Aerosol-generating material

Abstract

The invention provides an aerosol-generating material comprising tobacco powder, wherein the D90 of the tobacco powder is at least about 45% of the thickness of the aerosol-generating material and / or wherein the tobacco powder has a D90 of about 400 µm or less. The invention also provides a consumable for use within a non-combustible aerosol provision system, the consumable comprising the aerosol-generating material of the invention. The invention also provides a non-combustible aerosol provision system comprising a consumable of the invention, and a non-combustible aerosol-provision device. The invention also provides a method of forming the aerosol-generating material of the invention.

Description

[0001] AEROSOL-GENERATING MATERIAL

[0002] Technical Field

[0003] The present invention relates to aerosol generation. In particular, the present invention relates to aerosol-generating materials, a consumable, a non-combustible aerosol provision system, a method of generating aerosol and a method of forming the aerosolgenerating material.

[0004] Background

[0005] Smoking consumables such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Alternatives to these types of consumables release an inhalable aerosol or vapour by releasing compounds from a substrate material by heating without burning. These may be referred to as non-combustible smoking consumables or aerosol generating assemblies.

[0006] One example of such a product is a heating device which release compounds by heating, but not burning, a solid aerosol-generating material. This solid aerosolgenerating material may, in some cases, contain a botanical material. The heating volatilises at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as heat-not-burn devices, tobacco heating devices or tobacco heating products. Various different arrangements for volatilising at least one component of the solid aerosol-generating material are known.

[0007] As another example, there are hybrid devices. These contain a liquid source (which may or may not contain nicotine) which is vaporised by heating to produce an inhalable vapour or aerosol. The device additionally contains a solid aerosol-generating material (which may or may not contain a tobacco material) and components of this material are entrained in the inhalable vapour or aerosol to produce the inhaled medium.

[0008] P13125297WO01 (171549 / 02) Summary

[0009] In a first aspect, there is provided an aerosol-generating material comprising tobacco powder, wherein the D90 of the tobacco powder is at least about 45% of the thickness of the aerosol-generating material.

[0010] In a second aspect, there is provided an aerosol-generating material comprising tobacco powder wherein the tobacco powder has a D90 of less than about 400 pm.

[0011] Features and embodiments described herein in relation to the first aspect apply equally to the second aspect and vice versa.

[0012] Also provided is a consumable for use within a non-combustible aerosol provision system, the consumable comprising the aerosol-generating material of the first or second aspect described herein. The consumable may comprise from about 100 to about 500 mg of the aerosol-generating material. The aerosol-generating material may be in the form of a gathered sheet, elongate strips, or a shredded sheet.

[0013] In some embodiments, the consumable may comprise less than about 2 wt% of tobacco, such as from about 0.05 to about 2 wt% or from about 0.1 to about 1 wt%. These wt% refer to % amounts of all forms of tobacco (including the tobacco powder in the aerosol-generating material) by weight relative to the total weight of the consumable.

[0014] The invention also provides a method of generating an aerosol from the consumable, the method comprising heating a portion of the aerosol-generating material within the consumable to a temperature of at least 120°C.

[0015] Also provided by the invention is a non-combustible aerosol provision system comprising a consumable as described herein and a non-combustible aerosol provision device, the non-combustible aerosol provision device comprising a heater configured heat but not burn the consumable.

[0016] P13125297WO01 (171549 / 02) The invention also provides the use of the consumable as described herein in a noncombustible aerosol provision device, the non-combustible aerosol provision device comprising a heater configured heat but not burn the consumable.

[0017] The invention also provides a method of forming the aerosol-generating material of the invention, the method comprising:

[0018] (a) providing a slurry comprising components of the aerosol-generating material or precursors thereof;

[0019] (b) forming a layer of the slurry; and

[0020] (c) drying the slurry to form the aerosol-generating material.

[0021] The aerosol-generating material of the present invention may be incorporated into a consumable. The invention also provides a method of forming a consumable as defined herein, the method comprising forming the aerosol-generating material according to the method described above and incorporating the aerosol-generating material into the consumable. The consumable may optionally be as described above, i.e. it may comprise from about 100 to about 500 mg of the aerosol-generating material; and / or the aerosol-generating material may be in the form of a gathered sheet, elongate strips, or a shredded sheet, and / or the consumable may comprise less than about 2 wt% of tobacco, such as from about 0.05 to about 2 wt% or from about 0.1 to about 1 wt%.

[0022] The slurry comprises the tobacco powder. The slurry may further comprise a solvent and: a binder, an aerosol-former material, a filler, one or more flavourants, and / or one or more additional actives.

[0023] Further features and advantages of the invention will become apparent from the following description of embodiments of the invention, given by way of example only, which is made with reference to the accompanying drawings.

[0024] Brief Description of the Drawings

[0025] Figure 1 shows a section view of an example of a consumable.

[0026] Figure 2 shows a perspective view of the consumable of Figure 1.

[0027] P13125297WO01 (171549 / 02) Figure 3 shows a sectional elevation of an example of a consumable.

[0028] Figure 4 shows a perspective view of the consumable of Figure 3.

[0029] Figure 5 shows a perspective view of an example of a non-combustible aerosol provision system.

[0030] Figure 6 shows a cross-sectional front view of the aerosol provision device of Figure 5.

[0031] Figure 7 shows a close up of part of Figure 6.

[0032] Figure 8 is a side-on cross sectional view of an article for use with a non-combustible aerosol provision device, the article including a mouthpiece.

[0033] Figure 9 shows an example non-combustible aerosol provision device.

[0034] Figure 10 shows a schematic cross-section of a non-combustible aerosol-provision device of the type shown in Figure 9.

[0035] Figure 11 shows a particle size distribution histogram for an exemplary tobacco powder (x-axis denotes particle size / pm; y-axis denotes probability).

[0036] Figure 12 shows the D90 values of the tobacco particles and the thickness of the aerosol-generating materials prepared in Example 2.

[0037] Detailed Description

[0038] The aerosol-generating materials described herein are materials that are capable of generating aerosol, for example when heated, irradiated or energized in any other way. The aerosol-generating material may, for example, be in the form of a solid or gel which may or may not contain nicotine as an additional active substance. In some embodiments, the aerosol-generating material is a homogeneous solid.

[0039] P13125297WO01 (171549 / 02) The aerosol-generating material may be an “amorphous solid”. In some embodiments, the amorphous solid is a “monolithic solid”. The aerosol-generating material may be non-fibrous or fibrous. In some embodiments, the aerosol-generating material may be a dried gel. The aerosol-generating material may be a solid material that may retain some fluid, such as liquid, within it. In some embodiments the retained fluid may be water (such as water absorbed from the surroundings of the aerosol-generating material) or the retained fluid may be solvent (such as when the aerosol-generating material is formed from a slurry). In some embodiments, the solvent may be water.

[0040] The aerosol-generating material may have any suitable water content, such as from about 1wt % to about 20wt% or about 1wt% to about 15 wt%. Suitably, the water content of the aerosol-generating material may be from about 1 wt%, 5wt%, 7wt% or 8wt% to about 20 wt%, 15wt%, 13wt% or 11 wt% (wet weight basis) (WWB). The water content of the aerosol-generating material may, for example, be determined by Karl- Fischer-titration or Gas Chromatography with Thermal Conductivity Detector (GC- TCD).

[0041] Tobacco powder and D90, D50 and D10 values

[0042] D90, D50 and / or D10 values may be used to define particle size distributions. As used herein, a D90 value means that 90% by volume of the particles in the sample have a particle size smaller than or equal to the D90 value, a D50 value means that 50% by volume of the particles in the sample have a particle size smaller than or equal to the D50 value, and a D10 value means that 10% by volume of the particles in the sample have a particle size smaller than or equal to the D10 value. D90, D50 and D10 values may be measured by dynamic image analysis in accordance with ISO 13322-2 Particle size analysis - Image analysis methods - Part 2: Dynamic image analysis methods. The particle size may be defined as the minimum largest chord diameter (xcmin). Suitable apparatus for dynamic image analysis are commercially available, for example a CAMSIZER X2 particle analyser (Resch Technology) may be used.

[0043] In the first aspect of this invention, the aerosol-generating material comprises tobacco powder and the D90 of the tobacco powder is at least about 45% of the thickness of the aerosol-generating material. In some embodiments, the D90 of the tobacco powder is at least about 47.5%, such as at least about 50%, at least about 52%, at

[0044] P13125297WO01 (171549 / 02) least about 53%, or at least about 55%, of the thickness of the aerosol-generating material. The D90 of the tobacco powder may be about 100%, such about 90% or less, about 85% or less, about 80% or less, about 77.5% or less, about 75% or less, about 70% or less, or about 67.5% or less of the thickness of the aerosol-generating material. These upper and lower limits can be combined in any manner. For example, the tobacco powder may have a D90 of from about 45% to about 100%, such as from about 45% to about 90%, 47.5% to about 80%, from about 50% to about 77.5%, from about 50 to about 75%, from about 52 to about 70%, from about 53% to about 70% or from about 55% to about 67.5%, of the thickness of the aerosol-generating material. These embodiments may also apply to the second aspect.

[0045] The inventors have unexpectedly identified that the thickness of the aerosol-generating material can be controlled by selecting a tobacco powder having a D90 particle size which is sufficiently similar to the target thickness of the aerosol-generating material. The D90 value is a measure of the size of the largest particles in the tobacco powder. Without wishing to be bound by theory, the inventors believe that in order for particle size distribution to impact the thickness of the aerosol-generating material, the largest particles (or the D90 value) in the tobacco powder must be sufficiently similar to the target thickness of the aerosol generating material. On the other hand, if the largest particles of the tobacco powder (or the D90 value) are too small relative to the thickness of the aerosol-generating material, the ability to control the thickness via control of the particle size distribution may be lost.

[0046] If the aerosol-generating material (for example in the form of a sheet or shredded sheet) is too thick, then heating efficiency can be compromised. This can adversely affect power consumption in use, for instance the power consumption for release of flavour and / or active substance from the aerosol-generating material. Conversely, if the aerosol-generating material is too thin, it can be difficult to manufacture and handle; a very thin material can be harder to cast and may be fragile, compromising aerosol formation in use. It is postulated that if the sheet or shredded sheet of aerosolgenerating material is too thin (e.g. less than 100 pm), then it may be necessary to increase the cut width of the shredded sheet to achieve sufficient packing of the aerosol-generating material when it is incorporated into the article. As discussed below, increasing the cut width of the shredded sheet can increase the pressure drop, which is undesirable.

[0047] P13125297WO01 (171549 / 02) The thickness of aerosol-generating materials disclosed herein may be measured using a micrometer in accordance with ISO 534:2011 “Paper and Board- Determination of Thickness”. The measurement conditions may be a pressure of 100 kPa, a lowering speed of 2 mm / s, a contact time of 2 s, and an area of measurement of 2 cm2. The thickness may be measured as a single sheet thickness. The test atmosphere during the thickness measurement may be in accordance with ISO 3402, i.e. a temperature of 22 ± 2°C and a relative humidity of 60 ± 5 %.

[0048] For the avoidance of doubt, the following embodiments apply equally to both the first and second aspect (including but not limited to the embodiments relating to: thicknesses of the aerosol-generating materials, D90 values, D50 values, D10 values, the size of the difference between the D90 and D50 values relative to the difference between the D50 and D10 values, D90 / D10 and D50 / D10 ratios, the amount of the tobacco powder, and the nature and amounts of as other components of the aerosol generating material such as aerosol-former material, binder and filler).

[0049] The aerosol-generating material (for example in the form of a sheet or shredded sheet) may have a thickness of at least about 100 pm. The aerosol-generating material may have a thickness of at least about 120 pm, at least about 140 pm, at least about 160 pm, at least about 180 pm, at least about 200 pm or at least about 220 microns. The aerosol-generating material may have a thickness of about 400 pm or less, about 380 pm or less, about 360 pm or less, about 340 pm or less, about 320 pm or less, about 300 pm or less or about 295 pm or less. These lower and upper limits can be combined in any manner. For example, in some embodiments, the aerosol-generating material has a thickness of from about 100 pm to about 400 pm, from about 120 pm to about 380 pm, from about 140 pm to about 360 pm, from about 180 pm to about 340 pm, from about 200 pm to about 320 pm, from about 220 pm to about 300 pm, from about 220 pm to about 295 pm,

[0050] In the second aspect of the invention, the aerosol-generating material comprises tobacco powder having a D90 of about 400 pm or less. In some embodiments, the tobacco powder in the aerosol-generating material of the first aspect may have a D90 of 400 pm or less.

[0051] P13125297WO01 (171549 / 02) In some embodiments, the tobacco powder has a D90 of about 350 pm or less, such as about 300 pm or less, about 250 pm or less, about 230 or less, about 225 pm or less, about 200 pm or less, about 195 pm or less, about 190 pm or less, or about 185 pm or less. In some embodiments, the tobacco powder has a D90 of about 85 pm or more, such as about 90 pm or more, about 100 pm or more, about 110 pm or more, about 120 pm or more, about 125 pm or more, or about 130 pm or more. These upper and lower limits can be combined in any manner. For example, the tobacco powder may have a D90 of from about 85 to about 400 pm, such as from about 90 to about 350 pm, from about 90 to about 300 pm, from about 90 to about 250 pm, from about 100 to about 250 pm, from about 100 to about 230 pm, from about 110 to about 225 pm, from about 120 to about 200 pm, from about 125 to about 195 pm, from about 130 to about 190 pm or from about 130 to about 185 pm.

[0052] The tobacco powder may have a D50 of about 100 pm or less, such as about 90 pm or less, about 85 pm or less, about 80 pm or less, about 75 pm or less, or about 70 pm or less. The tobacco powder may have a D50 of about 25 pm or more, such as about 30 pm or more, about 32.5 pm or more, about 35 pm or more, or about 37.5 pm or more, or about 40 pm or more. These upper and lower limits can be combined in any manner. For example, the tobacco powder may have a D50 of from about 25 to about 100 pm, such as from about 30 to about 90 pm, from about 32.5 to about 80 pm, or from about 35 to about 75 pm, or about 37.5 to about 70 pm.

[0053] The tobacco powder may have a D10 of about 25 pm or less, such as about 23 pm or less, about 22.5 pm or less, or about 20 pm or less. The tobacco powder may have a D10 of about 5 pm or more, such as about 7.5 pm or more, about 9 pm or more, or about 10 pm or more. These upper and lower limits can be combined in any manner. For example, the tobacco powder may have a D10 of from about 5 to about 25 pm, such as from about 5 to about 22.5 pm, from about 7.5 to about 22.5 pm, or from about 9 to about 20 pm.

[0054] For the avoidance of doubt, any of the D90, D50 and / or D10 values above may be combined in any manner. For example, the tobacco powder may have a D90 of about 300 pm or less (such as from about 90 to about 300 pm, from about 90 to about 250 pm, from about 120 to about 200 pm, or from about 125 to about 195 pm) and a D50 of about 100 pm or less (such as from about 30 to about 90 pm or from about 35 to

[0055] P13125297WO01 (171549 / 02) about 75 pm) and, optionally, a D10 of about 25 pm or less (such as from about 5 to about 22.5 pm or from about 9 to about 20 pm).

[0056] In some embodiments the difference between the D90 and D50 values is at least about 2 times greater (such as from about 2 to about 5 times greater, from about 2 to about 4.5 times greater, or from about 2.25 to about 4 times greater) than the difference between the D50 and D10 values. In such embodiments, the D10 and D50 values are closer together than the D90 and D50 values. An example of such a particle size distribution is shown in Figure 11.

[0057] In some embodiments, the ratio of the D90 to D10 (D90 / D10) of the tobacco powder is from about 8 to about 16, such as from about 8.5 to about 14.5, or from about 8.75 to about 14.25. In some embodiments, the ratio of the D50 to D10 (D50 / D10) of the tobacco powder is from about 2.75 to about 4.75, such as from about 3 to about 4.75, from about 3 to about 4.5. Any of these D90 / D10 and D50 / D10 ranges can be combined in any manner. For example, the tobacco powder may have a D90 / D10 of from about 8.5 to about 14.5 and a D50 / D10 of about 3 to about 4.75.

[0058] The use of fine tobacco powder, such as tobacco powder having a D90 of about 400 pm or less, about 300 pm or less, or about 200 pm or less may improve the homogeneity of the aerosol-generating materials and provide a more consistent appearance. Furthermore, the use of fine tobacco powder may also provide more consistent tobacco flavour, for example when the amount of the tobacco powder in the aerosol generating material is greater than about 2 wt% (dry weight basis).

[0059] In some embodiments, the aerosol-generating material comprises from about 0.05 wt%, 0.1 wt% or 0.2wt% to about 1 wt%, 2 wt%, 5 wt%, 10 wt%, 12.5 wt% or 15 wt% of the tobacco powder (dry weight basis). For example, the aerosol-generating material can contain the tobacco powder in an amount of from about 0.05 to about 15 wt%, such as from about 0.05 to about 10 wt%, from about 0.1 to about 5 wt%, from about 0.1 to about 2 wt%, from about 0.2 to about 2 wt%, or from about 0.2 to about 1 wt% (dry weight basis). These amounts are particularly suitable for the aerosolgenerating material of the second aspect although they may also apply to the first aspect. These amounts are also particularly suitable for the aspects described herein in which the consumable comprises from about 100 to about 500 mg of the aerosol-

[0060] P13125297WO01 (171549 / 02) generating material, optionally wherein the aerosol-generating material is in the form of a gathered sheet, elongate strips, or a shredded sheet.

