Aerosol generating segment

Abstract

An aerosol-generating segment 100 for a heat-not-burn consumable 70, an aerosol forming material 6, comprising a substrate and an aerosol former; and a wrapper 140 circumscribing the aerosol forming material 6; wherein the aerosol forming material 6 comprises a high concentration region of liquid aerosol former 150 and a low concentration region of liquid aerosol former, wherein the high concentration region 150 is located adjacent to a portion of the interface between the aerosol forming material 6 and wrapper 140; a heat-not-burn consumable 70 comprising such an aerosol-generating segment 100; an aerosol-generating system comprising a heat-not-burn consumable 70 and an aerosol-generating apparatus 1, the aerosol-generating apparatus 1 comprising an aerosol generating unit 4; and a method of manufacturing such an aerosol-generating segment 100.

Description

FIELD

[0001] The present disclosure relates to an aerosol generating segment for a heat-not-burn consumable, an aerosol generating system comprising a heat-not-burn consumable and an aerosol generating unit, and a method of manufacturing an aerosol generating segment. The present disclosure further provides a use of the aerosol generating segment and use of a seam line applicator to apply liquid aerosol former to an aerosol generating segment.BACKGROUND

[0002] A typical aerosol generating apparatus may comprise a power supply, an aerosol generating unit that is driven by the power supply, an 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.

[0003] One approach for an aerosol generating system is the "heat-not-burn" ("HNB") approach in which a solid aerosol forming material comprising a substrate such as tobacco and a liquid aerosol former such as glycerol is heated or warmed to release vapour. In this approach the intention is that the aerosol generating substrate, such as tobacco, is heated but not burned, i.e. the aerosol generating substrate does not undergo combustion.

[0004] A typical heat-not-burn aerosol generating system may include a heating system and a consumable. The consumable may have an aerosol generating segment housing the aerosol forming material.

[0005] In use, the aerosol forming material is heated by the heating system, wherein airflow through the aerosol forming material causes moisture, aerosol former, and / or volatile compounds in the aerosol forming material to be released as vapour. The released vapour may be entrained in the airflow drawn through the aerosol forming material.

[0006] High temperatures are needed for vaporisation of liquid aerosol former, such as propylene glycol and glycerol. Therefore, at the start of a session, a high rate of heating is needed to achieve these high temperatures quickly and provide the vapour desired by the user. However, both the high temperature and high rate of heating may burn or char the aerosol forming material, resulting in a bitter taste. Overheating of the substrate can lead to burning and compromised user experience. Moreover, the high temperature and high rate of heating may cause any flavourant to be released from the aerosol forming material prematurely, resulting in a high level of flavour at the start of the session but a low level of flavour later in the session.

[0007] Aerosol forming materials including a high level of liquid aerosol forming material are typically difficult to handle during manufacturing processes, and are difficult to store in the assembled consumable. The high level of liquid aerosol forming material makes the aerosol forming material sticky and liable to take on water during storage.

[0008] There is a general desire to improve the overall quality of the vapour generated by such systems, while minimising (or entirely avoiding) any burning of the precursor material. In spite of the effort already invested in the development of aerosol generating apparatuses / systems further improvements are desirable.

[0009] It is against this background that the present invention has been developed.SUMMARY

[0010] In general, the present disclosure provides an aerosol generating segment comprising a high concentration region of liquid aerosol former and a low concentration region of liquid aerosol former, wherein the high concentration region is located adjacent to a portion of the interface between an aerosol forming material and a wrapper.

[0011] In a first aspect the present disclosure provides an aerosol generating segment that comprises an aerosol forming material, and a wrapper circumscribing the aerosol forming material, wherein the aerosol generating segment comprises a high concentration region of liquid aerosol former and a low concentration region of liquid aerosol former, wherein the high concentration region is located adjacent to a portion of the interface between the aerosol forming material and wrapper.

[0012] In aerosol generating segments comprising liquid aerosol former (e.g. propylene glycol or glycerol, such as vegetable glycerine), it is desirable to have localised regions of high concentration of liquid aerosol former which may be preferentially heated over the substrate. In particular, the high concentration region of liquid aerosol former allows for preferential vaporisation of the aerosol forming material, to generate vapour from the aerosol forming material. Thus, even when the average concentration of liquid aerosol former is low, the high local concentration of liquid aerosol former provides a high rate of aerosol generation, especially, at the start of a session. The regions of low liquid aerosol former concentration may have a lower rate of vaporisation and heating, and so flavour release may be more gradual.

[0013] In this way, differential heating of the liquid aerosol former and aerosol generating substrate can be achieved with a single heater. In general, it is desirable to heat the liquid aerosol former to a higher temperature and / or at a higher rate than other components of the aerosol forming material, such as tobacco and / or flavourants. When a high concentration region of liquid aerosol former is located adjacent the interface between the aerosol forming material and wrapper the liquid aerosol former in this region will reach a higher temperature in a shorter time compared with the substrate when the segment is heated from the outside-in (for example, with an annular heating element adjacent to the circumference of the segment). This may enable preferential vaporisation of the liquid aerosol former in the high concentration region located adjacent the interface between the aerosol forming material and wrapper due to its proximity to the heater. Thus, the substrate is heated to a lower temperature than the high concentration region of liquid aerosol former in the same time, which reduces the risk of burning the substrate and may provide more even heating. It is desirable to heat the liquid aerosol former to a higher temperature at a faster rate to increase vaporisation, especially at the start of a session, to improve the experience for the user. It is also desirable to heat the substrate and / or flavourant to a lower temperature than the liquid aerosol former to provide gradual release over the session and prevent charring or burning which can compromise taste.

[0014] Specific, localised high concentration regions are advantageous over generally increasing liquid aerosol former in a peripheral region of the aerosol forming material as problems with liquid aerosol former migration may be reduced or prevented. Additionally, heating can be localised to control the temperature of the high concentration region of liquid aerosol former relative to the rest of the aerosol forming material.

[0015] In this way, a single heater with a single heating temperature can be used to provide differential heating of the components of the aerosol generating segment. This reduces the complexity of the consumable and the unit or device it is configured for use with, and thus the aerosol generating system as a whole. This may reduce cost, whilst still providing an improved user experience relative to a single segment consumable with a uniform distribution of liquid aerosol former. This also increases customisability of a consumable containing the aerosol generating segment, for example, different components can be incorporated in different aerosol generating segments or sections or, for example, the ratio of vapour to flavour can be increased or decreased. The increased design flexibility allows for a larger variety of products to be built around the same segment architecture, with more tailored flavour profile, vapour generation, and user experience.

[0016] The aerosol generating segment of the present invention is for use in an aerosol generating unit, for example a heat-not-burn (HNB) aerosol generating device. The aerosol generating segment can be used in a consumable, for example a HNB consumable, which in some examples comprises further segments, for example cooling segments, filter segments, or further aerosol generating segments.

[0017] The aerosol generating segment comprises a substrate (also referred to herein as an aerosol generating substrate) which is capable of generating a vapour or an aerosol when heated with a liquid aerosol former. Herein, a combination of substrate and liquid aerosol former, possibly including further components, may be referred to as an aerosol forming material ("precursor"). The substrate material is able to carry the liquid aerosol former.

[0018] The wrapper circumscribes the aerosol forming material and defines the perimeter of the aerosol-generating segment. Any suitable wrapper may be used. In some examples, the wrapper is a paper wrapper or paper-based wrapper. The wrapper may comprise a laminate wrapping paper. The laminate wrapping paper may be a foil-paper laminate. The foil may be an aluminium foil. The wrapping paper may be fixed in place with an adhesive. Any suitable adhesive may be used. In some examples, the same wrapper wraps more than one segment together, for example in a heat-not-burn consumable comprising further segments.

[0019] 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).

[0020] 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. 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.

[0021] 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.

[0022] In some examples, the substrate takes up 50% or more of the volume of the aerosol-generating segment, wherein the total volume of the aerosol-generating segment is 100%. In some examples, the substrate takes up 60% or more of the volume of the aerosol-generating segment, such as 70% or more, 80% or more, 90% or more, or 95% or more of the volume of the aerosol-generating segment. In some examples, the substrate takes up substantially all of the volume of the aerosol-generating segment.

