A wetlaid nonwoven material

Abstract

Described herein are wetlaid nonwoven materials for use in or as a component in an aerosol generating article, the nonwoven material comprising: a plurality of fibres, and a binder, wherein the wetlaid nonwoven material has a tensile strength of from about 5 N / 15mm to about 50 N / 15mm; and a filter for an aerosol generating article comprising a wetlaid nonwoven material, the wetlaid nonwoven material comprising: a plurality of fibres, and a binder, wherein the wetlaid nonwoven material has a width of from about 110 mm to about 160 mm.

Description

[0001] A Wetlaid Nonwoven Material

[0002] Field of the Invention

[0003] The present invention relates to a wetlaid nonwoven material for use in or as a component in an aerosol generating article.

[0004] Background of the Invention

[0005] Aerosol generating articles can have a substantially cylindrical rod-shaped structure and can include a charge, roll, or column of smokable material, such as shredded tobacco (e.g. in cut filler form), surrounded by a paper wrapper, thereby forming a rod of aerosolisable material. Normally, an aerosol generating article has a filter element aligned in an end-to-end relationship with the rod of aerosolisable material. Typically, a filter element comprises a rod of plasticised cellulose acetate tow circumscribed by a paper material known as a plug wrap, and the filter is attached to one end of the rod of aerosolisable material using a circumscribing wrapping material know as tipping material.

[0006] Summary of the Invention

[0007] According to a first aspect, there is described a wetlaid nonwoven material for use in or as a component in an aerosol generating article, the nonwoven material comprising: a plurality of fibres, and a binder, wherein the wetlaid nonwoven material has a tensile strength of from about 5 N / 15mm to about 50 N / 15mm.

[0008] According to a second aspect, there is a described filter for an aerosol generating article comprising a wetlaid nonwoven material, the wetlaid nonwoven material comprising: a plurality of fibres, and a binder, wherein the wetlaid nonwoven material has a width of from about 110 mm to about 160 mm.

[0009] According to a third aspect, there is described an aerosol generating article comprising a wetlaid nonwoven material according to the first aspect or a filter according to the second aspect.

[0010] According to a fourth aspect, there is described the use of a wetlaid nonwoven material according to the first aspect.

[0011] According to a fifth aspect, there is described a method of preparing a wetlaid nonwoven material according to the first aspect, the method comprising dispersing fibres in a liquid, forming a web, and drying and bonding the web.According to a sixth aspect, there is described a method of making a filter according to the second aspect, the method comprising supplying a wetlaid nonwoven material into a rod former to form a band, wrapping the band with a plug wrap, and cutting wrapped band into components of a desired length.

[0012] According to a seventh aspect, there is described a consumable comprising a wetlaid nonwoven material according to the first aspect.

[0013] Brief Description of the Drawings

[0014] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0015] Fig. 1 shows an aerosol generating article;

[0016] Fig. 2 shows a schematic view of a filter making apparatus;

[0017] Fig. 3 shows the pressure drop of Examples according to the invention; and

[0018] Fig. 4 shows the hardness of Examples according to the invention.

[0019] Detailed Description

[0020] The present invention will be described more fully hereinafter. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. As used in this specification and the claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0021] The term "nonwoven" is used herein in reference to fibrous materials, webs, mats, batts, or sheets in which fibres are aligned in an undefined or random orientation. The nonwoven fibres are initially presented as unbound fibres or filaments. An important step in the manufacturing of nonwovens involves binding the various fibres or filaments together. The manner in which the fibres or filaments are bound can vary, and include thermal, mechanical and chemical techniques that are selected in part based on the desired characteristics of the final product.

[0022] As used herein, the term "fibre" is defined as a basic element of textiles. Fibres are often in the form of a rope- or string-like element. As used herein, the term "fibre" is intended to include fibres, filaments, continuous filaments, staple fibres, and the like.The term "staple fibres", as used herein refers to fibres cut to a discrete length.

[0023] The term "multicomponent fibres" refers to fibres that comprise two or more components that differ in their physical or chemical nature, including bicomponent fibres. Specifically, the term "multicomponent fibres" includes staple and continuous fibres prepared from two or more polymers present in discrete structured domains in the fibre, as opposed to blends where the domains tend to be dispersed, random or unstructured.

[0024] The term "wetlaid", as used herein, generally refers to a process for producing a fibrous sheet of material through a means similar to paper making where the fibres are suspended in an aqueous medium and the sheet is formed by filtering the suspension on a conveyor belt or perforated drum.

[0025] As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user, and includes:

[0026] combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); and

[0027] non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

[0028] According to the present disclosure, a "combustible" aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user.

[0029] 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.

[0030] "Starch" as used herein may refer to pure starch from any source, modified starch, or starch derivatives. Starch is present, typically in granular form, in almost all greenplants and in various types of plant tissues and organs (e.g., seeds, leaves, rhizomes, roots, tubers, shoots, fruits, grains, and stems). Starch can vary in composition, as well as in granular shape and size. Often, starch from different sources has different chemical and physical characteristics. Starches derived from various sources can be used. For example, major sources of starch include cereal grains (e.g., rice, wheat, and maize) and root vegetables (e.g., potatoes and cassava). Other examples of sources of starch include acorns, arrowroot, arracacha, bananas, barley, beans (e.g., favas, lentils, mung beans, peas, chickpeas), breadfruit, buckwheat, canna, chestnuts, colacasia, katakuri, kudzu, malanga, millet, oats, oca, Polynesian arrowroot, sago, sorghum, sweet potato, quinoa, rye, tapioca, taro, tobacco, water chestnuts, and yams. Certain starches are modified starches. A modified starch has undergone one or more structural modifications, often designed to alter its high heat properties. Some starches have been developed by genetic modifications, and are considered to be "genetically modified" starches. Other starches are obtained and subsequently modified by chemical, enzymatic, or physical means. For example, modified starches can be starches that have been subjected to chemical reactions, such as esterification, etherification, oxidation, depolymerization (thinning) by acid catalysis or oxidation in the presence of base, bleaching, transglycosylation and depolymerization (e.g., dextrinization in the presence of a catalyst), cross-linking, acetylation,

[0031] hydroxy propylation, and / or partial hydrolysis. Enzymatic treatment includes subjecting native starches to enzyme isolates or concentrates, microbial enzymes, and / or enzymes native to plant materials, e.g., amylase present in corn kernels to modify corn starch. Other starches are modified by heat treatments, such as pregelatinization, dextrinization, and / or cold water swelling processes. Certain modified starches include monostarch phosphate, distarch glycerol, distarch phosphate esterified with sodium trimetaphosphate, phosphate distarch phosphate, acetylated distarch phosphate, starch acetate esterified with acetic anhydride, starch acetate esterified with vinyl acetate, acetylated distarch adipate, acetylated distarch glycerol, hydroxypropyl starch, hydroxypropyl distarch glycerol, starch sodium octenyl succinate.

