Article for use in a non-combustible aerosol provision system

Abstract

An article for insertion into a non-combustible aerosol provision device to generate an aerosol includes an aerosol-generating material section comprising aerosol-generating material and one or more empty regions, the one or more empty regions having a combined first volume and a tubular portion downstream of the aerosol-generating material section, the tubular portion defining a hollow cavity, wherein the hollow cavity has a second volume and the second volume is no greater than 15 times the first volume. A non-combustible aerosol provision system including a non-combustible aerosol provision device and the article are also described.

Description

[0001] Article for use in a non-combustible aerosol provision system

[0002] Technical field

[0003] The present invention relates to an article for use in a non-combustible aerosol provision system and a non-combustible aerosol provision system.

[0004] Background

[0005] Certain tobacco industry products produce an aerosol during use, which is inhaled by a user. For example, tobacco heating devices heat an aerosol generating substrate such as tobacco to form an aerosol by heating, but not burning, the substrate. Such tobacco industry products commonly include mouthpieces through which the aerosol passes to reach the user's mouth.

[0006] Summary

[0007] In accordance with a first aspect of the invention, there is provided an article for insertion into a non-combustible aerosol provision device to generate an aerosol, the article comprising: an aerosol-generating material section comprising aerosol-generating material and one or more empty regions, the one or more empty regions having a combined first volume; and a tubular portion downstream of the aerosol-generating material section, the tubular portion defining a hollow cavity, wherein the hollow cavity has a second volume and the second volume is no greater than 15 times the first volume.

[0008] In accordance with a second aspect of the invention, there is provided a non- combustible aerosol provision system comprising a non-combustible aerosol provision device and an article according to the first aspect.

[0009] Brief Description of the Drawings

[0010] Embodiments of the invention will now be described, by way of example only, with reference to accompanying drawings, in which:

[0011] Figure 1 is a side-on cross-sectional view of an article for insertion into a non- combustible aerosol provision device to generate an aerosol, the article including aerosol-generating material having one or more empty regions;

[0012] Figure 2 is a side-on cross-sectional view of a further article for insertion into a non- combustible aerosol provision device to generate an aerosol, the article including aerosol-generating material having one or more hollow channels; Figure 3a is a cross sectional illustration of the aerosol-generating material section of the article of Figure 1, taken along line A-A' shown in Figure 1;

[0013] Figure 3b is a cross sectional illustration of the aerosol-generating material section of the article of Figure 2, taken along line A-A' shown in Figure 2;

[0014] Figures 3c and 3d are cross sectional illustrations of further aerosol-generating material sections for use in the articles of Figure 1 or 2, taken along line A-A' shown in either Figure 1 or Figure 2;

[0015] Figure 4 is a side-on cross-sectional view of the article of Figure 1 inserted into a noncombustible aerosol provision device;

[0016] Figure 5 is a side-on cross-sectional view of the article of Figure 2 inserted into a noncombustible aerosol provision device;

[0017] Figures 6a to 6d are cross sectional illustrations of the aerosol-generating material sections of Figures 3a to 3d respectively with the article in which they are provided inserted into a non-combustible aerosol provision device; and

[0018] Figure 7 is a simplified schematic illustration of the components within the housing of the non-combustible aerosol provision devices shown in Figures 4 and 5.

[0019] Detailed description

[0020] In the figures described herein, like reference numerals are used to illustrate equivalent features, articles or components. The terms 'upstream' and 'downstream' used herein are relative terms defined in relation to the direction of mainstream aerosol drawn through an article or device in use.

[0021] Figure 1 is a side-on cross-sectional view of an article 1 for use in an aerosol delivery system. Figure 3a is a cross-sectional view of the article 1 of Figure 1 taken along line A-A' shown in Figure 1. Figure 4 is a side-on cross-sectional view of the article 1 for use in an aerosol delivery system, inserted into a receiving portion 2, in the present case a recess, of a non-combustible aerosol provision device 3.

[0022] The article 1 comprises an aerosol-generating material section 4 including aerosolgenerating material. The aerosol-generating material can include at least 5% aerosolformer material by weight of the aerosol-generating material, for instance between 10% and 60% by weight. Such percentage weights described herein are calculated on a dry weight basis unless otherwise specified. The aerosol-generating material section 4 includes one or more empty regions 4a having a combined first volume. The combined first volume can be at least 50mm3, at least 100mm3, at least 150mm3, at least 200mm3, or at least 250mm3. The combined first volume can be between 150mm3and 600mm3, or between 200mm3and 400mm3. A tubular portion 8a, 8b of the article 1 is arranged downstream of the aerosol-generating material section 4, the tubular portion 8a, 8b defining a hollow cavity 8c. In some examples, the hollow cavity 8c has a second volume of at least 70 mm3, at least 100mm3, at least 200mm3, at least 300mm3, or at least 400mm3. The second volume can be between 200mm3and 1000mm3, or between 250mm3and 800mm3.

[0023] In some preferred examples, the combined first volume is between 150mm3and 600mm3and the second volume is between 200mm3and 800mm3.

[0024] In some examples, the second volume is no greater than 15 times the first volume, or no greater than 10 times the first volume or no greater than 5 times the first volume. Advantageously, since one or more empty regions 4a are provided in the aerosolgenerating material section 4, these can provide a space into which aerosol generated in the aerosol-generating material can flow and expand, meaning that the hollow cavity 8c downstream of the aerosol-generating material section 4 can have a second volume which is more similar in size to the first volume, while providing an improved aerosol as compared to previous articles. Furthermore, the one or more empty regions 4a can allow additional cooling of the aerosol soon after it has formed within the aerosol-generating material, meaning that the aerosol generating material can be heated to a higher temperature without significantly increasing the risk of producing aerosol which is too warm for comfortable inhalation by a consumer. The higher temperature to which the aerosol-generating material can be heated can result in an improved aerosol, for instance having better sensorial performance and / or improved aerosol density. The heating element 2a used to heat the aerosol-generating material can, for instance, reach a peak temperature, for instance in a pre-heating phase, of between 250°C and 600°C or between 350°C and 575°C, and the temperature of the heating element 2a during a smoking session can be between 300°C and 400°C, such as between 320°C and 370°C.

[0025] The second volume (i.e. of the hollow cavity 8c) can be greater than the combined first volume of the one or more empty regions 4a. By providing an aerosol-generating material section 4 including one or more empty regions 4a, a relatively low weight aerosol generating section 4 can be provided which can have a relatively low resistance to draw. Advantageously, providing a hollow cavity 8c downstream of the aerosol-generating material section 4 with a larger, second volume than the first volume of the one or more empty regions 4a provides a sufficiently large space into which the aerosol leaving the empty regions 4a can expand. The flow of aerosol can also be slowed as compared to the flow through the empty regions 4a. Given the relatively high combined first volume of the one or more empty regions 4a in the aerosol-generating material section 4, the hollow cavity 8c can advantageously be less than 15 times the first volume, or less than 10 times the first volume, or less than 5 times the first volume.

[0026] In some embodiments, the tubular portion 8a, 8b includes a ventilation region 12 for admitting external air into the hollow cavity 8c. The length of the tubular portion 8a, 8b can be between about 20 mm and about 30 mm, or between about 22 mm and about 26 mm. In one example, the length of the tubular portion 8a, 8b is about 24 mm. The volume of the hollow cavity 8c can advantageously be greater than 500 mm3or greater than 600 mm3, for instance between 500 mm3and 900 mm3or between 600 mm3and 800 mm3. For example, the volume of the hollow cavity 8c can be about 680 mm3.

[0027] In some examples, the combined first volume of the one or more empty spaces 4a can be between about 50mm3and about 550mm3, for instance between about 200mm3and about 400mm3, or between about 250mm3and about 350mm3.

[0028] The tubular portion 8a, 8b can be immediately downstream of the aerosol-generating material section 4. The tubular portion 8a, 8b can be formed from a first tubular element 8a immediately downstream of the aerosol-generating material section 4 and a second tubular element 8b immediately downstream of the first tubular element 8a. The first tubular element 8a can define a first portion of the hollow cavity 8c. The first tubular element 8a can be formed from fibrous material, for instance sheet material such as paper or other fibrous sheet material gathered to form a tube, or fibrous material such as cellulose acetate or regenerated cellulose in tow form which is gathered to form a tube. In some embodiments, a hollow straw formed from paper or other sheet material is inserted into the fibrous material forming the body of the tube, to define the first portion of the hollow cavity 8c.