[0061] In other embodiments, the aerosol-generating material comprises about 20 wt% or more, such as about 25 wt% or more, about 30 wt% or more, about 35 wt% or more, about 40 wt% or more, about 45 wt% or more, about 50 wt% or more, about 55 wt% or more, about 60 wt% or more, or about 65 wt% or more, of the tobacco powder (dry weight basis). The aerosol-generating material may comprise about 90 wt% or less, such as about 87.5 wt% or less, about 85 wt% or less, about 80 wt% or less, or about 75 wt% or less of the tobacco powder (dry weight basis). These lower and upper limits may be combined in any manner. For example, the aerosol-generating material may comprise from about 20 to about 90 wt%, from about 25 to about 90 wt%, from about 30 to about 87.5 wt%, from about 35 to about 87.5 wt%, from about 40 to about 85 wt%, from about 40 to about 85 wt%, from about 45 to about 80 wt%, from about 50 to about 80 wt%, from about 60 to about 80 wt%, from about 65 to about 75 wt% of the tobacco powder (dry weight basis). These amounts are particularly suitable for the aerosol-generating material of the first aspect, although they may also apply to the second aspect.

[0062] In some embodiments the tobacco powder is homogeneously dispersed through the aerosol-generating material.

[0063] It is postulated that an aerosol-generating material (for example in the form of a sheet or shredded sheet) having a thickness of at least about 100 pm, along with an area density of from about 100 g / m2to about 250 g / m2is less liable to tear, split or become otherwise deformed during its manufacture. A thickness of at least about 100 pm may have a positive effect on the overall structural integrity and strength of the material. For example, it may have a good tensile strength and thus be relatively easy to process.

[0064] The thickness of the aerosol-generating material (for example in the form of a sheet or shredded sheet) is also thought to have a bearing on its area density. That is to say, increasing the thickness of the sheet or shredded sheet may increase the area density of the sheet or shredded sheet.

[0065] P13125297WO01 (171549 / 02) Conversely, decreasing the thickness of the aerosol-generating material (for example in the form of a sheet or shredded sheet) may decrease the area density of material. For the avoidance of doubt, where reference is made herein to area density, this refers to an average area density calculated for a given strip, strand, piece or sheet of the aerosol-generating material, the area density calculated by measuring the surface area and weight of the given strip, strand, piece or sheet of aerosol-generating material.

[0066] It has been found that an article comprising a shredded sheet of aerosol-generating material having an area density of around 180 gsm and a minimum thickness of 220- 230 pm can be can be packed such that the aerosol-generating material stays in place within the article whilst maintaining a desired weight of aerosol-generating material within the article and delivering acceptable organoleptic properties (e.g. taste and smell) when heated in a non-combustible aerosol provision device. The flexibility of the sheet or shredded sheet is considered be dependent, at least in part, upon the thickness and area density of the sheet or shredded sheet. A thicker sheet or shredded sheet may be less flexible than a thinner sheet or shredded sheet. Also, the greater the area density of the sheet, the less flexible the sheet or shredded sheet is. It is thought that the combined thickness and area density of the aerosol-generating material described herein provides a sheet or shredded sheet that is relatively flexible.

[0067] When the aerosol-generating material is incorporated into an article for use in a noncombustible aerosol-provision device, this flexibility may give rise to various advantages. For example, the strands or strips are able to readily deform and flex when a heater or an aerosol generator is inserted into the aerosol generating material, thus facilitating insertion of an aerosol generator (e.g. a heater) into the material and also improving retention of the aerosol generator by the aerosol-generating material.

[0068] The aerosol-generating material may further comprise a binder, an aerosol-former material, filler, one or more flavourants and / or one or more additional actives. In one embodiment, the aerosol-generating material further comprises the aerosol-former material and the binder; and optionally: the filler, the one or more flavourants and / or the one or more additional actives. In one embodiment, the aerosol-generating material further comprises the binder, the aerosol-former material and the filler; and the material optionally further comprises the one or more flavourants and / or the one or more additional actives.

[0069] P13125297WO01 (171549 / 02) Aerosol-former material

[0070] The aerosol generating material may comprise an aerosol-former material. The aerosol-generating material may comprise from about 1wt%, 5wt%, 10wt%, 12wt% or 13wt% to about 20wt%, 22.5wt%, 25wt%, 30wt%, 35wt%, 45wt%, 55wt%, 65wt%, 75wt% or 80wt% of an aerosol-former material (all calculated on a dry weight basis). In exemplary embodiments, the aerosol-generating material comprises from about 1 to about 80 wt%, from about 1 to about 50 wt%, from about 5 to about 35 wt%, from about 10 to about 25 wt%, or from about 12 to about 22.5 wt% or from about 13 to about 20 wt% of an aerosol-former material (all calculated on a dry weight basis).

[0071] As used herein, the term “aerosol-former material” refers to an agent that promotes the generation of an aerosol. An aerosol-former material may promote the generation of an aerosol by promoting an initial vaporisation and / or the condensation of a gas to an inhalable solid and / or liquid aerosol.

[0072] The aerosol-former material may comprise one or more of glycerol, propylene glycol, 1 ,3-propanediol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1 ,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0073] In some embodiments, the aerosol-former material comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1 ,3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and / or aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0074] In some embodiments the aerosol-former material may comprise glycerol and / or propylene glycol.

[0075] In some embodiments the aerosol-former material is glycerol.

[0076] Binder

[0077] P13125297WO01 (171549 / 02) The aerosol generating material may comprise a binder.

[0078] In some embodiments, the aerosol generating material comprises from about 0.5 wt% to about 60 wt% of a binder, such as from about 1 wt% to about 30 wt%, from about 1 wt% to about 20 wt%, from about 1 wt% to about 10 wt%, or from about 2 wt% to about 6 wt% (all calculated on a dry weight basis). These amounts are particularly suitable for the aerosol-generating material of the first aspect, although they may also apply to the second aspect.

[0079] In some embodiments, the aerosol generating material comprises from about 0.5 wt% to about 60 wt% of a binder, such as from about 5 wt% to about 50 wt%, from about 10 wt% to about 35 wt%, from about 15 wt% to about 30 wt%, or from about 15 wt% to about 25 wt% (all calculated on a dry weight basis). These amounts are particularly suitable for the aerosol-generating material of the second aspect, although they may also apply to the first aspect.

[0080] In some embodiments, the binder comprises (or is) a hydrocolloid. In some embodiments, the binder comprises (or is) one or more compounds selected from the group consisting of alginates, pectins, starches (and derivatives), celluloses (and derivatives, such as such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)), gums (such as xanthan gum, guar gum, acacia gum and locust bean gum), silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, the binder comprises (or is) one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol.

[0081] In some embodiments, the binder is a cellulosic binder, which may be selected from the group consisting of: hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP) and combinations thereof.

[0082] P13125297WO01 (171549 / 02) In some embodiments, the binder comprises (or is) a non-cellulosic binder, which may be selected from the group consisting of agar, xanthan gum, gum Arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In some embodiments, the non-cellulose binder is alginate.

[0083] In some embodiments, the binder comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose, alginate, pectin, guar gum, and acacia gum.

[0084] In some embodiments, the binder comprises alginate and / or pectin.

[0085] In some embodiments, the binder comprises, consists essentially of, or consists of alginate and pectin.

[0086] In some embodiments, the binder comprises, consists essentially of, or consists of one or more of carboxymethylcellulose, alginate, and pectin.

[0087] In some embodiments, the binder is carboxymethylcellulose or guar gum.

[0088] In some embodiments of the first aspect, the aerosol-generating material further comprises a binder and the binder is guar gum.

[0089] In some embodiments of the second aspect, the aerosol-generating material further comprises a binder and the binder is carboxymethylcellulose.

[0090] Filler

[0091] The aerosol generating material may further comprise a filler. Use of a filler may help to reduce tackiness of the aerosol-generating material, for example if high levels of aerosol-former material are present.

[0092] In some embodiments, the aerosol generating material comprises (on a dry weight basis) about 60 wt% or less of a filler, such as from about 1 wt% to about 60 wt%, or from about 5 wt% to about 57.5 wt%, or from about 10 wt% to about 55 wt% or from about 20 wt% to about 55 wt% or from about 30 to about 55 wt%. These amounts

[0093] P13125297WO01 (171549 / 02) represent the total amount of filler(s) in the aerosol-generating material. These amounts are particularly suitable for the aerosol-generating material of the second aspect, although they may also apply to the first aspect. The filler in these embodiments may comprise, consist essentially of, or consists of microcrystalline cellulose and / or ground cellulose.

[0094] In some embodiments, the aerosol generating material may comprise from about 0.5 wt%, such as from about 1wt%, from about 1.5 wt% or from about 2wt% to about 20 wt%, about 15 wt%, about 10 wt%, or about 8 wt% of filler (all calculated on a dry weight basis). For example, the aerosol generating material may comprise from about 0.5 to about 20 wt%, such as from about 0.5 to about 15 wt%, from about 1 to about 10 wt%, from about 1 to about 8 wt% or about 2 to about 8 wt% of filler (dry weight basis). These amounts represent the total amount of filler(s) in the aerosol-generating material. These amounts are particularly suitable for the aerosol-generating material of the first aspect, although they may also apply to the second aspect. The filler in these embodiments may comprise, consist essentially of, or consists of wood pulp.

[0095] The filler, if present, may comprise one or more inorganic filler materials, such as calcium carbonate, chitosan, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp; hemp fibre; starch and starch derivatives, such as maltodextrin; and cellulose and cellulose derivatives, such as ground cellulose, microcrystalline cellulose and nanocrystalline cellulose. In particular cases, the aerosol-generating material comprises no calcium carbonate such as chalk.

[0096] In some embodiments, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives, such as microcrystalline cellulose (MCC) and / or nanocrystalline cellulose.

[0097] In some cases, the filler comprises maltodextrin or microcrystalline cellulose (MCC).

[0098] In some cases, the filler comprises, consists essentially of, or consists of microcrystalline cellulose (MCC), ground cellulose or combinations thereof.

[0099] P13125297WO01 (171549 / 02) In some cases, the filler comprises, consists essentially of, or consists of a combination of microcrystalline cellulose (MCC) and ground cellulose.

[0100] As would be well understood by the skilled person, microcrystalline cellulose may be formed by depolymerising cellulose by a chemical process (e.g. using an acid or enzyme). One example method for forming microcrystalline cellulose involves acid hydrolysis of cellulose, using an acid such as HCI. The cellulose produced after this treatment is crystalline (i.e. no amorphous regions remain). Suitable methods and conditions for forming microcrystalline cellulose are well-known in the art.

[0101] In some cases, the filler comprises, consists essentially of or consists of wood pulp, calcium carbonate or combinations thereof.

[0102] In some cases, the filler comprises, consists essentially of or consists of wood pulp and calcium carbonate.

[0103] In some cases, the filler comprises, consists essentially of or consists of wood pulp. In some cases, the aerosol generating material does not comprise any inorganic filler, such as calcium carbonate.

[0104] Acid

[0105] The aerosol generating material may comprise an acid. The acid may be an organic acid. In some embodiments, the acid may be at least one of a monoprotic acid, a diprotic acid and a triprotic acid. In some such embodiments, the acid may contain at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, carboxylic acid, dicarboxylic acid, tricarboxylic acid and keto acid. In some such embodiments, the acid may be an alpha-keto acid.

[0106] In some embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic and pyruvic acid.

[0107] P13125297WO01 (171549 / 02) In some embodiments, the acid may be at least one of levulinic acid and benzoic acid. In some embodiments, the acid is levulinic acid. In other embodiments, the acid is benzoic acid. In some embodiments the acid comprises levulinic acid and benzoic acid.

[0108] In other embodiments the acid may be an inorganic acid. In some of these embodiments the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulphuric acid, hydrochloric acid, boric acid and phosphoric acid. In some embodiments, the acid is levulinic acid.

[0109] The inclusion of an acid is particularly useful in embodiments in which the aerosol generating material comprises nicotine. In such embodiments, the presence of an acid may stabilise dissolved species in the slurry from which the aerosol-generating material is formed. The presence of the acid may reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing loss of nicotine during manufacturing.

[0110] The aerosol-generating material may comprise the acid in an amount of from about 0.1 to about 2 wt%, such as from about 0.5 to about 1 .75 wt% or from about 0.75 to about 1.5 wt% (on a dry weight basis). These amounts represent the total amount of acid(s) in the aerosol-generating material.

[0111] Flavour

[0112] In some embodiments the aerosol-generating material may further comprise a flavour. In some embodiments, the aerosol-generating material does not further comprise a flavour.

[0113] The aerosol-generating material may comprise about 0.1 wt%, 0.5 wt%, 1wt%, 5wt%, 10wt%, 15wt%, 20wt%, 25wt%, 30wt% or 35wt% to about 45wt%, 50wt% or 60wt% of flavour (all calculated on a dry weight basis). In exemplary embodiments, the aerosolgenerating material comprises from about 1 wt%, 5 wt%, 10 wt%, 20 wt%, 30wt%, or 35wt% to about 42wt%, 45wt% or 47wt% of flavour (dry weight basis). For example, the aerosol-generating material may comprise from about 1 to about 60 wt%, from about 1 to about 45 wt%, from about 10 to about 45 wt%, from about 20 to about 50

[0114] P13125297WO01 (171549 / 02) wt%, from about 30 to about 50 wt%, from about 30 to about 45 wt% or from about 35 to about 45 wt% of flavour (dry weight basis).

[0115] In some embodiments, the aerosol-generating material may comprise from about 1 to about 15 wt%, from about 1 to about 10 wt%, from about 2 to about 9 wt%, or from about 3 to about 8 wt% of flavour (dry weight basis).

[0116] As used herein, the terms “flavour” and “flavourant” refer to materials which, where local regulations permit, may be used to create a desired taste, aroma, or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, Wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

[0117] P13125297WO01 (171549 / 02) In some embodiments, the flavour comprises menthol, spearmint and / or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and / or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco.

[0118] In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucalyptol or WS-3 ( / V-ethyl-2-isopropyl-5-methylcyclohexanecarboxamide).

[0119] In some embodiments, the flavour may comprise eucalyptus, star anise, rooibos, fennel, jasmine and / or lavender. In some embodiments, the flavour may comprise eucalyptus and / or rooibos.

[0120] Colourant

[0121] The aerosol-generating material may comprise a colourant. The addition of a colourant may alter the visual appearance of the aerosol-generating material. The presence of colourant in the aerosol-generating material may enhance the visual appearance of the aerosol-generating material. By adding a colourant to the aerosol-generating material, the aerosol-generating material may be colour-matched to other components of an article comprising the aerosol-generating material. Alternatively the colourant may simply give the aerosol-generating material a desired colour.

[0122] A variety of colourants may be used depending on the desired colour of the aerosolgenerating material. The colour of aerosol-generating material may be, for example, white, green, red, purple, blue, brown or black. Other colours are also envisaged. Natural or synthetic colourants, such as natural or synthetic dyes, food-grade colourants and pharmaceutical-grade colourants may be used. In certain

[0123] P13125297WO01 (171549 / 02) embodiments, the colourant is caramel, which may confer the aerosol-generating material with a brown appearance.

[0124] The colourant may be incorporated during the formation of the aerosol-generating material (e.g. when forming a slurry comprising the materials that form the aerosolgenerating material) or it may be applied to the aerosol-generating material after its formation (e.g. by spraying it onto the aerosol-generating material).

[0125] The aerosol-generating material may comprise the colourant (such as caramel) in an amount of about 0.5 to about 10 wt%, such as about 0.5 to about 7 wt% or about 1 to about 5 wt% (dry weight basis).

[0126] Additional active substance

[0127] The aerosol-generating material may comprise one or more additional active substances (in addition to the tobacco powder). However, in some embodiments, tobacco powder is the only active substance in the aerosol-generating material. The additional active substances may also be referred to as additional actives herein.

[0128] In some embodiments, the aerosol-generating material comprises tobacco powder and further comprises one or more additional active substances. For example, the aerosolgenerating material may further comprise nicotine, optionally in the form of one or more nicotine salts.

[0129] The additional active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The additional active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The additional active substance may be naturally occurring or synthetically obtained. The additional active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, or constituents, derivatives, or combinations thereof.

[0130] In one embodiment the additional active substance is a legally permissible recreational drug.

[0131] P13125297WO01 (171549 / 02) In some embodiments, the additional active substance comprises nicotine. In some embodiments, the additional active substance comprises caffeine, melatonin or vitamin B12.

[0132] In some embodiments, the additional active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, Wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens

[0133] In some embodiments, the additional active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.

[0134] In some embodiments, the additional active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, rooibos, fennel, jasmine and lavender.

[0135] P13125297WO01 (171549 / 02) In some embodiments, the additional active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus and rooibos.

[0136] In some embodiments, the additional active substance comprises one or more cannabinoid compounds selected from the group consisting of: cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM) and cannabielsoin (CBE), cannabicitran (CBT).

[0137] The additional active substance may comprise one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0138] The additional active substance may comprise cannabidiol (CBD).

[0139] The additional active substance may comprise nicotine and cannabidiol (CBD).

[0140] The additional active substance may comprise nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0141] In some embodiments the aerosol-generating material comprises from about 0.5wt%, 0.75wt%. 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt%, 12wt%, 10wt% or 5 wt% (calculated on a dry weight basis) of nicotine. For example, the aerosolgenerating material may comprise from about 0.5 to about 20 wt%, from about 0.5 to about 10 wt%, from about 0.75 to about 10 wt% or from about 1 to about 5 wt% of nicotine (all calculated on a dry weight basis). These amounts relate to additional nicotine which may be added as an additional active substance (i.e. they do not include any nicotine which is present in the tobacco powder). As set out above, the nicotine may be in the form of a salt and these amounts apply equally when the nicotine is the form of one or more nicotine salts. These embodiments may be particularly suitable for the second aspect of the invention.

