An article for use in an aerosol provision system and a method of manufacturing an article for use in an aerosol provision system

Abstract

The present disclosure relates to an article for use in an aerosol provision system. The article comprises a sheet material comprising a first aerosol generating material, wherein the sheet material is gathered to form a body. The article further comprises a second aerosol generating material that is engaged by the sheet material such that the second aerosol generating material is held within the body by the sheet material. The present disclosure also relates to a method of manufacturing an article for an aerosol provision device, a kit of parts comprising an article and an aerosol provision device, and to a package of articles.

1 . An article for use in an aerosol provision system, the article comprising:
 a sheet material comprising a first aerosol generating material, wherein the sheet material is gathered to form a body; and,   a second aerosol generating material that is engaged by the sheet material such that the second aerosol generating material is held within the body by the sheet material.   
     
     
         2 . An article according to  claim 1 , wherein the second aerosol generating material is held within the body by friction. 
     
     
         3 . An article according to  claim 1 or claim 2 , wherein the second aerosol generating material is held between portions of the sheet material and, preferably, wherein the body comprises a plurality of layers of the sheet material and the second aerosol generating material is held between the layers of the sheet material. 
     
     
         4 . An article according to  any one of the preceding claims , wherein the sheet material is formed into strips or strands, wherein the second aerosol generating material is held between the strips or strands. 
     
     
         5 . An article according to  claim 4 , wherein the strips or strands extend in a direction from a first end towards a second end of the article. 
     
     
         6 . An article according to  any one of the preceding claims , wherein the sheet material is crimped. 
     
     
         7 . An article according to  any one of the preceding claims , wherein the article does not comprise additive or binder to retain the second aerosol generating material within the body. 
     
     
         8 . An article according to  any one of the preceding claims , wherein the body of material extends from a first end of the article to a second end of the article. 
     
     
         9 . An article according to  any one of the preceding claims , wherein the first and second aerosol generating materials form a collation of aerosol generating material that extends at least 90% of the length of the article and, preferably, at least 92%, 94%, 96%, 98% or 99% of the length of the article and, preferably, extends the entire length of the article. 
     
     
         10 . An article according to  any one of the preceding claims , wherein the first and/or second aerosol generating material comprises, consists of, or essentially consists of, tobacco material. 
     
     
         11 . An article according to  claim 10 , wherein the first aerosol generating material comprises reconstituted tobacco. 
     
     
         12 . An article according to  claim 10 or claim 11 , wherein the first aerosol generating material comprises tobacco lamina. 
     
     
         13 . An article according to any one of  claims 1 to 9 , wherein the first aerosol generating material is substantially tobacco free. 
     
     
         14 . An article according to  any one of the preceding claims , wherein the first aerosol generating material comprises a filler. 
     
     
         15 . An article according to  claim 14 , wherein the filler is a non-tobacco fibre. 
     
     
         16 . An article according to  claim 14 or claim 15 , wherein the filler is wood fibre or pulp or wheat fibre. 
     
     
         17 . An article according to any one of  claims 14 to 16 , wherein the filler comprises cellulose. 
     
     
         18 . An article according to any one of  claims 14 to 17 , wherein the filler is a non-tobacco cast material or a non-tobacco extruded material. 
     
     
         19 . An article according to  any one of the preceding claims , wherein the article comprises an aerosol-former material. 
     
     
         20 . An article according to  claim 19 , wherein the first and/or second aerosol generating material comprises the aerosol-former material. 
     
     
         21 . An article according to  claim 19 or claim 20 , wherein 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. 
     
     
         22 . An article according to  any one of the preceding claims , wherein the second aerosol generating material comprises extruded and/or compressed aerosol generating material and, preferably, comprises extruded and/or compressed tobacco. 
     
     
         23 . An article according to  any one of the preceding claims , wherein the second aerosol generating material comprises beads of aerosol generating material. 
     