[0029] The second tubular element 8b can define a second portion of the hollow cavity 8c. The volume of the second portion can advantageously be larger than the volume of the first portion, which can result in the aerosol slowing and expanding as it passes into the second portion of the hollow cavity 8c. For example, the volume of the second portion of the hollow cavity can be between 1.5 and 8 times larger than the volume of the first portion, or between 5 and 8 times larger than the volume of the first portion. In one example, the volume of the first portion is about 90 mm3and the volume of the second portion is about 600 mm3. Referring to Figure 3a, the aerosol generating material section 4 can be formed from a sheet of aerosol generating material which is gathered and wrapped in a wrapper 15 to form the section 4. For instance, the sheet of aerosol generating material can be a tobacco or non-tobacco sheet material. The sheet can be crimped and / or folded and gathered to form the section 4. One or more empty spaces 4a are present in the section, in between the gathered portions of sheet material. The one or more empty spaces 4a can be present as one or more channels extending longitudinally through the section 4.

[0030] Referring to Figure 2, Figure 3b and Figure 5, a further article 1' includes aerosolgenerating material having one or more hollow channels 4b, 4c. The one or more hollow channels 4b, 4c include a first hollow channel 4b located substantially centrally within the cross-section of the aerosol-generating material section 4'. Where crosssections are referred to herein, these mean a cross-section taken in a plane perpendicular to the longitudinal direction through the article or component. The one or more hollow channels 4b, 4c also include one or more second hollow channels 4c located non-centrally within the cross-section of the aerosol-generating material section 4'. The one or more second hollow channels 4c can, for instance, be arranged around the first hollow channel 4b. There can, for instance, be between 2 and 100 second hollow channels 4c, and there are four in the present example. The one or more second hollow channels 4c can have a cross-sectional area which is between 40% and 90% or between 50% and 80% of the total cross-sectional area of the one or more hollow channels 4b, 4c. The one or more second hollow channels 4c can have a cross-sectional shape in the form of a circle, as illustrated, or other shapes such as polygons including triangles, squares, trapezoids, pentagons, hexagons etc. The aerosol-generating material can be formed into the illustrated shape using techniques known to those skilled in the art, such as moulding.

[0031] Referring to Figure 3c, a further aerosol-generating material section 4" includes aerosol generating material having one or more hollow channels 4b, 4c. Similarly to the section 4' of Figure 3b, the one or more hollow channels 4b, 4c include a first hollow channel 4b located substantially centrally within the cross section of the aerosol-generating material section 4". The one or more hollow channels 4b, 4c also include one or more second hollow channels 4c located non-centrally within the crosssection of the aerosol-generating material section 4", in the present case two second hollow channels 4c. The one or more second hollow channels 4c can, for instance, be arranged around the first hollow channel 4b. The one or more second hollow channels 4c can have a cross-sectional area which is between 40% and 90% or between 50% and 80% of the total cross-sectional area of the one or more hollow channels 4b, 4c. The one or more second hollow channels 4c can have a cross-sectional shape in the form of a circle, as illustrated, or other shapes such as polygons including triangles, squares, trapezoids, pentagons, hexagons etc. The aerosol-generating material can be formed into the illustrated shape using techniques known to those skilled in the art, such as moulding.

[0032] Referring to Figure 3d, a further aerosol-generating material section 4"' includes aerosol generating material having one or more hollow channels 4b, 4c'. Similarly to the section 4' of Figure 3b, the one or more hollow channels 4b, 4c' include a first hollow channel 4b located substantially centrally within the cross section of the aerosol-generating material section 4'". The one or more hollow channels 4b, 4c' also include one or more second hollow channels 4c' located non-centrally within the crosssection of the aerosol-generating material section 4'", in the present case eight second hollow channels 4c'. The one or more second hollow channels 4c' can, for instance, be arranged around the first hollow channel 4b. The one or more second hollow channels 4c' can have a cross-sectional area which is between 40% and 90% or between 50% and 80% of the total cross-sectional area of the one or more hollow channels 4b, 4c'. The one or more second hollow channels 4c' can have a cross-sectional shape in the form of a trapezoid, as illustrated, or other shapes such as circles or polygons including triangles, squares, pentagons, hexagons etc. The aerosol-generating material can be formed into the illustrated shape using techniques known to those skilled in the art, such as moulding.

[0033] As illustrated in Figures 3a, 3b, 3c and 3d, the first tubular element 8a defines the first portion of the hollow cavity 8c such that this overlaps with a portion of the one or more empty spaces 4a (Figure 3a) and hollow channels 4b, 4c, 4c' (Figures 3b to 3d). In connection with Figures 3b to 3d, in some examples, the first hollow channel 4b entirely overlaps with the first portion of the hollow cavity 8c defined by the first tubular element 8a, and a portion of the second hollow channels 4c, 4c' overlaps with the first portion of the hollow cavity 8c.

[0034] The cross-sectional area of overlap of the hollow cavity 8c of the tubular portion 8a, 8b and of the one or more empty spaces 4a or one or more hollow channels 4b, 4c, 4c' is at least about 5mm2, at least about 6mm2, at least about 7mm2, or at least about 8mm2, optionally wherein the cross-sectional area of overlap is between 20% and 50% or between 30% and 45% of the total cross-sectional area of the one or more empty spaces 4a or one or more hollow channels 4b, 4c, 4c'.

[0035] Referring to Figures 1 and 2, the articles 1, 1' each comprise the aerosol-generating section 4, 4' and a downstream section 5 downstream of the aerosol-generating section 4, 4'. The downstream section 5 can be or include a mouthpiece designed to be inserted into a user's mouth in use, or alternatively may be arranged to work with a separate mouthpiece such as one provided as a separate attachment to the downstream section 5 or as part of the device 3. The downstream section 5 has an upstream end 5a and a downstream end 5b. In the present examples, the aerosolgenerating sections 4, 4' comprise a source of aerosol-generating material in the form of a cylindrical rod of aerosol-generating material. The aerosol-generating material can include at least 5% aerosol-former material by weight of the aerosol-generating material, calculated on a dry weight basis, the aerosol-former material being, for instance, one of the aerosol-former materials described herein.

[0036] Referring to Figures 4 and 5, in the present examples, the receiving portion 2 is a recess in the device 3 including a heating element 2a in the form of a pin-shaped heater 2a which penetrates the aerosol generating section 4, 4'. The pin-shaped heater 2a is resistively heated in the present example, although may alternatively be formed of a heating material as described herein which can be inductively heated, such as a susceptor, or make use of a pin-shaped heater which is heated in other ways. The pin-shaped heaters described herein can be in the general form of a cylinder which and has a diameter of between 1.8 mm and 3 mm, or between 2.2 mm and 2.6 mm. The length of the pin-shaped heater can be between 11 mm and 20 mm, for instance between 15 mm and 18 mm. The length of the pin-shaped heater can be approximately 1 mm shorter than the combined length of the upstream body of material 17 and aerosol-generating material section 4, 4', 4", 4'". In other examples, the aerosol generating section 4, 4', 4", 4'" of the articles 1, 1' can include a heating material, for instance one which can be inductively heated, such as a susceptor.

[0037] Figures 6a to 6d are cross-sectional illustrations of the aerosol-generating material sections 4, 4', 4", 4'" of Figures 3a to 3d respectively with the article in which they are provided inserted into a non-combustible aerosol provision device, illustrating the location of the heating element 2a, such as the pin heater 2a, within the sections 4, 4', 4", 4'". The heating element is received in the first hollow channel 4b of the aerosol-generating material section 4', 4", 4'" of Figures 6b to 6d. The mouthpiece or downstream portion 5 includes the first tubular element 8a immediately downstream of the aerosol-generating material section 4, 4', 4", 4"', the first tubular element 8a defining a first portion of the hollow cavity 8c. In the present example, the first tubular element 8a is in an abutting relationship with the aerosolgenerating material. The first tubular element 8a has a first tubular wall. The mouthpiece or downstream portion 5 also includes the second tubular element 8b immediately downstream of the first tubular element 8a. In the present example, the second tubular element 8b is in an abutting relationship with the first tubular element 8a. The second tubular element 8b has a second tubular wall having a wall thickness of less than about 320 pm. The second tubular element 8b has an axial length of greater than about 15 mm, for instance between about 15 mm and about 25 mm. In the present example, a downstream body of material 6 is provided at the downstream end 5b of the downstream section 5. The first and second tubular elements 8a, 8b, and the downstream body of material 6, in the present example, each define a cylindrical outer shape and are arranged end-to-end on a common axis. The first and second tubular elements 8a, 8b, aerosol-generating material section 4 and body of material 6 have approximately the same outer diameter.

[0038] An upstream body of material 17 can be provided upstream of the aerosol-generating material section 4, 4', 4", 4"'. When inserted into the device 3, the heating element 2a, or pin heater, of the device 3 penetrates the upstream body of material 17 and aerosol-generating material section 4, 4', 4", 4"' of the article 1, 1'. A portion of the heating element 2a within the aerosol-generating material section 4, 4', 4", 4"' can thereby heat the aerosol-generating material of the aerosol-generating material section 4, 4', 4", 4"'.