[0023] In some examples, the shape formed by the substrate within the aerosol-generating segment is approximately the same shape as the aerosol-generating segment. In some examples, the length of the substrate is the same or substantially the same as that of the aerosol-generating segment, for example when both the aerosol-generating segment and the substrate are elongate. In some examples, the shape of the aerosol-generating segment is defined by the wrapper.

[0024] In some examples the aerosol generating segment has a length of 1 to 50 mm. In some examples the length of the aerosol generating segment is 5 to 30 mm. In some examples the aerosol generating segment has a thickness (e.g. diameter) of 1 to 15 mm. In some examples the thickness of the aerosol generating segment is 4 to 12 mm. In some examples, the elongate substrate is continuous or unbroken / uninterrupted.

[0025] In some examples, liquid aerosol former is held within pores of the substrate and can be described as being impregnated within the substrate. In some examples, liquid aerosol former is coated on constituent particles (e.g. fibres, beads, flakes, etc) of the substrate. In some examples, liquid aerosol former is located between constituent particles (e.g. fibres, beads, flakes, etc) of the substrate.

[0026] In some examples the liquid aerosol former is non-uniformly distributed in the aerosol-generating segment. In some examples, the liquid aerosol former is non-uniformly distributed about the axis of rotation of the aerosol forming material.

[0027] Herein, a uniform distribution is understood to mean a substantially uniform distribution. In such distributions, the liquid aerosol former may be present at substantially the same average concentration across the entirety of the aerosol- generating substrate or aerosol generating segment. A uniform distribution is capable of having localised fluctuations in concentration, but globally comprises no significant maxima or minima in average concentration. Herein, "uniform" might also be described as being "constant" or "substantially constant".

[0028] In contrast, the aerosol generating segment of the first aspect comprises a high concentration region of liquid aerosol former and a low concentration region of liquid aerosol former, wherein the high concentration region is located adjacent the interface between the aerosol forming material and wrapper.

[0029] The high concentration region of liquid aerosol former is a specific or localised region of the aerosol generating segment comprising additional liquid aerosol former relative to a low concentration region. This may be a high concentration of liquid aerosol former compared to the surrounding area. In particular, the high concentration region of liquid aerosol former may be a region of the aerosol generating segment with a higher concentration of liquid aerosol former than the average concentration of liquid aerosol former in the aerosol forming material. The high concentration region may be referred to as a high point concentration region.

[0030] Concentration may refer to the amount of liquid aerosol former per unit of substrate material in the aerosol forming material. The concentration of the liquid aerosol former may be measured using any suitable means. The concentration may be a local concentration. The concentration may be a point concentration. That is, the concentration is the concentration at a specific location or point of (for example, a sheet of) aerosol forming material. The concentration may be determined at a specific area of a sheet of aerosol forming material.

[0031] In some examples, concentration may be calculated on a mass basis, wherein the concentration is calculated as the mass of liquid aerosol former per unit mass of the substrate. The mass of liquid aerosol former may be measured using any suitable means. In some examples, concentration may be calculated on a volume basis, wherein the concentration is calculated as the volume of liquid aerosol former which is absorbed per unit volume of the substrate. In some examples, the concentration may be calculated on a surface area basis, wherein the concentration is calculated as the mass of liquid aerosol former per unit area of the substrate.

[0032] In some examples, the ratio of the concentration of liquid aerosol former in the high concentration region to the concentration of liquid aerosol former in the low concentration region may be 51:49 or more, 60:40 or more, 70:30 or more, 80:20 or more, 90:10 or more, or 95:5 or more.

[0033] In some examples, the ratio of the concentration of liquid aerosol former in the high concentration region to the concentration of liquid aerosol former in the low concentration region is 51:49 to 99:1, such as 60:40 to 95:5, such as 70:30 to 90:10, such as 80:20 to 85:15.

[0034] In some examples, the concentration of liquid aerosol former in the high concentration region is 10% or more greater than the concentration of liquid aerosol former in the low concentration region, such as 20% or more, 30% or more, 40% or more, 50% or more, 60% or more, 70% or more, 80% or more, 90% or more greater.

[0035] In some examples, the concentration of liquid aerosol former in the high concentration region is from 10 to 1000% greater than the concentration of liquid aerosol former in the low concentration region, such as 20 to 500%, 30 to 200%, 40 to 100%, 50 to 90%, 70 to 80% greater than the concentration of liquid aerosol former in the low concentration region.

[0036] The concentration of liquid aerosol former in the high concentration region may be 50 mg / cm 3< or more, based on the mass of precursor (that is, substrate and liquid aerosol former) in the high concentration region. The concentration of liquid aerosol former in the high concentration region may be 100 mg / cm 3< or more, 150 mg / cm 3< or more, 200 mg / cm 3< or more, 250 mg / cm 3< or more, 300 mg / cm 3< or more, based on the mass of precursor in the high concentration region.

[0037] The concentration of liquid aerosol former in the high concentration region may be from 50 to 400 mg / cm 3< , based on the mass of precursor in the high concentration region. The concentration of liquid aerosol former in the high concentration region may be from 100 to 300 mg / cm 3< , from 150 to 250 mg / cm 3< , from 180 to 220 mg / cm 3< based on the mass of precursor in the high concentration region.

[0038] The concentration of liquid aerosol former in the low concentration region may be 200 mg / cm 3< or less, based on the mass of precursor in the low concentration region. The concentration of liquid aerosol former in the low concentration region may be 150 mg / cm 3< or less, 100 mg / cm 3< or less, 50 mg / cm 3< or less, 20 mg / cm 3< or less, based on the mass of precursor in the low concentration region.

[0039] The concentration of liquid aerosol former in the low concentration region may be from 0 to 200 mg / cm 3< , based on the mass of precursor in the low concentration region. The concentration of liquid aerosol former in the low concentration region may be from 10 to 150 mg / cm 3< , from 20 to 100 mg / cm 3< , from 30 to 50 mg / cm 3< based on the mass of precursor in the low concentration region.

[0040] The areal concentration of liquid aerosol former in the high concentration region may be 20 g / m 2< or more, based on the mass of liquid aerosol former and the area of the substrate in the high concentration region. The areal concentration liquid aerosol former in the high concentration region may be 30 g / m 2< or more, 40 g / m 2< or more, 50 g / m 2< or more, 60 g / m 2< or more, 70 g / m 2< or more, based on the mass of liquid aerosol former and the area of the substrate in the high concentration region.

[0041] The areal concentration of liquid aerosol former in the high concentration region may be from 20 to 100 g / m 2< , based on the mass of liquid aerosol former and the area of the substrate in the high concentration region. The areal concentration of liquid aerosol former in the high concentration region may be from 30 to 90 g / m 2< , from 40 to 80 g / m 2< , from 50 to 70 g / m 2< based on the mass of liquid aerosol former and the area of the substrate in the high concentration region.

[0042] The areal concentration of liquid aerosol former in the low concentration region may be 50 g / m 2< or less, the mass of liquid aerosol former and the area of the substrate in the low concentration region. The areal concentration of liquid aerosol former in the low concentration may be 40 g / m 2< or less, 30 g / m 2< or less, 20 g / m 2< or less, 10 g / m 2< or less, based on the mass of liquid aerosol former and the area of the substrate in the low concentration region.

[0043] The areal concentration of liquid aerosol former in the low concentration may be from 0 to 50 g / m 2< , based on the mass of liquid aerosol former and the area of the substrate in the low concentration region.

[0044] The areal concentration liquid aerosol former in the low concentration may be from 1 to 30 g / m 2< , from 2 to 20 g / m 2< , from 3 to 10 g / m 2< based on the mass of liquid aerosol former and the area of the substrate in the low concentration region.