[0032] "Pectin" as used herein refers to a high molar mass heteropolysaccharide having at least 65% by weight of units based on alpha-linked D-galacturonic acid. These units may exist as free acids, salts (sodium, potassium, calcium, ammonium), naturally esterified with methanol or as amine acid forms in amidated pectins. In addition, a range of neutral sugars (e.g., L-rhamnose, D-galactose, L-arabinose, D-xylose and small amounts of other sugars) may be part of the polymer chain. Pectin exhibits a very complex non-random structure with linear homo (galacturonic acid) blocks andwith highly branched blocks. Pectin may differ in the degree of esterification of the galacturonic acid carboxyl groups, which is typically in the range of 20-80%. Pectin having more than 50% esterification is designated as high esterified (HM, high methoxylated) pectin and differs from low esterified (LM, low methoxylated) pectin containing less than 50% ester groups. A small proportion of the hydroxyl groups in sugar beet pectin can be acetylated, but the hydroxyl groups in citrus pectin cannot.

[0033] "Tensile Strength", as used herein refers to the maximum tensile force developed in a test specimen before rupture on a tensile test carried to rupture under prescribed conditions. Tensile strength is the force per unit width of the test specimen. Common phrases used when assessing tensile strength are: "stretch", which refers to the maximum tensile strain developed in the test specimen before rupture in a tensile test carried to rupture under prescribed conditions. The stretch is expressed as a percentage, e.g. one hundred times the ratio of the increase in length of the test specimen to the original test span; "tensile energy absorption" (TEA), which is the work done when a specimen is stressed to rupture in tension under prescribed conditions as measure by the integral of the tensile strength over the range of tensile strain from zero to maximum strain. TEA is expressed as energy per unit area (test span x width) of the test specimen; "breaking length" which is the calculated limiting length of a strip of uniform width, beyond which, if such a strip were suspended by one end, it would break of its own weight; and "tensile index" which is the tensile strength in N / m divided by grammage.

[0034] Conventional filter elements used in aerosol generating articles, such as cigarettes and consumables used in modern heated devices, typically use fibres of cellulose acetate. Cellulose acetate fibres are a modified form of cellulose whereby acetyl groups are added to the cellulose polymer. Although cellulose acetate is biodegradable, its degradation is a relatively slow process which requires partial deacetylation, biologically active soil, and / or chemical hydrolysis in order to accelerate the degradation. The present inventors have investigated alternative materials suitable for use in or as a component in an aerosol generating article.

[0035] Wetlaid nonwoven materials are commonly used in teabags, coffee pads, wall papers, wipes, glass fibre mats, and security papers. Generally, wet laid nonwovens are made by suspending short fibres in water and then depositing them onto a mesh, such as a wire mesh. The water is subsequently removed, and the fibres are entangled to create a web. Methods of forming wetlaid nonwoven materials would be well known to those skilled in the art.The wetlaid nonwoven comprises a plurality of fibres. In some embodiments, the fibres comprise regenerated cellulose. In some embodiments, the plurality of fibres may be described as a plurality of regenerated cellulose fibres. In some embodiments, the plurality of fibres consist of regenerated cellulose fibres.

[0036] Regenerated cellulose may be considered to be a class of materials that is manufactured by the conversion of natural cellulose to a soluble cellulosic derivative or direct dissolution of cellulosic pulp and subsequent regeneration via wet-spinning process. Therefore, regenerated cellulose fibres may be considered to be a class of materials that is manufactured by the conversion of natural cellulose to a soluble cellulosic derivative or direct dissolution of cellulosic pulp and subsequent regeneration in fibre form. The main distinction between regenerated cellulose fibres and known materials for use in filters such as cellulose acetate is that the regenerated cellulose fibres are a pure form of cellulose whilst the cellulose acetate fibres are a modified form of cellulose that is modified by the addition of acetyl groups to the cellulose polymer.

[0037] Regenerated cellulose fibres are typically prepared by extracting non-cellulosic compounds from wood, contacting the extracted wood with caustic soda, followed by carbon disulfide and then by sodium hydroxide, giving a viscous solution by direct dissolution of high purity cellulose pulp using NMMO. The solution is subsequently forced through spinneret heads to create viscous threads of regenerated fibres. The manner in which the regenerated cellulose is made is not considered limiting on the scope of the present invention.

[0038] In some embodiments, the plurality of fibres comprise regenerated cellulose comprising viscose, lyocell, rayon, viscose rayon, cupro, modal, and combinations thereof. In some embodiments, the plurality of fibres comprise viscose, lyocell, rayon, viscose rayon, cupro, modal, and combinations thereof. In some embodiments, the plurality of fibres comprise fibres made of viscose, lyocell, rayon, viscose rayon, cupro, modal, and combinations thereof. In some embodiments, the plurality of fibres consist of fibres made of viscose, lyocell, rayon, viscose rayon, cupro, modal, and combinations thereof. In some embodiments, the plurality of fibres consist of viscose, lyocell, rayon, viscose rayon, cupro, modal, and combinations thereof.