[0039] The first and second tubular elements 8a, 8b together define a chamber 8c into which aerosol formed in the aerosol-generating section 4, 4', 4", 4"' is drawn and expands and cools. The provision of discrete first and second tubular elements 8a, 8b enables these components to be designed to achieve different functional effects. For instance, the first tubular element 8a can be arranged to provide functions such as helping to reduce movement of the aerosol-generating material in use, as the article 1, 1' is inserted into the recess 2 and the pin heater 2a penetrates the aerosol-generating material section 4, 4', 4", 4"'. For this purpose, the first tubular element 8a can have a wall thickness of, for instance, between 1mm and 3.5mm, or between 1.5mm and 2.5mm. Alternatively or additionally, the first tubular element 8a can be arranged to help with providing rigidity to the article 1, 1'. Alternatively or additionally, the first tubular element 8a can be arranged to encourage aerosol to flow predominantly into an axial region of the second tubular element 8b, for instance to assist with aerosol formation. The second tubular element 8b can be designed to define a relatively large chamber as compared to the first tubular element 8a, providing greater space into which the aerosol formed in the aerosol-generating section 4, 4', 4", 4"' can be drawn to expand and cool. In addition, for a given weight of the second tubular element 8b, providing a relatively thin wall thickness of less than 320 pm enables material to be concentrated in the outer region of the second tubular element 8b, which can provide a higher bending stiffness as compared to components with thicker walls and the same weight.

[0040] In some examples, articles as described with reference to Figures 1 and 2 have the specific features set out in table 1.0 below.

[0041] Table 1.0

[0042] Although in the present case, the downstream body of material 6 is provided at the mouth or downstream end lb of the articles 1, 1', in other examples a further component can be provided downstream of the downstream body of material 6. For instance, a further body of material can be provided.

[0043] The aerosol-generating material may comprise a single sheet material as described above or a plurality of strands or strips of aerosol-generating material. For example, the aerosol-generating material may comprise a plurality of strands or strips of an aerosolisable material and / or a plurality of strands or strips of an amorphous solid, as described hereinbelow. In some embodiments, the aerosol-generating material consists of a plurality of strands or strips of an aerosolisable material. In other embodiments, the aerosol-generating material consists of a single strand, strip or sheet of an aerosolisable material. The strands or strips of aerosol-generating material can be arranged such that their longitudinal dimension is substantially parallel with the longitudinal axis of the article 1, 1'. The aerosol-generating material can be in the form of reconstituted sheet tobacco material or reconstituted sheet nontobacco botanical material such as bandcast reconstituted botanical material.

[0044] Alternatively, the aerosol-generating material can be in the form of a non-botanical sheet material, such as paper or other fibrous material, to which active agents and aerosol former materials as described herein have been applied.

[0045] In the present examples, the first tubular element 8a has an axial length of about 7mm, but in other examples the first tubular element 8a can have an axial length between about 5mm and about 14mm. In the present examples, the first tubular element 8a has a wall thickness of about 1.6mm and an inner radius of the hollow cavity defined by the first tubular element 8a is about 1.95 mm. This results in a ratio between the thickness of the first tubular wall to the internal radius of the first hollow cavity of about 0.82. In other examples, the ratio of the thickness of the first tubular wall to the internal radius of the first hollow cavity can be between about 0.6 and about 1.1, or between about 0.7 and about 0.9.

[0046] In some examples, the volume of the second portion of the hollow cavity 8c defined by the second tubular element 8b can be about 588 mm3. The volume of the first portion of the hollow cavity 8c defined by the first tubular element 8a can be about 84 mm3. The ratio of the volume of the second portion to the volume of the first portion is therefore about 7 times. The ratio of the volume of the second portion to the volume of the first portion can alternatively be between about 6.5 and about 8. This provides an arrangement in which aerosol can expand from a relatively small cavity within the first tubular element 8a into the much larger cavity of the second tubular element 8b. The second tubular element 8b can define a second portion of the hollow cavity 8c having a volume of at least about 520 mm3. The combined volumes of the first and second portions of the hollow cavity 8c can, for instance, be at least about 580 mm3, or at least about 620 mm3or at least about 650 mm3.

[0047] The second tubular wall can comprise at least first and second overlapping paper layers each extending around substantially the whole circumference of the second tubular element 8b. The at least first and second overlapping paper layers can each have a thickness of between 30 and 150 pm. Alternatively or in addition, the at least first and second overlapping paper layers can each have a basis weight of between 25 and 130 gsm. The at least first and second overlapping paper layers can be connected to each other by a layer of adhesive. The first and second overlapping paper layers can each be non-porous.

[0048] The aerosol-generating material section 4, 4', 4", 4"' can be in the form of a rod having an axial length which is less than or equal to the axial length of the second tubular element 8b. For instance, the aerosol-generating material section 4, 4', 4", 4"' can be in the form of a rod having an axial length which is between 50% and 80% of the axial length of the second tubular element 8b. These arrangements result in an article with a relatively large cavity size defined by the second tubular element 8b as compared to the volume occupied by the aerosol-generating material. Such a cavity can allow for improved expansion of the volume of aerosol passing though the article 1, 1' and better aerosol formation. Preferably, ventilation apertures are provided into the wall of the second tubular element 8b such that cool air enters the cavity defined by the second tubular element 8b in use, further enhancing aerosol formation via condensation of aerosol components within the cavity 8c. The second tubular element 8b can have an axial length of greater than about 16mm or greater than about 16.5mm. For instance, in some examples, the second tubular element 8b can have an axial length which is at least 1.5 or at least 2 times greater than the axial length of the first tubular element 8a.

[0049] As set out above, a ventilation region 12 can be provided into the tubular portion 8a, 8b, for instance in the form of ventilation apertures. The ventilation apertures may comprise a row of perforations which extend circumferentially around and pass through the wall of the second tubular element 8b. Alternatively or in addition, the ventilation apertures may comprise a row of perforations which extend circumferentially around and pass through the wall of the first tubular element 8a. The row of ventilation apertures can be provided at a location of between 13mm and 35mm from the downstream end 5b of the downstream section 5, for instance between 15mm and 30mm, or between 18mm and 25mm. In some cases, the row of ventilation apertures is provided at a location in the range of 20mm to 24mm from the downstream end 5b of the downstream section 5, for instance at 21mm or 22mm from the downstream end 5b. Use of a second tubular element 8b immediately downstream of the first tubular element 8a, which has a wall thickness of less than about 320 m and an axial length of greater than about 15mm, can result in an article which has an overall weight which is lower than previous designs. In the present examples, the aerosol-generating material section 4 has a weight of between about 200 mg and about 280 mg and the non-aerosol-generating material components of the article 1 have a combined weight of about 320 mg. The total weight is therefore between about 520 grams and about 600 mg for an article 1, 1' with an overall length of 54mm, resulting in an average weight of between 9.6 and 11.1 mg / mm. In some examples, the average weight per mm of axial length of the article can be less than about 12.5 mg / mm or less than about 12 mg / mm or less than about 11.5 mg / mm. In some examples, the average weight per mm of axial length of the article can be between 8.0 and 12.5 mg / mm, or between 9.0 and 11.5 mg / mm. The non-aerosol-generating material weight of the article can be between 45% and 55% of the overall article weight, for instance between 46% and 53%.

[0050] The tubular wall of the second tubular element 8b, in the present example, is formed from first and second overlapping paper sheets, resulting in an overall thickness of about 200pm. In alternative examples, the second tubular wall can have a thickness of between about 160pm and about 250 pm. The second hollow cavity defined by the second tubular element has a diameter of about 6.6mm and a radius 'r' of about 3.3mm. The second tubular wall can, for instance, have a thickness which is less than about 15% or less than about 10% of the internal radius 'r' of the second hollow cavity.

[0051] As shown in Figures 4 and 5, the non-combustible aerosol provision device 3 and the respective articles 1, 1' together form a non-combustible aerosol provision system. The non-combustible aerosol provision device 3 includes a heating element 2a configured for insertion into the aerosol-generating material of the article 1, 1'. In the present example, the heating element is a pin-shaped heater 2a which penetrates the aerosol-generating material. For instance, the heating element 2a is inserted through the upstream body of material 17 and into the aerosol-generating material section 4, 4', 4", 4"'.

