Aerosol-generating segment

Abstract

Disclosed herein is an aerosol-generating segment for use in an aerosol-generating apparatus, the aerosol-generating segment having an axial direction aligned with a flowpath of the aerosol-generating segment, and wherein the aerosol-generating segment comprises an aerosol-forming material extending in the axial direction, the aerosol-forming material comprising a fibrous filler having a density of 0.03 - 0.16 mg / mm3. Also disclosed are methods, uses, consumables and kits.

Description

FIELD

[0001] The present disclosure relates to an aerosol-generating segment for a heat-not-burn consumable. The aerosol-generating segment comprises an aerosol-forming material comprising a fibrous filler. The present disclosure also relates to a method of manufacturing the aerosol-generating segment; a heat-not-burn consumable comprising the aerosol-generating segment; an aerosol-generating apparatus comprising the aerosol-generating segment or the heat-not-burn consumable; a kit comprising the aerosol-generating segment; and a use of the aerosol-generating segment.BACKGROUND

[0002] A typical aerosol-generating consumable (or aerosol-generating article) comprises an aerosol-generating apparatus, itself comprising one or more aerosol-generating segment. A typical aerosol-generating apparatus may comprise a power supply, an aerosol-generating unit that is driven by the power supply, an aerosol aerosol-forming material, which in use is aerosolised by the aerosol-generating unit to generate an aerosol, and a delivery system for delivery of the aerosol to a user. The aerosol aerosol-forming material may be contained within the aerosol-generating consumable.

[0003] A drawback with known aerosol-generating segments, especially those comprising aerosol-generating aerosol-forming materials that are soft (for example, cotton or gel-based precursors), is that they can have low and / or inconsistent hardness. The low and / or inconsistent hardness can result in deformation during manufacture or in use.

[0004] It is against this background that the present invention has been developed.SUMMARY

[0005] A general aspect the present disclosure provides an aerosol-generating segment for a heat-not-burn consumable, where the aerosol-generating segment has an axial direction aligned with a flowpath of the aerosol-generating segment. In some examples the aerosol-generating segment comprises an aerosol-forming material extending in the axial direction. In some examples the aerosol-forming material comprises a filler containing a plurality of fibres, herein termed a fibrous filler. In some examples, the fibrous filler has a density of 0.03 - 0.16 mg / mm 3< . In some examples, the fibrous filler has a density in the axial direction, herein termed an axial density, of 1.14 - 6.15 mg / mm. Put differently, in some examples the density of the filler containing the plurality of fibres is 0.03 - 0.16 mg / mm 3< . In some examples, the axial density of the filler containing the plurality of fibres is 1.14 - 6.15 mg / mm.

[0006] A first aspect the present disclosure provides an aerosol-generating segment for a heat-not-burn consumable, the aerosol-generating segment having an axial direction aligned with a flowpath of the aerosol-generating segment, and wherein the aerosol-generating segment comprises an aerosol-forming material extending in the axial direction, the aerosol-forming material comprising a fibrous filler having a density of 0.03 - 0.16 mg / mm 3< .

[0007] As used herein, the density refers to the bulk density of the fibrous filler. In other words, the density refers to the mass of the fibres divided by the bulk volume. The bulk volume is the volume taken up by the fibres and the spaces between them (e.g., their bulk volume).

[0008] As used herein, "axial density" refers to the average (mean) density of the fibrous filler along the axial direction of the aerosol-generating segment. The axial direction refers to a line in the axis of rotation of the aerosol generating segment. The axial direction is typically aligned with a flowpath of the aerosol-generating segment, The axial density may refer to the mass of material for every unit distance in the axial direction.

[0009] In some examples, provision of an aerosol-forming material comprising a fibrous filler having a density in this range increases the strength of the aerosol-generating segment compared with the strength of a corresponding segment whose fibrous filler has a lower density. In particular, where the axial density is greater the strength of the segment may be increased compared to a filler with a lower axial density. In some examples, the increased strength can provide the aerosol-generating segment with increased hardness. In some examples, increased axial alignment leads to one or more of higher strength, higher hardness, and reduced compressibility of the filler material, and consequently of the aerosol-generating segment, in the axial direction. In some examples the hardness or strength or compressibility of the aerosol-generating segment is more comparable to the hardness or strength or compressibility, respectively, of other segments of a heat-not-burn consumable.

[0010] In some examples, the density, such as axial density, may be increased by increasing the mass of the fibrous filler in the occupied volume in the axial direction. In some examples, the mass is increased by including more fibres in the axial direction and / or by reducing the number of voids in the axial direction. In some examples, the density, such as axial density, may be increased by reducing the volume occupied by the fibrous filler in the axial direction. In some examples, the volume occupied by the fibrous filler in the axial direction may be reduced by e.g. stretching and relaxing of the fibres of the fibrous filler. In some examples, the volume occupied by the fibrous filler may be reduced in the axial direction through compression of the fibres in the axial direction. In some examples, the volume occupied by the fibrous filler in the axial direction may be influenced by the extent of alignment of the fibres of the fibrous filler.

[0011] In some examples, porosity is influenced by factors including the number and / or volume of voids.. In some examples the porosity of the aerosol-generating segment may be increased by increasing the number of voids, or by increasing the size distribution of the voids. In some examples a higher axial density of the fibrous filler allows for the porosity of the aerosol-generating segment to be retained or increased e.g. by decreasing the volume occupied by the fibres of the fibrous filler in the axial direction. In some examples, a high porosity may preserve good air flow through the aerosol-generating segment, and / or may maintain the pressure reduction during use which induces flow through the flow path of the consumable. The consistency of the pressure drop among different consumables may also be improved by maintaining a high porosity.

[0012] In some examples, a higher density, such as a higher axial density, may improve the consistency of the hardness e.g. by providing a more consistent distribution of fibres across the axial direction of the aerosol-generating segment compared to a fibrous filler having a lower axial density. A typical aerosol-generating segment may have an inconsistent hardness. The inconsistency may be among different aerosol-generating segments produced in a batch, or may be along an axial length of an individual aerosol-generating segment. A fibrous filler with a high axial density may improve the consistency of hardness among different aerosol-generating segments of a batch, and / or along an axial length of an individual aerosol-generating segment, e.g. by providing a greater contribution to the hardness of the aerosol-generating segment. This in turn may lead to a lower variance.