[0142] P13125297WO01 (171549 / 02) In some cases, the aerosol-generating material comprises at least about 0.1 wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt% or 30wt% of additional active and / or flavourant. In some cases, the aerosol-generating material comprises less than about 90wt%, 80wt%, 70wt%, 60wt%, 50wt% or 40wt% of additional active and / or flavourant (all calculated on a dry weight basis).

[0143] In some cases, the aerosol-generating material comprises a total of at least about 0.1wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt% or 30wt% botanical material, nicotine and flavourant. In some cases, the total content of additional active substance and / or flavourant may be less than about 90wt%, 80wt%, 70wt%, 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis).

[0144] In one embodiment, the aerosol-generating material does not contain any further tobacco other than the tobacco powder.

[0145] In some embodiments, the aerosol-generating material is formed as a sheet. In some cases, the aerosol-generating material may be incorporated into the consumable in sheet form. The aerosol-generating material sheet may be incorporated as a planar sheet, as a gathered or bunched sheet, as a crimped sheet, or as a rolled sheet (i.e. in the form of a tube). For example, the aerosol-generating material sheet may be formed on a wrapping paper which circumscribes a further aerosol-generating material, which may be the same or a different aerosol-generating material. In other cases, the sheet may be shredded and then incorporated into the consumable.

[0146] Carrier

[0147] The aerosol generating material may be present on or in a carrier support (or carrier component). The carrier may function as a support on which the aerosol-generating material is formed, thereby easing manufacture. The carrier may also provide rigidity to the aerosol-generating material, easing handling.

[0148] The carrier may be any suitable material which can be used to support an aerosolgenerating material. In some cases, the carrier may be formed from materials selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes

[0149] P13125297WO01 (171549 / 02) such as graphite and graphene, plastic, cardboard, wood or combinations thereof. In some cases, the carrier may be formed from materials selected from metal foil, paper, cardboard, wood or combinations thereof. In some cases, the carrier comprises paper. In some cases, the carrier itself may be a laminate structure comprising layers of materials selected from the preceding lists. In some cases, the carrier may also function as a flavour support. For example, the carrier may be impregnated with a flavourant.

[0150] In some cases, the carrier may be magnetic. This functionality may be used to fasten the carrier to the assembly in use, or may be used to generate particular aerosolgenerating material shapes. In some cases, the consumable may comprise one or more magnets which can be used to fasten the consumable to an induction heater in use.

[0151] In some cases, the carrier may be substantially or wholly impermeable to gas and / or aerosol. This prevents aerosol or gas passage through the carrier layer, thereby controlling the flow and ensuring it is delivered to the user. This can also be used to prevent condensation or other deposition of the gas / aerosol in use on, for example, the surface of a heater provided in an aerosol generating assembly. Thus, consumption efficiency and hygiene can be improved in some cases.

[0152] In some cases, the surface of the carrier that abuts the aerosol-generating material may be porous. For example, in one case, the carrier comprises paper. A porous carrier such as paper is particularly suitable for the present invention; the porous (e.g. paper) layer abuts the aerosol-generating layer and forms a strong bond. The aerosolgenerating material may be formed by drying a gel and, without being limited by theory, it is thought that the slurry from which the gel is formed partially impregnates the porous carrier (e.g. paper) so that when the gel sets and forms cross-links, the carrier is partially bound into the gel. This provides a strong binding between the gel and the carrier (and between the dried gel and the carrier).

[0153] Additionally, surface roughness may contribute to the strength of bond between the aerosol-generating material and the carrier. The paper roughness (for the surface abutting the carrier) may suitably be in the range of 50-1000 Bekk seconds, suitably 50-150 Bekk seconds, suitably 100 Bekk seconds (measured over an air pressure

[0154] P13125297WO01 (171549 / 02) interval of 50.66-48.00 kPa). (A Bekk smoothness tester is an instrument used to determine the smoothness of a paper surface, in which air at a specified pressure is leaked between a smooth glass surface and a paper sample, and the time (in seconds) for a fixed volume of air to seep between these surfaces is the "Bekk smoothness”.)

[0155] Conversely, the surface of the carrier facing away from the aerosol-generating material may be arranged in contact with the heater, and a smoother surface may provide more efficient heat transfer. Thus, in some cases, the carrier is disposed so as to have a rougher side abutting the aerosol-generating material and a smoother side facing away from the aerosol-generating material.

[0156] In one particular case, the carrier may be a paper-backed foil; the paper layer abuts the aerosol-generating material layer and the properties discussed in the previous paragraphs are afforded by this abutment. The foil backing is substantially impermeable, providing control of the aerosol flow path. A metal foil backing may also serve to conduct heat to the aerosol-generating material.

[0157] In another case, the foil layer of the paper-backed foil abuts the aerosol-generating material. The foil is substantially impermeable, thereby preventing water provided in the aerosol-generating material to be absorbed into the paper which could weaken its structural integrity.

[0158] In some cases, the carrier is formed from or comprises metal foil, such as aluminium foil. A metallic carrier may allow for better conduction of thermal energy to the aerosolgenerating material. Additionally, or alternatively, a metal foil may function as a susceptor in an induction heating system. In particular embodiments, the carrier comprises a metal foil layer and a carrier layer, such as cardboard. In these embodiments, the metal foil layer may have a thickness of less than 20pm, such as from about 1 m to about 10pm, suitably about 5pm.

[0159] In some cases, the carrier may have a thickness of between about 0.017mm and about 2.0mm, suitably from about 0.02mm, 0.05mm or 0.1mm to about 1.5mm, 1.0mm, or 0.5mm.

[0160] Consumable

[0161] P13125297WO01 (171549 / 02) There is also provided a consumable for use in an aerosol provision system, such as a non-combustible aerosol provision system, the consumable comprising the aerosolgenerating material as defined herein. The consumables are sometimes referred to as “articles” or “aerosol generating articles” throughout the disclosure.

[0162] The article is dimensioned to be at least partially received within a heater assembly as described herein. The heater assembly comprises a receptacle defining a heating chamber arranged to removably receive at least a portion of an article comprising aerosol generating material, and a heating element for heating at least a portion of an article comprising aerosol generating material received in the heating chamber. The heater assembly includes a heating element for heating the article during use. In one embodiment, the heating element is a susceptor arrangement (herein referred to as “a susceptor”). The heating element may be a blade-shaped heating element. The article can be inserted onto or around the heating element. Any other suitable shape or form of heating element may be used. For example, the heating element could be pinshaped e.g. with a constant circular cross-section along its axial length that tapers to a pin tip, or rodshaped (e.g. a cylindrical rod or a square rod) with a constant or varying cross-section along its axial length that omits a tip or tapered portion.

[0163] As noted above, there is also provided a consumable for use within a non-combustible aerosol provision system, the consumable comprising the aerosol-generating material described herein.

[0164] In one embodiment, the consumable comprises from about 100 to about 500 mg of the aerosol-generating material. The aerosol-generating material may be in the form of a gathered sheet, elongate strips, or a shredded sheet. The consumable may comprise less than about 2 wt% of tobacco, such as from about 0.05 to about 2 wt% or from about 0.1 to about 1 wt%. These wt% refer to % amounts by weight of all forms of tobacco (including the tobacco powder in the aerosol-generating material) relative to the total weight of the consumable.

[0165] In one embodiment, the consumable does not contain any further tobacco other than the tobacco powder in the aerosol generating material.

[0166] P13125297WO01 (171549 / 02) The inventors have found that the consumables of the present invention may be used in a non-combustible aerosol provision device to form an aerosol despite containing less than about 2 wt% tobacco in some embodiments. Furthermore, since the consumable may comprise less than about 2% tobacco, the weight of the consumable is less restricted for tax reasons. As such, a higher weight of aerosol-generating material can be contained in the consumable than for a consumable or aerosolgenerating material which comprises tobacco in a greater proportion. This means that each consumable may last longer during use.

[0167] Thus, the consumable may comprise from about 100 to about 500 mg of the aerosolgenerating material, such as from about 200 to about 500 mg, from about 250 to about 500 mg, from about 300 to about 500 mg, from about 350 to about 500 mg, or from about 400 to about 500 mg.

[0168] In one aspect the aerosol-generating material further comprises one or more flavourants but no additional actives.

[0169] In another aspect the aerosol-generating material further comprises one or more additional actives, but no flavourant.

[0170] In another aspect the aerosol-generating material comprises one or more additional actives and one or more flavourants.

[0171] In one aspect the aerosol-generating material has a GSM of less than about 350 gsm, such as less than about 300 gsm or less than about 250 gsm. In some embodiments, the aerosol-generating material has a GSM of from about 50 gsm to about 300 gsm, such as from about 70 gsm to about 250 gsm.

[0172] In one aspect the aerosol-generating material has a specific heat capacity of less than about 6 JK / g, such as less than about 5 JK / g.

[0173] A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol

[0174] P13125297WO01 (171549 / 02) generation area, a housing, a wrapper, a mouthpiece, a filter and / or an aerosolmodifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

[0175] A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms.

[0176] An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent.

[0177] The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

[0178] An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0179] P13125297WO01 (171549 / 02) Methods

[0180] A further aspect of the invention provides a method of making the aerosol-generating materials of the invention.

[0181] The method may comprise (a) providing a slurry comprising components of the aerosol-generating material or precursors thereof, (b) forming a layer of the slurry, and (c) drying the slurry to form the aerosol-generating material.

[0182] The slurry comprises the tobacco powder. The slurry may further comprise a solvent and one or more of: a binder, an aerosol-former material, a filler, one or more flavourants and / or one or more additional actives. In some embodiments, the slurry comprises the tobacco powder, the binder, the aerosol-former material and the filler.

[0183] In one aspect, the steps of forming the aerosol-generating material comprise:

[0184] (a) providing a slurry comprising:

[0185] (i) a binder;

[0186] (ii) an aerosol-former material;

[0187] (iii) filler;

[0188] (iv) optionally one or more flavourants and / or one or more additional actives;

[0189] (v) solvent; and

[0190] (vi) tobacco powder;

[0191] (b) forming a layer of the slurry; and

[0192] (c) drying the slurry.

[0193] Drying the slurry forms the aerosol-generating material.

[0194] In another aspect, any flavourants are added to the slurry after it is formed and dried. In this case after step (c) the method comprises adding one or more flavourants to the aerosol-generating material, for example by spraying the flavourant(s) (or a composition comprising the flavourant(s)) onto the aerosol-generating material.

[0195] Thus, the steps of forming the aerosol-generating material may comprise:

[0196] P13125297WO01 (171549 / 02) (a) providing a slurry comprising:

[0197] (i) a binder;

[0198] (ii) an aerosol-former material;

[0199] (iii) filler;

[0200] (iv) optionally one or more additional actives;

[0201] (v) solvent; and

[0202] (vi) tobacco powder

[0203] (b) forming a layer of the slurry;

[0204] (c) drying the slurry thereby forming an aerosol-generating material; and

[0205] (d) adding one or more flavourants to the aerosol-generating material, for example by spraying the flavourant(s) (or a composition comprising the flavourant(s)) onto the aerosol-generating material.

[0206] The aerosol-generating material formed as described above may then be incorporated or formed into a consumable in any of the amounts described herein.

[0207] Step (b) of forming a layer of the slurry may comprise spraying, casting or extruding the slurry. In some cases, the layer of slurry is formed by casting the slurry.

[0208] In some cases, a setting agent (such as a calcium source) may be added to the slurry before or during step (b). This is appropriate in instances where gelation occurs relatively slowly, and thus the slurry may be, e.g. cast, after the setting agent is added.

[0209] In other cases, step (c) of drying the slurry as a gel may comprise the addition of a setting agent to the slurry layer. The setting agent may be sprayed onto the gel, for example, or may be preloaded onto the surface on which the slurry is layered.

[0210] For example, a setting agent comprising a calcium source may be added to a slurry containing alginate and / or pectin to form a calcium-crosslinked alginate / pectin gel. In some cases where gelation occurs rapidly (such as those in which a alginate or pectin gelling agent is used), the calcium should be added after casting (because the gel is too viscous to cast).

[0211] In examples, the setting agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride, calcium

[0212] P13125297WO01 (171549 / 02) lactate, or a combination thereof. In some examples, the setting agent comprises or consists of calcium formate and / or calcium lactate. In particular examples, the setting agent comprises or consists of calcium formate.

[0213] The total amount of the setting agent, such as a calcium source, may be from about 0.5 to about 5wt% of the slurry or the aerosol-generating material (calculated on a dry weight basis). Suitably, the total amount may be from about 1wt%, 2.5wt% or 4wt% to about 4.8wt% or 4.5wt% of the slurry or the aerosol-generating material. The addition of too little setting agent may result in a gel which does not stabilise the flavourant and results in the flavourant dropping out of the gel. Conversely, the addition of too much setting agent may result in a gel that is very viscous and difficult to cast.

[0214] When present, step (d) comprises the addition of one or more flavourants to the slurry layer. The flavourant(s) may be sprayed onto the slurry. The flavourant(s) may be applied neat, i.e. in pure form, or may be applied as part of a composition. For example, the one or more flavourants may be dissolved in a solvent (e.g. ethanol), before the solution is applied to the dried slurry or aerosol-generating material. The solvent (e.g. ethanol) may then be removed by evaporation, such as flash evaporation. Where multiple flavourants are present these may be added simultaneously (optionally as part of a composition also comprising a solvent such as ethanol), or may be applied sequentially (optionally each as part of a composition also comprising a solvent such as ethanol).

[0215] Alginate salts are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of p-D-mannuronic (M) and a-L- guluronic acid (G) units (blocks) linked together with (1 ,4)-glycosidic bonds to form a polysaccharide. On addition of calcium cations, the alginate crosslinks to form a gel. Alginate salts with a high G monomer content more readily form a gel on addition of the calcium source. In some cases therefore, the gel-precursor may comprise an alginate salt in which at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginate copolymer are a-L-guluronic acid (G) units.

[0216] In some cases, the slurry may be warmed prior to and during casting. This can slow gelation, improving handleability and easing the casting process. Further, warming the slurry may melt the flavourant components (e.g. menthol) easing handleability.

[0217] P13125297WO01 (171549 / 02) In some cases, the slurry may be cast as a bandcast sheet. The sheet may be loaded with a releasing agent, such as lecithin, which can aid separation of the bandcast and the aerosol-generating material. In other instances, the band may be covered with a film of releasing agent, such as lecithin, to aid the separation.

[0218] In cases where the solvent consists of water, the dry weight content of the slurry will match the dry weight content of the aerosol-generating material. Thus, the discussion herein relating to the aerosol-generating material is explicitly disclosed in combination with any slurry aspect of the invention.

[0219] A further aspect of the invention provides a method of making the consumable of the invention. This method comprises making the aerosol-generating material and incorporating the aerosol-generating material into the consumable. The method of making the aerosol-generating material may comprise the steps discussed above.

[0220] The consumable described herein can be used in a combustible aerosol provision system or a non-combustible aerosol provision system.

[0221] Combustible Aerosol Provision System

[0222] An aspect of the invention provides a combustible aerosol provision system where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user.

[0223] In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar.

[0224] Non-combustible aerosol provision device

[0225] An aspect of the invention provides non-combustible aerosol provision system comprising a consumable (also called an article) as described herein and non- combustible aerosol provision device comprising a heater which is configured to heat

[0226] P13125297WO01 (171549 / 02) not burn the consumable. A non-combustible aerosol provision system may also be referred to as an aerosol generating assembly. A non-combustible aerosol provision device may be referred to as an aerosol generating apparatus.

[0227] In one aspect, the invention provides an aerosol provision device comprising: a device housing defining a device chamber; and a heater assembly comprising: a receptacle defining a heating chamber arranged to removably receive at least a portion of the article described herein; and a heating element for heating at least a portion of an article comprising aerosol generating material received in the heating chamber. The heating element and article are configured such that the article can be inserted onto or around the heating element.

[0228] In some cases, in use, the heater may heat, without burning, the aerosol-generating material to a temperature equal to or less than 350 °C, such as between 120°C and 350 °C. In some cases, the heater may heat, without burning, the aerosol-generating material to between 140 °C and 250 °C in use, or between 220 °C and 280 °C. In some cases in use, substantially all of the aerosol-generating material is less than about 4mm, 3mm, 2mm or 1mm from the heater. In some cases, the material is disposed between about 0.010mm and 2.0mm from the heater, suitably between about 0.02mm and 1 .0mm, suitably 0.1 mm to 0.5mm. These minimum distances may, in some cases, reflect the thickness of a support that supports the aerosol-generating material. In some cases, a surface of the aerosol-generating material may directly abut the heater.

[0229] The heater is configured to heat not burn the aerosol-generating article, and thus the aerosol-generating material. The heater may be, in some cases, a thin film, electrically resistive heater. In other cases, the heater may comprise an induction heater or the like. The heater may be a combustible heat source or a chemical heat source which undergoes an exothermic reaction to produce heat in use. The aerosol generating assembly may comprise a plurality of heaters. The heater(s) may be powered by a battery.

[0230] The aerosol-generating article may additionally comprise a cooling element and / or a filter. The cooling element, if present, may act or function to cool gaseous or aerosol components. In some cases, it may act to cool gaseous components such that they condense to form an aerosol. It may also act to space the very hot parts of the non-

[0231] P13125297WO01 (171549 / 02) combustible aerosol provision device from the user. The filter, if present, may comprise any suitable filter known in the art such as a cellulose acetate plug.

[0232] In some cases, the aerosol generating assembly may be a heat-not-burn device. That is, it may contain a solid aerosol-generating material (and no liquid aerosol-generating material). A heat-not-burn device is disclosed in WO 2015 / 062983 A2, which is incorporated by reference in its entirety.

