A component for an article for use in or as an aerosol delivery system

Abstract

A component for an article for use in or as an aerosol delivery system. The component comprises a body and a tubular element extending through the body substantially along a common axis. The component comprises a cavity between an end of the body and an end of the tubular element. Another component for an article for use in or as an aerosol delivery system, an article for use in or as an aerosol delivery system, an aerosol delivery system, and methods for forming a component for an article for use in or as an aerosol delivery system are also disclosed.

Description

[0001] P10024595

[0002] 131247GB1 - 1 - A Component for an Article for use in or as an Aerosol Delivery System

[0003] Technical Field

[0004] The present disclosure relates to a component for an article for use in or as an aerosol delivery system. Another component for an article for use in or as an aerosol delivery system, an article for use in or as an aerosol delivery system, an aerosol delivery system, and methods for forming a component for an article for use in or as an aerosol delivery system are also disclosed.

[0005] Background

[0006] 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.

[0007] Summary

[0008] According to an aspect of the present disclosure, there is provided a component for an article for use in or as an aerosol delivery system, the component comprising:

[0009] a body; and

[0010] a tubular element extending through said body substantially along a common axis; wherein the component comprises a cavity between an end of the body and an end of the tubular element.

[0011] Optionally, the tubular element extends through the body such that the body circumferentially surrounds the tubular element.

[0012] Optionally, the body is a body of fibrous material.

[0013] Optionally, the cavity has a (e.g. axial) length (for example along the common axis) between 1 mm and 6 mm.

[0014] Optionally, a proximal end of the tubular element is (e.g. axially) aligned with a proximal end of the body of fibrous material. Optionally, the cavity is between a first end of the body of fibrous material and a first end of the tubular element and wherein a second end of the tubular element, opposed to and spaced apart from the first end of the tubular element, isP10024595

[0015] 131247GB1 _ 2 >

[0016] axially aligned with a second end of the body of fibrous material, opposed to and spaced apart from the first end of the body of fibrous material.

[0017] Optionally, the closed pressure drop through the component is between 5 mmWG and 30 mmWG.

[0018] Optionally, the tubular element has a (e.g. axial) length (for example, along the common axis) between 4 mm and 20 mm.

[0019] Optionally, the body circumferentially surrounding the tubular element has a wall thickness between 1 mm and 2 mm.

[0020] Optionally, the fibrous material circumferentially surrounding the tubular element has a wall thickness between 1 mm and 2 mm.

[0021] Optionally, the tubular element comprises at least one layer of sheet material which is corrugated or crimped so as to provide a plurality of grooves configured to extend in a longitudinal direction of the tubular element, each of the plurality of grooves defining a longitudinally-extending air passage extending through the tubular element.

[0022] Optionally, the component comprises a cavity between an end of the body of fibrous material and an end of the tubular element.

[0023] Optionally, the cavity has a length between 1 mm and 6 mm.

[0024] Optionally, a proximal end of the tubular element is aligned with a proximal end of the body of fibrous material.

[0025] Optionally, the closed pressure drop through the component is between 5 mmWG and 30 mmWG.

[0026] Optionally, the tubular element has a length between 4 mm and 20 mm.

[0027] Optionally, the fibrous material circumferentially surrounding the tubular element has a wall thickness between 1 mm and 2 mm.P10024595

[0028] 131247GB1 - 3 - Optionally, the tubular element comprises at least three layers of sheet material at least one of which is crimped or corrugated.

[0029] Optionally, the tubular element comprises a plurality of concentrically arranged layers of sheet material.

[0030] Optionally, the tubular element comprises a first layer, an inner layer arranged adjacent to the first layer, and an outer layer arranged adjacent to the first layer.

[0031] Optionally, the first layer is crimped or corrugated.

[0032] Optionally, the inner and / or outer layers are crimped or corrugated.

[0033] Optionally, the inner and / or outer layers are non-crimped or corrugated.

[0034] Optionally, the first layer is non-crimped or corrugated.

[0035] Optionally, the inner and / or outer layers are crimped or corrugated.

[0036] Optionally, the inner and / or outer layers are non-crimped or corrugated.

[0037] Optionally, the tubular element comprises a sheet material comprising at least one crimped or corrugated section.

[0038] Optionally, the sheet material comprises at least one non-crimped or non-corrugated section.

[0039] Optionally, at least one of the crimped or corrugated sections of the sheet material are arranged adjacent to at least one non-crimped or non-corrugated section of the sheet material.