[0039] In some embodiments, at least about 30% of the plurality of fibres may be viscose fibres. For example, at least about 40% of the plurality of fibres may be viscose fibres,such as at least about 45%, such as at least about 50%, such as at least about 55%, such as at least about 60%, such as at least about 65%, such as at least about 70%, such as at least about 75%, such as at least about 80%, such as at least about 85%, such as at least about 90%, such as at least about 95%, such as at least about 96%, such as at least about 97%, such as at least about 98%, such as at least about 99%.

[0040] In some embodiments, at least about 30% of the plurality of fibres may be lyocell fibres. For example, at least about 40% of the plurality of fibres may be lyocell fibres, such as at least about 45%, such as at least about 50%, such as at least about 55%, such as at least about 60%, such as at least about 65%, such as at least about 70%, such as at least about 75%, such as at least about 80%, such as at least about 85%, such as at least about 90%, such as at least about 95%, such as at least about 96%, such as at least about 97%, such as at least about 98%, such as at least about 99%.

[0041] In some embodiments, the plurality of fibres may be mono-component fibres of regenerated cellulose. In other words, the plurality of fibres can be described as having a uniform composition throughout the fibre.

[0042] In some embodiments, the plurality of fibres may be multi-component fibres of regenerated cellulose. For example, the fibres can have a sheath / core structure, island-in-the-sea structure, side-by-side structure, segmented pie structure, segmented cross structure, or segmented ribbon structure.

[0043] In some embodiments, the wetlaid nonwoven material described herein is used as a component in an aerosol generating article. Such a wetlaid nonwoven material may produce a more consistent, or homogenous, component. For example, the component may be more consistent along its length. Achieving improved consistency along the length of a component is achieved by using a wetlaid nonwoven material such as that set out in herein.

[0044] In some embodiments, the plurality of fibres have a length from about 4 mm to about 15 mm, such as from about 4 mm to about 12.5 mm, such as from about 4 mm to about 10 mm, such as from about 4 mm to about 9mm, such as from about 4 mm to about 8 mm, such as from about 5 mm to about 8 mm, such as from about 5 mm to about 7 mm, such as from about 5.5 mm to about 7 mm, such as from about 5.5 mm to about 6.5 mm. In some embodiments, the plurality of fibres have a length of aboutIn some embodiments, the plurality of fibres have a staple fibre length. For example, fibres may be prepared by combining multiple fibres into longer fibres and then are cut into desired lengths. Because of this, the plurality of fibres tend to have the same length. In some embodiments, the plurality of fibres have an average fibre length (number average) of from about 4 mm to about 15 mm, such as from about 4 mm to about 12.5 mm, such as from about 4 mm to about 10 mm, such as from about 4 mm to about 9mm, such as from about 4 mm to about 8 mm, such as from about 5 mm to about 8 mm, such as from about 5 mm to about 7 mm, such as from about 5.5 mm to about 7 mm, such as from about 5.5 mm to about 6.5 mm. In some embodiments, the plurality of fibres have an average fibre length (number average) of about 6 mm.

[0045] It is thought that tensile strength can be modified by combining fibres of varying lengths into a single wetlaid nonwoven material.

[0046] In some embodiments, the wetlaid nonwoven material has a thickness of from about 0.1 mm to about 2 mm. In some embodiments, the wetlaid nonwoven material has a thickness of from about 0.1 mm to about 1.8 mm, such as from about 0.1 mm to about 1.6 mm, such as from about 0.1 mm to about 1.4 mm, such as from about 0.1 mm to about 1.2 mm, such as from about 0.1 mm to about 1.0 mm, such as from about 0.1 mm to about 0.8 mm, such as from about 0.1 mm to about 0.7 mm, such as from about 0.15 mm to about 0.65 mm, such as from about 0.2 mm to about 0.6 mm, such as from about 0.25 mm to about 0.55 mm, such as from about 0.25 mm to about 0.5 mm, such as from about 0.25 mm to about 0.45 mm, such as from about 0.25 mm to about 0.4 mm, such as from about 0.3 mm to about 0.4 mm, such as from about 0.35 mm to about 0.4 mm. In some embodiments, the wetlaid nonwoven material has a thickness of from about 0.25 mm to about 0.45 mm. In some embodiments, the wetlaid nonwoven material has a thickness of from about 0.3 mm to about 0.4 mm. In some embodiments, the wetlaid nonwoven material has a thickness of about 0.35 mm. In some embodiments, the wetlaid nonwoven material has a thickness of about 0.4 mm.

[0047] In some embodiments, the wetlaid nonwoven material may be provided in the form of a sheet or an elongate body of material. Such a wetlaid nonwoven material has a length, a width, and a thickness. In some embodiments, the length of a wetlaid nonwoven material in the form of a sheet is greater than about 5m, such as greater than about 7.5m, such as greater than about 10m, such as greater than about 15m, such as greater than about 20m, such as greater than about 25m, such as great than about 30m. During processing the length and / or the width of a wetlaid nonwovenmaterial may be adjusted, for example the wetlaid nonwoven material may be cut into different lengths and / or widths, as required in order to improve runnability, pressure drop characteristics, aerosol characteristics, and other properties of an aerosol generating article.

[0048] The wetlaid nonwoven comprises a binder. The binder may be configured to bind the plurality of fibres together. The binder may be introduced to achieve the desired final properties in the wetlaid nonwoven material.

[0049] In some embodiments, the binder may be, for example, but not limited to, polyvinyl alcohol (PVOH), pectin, starch, microfibrillated cellulose (MFC), polysaccharide, shellac, and combinations thereof. In some embodiments, the binder may be an alternative natural polymer not mentioned in the preceding list. In some embodiments, the binder is pectin. In some embodiments, the binder is starch.

[0050] In some embodiments, the binder may be applied to a nonwoven web of material before, during, or after the formation thereof. In some embodiments, the binder may be added to the non-woven web of material during component formation to provide the desired sensory characteristics and / or to improve aerosol chemistry. The binder, which in some embodiments may comprise pectin or starch, may be applied to the non-woven web of material using known techniques.

[0051] In some embodiments, a nonwoven web of material may be used to describe a material which has not had a binder applied to it. In some instances, a nonwoven material which has had a binder applied may be called a fleece.