[0233] The aerosol-generating article (which may be referred to herein as an article, a cartridge or a consumable) may be adapted for use in a THP or another aerosol generating device. In some cases, the article may additionally comprise a filter and / or cooling element (which have been described above). In some cases, the aerosolgenerating article may be circumscribed by a wrapping material such as paper.

[0234] The aerosol-generating article may additionally comprise ventilation apertures. These may be provided in the sidewall of the article. In some cases, the ventilation apertures may be provided in the filter and / or cooling element. These apertures may allow cool air to be drawn into the article during use, which can mix with the heated volatilised components thereby cooling the aerosol.

[0235] The ventilation enhances the generation of visible heated volatilised components from the article when it is heated in use. The heated volatilised components are made visible by the process of cooling the heated volatilised components such that supersaturation of the heated volatilised components occurs. The heated volatilised components then undergo droplet formation, otherwise known as nucleation, and eventually the size of the aerosol particles of the heated volatilised components increases by further condensation of the heated volatilised components and by coagulation of newly formed droplets from the heated volatilised components.

[0236] In some cases, the ratio of the cool air to the sum of the heated volatilised components and the cool air, known as the ventilation ratio, is at least 15%. A ventilation ratio of 15% enables the heated volatilised components to be made visible by the method described above. The visibility of the heated volatilised components enables the user to identify that the volatilised components have been generated and adds to the sensory experience of the smoking experience.

[0237] P13125297WO01 (171549 / 02) In another example, the ventilation ratio is between 50% and 85% to provide additional cooling to the heated volatilised components. In some cases, the ventilation ratio may be at least 60% or 65%.

[0238] In some cases, the aerosol-generating material may be included in the article / assembly in sheet form. In some cases, the aerosol-generating material may be included as a planar sheet. In some cases, the aerosol-generating material may be included as a planar sheet, as a bunched or gathered sheet, as a crimped sheet, or as a rolled sheet (i.e. in the form of a tube). In some cases, the aerosol-generating material may be formed as a sheet and then shredded and incorporated into the article.

[0239] In some embodiments, the aerosol-generating material is gathered to form at least a part of the consumable. The aerosol-generating material may be crimped prior to being gathered. Thus, in some embodiments the aerosol-generating material may be crimped and gathered. For instance, the aerosol-generating material may be crimped by passing the material through a pair of crimping rollers. The crimping may make it easier to gather the aerosol-generating material.

[0240] In some embodiments, the aerosol-generating material is crimped to a crimp depth of at least 0.1 mm and, in some examples, at least 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.5 mm, or 2 mm. In some embodiments, the aerosol-generating material to is crimped to a crimp depth of at most 2 mm. In some embodiments, the aerosol-generating material is crimped to a crimp depth in the range of 0.1 mm to 2 mm and, in some examples, in the range of 0.1 mm to 1 mm, or in the range of 0.2 mm to 0.7 mm.

[0241] The crimp depth (also known as “crimping factor”) refers to the depth of the grooves the crimping forms in the aerosol-generating material. That is, crimping the aerosolgenerating material produces a plurality of troughs in the aerosol-generating material when viewed from a first side of the aerosol-generating material, wherein the crimp depth is the depth of the troughs. The crimping may form a zig-zag formation or another shape. In some embodiments, adjacent grooves of the crimped aerosol-generating material are spaced by a distance in the range of 0.1 to 3 mm and, in some examples, in the range of 0.2 to 2 mm. In some embodiments, the aerosol-generating material is

[0242] P13125297WO01 (171549 / 02) heated as it is crimped. For example, the aerosol-generating material may be passed between crimping rollers, wherein one or both of the crimping rollers is heated.

[0243] In some embodiments, the aerosol-generating material is formed as a foam on a support. The aerosol-generating foam may be a continuous foam or a discontinuous foam, such as an arrangement of discrete portions of foam on a support.

[0244] Referring to Figures 1 and 2, there are shown a partially cut-away section view and a perspective view of an example of an aerosol-generating article 101. The article 101 is adapted for use with a device having a power source and a heater. The article 101 of this embodiment is particularly suitable for use with the device 1 shown in Figures 5 to 7, described below. In use, the article 101 may be removably inserted into the device shown in Figure 5 at an insertion point of the device 1 .

[0245] The article 101 of one example is in the form of a substantially cylindrical rod that includes a body of aerosol-generating material 103 and a filter assembly 105 in the form of a rod. The aerosol-generating material may be included in sheet form. In some embodiments it may be included in the form of a shredded sheet. In some embodiments, the aerosol-generating material described herein may be incorporated in sheet form and in shredded form.

[0246] The filter assembly 105 includes three segments, a cooling segment 107, a filter segment 109 and a mouth end segment 111. The article 101 has a first end 113, also known as a mouth end or a proximal end and a second end 115, also known as a distal end. The body of aerosol-generating material 103 is located towards the distal end 115 of the article 101. In one example, the cooling segment 107 is located adjacent the body of aerosol-generating material 103 between the body of aerosol-generating material 103 and the filter segment 109, such that the cooling segment 107 is in an abutting relationship with the aerosol-generating material 103 and the filter segment 103. In other examples, there may be a separation between the body of aerosolgenerating material 103 and the cooling segment 107 and between the body of aerosol-generating material 103 and the filter segment 109. The filter segment 109 is located in between the cooling segment 107 and the mouth end segment 111. The mouth end segment 111 is located towards the proximal end 113 of the article 101 , adjacent the filter segment 109. In one example, the filter segment 109 is in an abutting

[0247] P13125297WO01 (171549 / 02) relationship with the mouth end segment 111. In one embodiment, the total length of the filter assembly 105 is between 37mm and 45mm, more suitably, the total length of the filter assembly 105 is 41mm.

[0248] In one example, the rod of aerosol-generating material 103 is between 34mm and 50mm in length, suitably between 38mm and 46mm in length, suitably 42mm in length.

[0249] In one example, the total length of the article 101 is between 71 mm and 95mm, suitably between 79mm and 87mm, suitably 83mm.

[0250] An axial end of the body of aerosol-generating material 103 is visible at the distal end 115 of the article 101. However, in other embodiments, the distal end 115 of the article 101 may comprise an end member (not shown) covering the axial end of the body of aerosol-generating material 103.

[0251] The body of aerosol-generating material 103 is joined to the filter assembly 105 by annular tipping paper (not shown), which is located substantially around the circumference of the filter assembly 105 to surround the filter assembly 105 and extends partially along the length of the body of aerosol-generating material 103. In one example, the tipping paper is made of 58GSM standard tipping base paper. In one example the tipping paper has a length of between 42mm and 50mm, suitably of 46mm.

[0252] In one example, the cooling segment 107 is an annular tube and is located around and defines an air gap within the cooling segment. The air gap provides a chamber for heated volatilised components generated from the body of aerosol-generating material 103 to flow. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article 101 is in use during insertion into the device 1. In one example, the thickness of the wall of the cooling segment 107 is approximately 0.29mm.

[0253] The cooling segment 107 provides a physical displacement between the aerosolgenerating material 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 will provide a thermal gradient across the length

[0254] P13125297WO01 (171549 / 02) of the cooling segment 107. In one example the cooling segment 107 is configured to provide a temperature differential of at least 40 degrees Celsius between a heated volatilised component entering a first end of the cooling segment 107 and a heated volatilised component exiting a second end of the cooling segment 107. In one example the cooling segment 107 is configured to provide a temperature differential of at least 60 degrees Celsius between a heated volatilised component entering a first end of the cooling segment 107 and a heated volatilised component exiting a second end of the cooling segment 107. This temperature differential across the length of the cooling element 107 protects the temperature sensitive filter segment 109 from the high temperatures of the aerosol-generating material 103 when it is heated by the device 1. If the physical displacement was not provided between the filter segment 109 and the body of aerosol-generating material 103 and the heating elements of the device 1 , then the temperature sensitive filter segment may 109 become damaged in use, so it would not perform its required functions as effectively.

[0255] In one example the length of the cooling segment 107 is at least 15mm. In one example, the length of the cooling segment 107 is between 20mm and 30mm, more particularly 23mm to 27mm, more particularly 25mm to 27mm, suitably 25mm.

[0256] The cooling segment 107 is made of paper, which means that it is comprised of a material that does not generate compounds of concern, for example, toxic compounds when in use adjacent to the heater of the device 1. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube which provides a hollow internal chamber yet maintains mechanical rigidity. Spirally wound paper tubes are able to meet the tight dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness and straightness.

[0257] In another example, the cooling segment 107 is a recess created from stiff plug wrap or tipping paper. The stiff plug wrap or tipping paper is manufactured to have a rigidity that is sufficient to withstand the axial compressive forces and bending moments that might arise during manufacture and whilst the article 101 is in use during insertion into the device 1.

[0258] P13125297WO01 (171549 / 02) The filter segment 109 may be formed of any filter material sufficient to remove one or more volatilised compounds from heated volatilised components from the aerosolgenerating material. In one example the filter segment 109 is made of a mono-acetate material, such as cellulose acetate. The filter segment 109 provides cooling and irritation-reduction from the heated volatilised components without depleting the quantity of the heated volatilised components to an unsatisfactory level for a user.

[0259] In some embodiments, a capsule (not illustrated) may be provided in filter segment 109. It may be disposed substantially centrally in the filter segment 109, both across the filter segment 109 diameter and along the filter segment 109 length. In other cases, it may be offset in one or more dimension. The capsule may in some cases, where present, contain a volatile component such as a flavourant or aerosol-former material.

[0260] The density of the cellulose acetate tow material of the filter segment 109 controls the pressure drop across the filter segment 109, which in turn controls the draw resistance of the article 101. Therefore the selection of the material of the filter segment 109 is important in controlling the resistance to draw of the article 101. In addition, the filter segment performs a filtration function in the article 101.

[0261] In one example, the filter segment 109 is made of a 8Y15 grade of filter tow material, which provides a filtration effect on the heated volatilised material, whilst also reducing the size of condensed aerosol droplets which result from the heated volatilised material.

[0262] The presence of the filter segment 109 provides an insulating effect by providing further cooling to the heated volatilised components that exit the cooling segment 107. This further cooling effect reduces the contact temperature of the user’s lips on the surface of the filter segment 109.

[0263] In one example, the filter segment 109 is between 6mm to 10mm in length, suitably 8mm.

[0264] The mouth end segment 111 is an annular tube and is located around and defines an air gap within the mouth end segment 111. The air gap provides a chamber for heated volatilised components that flow from the filter segment 109. The mouth end segment

[0265] P13125297WO01 (171549 / 02) 111 is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article is in use during insertion into the device 1. In one example, the thickness of the wall of the mouth end segment 111 is approximately 0.29mm. In one example, the length of the mouth end segment 111 is between 6mm to 10mm, suitably 8mm.

[0266] The mouth end segment 111 may be manufactured from a spirally wound paper tube which provides a hollow internal chamber yet maintains critical mechanical rigidity. Spirally wound paper tubes are able to meet the tight dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness and straightness.

[0267] The mouth end segment 111 provides the function of preventing any liquid condensate that accumulates at the exit of the filter segment 109 from coming into direct contact with a user.

[0268] It should be appreciated that, in one example, the mouth end segment 111 and the cooling segment 107 may be formed of a single tube and the filter segment 109 is located within that tube separating the mouth end segment 111 and the cooling segment 107.

[0269] Referring to Figures 3 and 4, there are shown a partially cut-away section and perspective views of an example of an article 301. The reference signs shown in Figures 3 and 4 are equivalent to the reference signs shown in Figures 1 and 2, but with an increment of 200.

[0270] In the example of the article 301 shown in Figures 3 and 4, a ventilation region 317 is provided in the article 301 to enable air to flow into the interior of the article 301 from the exterior of the article 301. In one example the ventilation region 317 takes the form of one or more ventilation holes 317 formed through the outer layer of the article 301. The ventilation holes may be located in the cooling segment 307 to aid with the cooling of the article 301. In one example, the ventilation region 317 comprises one or more rows of holes, and suitably, each row of holes is arranged circumferentially around the

[0271] P13125297WO01 (171549 / 02) article 301 in a cross-section that is substantially perpendicular to a longitudinal axis of the article 301.

[0272] In one example, there are between one to four rows of ventilation holes to provide ventilation for the article 301. Each row of ventilation holes may have between 12 to 36 ventilation holes 317. The ventilation holes 317 may, for example, be between 100 to 500pm in diameter. In one example, an axial separation between rows of ventilation holes 317 is between 0.25mm and 0.75mm, suitably 0.5mm.

[0273] In one example, the ventilation holes 317 are of uniform size. In another example, the ventilation holes 317 vary in size. The ventilation holes can be made using any suitable technique, for example, one or more of the following techniques: laser technology, mechanical perforation of the cooling segment 307 or pre-perforation of the cooling segment 307 before it is formed into the article 301. The ventilation holes 317 are positioned so as to provide effective cooling to the article 301 .

[0274] In one example, the rows of ventilation holes 317 are located at least 11 mm from the proximal end 313 of the article, suitably between 17mm and 20mm from the proximal end 313 of the article 301. The location of the ventilation holes 317 is positioned such that user does not block the ventilation holes 317 when the article 301 is in use.

[0275] Providing the rows of ventilation holes between 17mm and 20mm from the proximal end 313 of the article 301 enables the ventilation holes 317 to be located outside of the device 1 , when the article 301 is fully inserted in the device 1 , as can be seen in Figures 6 and 7. By locating the ventilation holes outside of the device, non-heated air is able to enter the article 301 through the ventilation holes from outside the device 1 to aid with the cooling of the article 301.

[0276] The length of the cooling segment 307 is such that the cooling segment 307 will be partially inserted into the device 1 , when the article 301 is fully inserted into the device 1. The length of the cooling segment 307 provides a first function of providing a physical gap between the heater arrangement of the device 1 and the heat sensitive filter arrangement 309, and a second function of enabling the ventilation holes 317 to be located in the cooling segment, whilst also being located outside of the device 1 , when the article 301 is fully inserted into the device 1. As can be seen from Figures 6

[0277] P13125297WO01 (171549 / 02) and 7, the majority of the cooling element 307 is located within the device 1. However, there is a portion of the cooling element 307 that extends out of the device 1. It is in this portion of the cooling element 307 that extends out of the device 1 in which the ventilation holes 317 are located.

[0278] Referring now to Figures 5 to 7 in more detail, there is shown an example of a device 100 arranged to heat aerosol-generating material to volatilise at least one component of said aerosol-generating material, typically to form an aerosol which can be inhaled. The device 100 is a heating device which releases compounds by heating, but not burning, the aerosol-generating material.

[0279] Figure 5 shows an example of an aerosol provision device 100 for generating aerosol from an aerosol generating medium / material. In broad outline, the device 100 may be used to heat a consumable or replaceable article 110 as described herein, the consumable comprising the aerosol generating material, to generate an aerosol or other inhalable medium which is inhaled by a user of the device 100.

[0280] The device 100 comprises a housing 102 (including an outer cover 108) which surrounds and houses various components of the device 100. The device 100 has an opening 104 in one end, through which the article 110 may be inserted for heating by a heater assembly 200 (refer to Figure 6). In use, the article 110 may be fully or partially inserted into the heater assembly 200 where it may be heated by one or more components of the heater assembly 200.

[0281] The device 100 may also include a user-operable control element 112, such as a button or switch, which operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the switch 112.

[0282] The device 100 defines a longitudinal axis 101.

[0283] Figure 6 depicts a schematic cross-sectional front view of the device 100 of Figure 5. The device 100 comprises the outer cover 108, a first end member 106 and a second end member 116. The device 100 includes a chassis 109, a power source 118, and an aerosol generating assembly 111 including the heater assembly 200. The device 100 further comprises at least one electronics module 122. The outer cover 108 forms part

[0284] P13125297WO01 (171549 / 02) of a device shell. The first end member 106 is arranged at one end of the device 100 and the second end members 116 is arranged at an opposite end of the device 100. The first and second end members 106, 116 close the outer cover 108. The first and second end members 106, 116 form part of the shell. The device 100 in embodiments comprises a lid (not shown) which is moveable relative to the first end member 106 to close the opening 104 when no article 110 is in place.

[0285] The device 100 may also comprise an electrical component, such as a connector / port 120, which can receive a cable to charge a battery of the device 100. For example, the connector may be a charging port, such as a USB charging port. In some examples the connector may be used additionally or alternatively to transfer data between the device 100 and another device, such as a computing device.

[0286] The device 100 includes the chassis 109. The chassis 109 is received by the outer cover 108. The aerosol generating assembly 111 comprises the heater assembly 200 into which, in use, the article 110 may be fully or partially inserted where it may be heated by one or more components of the heater assembly 200. The aerosol generating assembly 111 and the power source 118 are mounted on the chassis 109. The chassis 109 is a one piece component.

[0287] One-piece component refers to a component of the device 100 which is not separable into two or more components following assembly of the device 100. Integrally formed relates to two or more features that are formed into a one piece component during a manufacturing stage of the component.

[0288] The first and second end members 106, 116 together at least partially define end surfaces of the device 100. For example, the bottom surface of the second end member 116 at least partially defines a bottom surface of the device 100. Edges of the outer cover 108 may also define a portion of the end surfaces. The first and second end members 116 close open ends of the outer cover 108. The second end member 116 is at one end of the chassis 109.

[0289] The end of the device 100 closest to the opening 104 may be known as the proximal end (or mouth end) of the device 100 because, in use, it is closest to the mouth of the user. In use, a user inserts an article 110 into the opening 104, operates the user

[0290] P13125297WO01 (171549 / 02) control 112 to begin heating the aerosol generating material and draws on the aerosol generated in the device. This causes the aerosol to flow through the device 100 along a flow path towards the proximal end of the device 100.