[0013] In some examples, the density of the fibrous filler is at least 0.04 mg / mm 3< . In some examples, the density of the fibrous filler is at least 0.05 mg / mm 3< . In some examples the density of the fibrous filler is at least 0.06 mg / mm 3< . In some examples, the density of the fibrous filler is at least 0.07 mg / mm 3< . In some examples, the density of the fibrous filler is at least 0.08 mg / mm 3< . In some examples, the density of the fibrous filler is at least 0.09 mg / mm 3< . In some examples, the density of the fibrous filler is at least 0.10 mg / mm 3< . In some examples, the density of the fibrous filler is at least 0.11 mg / mm 3< . In some examples, the density of the fibrous filler is at least 0.12 mg / mm 3< . In some examples, the density of the fibrous filler is at least 0.13 mg / mm 3< . In some examples, the density of the fibrous filler is at least or up to 0.14 mg / mm 3< . In some examples, the density of the fibrous filler is at least or up to 0.15 mg / mm 3< . Any of the foregoing may be combined to form a suitable range, such as between 0.04 and 0.15 mg / mm 3< m between 0.04 and 0.14 mg / mm 3< , between 0.07 and 0.15 mg / mm 3< , between 0.09 and 0.14 mg / mm 3< , or between 0.14 and 0.15 mg / mm 3< . In some examples, a higher density of the fibrous filler may result in one or more of increased strength of the segment, increased hardness of the segment, and / or retained or increased porosity of the fibrous filler or the segment.

[0014] In some examples, the axial density of the fibrous filler is at least 1.5 mg / mm. In some examples, the axial density of the fibrous filler is at least 1.9 mg / mm. In some examples the axial density of the fibrous filler is at least 2.3 mg / mm. In some examples, the axial density of the fibrous filler is at least 2.7 mg / mm. In some examples, the axial density of the fibrous filler is at least 3.1 mg / mm. In some examples, the axial density of the fibrous filler is at least 3.5 mg / mm. In some examples, the axial density of the fibrous filler is at least 3.8 mg / mm. In some examples, the axial density of the fibrous filler is at least 4.2 mg / mm. In some examples, the axial density of the fibrous filler is at least 4.6 mg / mm. In some examples, the axial density of the fibrous filler is at least 5 mg / mm. In some examples, the axial density of the fibrous filler is at least or up to 5.4 mg / mm. In some examples, the axial density of the fibrous filler is at least or up to 5.7 mg / mm. Any of the foregoing may be combined to form a suitable range, such as 3.5 and 5.7 mg / mm between 4 and 5 mg / mm, between 4.2 and 4.8 mg / mm, between 4.3 and 4.7 mg / mm, or between 4.4 and 4.6 mg / mm. In some examples, a higher axial density of the fibrous filler may result in one or more of increased strength of the segment, increased hardness of the segment, and / or retained or increased porosity of the fibrous filler or the segment.

[0015] The axial density of the fibrous filler may be provided by the fibrous filler supplier.

[0016] The axial density of the fibrous filler may be calculated based on the mass of the fibrous filler per length of aerosol-generating segment, the aerosol-generating segment having a certain diameter. The mass, length and diameter of the aerosol-generating segment may be measured using any suitable measuring technique and apparatus. In some examples, the mass is measured using a scale or balance. In some examples, the length and / or diameter of the aerosol-generating segment are measured using a laser measuring unit. In some examples, particle size may be measured using a sieve analysis technique, for example one in which a known quantity of particles is applied to a sieve of known mesh size and record the weight of the retained sample. The laser measuring unit may provide particularly specific dimensions. The density of the fibrous filler is typically calculated based on the mass of the fibres alone. In other words, the density of the fibrous filler does not include contributions to the mass from additional components, such as an aerosol forming liquid, nicotine, flavours or non-fibrous fillers, which may be present in the aerosol forming segment with the fibrous filler.

[0017] In some examples, the fibrous filler is formed by stretching and relaxing fibres of the fibrous filler. In some examples. The fibrous filler may be obtained by stretching and relaxing fibres. In some examples, the fibrous filler comprises or is stretched and relaxed cellulose acetate fibres. In some examples, stretching of the fibres is achieved by applying tension to the fibres. In some examples, relaxing of the fibres is achieved by removing any tension which has been applied to the fibres. In some examples, the fibres are stretched using stretching or guidance rollers.

[0018] In some examples, the fibrous filler is embossed, crimped and / or patterned; and / or is formed by stretching and relaxing fibres of the fibrous filler.

[0019] In some examples, the aerosol-forming material comprises a fibrous filler, which is a material comprising a plurality of fibres. In some examples, the fibres of the fibrous filler are elongate. In some examples, the fibres of the fibrous filler are of any suitable shape and size, and may be the same or different to each other in shape and size.

[0020] In some examples, the aerosol-forming material comprises a fibrous filler comprising cellulose-containing material. In some examples, the cellulose-containing material is a non-tobacco cellulose-containing material. In some examples, the cellulose-containing material comprises at least one of cotton, cellulose acetate, hemp, tea, or cellulose such as paper. In some examples the cellulose-containing plant-based material comprises two of cotton, cellulose acetate, hemp, tea, or cellulose such as paper. In some examples, the cellulose-containing material comprises cotton or cellulose acetate. In some examples, the cellulose-containing material is one of cotton, cellulose acetate, hemp, tea and cellulose such as paper. In some examples, the cellulose-containing material is cotton or is cellulose acetate. In some examples the aerosol-forming material is two of these materials. In some examples, the cellulose-containing material is cotton and cellulose acetate.

[0021] As used herein, "cellulose-containing material" describes processed or unprocessed cellulose, or a cellulose-derived product, such as cellulose acetate. As used herein, "cotton" describes processed or unprocessed cotton or a cotton derived product. Cellulose and cotted used herein may be naturally derived, for example from renewable, sustainable sources. In some examples, the cellulose-containing material is plant-derived.

