may have a higher mass
of
material per mm axial length of the rod 16 than said another portion 18.
In some embodiments, the blocking member 4 comprises a plug of material. In
some
embodiments, the body of material 12 is formed into a plug of material.
In some embodiments, the step S2 of providing the blocking member 4 comprises
arranging the body of material 12 such that the body 12 is disposed adjacent
to the open end 7
of the receiving member 2.
In some embodiments, at least a portion of the body of material 12 is received
within
the open end 7 of the receiving member 2. In other embodiments, the body of
material 12 is
not receiving within the open end 7 of the receiving member 2.
As explained previously, the body of material 12 may comprise an aerosol-
generating
material 14 and/or may comprise an aerosol-former material.
In some embodiments, the blocking member 4 comprises an aerosol-generating
material 14 comprising: from about 10 to about 50 wt% aerosol-former material;
from about
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15 to about 60 wt% gelling agent; and optionally filler; wherein the wt%
values are calculated
on a dry weight basis.
In some embodiments, the aerosol-generating material 14 of the blocking member
comprises 4 a flavour.
In some embodiments, the blocking member 4 comprises an amorphous solid and,
preferably, the amorphous solid is a gel.
In some embodiments, the blocking member 4 comprises tobacco material.
In some embodiments, the blocking member 4 comprises a sheet material and,
preferably, wherein the method comprises gathering the sheet material into a
body of material.
The sheet material may comprise paper.
In some embodiments, the sheet material of the blocking member 4 is crimped.
The
step S2 of providing the blocking member 4 may comprise crimping the sheet
material. For
example, step S2 may comprise passing the sheet material used to form the
blocking member
4 through a pair of crimping rollers.
In some embodiments, the sheet material of the blocking member 4 comprises one
or
more of: aerosol generating material and/or paper. The sheet material 4 may
comprise tobacco
material. The sheet material 4 may comprise a gel.
In some embodiments, the sheet material 9 of the receiving member 2 comprises
one
or more of: aerosol generating material, foil and/or paper. The sheet material
9 may comprise
tobacco material. The sheet material 9 may comprise a gel.
In some embodiment, the blocking member 4 comprises an end surface 4A that
contacts
the aerosol-generating material 3.
In some embodiments, the blocking member 4 comprises in the range of 7 mg per
mm
to 13 mg of aerosol generating material per mm length of the blocking member 4
and,
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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 blocking member 4.
In some embodiments, the space 6 contains in the range of 7 mg per mm to 13 mg
of
aerosol generating material per mm length of the space 6 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
space 6.
In some embodiments, the article 1 contains in the range of 7 mg per nana to
13 mg of
aerosol generating material per mm length of the article 1 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 1.
In some embodiments, the aerosol-generating material 3 provided in the space 6
is
provided as a loose material, for example, a loose tobacco material. The loose
material may be
poured into the space 6 of the receiving member 2 or deposited on the sheet
material 9 which
is then wrapped about the aerosol generating material 3 to form the receiving
member 2. The
aerosol-generating material 3 may be provided as discrete particles.
In some embodiments, the aerosol-generating material 3 in the space 6 of the
receiving
member 2 comprises, consists of, or essentially consists of, tobacco material.
In some
embodiments, the tobacco material comprises beads/pellets of tobacco material,
as previously
described. In some embodiments, the tobacco material further comprises another
tobacco
material other than tobacco beads/pellets.
In some embodiments, the method 100 further comprises providing a cooling
section
and incorporating the cooling section into the article and, preferably,
wherein the cooling
section is disposed such that, in use of the article 1, the cooling section is
downstream of the
receiving member. In some embodiments, the cooling section comprises aerosol-
generating
material and, preferably, comprises a plug of aerosol generating material. In
some
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embodiments, the cooling section comprises a flavourant, for example, the
aerosol-generating
material of the cooling section may comprise a flavourant. The cooling section
may comprise
gel, for example, a gel plug.