[0291] The other end of the device furthest away from the opening 104 may be known as the distal end of the device 100 because, in use, it is the end furthest away from the mouth of the user. As a user draws on the aerosol generated in the device, the aerosol flows in a direction towards the proximal end of the device 100. The terms proximal and distal as applied to features of the device 100 will be described by reference to the relative positioning of such features with respect to each other in a proximal-distal direction along the axis 101.

[0292] The power source 118 is, for example, a battery, such as a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, a lithium battery (such as a lithium-ion battery), a nickel battery (such as a nickelcadmium battery), and an alkaline battery. The battery is electrically coupled to the aerosol generating assembly 111 to supply electrical power when required and under control of a controller 121 to heat the aerosol generating material.

[0293] The power source 118 and aerosol generating assembly 111 are disposed in an axial arrangement, with the power source 118 at the distal end of the device 100 and the aerosol generating assembly 111 at the proximal end of the device 100. Other configurations are anticipated.

[0294] The electronics module 122 may comprise, for example, a printed circuit board (PCB) 123. The PCB 123 may support at least one controller 121 , such as a processor, and memory. The PCB 123 may also comprise one or more electrical tracks to electrically connect together various electronic components of the device 100. For example, the battery terminals 119a, 119b may be electrically connected to the PCB 123 so that power can be distributed throughout the device 100. The connector 120 may also be electrically coupled to the battery 118 via the electrical tracks.

[0295] The aerosol generating assembly shown 111 is an inductive heating assembly and comprises various components to heat the aerosol generating material of the article 110 via an inductive heating process. Induction heating is a process of heating an

[0296] P13125297WO01 (171549 / 02) electrically conducting object (such as a susceptor) by electromagnetic induction. An induction heating assembly may comprise an inductive element, for example, one or more inductor coils, and a device for passing a varying electric current, such as an alternating electric current, through the inductive element. The varying electric current in the inductive element produces a varying magnetic field. The varying magnetic field penetrates a susceptor suitably positioned with respect to the inductive element, and generates eddy currents inside the susceptor. The susceptor has electrical resistance to the eddy currents, and hence the flow of the eddy currents against this resistance causes the susceptor to be heated by Joule heating. In cases where the susceptor comprises ferromagnetic material such as iron, nickel or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e. by the varying orientation of magnetic dipoles in the magnetic material as a result of their alignment with the varying magnetic field. In inductive heating, as compared to heating by conduction for example, heat is generated inside the susceptor, allowing for rapid heating. Further, there need not be any physical contact between the inductive heater and the susceptor, allowing for enhanced freedom in construction and application.

[0297] A temperature sensor in the form of a thermocouple 150 is in thermal communication with the susceptor, and is connected to the electronics module 122. In the depicted embodiment, a thermally conductive plate 140 is placed between the thermocouple 150 and the susceptor to facilitate thermal communication between the thermocouple 150 and the susceptor (as discussed in more detail below in relation to Figure 7). In other examples, the plate 140 can be omitted.

[0298] The thermocouple 150 monitors the temperature of the susceptor during use of the device 100 and feeds this information to the electronics module 122. This allows the electronics module 122 and the controller 121 to monitor and adjust the temperature of the susceptor as may be necessary during use of the device 100, e.g. by adjusting the amount of electrical power supplied by the power source 118. The thermocouple 150 can be any suitable thermocouple, such as a platinum rhodium thermocouple (i.e. B type).

[0299] Compared to other devices for sensing temperature, the thermocouple 150 may facilitate more robust, durable, power-efficient and accurate temperature measurements. Nonetheless, in other examples within the scope of this disclosure, the

[0300] P13125297WO01 (171549 / 02) temperature sensor can be any other suitable temperature sensor, such as a resistance temperature detector, thermistor, infra-red sensor etc. Figure 7 shows a close up view of part of the aerosol generating assembly 111 in cross-section that includes the heater assembly 200 and an inductor coil assembly 127.

[0301] The aerosol generating assembly 111 comprises the inductor coil assembly 127 and the heater assembly 200. The inductor coil assembly 127 extends around the heater assembly 200. The inductor coil assembly 127 comprises a coil support 126. The inductor coil assembly 127 includes an inductor coil 124 wrapped around (i.e. surrounding) the heater assembly 200, disposed in a groove 129 defined in the support 126. The inductor coil assembly 127 is fixedly mounted in the device housing 102. The coil support 126 may form part of the device housing 102.

[0302] The heater assembly 200 includes a heating element 210 for heating the article 110 during use. In the exemplified embodiment of Figure 7, the heating element is a susceptor arrangement 210 (herein referred to as “a susceptor”). The susceptor 210 of this example is a blade-shaped susceptor 210. The article 110 can be inserted onto or around the susceptor 210. The blade-shaped susceptor 210 may have a constant rectangular cross-section along the majority of its axial length and then taper to a blade tip 212. In other examples, the axial cross-section may vary along the axial length of the susceptor 210 to the blade tip 212.

[0303] Although a blade-shaped susceptor 210 is depicted, it is to be understood than any other suitable shape or form of susceptor 210 may be used within the scope of this disclosure. For example, the susceptor 210 could be pin-shaped e.g. with a constant circular cross-section along its axial length that tapers to a pin tip, or rod-shaped (e.g. a cylindrical rod or a square rod) with a constant or varying cross-section along its axial length that omits a tip or tapered portion. In further examples, the susceptor 210 may be a tubular member within which the article 110 / aerosol generating material is received. Such a susceptor is an outer susceptor. In such an example, the susceptor may define a peripheral wall (e.g. an annular wall) that defines at least part of a heating chamber within which the article 110 can be received and heated. In such an example, the susceptor surrounds the article 110, instead of the article 110 surrounding the susceptor as in the blade-shaped embodiment discussed above. It will be understood that the cross-sectional profile of the outer susceptor may be formed in a variety of

[0304] P13125297WO01 (171549 / 02) profile shapes. In further examples, multiple susceptors (e.g. two or more separate susceptors) may also be provided, and may be of differing or similar configurations (e.g. pin-shaped, blade-shaped, rod-shape or tubular-type etc.), as required.

[0305] The susceptor 210 is formed from an electrically conducting material suitable for heating by electromagnetic induction. The susceptor in the present example is formed from a carbon steel. It will be understood that other suitable materials may be used, for example a ferromagnetic material such as iron, nickel or cobalt.

[0306] In other embodiments, the feature acting as the heating element may not be limited to being inductively heated. The feature, acting as a heating element, may therefore be heatable by electrical resistance. The heater assembly 200 may therefore comprise electrical contacts for electrical connection with the apparatus for electrically activating the heating element by passing a flow of electrical energy through the heating element. In such embodiments, inductive coil assembly 127 can be omitted as appropriate.

[0307] The inductor coil 124 is made from an electrically conducting material. In this example, the inductor coil 124 is made from Litz wire / cable which is wound in a helical fashion to provide a helical inductor coil 124. Litz wire comprises a plurality of individual wires which are individually insulated and are twisted together to form a single wire. Litz wires are designed to reduce the skin effect losses in a conductor. In the example device 100, the inductor coil 124 is made from copper Litz wire which has a circular cross section. In other examples the Litz wire can have other shape cross sections, such as rectangular. The inductor coil 124 can be connected to the PCB 123 to control the activation of inductive heating therefrom using the electronics module 122 and switch 112.

[0308] The number of inductor coils used may also differ. For example, although the heater assembly 200 shown in Figure 7 includes an inductor coil assembly 127 with only a single coil 124, it should be understood that the inductor coil assembly 127 can feature any number of suitable coils. Additional coils may be used to provide different heating zones with different heating characteristics for the susceptor 210 (e.g. provide different heating conditions to different areas along the axial length of the susceptor 210 and / or provide different heating conditions to the susceptor 210 at different times or for different use cases). Additional coils may also be provided to generate heating in

[0309] P13125297WO01 (171549 / 02) additional susceptors that may be disposed in the heater assembly 200 (not shown). The heater assembly 200 may also include a receptacle 230. The receptacle 230 defines a heating chamber 220 within which the article 110 is received during use. In the depicted embodiment, the receptacle 230 is an annular body that encircles the susceptor 210 and provides an annular space between the susceptor 210 and the receptacle within which the article 110 can be received and heated during use.

[0310] The coil support 126 and opening 104 define a device chamber 105 within the device housing 102 that receives the receptacle 230 and interacts therewith in order to secure the heater assembly 200 in place. In embodiments, the device chamber 105 is defined by another feature other than the coil support 126. The coil support 105 forms an internal wall. The internal wall is cup shaped.

[0311] The receptacle 230 may be removeably disposed within the chamber 105, such that it can be removed therefrom and replaced therein during use. This feature may facilitate the cleaning of the receptacle 230 (and other heater assembly components part thereof), as well as replacement of the receptacle 230 (and other heater assembly components part thereof) in the event of breakage or failure.

[0312] In the depicted example, the receptacle 230 is completely disposed inside the chamber 105. In other examples, when the receptacle 230 is received in the chamber 105 a portion of the receptacle 230 (e.g. such as a lip or a flange at its proximal end) may still extend outside of the device chamber 105. In such examples, the receptacle 230 may therefore be ‘partially removably disposed’ in the chamber 105. This disclosure covers all such examples.

[0313] In Figure 8 is a side-on cross sectional view of an article or consumable 1 for use in an aerosol delivery system.

[0314] The article 1 comprises a mouthpiece 2, and an aerosol-generating section, connected to the mouthpiece 2. In the present example, the aerosol generating section comprises a source of aerosol-generating material in the form of a cylindrical rod of aerosolgenerating material 3. In other examples, the aerosol-generating section may comprise a cavity for receiving a source of aerosol-generating material. The aerosol-generating material may comprise a plurality of strands or strips of aerosol-generating material.

[0315] P13125297WO01 (171549 / 02) The aerosol-generating material may be crimped or uncrimped.

[0316] In the present example, the cylindrical rod of aerosol-generating material 3 comprises a plurality of strands and / or strips of aerosol-generating material, and is circumscribed by a wrapper 10. In the present example, the wrapper 10 is a moisture impermeable wrapper. The plurality of strands or strips of aerosol-generating material may be aligned within the aerosol-generating section such that their longitudinal dimension is in parallel alignment with the longitudinal axis, X-X’ of the article 1. Alternatively, the strands or strips may generally be arranged such that their longitudinal dimension aligned is transverse to the longitudinal axis of the article. At least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or 95 % of the plurality of strands or strips maybe arranged such that their longitudinal dimension is in parallel alignment with the longitudinal axis of the article. A majority of the strands or strips may be arranged such that their longitudinal dimensions are in parallel alignment with the longitudinal axis of the article. In some embodiments, about 95% to about 100% of the plurality of strands or strips are arranged such that their longitudinal dimension is in parallel alignment with the longitudinal axis of the article. In some embodiments, substantially all of the strands or strips are arranged in the aerosol-generating section such that their longitudinal dimension is in parallel alignment with the longitudinal axis of the aerosolgenerating section of the article.

[0317] Where the majority of the strands or strips are arranged in the aerosol-generating section such that their longitudinal axis is parallel with the longitudinal axis of the aerosol-generating section of the article, the force required to insert an aerosol generator into the aerosol-generating material can be relatively low. This can result in an article which is easier to use.

[0318] In the present example, the rod of aerosol-generating material 3 has a circumference of about 22.7 mm. In alternative embodiments, the rod of aerosol-generating material 3 may have any suitable circumference, for example between about 20 mm and about 26 mm.

[0319] The article 1 is configured for use in a non-combustible aerosol provision device comprising an aerosol generator for insertion into the aerosol generating section. In

[0320] P13125297WO01 (171549 / 02) the present example, the aerosol generator is a heater, and the article is configured to receive the aerosol generator in the rod of aerosol-generating material.

[0321] The mouthpiece 2 includes a cooling section 8, also referred to as a cooling element, positioned immediately downstream of and adjacent to the source of aerosolgenerating material 3. In the present example, the cooling section 8 is in an abutting relationship with the source of aerosol-generating material. The mouthpiece 2 also includes, in the present example, a body of material 6 downstream of the cooling section 8, and a hollow tubular element 4 downstream of the body of material 6, at the mouth end of the article 1. The cooling section 8 comprises a hollow channel, having an internal diameter of between about 1 mm and about 4 mm, for example between about 2 mm and about 4 mm. In the present example, the hollow channel has an internal diameter of about 3 mm. The hollow channel extends along the full length of the cooling section 8. In the present example, the cooling section 8 comprises a single hollow channel. In alternative embodiments, the cooling section can comprise multiple channels, for example, 2, 3 or 4 channels. In the present example, the single hollow channel is substantially cylindrical, although in alternative embodiments, other channel geometries / cross- sections maybe used. The hollow channel can provide a space into which aerosol drawn into the cooling section 8 can expand and cool down. In all embodiments, the cooling section is configured to limit the cross-sectional area of the hollow channel / s, to limit displacement of aerosol-generating material 3 into the cooling section, in use.

[0322] The moisture impermeable wrapper 10 can have a lower friction with the aerosolgenerating material, which can result in strands and / or strips of aerosol-generating material being more easily displaced longitudinally, into the cooling section, when the aerosol generator is inserted into the rod of aerosol-generating material. The inventors have found that providing a cooling section 8 directly adjacent to the source of aerosol generating material, and comprising an inner channel with a diameter in this range, advantageously reduces the longitudinal displacement of strands and / or strips of aerosol-generating material when the aerosol generator is inserted into the rod of aerosol-generating material. It has been found that reducing the displacement of aerosol-generating material, in use, can advantageously result in a more consistent packing density of aerosol-generating material along the length of the rod and / or within a cavity, which can result in more consistent and improved aerosol generation.

[0323] P13125297WO01 (171549 / 02) The rod of aerosol generating material 3 and the cooling section 8 each have a cross- sectional area, measured perpendicular to the longitudinal axis of the article 1 , indicated by the line X-X’ in Figure 8. The cooling section is configured so that a maximum percentage of the cross sectional area of the cooling section is occupied by the one or more hollow channels, for example less than about 45% of the cross sectional area, less than about 32% of the cross sectional area, or less than about 25% of the cross sectional area. In the present example, about 18% of the cross sectional area of the cooling section is occupied by the hollow channel. Additionally or alternatively, at least about 4% of the cross sectional area of the cooling section can be occupied by the hollow channel, or at least about 6%, or at least about 8%. In some examples, between 4% and 32% of the cross sectional area of the cooling section is occupied by the hollow channel. Table 1 provides exemplary percentages of cooling section cross sectional area occupied by a hollow channel of either 3 or 3.9 mm internal diameter, for a range of cooling section diameters. For the purpose of this calculation, the cross sectional area of the cooling section is calculated based on the diameter of the cooling section without tipping paper applied, and the measurement is based on the dimensions of the cooling section which directly abuts the aerosol-generating section.

[0324] Table i

[0325] The cooling section 8 suitably has a wall thickness in a radial direction, which can be measured, for example, using a calliper. The wall thickness of the cooling section 8, for a given outer diameter of cooling section, defines the internal diameter for the cavity surrounded by the walls of the cooling section 8. The cooling section 8 can have a wall thickness of at least about 1.5 mm and up to about 2 mm. In the present example, the cooling section 8 has a wall thickness of about 2 mm. The inventors have advantageously found that providing a cooling section 8 having a wall thickness within this range improves the retention of the source of aerosol-generating material in the

[0326] P13125297WO01 (171549 / 02) aerosol generating section, in use, by reducing the longitudinal displacement of strands and / or strips of aerosol-generating material when the aerosol generator is inserted into the article.

[0327] The cooling section 8 is formed from filamentary tow. Other constructions can be used, such as a plurality of layers of paper which are parallel wound, with butted seams, to form the cooling section 8; or spirally wound layers of paper, cardboard tubes, tubes formed using a papier-mulch type process, moulded or extruded plastic tubes or similar. The cooling section 8 is manufactured to have a rigidity that is sufficient to withstand the axial compressive forces and bending moments that might arise during manufacture and whilst the article 1 is in use.

[0328] The wall material of the cooling section 8 can be relatively non-porous, such that at least 90% of the aerosol generated by the aerosol generating material 3 passes longitudinally through the one or more hollow channels rather than through the wall material of the cooling section 8. For instance, at least 92% or at least 95% of the aerosol generated by the aerosol generating material 3 can pass longitudinally through the one or more hollow channels.

[0329] The filamentary tow forming the cooling section 8 suitably has a total denier of less than 45,000, more suitably less than 42,000. This total denier has been found to allow the formation of a cooling section 8 which is not too dense. Suitably, the total denier is at least 20,000, more suitably at least 25,000. In embodiments, the filamentary tow forming the cooling section 8 has a total denier between 25,000 and 45,000, more suitably between 35,000 and 45,000.

[0330] Suitably, the density of the material forming the cooling section 8 is at least about 0.20 grams per cubic centimetre (g / cc), more suitably at least about 0.25 g / cc. Suitably, the density of the material forming the cooling section 8 is less than about 0.80 grams per cubic centimetre (g / cc), more suitably less than 0.6 g / cc. In some embodiments, the density of the material forming the cooling section 8 is between 0.20 and 0.8 g / cc, more suitably between 0.3 and 0.6 g / cc, or between 0.4 g / cc and 0.6 g / cc or about 0.5 g / cc. These densities have been found to provide a good balance between improved firmness afforded by denser material and minimising the overall weight of the article. For the purposes of the present invention, the "density" of the material forming the

[0331] P13125297WO01 (171549 / 02) cooling section 8 refers to the density of any filamentary tow forming the element with any plasticiser incorporated. The density maybe determined by dividing the total weight of the material forming the cooling section 8 by the total volume of the material forming the cooling section 8, wherein the total volume can be calculated using appropriate measurements of the material forming the cooling section 8 taken, for example, using callipers. Where necessary, the appropriate dimensions maybe measured using a microscope. Suitably, the length of the cooling section 8 is less than about 30 mm. More suitably, the length of the cooling section 8 is less than about 25 mm. Still more suitably, the length of the cooling section 8 is less than about 20 mm. In addition, or as an alternative, the length of the cooling section 8 is suitably at least about 10 mm. Suitably, the length of the cooling section 8 is at least about 15 mm. In some embodiments, the length of the cooling section 8 is from about 15 mm to about 20 mm, more suitably from about 16 mm to about 19 mm. In the present example, the length of the cooling section 8 is 19 mm.