[0045] The concentration as described herein may be an average concentration. Average concentration as used herein may refer to a spatially averaged concentration. The concentration may be measured at a predetermined number of points on the surface of the precursor and these values may be used to calculate a mean average concentration for the area sampled. For example, a concentration value can be obtained by sampling a portion of aerosol forming material and measuring the amount of liquid aerosol former (for example, in g), measuring the volume of aerosol forming material sampled, and then calculating the volume average mass (= g / mm 3< ). The volume of aerosol forming material used in such a calculation should be small enough to obtain a meaningfully localised value of average concentration, and should be located such that it can be confirmed that the localised high concentration region comprises a higher average concentration than a low concentration region such as an adjacent region. For example, it would be satisfactory to take such a measurement for the entire high concentration region, as compared to the adjacent region or entire aerosol forming material. Alternatively, (for example, where the substrate is in the form of sheets) the concentration value can be obtained by sampling a portion of aerosol forming material and measuring the amount of liquid aerosol former (for example, in g), measuring the surface area of the region of aerosol forming material sampled, and then calculating the areal average mass (= g / m 2< ).

[0046] In some examples, the high concentration region has a volume of ≤ 2%, ≤ 5%, ≤ 8%, ≤ 10%, ≤ or 15% of the entire volume of the aerosol forming material. In some examples, the high concentration region has a volume of ≥ 1%, ≥ 2%, or ≥ 3% of the entire volume of the aerosol forming material. All of the foregoing values can be combined freely to generate a range bound by a minimum and a maximum (for example, ≥ 1% and ≤ 15%).

[0047] In some examples, the aerosol forming material comprises a central region and a peripheral region. The region adjacent the interface between the aerosol forming material and wrapper may be the peripheral region.

[0048] In some examples, the peripheral region is defined as being adjacent to one or more of the outer edges (e.g. all of the outer edges) or the periphery (e.g. the entire periphery) of the volume taken up by the aerosol- generating substrate. In some examples, the peripheral region is in contact with one or more outer edges or the periphery of the volume taken up by the precursor. In some examples the peripheral region is in contact with the wrapper which defines the outer edge or the periphery of the precursor. The peripheral region does not take up all of the volume of the precursor (i.e. there exists a central region).

[0049] In some examples, the peripheral region takes up ≥ 1%, ≥ 2%, ≥ 3%, ≥ 4%, ≥ 5%, ≥ 10%, ≥ 20%, or ≥ 30% of the volume of the precursor, wherein the total volume of the precursor is 100%. In some examples, the peripheral region takes up ≤ 10%, ≤ 15%, ≤ 20%, ≤ 25%, ≤ 30%, ≤ 35%, ≤ 40%, ≤ 45%, ≤ 50%, ≤ 55%, ≤ 60%, ≤ 65%, ≤ 70%, ≤ 75%, ≤ 80%, ≤ 85%, ≤ 90%, or ≤ 95% of the total volume of the precursor. All of the foregoing values can be combined freely to generate a range bound by a minimum and a maximum (for example, ≥ 50% and ≤ 60%).

[0050] In some examples, the peripheral region takes up ≥ 1% and ≤ 95% of the volume of the precursor. In some examples, the peripheral region takes up ≥ 10% and ≤ 90%, ≥ 20% and ≤ 80%, ≥ 30% and ≤ 70%, ≥ 40% and ≤ 60%, or about 50% of the volume of the precursor. In some examples, whatever % of the volume of the precursor is taken up by the peripheral region, the central region is included in the remaining volume.

[0051] In some examples, the high concentration region of liquid aerosol former is within the peripheral region and the low concentration region is within the central region.

[0052] In some examples, the high concentration region of liquid aerosol former is adjacent to the wrapper. The liquid aerosol former may be in contact with the wrapper. The liquid aerosol former may be applied to the outer surface of the aerosol forming material and / or to the wrapper. The liquid aerosol former may be applied to the inner surface or the wrapper, that is the surface of the wrapper in contact with the aerosol forming material when the wrapper encases the aerosol forming material. In this way, the liquid aerosol former can be easily applied after preparation of the aerosol generating substrate and will be close to the heater during outside-in heating of the aerosol generating segment.

[0053] In some examples, the high point concentration region of liquid aerosol former is an elongate region, that is, it may form a line of liquid aerosol former. In some examples, the aerosol generating substrate and the aerosol generating segment are elongate. In some examples, the aerosol-generating segment is prolate, or rod-shaped, or has a prismatic shape, or has a cylindrical shape. In some examples, the aerosol forming material is prolate, or rod-shaped, or has a prismatic shape, or has a cylindrical shape. For each of the elongate high concentration region of liquid aerosol former and the elongate aerosol generating segment the elongate length defines a longitudinal axis. The longitudinal axes may be aligned, that is, the high point concentration region of liquid aerosol former may run along the elongate length of the aerosol generating segment. The high point concentration region of liquid aerosol former may run along at least 50%, at least 80%, or at least 90% of the elongate length of the aerosol generating segment.

[0054] In some examples, the high concentration region of liquid aerosol former extends along 50% or more of the distance from an upstream end to a downstream end of the aerosol forming material, optionally 80% or more of the distance from the upstream end to the downstream end of the aerosol forming material, optionally 90% or more of the distance from the upstream end to the downstream end of the aerosol forming material.

[0055] In some examples, the high concentration region of liquid aerosol former extends along 50 to 100% of the distance from an upstream end to a downstream end of the aerosol forming material, optionally 80 to 98% of the distance from the upstream end to the downstream end of the aerosol forming material, optionally 90 to 95% of the distance from the upstream end to the downstream end of the aerosol forming material.

[0056] In some examples, the high concentration region of liquid aerosol former is continuous. In some examples, the high concentration region of liquid aerosol former extends continuously along 50% or more of the distance from an upstream end to a downstream end of the aerosol forming material, optionally 80% or more of the distance from the upstream end to the downstream end of the aerosol forming material, optionally 90% or more of the distance from the upstream end to the downstream end of the aerosol forming material.

[0057] In some examples, the region of liquid aerosol former continuously extends along 50 to 100% of the distance from an upstream end to a downstream end of the aerosol forming material, optionally 80 to 98% of the distance from the upstream end to the downstream end of the aerosol forming material, optionally 90 to 95% of the distance from the upstream end to the downstream end of the aerosol forming material.

[0058] In some examples, the high concentration region of liquid aerosol former extends continuously from an upstream end to a downstream end of the aerosol forming material.

[0059] In some examples, the high concentration region of liquid aerosol former is located adjacent a portion of the interface between the aerosol forming material and wrapper, wherein the portion covers 50% or less of the interface on an area basis, optionally 30% or less, optionally 20% or less.

[0060] In some examples, the high concentration region takes up ≥ 1%, ≥ 2%, ≥ 3%, ≥ 4%, ≥ 5%, ≥ 10%, ≥ 20%, or ≥ 30% of the surface area of the interface, wherein the total surface area of the interface is 100%. In some examples, the high concentration region takes up ≤ 10%, ≤ 15%, ≤ 20%, ≤ 25%, ≤ 30%, ≤ 35%, ≤ 40%, ≤ 45%, ≤ 50%, ≤ 55%, ≤ 60%, ≤ 65%, ≤ 70%, ≤ 75%, ≤ 80%, ≤ 85%, ≤ 90%, or ≤ 95% of the total surface area of the interface. All of the foregoing values can be combined freely to generate a range bound by a minimum and a maximum (for example, ≥ 50% and ≤ 60%).

[0061] In some examples, the high concentration region takes up ≥ 1% and ≤ 95% of the surface area of the interface of the precursor and wrapper. In some examples, the peripheral region takes up ≥ 10% and ≤ 90%, ≥ 20% and ≤ 80%, = 30% and ≤ 70%, ≥ 40% and ≤ 60%, or about 50% of the surface area of the interface.

[0062] In some examples, the high concentration region extends in an axial direction along the surface of the interface of the precursor and wrapper and the high concentration region covers ≥ 5°, ≥ 10°, ≥ 20°, ≥ 30°, ≥ 60°, ≥ 90°, ≥ 120°, or ≥ 180° of the circumference of the interface, wherein the total circumference of the precursor is 360°. The circumference of the precursor refers to the circumference of a cross-section of the precursor in a plane orthogonal to the longitudinal axis of the precursor (the axis extending from an upstream end to a downstream end).