[0052] In some embodiments, the binder may be applied to the nonwoven web of material in an amount of from about 0.25% to about 30% by weight, based on the total weight of the wetlaid nonwoven material. The amount of binder may be determined based on the dpf of the fibres and the weight of the sheet of material. For example, too much binder may produce a material that is too stiff and hard to be run on manufacturing apparatus.

[0053] In some embodiments, the binder may be present in an amount of from about 0.25% to about 27.5% by weight, based on the total weight of the wetlaid nonwoven material, such as from about 0.25% to about 25%, such as from about 0.25% to about 22.5%, such as from about 0.25% to about 20%, such as from about 0.25% to about 17.5%, such as from about 0.25% to about 15%, such as from about 0.25% toabout 12.5%, such as from about 0.25% to about 11%, such as from about 0.25% to about 10.5%, such as from about 0.25% to about 10%, such as from about 0.5% to about 10%, such as from about 0.5% to about 9.5%, such as from about 0.5% to about 9%, such as from about 0.5% to about 8.5%, such as from about 0.5% to about 8%, such as from about 0.5% to about 7.5%, such as from about 0.5% to about 7%, such as from about 0.5% to about 6.5%, such as from about 0.5% to about 6%, by weight, based on the total weight of the wetlaid nonwoven material.

[0054] In some embodiments, the binder may be present in an amount of from about 0.25% to about 1.5%, by weight, based on the total weight of the wetlaid nonwoven material. In some embodiments, the binder may be present in an amount of from about 0.5% to about 1%, by weight, based on the total weight of the wetlaid nonwoven material.

[0055] In some embodiments, the binder may be present in an amount of from about 3% to about 7%, by weight, based on the total weight of the wetlaid nonwoven material. In some embodiments, the binder may be present in an amount of from about 3.5% to about 6%, by weight, based on the total weight of the wetlaid nonwoven material.

[0056] In some embodiments, the binder may be present in an amount of from about 3% to about 4%, by weight, based on the total weight of the wetlaid nonwoven material.

[0057] In some embodiments, the binder may be present in an amount of from about 5.5% to about 6.5%, by weight, based on the total weight of the wetlaid nonwoven material.

[0058] It is thought that the amount of binder present in the wetlaid nonwoven material may impact the tensile strength of the nonwoven material. For example, increasing the amount of binder may increase the tensile strength.

[0059] It is thought that the type of binder present in the wetlaid nonwoven material may impact tensile strength. For example, when pectin and / or starch are used as the binder, the wetlaid nonwoven material may exhibit a favourable tensile strength.

[0060] Tensile strength represents the ability for a material to withstand stress without breaking, when stretched. Tensile strength is therefore a particularly important measurement when considering materials which may be used in processes whereby they're pulled / stretched. The tensile strength of a material provides insight into how amaterial will behave when under load. A material exhibiting a higher tensile strength may be improve runnability of the material when it is placed under load during processing.

[0061] The tensile strength of the wetlaid nonwoven material may be measured by any method known in the art. For example, one may use a constant rate of elongation type of tensile testing machine which has two clamping jaws, each with a line of contact for gripping a sample and with the line of contact perpendicular to the direction of the applied load and with means for controlling and adjusting the clamping pressure. The two clamping surfaces shall be in the same plane and aligned so that they hold the test sample in that plane throughout the test. A sample of the wetlaid nonwoven material is cut to 15 mm in width and approximately 180 mm in length. The length of the sample must be such that it can be clamped between the jaws of the testing machine, leaving enough length so that any slack can be removed from the sample. The machine controls the rate of separation of the two clamping jaws to 25 mm / min and the tensile strength is measured.

[0062] The wetlaid nonwoven material has a tensile strength of from about 5 N / 15mm to about 50 N / 15mm.

[0063] In some embodiments, the wetlaid nonwoven material may have a tensile strength of from about 5 N / 15mm to about 45 N / 15mm, such as from about 5 N / 15mm to about 40 N / 15mm, such as from about 5 N / 15mm to about 35 N / 15mm, such as from about 10 N / 15mm to about 35 N / 15mm, such as from about 10 N / 15mm to about 35 N / 15mm, such as from about 10 N / 15mm to about 30 N / 15mm, such as from about 15 N / 15mm to about 30 N / 15mm, such as from about 20 N / 15mm to about 30 N / 15mm.

[0064] In some embodiments, the wetlaid nonwoven material may have a tensile strength of from about 10 N / 15mm to about 25 N / 15mm, such as from about 12 N / 15mm to about 25 N / 15mm, such as from about 15 N / 15mm to about 25 N / 15mm, such as from about 15 N / 15mm to about 22 N / 15mm, such as from about 18 N / 15mm to about 22 N / 15mm.

[0065] In some embodiments, the wetlaid nonwoven material may have a tensile strength of from about 25 N / 15mm to about 40 N / 15mm, such as from about 28 N / 15mm to about 40 N / 15mm, such as from about 30 N / 15mm to about 40 N / 15mm, such asfrom about 32 N / 15mm to about 40 N / 15mm, such as from about 34 N / 15mm to about 40 N / 15mm, such as from about 35 N / 15mm to about 40 N / 15mm.

[0066] When the tensile strength of the wetlaid nonwoven material is within these ranges, the material is particularly suitable for processing into components for use in aerosol generating articles, such as a filter element. For example, nonwoven materials are typically provided on a bobbin which is placed on an axle allowing it to freely rotate. The nonwoven material is then fed through the machinery and into the filter making machine. In order to pass through the machine, the material must have the necessary tensile strength such that it can be placed under tension, to be pulled through the machinery, but does not break. Having a tensile strength within these ranges improves the runnability of the wetlaid nonwoven material in manufacturing apparatus, such as, for example, filter making machines.

[0067] In some embodiments, the wetlaid nonwoven has a basis weight of from about 30 g / m2to about 80 g / m2. In some embodiments, the wetlaid nonwoven has a basis weight of from about 30 g / m2to about 75 g / m2, such as from about 35 g / m2to about 75 g / m2, such as from about 35 g / m2to about 70 g / m2, such as from about 40 g / m2to about 70 g / m2, such as from about 40 g / m2to about 65 g / m2, such as from about 40 g / m2to about 60 g / m2.