     
         24 . An article according to  claim 22 , wherein the beads have a particle size in the range of about 0.5 mm to about 3 mm. 
     
     
         25 . An article according to  any one of the preceding claims , wherein first and second aerosol generating materials have different densities and, preferably, the density of the second aerosol-generating material is at least 25% higher than the density of the first aerosol-generating material. 
     
     
         26 . An article according to  any one of the preceding claims , wherein the second aerosol-generating material has a density in the range of about 0.4 g/cm 3  to about 2 g/cm 3 . 
     
     
         27 . An article according to  any one of the preceding claims , wherein the first aerosol-generating material with a density in the range of about 0.1 g/cm 3  to about 1 g/cm 3 . 
     
     
         28 . An article according to  any one of the preceding claims , wherein the second aerosol generating material comprises fibres of aerosol generating material. 
     
     
         29 . An article according to  any one of the preceding claims , wherein the sheet material comprises 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. 
     
     
         30 . An article according to  any one of the preceding claims , wherein the aerosol-generating material of the sheet comprises a flavourant. 
     
     
         31 . An article according to  any one of the preceding claims , wherein the sheet material is resiliently deformable. 
     
     
         32 . An article according to  any one of the preceding claims , the first and second aerosol-generating materials are present in the article in a ratio of from 1:10 to 10:1, by weight. 
     
     
         33 . An article according to  any one of the preceding claims , wherein the article comprises from about 20 to about 330 mg of the first aerosol generating material and, preferably, from about 50 to about 300 mg, or from about 40 to about 125 mg of the first aerosol generating material. 
     
     
         34 . An article according to  any one of the preceding claims , wherein the article comprises from about 20 to about 330 mg of the second aerosol generating material and, preferably, from about 50 to about 300 mg, or from about 40 to about 125 mg of the second aerosol generating material. 
     
     
         35 . An article according to  any one of the preceding claims , comprising a cooling element immediately downstream of the body. 
     
     
         36 . An article according to  claim 35 , wherein the cooling element comprises a hollow channel. 
     
     
         37 . An article according to  claim 35 or claim 36 , comprising a further body of material downstream of the cooling element. 
     
     
         38 . An article according to  claim 37 , wherein the further body of material comprises flavouring and/or filtering material. 
     
     
         39 . An article according to  any one of the preceding claims , comprising a segment upstream of the body. 
     
     
         40 . A method of manufacturing an article for use in an aerosol provision system, the method comprising:
 providing a sheet material comprising a first aerosol generating material;   providing a second aerosol generating material; and,   gathering the sheet material to form a body such that the second aerosol generating material is engaged by the sheet material such that the second aerosol generating material is held within the body by the sheet material.   
     
     
         41 . A method according to  claim 40 , comprising combining the sheet material and the second aerosol generating material and then gathering the sheet material to form the body. 
     
     
         42 . A method according to  claim 40 , comprising combining the sheet material and the second aerosol generating material whilst gathering the sheet material to form the body. 
     
     
         43 . A method according to any one of  claims 40 to 42 , comprising forming the sheet material into strips or stands. 
     
     
         44 . A method according to  claim 43 , comprising shredding and/or cutting the sheet material. 
     
     
         45 . A method according to  claim 43 or claim 44 , wherein the strips or strands extend in a direction from a first end towards a second end of the article. 
     
     
         46 . A method according to any one of  claims 40 to 45 , comprising crimping the sheet material. 
     
     
         47 . A method according to any one of  claims 40 to 46 , wherein gathering the sheet material comprises gathering the sheet material such that the second aerosol generating material is held between portions of the sheet material and, preferably, such that the body comprises a plurality of layers of the sheet material and the second aerosol generating material is held between the layers of the sheet material. 
     
     
         48 . A method according to any one of  claims 40 to 47 , wherein the method does not comprise using additive or binder to hold the second aerosol generating material within the body. 
     