[0063] In some examples, the high concentration region extends in an axial direction along the surface of the interface of the precursor and wrapper and the high concentration region covers ≤ 30°, ≤ 35°, ≤ 40°, ≤ 45°, ≤ 50°, ≤ 55°, ≤ 60°, ≤ 65°, ≤ 70°, ≤ 75°, ≤ 80°, ≤ 85°, ≤ 90°, ≤ 100°, ≤ 120°, ≤ 150°, ≤ 180°, or ≤ 270° of the total circumference of the precursor. All of the foregoing values can be combined freely to generate a range bound by a minimum and a maximum (for example, ≥ 50° and ≤ 60°).

[0064] In some examples, the high concentration region takes up ≥ 1° and ≤ 300° of the circumference of the interface of the precursor and wrapper. In some examples, the high concentration region takes up ≥ 10° and ≤ 270°, ≥ 30° and ≤ 180°, ≥ 30° and ≤ 90°.

[0065] In some examples, the aerosol generating segment comprises one high concentration region of liquid aerosol former, for example, one line of liquid aerosol former is applied to the interface of the precursor and wrapper.

[0066] In some examples, the aerosol generating segment comprises a plurality of high concentration regions of liquid aerosol former located adjacent the interface of the aerosol forming material and wrapper. For example, multiple lines of liquid aerosol former may be applied to the interface of the precursor and wrapper.

[0067] There may be other small, localised fluctuations in concentration, but globally the aerosol generating segment comprises no other significant maxima in average concentration of liquid aerosol former aside from the high concentration regions.

[0068] In some examples, the wrapper comprises opposing edges which overwrap to form a seam line when circumscribing the aerosol forming material. In this case, at least one of the high concentration regions of liquid aerosol former may be located adjacent to the seam line of the wrapper. In this way, the liquid aerosol former may be easily applied using a seam line applicator. The liquid aerosol former may be particularly close to the heater during outside-in heating of the aerosol generating segment. A heater for localised heating along the seam line may be easily provided for preferential heating of the liquid aerosol former.

[0069] The total amount of liquid aerosol former in the aerosol generating segment may be at most 20 wt.% based on the mass of the liquid aerosol former relative to the mass of the aerosol forming material.

[0070] The aerosol forming material may comprise 30 wt.% or less of liquid aerosol former, based on the mass of the liquid aerosol former and substrate. The liquid aerosol former may comprise 25 wt.% or less of liquid aerosol former, such as 20 wt.% or less, 15 wt.% or less, 10 wt.% or less, 5 wt.% or less, based on the mass of the liquid aerosol former and substrate.

[0071] The aerosol forming material may comprise from 1 to 30 wt.% of liquid aerosol former, based on the mass of the liquid aerosol former and substrate. The aerosol forming material may comprise from 1 to 25 wt.% of first liquid aerosol forming material, such as from 2 to 20 wt.%, from 3 to 15 wt.%, from 4 to 10 wt.%, or about 5 wt.%, based on the mass of the liquid aerosol former and substrate.

[0072] The aerosol forming material may comprise liquid aerosol forming material applied by two or more different methods. For example, the aerosol forming material may comprise liquid aerosol former applied by a seam line applicator and another application method, such as spraying, rolling, or present in the substrate material formed from a slurry.

[0073] The liquid aerosol former applied by the seam line applicator may be used to provide the concentration gradient between the high concentration region and the low concentration region. In this way, the seam line applicator provides a high concentration region in a portion of the interface between the precursor and the wrapper.

[0074] The amount of liquid aerosol former applied by a seam line applicator may be controlled. In some examples, the liquid aerosol former is applied by a seam line applicator at a rate of 6 to 90 mg / m. For an aerosol forming material segment having a length of 14 mm, the seam line applicator may apply 0.084 to 1.26 mg of liquid aerosol former per segment. Multiple seam line applicators may be used to provide multiple high concentration regions.

[0075] In some examples, the aerosol forming material may comprise 0.08 to 1.3 mg, such as 0.1 to 1 mg, such as 0.3 to 0.7 mg of liquid aerosol former applied by the seam line applicator. In some examples, the aerosol forming material may comprise a high concentration region comprising 0.08 to 1.3 mg, such as 0.1 to 1 mg, such as 0.3 to 0.7 mg of liquid aerosol former. In some examples, the aerosol forming material may comprise multiple high concentration regions each comprising 0.08 to 1.3 mg, such as 0.1 to 1 mg, such as 0.3 to 0.7 mg of liquid aerosol former. The 0.08 to 1.3 mg, such as 0.1 to 1 mg, such as 0.3 to 0.7 mg of liquid aerosol former may be provided in addition to other liquid aerosol former present in the substrate, which is not applied using a seam line applicator.

[0076] In some examples, the liquid aerosol former comprises propylene glycol, vegetable glycerine, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,2-butanediol and 1,3-butadediol, glycerol mono-, di- or triacetate, or a mixture thereof. In some examples, the liquid aerosol former comprises propylene glycol (PG), vegetable glycerine (VG), or a mixture thereof.

[0077] In some examples, the liquid aerosol former is selected from propylene glycol, vegetable glycerine, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,2-butanediol and 1,3-butadediol, glycerol mono-, di- or triacetate or a mixture thereof. In some examples, the liquid aerosol former is propylene glycol (PG), vegetable glycerine (VG), or a mixture thereof.

[0078] In some examples the liquid aerosol former comprises PG and VG. In some examples, the liquid aerosol former has a mass ratio of PG:VG of 80:20 or less, 70:30 or less, 60:40 or less, 50:50 or less, 40:60 or less, 10:90 or more, 20:80 or more, 30:70 or more, 40:60 or more. In some examples, the liquid aerosol former has a mass ratio of PG:VG of from 80:20 to 10:90, from 70:30 to 20:80, from 60:40 to 30:70, from 60:40 to 40:60 or from 55:45 to 45:55.

[0079] In some examples, the liquid aerosol former may have a mass ratio of glycerine / propylene glycol of 1.1 or more, such as 2 or more, such as 3 or more. In some examples, the liquid aerosol former may have a mass ratio of glycerine / propylene glycol of 5 or less, such as 4 or less, 3 or less, or 2 or less. In some examples, the liquid aerosol former may have a mass ratio of glycerine / propylene glycol selected from a range with upper and lower amounts selected from the values given above. In some examples the liquid aerosol former may have a mass ratio of glycerine / propylene glycol of from 1.1 to 5, such as from 1.5 to 4, such as from 2 to 3.

[0080] In some examples, the liquid aerosol former further comprises a gelling agent. In this way migration of the liquid aerosol former into the aerosol generating substrate is reduced and a more localised high concentration region can be maintained with a higher concentration compared to the low concentration region.

[0081] The gelling agent may be a gum binder. The gelling agent may be a cellulose binder. The gelling agent may be a konjac manan, guar gum, carregennan, gelatine, alginate or pectin.

[0082] The substrate may be any suitable carrier material, which is able to carry an aerosol former (for example, a liquid aerosol former). The aerosol former can be released from the substrate upon heating, to form an aerosol. The substrate may be an absorbent material. The substrate may be a porous material. The liquid aerosol former may be absorbed into the substrate. That is, the liquid aerosol former is hosted in the pores and / or interstices in the substrate.

[0083] The substrate may comprise plant material.

[0084] 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.

[0085] 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.

[0086] The aerosol-forming material may be absent of tobacco and / or nicotine.

[0087] 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.

[0088] In some examples, the substrate comprises a cellulose based material such as cotton, wood pulp, paper, hemp, maize fibres, oat fibres, tomato fibres, barley fibres, rye fibres, sugar beet fibres, buck wheat fibres, wheat fibres, pea fibres, potato fibres, apple fibres, cocoa fibres, bamboo fibres, citrus fibres, tea, microcrystalline cellulose or any combination thereof. In some examples, the substrate is free of tobacco.

[0089] The aerosol-forming material may comprise one or more additives selected from vapour generators, carrier agents, humectants, flavourants, fillers, aqueous / non-aqueous solvents and binders.

[0090] 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.

[0091] 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.

[0092] The cannabinoid compounds may be selected from the non-exhaustive list comprising: tetrahydrocannabinol (THC), cannabidiol (CBD), cannabinol (CBN).

[0093] Fillers can strengthen the aerosol-forming material. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g. wood fibres), jute fibres and combinations thereof.

[0094] 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.

[0095] In some examples, the substrate comprises cotton, paper, or microcrystalline cellulose.