[0022] In some examples, the fibrous filler of the aerosol-forming material further comprises a plasticizer. The plasticizer may be any plasticizer known to the skilled person. The plasticizer may increase the density of the fibrous filler, improving the hardness of the aerosol-generating segment. Any suitable plasticizer may be used, such as an ortho phthalate, terephthalate, trimellitate, adipates, sebacates or organophosphate.

[0023] In some examples, the fibrous filler described herein is only present in the aerosol-generating segment of the heat-not-burn consumable. For example, such fibrous filler is not present in other segments, such as a filter segment, of the heat-not-burn consumable. In some examples other kinds of fibrous filler may be present in other segments.

[0024] In some examples, the aerosol-generating segment has a Filtrona hardness of 91-95%. In some examples, the Filtrona hardness of the aerosol-generating segment is 92-95%. In some examples, the Filtrona hardness of the aerosol-generating segment is 93-95%. In some examples, the Filtrona hardness is 94-95%. In some examples, the Filtrona hardness of the aerosol-generating segment is at least or up to 93%. In some examples, the Filtrona hardness of the aerosol-generating segment is at least or up to 94%. Such aerosol-generating segment may have a hardness which is more comparable to other segments, particularly an adjacent segment, of the heat-not-burn consumable. In some examples this may improve the ease of manufacturing. The Filtrona Hardness Unit scale of hardness is known in the art.

[0025] The Filtrona hardness may be measured using a Borgwaldt DD60A method. In some examples, the Filtrona hardness is calculated from a Borgwaldt hardness using a correlation formula. In some examples, each of the Borgwaldt and Filtrona hardness values is an average of 50 samples. In some examples, each of the Borgwaldt and Filtrona hardness is measured by a method in which the average (mean) diameter of the samples (in mm) and the mass of the samples (in g) is taken before and after application of a load. In some examples, the load is around or is 3 kg. In some examples, the load is applied for a specified number of seconds, such as around 10 s or 10 s. In some examples, a 3 kg load is applied for 10 s.

[0026] In some examples, the method involves measuring an average diameter of the samples (in mm) before application of the load, using any suitable method such as SEM, and measuring the weight (in g) of those samples using any suitable method, such as a weighing scale, and determining the average (mean) weight per sample. In some examples, the method includes measuring an average (mean) diameter of a sample (mm) after application of the load.

[0027] In some examples, a Borgwaldt hardness (%) may be calculated as follows: average diameter after applying load mm / average diameter before applying load mm × 100

[0028] In some examples, a Filtrona hardness (%) may be calculated as follows: Borgwaldt hardness % × 38.885 / 1.3156

[0029] The aerosol-forming material may comprise plant material. The plant material may be used as the fibrous filler, where the plant material is a fibrous filler having the properties described herein. Alternatively, the plant material may be present in addition to the fibrous filler.

[0030] The plant material may comprise or be formed of tobacco. Any type of tobacco may be used, including, but is not limited to, flue-cured tobacco, burley tobacco, Virginia tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco, rustica tobacco. This also includes blends of the above mentioned tobaccos. Any suitable parts of the tobacco plant may be used, including leaves, stems, roots, bark, seeds and flowers. The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and / or reconstituted tobacco (e.g. slurry recon or paper recon). For example, the aerosol-forming material may comprise a gathered sheet of homogenised (e.g. paper / slurry recon) tobacco or gathered shreds / strips formed from such a sheet.

[0031] The tobacco may be processed tobacco, steam treated stems or shredded dried stems. The tobacco material may be fermented, cured, uncured, toasted, or otherwise pre-treated. The tobacco may be unprocessed and / or untreated.

[0032] The aerosol-forming material may be absent of tobacco and / or nicotine.

[0033] The plant material may comprise at least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Oestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia califomica (California Poppy), Fittonia albivenis, Hippobroma longi flora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombi folia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and / or synthetic alternatives of the foregoing.

[0034] The aerosol-forming material may comprise one or more additives selected from vapour generators, carrier agents, humectants, flavourants, aqueous / non-aqueous solvents and binders. The aerosol-forming material may comprise one or more additives selected from an aerosol forming liquid, a flavourant and / or a binder

[0035] The aerosol-forming material may comprise propylene glycol (PG) and / or vegetable glycerin (VG). Propylene glycol (PG) and vegetable glycerin (VG) are typically used as base materials that act as aerosol generators (alternatively referred to as aerosol-formers), carrier agents, and / or humectants. The aerosol-forming material may comprise, alternatively or in addition, other substances that function as one or more of aerosol generators, carrier agents, and humectants.

[0036] The humectant content of the aerosol-forming material may have a lower limit of at least 5 wt %, such as at least 10 wt %. The humectant content of the combustible material of the smoking body may have an upper limit of at most 50 % by weight of the plant material, such as at most 40 wt %.

[0037] Flavourants may be provided in solid form, liquid form, gel form, or a combination thereof. Flavourants may include one or more of menthol (e.g. peppermint (mentha piperita), spearmint (mentha spicata), wild mint (Mentha Arventis), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), applemint (Mentha suaveolens), pennyroyal (Mentha pulegium)), liquorice, chocolate / cocoa, fruit flavour (including e.g. apple, citrus, cherry, banana (Isoamyl acetate)), rose, vanilla (Ethylvanillin), spice (e.g. ginger, clove, cinnamon, star anise), tobacco extract / flavour, marijuana, hemp, cannabinoid compounds, citronella, orange, lemon, geraniol, thyme, fennel, green tea, black tea, coffee, salvia dorrii, salvia, passiflora incarnata, arctostaphylos uva-ursi, lobelia inflata, matcha, Yerba mate, lemon grass, flax, cedar wood, coumarin, helio, eucalyptus, ginkgo biloba, hazel, hibiscus, laurel, chamomile, rosemary, lavender, rooibos, or combinations thereof. The flavourant may be evenly dispersed throughout the aerosol-forming material or may be provided in isolated locations and / or varying concentrations throughout the aerosol-forming material.

[0038] The cannabinoid compounds may be selected from the non-exhaustive list comprising: tetrahydrocannabinol (THC), cannabidiol (CBD), cannabinol (CBN).

