A body of aerosol-generating material for use with a non-combustible aerosol provision device

Abstract

A body of aerosol-generating material for use in a non-combustible aerosol provision system. The body of aerosol-generating material includes an aerosol-generating material and a recess or cavity in the aerosol-generating material at least partially bounded by a material layer. Also described is a body of aerosol-generating material for use in a non-combustible aerosol provision system, the body including one or more channels extending at least partially or completely through the body. Articles including the body are also described, as well as an article for use with a non-combustible aerosol provision device, the article including a body of aerosol-generating material and a downstream portion downstream of the body, the downstream portion comprising a main path for mainstream aerosol emitted from the body of aerosol-generating material and an airflow path arranged laterally of the main path, the airflow path allowing air to flow through the article in a direction opposite to that of mainstream aerosol. Methods of manufacture are also described.

1 . A body of aerosol-generating material for use in a non-combustible aerosol provision system, the body comprising aerosol-generating material and a recess or cavity in the aerosol-generating material at least partially bounded by a material layer. 
     
     
         2 . A body of aerosol-generating material according to  claim 1 , wherein the material layer lines an inner surface of the recess or cavity. 
     
     
         3 . A body of aerosol-generating material according to  claim 1 , wherein the aerosol-generating material comprises a first aerosol-generating material and the recess or cavity is at least partially filled with a second aerosol-generating material. 
     
     
         4 . A body of aerosol-generating material according to  claim 1 , wherein the material layer comprises an amorphous solid, and/or a sheet material, and/or wherein the material layer comprises a density of greater than 1.2 grams/cm3. 
     
     
         5 . A body of aerosol-generating material according to  claim 1 , wherein the body comprises a longitudinal axis and the length of the recess or cavity is less than the length of the body along the longitudinal axis. 
     
     
         6 . A body of aerosol-generating material according to  claim 1 , wherein the body comprises a first longitudinal end and a second longitudinal end, and the material layer covers or at least partially covers the first longitudinal end. 
     
     
         7 . A body of aerosol-generating material according to  claim 6 , wherein the material layer comprises a first material layer and further comprising a second material layer which lines an inner surface of the recess or cavity. 
     
     
         8 . A body of aerosol-generating material according to  claim 1 , wherein the body comprises a first longitudinal end and a second longitudinal end, and first and second longitudinal ends are free of the material layer. 
     
     
         9 . A body of aerosol-generating material according to  claim 1 , wherein the material layer, first material layer and/or second material layer substantially prevent the flow of air into the aerosol-generating material though the respective material layer. 
     
     
         10 . A body of aerosol-generating material according to  claim 9 , wherein, the first material layer and/or the second material layer comprises a sealing element comprising at least one of a material having a permeability below 100 Coresta Units, an impervious membrane, a cap, a varnished paper, or a gasket seal. 
     
     
         11 . A body of aerosol-generating material according to  claim 1 , wherein the material layer comprises a body of fibrous material. 
     
     
         12 . A body of aerosol-generating material according to  claim 11 , wherein the material layer comprises a first material layer and further comprising a second material layer covering at least a portion of the first material layer. 
     
     
         13 . A body of aerosol-generating material according to  claim 11 , wherein the body of fibrous material comprises a recess or cavity for receiving a heating element of the non-combustible aerosol provision device. 
     
     
         14 . A body of aerosol-generating material according to  claim 1 , comprising one or more channels extending at least partially or completely through the body. 
     
     
         15 . A body of aerosol-generating material according to  claim 14 , wherein said one or more channels pass longitudinally through the body. 
     
     
         16 . A body of aerosol-generating material according to  claim 14 , wherein said body comprises a longitudinal axis and said one or more channels pass through said body at an angle to the longitudinal axis. 
     
     
         17 . A body of aerosol-generating material according to  claim 16 , wherein said one or more channels form a helix around an outer region of the body. 
     
     
         18 . A body of aerosol-generating material according to  claim 14 , wherein said one or more channels are defined between said aerosol-generating material and a wrapper surrounding the aerosol-generating material. 
     
     
         19 . A body of aerosol-generating material according to  claim 1 , wherein said aerosol-generating material comprises a plant-based material, such as a tobacco material, and/or extruded or molded material. 
     
     
         20 . A body of aerosol-generating material for use in a non-combustible aerosol provision system, the body comprising one or more channels extending at least partially or completely through the body. 
     
     
         21 . A body of aerosol-generating material according to  claim 20 , wherein:
 said one or more channels pass longitudinally through the body; or   said body comprises a longitudinal axis and said one or more channels pass through said body at an angle to the longitudinal axis; or   wherein said one or more channels form a helix around an outer region of the body; or   wherein said one or more channels are defined between said aerosol-generating material and a wrapper surrounding the aerosol-generating material.   
     
     
         22 . An article for use with a non-combustible aerosol provision device, the article comprising a body of aerosol-generating material according to  claim 1  and a downstream portion downstream of said body. 
     
     
         23 . An article for use with a non-combustible aerosol provision device, the article comprising a body of aerosol-generating material and a downstream portion downstream of the body, the downstream portion comprising a main path for mainstream aerosol emitted from the body of aerosol-generating material and an airflow path arranged laterally of the main path, the airflow path allowing air to flow through the article in a direction opposite to that of mainstream aerosol. 
     
     
         24 . An article according to  claim 23 , wherein:
 the airflow path begins at a ventilation area on an outer surface of the article; and/or   the airflow path extends through and/or adjacent to the body of aerosol-generating material; and/or   the airflow path joins the main path for mainstream aerosol.   
     
     
         25 . An article according to  claim 23 , wherein the body of aerosol-generating material comprises a body according to  claim 1 . 
     
     
         26 . A non-combustible aerosol provision system comprising an article according to  claim 22  and a non-combustible aerosol provision device. 
     
     
         27 . A non-combustible aerosol provision system according to  claim 26 , wherein said device comprises a heating element arranged to penetrate the material layer in use. 
     
     
         28 . A method of forming a body of aerosol-generating material, the method comprising:
 providing a body of aerosol-generating material having a recess or cavity in the aerosol-generating material; and   applying a material layer to said aerosol-generating material such that the recess or cavity is at least partially bounded by the material layer.   
     
     
         29 . A method according to  claim 23 , wherein providing the body of aerosol-generating material comprises extruding aerosol-generating material over a die head, and wherein applying the material layer comprises feeding a central sleeve through said aerosol-generating material. 
     
     
         30 . A method of forming an article for use in a non-combustible aerosol provision system, the method comprising:
 providing a body of aerosol-generating material having one or more channels extending at least partially or completely through the body of aerosol-generating material; and aligning the one or more channels with an air flow path to allow external air to flow into the one or more channels.