[0096] In some examples, the substrate comprises at least one selected from the group consisting of: reconstituted (recon) tobacco, cut tobacco rag, and tobacco granules.

[0097] In some examples, the substrate is free of tobacco.

[0098] In some examples, the substrate additionally comprises one or more additives. In some examples, the first carrier material additionally comprises one or more additives selected from the list consisting of actives (e.g., nicotine), flavourant, filler and binder.

[0099] In some examples, the substrate comprises reconstituted tobacco. The reconstituted tobacco may comprise tobacco and a binder. The reconstituted tobacco may comprise tobacco, binder and cellulose. The reconstituted tobacco may comprise tobacco, binder, cellulose and an aerosol forming material. The reconstituted tobacco may comprise tobacco, binder, cellulose, an aerosol forming material and flavour.

[0100] The binder may be a gum binder. The binder may be a cellulose binder. The binder may be a konjac manan, guar gum, carregennan, gelatine, alginate or pectin.

[0101] In some examples, the substrate may comprise 60 wt.% or more by mass tobacco material, such as 70 wt.% or more, such as 75 wt.% or more. In some examples, the substrate is recon tobacco.

[0102] In some examples, the substrate tobacco material having a nicotine level of 0.5 wt.% or more by mass of the tobacco material, such as 1 wt.% or more. In some examples, the substrate comprises tobacco material having a nicotine level of 3% or less by mass of the tobacco material, such as 2.5 wt.% or less, such as 2.1 wt.% or less. In some examples, the substrate comprises tobacco material having a nicotine level in the range of 0.5 wt. % to 2.5 wt.% by mass of the tobacco, such as from 1 wt.% to 2.1 wt.%.

[0103] In some examples, the substrate is substantially free from tobacco material. In some examples, the substrate comprises 1 wt.% or less of tobacco material, such as 0.1 wt.% or less, such as 0.01 wt.% or less.

[0104] In some examples, the substrate or precursor may be provided as one or more sheets (for example, sheets of recon tobacco).

[0105] In some examples, the one or more sheets of aerosol precursor are multiple strips of aerosol precursor. In some examples, the strips extend in an axial direction from an upstream end of the aerosol generating segment to a downstream end of the aerosol generating segment. In some examples, the strips extend continuously from an upstream end of the aerosol generating segment to a downstream end of the aerosol generating segment.

[0106] In some examples, the strips are arranged in layers. In some examples, the strips are gathered into a bunch.

[0107] In some examples, the strips have a length of from 6 to 20 mm, such as from 8 to 16 mm, such as from 10 to 14 mm. The strips may have a length of about 12 mm. The strips may have a length which is the same as the axial length of the aerosol generating segment. The length may refer to the dimension of the sheet aligned with the axial direction of the aerosol generating segment, such as along the flow path of the aerosol generating segment.

[0108] In some examples, the strips have a width of 0.01 to 3 mm, such as 0.1 to 1 mm, such a 0.2 to 0.3 mm. The width of the strips may be measured as the longest distance perpendicular to the length direction of the strips. The width may refer to the dimension of the sheet perpendicular to the axial direction of the aerosol generating segment, such as perpendicular to the flow path of the aerosol generating segment.

[0109] In some examples, the strips have a thickness of about 0.01 to 0.6 mm, such as 0.2 to 0.5 mm, such as 0.3 to 0.45 mm.

[0110] The strips may be crimped and / or embossed. The strips may be divided. The strips may be substantially cuboidal.

[0111] In some examples, the aerosol generating segment comprises a single sheet of aerosol precursor. The sheet may be a single continuous sheet of aerosol forming material. The sheet may be crimped, embossed, folded, slit and / or gathered.

[0112] In some examples, the aerosol generating segment comprises a plurality of sheets of aerosol forming material. The plurality of sheets may be arranged in layers. The sheets may be crimped, embossed, folded, slit and / or gathered. In some examples, the aerosol generating segment comprises 2 or more sheets, such as 4 or more sheets, such as 6 or more sheets. In some examples, the aerosol generating segment comprises 1 or less sheets, such as 8 or less sheets. Typically, the aerosol generating segment comprises from 2 to 10 sheets.

[0113] In some examples, the sheets have a length of from 6 to 20 mm, such as from 8 to 16 mm, such as from 10 to 14 mm. The sheets may have a length of about 12 mm. The sheets may have a length which is the same as the axial length of the aerosol generating segment. The length may refer to the dimension of the sheet aligned with the axial direction of the aerosol generating segment, such as along the flow path of the aerosol generating segment.

[0114] In some examples, the sheets have a width of from 5 to 30 mm, such as from 10 to 25 mm, such as from 15 to 20 mm. The sheets may have a width which is the same as the diameter of the aerosol generating segment. The width may refer to the dimension of the sheet perpendicular to the axial direction of the aerosol generating segment, such as perpendicular to the flow path of the aerosol generating segment.

[0115] In some examples, the sheets have a thickness of about 0.1 to 0.6 mm, such as 0.2 to 0.5 mm, such as 0.3 to 0.45 mm.

[0116] In a second aspect , the present disclosure provides a heat-not-burn consumable comprising the aerosol generating segment of the first aspect.

[0117] In some examples, the heat-not-burn consumable is described as such because the precursor in the aerosol generating segment exhibits heat-not-burn characteristics. In some examples the heat-not-burn consumable comprises further segments. In some examples the heat-not-burn consumable comprises further segments in series with the aerosol-generating segment.

[0118] The heat-not-burn consumable may further comprise a filter segment, a cooling segment, a combining paper, and / or a tipping paper. The heat-not-burn consumable may comprise an aerosol generating segment, a cooling segment downstream of the aerosol generating segment, and a mouthpiece filter downstream of the cooling segment. The heat-not-burn consumable may comprise an aerosol generating segment, a cooling segment adjacent to and downstream of the aerosol generating segment, and a mouthpiece filter adjacent to and downstream of the cooling segment.

[0119] The heat-not-burn consumable may comprise an aerosol generating segment, a filter segment downstream of the aerosol generating segment, a cooling segment downstream of the filter segment, and a mouthpiece filter downstream of the cooling segment. The heat-not-burn consumable may comprise an aerosol generating segment, a filter segment adjacent to and downstream of the aerosol generating segment, a cooling segment adjacent to and downstream of the filter segment, and a mouthpiece filter adjacent to and downstream of the cooling segment.

[0120] The aerosol generating segment may be at the upstream end of the heat-not-burn consumable.

[0121] In some examples, the heat-not-burn consumable comprises a cover, for example, a paper cover, in contact with an end of the aerosol generating segment. In some examples, the heat-not-burn consumable comprises an additional segment in contact with the aerosol generating segment. In some examples, the additional segment and / or cover are in contact with to the upstream end of the aerosol generating segment in the heat-not-burn consumable.

[0122] In some examples, the heat-not-burn consumable may further comprise a further segment upstream of the aerosol generating segment and a covering over the upstream end of the aerosol generating segment.

[0123] The presence of a further segment and / or a covering over the upstream end of the aerosol generating segment is beneficial for the prevention of migration of liquid aerosol former (for example, propylene glycol and / or glycerine) from the aerosol generating segment e.g., into the packaging of the consumable, particularly when there is a high loading of liquid aerosol former in the substrate. Migration of liquid aerosol former may lead to discoloration of the product or otherwise visually affect the consumable, and it may structurally weaken the consumable due to saturation or partial saturation of the various segments and / or wrapper (when present) which can lead to breakage. Provision of the further segment and / or covering can therefore lead to improved shelf life and strength of the product and improved user experience.

[0124] In some examples, the heat-not-burn consumable comprises a cooling segment. In some examples the cooling segment is down stream of the aerosol-generating segment. In such examples the cooling segment is so-called as it 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. In some examples the heat-not-burn consumable comprises further aerosol-generating segments.

[0125] In some examples the heat-not-burn consumable comprises one or more filter segments in series, for example downstream, of the aerosol-generating segment. In some examples, all segments of the heat-not-burn consumable are held together by a combination of combining paper and tipping paper which form a wrapping. In some examples the heat-not-burn consumable comprises a mouthpiece filter, at the end of the consumable configured to be engaged by a user when in use.