[0040] Optionally, the at least one crimped or corrugated sections of the sheet material are arranged across a width of the sheet material so as to provide the plurality of grooves, each of the plurality of grooves defining a longitudinally-extending air passage extending through the tubular element.P10024595

[0041] 131247GB1 - 4 - Optionally, the tubular element comprises a plurality of crimped or corrugated sections of the sheet material and a plurality of non-crimped or non-corrugated sections, wherein the plurality of crimped or corrugated sections and the plurality of non-crimped or noncorrugated sections are arranged in an alternating pattern across a width of the sheet material.

[0042] Optionally, the sheet material is arranged in a spiral configuration.

[0043] According to another aspect of the present disclosure, there is provided a component for an article for use in or as an aerosol delivery system, the component comprising:

[0044] a body; and

[0045] a tubular element extending through said body substantially along a common axis; wherein the body comprises a first longitudinal region circumferentially surrounding the tubular element and a second longitudinal region, and

[0046] wherein the bulk density of the first longitudinal region is greater than the bulk density of second longitudinal region.

[0047] Optionally, the tubular element extends through the body such that the body circumferentially surrounds the tubular element.

[0048] Optionally, the body is a body of fibrous material.

[0049] Optionally, the tubular element does not extend through the second longitudinal region.

[0050] Optionally, the closed pressure drop per unit cross-sectional area of the component is larger across the first longitudinal region than the second longitudinal region.

[0051] Optionally, the closed pressure drop is along the longitudinal length of the first and second regions respectively.

[0052] Optionally, the closed pressure drop per unit cross-sectional area of the component in the first longitudinal region is between 0.03 mmWG / mm2and 7 mmWG / mm2, for example 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 0.75, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5 mmWG / mm2, or a range defined by any two of these values.

[0053] Optionally, the closed pressure drop per unit cross-sectional area of the component in the second longitudinal region is between 0.015 mmWG / mm2and 4 mmWG / mm2, for exampleP10024595

[0054] 131247GB1 - 5 - 0.02, 0.1 , 0.2, 0.3, 0.4, 0.5, 0.75, 1 , 1.5, 2, 2.5, 3 or 3.5 mmWG / mm2, or a range defined by any two of these values.

[0055] Optionally, the first longitudinal region comprises a first crimping factor and the second longitudinal region comprises a second crimping factor.

[0056] Optionally, the tubular element is hollow.

[0057] Optionally, the tubular element is a spiral tubular element.

[0058] Optionally, the tubular element is a coaxial tubular element.

[0059] Optionally, the tubular element is perforated.

[0060] Optionally, the tubular element is unperforated and / or non-porous.

[0061] Optionally, the tubular element is permeable.

[0062] Optionally, the component forms a mouthpiece of a single article.

[0063] Optionally, the tubular element is formed from a cellulose-based material.

[0064] Optionally, the body is a body of fibrous material and wherein the fibrous material is formed from a cellulose-based material.

[0065] Optionally, the cellulose-based material is paper.

[0066] Optionally, the paper is formed from wood-pulp.

[0067] Optionally, the cellulose-based material is a reconstituted tobacco sheet.

[0068] Optionally, the cellulose-based material is a regenerated cellulose material.

[0069] Optionally, the regenerated cellulose material may comprise a plurality of regenerated cellulose fibres. Optionally, the plurality of regenerated cellulose fibres may have a denier per filament in the range of between about 1 dpf and about 30 dpf.P10024595

[0070] 131247GB1 - 6 - Optionally, the plurality of regenerated cellulose fibres may comprise a first plurality of regenerated cellulose fibres and a second plurality of regenerated cellulose fibres, wherein the first plurality of regenerated cellulose fibres may have a denier per filament which is greater than the second plurality of regenerated cellulose fibres. In some embodiments, the first plurality of regenerated cellulose fibres may have a denier per filament in the range of about 10 dpf to about 30 dpf and the second plurality of regenerated cellulose fibres may have a denier per filament in the range of about 1 dpf to about 10 dpf.

[0071] Optionally, the plurality of regenerated cellulose fibres comprise in the range of about 60% to about 90%, by weight, of the first plurality of regenerated cellulose fibres and in the range of about 10% to 40%, by weight, of the second plurality of regenerated cellulose fibres.

[0072] Optionally, the regenerated cellulose material comprises at least one of lyocell, viscose, rayon, viscose rayon, cupro and modal.