[0039] Binders can act to bind together the components forming the aerosol-forming material. Binders may comprise starches and / or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxy propyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and / or locust bean gum, organic acids and their salts such as alginic acid / sodium alginate, agar and pectins.

[0040] In a second aspect the present disclosure provides a method of manufacturing an aerosol-generating segment according to the first aspect. Accordingly, the disclosures relating to the first aspect apply to the second aspect. In some examples the method comprises a step of increasing the density of the fibrous filler in order to achieve a target density. In some examples the target density is a density as described in the first aspect. In some examples, the target density is 0.03 - 0.16 mg / mm 3< . In some examples, the target density is as described for the first aspect. In some examples, the target density is at least 0.06 mg / mm 3< , at least 0.10 mg / mm 3< or at least 0.13 mg / mm 3< . In some examples, the step of increasing the density of the fibrous filler comprises increasing the density of the fibrous filler. In some examples, the target density is a target axial density. In some examples, the target axial density is 1 to 6 mg / mm. In some examples, the target axial density is as described for the first aspect. In some examples, the target density is at least 1 mg / mm, at least 3 mg / mm or at least 4.5 mg / mm.

[0041] In some examples, the step of increasing the density (or axial density) of the fibrous filler comprises stretching and relaxing the fibres of the fibrous filler. In some examples, the step comprises stretching and relaxing cellulose acetate fibres. In some examples, stretching of the fibres is achieved by applying tension to the fibres. In some examples, relaxing of the fibres is achieved by removing any tension which has been applied to the fibres. In some examples, the fibres are stretched using stretching or guidance rollers.

[0042] In a third aspect the present disclosure provides a heat-not-burn consumable that comprises an aerosol-generating segment according to the first aspect. The disclosures relating to the first aspect therefore apply to the third aspect.

[0043] In some examples, the heat-not-burn consumable further comprises a hard segment adjacent to the aerosol-generating segment. In some examples, the aerosol-generating segment comprising a fibrous filler as described herein (e.g. comprising a cellulose-containing material) except having a lower axial density may be considered "soft". In some examples, having a hard segment directly adjacent such "soft" segment in a heat-not-burn consumable may be disadvantageous e.g. by increasing the possibility of accidental bending, crushing or breaking by a user where there is weakness between adjacent segments. In some examples, an aerosol-generating segment comprising a fibrous filler with the axial density as described herein may reduce, minimise or avoid some or all of those disadvantages, e.g. where the axial density increases the relative hardness.

[0044] In some examples, the hard segment comprises a filler other than the fibrous filler described herein. In some examples, the hard segment comprises a filler which is other than a cellulose-based material. In some examples, the hard segment has a Filtrona hardness of 93% or more, such as 94% or more, 95% or more, 96% or more, 97% or more, or 98% or more. In some examples, the hard segment is made using a material that has inherent hardness (i.e. the hardness is not provided by a wrapping or similar). In some examples, the aerosol-generating segment of the first aspect is harder than the hard segment. In some examples, the aerosol-generating segment of the first aspect is softer than the hard segment. In some examples the aerosol-generating segment and the hard segment are of a comparable, or approximately equal hardness. In some examples the hard segment is upstream of the aerosol-generating segment. In some examples the hard segment is downstream of the aerosol-generating segment. Upstream and downstream are set in accordance with the direction of the flow of aerosol when the consumable is in use (i.e. the flowpath).

[0045] Where a soft segment, resulting from a relatively soft aerosol-forming material such as cellulose-containing material or cotton, is used adjacent a harder segment, it is particularly prone to deformation during manufacture or in use. Therefore, providing an aerosol-generating segment having greater axial density and so better strength may improve the hardness to make the hardness of the aerosol-generating segment comparable to other segments of the heat-not-burn consumable. This may in turn enhance the handling properties of the aerosol-generating segment during manufacture and use. In some examples an aerosol-generating segment described herein may prevent, reduce or minimize crushing, bending or breaking of the heat-not-burn consumable by the user or during manufacture, such as during insertion or removal from an aerosol-generating apparatus.

[0046] In some examples, the hard segment is an additional aerosol-generating segment, a filter segment or a cooling segment.

[0047] In some examples, the hard segment is an additional aerosol-generating segment. For example, the additional aerosol-generating segment may comprise a reconstituted aerosol-generating aerosol-forming material that is harder than the aerosol-forming material used in the aerosol-generating segment described herein.

[0048] In some examples, the hard segment is a filter segment. In some examples, the filter segment is a hollow bore filter. In some examples, the bore is positioned longitudinally in the centre of the filter.

[0049] A filter segment is defined as a porous element configured to remove one or more components of the fluid passing therethrough, e.g. solid particles from a liquid or gas passed through the filter. The filter elements may be formed from materials including cellulose acetate, polypropylene tow, activated charcoal, paper, extruded plant material, and like materials. The filter elements may be circumscribed with a plug wrap, e.g. a paper plug wrap, to help maintain the form of the filter element. The filter elements may be solid. The filter elements may be hollow bore filter elements comprising one or more bores extending longitudinally through the filter element. The filter elements may retain flavorant elements, such as granules, pellets, strips, capsules or other objects.

[0050] In some examples, the hard segment is a cooling segment. The cooling segment cools the aerosol generated when the consumable is in use. In some examples, the cooling segment comprises a paper tube. In some examples, the cooling segment comprises a spiral paper tube, that is a continuous paper tube, wound in a spiral.

[0051] The cooling segment may be referred to as supporting element. A "supporting element" relates to an element configured to provide support to the consumable, e.g. support the wrapping layer(s) of the consumable. The supporting element may be an inactive element insofar as it is configured not to generate a vapour, even if heated.

[0052] The supporting element may comprise an internal cavity. The internal cavity may be substantially empty and extend along the length of the cooling element to provide a substantially unrestricted air flow therethrough. The walls of the internal cavity may be substantially impermeable to aerosol such that the supporting element does not filter aerosol flowing therethrough. The internal cavity may define a mixing zone for aerosols therein. For instance, the turbulent flow resulting from pressure changes as air enters and exits the internal cavity can enhance aerosol mixing.