[0068] In some embodiments, the wetlaid nonwoven has a basis weight of about 40 g / m2. In some embodiments, the wetlaid nonwoven has a basis weight of about 60 g / m2.

[0069] It is thought that basis weight can influence the tensile strength of the nonwoven material. For example, increasing the basis weight of a nonwoven material may increase the tensile strength.

[0070] In some embodiments, the wetlaid nonwoven has a denier per filament of from about 1.0 dpf (denier per filament) to about 5.0 dpf. Denier per filament, or denier per fibre, is a measurement of the weight per unit length of the individual filaments of the fibres. The denier per filament of the regenerated cellulose fibres is expressed in units of grams / 9000 meters. The denier per filament may be manipulated or chosen to achieve a desired pressure drop across the material or across a component formed from the material, such as a filter element.

[0071] As the denier per filament is measured based on a standard length of fibre, the value represents the fineness / thickness of individual filaments / fibres within a sample. Thelower the denier per filament value, the finer the individual fibres, which may result in a smoother and more lightweight material. In contrast, a higher denier per filament value, results in thicker, and possibly rougher fibres, and therefore materials. Higher denier per filament values are often associated with heavier and stiffer materials. Therefore, when seeking to achieve a softer, smoother material, one may consider using a fibre with a lower dpf.

[0072] In some embodiments, the denier per filament of the plurality of fibres may be from about 1.0 dpf to about 5.0 dpf, such as from about 1.1 dpf to about 4.5 dpf, such as from about 1.1 dpf to about 4.0 dpf, such as from about 1.2 dpf to about 3.5 dpf, such as from about 1.2 dpf to about 3.0 dpf, such as from about 1.25 dpf to about 2.5 dpf, such as from about 1.25 dpf to about 2.25 dpf, such as from about 1.25 dpf to about 2.0 dpf, such as from about 1.25 dpf to about 1.75 dpf, such as from about 1.3 dpf to about 1.6 dpf, such as from about 1.35 dpf to about 1.6 dpf, such as from about 1.4 dpf to about 1.6 dpf, such as from about 1.45 dpf to about 1.55 dpf.

[0073] In some embodiments, the denier per filament of the plurality of fibres is about 1.0 dpf, about 1.1 dpf, about 1.2 dpf, about 1.3 dpf, about 1.4 dpf, about 1.5 dpf, about 1.6 dpf, about 1.7 dpf, about 1.8 dpf, about 1.9 dpf, about 2.0 dpf, about 2.1 dpf, about 2.2 dpf, about 2.3 dpf, about 2.4 dpf, about 2.5 dpf.

[0074] In some embodiments, the denier per filament of the plurality of fibres is about 1.5 dpf.

[0075] It is thought that the denier of a nonwoven material can influence the tensile strength of the material. In particular, increasing the denier per filament may increase the tensile strength. When the denier per filament of the nonwoven materials described herein is between these ranges, the material may be particularly suitable for manufacturing into components for use in an aerosol generating article.

[0076] In some embodiments, the wetlaid nonwoven material comprises a single web layer. In some embodiments, the wetlaid nonwoven material comprises a multi-layered web configuration. For example, the wetlaid nonwoven material may comprise two web layers, arranged in a laminate configuration.

[0077] In some embodiments, the wetlaid nonwoven material has a width of from about 110 mm to about 160 mm. For example, the wetlaid nonwoven material may have a width from about 115 mm to about 160 mm, such as from about 115 mm to about 155 mm,such as from about 115 mm to about 150 mm, such as from about 115 mm to about 145 mm, such as from about 120 mm to about 145 mm, such as from about 120 mm to about 140 mm, such as from about 125 mm to about 140 mm, such as from about 125 mm to about 135 mm. In some embodiments, the wetlaid nonwoven material has a width of about 130 mm.

[0078] In some embodiments, the plurality of fibres may be any shape and have any type of cross-section, including but not limited to circular, rectangular, square, oval, triangular, and multilobal. In some embodiments, the plurality of fibres have a circular cross-section.

[0079] Wetlaid nonwoven materials are made in a multistage process which includes the steps of dispersing fibres in a liquid, forming a web, and drying and bonding the web. Fibres are typically suspended and mixed in water to form a fibre-water suspension. The suspension may then be passed through a headbox to a perforated wire mesh screen. Water is drained through the perforations and the fibres, laid on the wire screen, form a web. Water can be removed under reduce pressure. The wetlaid web is then dried and bonded into place by a binder. The binder may then be dried, if necessary, and the nonwoven material is wound onto a roll / bobbin.

[0080] In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar.

[0081] In some embodiments, the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.

[0082] In some embodiments, the component comprises an aerosol generating material. When the component comprises an aerosol generating material, the component may be located in an aerosol generating portion of the aerosol generating article. In some embodiments, the component comprises an aerosol generating material, such as an aerosol former, an active, a flavourant, an acid, and combinations thereof, such as those described herein below.

[0083] In some embodiments, the non-combustible aerosol provision system, such as a noncombustible aerosol provision device thereof, may comprise a power source and acontroller. 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.

[0084] In some embodiments, the non-combustible aerosol provision system may comprise 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.

[0085] 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.

[0086] In some embodiments, the substance to be delivered comprises an active substance.

[0087] 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.

[0088] In one embodiment the active substance is a legally permissible recreational drug

[0089] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

[0090] As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes. The active substance may be CBD or a derivative thereof

[0091] 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.

[0092] 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.

[0093] 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 selected from eucalyptus, star anise, cocoa and hemp.

[0094] 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 selected from rooibos (Aspalathus linearis) and fennel.

[0095] In some embodiments, the substance to be delivered comprises a flavour.

[0096] 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, syntheticallyobtained 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.

[0097] 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.

[0098] 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 notlimited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucalyptol, WS-3.

[0099] Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and / or flavourants.

[0100] The aerosol-generating material may comprise one or more active substances and / or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

[0101] The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former material. Optionally, a substance to be delivered and / or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In some embodiments, the aerosol-generating material is substantially tobacco free.