[0332] The cooling section 8 is located around and defines an air gap within the mouthpiece 2 which acts as a cooling section. The air gap provides a chamber through which heated volatilised components generated by the rod of aerosol-generating material 3 flow. The cooling section 8 is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article 1 is in use. The cooling section 8 provides a physical displacement between the aerosol-generating material 3 and the body of material 6. The physical displacement provided by the cooling section 8 can provide a thermal gradient across the length of the cooling section 8.

[0333] Suitably, the mouthpiece 2 comprises a cavity having an internal volume greater than 110 mm3. Providing a cavity of at least this volume has been found to enable the formation of an improved aerosol. More suitably, the mouthpiece 2 comprises a cavity, for instance formed within the cooling section 8, having an internal volume greater than 110 mm3, and still more suitably greater than 130 mm3, allowing further improvement of the aerosol. In some examples, the internal cavity comprises a volume of between about 130 mm3and about 230 mm3, for instance about 134 mm3or 227 mm3. The cooling section 8 can be configured to provide a temperature differential of at least 40 degrees Celsius between a heated volatilised component entering a first, upstream end of the cooling section 8 and a heated volatilised component exiting a second,

[0334] P13125297WO01 (171549 / 02) downstream end of the cooling section 8. The cooling section 8 is suitably configured to provide a temperature differential of at least 60 degrees Celsius, suitably at least 80 degrees Celsius and more suitably at least 100 degrees Celsius between a heated volatilised component entering a first, upstream end of the cooling section 8 and a heated volatilised component exiting a second, downstream end of the cooling section 8. This temperature differential across the length of the cooling section 8 protects the temperature sensitive body of material 6 from the high temperatures of the aerosolgenerating material 3 when it is heated.

[0335] When in use, the aerosol-generating section may exhibit a pressure drop of from about 15 to about 40 mm H2O. In some embodiments, the aerosol-generating section exhibits a pressure drop across the aerosol-generating section of from about 15 to about 30 mm H2O.

[0336] The aerosol-generating material may have a packing density of between about 400 mg / cm3and about 900 mg / cm3within the aerosol-generating section. A packing density higher than this may make it difficult to insert the aerosol-generator of the aerosol provision device into the aerosol-generating material and increase the pressure drop. A packing density lower than 400 mg / cm3may reduce the rigidity of the article. Furthermore, if the packing density is too low, the aerosol-generating material may not effectively grip the aerosol-generator of the aerosol provision.

[0337] At least about 70% of a volume of the aerosol-generating section is filled with the aerosol-generating material. In some embodiments, from about 75% to about 85% of the volume of the cavity is filled with the aerosol-generating material.

[0338] In the present embodiment, the moisture impermeable wrapper 10 which circumscribes the rod of aerosol-generating material comprises aluminium foil. In other embodiments, the wrapper 10 comprises a paper wrapper, optionally comprising a barrier coating to make the material of the wrapper substantially moisture impermeable. Aluminium foil has been found to be particularly effective at enhancing the formation of aerosol within the aerosol-generating material 3. In the present example, the aluminium foil has a metal layer having a thickness of about 6 pm. In the present example, the aluminium foil has a paper backing. However, in alternative arrangements, the aluminium foil can be other thicknesses, for instance between 4 pm

[0339] P13125297WO01 (171549 / 02) and 16 m in thickness. The aluminium foil also need not have a paper backing, but could have a backing formed from other materials, for instance to help provide an appropriate tensile strength to the foil, or it could have no backing material. Metallic layers or foils other than aluminium can also be used. The total thickness of the wrapper is suitably between 20 pm and 60 pm, more suitably between 30 pm and 50 pm, which can provide a wrapper having appropriate structural integrity and heat transfer characteristics. The tensile force which can be applied to the wrapper before it breaks can be greater than 3,000 grams force, for instance between 3,000 and 10,000 grams force or between 3,000 and 4,500 grams force. Where the wrapper comprises paper or a paper backing, i.e. a cellulose based material, the wrapper can have a basis weight greater than about 30 gsm. For example, the wrapper can have a basis weight in the range from about 40 gsm to about 70 gsm. The inventors have advantageously found such basis weights provide an improved rigidity to the rod of aerosol-generating material. The improved rigidity provided by wrappers having a basis weight in this range can make the rod of aerosol-generating material 3 more resistant to crumpling or other deformation under the forces to which the article is subject, in use, for example when the article is inserted into a device and / or a heat generator is inserted into the article. Providing a rod of aerosol-generating material having increased rigidity can be beneficial where the plurality of strands or strips of aerosol-generating material are aligned within the aerosol-generating section such that their longitudinal dimension is in parallel alignment with the longitudinal axis, since longitudinally aligned strands or strips of aerosol-generating material may provide less rigidity to the rod of aerosol generating material than when the strands or strips are not aligned. The improved rigidity of the rod of aerosol-generating material allows the article to withstand the increased forces to which the article is subject, in use. In the present example, the moisture impermeable wrapper 10 is also substantially impermeable to air. In alternative embodiments, the wrapper 10 suitably has a permeability of less than 100 Coresta Units, more suitably less than 60 Coresta Units. It has been found that low permeability wrappers, for instance having a permeability of less than 100 Coresta Units, more suitably less than 60 Coresta Units, result in an improvement in the aerosol formation in the aerosol-generating material 3. Without wishing to be bound by theory, it is hypothesised that this is due to reduced loss of aerosol compounds through the wrapper 10. The permeability of the wrapper 10 can be measured in accordance with ISO 2965:2009 concerning the determination of air

[0340] P13125297WO01 (171549 / 02) permeability for materials used as cigarette papers, filter plug wrap and filter joining paper.

[0341] The body of material 6 and hollow tubular element 4 each define a substantially cylindrical overall outer shape and share a common longitudinal axis. The body of material 6 is wrapped in a first plug wrap 7. Suitably, the first plug wrap 7 has a basis weight of less than 50 gsm, more suitably between about 20 gsm and 40 gsm. Suitably, the first plug wrap 7 has a thickness of between 30 pm and 60 pm, more suitably between 35 pm and 45 pm. Suitably, the first plug wrap 7 is a non-porous plug wrap, for instance having a permeability of less than 100 Coresta units, for instance less than 50 Coresta units. However, in other embodiments, the first plug wrap 7 can be a porous plug wrap, for instance having a permeability of greater than 200 Coresta Units.

[0342] Suitably, the length of the body of material 6 is less than about 15 mm. More suitably, the length of the body of material 6 is less than about 12 mm. In addition, or as an alternative, the length of the body of material 6 is at least about 5 mm.

[0343] Suitably, the length of the body of material 6 is at least about 8 mm. In some embodiments, the length of the body of material 6 is from about 5 mm to about 15 mm, more suitably from about 6 mm to about 12 mm, even more suitably from about 6 mm to about 12 mm, most suitably about 6 mm, 7 mm, 8 mm, 9 mm or 10 mm. In the present example, the length of the body of material 6 is 10 mm.

[0344] In the present example, the body of material 6 is formed from filamentary tow. In the present example, the tow used in the body of material 6 has a denier per filament (d.p.f.) of 5 and a total denier of 25,000. In the present example, the tow comprises plasticised cellulose acetate tow. The plasticiser used in the tow comprises about 9% by weight of the tow. In the present example, the plasticiser is triacetin. In other examples, different materials can be used to form the body of material 6. For instance, rather than tow, the body 6 can be formed from paper, for instance in a similar way to paper filters known for use in cigarettes. For instance, the paper, or other cellulose- based material, can be provided as one or more portions of sheet material which is folded and / or crimped to form body 6. The sheet material can have a basis weight of from 05gsm to 6ogsm, for instance between 20 and 50 gsm. The sheet material can, for instance, have a basis weight in any of the ranges between 15 and 25 gsm, between

[0345] P13125297WO01 (171549 / 02) 25 and 30 gsm, between 30 and 40 gsm, between 40 and 45 gsm and between 45 and 50 gsm. Additionally or alternatively, the sheet material can have a width of between 50mm and 200mm, for instance between 60mm and 150mm, or between 80mm and 150mm. For instance, the sheet material can have a basis weight of between 20 and 50 gsm and a width between 80mm and 150mm. This can, for instance, enable the cellulose-based bodies to have appropriate pressure drops for an article having dimensions as described herein. Alternatively, the body 6 can be formed from tows other than cellulose acetate, for instance polylactic acid (PLA), other materials described herein for filamentary tow or similar materials. The tow is suitably formed from cellulose acetate. The tow, whether formed from cellulose acetate or other materials, suitably has a d.p.f. of at least 5. Suitably, to achieve a sufficiently uniform body of material 6, the tow has a denier per filament of no more than 12 d.p.f., suitably no more than 11 d.p.f. and still more suitably no more than 10 d.p.f.

[0346] The total denier of the tow forming the body of material 6 is suitably at most 30,000, more suitably at most 28,000 and still more suitably at most 25,000. These values of total denier provide a tow which takes up a reduced proportion of the cross sectional area of the mouthpiece 2 which results in a lower pressure drop across the mouthpiece 2 than tows having higher total denier values. For appropriate firmness of the body of material 6, the tow suitably has a total denier of at least 8,000 and more suitably at least 10,000. Suitably, the denier perfilament is between 5 and 12 while the total denier is between 10,000 and 25,000. Suitably the cross-sectional shape of the filaments of tow are ‘Y’ shaped, although in other embodiments other shapes such as ‘X’ shaped filaments can be used, with the same d.p.f. and total denier values as provided herein. Irrespective of the material used to form the body 6, the pressure drop across body 6, can, for instance, be between 0.3 and smmWG per mm of length of the body 6, for instance between o. smmWG and 2mmWG per mm of length of the body 6. The pressure drop can, for instance, be between 0.5 and 1mmWG / mm of length, between 1 and 1.5mmWG / mm of length or between 1.5 and 2mmWG / mm of length. The total pressure drop across body 6 can, for instance, be between 3mmWG and 8mWG, or between 4mmWG and / mmWG. The total pressure drop across body 6 can be about 5, 6 or 7mmWG.

[0347] As shown in Figure 8, the mouthpiece 2 of the article 1 comprises an upstream end 2a adjacent to the rod of aerosol-generating material 3 and a downstream end 2b distal

[0348] P13125297WO01 (171549 / 02) from the rod of aerosol-generating material 3. At the downstream end 2b, the mouthpiece 2 has a hollow tubular element 4 formed from filamentary tow. This has advantageously been found to significantly reduce the temperature of the outer surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece which comes into contact with a consumer’s mouth when the article 1 is in use. In addition, the use of the tubular element 4 has also been found to significantly reduce the temperature of the outer surface of the mouthpiece 2 even upstream of the tubular element 4. Without wishing to be bound by theory, it is hypothesised that this is due to the tubular element

[0349] 4 channelling aerosol closer to the centre of the mouthpiece 2, and therefore reducing the transfer of heat from the aerosol to the outer surface of the mouthpiece 2.

[0350] The "wall thickness" of the hollow tubular element 4 corresponds to the thickness of the wall of the tube 4 in a radial direction. This maybe measured, for example, using a calliper. The wall thickness is advantageously greater than 0.9 mm, and more suitably 1.0mm or greater. Suitably, the wall thickness is substantially constant around the entire wall of the hollow tubular element 4. However, where the wall thickness is not substantially constant, the wall thickness is suitably greater than 0.9 mm at any point around the hollow tubular element 4, more suitably 1.0 mm or greater. In the present example, the wall thickness of the hollow tubular element 4 is about 1.3 mm.

[0351] Suitably, the length of the hollow tubular element 4 is less than about 20 mm. More suitably, the length of the hollow tubular element 4 is less than about 15 mm. Still more suitably, the length of the hollow tubular element 4 is less than about 10 mm. In addition, or as an alternative, the length of the hollow tubular element 4 is at least about

[0352] 5 mm. Suitably, the length of the hollow tubular element 4 is at least about 6 mm. In some embodiments, the length of the hollow tubular element 4 is from about 5 mm to about 20 mm, more suitably from about 6 mm to about 10 mm, even more suitably from about 6 mm to about 8 mm, most suitably about 6 mm, 7 mm or about 8 mm. In the present example, the length of the hollow tubular element 4 is 7 mm.

[0353] Suitably, the density of the hollow tubular element 4 is at least about 0.25 grams per cubic centimetre (g / cc), more suitably at least about 0.3 g / cc. Suitably, the density of the hollow tubular element 4 is less than about 0.75 grams per cubic centimetre (g / cc), more suitably less than 0.6 g / cc. In some embodiments, the density of the hollow tubular element 4 is between 0.25 and 0.75 g / cc, more suitably between 0.3 and 0.6

[0354] P13125297WO01 (171549 / 02) g / cc, and more suitably between 0.4 g / cc and 0.6 g / cc or about 0.5 g / cc. These densities have been found to provide a good balance between improved firmness afforded by denser material and the lower heat transfer properties of lower density material. For the purposes of the present invention, the "density" of the hollow tubular element 4 refers to the density of the filamentary tow forming the element with any plasticiser incorporated. The density maybe determined by dividing the total weight of the hollow tubular element 4 by the total volume of the hollow tubular element 4, wherein the total volume can be calculated using appropriate measurements of the hollow tubular element 4 taken, for example, using callipers. Where necessary, the appropriate dimensions maybe measured using a microscope.

[0355] The filamentary tow forming the hollow tubular element 4 suitably has a total denier of less than 45,000, more suitably less than 42,000. This total denier has been found to allow the formation of a tubular element 4 which is not too dense. Suitably, the total denier is at least 20,000, more suitably at least 25,000. In embodiments, the filamentary tow forming the hollow tubular element 4 has a total denier between 25,000 and 45,000, more suitably between 35,000 and 45,000. Suitably the cross-sectional shape of the filaments of tow are ‘Y’ shaped, although in other embodiments other shapes such as ‘X’ shaped filaments can be used.

[0356] The filamentary tow forming the hollow tubular element 4 suitably has a denier per filament of greater than 3. This denier per filament has been found to allow the formation of a tubular element 4 which is not too dense. Suitably, the denier per filament is at least 4, more suitably at least 5. In embodiments, the filamentary tow forming the hollow tubular element 4 has a denier per filament between 4 and 10, more suitably between 4 and 9.

[0357] The hollow tubular element 4 suitably comprises from 15% to 22% by weight of plasticiser. For cellulose acetate tow, the plasticiser is suitably triacetin, although other plasticisers such as polyethelyne glycol (PEG) can be used. More suitably, the hollow tubular element 4 comprises from 16% to 20% by weight of plasticiser, for instance about 17%, about 18% or about 19% plasticiser.

[0358] In the present example, the first hollow tubular element 4, body of material 6 and cooling section 8 are combined using a second plug wrap 9 which is wrapped around

[0359] P13125297WO01 (171549 / 02) all three sections. Suitably, the second plug wrap 9 has a basis weight of less than 50 gsm, more suitably between about 20 gsm and 45 gsm. Suitably, the second plug wrap 9 has a thickness of between 30 pm and 60 pm, more suitably between 35 pm and 45 pm. The second plug wrap 9 is suitably a non-porous plug wrap having a permeability of less than 100 Coresta Units, for instance less than 50 Coresta Units. However, in alternative embodiments, the second plug wrap 9 can be a porous plug wrap, for instance having a permeability of greater than 200 Coresta Units.

[0360] In the present example, the article 1 has an outer circumference of about 23 mm. In other examples, the article can be provided in any of the formats described herein, for instance having an outer circumference of between 20mm and 26mm. Since the article is to be heated to release an aerosol, improved heating efficiency can be achieved using articles having lower outer circumferences within this range, for instance circumferences of less than 23mm. To achieve improved aerosol via heating, while maintaining a suitable product length, article circumferences of greater than 19mm have also been found to be particularly effective. Articles having circumferences of between 20mm and 24mm, and more suitably between 20mm and 23 mm, have been found to provide a good balance between providing effective aerosol delivery while allowing for efficient heating.

[0361] A tipping paper 5 is wrapped around the full length of the mouthpiece 2 and over part of the rod of aerosol-generating material 3 and has an adhesive on its inner surface to connect the mouthpiece 2 and rod 3. In the present example, the rod of aerosolgenerating material 3 is wrapped in wrapper 10, which forms a first wrapping material, and the tipping paper 5 forms an outer wrapping material which extends at least partially over the rod of aerosol-generating material 3 to connect the mouthpiece 2 and rod 3. In some examples, the tipping paper can extend only partially over the rod of aerosol-generating material.

[0362] In the present example, the tipping paper 5 extends 5 mm over the rod of aerosolgenerating material 3 but it can alternatively extend between 3 mm and 10 mm over the rod 3, or more suitably between 4 mm and 6 mm, to provide a secure attachment between the mouthpiece 2 and rod 3. The tipping paper can have a basis weight greater than 20 gsm, for instance greater than 25 gsm, or suitably greater than 30 gsm, for example 37 gsm. These ranges of basis weights have been found to result in tipping

[0363] P13125297WO01 (171549 / 02) papers having acceptable tensile strength while being flexible enough to wrap around the article 1 and adhere to itself along a longitudinal lap seam on the paper. The outer circumference of the tipping paper 5, once wrapped around the mouthpiece 2, is about 23 mm.