[0126] In a third aspect , the present disclosure provides an aerosol-generating system comprising a heat-not-burn consumable and an aerosol generating unit, wherein the aerosol generating unit comprises an aerosol generating unit, and the heat-not-burn consumable comprises the aerosol generating segment according to any aspect disclosed herein.

[0127] The heat-not-burn consumable may be according to the second aspect.

[0128] The aerosol generating unit is as described herein.

[0129] In some examples, the aerosol generating unit comprises a power supply which drives the aerosol generating unit to aerosolise the heat-not-burn consumable during use. In some examples, the aerosol generating unit comprises an outside-in heater, otherwise known as an external or circumferential heater. Outside-in heaters comprise a heating element arranged in or on a side wall of a cavity of the aerosol-generating unit into which the consumable in inserted. In this way, the heating element heats an outer surface of the consumable when inserted into the cavity, and thus preferential heating may be provided to the liquid aerosol former adjacent the outer surface of the aerosol generating segment.

[0130] The present disclosure may provide an aerosol-generating system comprising a heat-not-burn consumable according to the previous aspects and an aerosol generating unit according to the third aspect.

[0131] In a fourth aspect , a method of manufacturing an aerosol generating segment for a heat-not-burn consumable is provided. The aerosol generating segment may be according to any aspect disclosed herein. In this way an aerosol generating segment comprising a high concentration region of liquid aerosol former can be provided in an efficient manner.

[0132] The method may comprise the steps of: (i) applying a liquid aerosol former to a region of a substrate to form an aerosol forming material having a high concentration region of aerosol former; (ii) optionally applying a liquid aerosol former to a region of a wrapper to provide the high concentration region of aerosol former; (ii) wrapping the substrate in the wrapper, such that the high concentration region of aerosol former is located adjacent to a portion of the interface between the aerosol forming material and wrapper.

[0133] The method may comprise the steps of: (i) providing an aerosol forming material comprising a substrate and an aerosol former; (ii) providing a wrapper, (iii) applying a liquid aerosol former to a region of a substrate to form an aerosol forming material having a high concentration region of aerosol former; (iv) optionally applying a liquid aerosol former to a region of a wrapper to provide the high concentration region of aerosol former; (v) wrapping the substrate in the wrapper, such that the high concentration region of aerosol former is located adjacent to a portion of the interface between the aerosol forming material and wrapper.

[0134] In some examples, the wrapper comprises opposing edges which overwrap to form a seam line when circumscribing the aerosol forming material, and the liquid aerosol former is applied adjacent to the seam line of the wrapper.

[0135] The liquid aerosol former may be applied by any suitable means.

[0136] In some examples, the liquid aerosol former is applied with a seam line applicator. Seam line applicators are commonly used to apply glue to the wrapper seam line, but here a seam line applicator repurposed to apply liquid aerosol former (humectant). The seam line applicator provides specific and localised application of liquid aerosol former. In this way, a non-localised and spray application step may be avoided.

[0137] In some examples, multiple applicator heads can be use with a single seam line applicator to apply multiple high point concentration regions of liquid aerosol former simultaneously.

[0138] The amount of liquid aerosol former applied by a seam line applicator may be controlled. In some examples, the liquid aerosol former is applied by a seam line applicator at a rate of 6 to 90 mg / m. For an aerosol forming material segment having a length of 14 mm, the seam line applicator may apply 0.084 to 1.26 mg of liquid aerosol former per segment. Multiple seam line applicators may be used to provide multiple high concentration regions. In some examples, liquid aerosol forming material is applied at a rate of 6 to 90 mg / m, such as 20 to 80 mg / m, such as 40 to 60 mg / m. In some examples, 0.08 to 1.3 mg, such as 0.1 to 1 mg, such as 0.3 to 0.7 mg of liquid aerosol former is applied by the seam line applicator per segment.

[0139] Any suitable seam line applicator may be used. The seam line applicator may be an applicator suitable for use with a G.D 121 double rod cigarette maker. The seam line applicator may be a Hauni G.D 121 cold glue seam line applicator unit.

[0140] The present disclosure may provide a method of preparing an aerosol forming material (for example, for providing an aerosol forming material for the method above). The method may comprise: providing a sheet of substrate material; applying a liquid aerosol former to the substrate material to form a sheet of aerosol forming material; forming an aerosol generating segment from one or more sheets of aerosol forming material.

[0141] In some examples, the method further comprises a step of dividing the sheet of an aerosol forming material to form one or more sheets of aerosol forming material. In some examples, the method further comprises a step of dividing the sheet of an aerosol forming material to form multiple strips of aerosol forming material. This dividing step may take place between the step of applying a liquid aerosol forming material and the step of forming an aerosol generating segment.

[0142] The dividing step may take place using any suitable means. In some examples, the dividing step may comprise cutting the sheet of aerosol precursor.

[0143] In some examples, the method further comprises a step of crimping the sheet of an aerosol forming material to form one or more crimped sheets of aerosol forming material.

[0144] In some examples, the method further comprises a step of embossing the sheet of an aerosol forming material to form one or more embossed sheets of aerosol forming material.

[0145] The method comprises a step of providing a sheet of substrate material.

[0146] The substrate is as described above.

[0147] The application may be achieved by any suitable means. In some examples, the liquid aerosol former is applied by spraying. In some examples, the liquid aerosol former is applied by rolling. In some examples, the liquid aerosol former is applied by brushing.

[0148] The step of forming an aerosol generating segment may use any suitable means. In some examples, the aerosol generating segment is formed by forming a rod comprising the one or more sheets of aerosol forming material. The rod may be formed by gathering the one or more sheets (e.g., strips) of aerosol forming material and wrapping the one or more sheets of aerosol forming material in a combining paper. The combining paper may be fixed in place with an adhesive.

[0149] The one or more sheets (e.g., strips) may be gathered such that they are aligned parallel to the axial direction of the rod.

[0150] The one or more sheets may be wrapper using any suitable combining paper. The combining paper may be a foil-paper laminate. The adhesive may be applied to the combining paper along a seam line. In this way, the combining paper may be closed around the one or more sheets of aerosol forming material.

[0151] The rod may be divided to form multiple aerosol generating segments. Aerosol former may be applied to a region of the precursor and / or to a region of the wrapper to provide a high concentration region of aerosol former before the rod is divided. In this way the aerosol former may be applied continuously along the rod in an axial direction, thus providing the high concentration region of aerosol former for a plurality of aerosol generating segments in a continuous manner. This may increase manufacturing efficiency.

[0152] In a further aspect, there is provided an aerosol generating segment obtained or obtainable by a method of the fourth aspect.

[0153] The aerosol generating segment may be assembled into a heat-not-burn consumable.

[0154] The present disclosure may further provide a use of a seam line applicator to apply liquid aerosol former to an aerosol forming material or a wrapper for an aerosol generating segment for a heat-not-burn consumable.

[0155] In this way high point concentration regions of liquid aerosol former may be provided adjacent the outer surface of an aerosol generating segment and spray application of liquid aerosol former may be avoided.

[0156] The aerosol generating segment may be according to any aspect disclosed herein. The heat-not-burn consumable may be according to any aspect disclosed herein.

[0157] The present disclosure may provide a method of generating an aerosol, which may implement any one or more features disclosed herein.

[0158] The present disclosure may provide a use of an aerosol generating segment according to the first aspect or the heat-not-burn consumable comprising the aerosol generating segment of the first aspect, with an aerosol generating unit .

[0159] The use may comprise heating the aerosol generating segment with a heating system. In some examples, the use may comprise heating the high concentration and low concentration regions of liquid aerosol former at different rates. In some examples, the heating system may comprise an outside-in heater.

[0160] In some examples, the volume of aerosol produced is increased compared to an aerosol generating segment wherein the aerosol forming material comprises a uniform distribution of liquid aerosol former.

[0161] In some examples, the volume of aerosol produced is the initial aerosol volume. That is, the aerosol generated from the first puff of the consumable. In some examples, the volume of aerosol produced is increased at the start of a session. In some examples, the volume of aerosol produced is increased for the first five puffs of the session.