[0102] The aerosol-generating material may comprise or be in the form of an aerosolgenerating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former material. Optionally, a substance to be delivered and / or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

[0103] The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

[0104] The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, it may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosolgenerating material.The aerosol-generating film may be discontinuous. For example, the aerosolgenerating film may comprise one or more discrete portions or regions of aerosolgenerating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.

[0105] The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former material and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film.

[0106] The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.

[0107] The aerosol-generating material may comprise or be an "amorphous solid". In some embodiments, the aerosol-generating materiel comprises an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid". The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.

[0108] The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free.

[0109] The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of 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.

[0110] The one or more other functional materials may comprise one or more of a pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and / or antioxidants.The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.

[0111] 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.

[0112] 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.

[0113] 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.

[0114] 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.

[0115] 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.

[0116] In some embodiments, the wetlaid nonwoven material may be formed into a component for use in an aerosol generating article. In particular, the wetlaid nonwoven material may be formed into a filtration component, whereby the filter material is formed from the wetlaid nonwoven material. The component formed from the wetlaid nonwoven material may be included in an aerosol generating article to help achieve the desired pressure drop across the aerosol generating article. The wetlaid nonwoven material may be manufactured into a filter element using traditional methods and techniques.

[0117] The wetlaid nonwoven material may provide increased biodegradability when compared to fibres normally used in, for example, filter segments of conventional cigarettes and / or aerosol generating articles, such as cellulose acetate.

[0118] Referring to Fig. 1, an aerosol generating article 1 comprising a component 2 formed from the wetlaid nonwoven material of the present invention is shown. The dimensions of a representative aerosol generating article 1 according to the present invention may vary.

[0119] In some embodiments, aerosol generating articles 1 may be rod shaped. The aerosol generating articles 1 may have a diameter of about 7.5 mm and a circumference of about 23.5 mm. In some embodiments the aerosol provision articles 1 may have a diameter in the range of about 3.1 mm to about 11.2 mm and a circumference of about 10 mm to about 35 mm. In some embodiments, the aerosol generating articles 1 may have a diameter in the range of about 5 mm to about 7.7 mm and a circumference in the range of about 16 mm to about 24 mm.In some embodiments, the aerosol generating article 1 may have a total length in the range of about 60 mm to about 150 mm. In some embodiments, the aerosol generating article 1 may have a total length in the range of about 80 mm to about 144 mm. However, the lengths of the aerosol generating article 1 may vary. In some embodiments, for example, the aerosol generating articles 1 may have total lengths of about 140 mm or less, about 100 mm or less, about 80 mm or less, about 60 mm or less, or about 40 mm or less. The length of the component 2 formed by the wetlaid nonwoven material may also vary. When the component formed by the wetlaid nonwoven material is a filter component, the component 2 may have a total length in the range of about 15 mm to about 40 mm, often in the range of about 20 mm to about 35 mm.

[0120] The component 2 formed from the wetlaid nonwoven material according to the present invention may exhibit a desirable resistance to draw. That is, the component 2 may exhibit a desirable pressure drop across its length when gas is drawn from one side to the other. In some embodiments, the pressure drop may be in the range of between about 40 mmWG and about 650 mmWG. In some embodiment, the pressure drop may be in the range of between about 100 mmWG and about 350 mmWG, about 150 mmWG to about 325 mmWG, or about 200 mmWG to about 300 mmWG, or about 250 mmWG to about 200 mmWG.

[0121] Alternatively, the pressure drop of the component 2 may be measured in mm / WG per mm of the component in the longitudinal direction of the component 2. The component 2 may be a standard circumference component, i.e. about 23 mm to about 25 mm. The pressure drop may be in the range of between about 1 mm / WG per mm of length of the component to about 6.5 mm / WG per mm of length of component 2. In some embodiments, the pressure drop may be in the range of between about 2 mm / WG per mm of length of the component 2 to about 4.5 mm / WG per mm of length of the component 2. In some embodiments, the pressure drop may be in the range of between about 4.5 mm / WG per mm of length of the component 2 to about 6.5 mm / WG per mm of length of the component 2.

[0122] It will be appreciated that the aerosol generating article described previously and depicted herein is not intended to be limiting of the present invention. In particular, the wetlaid nonwoven material and component 2 of the present invention may be incorporated into a variety of different aerosol generating articles, including but not limited to, conventional cigarettes, heat-not-burn devices, tobacco heating products, electronic smoking articles, aerosol delivery devices, and the like, as well as aerosolgenerating articles that may comprise features from each of the previously mentioned categories of aerosol generating article.

[0123] The wetlaid nonwoven material may be manufactured into a filter using a filter manufacturing apparatus such as the Turmalin apparatus from Hauni Maschinenbau AG in Germany.

[0124] Referring to Fig. 2, a schematic illustration of a component making apparatus 100, 15 such as the Turmalin apparatus, for use in manufacturing filters. The components formed in the component making apparatus 100 may be used as filter segments. Referring to Fig. 2, a source 101 of a wetlaid nonwoven material is supplied to the filter making apparatus, which comprises a plurality of modules 102-106. A feeder module 102 receives the supply of wetlaid nonwoven material from which it is fed. A filter bander 104 comprises a vacuum band into which the material is provided, after passing through an optional randomiser 103. This is fed into a rod former 105, for forming the band into a rod which is wrapped with a plug wrap. Finally, a component cutter 106 is used to cut the rod into components of a desired length.

[0125] Examples

[0126] Wetlaid nonwoven materials were made according to the following specifications.

[0127] Table 1

[0128]

[0129] The wetlaid nonwoven materials described in Table 1 were manufactured into filters, using a typical filter making machine as depicted in Fig. 2. The pressure drop of the manufactured filters was measured as set out in Table 2, where the "Pressure Drop" is a measure of the pressure drop across a rod of 108 mm in length with a 24 mmdiameter; and the "Plug Pressure Drop" is the pressure drop across a rod of 27 mm in length with a diameter of 24 mm.