In some embodiments, the blocking member 4 is upstream of the space 6 when the
article 1 is in use in an aerosol provision device 200. In other embodiments,
the blocking
member 4 is downstream of the space 6.
In some embodiments, the end wall 8 of the receiving member 2 is upstream of
the
space 6 when the article 1 is in use in an aerosol provision device 200. In
other embodiments,
the end wall 8 is downstream of the space 6.
In some embodiments, the method 100 further comprises providing a further plug
of
material (not shown) on the other side of the end wall 8 to the space 6. The
further plug of
material may comprise, for example, a section of filtration material or a
cooling section and/or
flavouring section.
Referring now to Fig. 9, an alternative embodiment of sheet material 9 for
forming a
receiving member 2 of an article 1 is shown. The sheet material 9 may have any
of the features
of the sheet material 9 of the article 1 described herein, including any of
the features of the
sheet material 9 described above in reference to Figs. 1 to 8. A difference is
that the sheet
material 9 further comprises one or more regions of strength discontinuity 20.
The one or more regions of strength discontinuity 20 are arranged such that
the sheet
material 9 can be folded along the one or more regions of strength
discontinuity 20 to form the
end wall 8 of the receiving member 2.
In some embodiments, the region(s) of strength discontinuity 20 comprise
regions of
weakening of the sheet material 9. Therefore, when the sheet material 9 is
folded, the sheet
material 9 folds along the region(s) of weakening. For example, the regions of
weakening may
comprise one or more of: cuts partially or entirely through the thickness of
the sheet material
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9; embossing; pin holes; pre-formed crease lines; score lines; and/or, regions
of reduced
thickness of the sheet material 9. In one embodiment (not shown), the region
of reduced
strength is achieved by strengthening at least a portion of the remainder of
the sheet material
9, for example, applying a strengthening coating (e.g. a varnish) to the sheet
material 9 in areas
about the region(s) of weakening or to the entire rest of the sheet material
9.
In some embodiments, the region(s) of strength discontinuity 20 comprise
regions of
increased strength of the sheet material 9. Therefore, when the sheet material
9 is folded, the
sheet material 9 folds in proximity to the regions of increased strength. For
example, the
region(s) of increased strength may comprise embossing, a coating (for
example, a varnish or
other coating) or regions of increased thickness of the sheet material.
In some embodiments, the one or more regions of strength discontinuity 20
comprise
embossing.
In some embodiments, the one or more lines of strength discontinuity 20 are
continuous.
In other embodiments, the one or more lines of strength discontinuity 20 are
discontinuous.
In some embodiments, the one or more regions of strength discontinuity 20 are
lines of
strength discontinuity 20. The regions of strength discontinuity 20 may extend
substantially
linearly.
In some embodiments, the sheet material 9 has a first axis A-A that extends
parallel to
the first and second ends 9A, 9B of the sheet material 9, wherein at least one
line of strength
discontinuity 20 extends substantially perpendicular to the first axis A-A. In
some
embodiments, the first axis A-A extends from the end portions 10 to an
opposite end of the
sheet material 9. It should be recognised that in other embodiments (not
shown), the or each
region 20 of strength discontinuity 20 extends at an angle to said first axis
A-A.
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In some embodiments, the sheet material 9 has basis weight of at least 35 GSM
and,
preferably, at least 100, 150 or 200 GSM.
In some embodiments, the sheet material 9 has basis weight of at most 300 GSM
and,
preferably, at most 250, 200 or 150 GSM.
In the present example, the sheet material 9 comprises a plurality of end
portions 10
that are each folded radially inwardly once the peripheral wall 5 has been
formed such that the
end portions 10 form the end wall 8. Alternatively, each end portion 10 may be
folded and then
the sheet material 9 is rolled to form the peripheral wall 5, wherein said
rolling of the sheet
material 9 causes the end portions 10 to come together to form the end wall S.