[0162] In some examples, the concentration of aerosol produced is increased compared to an aerosol generating segment wherein the aerosol forming material comprises a uniform distribution of liquid aerosol former.

[0163] In some examples, the concentration of aerosol produced is the initial aerosol concentration. That is, the aerosol generated from the first puff of the consumable. In some examples, the concentration of aerosol produced is increased at the start of a session. In some examples, the concentration of aerosol produced is increased for the first five puffs of the session.

[0164] In some examples, the mass of aerosol produced is increased compared to an aerosol generating segment wherein the aerosol forming material comprises a uniform distribution of liquid aerosol former.

[0165] In some examples, the mass of aerosol produced is the initial aerosol mass. That is, the aerosol generated from the first puff of the consumable. In some examples, the mass of aerosol produced is increased at the start of a session. In some examples, the mass of aerosol produced is increased for the first five puffs of the session.

[0166] In some examples, an improved flavour profile is achieved. In some examples, an improved flavour profile may comprise a more gradual release of flavourant. In some examples, the flavour profile may be compared for five puffs at the start of the session to five puffs at the end of a session (e.g., puffs 21-25). A smaller difference between the flavourant concentration at the start and end of a session may be indicative of an improved flavour profile.

[0167] In some examples, the improved flavour profile may comprise a lower concentration of burnt or charred compounds. In some examples, burnt or charred compounds may include acrylamide, carbon monoxide or carbon. A lower concentration of burnt or charred compounds is indicative of an improved flavour profile, as such compounds can contribute to a bitter taste.

[0168] 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

[0169] 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 precursor. Fig. 3 is a schematic diagram showing an example implementation of the apparatus of Fig. 2. Fig. 4 is a schematic diagram showing an example implementation of an aerosol generating segment according to the present disclosure, illustrating a high point concentration region of liquid aerosol former at the outer surface of the aerosol generating precursor of such a segment. Fig. 5 is a cross-sectional diagram showing an example implementation of the aerosol generating segment, including strips of aerosol forming material. Fig. 6 is a cross-sectional diagram of an example implementation of a heat-not-burn consumable. including the aerosol generating segment of Fig. 5. Fig. 7 is a cross-sectional diagram of an example implementation of a heat-not-burn consumable. including the aerosol generating segment of Fig. 5, when the consumable is engaged with the heater elements of an aerosol generating apparatus. Fig. 8 is a flow diagram representing some of the steps of a method of manufacturing an aerosol generating segment for a heat-not-burn consumable. DETAILED DESCRIPTION OF EMBODIMENTS

[0170] 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.

[0171] 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.

[0172] Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.

[0173] 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.

[0174] 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.

[0175] 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).

[0176] 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.

[0177] 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.

[0178] 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: 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).

[0179] As used herein, a "consumable " may refer to a component that includes an aerosol forming material (i.e. an aerosol generating substrate and liquid aerosol former). The component may include a mouthpiece. The component may be referred to as a "stick" or "package" or "heat-not-burn consumable". In a heat-not-burn consumable, the mouthpiece may be implemented as a filter and the consumable may be arranged to carry the precursor. The consumable may be implemented as a dosage or pre-portioned amount of material, including a loose-leaf product.

[0180] The aerosol generating component e.g. the stick, package or consumable may be for releasable coupling to a device body comprising an aerosol generating unit to form the aerosol generating apparatus. The device body may comprise a power supply for powering the aerosol generating unit.

[0181] 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.

[0182] 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).

[0183] 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.

[0184] 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).

[0185] 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.

[0186] 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.

[0187] As used herein, an "aerosol " may include a suspension of precursor, 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 precursor.

[0188] As used herein, a "precursor " may include one or more of a: liquid; solid; gel; loose leaf material; other substance. In some examples, the precursor specifically includes at least an aerosol generating substrate and liquid aerosol former. The precursor may be processed by an aerosol generating unit of an aerosol generating apparatus to generate an aerosol. The precursor 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 substrate may be, e.g., reconstituted tobacco to carry one or more of the active component; a carrier; a flavouring.

[0189] As used herein, a "storage portion " may be a portion of the apparatus adapted to store the precursor.

[0190] 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.

[0191] 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. The delivery system may be at least partly within the aerosol generating component.

[0192] As used herein, a "flow " may refer to a flow in a flow path. A flow may include aerosol generated from the precursor. The flow may include air, which may be induced into the flow path via a puff by a user.

[0193] 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.

[0194] As used herein, an "aerosol generating unit " may refer to a device configured to generate an aerosol from a precursor. The aerosol generating unit may include a unit to generate a vapour directly from the precursor (e.g. a heating system or other system). A plurality of aerosol generating units to generate a plurality of aerosols (for example, from a plurality of different aerosol forming materials) may be present in an aerosol generating apparatus.

[0195] As used herein, a "heating system " may refer to an arrangement of at least one heating element, which is operable to aerosolise a precursor 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 precursor to below 300 or 350 degrees C, including without combustion. The heating system may be provided within the aerosol generating component or within the device body.

[0196] 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).

[0197] As used herein "heat-not-burn " (or "HNB " or "heated precursor ") may refer to the heating of a precursor, typically tobacco, without combustion, or without substantial combustion (i.e. localised combustion may be experienced of limited portions of the precursor, including of less than 5% of the total volume).

[0198] As used herein a "non-uniform " distribution describes a distribution which comprises some combination of global maxima and minima. A non-unform distribution of aerosol-former features some combination of global maxima and minima in aerosol former concentration.

[0199] As used herein "aerosol generating substrate " refers to material which is capable of generating an aerosol when heated in combination with an aerosol former. Examples include cotton, tobacco, tea, hemp, cellulose and paper. The aerosol-generating substrate and aerosol former combination can be referred to as a precursor. The aerosol-generating substrate and former (i.e. precursor) is wrapped in a wrapper (e.g. combining paper) to form an "aerosol generating segment ", usable in a consumable.

[0200] As used herein "aerosol former " refers to a liquid substance capable of being aerosolised. Examples include propylene glycol and vegetable glycerine.

[0201] As used herein, "circumscribing " refers to the wrapping of a shape, such that the wrapper is in contact with the shape. For example, the wrapper may circumscribe the aerosol forming material, such that the wrapper is in contact with an outer surface of the aerosol forming material.

[0202] As used herein, "adjacent " may be understood as "at or near"; such as "at".

[0203] 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 precursor 6, which in use is aerosolised by the aerosol generating unit 4 to generate an aerosol. The apparatus 1 includes a delivery system 8 for delivery of the aerosol to a user. Electrical circuitry (not shown in figure 1) may be implemented to control the interoperability of the power supply 2 and aerosol generating unit 4.

[0204] 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.

[0205] In this example, the apparatus 1 includes a device body 50 and a consumable 70. In this example, the body 50 includes the power supply 2 and a heating system 52. The heating system 52 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. 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. The wireless interface 60 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.

[0206] 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).

[0207] The body 50 may be 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 precursor 6 of the consumable. The body 50 may be configured to engage with the consumable 70 such that the at least one heating element 54 of the heating system 52 heats an outer surface of the consumable when inserted into the cavity e.g. the heating element may be arranged in or on a side wall of a cavity of the aerosol-generating unit into which the consumable in inserted. 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 precursor 6 of the consumable (without combusting it) by conductive heat transfer, to generate an aerosol which is inhaled by the user.

[0208] Fig. 3 shows an example implementation of the aerosol generating device 1 of Fig. 2.

[0209] 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 may cause the at least one heating element 54 of the heating system 52 to penetrate into the solid precursor 6 (inside-out heating) or to surround a portion of the solid precursor 6 (outside-in heating).

[0210] The consumable 70 includes the solid precursor 6, part of an aerosol generating segment, 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 precursor 6 may be a reconstituted tobacco formulation.

[0211] In this example, the at least one heating element 54 is a cup-shaped element. Other heating element shapes are possible, e.g. the at least one heating element may be rod-shaped (with a circular transverse profile), or blade-shaped (with a rectangular transverse profile), or tube-shaped (e.g. with a hollow transverse profile).

[0212] 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. 3, 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.

[0213] 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.

[0214] 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 2. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.

[0215] 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.

[0216] 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.

[0217] 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.