[0052] The non-combustible aerosol provision device 3 includes a housing 9 and an aperture 10 in the housing 9 into which the article 1, 1' is inserted in use. The system is configured such that the second tubular element 8b extends partially within and partially outside the housing 9 when the article 1, 1' is fully inserted into the non- combustible aerosol provision device 3, as shown in Figures 4 and 5. The system can be configured such that the second tubular element 8b extends at least about 5mm within and at least about 8mm outside the housing 9 when the article 1, 1' is fully inserted into the non-combustible aerosol provision device 3. In the present example, the articles 1, 1' have upstream bodies of material of length 6mm, aerosol-generating material sections 4, 4', 4", 4"' having a length of about 12mm, a first tubular element 8a having a length of about 7mm and a second tubular element 8b having a length of about 17mm. The article 1, 1' is inserted into the device 3 to an insertion depth of about 31mm, as shown by arrow 'B' in Figures 4 and 5. In the present case, about 6mm of the second tubular element 8b, between the upstream end 8b' of the second tubular element and the location 'B' on the article 1, 1' aligned with the entrance to the recess 2 in the device 3, extends within the device 3. About 11mm of the second tubular element 8b, between the location 'B' on the article 1 aligned with the entrance to the recess 2 in the device 3 and the downstream end 8b" of the second tubular element 8b, extends outside the device 3 when the article 1, 1' is fully inserted into the device 3.

[0053] The articles 1, 1' include one or more ventilation apertures 12 extending through the second tubular element 8b at a location in the second tubular element 8b which is outside the housing 9 when the article 1, 1' is fully inserted into the non-combustible aerosol provision device 3. The one or more ventilation apertures 12 can be provided as one or more rows of apertures, such as laser or mechanically formed perforations, circumscribing the article 1, 1'. In some examples, the level of ventilation is between about 10% and about 60%, for instance between about 20% and about 55% of the mainstream aerosol.

[0054] In some examples, the cylindrical rod of aerosol-generating material comprises a plurality of strands and / or strips of aerosol-generating material, and is circumscribed by a wrapper 15. The wrapper 15 may be a moisture impermeable wrapper.

[0055] The plurality of strands or strips of aerosol-generating material may be aligned within the aerosol-generating section 4 such that their longitudinal dimension is in parallel alignment with the longitudinal axis, X-X' of the article 1, 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 1.

[0056] In the present example, the rod of aerosol-generating material has a circumference of about 22.7 mm. In alternative embodiments, the rod of aerosol-generating material may have any suitable circumference, for example between about 20 mm and about 26 mm.

[0057] The first tubular element 8a can be formed from filamentary tow, in the present example plasticised cellulose acetate tow. Other constructions can be used, such as a tubular element 8a formed having inner and outer paper tubes sandwiching a crimped paper sheet material. The wall of the first tubular element can be relatively non- porous, such that at least 80% of the aerosol generated by the aerosol generating material passes longitudinally through the hollow channels through the tube rather than through the wall material itself. For instance, at least 92% or at least 95% of the aerosol generated by the aerosol generating material can pass longitudinally through the first hollow cavity.

[0058] The filamentary tow forming the first tubular element 8a preferably has a total denier of between 25,000 and 56,000, for instance between 35,000 and 45,000. Preferably the cross-sectional shape of the filaments of tow are 'Y' shaped, although in other embodiments other shapes such as 'X', 'O' and 'C' shaped filaments can be used.

[0059] The filamentary tow forming the first tubular element 8a preferably has a denier per filament between 4 and 10, more preferably between 4 and 9. In one example, the filamentary tow forming the first tubular element 8a has an 8Y40,000 tow formed from cellulose acetate. The tow described herein can comprise between 10% and 25% plasticiser and can comprise 18% plasticiser, for instance triacetin, in some examples.

[0060] Preferably, the density of the material forming the first tubular element 8a is at least about 0.20 grams per cubic centimetre (g / cc), more preferably at least about 0.25 g / cc. Preferably, the density of the material forming the first tubular element 8a is less than about 0.80 grams per cubic centimetre (g / cc), more preferably less than 0.6 g / cc. In some embodiments, the density of the material forming the first tubular element 8a is between 0.20 and 0.8 g / cc, more preferably 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 first tubular element 8a refers to the density of any filamentary tow or other material forming the element with any plasticiser incorporated. The density may be determined by dividing the total weight of the material forming the first tubular element 8a by the total volume of the material forming the first tubular element 8a, wherein the total volume can be calculated using appropriate measurements of the material forming the first tubular element 8a taken, for example, using callipers. Where necessary, the appropriate dimensions may be measured using a microscope.

[0061] The first and second tubular elements 8a, 8b 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 first and second tubular elements 8a, 8b and a heated volatilised component exiting a second, downstream end of the first and second tubular elements 8a, 8b. The first and second tubular elements 8a, 8b are preferably configured to provide a temperature differential of at least 60 degrees Celsius, preferably at least 80 degrees Celsius and more preferably at least 100 degrees Celsius between a heated volatilised component entering a first, upstream end of the first and second tubular elements 8a, 8b and a heated volatilised component exiting a second, downstream end of the first and second tubular elements 8a, 8b. This temperature differential across the length of the first and second tubular elements 8a, 8b protects the temperature sensitive downstream body of material 6 from the high temperatures of the aerosol-generating material when it is heated.

[0062] The aerosol-generating section 4, 4' may exhibit a pressure drop of less than about 20 mm H2O. In some embodiments, the aerosol-generating section 4 exhibits a pressure drop through the length of the aerosol-generating section 4 of from about 1 to about 15 mm H2O or from about 1 to about 5 mm H2O.

[0063] The resistance to draw or pressure drop through the length of a section, component or article as defined herein is determined according to the ISO standard method (ISO6565:2015). The resistance to draw or pressure drop refers to the 'closed pressure drop', in which any ventilation zones into the section, component or article under measurement are closed, unless otherwise stated.

[0064] The aerosol-generating material may have a packing density or bulk density of between about 400 mg / cm3 and about 600 mg / cm3 within the aerosol-generating section. A packing density higher than this may make it difficult to insert the aerosolgenerator of the aerosol provision device into the aerosol-generating material and increase the pressure drop. A packing density lower than 400 mg / cm3 may reduce the rigidity of the article. Furthermore, if the packing density is too low, the aerosolgenerating material may not effectively grip the aerosol-generator of the aerosol provision device. Between about 30% and about 50% of a volume of the aerosol-generating section 4, 4' is composed of the aerosol-generating material. In some embodiments, from about 35% to about 45% of the volume of the aerosol-generating section 4, 4' is filled with the aerosol-generating material, and the remainder is the one or more empty spaces 4a or the one of more hollow channels 4b, 4c.

[0065] In the present embodiment, the moisture impermeable wrapper 15 which circumscribes the rod of aerosol-generating material comprises aluminium foil. In other embodiments, the wrapper may not be moisture impermeable and, for instance, may not include aluminium foil. The wrapper 15 can comprise a paper wrapper, optionally comprising a barrier coating to make the material of the wrapper substantially moisture impermeable. 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 27 gsm to about lOOgsm, for instance from about 40 gsm to about 70 gsm.

[0066] In the present example, the moisture impermeable wrapper 15 is also substantially impermeable to air. The wrapper 15 preferably has a permeability of less than 100 Coresta Units, more preferably 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 preferably less than 60 Coresta Units, result in an improvement in the aerosol formation in the aerosol-generating material. The permeability of the wrapper 15 can be measured in accordance with ISO 2965:2009 concerning the determination of air permeability for materials used as cigarette papers, filter plug wrap and filter joining paper. In alternative examples, the wrapper 15 can have a permeability of up to 24000 Coresta Units, for instance between 1000 and 24000 Coresta Units.

[0067] The downstream body of material 6 is wrapped in a first plug wrap 7. A second plug wrap 13 is provided to connect the downstream body of material 6 and second tubular element 8b. The upstream body of material 17 is wrapped in a third plug wrap 18. Preferably, the first, second and third plug wraps 7, 13, 18 each have a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. Preferably, the first, second and third plug wraps 7, 13, 18 each have a thickness of between 30 pm and 60 pm, more preferably between 35 pm and 45 pm. Preferably, the first, second and third plug wraps 7, 13, 18 are non-porous plug wraps, for instance having a permeability of less than 100 Coresta units, for instance less than 50 Coresta units. However, in other embodiments, the first, second and / or third plug wrap 7, 13, 18 can be a porous plug wrap, for instance having a permeability of greater than 200 Coresta Units.

[0068] A combining wrapper 19 is provided to connect the upstream body of material 17, aerosol generating material section 4, 4' and first tubular element 8a. The combining wrapper 19 can have a basis weight of between about 30 gsm and about 70 gsm. Preferably, the combining wrapper 19 has a thickness of between 35 pm and 70 pm, more preferably between 40 pm and 60 pm. Preferably, the combining wrapper 19 is non-porous, for instance having a permeability of less than 100 Coresta units, for instance less than 50 Coresta units. However, in other embodiments, the combining wrapper 19 can be a porous wrapper, for instance having a permeability of greater than 200 Coresta Units.