In some embodiments, each end portion 10 comprises a flap 10 of the sheet
material 9.
Each flap 10 may be generally triangular. That is, a plurality of triangular
cut-outs may be
formed into the sheet material. However, the skilled person will recognise
that other shapes of
flap 10 are possible, for example, semi-circular or rectangular flaps.
In the present example, the sheet material 9 comprises a plurality of regions
of strength
discontinuity 20 that are discrete and spaced from each other. In the present
example, the
regions comprise lines of weakening 20 formed by embossing the sheet material
9. Each region
of strength discontinuity 20 is disposed at an edge of a corresponding end
portion 10, where
said end portion 10 is joined to the remainder of the sheet material 9. Thus,
each region 20
facilitates the folding of a respective end portion 10 to form the end wall 8
of the receiving
member 2.
Referring now to Fig. 10, yet embodiment of sheet material 9 for forming a
receiving
member 2 of an article 1 is shown. The sheet material 9 may have any of the
features of the
sheet material 9 of the article 1 described above in reference to Figs. 1 to 8
or Fig. 9. A
difference is that the sheet material 9 comprises a single region of strength
discontinuity 20
that extends across the entire width of the sheet material 9. Also, the end
portions 10 are
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rectangular and are formed by cuts 10A that are substantially parallel to the
first and second
ends 9A, 9B of the sheet material 9.
Referring now to Figs. 13 to 15, an embodiment of an aerosol provision device
200 is
shown.
The article 1 is configured for use in an aerosol provision device 200 (see
Figure 13)
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 into the
aerosol generating material 3 in the space 6 and/or into the body of material
12 of the blocking
member 4. In other embodiments (not shown), the article 1 may comprise the
heating element
which, for example, may be embedded in the aerosol generating material 3
and/or blocking
member 4.
In Figure 13, the components of an embodiment of an aerosol provision device
200 are
shown in a simplified manner. Particularly, the elements of the aerosol
provision device 200
are not drawn to scale in Figure 13. Elements that are not relevant for the
understanding of this
embodiment have been omitted to simplify Figure 13.
In the example of Figure 13, 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 aerosol
generating material 3 in the space 6 and/or the aerosol generating material 14
of the body of
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material 12 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 wrapper 13
of the article 1.
In another embodiment, the heater 203 comprises a blade or pin that contacts
the inside of the
article 1, for example, contacting the aerosol generating material 3 in the
space 6 and/or the
body of material 12 of the blocking member 4.
When the article 1 is heated, the aerosol generating material 3 in the space 6
and/or the
aerosol generating material 14 of the blocking member 4 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 Figure 14, 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.
Figure 15 is a schematic cross-section of a non-combustible aerosol-provision
device
200 of the type shown in Figure 13, 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
an article 1 has
been provided in the area 202, the mouthpiece 207 can be reattached. In some
embodiments,
the mouthpiece 207 is removably attached to the housing 201 of the device 200,
for example,
by a screw thread or bayonet connection.
As a user draws on the mouthpiece 207, air is drawn into the 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 end wall 8 of the receiving member 2
forms
a first end (i.e. the proximal end P or distal end D) of the article 1 and the
blocking member 4
forms a second end (i.e. the other one of the proximal end P or distal end 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 that
is on the
opposite side of the end wall 8 to the space 6 and/or on the opposite side of
the blocking
member 4 to the space 6.
For example, an alternative embodiment of an article 1 is shown in Fig. 16
which further
comprises a cooling section 25, also referred to as a cooling element,
positioned immediately
downstream of and adjacent to the receiving member 2. In the present example,
the cooling
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element 25 is immediately downstream of and adjacent to the end wall 8 of the
receiving
member 2. In some such embodiments, the cooling element 25 is in an abutting
relationship
with the end wall 8. 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.