[0364] The article has a ventilation level of about 10% of the aerosol drawn through the article. In alternative embodiments, the article can have a ventilation level of between 1% and 20% of aerosol drawn through the article, for instance between 1 % and 12%.

[0365] Ventilation at these levels helps to increase the consistency of the aerosol inhaled by the user at the mouth end 2b, while assisting the aerosol cooling process. The ventilation is provided directly into the mouthpiece 2 of the article 1. In the present example, the ventilation is provided into the cooling section 8, which has been found to be particularly beneficial in assisting with the aerosol generation process. The ventilation is provided via perforations 12, in the present case formed as a single row of laser perforations, positioned 13 mm from the downstream, mouth-end 2b of the mouthpiece 2. In alternative embodiments, two or more rows of ventilation perforations maybe provided. These perforations pass though the tipping paper 5, second plug wrap 9 and cooling section 8. In alternative embodiments, the ventilation can be provided into the mouthpiece at other locations, for instance into the body of material 6 or first tubular element 4. Suitably, the article is configured such that the perforations are provided about 28mm or less from the upstream end of the article 1 , suitably between 20mm and 28mm from the upstream end of the article 1. In the present example, the apertures are provided about 25mm from the upstream end of the article.

[0366] A first dimension, or cut width, of the strands or strips of aerosol-generating material may be between 0.9 mm and 1.5 mm. When strands or strips of aerosol-generating material having a cut width of below 0.9 mm are incorporated into an article for use in a non-combustible aerosol provision system, the pressure drop across the article maybe increased to a level that renders the article unsuitable for use in a noncombustible aerosol-provision device. However, if the strands or strips have a cut width above 2 mm (e.g. greater than 2 mm), then it may be challenging to insert the strands or strips of aerosol-generating material into the article during its manufacture. In a embodiment, the cut width of the strands or strips of aerosol-generating material is between about 1 mm and 1.5 mm.

[0367] P13125297WO01 (171549 / 02) The strands or strips of material may be formed by shredding a sheet of aerosolgenerating material. The sheet of aerosol-generating material may be cut width-wise, for example in a cross-cut type shredding process, to define a cut length for the strands or strips of aerosol-generating material, in addition to a cut width. The cut length of the shredded aerosol-generating material may be at least 5 mm, for instance at least 10 mm, or at least 20 mm. The cut length of the shredded aerosol-generating material can be less than 60 mm, less than 50 mm, or less than 40 mm. In some embodiments, a plurality of strands or strips of aerosol-generating material is provided and at least one of the plurality of strands or strips of aerosol-generating material has a length greater than about 10 mm. At least one of the plurality of strands or strips of aerosol-generating material can alternatively or in addition have a length between about 10 mm and about 60 mm, or between about 20 mm and about 50 mm. Each of the plurality of strands or strips of aerosol-generating material can have a length between about 10 mm and about 60 mm, or between about 20 mm and about 50 mm.

[0368] P13125297WO01 (171549 / 02) The sheet or shredded sheet of aerosol-generating material may have a tensile strength in the range of about 2 N / 15mm to about 300 N / 15mm. The tensile strength may be greater than about 2 N / 15m, for instance greater than about 3 N / 15mm or greater than about 4 N / 15 mm or greater than about 5 N / 15mm or greater than about 6 N / 15mm. The tensile strength may be in the range of about 6 N / 15mm to about 100 N / 15mm.

[0369] As shown in Figure 9, the non-combustible aerosol provision device 100 may comprise a non-combustible aerosol-provision device having a housing 101 comprising an area 102 for receiving an article 1. The area 102 is arranged to receive the article 1. When the article 1 is received into the area 102, at least a portion of the aerosol-generating material comes into thermal proximity with the heater 103. When the article 1 is fully received in the area 102, at least a portion of the aerosol-generating material may be in direct contact with the heater 103. The aerosol-forming substrate will release a range of volatile compounds at different temperatures. By controlling the maximum operation temperature of the electrically heated aerosol generating system 100, the selective release of undesirable compounds may be controlled by preventing the release of select volatile compounds.

[0370] Figure 10 is a schematic cross-section of a non-combustible aerosol-provision device of the type shown in Figure 9, with the heater 103 inserted into the aerosol-generating material 3 of an article 1. The non-combustible aerosol provision device is illustrated in engagement with the aerosol-generating article 1 for consumption of the aerosolgenerating article 1 by a user. The housing 101 of non-combustible aerosol provision device defines an area 102 in the form of a cavity, open at the proximal end (or mouth end), for receiving an aerosol-generating article 1 for consumption. The distal end of the cavity is spanned by a heating assembly comprising a heater 103. The heater 103 is retained by a heater mount (not shown) such that an active heating area of the heater is located within the cavity. The active heating area of the heater 103 is positioned within the aerosol-generating section of the aerosol-generating article 1 when the aerosol-generating article 1 is fully received within the cavity. The heater 103 is configured for insertion into the aerosol generating material 3.

[0371] P13125297WO01 (171549 / 02) In Figures 9 and 10 the heater 103 is shaped in the form of a blade terminating in a point. That is, the heater has a length dimension that is greater than its width dimension, which is greater than its thickness dimension. First and second faces of the heater are defined by the width and length of the heater. However, other shapes of heater are possible. For example, the heater could be pin-shaped e.g. with a constant circular cross-section along its axial length that tapers to a pin tip, or rodshaped (e.g. a cylindrical rod or a square rod) with a constant or varying cross-section along its axial length that omits a tip or tapered portion.

[0372] As the article 1 is pushed into the cavity, the tapered point of the heater engages with the aerosol-generating material 3. The heater is shaped for easy insertion and removal from an aerosol-generating material 3. By applying a force to the article 1 , the heater penetrates into the aerosol-generating material 3. When the article 1 is properly engaged with the non-combustible aerosol provision device, the heater 103 is inserted into the aerosol-generating material 3. When the heater is actuated, aerosolgenerating material 3 is warmed and volatile substances are generated or evolved. As a user draws on the mouthpiece 2, air is drawn into the article 1 and the volatile substances condense to form an inhalable aerosol. This aerosol passes through the mouthpiece 2 of the article 1 and into the user's mouth.

[0373] It has been found that the aerosol generator can be inserted into the aerosolgenerating material with relative ease. Furthermore, once the aerosol generator is inserted into the aerosol-generating material, the article securely retained. This makes the article and device easier to use and also safer because the article may be less likely to become displaced from the aerosol generator during use.

[0374] A weight percentage quoted herein on a dry weight basis refers to the whole of the material or slurry, other than the water, and may include components which by themselves are liquid at room temperature and pressure, such as glycerol. Conversely, a weight percentage quoted on a wet weight basis refers to all components, including water.

[0375] P13125297WO01 (171549 / 02) Exemplary Embodiments

[0376] Further aspects of the invention are set out in numbered Embodiments 1-165 below.

[0377] 1. The aerosol-generating material of the second aspect, wherein the D90 of the tobacco powder is at least about 45% of the thickness of the aerosol-generating material.

[0378] 2. The aerosol-generating material of Embodiment 1 or the first aspect, wherein the D90 of the tobacco powder is at least about 47.5% of the thickness of the aerosolgenerating material.

[0379] 3. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is at least about 50% of the thickness of the aerosolgenerating material.

[0380] 4. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is at least about 52% of the thickness of the aerosolgenerating material

[0381] 5. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is at least about 53% of the thickness of the aerosolgenerating material.

[0382] 6. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is at least about 55% of the thickness of the aerosolgenerating material.

[0383] 7. The aerosol-generating material of the first or second aspects or any preceding Embodiment, wherein the D90 of the tobacco powder is about 100% or less of the thickness of the aerosol-generating material.

[0384] 8. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 90% or less of the thickness of the aerosolgenerating material.

[0385] 9. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 85% or less of the thickness of the aerosolgenerating material.

[0386] 10. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 80% or less of the thickness of the aerosolgenerating material.

[0387] P13125297WO01 (171549 / 02) 11. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 77.5% or less of the thickness of the aerosolgenerating material.

[0388] 12. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 75% or less of the thickness of the aerosolgenerating material.

[0389] 13. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 70% or less of the thickness of the aerosolgenerating material.

[0390] 14. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 67.5% or less of the thickness of the aerosolgenerating material.

[0391] 15. The aerosol-generating material of the first or second aspects or any preceding Embodiment, wherein the thickness of the aerosol-generating material is at least about 100 pm.

[0392] 16. The aerosol-generating material of any preceding Embodiment, wherein the thickness of the aerosol-generating material is at least about 120 pm.

[0393] 17. The aerosol-generating material of any preceding Embodiment, wherein the thickness of the aerosol-generating material is at least about 140 pm.

[0394] 18. The aerosol-generating material of any preceding Embodiment, wherein the thickness of the aerosol-generating material is at least about 160 pm.

[0395] 19. The aerosol-generating material of any preceding Embodiment, wherein the thickness of the aerosol-generating material is at least about 180 pm.

[0396] 20. The aerosol-generating material of any preceding Embodiment, wherein the thickness of the aerosol-generating material is at least about 200 pm.

[0397] 21. The aerosol-generating material of any preceding Embodiment, wherein the thickness of the aerosol-generating material is at least about 220 microns.

[0398] 22. The aerosol-generating material of the first or second aspects or any preceding Embodiment, wherein the thickness of the aerosol-generating material is about 400 pm or less.

[0399] 23. The aerosol-generating material of any preceding Embodiment, wherein the thickness of the aerosol-generating material is about 380 pm or less.

[0400] 24. The aerosol-generating material of any preceding Embodiment, wherein the thickness of the aerosol-generating material is about 360 pm or less.

[0401] P13125297WO01 (171549 / 02) 25. The aerosol-generating material of any preceding Embodiment, wherein the thickness of the aerosol-generating material is about 340 pm or less.

[0402] 26. The aerosol-generating material of any preceding Embodiment, wherein the thickness of the aerosol-generating material is about 320 pm or less.

[0403] 27. The aerosol-generating material of any preceding Embodiment, wherein the thickness of the aerosol-generating material is about 300 pm or less.

[0404] 28. The aerosol-generating material of any preceding Embodiment, wherein the thickness of the aerosol-generating material is about 295 pm or less.

[0405] 29. The aerosol-generating material of the first aspect or any preceding Embodiment, wherein the D90 of the tobacco powder is about 400 pm or less.

[0406] 30. The aerosol-generating material of the second aspect or any preceding Embodiment, wherein the D90 of the tobacco powder is about 350 pm or less.

[0407] 31. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 300 pm or less.

[0408] 32. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 250 pm or less.

[0409] 33. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 230 or less.

[0410] 34. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 225 pm or less.

[0411] 35. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 200 pm or less.

[0412] 36. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 195 pm or less.

[0413] 37. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 190 pm or less.

[0414] 38. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 185 pm or less.

[0415] 39. The aerosol-generating material of the first or second aspects or any preceding Embodiment, wherein the tobacco powder has a D90 of about 85 pm or more.

[0416] 40. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 90 pm or more.

[0417] 41. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 100 pm or more.

[0418] P13125297WO01 (171549 / 02) 42. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 110 pm or more.

[0419] 43. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 120 pm or more.

[0420] 44. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 125 pm or more.

[0421] 45. The aerosol-generating material of any preceding Embodiment, wherein the D90 of the tobacco powder is about 130 pm or more.

[0422] 46. The aerosol-generating material of the first or second aspects or any preceding Embodiment, wherein the tobacco powder has a D50 of about 100 pm or less.

[0423] 47. The aerosol-generating material of any preceding Embodiment, wherein the tobacco powder has a D50 of about 90 pm or less.

[0424] 48. The aerosol-generating material of any preceding Embodiment, wherein the tobacco powder has a D50 of about 85 pm or less.

[0425] 49. The aerosol-generating material of any preceding Embodiment, wherein the tobacco powder has a D50 of about 80 pm or less.

[0426] 50. The aerosol-generating material of any preceding Embodiment, wherein the tobacco powder has a D50 of about 75 pm or less.

[0427] 51. The aerosol-generating material of any preceding Embodiment, wherein the tobacco powder has a D50 of about 70 pm or less.

[0428] 52. The aerosol-generating material of the first or second aspects or any preceding Embodiment, wherein the tobacco powder has a D50 of about 25 pm or more.

[0429] 53. The aerosol-generating material of any preceding Embodiment, wherein the tobacco powder has a D50 of about 30 pm or more.

[0430] 54. The aerosol-generating material of any preceding Embodiment, wherein the tobacco powder has a D50 of about 32.5 pm or more.

[0431] 55. The aerosol-generating material of any preceding Embodiment, wherein the tobacco powder has a D50 of about 35 pm or more.

[0432] 56. The aerosol-generating material of any preceding Embodiment, wherein the tobacco powder has a D50 of about 37.5 pm or more.

[0433] 57. The aerosol-generating material of any preceding Embodiment, wherein the tobacco powder has a D50 of about 40 pm or more.

[0434] 58. The aerosol-generating material of the first or second aspects or any preceding Embodiment, wherein the tobacco powder has a D10 of about 25 pm or less.

[0435] P13125297WO01 (171549 / 02) 59. The aerosol-generating material of any preceding Embodiment, wherein the tobacco powder has a D10 of about 23 pm or less.

[0436] 60. The aerosol-generating material of any preceding Embodiment, wherein the tobacco powder has a D10 of about 22.5 pm or less.

[0437] 61. The aerosol-generating material of any preceding Embodiment, wherein the tobacco powder has a D10 of about 20 pm or less.

[0438] 62. The aerosol-generating material of the first or second aspects or any preceding

[0439] Embodiment, wherein the tobacco powder has a D10 of about 5 pm or more.

[0440] 63. The aerosol-generating material of any preceding Embodiment, wherein the tobacco powder has a D10 of about 7.5 pm or more.

[0441] 64. The aerosol-generating material of any preceding Embodiment, wherein the tobacco powder has a D10 of about 9 pm or more.

[0442] 65. The aerosol-generating material of any preceding Embodiment, wherein the tobacco powder has a D10 of about 10 pm or more.

[0443] 66. The aerosol-generating material of the first or second aspects or any preceding

[0444] Embodiment, wherein the difference between the D90 and D50 values is at least about 2 times greater than the difference between the D50 and D10 values.

[0445] 67. The aerosol-generating material of any preceding Embodiment, wherein the difference between the D90 and D50 values is from about 2 to about 5 times greater than the difference between the D50 and D10 values.

[0446] 68. The aerosol-generating material of any preceding Embodiment, wherein the difference between the D90 and D50 values is from about 2 to about 4.5 times greater than the difference between the D50 and D10 values.

[0447] 69. The aerosol-generating material of any preceding Embodiment, wherein the difference between the D90 and D50 values is from about 2.25 to about 4 times greater than the difference between the D50 and D10 values.

[0448] 70. The aerosol-generating material of the first or second aspects or any preceding Embodiment, wherein the ratio of the D90 to D10 (D90 / D10) of the tobacco powder is from about 8 to about 16.

[0449] 71. The aerosol-generating material of any preceding Embodiment, wherein the ratio of the D90 to D10 (D90 / D10) of the tobacco powder is from about 8.5 to about 14.5.

[0450] 72. The aerosol-generating material of any preceding Embodiment, wherein the ratio of the D90 to D10 (D90 / D10) of the tobacco powder is from about 8.75 to about 14.25.

[0451] P13125297WO01 (171549 / 02) 73. The aerosol-generating material of the first or second aspects or any preceding Embodiment, wherein the ratio of the D50 to D10 (D50 / D10) of the tobacco powder is from about 2.75 to about 4.75.

[0452] 74. The aerosol-generating material of any preceding Embodiment, wherein the ratio of the D50 to D10 (D50 / D10) of the tobacco powder is from about 3 to about 4.75.

[0453] 75. The aerosol-generating material of any preceding Embodiment, wherein the ratio of the D50 to D10 (D50 / D10) of the tobacco powder is from about 3 to about 4.5.

[0454] 76. The aerosol-generating material of the first or second aspects or any preceding Embodiment, wherein the aerosol-generating material contains the tobacco powder in an amount of about 20 wt% or more (dry weight basis).

[0455] 77. The aerosol-generating material of any preceding Embodiment, wherein the aerosol-generating material contains the tobacco powder in an amount of about 25 wt% or more (dry weight basis).

[0456] 78. The aerosol-generating material of any preceding Embodiment, wherein the aerosol-generating material contains the tobacco powder in an amount of about 30 wt% or more (dry weight basis).

[0457] 79. The aerosol-generating material of any preceding Embodiment, wherein the aerosol-generating material contains the tobacco powder in an amount of about 35 wt% or more (dry weight basis).

[0458] 80. The aerosol-generating material of any preceding Embodiment, wherein the aerosol-generating material contains the tobacco powder in an amount of about 40 wt% or more (dry weight basis).

[0459] 81. The aerosol-generating material of any preceding Embodiment, wherein the aerosol-generating material contains the tobacco powder in an amount of about 45 wt% or more (dry weight basis).

[0460] 82. The aerosol-generating material of any preceding Embodiment, wherein the aerosol-generating material contains the tobacco powder in an amount of about 50 wt% or more (dry weight basis).

[0461] 83. The aerosol-generating material of any preceding Embodiment, wherein the aerosol-generating material contains the tobacco powder in an amount of about 55 wt% or more (dry weight basis).

[0462] 84. The aerosol-generating material of any preceding Embodiment, wherein the aerosol-generating material contains the tobacco powder in an amount of about 60 wt% or more (dry weight basis).

[0463] P13125297WO01 (171549 / 02) 85. The aerosol-generating material of any preceding Embodiment, wherein the aerosol-generating material contains the tobacco powder in an amount of about 65 wt% or more (dry weight basis).