[0130] Table 2

[0131]

[0132] The results are also illustrated in Fig. 3 where it is evident that a higher binder content reduces pressure drop and increasing slit width increases pressure drop. Fig. 4 illustrates the hardness of the filters, where it is evident that a higher slit width increases hardness.

[0133] 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 suitable 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 claims in future.

[0134] Clauses

[0135] The following clauses describe embodiments of the present invention.

[0136] 1. A wetlaid nonwoven material for use in or as a component in an aerosol generating article, the nonwoven material comprising:

[0137] a. a plurality of fibres, and

[0138] b. a binder,wherein the wetlaid nonwoven material has a tensile strength of from about 5 N / 15mm to about 50 N / 15mm.

[0139] 2. The wetlaid nonwoven material according to clause 1, wherein the binder is selected from the list consisting of: polyvinyl alcohol (PVOH), pectin, starch, microfibrillated cellulose (MFC), polysaccharide, shellac, and combinations thereof.

[0140] 3. The wetlaid nonwoven material according to clause 2, wherein the binder is selected from starch and pectin.

[0141] 4. The wetlaid nonwoven material according to clause 2, wherein the binder is starch.

[0142] 5. The wetlaid nonwoven material according to clause 2, wherein the binder is pectin.

[0143] 6. The wetlaid nonwoven material according to any one of clauses 1 to 5, wherein the wetlaid nonwoven material has a basis weight of from about 30 g / m2to about 80 g / m2.

[0144] 7. The wetlaid nonwoven material according to clause 6, wherein the basis weight is from about 40 g / m2to about 60 g / m2.

[0145] 8. The wetlaid nonwoven material according to clause 6, wherein the basis weight is about 40 g / m2.

[0146] 9. The wetlaid nonwoven material according to clause 6, wherein the basis weight is about 60 g / m2.

[0147] 10. The wetlaid nonwoven material according to any one of clauses 1 to 9, wherein the wetlaid nonwoven material has a denier per filament of from about 1.0 dpf to about 5.0 dpf.

[0148] 11. The wetlaid nonwoven material according to clause 10, wherein the denier per filament is from about 1.5 dpf to about 4.5 dpf.

[0149] 12. The wetlaid nonwoven material according to clause 10, wherein the denier per filament is about 1.5 dpf.13. The wetlaid nonwoven material according to clause 10, wherein the denier per filament is about 4.5 dpf.

[0150] 14. The wetlaid nonwoven material according to any one of clauses 1 to 13, wherein the binder is present in an amount of from about 0.25 % to about 25 %, based on the weight of the wetlaid nonwoven material.

[0151] 15. The wetlaid nonwoven material according to clause 14, wherein the binder is present in an amount of from about 0.5 % to about 10 %, based on the weight of the wetlaid nonwoven material.

[0152] 16. The wetlaid nonwoven material according to clause 14, wherein the binder is present in an amount of from about 15 % to about 25 %, based on the weight of the wetlaid nonwoven material.

[0153] 17. The wetlaid nonwoven material according to any one of clauses 1 to 16, wherein the wetlaid nonwoven material has a width of from about 110 mm to about 160 mm.

[0154] 18. The wetlaid nonwoven material according to clause 17, wherein the wetlaid nonwoven material has a width of about 130 mm.

[0155] 19. The wetlaid nonwoven material according to any one of clauses 1 to 18, wherein the plurality of fibres comprise regenerated cellulose.

[0156] 20. The wetlaid nonwoven material according to clause 19, wherein the regenerated cellulose comprises viscose, lyocell, rayon, viscose rayon, cupro, modal, and any combinations thereof.

[0157] 21. The wetlaid nonwoven material according to clause 20, wherein the regenerated cellulose comprises viscose.

[0158] 22. A filter for an aerosol generating article comprising a wetlaid nonwoven material, the wetlaid nonwoven material comprising:

[0159] a. a plurality of fibres, and

[0160] b. a binder,

[0161] wherein the wetlaid nonwoven material has a width of from about 110 mm to about 160 mm.23. The filter according to clause 22, wherein the binder is selected from the list consisting of: polyvinyl alcohol (PVOH), pectin, starch, microfibrillated cellulose (MFC), polysaccharide, shellac, and combinations thereof.

[0162] 24. The filter according to clause 23, wherein the binder is selected from starch and pectin.

[0163] 25. The filter according to clause 23, wherein the binder is starch.

[0164] 26. The filter according to clause 23, wherein the binder is pectin.

[0165] 27. The filter according to any one of clauses 22 to 26, wherein the wetlaid nonwoven material has a basis weight of from about 30 g / m2to about 80 g / m2.

[0166] 28. The filter according to clause 27, wherein the basis weight is from about 40 g / m2to about 60 g / m2.

[0167] 29. The filter according to clause 27, wherein the basis weight is about 40 g / m2.

[0168] 30. The filter according to clause 27, wherein the basis weight is about 60 g / m2.

[0169] 31. The filter according to any one of clauses 22 to 30, wherein the wetlaid nonwoven material has a denier per filament of from about 1.0 dpf to about 5.0 dpf.

[0170] 32. The filter according to clause 31, wherein the denier per filament is from about 1.5 dpf to about 4.5 dpf.

[0171] 33. The filter according to clause 31, wherein the denier per filament is about 1.5 dpf.

[0172] 34. The filter according to clause 31, wherein the denier per filament is about 4.5 dpf.

[0173] 35. The filter according to any one of clauses 22 to 34, wherein the binder is present in an amount of from about 0.25 % to about 25 %, based on the weight of the wetlaid nonwoven material.36. The filter according to clause 35, wherein the binder is present in an amount of from about 0.5 % to about 10 %, based on the weight of the wetlaid nonwoven material.

[0174] 37. The filter according to clause 35, wherein the binder is present in an amount of from about 15 % to about 25 %, based on the weight of the wetlaid nonwoven material.

[0175] 38. The filter according to any one of clauses 22 to 37, wherein the wetlaid nonwoven material has a width of about 130 mm.

[0176] 39. The filter according to any one of clauses 22 to 38, wherein the plurality of fibres comprise regenerated cellulose.