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. 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 narn 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
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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 aerosol
generating material 3 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, 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 60 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 3 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 301.1M
and 60 ittm, or between 35 ium and 45 m. The plug wrap 28 may be a non-porous
plug wrap,
for instance having a permeability of less than 100 Coresta units, for
instance less than 50
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Coresta units. However, in other embodiments, the plug wrap 28 can be a porous
plug wrap,
for instance having a permeability of at least 100 or at least 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 29 is wrapped around the cooling element
25
and body of material 26 and also circumscribes the wrapper 13 that
circumscribes the receiving
element 2, and may be connected to these components by adhesive. Thus, the
tipping paper 29
connects the cooling element 25 and body of material 26 to the receiving
member 2 and
blocking member 4. In some embodiment, the wrapper 13 is omitted.
In the above described examples, the receiving member 2 is formed from a sheet
material 9. However, in other embodiments, the receiving member 2 may be
formed as, for
example, a moulded part or using an additive manufacturing process (e.g. 3D
printing).
In each of the examples of article described above (including each of the
articles shown
in Figs. 1 to 16), the first and second aerosol-generating materials 3, 14 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 3, 14 may be the same.
It has been found that providing different densities of first and second
aerosol
generating materials 3, 14 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 3 has a greater density
than the second
aerosol-generating material 14 so that the first aerosol generating material 3
heats up slower
than the second aerosol generating material 14 when exposed to the same
heating and will
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release its volatile compounds (e.g. nicotine) at a slower rate than the
second aerosol-generating
material 14 (however, in other embodiments the reverse may be true such that
the second
aerosol generating material 14 has a higher density than the first aerosol
generating material
3). 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
3, 14
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 3,14 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 3, 14 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
3, 14 and,
optionally, no more than about 150%, 125%, 100% or 75% higher. In some
embodiments, the
one of the first and second aerosol generating materials 3, 14 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 3, 14.
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In some embodiments, said one of the first and second aerosol generating
materials 3,
14 has a density of from at least about 0.4 g/cm3 and optionally from at least
about 0.5, 0.6,
0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm3. The
said one of the first and
second aerosol generating materials 3, 14may have a density of no more than
about 2 g/cm3
and, optionally no more than about 1.9, 1.8, 1.7, 1.6. 1.5, 1.4, 1.3, 1.2,
1.1, 1, 0.9, 0.8, 0.7, 0.6
or 0.5 g/cm3. In some embodiments, the density of said one of the first and
second aerosol
generating materials 3, 14 is from about 0.4 to 1.99 g/cm3.
In some embodiments, the said other one of the first and second aerosol
generating
materials 3, 14 has a density of from at least about 0.1 g/cm3 and optionally
from at least about
0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8 or 0.9 g/cm3. The said other one of the
first and second aerosol
generating materials 3, 14 may have a density of no more than about 1 g/cm3
and, optionally
no more than about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3 or 0.2 g/cm3. In some
embodiments, the
density of the said other one of the first and second aerosol-generating
materials 3, 14 is from
about 0.1 to 0.9 g/cm3.
In some embodiments, the first and second aerosol-generating materials 3, 14
comprise
the same components. Upon heating, they will therefore release very similar
aerosols,
potentially having the same content of active substance and/or flavour, etc.
Their different
densities allow the aerosol to be generated from the two materials at
different speeds and/or
different times during heating.
In other embodiments, the first and second aerosol-generating materials 3, 14
comprise
different components (and may have the same or different densities). Upon
heating, they will
therefore release different aerosols, potentially having different make-up of
active substance
and/or flavour, etc. Their different densities allow the different aerosols to
be generated from
the two materials at different speeds and/or different times during heating,
potentially providing
an aerosol that changes over the period of use.
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In some embodiments, the first aerosol-generating material 3 and the second
aerosol-
generating material 14 each comprise 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, 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 3, 14 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 3, 14 has a greater density
than the other one
of the first and second aerosol-generating materials 3, 14.