[0053] The supporting element may be provided in the form of a hollow tube, such that the internal cavity has a substantially constant cross-sectional area. The supporting element may have a high void fraction (cavity volume per total volume), for example having a porosity greater than 0.5, greater than 0.7, or greater than 0.9.

[0054] The supporting element may be formed of cardboard, paper, cellulose acetate, or other like material.

[0055] The supporting element may be configured to reduce the temperature of the aerosol generated during the heating process - and thus can be referred to as a "cooling element". As the aerosol passes through the cooling element, the temperature of the aerosol can be reduced due to transfer of thermal energy to the cooling element. In particular, the cooling element has a large surface area and low resistance to draw compared to upstream and / or downstream sections of the consumable.

[0056] The aerosol-forming material may be circumscribed by a wrapping layer e.g. a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper / foil laminate (with the foil innermost).

[0057] Any elements (e.g. filter elements, cooling element, spacer elements) downstream of the aerosol-forming material may be at least partially (e.g. entirely) circumscribed by the wrapping layer. Accordingly, the wrapping layer may alternatively be referred to as a 'combining layer'. The wrapping layer may at least partially (e.g. entirely) circumscribe elements upstream of the terminal filter element.

[0058] The terminal filter element (at the downstream end of the article / consumable) may be joined to the upstream elements forming the article / consumable by a circumscribing tipping layer e.g. a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

[0059] Any elements (e.g. filter elements, cooling element, spacer elements) may be further circumscribed by a respective plug wrap e.g. a paper plug wrap.

[0060] In a fourth aspect the present disclosure provides an aerosol-generating system comprising an aerosol-generating segment according to the first aspect or a heat-not-burn consumable according to the second aspect. In some examples , the aerosol-generating system comprises an aerosol-generating unit.

[0061] In a fifth aspect the present disclosure provides a use of a fibrous filler to increase the hardness of an aerosol-generating segment of a heat-not-burn consumable. In some examples the fibrous filler has a density of 0.03 - 0.16 mg / mm 3< . In some examples, the axial density of the fibrous filler is as described for the fibrous filler used in the first aspect.

[0062] The present disclosure also provides a use of a fibrous filler to improve the consistency of the hardness of an aerosol-generating segment of a heat-not-burn consumable. In some examples the fibrous filler has a density of 0.03 - 0.16 mg / mm 3< . In some examples, the axial density of the fibrous filler is as described for the fibrous filler used in the first aspect.

[0063] The present disclosure also provides a use of a fibrous filler to improve handling of an aerosol-generating segment during manufacture of a heat-not-burn consumable. In some examples the fibrous filler has a density of 0.03 - 0.16 mg / mm 3< . In some examples, the axial density of the fibrous filler is as described for the fibrous filler used in the first aspect.

[0064] The present disclosure also provides a method of generating an aerosol which may implement any one or more features disclosed herein. The method may comprise heating the aerosol-generating segment of the first aspect to generate an aerosol.

[0065] The preceding summary is provided for purposes of summarizing some examples to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the above-described features should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and / or proceeding examples may be combined in any suitable combination to provide further examples, except where such a combination is clearly impermissible or expressly avoided. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following text and the accompanying drawings.BRIEF DESCRIPTION OF THE FIGURES

[0066] Aspects, features and advantages of the present disclosure will become apparent from the following description of examples in reference to the appended drawings in which like numerals denote like elements. Fig. 1 is a block system diagram showing an example aerosol-generating apparatus. Fig. 2 is a block system diagram showing an example implementation of the apparatus of Fig. 1, where the aerosol-generating apparatus is configured to generate aerosol from a solid aerosol-forming material. Fig. 3 is a schematic diagram showing an example implementation of the apparatus of Fig. 2. Fig. 4 is a cross-sectional diagram of an example implementation of a heat-not-burn consumable. Fig. 5 is a cross-sectional diagram of an example implementation of a heat-not-burn consumable. Fig. 6 is a flow diagram of an example method of preparation of the aerosol generating segment. DETAILED DESCRIPTION OF EMBODIMENTS

[0067] Before describing several examples implementing the present disclosure, it is to be understood that the present disclosure is not limited by specific construction details or process steps set forth in the following description and accompanying drawings. Rather, it will be apparent to those skilled in the art having the benefit of the present disclosure that the systems, apparatuses and / or methods described herein could be embodied differently and / or be practiced or carried out in various alternative ways.

[0068] Unless otherwise defined herein, scientific and technical terms used in connection with the presently disclosed inventive concept(s) shall have the meanings that are commonly understood by those of ordinary skill in the art and known techniques and procedures may be performed according to conventional methods well known in the art and as described in various general and more specific references that may be cited and discussed in the present specification.

[0069] Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.

[0070] All examples implementing the present disclosure can be made and executed without undue experimentation in light of the present disclosure. While particular examples have been described, it will be apparent to those of skill in the art that variations may be applied to the systems, apparatus, and / or methods and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit, and scope of the inventive concept(s). All such similar substitutions and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the inventive concept(s) as defined by the appended claims.

[0071] The use of the term "a" or "an" in the claims and / or the specification may mean "one," as well as "one or more," "at least one," and "one or more than one." As such, the terms "a," "an," and "the," as well as all singular terms, include plural referents unless the context clearly indicates otherwise. Likewise, plural terms shall include the singular unless otherwise required by context.

[0072] The use of the term "or" in the present disclosure (including the claims) is used to mean an inclusive "and / or" unless explicitly indicated to refer to alternatives only or unless the alternatives are mutually exclusive. For example, a condition "A or B" is satisfied by any of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0073] As used in this specification and claim(s), the words "comprising, "having," "including," or "containing" (and any forms thereof, such as "comprise" and "comprises," "have" and "has," "includes" and "include," or "contains" and "contain," respectively) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[0074] Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, examples, or claims prevent such a combination, the features of examples disclosed herein, and of the claims, may be integrated together in any suitable arrangement, especially ones where there is a beneficial effect in doing so. This is not limited to only any specified benefit, and instead may arise from an "ex post facto" benefit. This is to say that the combination of features is not limited by the described forms, particularly the form (e.g. numbering) of example(s), embodiment(s), or dependency of claim(s). Moreover, this also applies to the phrase "in one embodiment," "according to an embodiment," and the like, which are merely a stylistic form of wording and are not to be construed as limiting the following features to a separate embodiment to all other instances of the same or similar wording. This is to say, a reference to 'an,' 'one,' or 'some' embodiment(s) may be a reference to any one or more, and / or all embodiments, or combination(s) thereof, disclosed. Also, similarly, the reference to "the" embodiment may not be limited to the immediately preceding embodiment. Further, all references to one or more embodiments or examples are to be construed as non-limiting to the claims.