[0177] 40. The filter according to clause 39, wherein the regenerated cellulose comprises viscose, lyocell, rayon, viscose rayon, cupro, modal, and any combinations thereof.

[0178] 41. The filter according to clause 39, wherein the regenerated cellulose comprises viscose.

[0179] 42. An aerosol generating article comprising a wetlaid nonwoven material according to any one of clauses 1 to 21, or a filter according to any one of clauses 22 to 41.

[0180] 43. The aerosol generating article according to clause 42, wherein the article is an article for use in a combustible aerosol generating system.

[0181] 44. The aerosol generating article according to clause 42, wherein the article is an article for use in a non-combustible aerosol generating system.

[0182] 45. Use of a wetlaid nonwoven material as a component in an aerosol generating article, the nonwoven material comprising:

[0183] a. a plurality of fibres, and

[0184] b. a binder,

[0185] wherein the wetlaid nonwoven material has a tensile strength of from about 5 N / 15mm to about 50 N / 15mm.46. A method of preparing a wetlaid nonwoven material according to any one of clauses 1 to 21, the method comprising dispersing fibres in a liquid, forming a web, and drying and bonding the web.

[0186] 47. A method of making a filter according to any one of clauses 22 to 41, the method comprising supplying a wetlaid nonwoven material into a rod former to form a band, wrapping the band with a plug wrap, and cutting wrapped band into components of a desired length.

Claims

Claims1. A wetlaid nonwoven material for use in or as a component in an aerosol generating article, the nonwoven material comprising:a. a plurality of fibres, andb. a binder,wherein the wetlaid nonwoven material has a tensile strength of from about 5 N / 15mm to about 50 N / 15mm.

2. The wetlaid nonwoven material according to claim 1, wherein the binder is selected from the list consisting of: polyvinyl alcohol (PVOH), pectin, starch, microfibrillated cellulose (MFC), polysaccharide, shellac, and combinations thereof.

3. The wetlaid nonwoven material according to claim 2, wherein the binder is selected from starch and / or pectin.

4. The wetlaid nonwoven material according to any one of claims 1 to 3, wherein the wetlaid nonwoven material has a basis weight of from about 30 g / m2to about 80 g / m2.

5. The wetlaid nonwoven material according to claim 4, wherein the basis weight is from about 40 g / m2to about 60 g / m2.

6. The wetlaid nonwoven material according to any one of claims 1 to 5, wherein the wetlaid nonwoven material has a denier per filament of from about 1.0 dpf to about 5.0 dpf, for example the denier per filament is from about 1.5 dpf to about 4.5 dpf.

7. The wetlaid nonwoven material according to any one of claims 1 to 6, wherein the binder is present in an amount of from about 0.25 % to about 25 %, based on the weight of the wetlaid nonwoven material, for example the binder is present in an amount of from about 0.5 % to about 10 %, based on the weight of the wetlaid nonwoven material.

8. The wetlaid nonwoven material according to any one of claims 1 to 7, wherein the binder is present in an amount of from about 15 % to about 25 %, based on the weight of the wetlaid nonwoven material.

9. The wetlaid nonwoven material according to any one of claims 1 to 8, wherein the wetlaid nonwoven material has a width of from about 110 mm to about 160 mm.

10. The wetlaid nonwoven material according to claim 9, wherein the wetlaid nonwoven material has a width of about 130 mm.

11. The wetlaid nonwoven material according to any one of claims 1 to 10, wherein the plurality of fibres comprise regenerated cellulose, for example the regenerated cellulose may comprise viscose, lyocell, rayon, viscose rayon, cupro, modal, and any combinations thereof.

12. The wetlaid nonwoven material according to claim 11, wherein the regenerated cellulose comprises viscose.

13. The wetlaid nonwoven material according to any one of claims 1 to 12, wherein the wetlaid nonwoven material comprises an aerosol former.

14. A filter for an aerosol generating article comprising a wetlaid nonwoven material, the wetlaid nonwoven material comprising:a. a plurality of fibres, andb. a binder,wherein the wetlaid nonwoven material has a width of from about 110 mm to about 160 mm.

15. The filter according to claim 14, wherein the binder is selected from the list consisting of: polyvinyl alcohol (PVOH), pectin, starch, microfibrillated cellulose (MFC), polysaccharide, shellac, and combinations thereof, for example the binder is selected from starch and pectin.

16. The filter according to claim 14 or claim 15, wherein the wetlaid nonwoven material has a basis weight of from about 30 g / m2to about 80 g / m2, for example the basis weight is from about 40 g / m2to about 60 g / m2.

17. The filter according to any one of claims 14 to 16, wherein the wetlaid nonwoven material has a denier per filament of from about 1.0 dpf to about 5.0 dpf.

18. The filter according to claim 17, wherein the denier per filament is from about 1.5 dpf to about 4.5 dpf.

19. The filter according to any one of claims 14 to 18, wherein the wetlaid nonwoven material has a width of about 130 mm.

20. The filter according to any one of claims 14 to 19, wherein the plurality of fibres comprise regenerated cellulose, for example the regenerated cellulose comprises viscose, lyocell, rayon, viscose rayon, cupro, modal, and any combinations thereof, in particular the regenerated cellulose comprises viscose.

21. An aerosol generating article comprising a wetlaid nonwoven material according to any one of claims 1 to 13, or a filter according to any one of claims 14 to 20.

22. Use of a wetlaid nonwoven material as a component in an aerosol generating article, the nonwoven material comprising:a. a plurality of fibres, andb. a binder,wherein the wetlaid nonwoven material has a tensile strength of from about 5 N / 15mm to about 50 N / 15mm.

23. A method of preparing a wetlaid nonwoven material according to any one of claims 1 to 13, the method comprising dispersing fibres in a liquid, forming a web, and drying and bonding the web.

24. A method of making a filter according to any one of claims 14 to 20, the method comprising supplying a wetlaid nonwoven material into a rod former to form a band, wrapping the band with a plug wrap, and cutting wrapped band into components of a desired length.

25. A consumable comprising a wetlaid nonwoven material according to any one of claims 1 to 13.

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