In sonic embodiments, the first aerosol-generating material 3 has at least one
(further)
different characteristic to the second aerosol generating material 14. 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 3, 14 (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 3, 14 do not have a different characteristic,
other than their
different densities. In other embodiments, the densities are the of the first
and second aerosol
generating materials is the same.
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In some embodiments, the second aerosol-generating material 14 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 14 is a
blend
comprising both lamina and reconstituted tobacco. For example, the ratio of
lamina and
reconstituted tobacco may from about 1:4 to about 4:1.
In some embodiments, the first aerosol-generating material 3 has a greater
density than
the second aerosol-generating material 14. In some embodiments, this more
dense, first
aerosol-generating material 3 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 14 may be denser than the first aerosol generating material 3 and,
for example, may
be in the form of beads or one or more sheets. In some embodiments, the both
of the first and
second aerosol generating materials 3, 14 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 3, 14 has a higher density than the other one of the first and
second aerosol generating
materials 3, 14.
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
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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 3,
14 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
3. 14
comprises particles of material that are agglomerated.
In the case of a sheet material, the sheet may be formed from particles of
material that
are bound and optionally compressed to form a sheet with the desired
dimensions and density.
In some embodiments, beads or pellets can be formed using a so called
marumarising
process.
In some embodiments, the agglomeration is by pelletisation. Pelletisation is
an
agglomeration process that converts fine particles of material, optionally
together with
excipient, into free-flowing units, referred to as pellets. Depending on the
type of equipment
and processes selected, pellet formation and growth may occur in a number of
ways. These
pellets 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 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.
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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 3, 14), which
will have an impact on the heat transfer within the material and the release
of the volatile
components.
Extrusion involves feeding a composition (also referred to as a precursor
composition)
through a die to produce an extruded product. The process applies pressure to
the composition
combined with shear forces.
Extrusion may be performed using one of the main classes of extruders: screw,
sieve
and basket, roll, ram and pin barrel extruders. A single screw or twin screw
extruder may be
used. Forming the tobacco beads by extrusion has the advantage that this
processing combines
compression, mixing, conditioning, homogenizing and moulding of the
composition.
In some embodiments, during extrusion the free-flowing composition comprising
particles, such as tobacco particles, is exposed to elevated pressure and
temperature and is
forced though an orifice, such as a shaping nozzle or die, to form an
extrudate. In some
embodiments, the extrudate has a rod-like form and it may be cut into segments
of a desired
length.
In some embodiments, the composition is exposed to temperatures from about 40
C to
about 150 C, or from about 80 C to about 130 C, or from about 60 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)
ranging from about 2 bat to about 100 bar, or from about 5 bar to about 60
bat, depending on
the design of the die or nozzle being used. The higher the pressure, the
greater the density of
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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 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
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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
carbox ymethylcellulo se.
In some embodiments, processing by extrusion is sufficient to provide the
higher
density of the first or second aerosol-generating material 3, 14, where
desired. However, in
other embodiments, the extrudate may be further treated to increase the
density of the first or
second aerosol-generating material 3, 14.
For example, in some embodiments, the extruded aerosol-generating material
undergoes spheronisation. In spheronisation, the extruded, cylindrically
shaped particles are
broken into uniform lengths and are gradually transformed into spherical
shapes due to plastic
deformation. Where the extrudate is first broken into uniform lengths, spheres
with a uniform
diameter will be produced by the spheronisation step.
According to one specific example of the embodiments discussed herein, samples
of
the first aerosol-generating material 3 were produced as follows (but note
that in some
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embodiments samples may be produced according to the below, which are instead
used for the
second 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
60 um.
Next, all of the dry (non-liquid) components of the formulation were combined
and
mixed or blended in a mixer. In this particular instance, the mixture was
mixed for 1 minute
at a speed to 75 RPM. This was to ensure that the dry components are
homogenously
distributed within the mixture.
Next, half of the glycerol and half of the water were added to the dry mixture
and mixed.