[0075] The present disclosure may be better understood in view of the following explanations, wherein the terms used that are separated by "or" may be used interchangeably.

[0076] As used herein, an "aerosol-generating apparatus " (or "electronic(e)-cigarette ") may be an apparatus configured to deliver an aerosol to a user for inhalation by the user. The apparatus may additionally / alternatively be referred to as a "smoking substitute apparatus", if it is intended to be used instead of a conventional combustible smoking article. As used herein a combustible "smoking article" may refer to a cigarette, cigar, pipe or other article, that produces smoke (an aerosol comprising solid particulates and gas) via heating above the thermal decomposition temperature (typically by combustion and / or pyrolysis). An aerosol generated by the apparatus may comprise an aerosol with particle sizes of 0.2 - 7 microns, or less than 10 microns, or less than 7 microns. This particle size may be achieved by control of one or more of: heater temperature; cooling rate as the vapour condenses to an aerosol; flow properties including turbulence and velocity. The generation of aerosol by the aerosol-generating apparatus may be controlled by an input device. The input device may be configured to be user-activated and may for example include or take the form of an actuator (e.g. actuation button) and / or an airflow sensor.

[0077] Each occurrence of the aerosol-generating apparatus being caused to generate aerosol for a period of time (which may be variable) may be referred to as an "activation " of the aerosol-generating apparatus. The aerosol-generating apparatus may be arranged to allow an amount of aerosol delivered to a user to be varied per activation (as opposed to delivering a fixed dose of aerosol), e.g. by activating an aerosol-generating unit of the apparatus for a variable amount of time, e.g. based on the strength / duration of a draw of a user through a flow path of the apparatus (to replicate an effect of smoking a conventional combustible smoking article).

[0078] The aerosol-generating apparatus may be portable. As used herein, the term "portable " may refer to the apparatus being for use when held by a user.

[0079] As used herein, an "aerosol-generating system " may be a system that includes an aerosol-generating apparatus and optionally other circuitry / components associated with the function of the apparatus, e.g. one or more external devices and / or one or more external components (here "external" is intended to mean external to the aerosol-generating apparatus). As used herein, an "external device" and "external component" may include one or more of a: a charging device, a mobile device (which may be connected to the aerosol-generating apparatus, e.g. via a wireless or wired connection); a networked-based computer (e.g. a remote server); a cloud-based computer; any other server system.

[0080] An example aerosol-generating system may be a system for managing an aerosol-generating apparatus. Such a system may include, for example, a mobile device, a network server, as well as the aerosol-generating apparatus.

[0081] As used herein, an "aerosol " may include a suspension of aerosol-forming material, including as one or more of: solid particles; liquid droplets; gas. Said suspension may be in a gas including air. An aerosol herein may generally refer to / include a vapour. An aerosol may include one or more components of the aerosol-forming material.

[0082] As used herein, a "aerosol-forming material " may include one or more of a: liquid; solid; gel; loose leaf material; other substance. The aerosol-forming material may be processed by an aerosol-generating unit of an aerosol-generating apparatus to generate an aerosol. The aerosol-forming material may include one or more of: an active component; a carrier; a flavouring. The active component may include one or more of nicotine; caffeine; a cannabidiol oil; a non-pharmaceutical formulation, e.g. a formulation which is not for treatment of a disease or physiological malfunction of the human body. The active component may be carried by the carrier, which may be a liquid, including propylene glycol and / or glycerine. The term "flavouring" may refer to a component that provides a taste and / or a smell to the user. The flavouring may include one or more of: Ethylvanillin (vanilla); menthol, Isoamyl acetate (banana oil); or other. The aerosol-forming material may include a substrate, e.g. reconstituted tobacco to carry one or more of the active component; a carrier; a flavouring.

[0083] As used herein, a "storage portion " may be a portion of the apparatus adapted to store the aerosol-forming material.

[0084] As used herein, a "flow path " may refer to a path or enclosed passageway through an aerosol-generating apparatus, e.g. for delivery of an aerosol to a user. The flow path may be arranged to receive aerosol from an aerosol-generating unit. When referring to the flow path, upstream and downstream may be defined in respect of a direction of flow in the flow path, e.g. with an outlet being downstream of an inlet.

[0085] As used herein, a "delivery system " may be a system operative to deliver an aerosol to a user. The delivery system may include a mouthpiece and a flow path.

[0086] As used herein, a "flow " may refer to a flow in a flow path. A flow may include aerosol generated from the aerosol-forming material. The flow may include air, which may be induced into the flow path via a puff by a user.

[0087] As used herein, a "puff " (or "inhale " or "draw ") by a user may refer to expansion of lungs and / or oral cavity of a user to create a pressure reduction that induces flow through the flow path.

[0088] As used herein, an "aerosol -generating unit " may refer to a device configured to generate an aerosol from a aerosol-forming material. The aerosol-generating unit may include a unit to generate a vapour directly from the aerosol-forming material (e.g. a heating system or other system) or an aerosol directly from the aerosol-forming material (e.g. an atomiser including an ultrasonic system, a flow expansion system operative to carry droplets of the aerosol-forming material in the flow without using electrical energy or other system). A plurality of aerosol-generating units to generate a plurality of aerosols (for example, from a plurality of different aerosol aerosol-forming materials) may be present in an aerosol-generating apparatus.