[0069] Preferably, the length of the downstream body of material 6 is less than about 15 mm. More preferably, the length of the downstream body of material 6 is less than about 14 mm. In addition, or as an alternative, the length of the downstream body of material 6 is at least about 5 mm. Preferably, the length of the downstream body of material 6 is at least about 8 mm. In some preferred embodiments, the length of the downstream body of material 6 is from about 5 mm to about 15 mm, more preferably from about 8 mm to about 14 mm, even more preferably from about 10 mm to about 14 mm, most preferably about 10 mm, 11 mm or 12 mm. In the present example, the length of the downstream body of material 6 is 12 mm.

[0070] Preferably, the length of the upstream body of material 17 is less than about 10 mm. More preferably, the length of the upstream body of material 17 is less than about 8 mm. In addition, or as an alternative, the length of the upstream body of material 17 is at least about 5 mm. Preferably, the length of the upstream body of material 17 is at least about 6 mm. In some preferred embodiments, the length of the upstream body of material 17 is from about 5 mm to about 10 mm, more preferably from about 6 mm to about 8 mm. In the present example, the length of the upstream body of material 17 is 6 mm.

[0071] In the present example, the downstream body of material 6 is formed from filamentary tow. In the present example, the tow used in the downstream body of material 6 has a denier per filament (d.p.f.) of 3.0 to 5.0, for instance 3.5, and a total denier of 15,000 to 35,000, for instance 30,000. In the present example, the tow comprises plasticised cellulose acetate tow. The plasticiser used in the tow comprises between about 5% and about 12%, for instance about 8% by weight of the tow. In the present example, the plasticiser is triacetin. Preferably the cross-sectional shape of the filaments of tow are 'Y' shaped, although in other embodiments other shapes such as 'X', 'O' and 'C' shaped filaments can be used. In other examples, different materials can be used to form the downstream body of material 6. For instance, rather than tow, the downstream 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 15gsm to 60gsm, 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 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 170mm, 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 180mm. This can, for instance, enable the cellulose-based bodies to have appropriate pressure drops for an article having dimensions as described herein.

[0072] Alternatively, the downstream 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 preferably formed from cellulose acetate. The tow, whether formed from cellulose acetate or other materials, preferably has a d.p.f. of at least 5. Preferably, to achieve a sufficiently uniform downstream body of material 6, the tow has a denier per filament of no more than 12 d.p.f., preferably no more than 11 d.p.f. and still more preferably no more than 10 d.p.f.

[0073] The total denier of the tow forming the downstream body of material 6 is preferably at most 35,000, more preferably at most 32,000 and still more preferably at most 30,000. These values of total denier provide a tow which takes up a reduced proportion of the cross-sectional area of the mouthpiece 5 which results in a lower pressure drop through the length of the mouthpiece 5 than tows having higher total denier values. For appropriate firmness of the downstream body of material 6, the tow preferably has a total denier of at least 8,000 and more preferably at least 10,000. Preferably, the denier per filament is between 3 and 10 while the total denier is between 10,000 and 35,000. Preferably 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.

[0074] Irrespective of the material used to form the downstream body 6, the pressure drop through the length of the downstream body 6, can, for instance, be between 0.3 and 5mmWG per mm of length of the downstream body 6, for instance between 0.5mmWG and 2.5mmWG per mm of length of the downstream body 6. The pressure drop can, for instance, be between 1.5 and 2.5mmWG / mm of length, on average. The total pressure drop through the length of the body 6 can, for instance, be between 12mmWG and 30mWG, or between 15mmWG and 25mmWG. Where the downstream body 6 includes an additive release component, the pressure drop refers to the average or total pressure drop prior to any rupture of that component.

[0075] The upstream body 17 can be formed from paper or other sheet material. For instance, the paper, or other cellulose-based material sheet, can be provided as one or more portions of sheet material which is folded and / or crimped to form the upstream body 17. The sheet material can have a basis weight of from 15gsm to 60gsm, for instance between 20 and 50 gsm, such as 36 gsm. The sheet material can, for instance, have a basis weight in any of the ranges between 15 and 25 gsm, between 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 80mm and 190mm, or between 100mm and 180mm. For instance, the sheet material can have a basis weight of between 20 and 50 gsm and a width between 120mm and 200mm. This can, for instance, enable the cellulose-based bodies to have appropriate pressure drops for an article having dimensions as described herein.

[0076] Irrespective of the material used to form the upstream body 17, the pressure drop through the length of the upstream body 17, can, for instance, be between 0.3 and 5mmWG per mm of length of the upstream body 17, for instance between 0.5mmWG and 2.5mmWG per mm of length of the upstream body 17. The pressure drop can, for instance, be between 1.0 and 2.0mmWG / mm of length, on average. The total pressure drop through the length of the upstream body 17 can, for instance, be between 5mmWG and 20mWG, or between 6mmWG and 12mmWG.

[0077] A tipping paper 16 is wrapped around part of the downstream portion 5 and over part of the rod of aerosol-generating material and has an adhesive on its inner surface to connect the pre-combined downstream body 6 and second tubular element 8b, with the pre-combined first tubular element 8a, aerosol-generating material section 4, 4' and upstream body of material 17. In the present example, the rod of aerosolgenerating material is wrapped in wrapper 15, which forms a first wrapping material, and the combining wrapper 19 forms an outer wrapper. In some examples, the tipping paper 16 can extend fully over the aerosol-generating material section 4, 4'.

[0078] In the present example, the tipping paper 16 extends 5 mm over the pre-combined first tubular element 8a, aerosol-generating material section 4, 4' and upstream body of material 17, but it can alternatively extend between 3 mm and 10 mm over the rod, or more preferably between 4 mm and 6 mm, to provide a secure attachment. The tipping paper 16 can have a basis weight greater than 20 gsm, for instance greater than 25 gsm, or preferably greater than 30 gsm, for example 36 or 37 gsm. These ranges of basis weights have been found to result in tipping papers having acceptable tensile strength while being flexible enough to wrap around the article 1, 1' and adhere to itself along a longitudinal lap seam on the paper.

[0079] The articles 1, 1' each have a ventilation level of about 20% or 30% of the total aerosol and ventilation drawn through the article 1, 1'. The article 1, 1' preferably includes ventilation apertures provided into the second tubular element 8b. In alternative embodiments, the article 1, 1' can have a ventilation level of between 10% and 60% of the total aerosol and ventilation drawn through the article 1, 1', for instance between 10% and 50%.

[0080] An aerosol modifying agent can be provided within the downstream body of material 6, for instance in the present example in the form of an additive release component, in the present case a capsule 11. However, the capsule 11 can be omitted in other embodiments. In the case that the capsule 11 is provided, the first plug wrap 7 can be an oil-resistant first plug wrap 7. In other examples, the aerosol modifying agent can be provided in other forms, such as material injected into the downstream body of material 6 or provided on a thread, for instance the thread carrying a flavourant or other aerosol modifying agent, which may also be disposed within the downstream body of material 6.

[0081] The capsule 11 can comprise a breakable capsule, for instance a capsule which has a solid, frangible shell surrounding a liquid payload. In the present example, a single capsule 11 is used. The capsule 11 is entirely embedded within the body of material 6. In other words, the capsule 11 is completely surrounded by the material forming the body 6. In other examples, a plurality of breakable capsules may be disposed within the body of material 6, for instance 2, 3 or more breakable capsules. The length of the body of material 6 can be increased to accommodate the number of capsules required. In examples where a plurality of capsules is used, the individual capsules may be the same as each other, or may differ from one another in terms of size and / or capsule payload. In other examples, multiple bodies of material 6 may be provided, with each body containing one or more capsules.

[0082] The capsule 11 has a core-shell structure. In other words, the capsule 11 comprises a shell encapsulating a liquid agent, for instance a flavourant or other agent, which can be any one of the flavourants or aerosol modifying agents described herein. The shell of the capsule can be ruptured by a user to release the flavourant or other agent into the body of material 6.

[0083] In the present example, the capsule 11 is spherical and has a diameter of about 3 mm. In other examples, other shapes and sizes of capsule can be used. For example, the capsule may have a diameter less than 4 mm, or less than 3.5 mm, or less than 3.25 mm. In alternative embodiments, the capsule may have a diameter greater than about 3.25 mm, for example greater than 3.5 mm, or greater than 4 mm. The total weight of the capsule 11 may be in the range about 10 mg to about 50 mg.

[0084] In the present example, the capsule 11 is located at a non-longitudinally central position within the downstream body of material 6. In the present example, the capsule 11 is located closer to the upstream end of the body of material 6 than to the downstream end. That is, the capsule 11 is positioned so that its centre is 5 mm from the upstream end of the downstream body of material 6 and 7mm from the downstream end, which can assist with ensuring that the capsule cannot be seen from the downstream end of the article 1, 1'.