Specifically, the mixture was mixed for a further minute at 75 RPM. The
remaining glycerol
and water was then added and mixed, again for 1 minute at 75 RPM. Then, to
ensure that a
homogenous mixture was achieved, mixing was continued until the mixture had a
crumbly
consistency that could be squeezed into a mass. In this specific instance, the
additional mixing
lasted 3 minutes.
The mixture was then extruded using a Caleva Multilab. The extruder was
operated at
approximately 1500 rpm to produce lengths of extrudate resembling spaghetti.
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The extrudate was broken into pieces of varying length as it came out of the
extruder.
These pieces were then spheronised. Spheronisation was carried out until
spherical beads were
formed. In this instance, the extrudate was initially spheronised in a Caleva
Multilab operating
at 2,500 RPM for 1 minute and then the beads were checked for any defects.
Then,
spheronisation continued for a further 1 to 2 minutes. This spheronisation
step broke the
extruded tobacco into the individual pieces and formed the dense, spherical
beads.
In a final step, the spheronised beads were dried in an oven at 65 C for 30
minute
periods. After each drying period, the beads were weighed and drying was
halted when the
desired moisture wcight 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 3, 14 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 3, 14, 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 3, 14, such as the formulation and/or the processing of
the material into
particles, beads or pellets.
In some embodiments, said one of the first and second aerosol-generating
materials 3,
14 comprises a combination of 60% 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 one
of the first and second aerosol-generating materials 3, 14 comprises from
about 30 to about
90% tobacco, with a density in the range of from about 0.4 to about 1.99
g/cm3. The amount
of aerosol forming material included in said one of the first and second
aerosol-generating
materials 3, 14 may be from about 8 to about 15%. The said one of the first
and second aerosol-
generating materials 3, 14 may comprise largely spherical beads with a
particle size between
about 0.5 and about 3 mm. In some embodiments, the aerosol generating material
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comprises approximately 50% of the first aerosol-generating material 3 and
about 50% of the
second aerosol-generating material 14, by weight. Thus, for example, an
article comprising
260 mg of aerosol-generating material may comprise 130 mg of the first aerosol-
generating
material 3 and 130 mg of the second aerosol-generating material 14.
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 2.5% or 0.5 to 2% by weight of the tobacco, and may he,
for example,
from 0.5 to 1.75% by weight of the tobacco. from 0.8 to 1.2% by weight of the
tobacco or from
about 0.8 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 3, 14
have the
same nicotine content.
In some embodiments, the first and second aerosol-generating materials 3, 14
comprise
one or more volatile components. In some embodiments, the fast and second
aerosol-
generating materials 3, 14 have the same volatile component content.
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In some embodiments, the first and/or second aerosol-generating materials 3,
14
comprise tobacco. For example, the first and/or second aerosol-generating
materials 3, 14 may
comprise from about 80 to about 350 mg of tobacco. In some specific
embodiments, the
aerosol-generating material in an article or consumable has a weight of 260
mg, comprising a
combination of 130 mg of a second aerosol-generating material 14, for example
comprising a
blend of lamina and reconstituted tobacco, and 130 mg of a first aerosol-
generating material 3,
for example comprising higher density tobacco beads.
In some embodiments, the article comprises regions of aerosol-generating
material,
wherein each region comprises aerosol-generating material contain an equal
amount of
tobacco. In alternative embodiments, the regions may contain different amounts
of tobacco.
Where the total amount of tobacco is from about 80 to about 350 mg, one region
of aerosol-
generating material comprises from about 20 to about 330 mg, or from about 50
to about 300
mg, or from about 40 to about 125 mg of tobacco and the other region of
aerosol-generating
material comprises from about 20 to about 330 mg, or from about 30 to about
300 mg or from
about 40 to about 125 mg of tobacco.
According to the present disclosure, there is also provided a kit of parts
comprising an
article according to any of the examples described herein and an aerosol
provision device.
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
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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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