[0464] 86. The aerosol-generating material of the first or second aspects or any preceding Embodiment, wherein the aerosol-generating material contains the tobacco powder in an amount of about 90 wt% or less (dry weight basis).

[0465] 87. The aerosol-generating material of any preceding Embodiment, wherein the aerosol-generating material contains the tobacco powder in an amount of about 87.5 wt% or less (dry weight basis).

[0466] 88. The aerosol-generating material of any preceding Embodiment, wherein the aerosol-generating material contains the tobacco powder in an amount of about 85 wt% or less (dry weight basis).

[0467] 89. The aerosol-generating material of any preceding Embodiment, wherein the aerosol-generating material contains the tobacco powder in an amount of about 80 wt% or less (dry weight basis).

[0468] 90. The aerosol-generating material of any preceding Embodiment, wherein the aerosol-generating material contains the tobacco powder in an amount of about 75 wt% or less (dry weight basis).

[0469] 91. The aerosol-generating material of the first or second aspects or any of Embodiments 1-75, wherein the aerosol-generating material contains the tobacco powder in an amount of from about 0.05 to about 15 wt% (dry weight basis).

[0470] 92. The aerosol-generating material of Embodiment 91 , wherein the aerosolgenerating material contains the tobacco powder in an amount of from about 0.05 to about 10 wt% (dry weight basis).

[0471] 93. The aerosol-generating material of Embodiment 92, wherein the aerosolgenerating material contains the tobacco powder in an amount of from about 0.1 to about 5 wt% (dry weight basis).

[0472] 94. The aerosol-generating material of Embodiment 93, wherein the aerosolgenerating material contains the tobacco powder in an amount of from about 0.1 to about 2 wt% (dry weight basis).

[0473] 95. The aerosol-generating material of Embodiment 94, wherein the aerosolgenerating material contains the tobacco powder in an amount of from about 0.2 to about 2 wt% (dry weight basis).

[0474] P13125297WO01 (171549 / 02) 96. The aerosol-generating material of Embodiment 95, wherein the aerosolgenerating material contains the tobacco powder in an amount of from about 0.2 to about 1 wt% (dry weight basis).

[0475] 97. The aerosol-generating material of the first or second aspects or any preceding Embodiment, wherein the tobacco powder is homogeneously dispersed through the aerosol-generating material.

[0476] 98. The aerosol-generating material of the first or second aspects or any preceding Embodiment, further comprising an aerosol-former material.

[0477] 99. The aerosol-generating material of Embodiment 98, comprising the aerosol-former material in an amount of from about 1 to about 80 wt% (dry weight basis).

[0478] 100. The aerosol-generating material of Embodiment 99, comprising the aerosolformer material in an amount of from about 1 to about 50 wt% (dry weight basis).

[0479] 101. The aerosol-generating material of Embodiment 100, comprising the aerosolformer material in an amount of from about 5 to about 35 wt% (dry weight basis).

[0480] 102. The aerosol-generating material of Embodiment 101 , comprising the aerosolformer material in an amount of from about 10 to about 25 wt% (dry weight basis).

[0481] 103. The aerosol-generating material of Embodiment 102, comprising the aerosolformer material in an amount of from about 12 to about 22.5 wt% (dry weight basis).

[0482] 104. The aerosol-generating material of Embodiment 103, comprising the aerosolformer material in an amount of from about 13 to about 20 wt% (dry weight basis).

[0483] 105. The aerosol-generating material of any of Embodiments 98-104, wherein the aerosol-former material comprises one or more of glycerol, propylene glycol, 1 ,3- propanediol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1 ,3- butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0484] 106. The aerosol-generating material of Embodiment 105, wherein the aerosolformer material comprises glycerol and / or propylene glycol.

[0485] 107. The aerosol-generating material of Embodiment 105 or 106, wherein the aerosol-former material is glycerol.

[0486] 108. The aerosol-generating material of the first or second aspects or any preceding Embodiment, further comprising a binder.

[0487] P13125297WO01 (171549 / 02) 109. The aerosol-generating material of Embodiment 108 comprising from about 0.5 wt% to about 60 wt% of the binder (dry weight basis).

[0488] 110. The aerosol-generating material of Embodiment 109 comprising from about 1 wt% to about 30 wt% of the binder (dry weight basis).

[0489] 111. The aerosol-generating material of Embodiment 110 comprising from about 1 wt% to about 20 wt% of the binder (dry weight basis).

[0490] 112. The aerosol-generating material of Embodiment 111 comprising from about 1 wt% to about 10 wt% of the binder (dry weight basis).

[0491] 113. The aerosol-generating material of Embodiment 112 comprising from about 2 wt% to about 6 wt% of the binder (dry weight basis).

[0492] 114. The aerosol-generating material of Embodiment 108 comprising from about 0.5 wt% to about 60 wt% of the binder (dry weight basis).

[0493] 115. The aerosol-generating material of Embodiment 114 comprising from about 5 wt% to about 50 wt% of the binder (dry weight basis).

[0494] 116. The aerosol-generating material of Embodiment 115 comprising from about 10 wt% to about 35 wt% of the binder (dry weight basis).

[0495] 117. The aerosol-generating material of Embodiment 116 comprising from about 15 wt% to about 30 wt% of the binder (dry weight basis).

[0496] 118. The aerosol-generating material of Embodiment 117 comprising from about 15 wt% to about 25 wt% of the binder (dry weight basis).

[0497] 119. The aerosol-generating material of any of Embodiments 108-118, wherein the binder comprises (or is) one or more compounds selected from the group consisting of alginates, pectins, starches (and derivatives), celluloses (and derivatives, such as such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)), gums (such as xanthan gum, guar gum, acacia gum and locust bean gum), silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof.

[0498] 120. The aerosol-generating material of any of Embodiments 108-118, wherein the binder comprises (or is) one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol.

[0499] 121. The aerosol-generating material of any of Embodiments 108-118, wherein the binder comprises a cellulosic binder.

[0500] P13125297WO01 (171549 / 02) 122. The aerosol-generating material of Embodiment 121 , wherein the cellulosic binder is selected from the group consisting of: hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP) and combinations thereof.

[0501] 123. The aerosol-generating material of any of Embodiments 108-118, wherein the binder is carboxymethylcellulose or guar gum.

[0502] 124. The aerosol-generating material of any of Embodiments 108-118, wherein the binder is carboxymethylcellulose.

[0503] 125. The aerosol-generating material of any of Embodiments 108-118, wherein the binder is guar gum.

[0504] 126. The aerosol-generating material of the first or second aspects or any preceding Embodiment, further comprising a filler.

[0505] 127. The aerosol-generating material of Embodiment 126, comprising about 60 wt% or less of a filler (dry weight basis).

[0506] 128. The aerosol-generating material of Embodiment 127, comprising from about 1 wt% to about 60 wt% of a filler (dry weight basis).

[0507] 129. The aerosol-generating material of Embodiment 128, comprising from about 5 wt% to about 57.5 wt% of a filler (dry weight basis).

[0508] 130. The aerosol-generating material of Embodiment 129, comprising from about 10 wt% to about 55 wt% of a filler (dry weight basis).

[0509] 131. The aerosol-generating material of Embodiment 130, comprising from about 20 wt% to about 55 wt% of a filler (dry weight basis).

[0510] 132. The aerosol-generating material of Embodiment 131 , comprising from about 30 to about 55 wt% of a filler (dry weight basis).

[0511] 133. The aerosol-generating material of Embodiment 126, comprising from 0.5 to about 20 wt% of filler (dry weight basis).

[0512] 134. The aerosol-generating material of Embodiment 133, comprising from about 0.5 to about 15 wt% of filler (dry weight basis).

[0513] 135. The aerosol-generating material of Embodiment 134, comprising from about 1 to about 10 wt% of filler (dry weight basis).

[0514] 136. The aerosol-generating material of Embodiment 135, comprising from about 1 to about 8 wt% of filler (dry weight basis).

[0515] P13125297WO01 (171549 / 02) 137. The aerosol-generating material of Embodiment 136, comprising from about 2 to about 8 wt% of filler (dry weight basis).

[0516] 138. The aerosol-generating material of any of Embodiments 126-137, wherein the filler comprises microcrystalline cellulose (MCC), ground cellulose or combinations thereof.

[0517] 139. The aerosol-generating material of any of Embodiments 126-137, wherein the filler comprises wood pulp.

[0518] 140. The aerosol-generating material of the first or second aspects or any preceding Embodiment, wherein aerosol generating material does not comprise any inorganic filler

[0519] 141. The aerosol-generating material of the first or second aspects or any preceding Embodiment, wherein aerosol generating material does not comprise calcium carbonate.

[0520] 142. The aerosol-generating material of the first or second aspects or any preceding Embodiment, further comprising one or more additional actives.

[0521] 143. The aerosol-generating material of Embodiment 142, wherein the one or more additional active is nicotine.

[0522] 144. The aerosol-generating material of Embodiment 143, comprising from about 0.5 to about 20 wt% of the nicotine (dry weight basis).

[0523] 145. The aerosol-generating material of Embodiment 144, comprising from about 0.5 to about 10 wt% of the nicotine (dry weight basis).

[0524] 146. The aerosol-generating material of Embodiment 145, comprising from about 0.75 to about 10 wt% of the nicotine (dry weight basis).

[0525] 147. The aerosol-generating material of Embodiment 146, comprising from about 1 to about 5 wt% of the nicotine (dry weight basis).

[0526] 148. The aerosol-generating material of the first or second aspects or any preceding Embodiment, wherein the aerosol-generating material does not contain any further tobacco other than the tobacco powder.

[0527] 149. The aerosol-generating material of the first or second aspects or any of Embodiments 1-141 , wherein the tobacco powder is the only active substance in the aerosol-generating material.

[0528] 150. The aerosol-generating material of the first or second aspects or any preceding Embodiment, further comprising an acid.

[0529] 151. The aerosol-generating material of Embodiment 150, comprising the acid in an amount of from about 0.1 to about 2 wt% (dry weight basis).

[0530] P13125297WO01 (171549 / 02) 152. The aerosol-generating material of Embodiment 151 , comprising the acid in an amount of from about 0.5 to about 1 .75 wt% (dry weight basis).

[0531] 153. The aerosol-generating material of Embodiment 152, comprising the acid in an amount of from or about 0.75 to about 1.5 wt% (dry weight basis).

[0532] 154. The aerosol-generating material of any of Embodiments 150-153, wherein the acid is at least one of levulinic acid and benzoic acid.

[0533] 155. The aerosol-generating material of Embodiment 154, wherein the acid is a combination of levulinic acid and benzoic acid.

[0534] 156. The aerosol-generating material of the first or second aspects or any preceding Embodiment, further comprising one or more flavourants.

[0535] 157. A consumable for use within a non-combustible aerosol provision system, the consumable comprising the aerosol-generating material of any preceding Embodiment.

[0536] 158. The consumable of Embodiment 157, comprising from about 100 to about 500 mg of the aerosol-generating material.

[0537] 159. The consumable of Embodiment 158, comprising from about 200 to about 500 mg of the aerosol-generating material.

[0538] 160. The consumable of Embodiment 159, comprising from about 250 to about 500 mg of the aerosol-generating material.

[0539] 161. The consumable of Embodiment 160, comprising from about 300 to about 500 mg of the aerosol-generating material.

[0540] 162. The consumable of Embodiment 161 , comprising from about 350 to about 500 mg of the aerosol-generating material.

[0541] 163. The consumable of Embodiment 162, comprising from about 400 to about 500 mg of the aerosol-generating material.

[0542] 164. The consumable of any of Embodiments 157-163, comprising less than about 2 wt% of tobacco by weight of the consumable.

[0543] 165. The consumable of any of Embodiments 157-164, wherein the aerosolgenerating material is in the form of a gathered sheet, elongate strips, or a shredded sheet.

[0544] The Embodiments above, including Embodiments 1-156, may apply equally to the methods of the invention. For example, the slurry may comprise the constituents recited in these Embodiments, optionally in the amounts recited in these Embodiments calculated on a dry weight basis.

[0545] P13125297WO01 (171549 / 02) Examples

[0546] Example 1

[0547] The particle size distribution of a number of tobacco powder samples was measured by dynamic image analysis in accordance with ISO 13322-2 using a CAMSIZER X2 particle analyser (Resch Technology). D90, D50, D10 values for the different samples are shown in the table below. The particle size was defined as xc min.

[0548] Figure 11 shows a particle size distribution histogram for an exemplary tobacco powder (x-axis denotes particle size / pm; y-axis denotes probability).

[0549] Example 2

[0550] Tobacco powders having varying particle size distributions were prepared by grinding tobacco and varying the frequency of the grinder. The particle size distributions of the ground tobacco powder samples were then measured by dynamic image analysis according to the procedure set out in Example 1.

[0551] The ground tobacco powders were incorporated into slurries further comprising guar gum, wood pulp, glycerol and water. Aerosol-generating materials were then prepared from the slurries by casting the slurries to provide layer of the slurries, and drying the slurries to provide aerosol-generating materials. The conditions of the preparation method were the same for all aerosol-generating materials. The amounts of the

[0552] P13125297WO01 (171549 / 02) components of the aerosol-generating materials are shown in the table below. The target water content of the aerosol-generating material was 8 wt% (wet weight basis).

[0553] The thicknesses of the aerosol generating materials were then measured using a micrometer (L&W Micrometer A-2) in accordance with ISO 534:2011. The equipment settings were as set out in the table below.

[0554] The test atmosphere during the thickness measurement was a temperature of 22 ± 2°C and a relative humidity of 60 ± 5 % in accordance with ISO 3402.

[0555] Figure 12 shows the relationship between thickness and D90 for aerosol-generation materials formed from tobacco powders having a D90 of 127-152 pm (Trial B2-T09b - left box plots in Figure 11a) and for aerosol generation materials formed from tobacco powders having a D90 of 147-187 pm (Trial B2 T09c - right box plots in Figure 11b). The tobacco powders of Trial B2-T09b provided aerosol-generating materials having a thickness of 230-268 pm. The tobacco powders of Trial B2-T09c provided aerosolgenerating materials having a thickness of 255-292 pm. In both these trials the thickness of the aerosol-generating materials increased as the D90 of tobacco powder increased. The thickness of the aerosol-generating materials could therefore be controlled by varying the D90 of the tobacco powder.

[0556] Example 3

[0557] P13125297WO01 (171549 / 02) An aerosol-generating material comprising a tobacco powder is prepared by casting a slurry comprising the constituents of the aerosol generating material and water to provide a layer of the slurry and then drying the slurry to provide the aerosol generating material. The composition of the aerosol-generating material is shown in the table below:

[0558] P13125297WO01 (171549 / 02)

Claims

1. CLAIMS1. An aerosol-generating material comprising tobacco powder, wherein the D90 of the tobacco powder is at least about 45% of the thickness of the aerosol-generating material.

2. An aerosol-generating material comprising tobacco powder wherein the tobacco powder has a D90 of about 400 pm or less.

3. The aerosol-generating material of claim 1 , wherein the tobacco powder has a D90 of about 400 pm or less.

4. The aerosol-generating material of any preceding claim, wherein the D90 of the tobacco powder is about 90% or less of the thickness of the aerosol-generating material.

5. The aerosol-generating material of any preceding claim, wherein the D90 of the tobacco powder is from about 47.5 to about 80% of the thickness of the aerosolgenerating material.

6. The aerosol-generating material of any preceding claim, wherein the thickness of the aerosol-generating material is from about 100 pm to about 400 pm.

7. The aerosol-generating material of any preceding claim, wherein the aerosolgenerating comprises the tobacco powder in an amount of from about 20 wt% or more calculated on a dry weight basis, such as from about 25 to about 90 wt% calculated on a dry weight basis.

8. The aerosol-generating material of any preceding claim, wherein the tobacco powder has a D90 of about 200 pm or less.

9. The aerosol-generating material of any preceding claim, wherein the tobacco powder has a D90 of about 195 pm or less.P13125297WO01 (171549 / 02)10. The aerosol-generating material of any preceding claim, wherein the tobacco powder has a D50 of about 100 pm or less.

11. The aerosol-generating material of any preceding claim, wherein the tobacco powder has a D10 of about 25 pm or less.

12. The aerosol-generating material of any preceding claim, wherein the difference between the D90 and D50 values is at least about 2 times greater than the difference between the D50 and D10 values.

13. The aerosol-generating material of any preceding claim, wherein the ratio of the D90 to D10 (D90 / D10) of the tobacco powder is from about 8 to about 16.

14. The aerosol-generating material of any preceding claim, wherein the aerosolgenerating material further comprises: a binder, an aerosol-former material, a filler, one or more flavourants, and / or one or more additional active substances.

15. The aerosol-generating material of claim 14, comprising the one or more additional active substances, wherein the one or more additional active substances are selected from nicotine or one or more salts thereof.

16. A consumable for use within a non-combustible aerosol provision system, the consumable comprising the aerosol-generating material of any preceding claim.

17. The consumable of claim 16 comprising from about 100 to about 500 mg of the aerosol-generating material.

18. The consumable of claim 16 or claim 17, comprising less than about 2 wt% of tobacco by weight of the consumable.

19. A non-combustible aerosol provision system comprising the consumable of any of claims 16-18 and a non-combustible aerosol provision device, the non-combustible aerosol provision device, the non-combustible aerosol provision device comprising a heater configured heat but not burn the consumable.P13125297WO01 (171549 / 02)20. A method of forming the aerosol-generating material of any of claims 1-15, the method comprising:(b) providing a slurry comprising components of the aerosol-generating material or precursors thereof; (b) forming a layer of the slurry; and(c) drying the slurry to form the aerosol-generating material.P13125297WO01 (171549 / 02)

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