     
         49 . A method according to any one of  claims 40 to 48 , wherein the first and/or second aerosol generating material comprises, consists of, or essentially consists of, tobacco material. 
     
     
         50 . A method according to  claim 49 , wherein the first aerosol generating material comprises reconstituted tobacco. 
     
     
         51 . A method according to  claim 49 or claim 50 , wherein the first aerosol generating material comprises tobacco lamina. 
     
     
         52 . A method according to any one of  claims 40 to 51 , wherein the first aerosol generating material is substantially tobacco free. 
     
     
         53 . A method according to any one of  claims 40 to 52 , wherein the first aerosol generating material comprises a filler. 
     
     
         54 . A method according to  claim 53 , wherein the filler is a non-tobacco fibre. 
     
     
         55 . A method according to  claim 53 or claim 54 , wherein the filler is wood fibre or pulp or wheat fibre. 
     
     
         56 . A method according to any one of  claims 53 to 55 , wherein the filler comprises cellulose. 
     
     
         57 . A method according to any one of  claims 53 to 56 , wherein the filler is a non-tobacco cast material or a non-tobacco extruded material. 
     
     
         58 . A method according to any one of  claims 40 to 57 , wherein the article comprises an aerosol-former material. 
     
     
         59 . A method according to  claim 58 , wherein the first and/or second aerosol generating material comprises the aerosol-former material. 
     
     
         60 . A method according to  claim 58 or claim 59 , wherein 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. 
     
     
         61 . A method according to any one of  claims 40 to 60 , wherein the second aerosol generating material comprises extruded and/or compressed aerosol generating material and, preferably, comprises extruded and/or compressed tobacco. 
     
     
         62 . A method according to any one of  claims 40 to 61 , wherein the second aerosol generating material comprises beads of aerosol generating material. 
     
     
         63 . A method according to any one of claims  40  to  3962  wherein the second aerosol generating material comprises fibres of aerosol generating material. 
     
     
         64 . A method according to any one of  claims 40 to 63 , wherein the first and second aerosol generating materials have different densities and, preferably, the density of the second aerosol generating material is at least 25% higher than the density of the first aerosol generating material. 
     
     
         65 . A method according to any one of  claims 40 to 64 , wherein the sheet material comprises 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. 
     
     
         66 . A method according to  claim 65 , wherein the aerosol generating material of the sheet material comprises a flavourant. 
     
     
         67 . A method according to any one of  claims 40 to 66 , wherein the sheet material is resiliently deformable and wherein gathering the sheet material causes the second aerosol generating material to be held between regions of the sheet material such that the sheet material is resiliently deformed. 
     
     
         68 . A method according to any one of  claims 40 to 67 , comprising a cooling element immediately downstream of the body. 
     
     
         69 . A method according to  claim 68 , wherein the cooling element comprises a hollow channel. 
     
     
         70 . A method according to  claim 68 or claim 69 , comprising a further body of material downstream of the cooling element. 
     
     
         71 . A method according to  claim 70 , wherein the further body of material comprises flavouring and/or filtering material. 
     
     
         72 . A method according to any one  claims 40 to 71 , comprising a segment upstream of the body. 
     
     
         73 . A method according to any one of  claims 40 to 72 , wherein the article comprises from about 20 to about 330 mg of the second aerosol generating material and, preferably, from about 50 to about 300 mg, or from about 40 to about 125 mg of the second aerosol generating material. 
     
     
         74 . An article manufactured according to the method of any one of  claims 40 to 73 . 
     
     
         75 . A package comprising a plurality of articles according to any one of  claims 1 to 39 or claim 74  and, preferably, wherein the package is hermetically sealed. 
     
     
         76 . A kit of parts comprising an article according to any one of  claims 1 to 39 or claim 74  and an aerosol provision device. 
     
     
         77 . A kit of parts according to  claim 76 , wherein the aerosol provision device comprises a heating zone for receiving the article to heat the first and second aerosol generating materials.