[0218] Fig. 4A and 4B illustrate an aerosol-generating segment 100 according to one implementation of the present disclosure. The aerosol-generating segment 100 comprises an aerosol forming material 6, and a wrapper 140. The aerosol forming material comprises an aerosol generating substrate and an aerosol former.

[0219] In Fig. 4A, the aerosol forming material 6 comprises a central region 122 and a peripheral region 124 adjacent the outer surface. There is a high concentration region of aerosol former 150 adjacent the outer surface of the aerosol forming material 6 (that is, in the peripheral region 124). In Fig. 4A the high point concentration region of aerosol former 150 is at the outer surface of the aerosol forming material and forms an elongate region (that is, the aerosol former is applied as a line on the outer surface). The high point concentration region in Fig. 4A extends from an upstream end to a downstream end of the aerosol generating segment 100 parallel to the longitudinal axis of the segment 130.

[0220] In Fig. 4B, the aerosol forming material 6 comprises a central region 122 and a peripheral region 124 adjacent the outer surface. There is a multiple high concentration region of aerosol former 150 adjacent the outer surface of the aerosol forming material 6 (that is, in the peripheral region 124). In Fig. 4B the high point concentration regions of aerosol former 150 are at the outer surface of the aerosol forming material and form an elongate region (that is, the aerosol former is applied as a line on the outer surface). The high point concentration regions in Fig. 4B extend from an upstream end to a downstream end of the aerosol generating segment 100 parallel to the longitudinal axis of the segment 130.

[0221] Referring to Fig. 5, an aerosol generating segment 100, which may be implemented in any of the preceding examples, such as in the consumable 70, includes strips 110 of aerosol forming material 6. The strips 110 of the aerosol forming material 6 include a substrate, having a concentration of aerosol former. The substrate may be a reconstituted tobacco.

[0222] The aerosol generating segment 100 is wrapped in a combining paper 140. The combining paper 140 may be a foil-paper laminate.

[0223] In some examples, the aerosol generating segment comprises 20 or more strips, such as 40 or more strips, such as 60 or more strips. In some examples, the aerosol generating segment comprises 100 or less trips, such as 80 or less trips. Typically, the aerosol generating segment comprises from 20 to 100 strips, such as from 40 to 80 strips.

[0224] A region (not shown) including a portion of one or more of the strips 110 at the outer surface of the aerosol forming material 6 has a high concentration relative to the average concentration of the aerosol forming material 6 where additional aerosol former has been applied adjacent the interface between the aerosol forming material 6 and the wrapper 140 .

[0225] Referring to Fig. 6, an aerosol generating segment 100 is shown in an example heat-not-burn consumable 70. The aerosol generating segment 100, corresponding to the segment 100 of Fig. 5, is located at the upstream end of the consumable 70. Downstream of the aerosol generating segment 100 is a tubular segment 172. The tubular segment 172 may be known as a cooling segment. Downstream of the tubular segment 172 is a mouthpiece filter 174. The mouthpiece filter 174 is at the downstream end of the consumable 70. The aerosol generating segment 100, the tubular segment 172 and the mouthpiece filter 174 are wrapped together using a combining paper 141. Combining paper 141 is wrapped around the segments and glued into place using an adhesive.

[0226] Any aerosol generating segment 100 described herein, as shown in Fig. 4 or Fig. 5, may be used in the consumable 70 shown in Fig. 6.

[0227] Referring to Fig. 7, the aerosol generating segment 100, as illustrated in Fig. 4, is provided in an example consumable 70. The consumable 70 is shown relative to the heater elements 54 of the aerosol generating apparatus. The consumable 70 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 be located adjacent to the aerosol forming material segment 100. In this example, the heating element 54 is an annular heating element that is positioned about the circumference of the aerosol generating segment 100. The high concentration region of aerosol former located adjacent the interface between the aerosol forming material 6 and wrapper 140 (not shown) is positioned close to the heating element 54.

[0228] Fig. 8 is a flow diagram representing some of the steps of a method of manufacturing an aerosol generating segment for a heat-not-burn consumable. For example, the aerosol generating segment of Fig. 4 or Fig. 5, or the heat-not-burn consumable of Fig. 6.

[0229] In step 801, an aerosol forming material and a wrapper are provided.

[0230] In step 802, aerosol former is applied to form a high concentration region of aerosol former. The aerosol former may be applied on the outer surface of the aerosol forming material or on the wrapper.

[0231] In step 803, the aerosol forming material is wrapped in the wrapper such that the wrapper circumscribes the aerosol forming material. The high concentration region of aerosol former on the outer surface of the aerosol forming material or the inner surface of the wrapper is thus located adjacent the interface between the aerosol forming material and the wrapper.

Claims

1. An aerosol generating segment for a heat-not-burn consumable, the aerosol generating segment comprising: an aerosol forming material, comprising a substrate and a liquid aerosol former; and a wrapper circumscribing the aerosol forming material; wherein the aerosol forming material comprises a high concentration region of the liquid aerosol former and a low concentration region of the liquid aerosol former, wherein the high concentration region is located adjacent to a portion of the interface between the aerosol forming material and wrapper.

2. The aerosol generating segment of claim 1, wherein the high concentration region of liquid aerosol former extends along 50% or more of the distance from an upstream end to a downstream end of the aerosol forming material, optionally 80% or more of the distance from the upstream end to the downstream end of the aerosol forming material.

3. The aerosol generating segment of claims 1 or 2, wherein the high concentration region of liquid aerosol former is located adjacent a portion of the interface between the aerosol forming material and wrapper, wherein the portion covers 50% or less of the interface on an area basis, optionally 30% or less, optionally 20% or less.

4. The aerosol generating segment of any preceding claim, wherein the high concentration region of the liquid aerosol former is non-uniformly distributed about the axis of rotation of the aerosol forming material.

5. The aerosol generating segment of any preceding claim, wherein the aerosol generating segment comprises a plurality of a high concentration regions of liquid aerosol former located adjacent the interface of the aerosol forming material and wrapper.

6. The aerosol generating segment of any preceding claim, wherein the wrapper comprises opposing edges which overwrap to form a seam line when circumscribing the aerosol forming material, and wherein at least one of the high concentration regions of liquid aerosol former is located adjacent to the seam line of the wrapper.

7. The aerosol generating segment of any preceding claim, wherein the high concentration region has a concentration of liquid aerosol former of from 15 to 50 wt.%, and / or the low concentration region has a concentration of liquid aerosol former of from 1 to 25 wt.%, based on the weight of the aerosol forming material.

8. The aerosol generating segment of any preceding claim, wherein the liquid aerosol former comprises propylene glycol (PG), vegetable glycerine (VG), or a mixture thereof, optionally wherein the liquid aerosol former comprises a mixture of PG and VG, and a mass ratio of PG / VG is 1.1 or more, such as 2 or more, such as 3 or more.

9. The aerosol generating segment of any preceding claim, wherein the liquid aerosol former comprises a gelling agent.

10. The aerosol generating segment of any preceding claim, wherein the substrate comprises a cellulose-based material, optionally wherein the substrate is cotton, paper, or microcrystalline cellulose.

11. A heat-not-burn consumable comprising the aerosol generating segment of any preceding claim.

12. An aerosol-generating system comprising a heat-not-burn consumable of claim 11 and an aerosol-generating unit, wherein the aerosol generating apparatus comprises an aerosol generating unit having an outside-in heater.

13. A method of manufacturing an aerosol generating segment for a heat-not-burn consumable, the method comprising the steps of: (i) applying a liquid aerosol former to a region of a substrate to form an aerosol forming material having a high concentration region of aerosol former; (ii) optionally applying a liquid aerosol former to a region of a wrapper to provide the high concentration region of aerosol former; (ii) wrapping the substrate in the wrapper, such that the high concentration region of aerosol former is located adjacent to a portion of the interface between the aerosol forming material and wrapper.

14. The method of claim 13, wherein the wrapper comprises opposing edges which overwrap to form a seam line when circumscribing the aerosol forming material, and wherein the high concentration region of liquid aerosol former is applied adjacent to the seam line of the wrapper.

15. The method of claims 13 or 14, wherein the liquid aerosol former is applied with a seam line applicator.

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