[0089] As used herein, a "heating system" may refer to an arrangement of at least one heating element, which is operable to aerosolise a aerosol-forming material once heated. The at least one heating element may be electrically resistive to produce heat from the flow of electrical current therethrough. The at least one heating element may be arranged as a susceptor to produce heat when penetrated by an alternating magnetic field. The heating system may be configured to heat a aerosol-forming material to below 300 or 350 degrees C, including without combustion.

[0090] As used herein, a "consumable " may refer to a unit that includes a aerosol-forming material. The consumable may include an aerosol-generating unit, e.g. it may be arranged as a cartomizer. The consumable may include a mouthpiece. The consumable may include an information carrying medium. In a heat-not-burn consumable, the mouthpiece may be implemented as a filter and the consumable may be arranged to carry the aerosol-forming material. The consumable may be implemented as a dosage or pre-portioned amount of material, including a loose-leaf product.

[0091] As used herein, an "information carrying medium " may include one or more arrangements for storage of information on any suitable medium. Examples include: a computer readable medium; a Radio Frequency Identification (RFID) transponder; codes encoding information, such as optical (e.g. a bar code or QR code) or mechanically read codes (e.g. a configuration of the absence or presents of cutouts to encode a bit, through which pins or a reader may be inserted).

[0092] As used herein "heat-not-burn " (or "HNB " or "heated aerosol-forming material ") may refer to the heating of a aerosol-forming material, typically tobacco, without combustion, or without substantial combustion (i.e. localised combustion may be experienced of limited portions of the aerosol-forming material, including of less than 5% of the total volume).

[0093] As used herein, "hard " and "soft ", and any comparative term derived therefrom, may refer to the relative hardness of a segment of the consumable and refer to the ease with which a material can be locally plastically deformed (i.e., dented, deformed, scratched, etc). In some examples, the hardness is measured using Filtrona Hardness Units.

[0094] Referring to Fig. 1, an example aerosol-generating apparatus 1 includes a power supply 2, for supply of electrical energy. The apparatus 1 includes an aerosol-generating unit 4 that is driven by the power supply 2. The power supply 2 may include an electric power supply in the form of a battery and / or an electrical connection to an external power source. The apparatus 1 includes a aerosol-forming material 6, which in use is aerosolised by the aerosol-generating unit 4 to generate an aerosol. The apparatus 2 includes a delivery system 8 for delivery of the aerosol to a user.

[0095] Electrical circuitry (not shown in figure 1) may be implemented to control the interoperability of the power supply 4 and aerosol-generating unit 6.

[0096] In variant examples, which are not illustrated, the power supply 2 may be omitted since, e.g. an aerosol-generating unit implemented as an atomiser with flow expansion may not require a power supply.

[0097] Fig. 2 shows an implementation of the apparatus 1 of Fig. 1, where the aerosol-generating apparatus 1 is configured to generate aerosol by a-heat not-burn process.

[0098] In this example, the apparatus 1 includes a device body 50 and a consumable 70.

[0099] In this example, the body 50 includes the power supply 4 and a heating system 52. The heating system 54 includes at least one heating element 54. The body may additionally include any one or more of electrical circuitry 56, a memory 58, a wireless interface 60, one or more other components 62.

[0100] The electrical circuitry 56 may include a processing resource for controlling one or more operations of the body 50, e.g. based on instructions stored in the memory 58.

[0101] The wireless interface 60 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.

[0102] The other component(s) 62 may include an actuator, one or more user interface devices configured to convey information to a user and / or a charging port, for example (see e.g. Fig. 3).

[0103] The body 50 is configured to engage with the consumable 70 such that the at least one heating element 54 of the heating system 52 penetrates into the solid aerosol-forming material 6 of the consumable. In use, a user may activate the aerosol-generating apparatus 1 to cause the heating system 52 of the body 50 to cause the at least one heating element 54 to heat the solid aerosol-forming material 6 of the consumable (without combusting it) by conductive heat transfer, to generate an aerosol which is inhaled by the user.

[0104] Fig. 3 shows an example implementation of the aerosol-generating device 1 of Fig. 2.

[0105] As depicted in Fig. 3, the consumable 70 is implemented as a stick, which is engaged with the body 50 by inserting the stick into an aperture at a top end 53 of the body 50, which causes the at least one heating element 54 of the heating system 52 to penetrate into the solid aerosol-forming material 6.

[0106] The consumable 70 includes the solid aerosol-forming material 6 proximal to the body 50, and a filter distal to the body 50. The filter serves as the mouthpiece of the consumable 70 and thus the apparatus 1 as a whole. The solid aerosol-forming material 6 may be a reconstituted tobacco formulation. The solid aerosol-forming material 6 comprises a fibrous filler.

[0107] In this example, the at least one heating element 54 is a rod-shaped element with a circular transverse profile. Other heating element shapes are possible, e.g. the at least one heating element may be blade-shaped (with a rectangular transverse profile) or tube-shaped (e.g. with a hollow transverse profile).

[0108] In this example, the body 50 includes a cap 51. In use the cap 51 is engaged at a top end 53 of the body 50. Although not apparent from Fig. 5, the cap 51 is moveable relative to the body 50. In particular, the cap 51 is slidable and can slide along a longitudinal axis of the body 50.

[0109] The body 50 also includes an actuator 55 on an outer surface of the body 50. In this example, the actuator 55 has the form of a button.

[0110] The body 50 also includes a user interface device configured to convey information to a user. Here, the user interface device is implemented as a plurality of lights 57, which may e.g. be configured to illuminate when the apparatus 1 is activated and / or to indicate a charging state of the power supply 4. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.

[0111] The body may also include an airflow sensor which detects airflow in the aerosol-generating apparatus 1 (e.g. caused by a user inhaling through the consumable 70). This may be used to count puffs, for example.

[0112] In this example, the consumable 70 includes a flow path which transmits aerosol generated by the at least one heating element 54 to the mouthpiece of the consumable.

[0113] In this example, the aerosol-generating unit 4 is provided by the above-described heating system 52 and the delivery system 8 is provided by the above-described flow path and mouthpiece of the consumable 70.