[0085] The aerosol-generating material comprises an aerosol-former material. The aerosolformer material comprises one or more constituents capable of forming an aerosol. The aerosol-former material comprises one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. Preferably, the aerosol-former material is glycerol or propylene glycol. The aerosol-former material is provided in an amount of up to about 50% on a dry weight base by weight of the aerosol-generating material. In some embodiments, the aerosol former material is provided in an amount of from about 5% to about 40% on a dry weight base by weight of the aerosol-generating material, from about 10% to about 30% on a dry weight base by weight of the aerosol-generating material or from about 10% to about 20% on a dry weight base by weight of the aerosol-generating material.

[0086] The aerosol-generating material herein can comprise an aerosol modifying agent, such as any of the flavours described herein. In one embodiment, the aerosol-generating material comprises menthol. When the aerosol-generating material is incorporated into an article for use in an aerosol-provision system, the article may be referred to as a mentholated article. The aerosol-generating material can comprise from 0.5mg to 20mg of menthol, from 0.7 mg to 20 mg of menthol, between Img and 18mg or between 8mg and 16mg of menthol. In the present example, the aerosol-generating material comprises 16mg of menthol. The aerosol-generating material can comprise between 1% and 8% by weight of menthol, preferably between 3% and 7% by weight of menthol and more preferably between 4% and 5.5% by weight of menthol. In one embodiment, the aerosol-generating material comprises 4.7% by weight of menthol. Such high levels of menthol loading can be achieved using a high percentage of reconstituted tobacco material, for instance greater than 50% of the tobacco material by weight.

[0087] In some embodiments, the aerosol-generating material includes or consists of an aerosol-forming "amorphous solid", which may alternatively be referred to as a "monolithic solid" (i.e. non-fibrous) or a gel-based aerosol-generating material. In some embodiments, the amorphous solid may comprise a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it.

[0088] In some examples, the amorphous solid comprises:

[0089] - 1-60 wt% of a gelling agent;

[0090] - 0.1-50 wt% of an aerosol-former material; and

[0091] - 0.1-80 wt% of a flavour; wherein these weights are calculated on a dry weight basis.

[0092] In some further embodiments, the amorphous solid comprises:

[0093] - 1-50 wt% of a gelling agent;

[0094] - 0.1-50 wt% of an aerosol-former material; and - 30-60 wt% of a flavour; wherein these weights are calculated on a dry weight basis.

[0095] The amorphous solid material may be provided in sheet or in shredded sheet form. The amorphous solid material may take the same form as the plurality of strands or strips of aerosol-generating material described previously.

[0096] Suitably, the amorphous solid may comprise from about lwt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt% or 35wt% of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise l-50wt%, 5-45wt%, 10-40wt% or 20-35wt% of a gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, the gelling agent comprises 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. In some cases, the gelling agent comprises alginate and / or pectin, and may be combined with a setting agent (such as a calcium source) during formation of the amorphous solid. In some cases, the amorphous solid may comprise a calcium- crosslinked alginate and / or a calcium-crosslinked pectin.

[0097] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of from 10-30wt% of the amorphous solid (calculated on a dry weight basis). In some embodiments, alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one further gelling agent, such as pectin.

[0098] In some embodiments the amorphous solid may include gelling agent comprising carrageenan.

[0099] Suitably, the amorphous solid may comprise from about 0.1wt%, 0.5wt%, lwt%, 3wt%, 5wt%, 7wt% or 10% to about 50wt%, 45wt%, 40wt%, 35wt%, 30wt% or 25wt% of an aerosol-former material (all calculated on a dry weight basis). The aerosol-former material may act as a plasticiser. For example, the amorphous solid may comprise 0.5-40wt%, 3-35wt% or 10-25wt% of an aerosol-former material. In some cases, the aerosol-former material comprises one or more compound selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases, the aerosol-former material comprises, consists essentially of or consists of glycerol.

[0100] The amorphous solid comprises a flavour. Suitably, the amorphous solid may comprise up to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt% or 45wt% of a flavour.

[0101] In some cases, the amorphous solid may comprise at least about 0.1wt%, lwt%, 10wt%, 20wt%, 30wt%, 35wt% or 40wt% of a flavour (all calculated on a dry weight basis).

[0102] For example, the amorphous solid may comprise l-80wt%, 10-80wt%, 20-70wt%, 30-60wt%, 35-55wt% or 30-45wt% of a flavour. In some cases, the flavour comprises, consists essentially of or consists of menthol.

[0103] In some cases, the amorphous solid may additionally comprise an emulsifying agent, which emulsified molten flavour during manufacture. For example, the amorphous solid may comprise from about 5wt% to about 15wt% of an emulsifying agent (calculated on a dry weight basis), suitably about 10wt%. The emulsifying agent may comprise acacia gum.

[0104] In some embodiments, the amorphous solid is a hydrogel and comprises less than about 20 wt% of water calculated on a wet weight basis. In some cases, the hydrogel may comprise less than about 15wt%, 12 wt% or 10 wt% of water calculated on a wet weight basis. In some cases, the hydrogel may comprise at least about lwt%, 2wt% or at least about 5wt% of water (WWB).

[0105] In some embodiments, the amorphous solid additionally comprises an active substance. For example, in some cases, the amorphous solid additionally comprises a tobacco material and / or nicotine. In some cases, the amorphous solid may comprise 5-60wt% (calculated on a dry weight basis) of a tobacco material and / or nicotine. In some cases, the amorphous solid may comprise from about lwt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of an active substance. In some cases, the amorphous solid may comprise from about lwt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of a tobacco material. For example, the amorphous solid may comprise 10-50wt%, 15-40wt% or 20-35wt% of a tobacco material. In some cases, the amorphous solid may comprise from about lwt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may comprise l-20wt%, 2-18wt% or 3-12wt% of nicotine.

[0106] In some cases, the amorphous solid comprises an active substance such as tobacco extract. In some cases, the amorphous solid may comprise 5-60wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid may comprise from about 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) tobacco extract. For example, the amorphous solid may comprise 10-50wt%, 15-40wt% or 20-35wt% of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the amorphous solid comprises lwt% 1.5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%, 4.5wt% or 4wt% (calculated on a dry weight basis) of nicotine.

[0107] In some cases, there may be no nicotine in the amorphous solid other than that which results from the tobacco extract.

[0108] In some embodiments the amorphous solid comprises no tobacco material but does comprise nicotine. In some such cases, the amorphous solid may comprise from about lwt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may comprise l-20wt%, 2-18wt% or 3-12wt% of nicotine.

[0109] In some cases, the total content of active substance and / or flavour may be at least about 0.1wt%, lwt%, 5wt%, 10wt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of active substance and / or flavour may be less than about 90wt%, 80wt%, 70wt%, 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis).

[0110] In some cases, the total content of tobacco material, nicotine and flavour may be at least about 0.1wt%, lwt%, 5wt%, 10wt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of active substance and / or flavour may be less than about 90wt%, 80wt%, 70wt%, 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis).

[0111] The amorphous solid may be made from a gel, and this gel may additionally comprise a solvent, included at 0.1-50wt%. However, the inventors have established that the inclusion of a solvent in which the flavour is soluble may reduce the gel stability and the flavour may crystallise out of the gel. As such, in some cases, the gel does not include a solvent in which the flavour is soluble.

[0112] In some embodiments, the amorphous solid comprises less than 60wt% of a filler, such as from lwt% to 60wt%, or 5wt% to 50wt%, or 5wt% to 30wt%, or 10wt% to 20wt%.

[0113] In other embodiments, the amorphous solid comprises less than 20wt%, suitably less than 10wt% or less than 5wt% of a filler. In some cases, the amorphous solid comprises less than lwt% of a filler, and in some cases, comprises no filler.

[0114] The filler, if present, may comprise one or more inorganic filler materials, such as calcium carbonate, 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, cellulose and cellulose derivatives. In particular cases, the amorphous solid comprises no calcium carbonate such as chalk.

[0115] In particular embodiments which include filler, 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. Without wishing to be bound by theory, it is believed that including fibrous filler in an amorphous solid may increase the tensile strength of the material.

[0116] In some embodiments, the amorphous solid does not comprise tobacco fibres.

[0117] In some examples, the amorphous solid in sheet form may have a tensile strength of from around 200 N / m to around 1500 N / m. In some examples, such as where the amorphous solid does not comprise a filler, the amorphous solid may have a tensile strength of from 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or about 250 N / m. Such tensile strengths may be particularly suitable for embodiments wherein the amorphous solid material is formed as a sheet and then shredded and incorporated into an aerosol-generating article.

[0118] In some examples, such as where the amorphous solid comprises a filler, the amorphous solid may have a tensile strength of from 600 N / m to 1500 N / m, or from 700 N / m to 900 N / m, or around 800 N / m. Such tensile strengths may be particularly suitable for embodiments wherein the amorphous solid material is included in an aerosol-generating article as a rolled sheet, suitably in the form of a tube.

[0119] In some cases, the amorphous solid may consist essentially of, or consist of a gelling agent, water, an aerosol-former material, a flavour, and optionally an active substance.

[0120] In some cases, the amorphous solid may consist essentially of, or consist of a gelling agent, water, an aerosol-former material, a flavour, and optionally a tobacco material and / or a nicotine source.

[0121] The amorphous solid may comprise one or more active substances and / or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

[0122] In embodiments described herein, the amorphous solid material may be incorporated into the article in sheet form. The amorphous solid material in sheet form may be shredded and then incorporated into the article, suitably mixed into with an aerosolisable material, such as the plurality of strands or strips of aerosol-generating material described herein.

[0123] In further embodiments the amorphous solid sheet may additionally 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). In some such cases, the amorphous solid of these embodiments may be included in an aerosol-generating article as a sheet, such as a sheet circumscribing a rod comprising aerosolisable material. For example, the amorphous solid sheet may be formed on a wrapping paper which circumscribes an aerosolisable material such as tobacco.

[0124] Figure 7 is a simplified schematic illustration of the components within the housing 9 of the non-combustible aerosol provision device 3 shown in Figures 4 and 5.

[0125] As shown in Figure 7, within the housing 9 there is an electrical energy supply 20, for example a rechargeable lithium ion battery. A controller 21 is connected to the heating element 2a, the electrical energy supply 20, and a user interface 22, for example a touch-sensitive display. The controller 21 controls the power supplied to the heating element 2a in order to regulate its temperature. Typically the aerosol- generating material is heated to a temperature of between 250 and 450 degrees centigrade.

[0126] The heating element 2a is configured for insertion into the aerosol generating material of the article 1, 1'. The heating element 2a is in the form of a pin heater in the present example, but in alternative examples can be shaped in the form of a blade terminating in a point. That is, such a blade heater can have a length dimension that is greater than its width dimension, which is greater than its thickness dimension. The heating element 2a used to heat the aerosol-generating material can, for instance, reach a peak temperature of between 250°C and 600°C or between 350°C and 575°C, and the temperature of the heating element 2a during a smoking session can be between 300°C and 400°C, such as between 320°C and 370°C.

[0127] The heating element 2a can have a width at its widest point of between about 1.5 mm and about 4 mm, or between about 2 mm and about 3 mm. The heating element 2a can have an insertion length of between about 10 mm and about 25 mm, or between about 15 mm and about 20 mm, for instance the portion of the heating element 2a which is within the article 1, 1' when the article 1, 1' is fully inserted into the device 3. The heating element 2a can, for instance, have an insertion length of at least 4 mm greater than the axial length of the aerosol-generating material section 4, 4', 4", 4"' of the article 1, 1'.

[0128] When the heater is actuated, the aerosol-generating material of the article is warmed and volatile substances are generated or evolved. As a user draws on the mouthpiece 5, air is drawn into the article 1, 1' and the volatile substances condense to form an inhalable aerosol. This aerosol passes through the mouthpiece 5 of the article 1, 1' and into the user's mouth.

[0129] As used herein, the term "non-combustible aerosol provision system" is intended to encompass systems that deliver at least one substance to a user by releasing compounds from an aerosol-generating material without combusting the aerosolgenerating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

[0130] According to the present disclosure, a "non-combustible" aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

[0131] In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system. In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0132] In some embodiments, the non-combustible aerosol provision system is an aerosolgenerating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system. In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product. For instance, the solid aerosolgenerating material can comprise non-tobacco botanical material.

[0133] Typically, the non-combustible aerosol provision system may comprise a non- combustible aerosol provision device and a consumable for use with the non- combustible aerosol provision device, such as the article 1 described herein.

[0134] In some embodiments, the disclosure relates to consumables comprising aerosolgenerating material and configured to be used with non-combustible aerosol provision devices. These consumables are referred to as articles throughout the disclosure.

[0135] In some embodiments, the non-combustible aerosol provision system, such as a non- combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source. In some embodiments, the non-combustible aerosol provision system comprises an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and / or an aerosol-modifying agent.

[0136] In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol-modifying agent.

[0137] In some embodiments, the consumable comprises a substance to be delivered. The substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolised. As appropriate, either material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and / or one or more other functional materials.

[0138] In some embodiments, the substance to be delivered comprises an active substance.

[0139] The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

[0140] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

[0141] As noted herein, the 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 tobacco, 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.

[0142] In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.

[0143] In some embodiments, the 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.

[0144] In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

[0145] In some embodiments, the substance to be delivered comprises a flavour.

[0146] 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., tobacco, 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.

[0147] 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. In some embodiments, the flavour comprises flavour components extracted from cannabis.

[0148] 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 eucolyptol, WS-3.

[0149] An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. An aerosolgenerating material may be in the form of a solid, liquid or gel which may or may not contain an active substance and / or flavourants. The aerosol-generating material may be incorporated into an article for use in the aerosol-generating system. The aerosolgenerating material can comprise tobacco or non-tobacco botanical material as described herein.

[0150] As used herein, the term "tobacco material" refers to any material comprising tobacco or derivatives or substitutes thereof. The tobacco material may be in any suitable form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and / or tobacco extract.

[0151] 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 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.

[0152] 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. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

[0153] 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 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.

[0154] 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.

[0155] The filamentary tow material described herein can comprise cellulose acetate fibre tow. The filamentary tow can also be formed using other materials used to form fibres, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(l-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT), starch based materials, cotton, aliphatic polyester materials and polysaccharide polymers or a combination thereof. The filamentary tow may be plasticised with a suitable plasticiser for the tow, such as triacetin where the material is cellulose acetate tow, or the tow may be non-plasticised. The tow can have any suitable specification, such as fibres having a 'Y' shaped or other cross section such as 'X' shaped, filamentary denier values between 2.5 and 15 denier per filament, for example between 8.0 and 11.0 denier per filament and total denier values of 5,000 to 50,000, for example between 10,000 and 40,000.

[0156] The invention can provide articles and systems according to the following numbered clauses.

[0157] Clause 1. An article for insertion into a non-combustible aerosol provision device to generate an aerosol, the article comprising: an aerosol-generating material section comprising aerosol-generating material and one or more empty regions, the one or more empty regions having a combined first volume; and a tubular portion downstream of the aerosol-generating material section, the tubular portion defining a hollow cavity, wherein the hollow cavity has a second volume and the second volume is no greater than 15 times the first volume. Clause 2. An article according to Clause 1, wherein the tubular portion comprises a ventilation region for admitting external air into the hollow cavity.

[0158] Clause 3. An article according to Clause 1 or 2, wherein the second volume is greater than 70 mm3, greater than 200 mm3, greater than 500 mm3or greater than 600 mm3, for instance between 500 mm3and 900 mm3or between 600 mm3and 800 mm3, optionally wherein the length of the tubular portion is between about 20 mm and about 30 mm, or between about 22 mm and about 26 mm.

[0159] Clause 4. An article according to any one of Clauses 1 to 3, wherein the first volume is greater than 50mm3, or greater than 150mm3, or between about 50mm3and about 550mm3, or between about 200mm3and about 400mm3, or between about 250mm3and about 350mm3.

[0160] Clause 5. An article according to any one of Clauses 1 to 4, wherein the one or more empty regions of the aerosol-generating material section comprise one or more hollow channels having the first volume.

[0161] Clause 6. An article according to Clause 5, wherein the tubular portion is immediately downstream of the aerosol-generating material section and wherein the cross sectional area of overlap of the hollow cavity of the tubular portion and of the one or more hollow channels is at least about 5mm2, at least about 6mm2, at least about 7mm2, or at least about 8mm2, optionally wherein the cross sectional area of overlap is between 20% and 50% or between 30% and 45% of the total cross sectional area of the one or more hollow channels.

[0162] Clause 7. An article according to Clause 5 or 6, wherein the one or more hollow channels comprise a first hollow channel located substantially centrally within the cross section of the aerosol-generating material section and one or more second hollow channels located non-centrally within the cross section of the aerosolgenerating material section, optionally wherein the one or more second hollow channels have a cross sectional area which is between 40% and 90% or between 50% and 80% of the total cross sectional area of the one or more hollow channels.

[0163] Clause 8. An article according to any one of Clauses 1 to 7, wherein the tubular portion comprises: a first tubular element immediately downstream of the aerosol-generating material section, the first tubular element defining a first portion of the hollow cavity; and a second tubular element immediately downstream of the first tubular element, the second tubular element defining a second portion of the hollow cavity, wherein, the volume of the second portion is larger than the volume of the first portion, optionally wherein the volume of the second portion is between 1.5 and 8 times larger than the volume of the first portion, or wherein the volume of the second portion is between 5 and 8 times larger than the volume of the first portion.

[0164] Clause 9. An article according to Clause 8, wherein the first volume is greater than the volume of the first portion and optionally less than the volume of the second portion.