[0114] Fig. 4 is a cross-sectional diagram of an example implementation of a heat-not-burn consumable 70, including the aerosol-generating segment 100 of the invention. The aerosol-generating segment 100 includes a fibrous filler 120 as described herein. The fibrous filler 120 has a density of 0.03 - 0.16 mg / mm 3< . In particular, the fibrous filler 120 has an axial density of 1 - 6 mg / mm. By providing a fibrous filler having this density, the aerosol generating segment is thought to have increased strength, increased and / or hardness, which in turn improves the handleability of the segment during manufacturer and storage. The fibrous filler 120 is made from a non-tobacco cellulose-containing material. The fibrous filler 120 is made from cellulose acetate. The fibrous filler 120 of the aerosol generating segment 100 is formulated with additional components, including an aerosol forming liquid (e.g., glycerine or propylene glycol) and flavourants.

[0115] The aerosol-generating segment 100, is located at or towards an upstream end of the consumable 70. Further upstream of the aerosol-generating segment 100 may be other elements, such as a filter or another segment, not shown. Downstream of the aerosol-generating segment 100 is a tubular segment 410. The tubular segment 410 may be known as a cooling segment. Downstream of the tubular segment 410 is a mouthpiece filter 420. The mouthpiece filter 420 is at the downstream end of the consumable 70. The aerosol-generating segment 100, the tubular segment 410 and the mouthpiece filter 420 are wrapped together using wrapper 140. The wrapper 140 is wrapped around the segments and glued into place using an adhesive.

[0116] Fig. 5 is a cross-sectional diagram of an example implementation of a heat-not-burn consumable 70, including the aerosol-generating segment 100 of the invention and a hard segment 122. The aerosol-generating segment 100 includes a fibrous filler 120 as described herein. The hard segment 122 is adjacent to the aerosol generating segment 100. The aerosol-generating segment 100, is located at or towards an upstream end of the consumable 70. Further upstream of the aerosol-generating segment 100 may be other elements, such as a filter or another segment, not shown. Downstream of the aerosol-generating segment 100 is the hard segment 122 followed by the tubular segment 410. The tubular segment 410 may be known as a cooling segment. Downstream of the tubular segment 410 is a mouthpiece filter 420. The mouthpiece filter 420 is at the downstream end of the consumable 70. The aerosol-generating segment 100, the tubular segment 410 and the mouthpiece filter 420 are wrapped together using wrapper 140. The wrapper 140 is wrapped around the segments and glued into place using an adhesive.

[0117] Generally, the aerosol-generating segments 100 in Fig. 4 to and 5 can be manufactured in a number of ways. Fig. 6 illustrates one method for preparing the segment. This include (i) providing the fibrous filler; (ii) increasing the density of the fibrous filler; and (iii) forming the fibrous filler into an aerosol generating segment. The aerosol generating segment may be wrapped using a paper wrapper. The aerosol generating segment may be combined with other segments, such as a hard segment of Figure 5. The aerosol generating segment may be combined into a heat-not-burn consumable. The step of increasing the density of the fibrous filler typically comprises: i) stretching and relaxing the fibres of the fibrous filler; and optionally ii) embossing, crimping or patterning the fibrous filler.

Claims

1. An aerosol-generating segment for a heat-not-burn consumable, the aerosol-generating segment having an axial direction aligned with a flowpath of the aerosol-generating segment, and wherein the aerosol-generating segment comprises an aerosol-forming material extending in the axial direction, the aerosol-forming material comprising a fibrous filler having a density of 0.03 - 0.16 mg / mm3.

2. The aerosol-generating segment according to claim 1, wherein the density of the fibrous filler is at least 0.06 mg / mm3, optionally at least 0.10 mg / mm3, optionally at least 0.13 mg / mm3.

3. The aerosol-generating segment according to claim 1 or claim 2, wherein the axial density of the fibrous filler is 1 to 6 mg / mm, optionally 3 to 5 mg / mm, optionally 4.2 to 4.8 mg / mm.

4. The aerosol-generating segment according to any of claims 1 to 3, wherein the fibrous filler is formed by stretching and relaxing fibres of the fibrous filler.

5. The aerosol-generating segment according to any of claims 1 to 4, wherein the fibrous filler of the aerosol-forming material comprises a cellulose-containing material, optionally wherein the cellulose-containing material is a non-tobacco cellulose-containing material.

6. The aerosol-generating segment according to any one of claims 1 to 5, wherein the fibrous filler of the aerosol-forming material comprises or is one or more selected from cotton, cellulose acetate, hemp or tea.

7. The aerosol-generating segment according to any of claims 1 to 6, wherein the fibrous filler of the aerosol-forming material further comprises a plasticizer.

8. The aerosol-generating segment according to any of claims 1 to 7, wherein the aerosol-generating segment has a Filtrona hardness of 91-95 %.

9. A method of manufacturing an aerosol-generating segment according to any of claims 1 to 8, wherein the method comprises providing a fibrous filler, and a step of increasing the density of the fibrous filler in order to achieve a target density, wherein the target density is in the range 0.03 - 0.16 mg / mm3.

10. The method according to claim 9, wherein the step of increasing the density of the fibrous filler comprises: i) stretching and relaxing the fibres of the fibrous filler; and / or ii) embossing, crimping or patterning the fibrous filler.

11. A heat-not-burn consumable comprising an aerosol-generating segment according to any of claims 1 to 8, or obtained or obtainable by the method according to claim 9 or 10.

12. The heat-not-burn consumable according to claim 11, wherein the heat-not-burn consumable further comprises a hard segment adjacent to the aerosol-generating segment. optionally wherein the hard segment is an additional aerosol-generating segment, a filter segment or a cooling segment.

13. The heat-not-burn consumable according to claim 12, wherein the aerosol-generating segment is softer than the hard segment, optionally wherein the aerosol-generating segment has a Filtrona hardness which is less than the hard segment.

14. An aerosol-generating system comprising the aerosol-generating segment according to any of claims 1 to 8, or the heat-not-burn consumable according to any of claims 11 to 13, and an aerosol-generating unit.

15. Use of a fibrous filler to increase the hardness of an aerosol-generating segment, wherein the fibrous filler has a density of 0.03 - 0.16 mg / mm3.

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