[0165] Clause 10. An article according to Clause 8 or 9, wherein the first tubular element comprises a first tubular wall and the second tubular element comprises a second tubular wall, wherein the first tubular wall has a wall thickness of between 1.2mm and 2mm and wherein the second tubular wall has a wall thickness of less than about 320 pm, optionally wherein the first tubular element has an axial length of between 5mm and 12mm and the second tubular element has an axial length of greater than about 15mm.

[0166] Clause 11. An article according to Clause 10, wherein the ratio of the thickness of the first tubular wall to the internal radius of the first portion is between about 0.6 and about 1.1, or, wherein the ratio of the volume of the second portion to the volume of the first portion is between about 6.5 and about 8.

[0167] Clause 12. An article according to Clause 10 or 11, wherein the second tubular wall comprises at least first and second overlapping paper layers each extending around substantially the whole circumference of the second tubular element, optionally wherein the at least first and second overlapping paper layers each comprise a thickness of between 30 and 150 pm and / or wherein the at least first and second overlapping paper layers each comprise a basis weight of between 25 and 130 gsm.

[0168] Clause 13. An article according to any one of the preceding Clauses, further comprising a body of material upstream of the aerosol-generating material section, optionally wherein the body of material has a resistance to draw through the length of the body of material which is greater than the combined resistance to draw through the aerosol-generating material section and the tubular portion.

[0169] Clause 14. An article according to Clause 13, wherein the body of material comprises a first body of material, and the article further comprises a second body of material downstream of the tubular portion, optionally wherein the first and second bodies of material define respective upstream and downstream ends of the article, and further optionally wherein the resistance to draw through the length of the second body of material is higher than the resistance to draw through the length of the first body of material.

[0170] Clause 15. An article according to any one of the preceding Clauses, wherein the average weight per mm of axial length of the article is less than about 12.5 mg / mm or less than about 12 mg / mm or less than about 11.5mg / mm.

[0171] Clause 16. An article according to any one of the preceding Clauses, wherein the aerosol-generating material section is in the form of a rod having an axial length which is less than or equal to the axial length of the second tubular element.

[0172] Clause 17. An article according to any one of the preceding Clauses, wherein the aerosol-generating material section is in the form of a rod having an axial length which is between 50% and 80% of the axial length of the second tubular element.

[0173] Clause 18. An article according to any one of the preceding Clauses, wherein the second tubular wall has a thickness of between about 160pm and about 250 pm, and / or wherein the second tubular wall has a thickness which is less than about 15% or less than about 10% of the internal radius of the second portion.

[0174] Clause 19. An article according to any one of the preceding Clauses, wherein the second tubular element defines a second portion having a volume of at least about 520 mm3.

[0175] Clause 20. An article according to any one of the preceding Clauses, wherein the second tubular element has an axial length of greater than about 16mm or greater than about 16.5mm and / or wherein the second tubular element has an axial length which is at least 1.5 or at least 2 times greater than the axial length of the first tubular element. Clause 21. An article according to any one of the preceding Clauses, wherein the combined volumes of the first and second portions is at least about 580 mm3, or at least about 620 mm3or at least about 650 mm3.

[0176] Clause 22. A non-combustible aerosol provision system comprising a noncombustible aerosol provision device and an article according to any one of the preceding Clauses.

[0177] Clause 23. A non-combustible aerosol provision system according to clause 22, wherein the non-combustible aerosol provision device comprises a heating element configured for insertion into the aerosol-generating material of the article.

[0178] Clause 24. A non-combustible aerosol provision system according to clause 22 or 23, wherein the non-combustible aerosol provision device comprises a housing and an aperture in the housing into which the article is inserted in use, and wherein the system is configured such that the second tubular element extends partially within and partially outside the housing when the article is fully inserted into the non-combustible aerosol provision device.

[0179] The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and / or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future."

Claims

Claims1. An article for insertion into a non-combustible aerosol provision device to generate an aerosol, the article comprising: an aerosol-generating material section comprising aerosol-generating material and one or more empty regions, the one or more empty regions having a combined first volume; and a tubular portion downstream of the aerosol-generating material section, the tubular portion defining a hollow cavity, wherein the hollow cavity has a second volume and the second volume is no greater than 15 times the first volume.

2. An article according to claim 1, wherein the tubular portion comprises a ventilation region for admitting external air into the hollow cavity.

3. An article according to claim 1 or 2, wherein the second volume is greater than 70 mm3, greater than 200 mm3, greater than 500 mm3or greater than 600 mm3, for instance between 500 mm3and 900 mm3or between 600 mm3and 800 mm3, optionally wherein the length of the tubular portion is between about 20 mm and about 30 mm, or between about 22 mm and about 26 mm.

4. An article according to any one of claims 1 to 3, wherein the first volume is greater than 50mm3, or greater than 150mm3, or between about 50mm3and about 550mm3, or between about 200mm3and about 400mm3, or between about 250mm3and about 350mm3.

5. An article according to any one of claims 1 to 4, wherein the one or more empty regions of the aerosol-generating material section comprise one or more hollow channels having the first volume.

6. An article according to claim 5, wherein the tubular portion is immediately downstream of the aerosol-generating material section and wherein the cross sectional area of overlap of the hollow cavity of the tubular portion and of the one or more hollow channels is at least about 5mm2, at least about 6mm2, at least about 7mm2, or at least about 8mm2, optionally wherein the cross sectional area of overlap is between 20% and 50% or between 30% and 45% of the total cross sectional area of the one or more hollow channels.

7. An article according to claim 5 or 6, wherein the one or more hollow channels comprise a first hollow channel located substantially centrally within the cross section of the aerosol-generating material section and one or more second hollow channels located non-centrally within the cross section of the aerosol-generating material section, optionally wherein the one or more second hollow channels have a cross sectional area which is between 40% and 90% or between 50% and 80% of the total cross sectional area of the one or more hollow channels.

8. An article according to any one of claims 1 to 7, wherein the tubular portion comprises: a first tubular element immediately downstream of the aerosol-generating material section, the first tubular element defining a first portion of the hollow cavity; and a second tubular element immediately downstream of the first tubular element, the second tubular element defining a second portion of the hollow cavity, wherein, the volume of the second portion is larger than the volume of the first portion, optionally wherein the volume of the second portion is between 1.5 and 8 times larger than the volume of the first portion, or wherein the volume of the second portion is between 5 and 8 times larger than the volume of the first portion.

9. An article according to claim 8, wherein the first volume is greater than the volume of the first portion and optionally less than the volume of the second portion.

10. An article according to claim 8 or 9, wherein the first tubular element comprises a first tubular wall and the second tubular element comprises a second tubular wall, wherein the first tubular wall has a wall thickness of between 1.2mm and 2mm and wherein the second tubular wall has a wall thickness of less than about 320 pm, optionally wherein the first tubular element has an axial length of between 5mm and 12mm and the second tubular element has an axial length of greater than about 15mm.

11. An article according to claim 10, wherein the ratio of the thickness of the first tubular wall to the internal radius of the first portion is between about 0.6 and about 1.1, or, wherein the ratio of the volume of the second portion to the volume of the first portion is between about 6.5 and about 8.

12. An article according to claim 10 or 11, wherein the second tubular wall comprises at least first and second overlapping paper layers each extending around substantially the whole circumference of the second tubular element, optionally wherein the at least first and second overlapping paper layers each comprise a thickness of between 30 and 150 pm and / or wherein the at least first and second overlapping paper layers each comprise a basis weight of between 25 and 130 gsm.

13. An article according to any one of the preceding claims, further comprising a body of material upstream of the aerosol-generating material section, optionally wherein the body of material has a resistance to draw through the length of the body of material which is greater than the combined resistance to draw through the aerosol-generating material section and the tubular portion.

14. An article according to claim 13, wherein the body of material comprises a first body of material, and the article further comprises a second body of material downstream of the tubular portion, optionally wherein the first and second bodies of material define respective upstream and downstream ends of the article, and further optionally wherein the resistance to draw through the length of the second body of material is higher than the resistance to draw through the length of the first body of material.

15. An article according to any one of the preceding claims, wherein the average weight per mm of axial length of the article is less than about 12.5 mg / mm or less than about 12 mg / mm or less than about 11.5mg / mm.

16. A non-combustible aerosol provision system comprising a non-combustible aerosol provision device and an article according to any one of the preceding claims.

17. A non-combustible aerosol provision system according to claim 16, wherein the non-combustible aerosol provision device comprises a heating element configured for insertion into the aerosol-generating material of the article.

18. A non-combustible aerosol provision system according to claim 16 or 17, wherein the non-combustible aerosol provision device comprises a housing and an aperture in the housing into which the article is inserted in use, and wherein the system is configured such that the second tubular element extends partially within and partially outside the housing when the article is fully inserted into the non-combustible aerosol provision device.

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