[0073] Optionally, the tubular element and / or the body comprises an aerosol forming material, optionally in the range of about 5% to about 60%, by weight, of the tubular element or body respectively.

[0074] Optionally, the fibrous material comprises an aerosol forming material, optionally in the range of about 5% to about 60%, by weight, of the fibrous material.

[0075] Optionally, the cellulose-based material comprises an aerosol former material in the range of about 5% to about 60%, by weight, of the cellulose-based material.

[0076] Optionally, the tubular element is secured within the body via adhesive.

[0077] Optionally, the tubular element comprises an active substance.

[0078] According to another aspect of the present disclosure, there is provided an article for use in or as an aerosol delivery system, the article comprising a component according to the present disclosure.

[0079] Optionally, the component is arranged downstream of a filter of the article.P10024595

[0080] 131247GB1 - 7 - Optionally, the component is arranged upstream of a filter of the article. Optionally, the component is arranged downstream of a body of aerosol generating material of the component.

[0081] Optionally, the component is arranged upstream of a filter of the article and upstream of a cooling element of the article. Optionally, the cooling element is arranged upstream of the filter. Optionally, the component is arranged downstream of a body of aerosol generating material of the component.

[0082] Optionally, the article comprises a first component according to the present disclosure and a second component according to the present disclosure, wherein the first component is arranged downstream of a filter of the article and wherein the second component is arranged upstream of the filter. Optionally, the second component is arranged upstream of a cooling element of the article. Optionally, the component is arranged downstream of a body of aerosol generating material of the component.

[0083] According to another aspect of the present disclosure, there is provided an aerosol delivery system comprising an article according to the present disclosure.

[0084] According to another aspect of the present disclosure, there is provided a method for forming a component for an article for use in or as an aerosol delivery system, the method comprising:

[0085] providing a sheet of material;

[0086] providing a tubular element; and

[0087] gathering said sheet of material around said tubular element to form a body of material in which the tubular element extends through said body substantially along a common axis and is circumferentially surrounded by said material, and such that a cavity is formed between the end of the body of material and an end of the tubular element.

[0088] Optionally, the sheet of material is a sheet of fibrous material.

[0089] Optionally, the method comprises applying a crimp pattern to the sheet of material.

[0090] Optionally, the crimp pattern comprises a series of substantially parallel ridges and grooves.P10024595

[0091] 131247GB1 _8>

[0092] According to another aspect of the present disclosure, there is provided a method for forming a component for an article for use in or as an aerosol delivery system, the method comprising:

[0093] providing a sheet of material;

[0094] providing a tubular element; and

[0095] gathering said sheet of material around said tubular element to form a body of material comprising a first longitudinal region, in which the tubular element extends through said body substantially along a common axis and is circumferentially surrounded by said material, and a second longitudinal region, and such that the bulk density of the first longitudinal region is greater than the bulk density of second longitudinal region.

[0096] Optionally, the sheet of material is a sheet of fibrous material.

[0097] Optionally, the closed pressure drop per unit cross-sectional area of the component is larger across the first longitudinal region than the second longitudinal region.

[0098] Optionally, the method comprises applying a crimp pattern to the sheet of material.

[0099] Optionally, the crimp pattern comprises a series of substantially parallel ridges and grooves.

[0100] Brief Description of the Drawings

[0101] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0102] Figure 1 is a side-on cross-sectional schematic view of an aerosol delivery system according to a first embodiment of the present invention.

[0103] Figure 2 is a side-on cross-sectional schematic view of an aerosol delivery system according to a second embodiment of the present invention.

[0104] Figure 3 is a side-on cross-sectional schematic view of an aerosol delivery system according to a third embodiment of the present invention.

[0105] Figure 4 is a side-on cross-sectional schematic view of an aerosol delivery system according to a fourth embodiment of the present invention.P10024595

[0106] 131247GB1 >g>

[0107] Figure 5 is a side-on cross-sectional schematic view of an aerosol delivery system according to a fifth embodiment of the present invention.

[0108] Figure 6A is an end-on schematic view of a first tubular element suitable for use with the aerosol delivery system of any one of Figures 1 to 5, viewed along a longitudinal axis of the tubular element. The tubular element of Figure 6A comprises a plurality of concentrically arranged layers.

[0109] Figure 6B is an end-on schematic view of a second tubular element suitable for use with the aerosol delivery system of any one of Figures 1 to 5, viewed along a longitudinal axis of the tubular element. The tubular element of Figure 6B comprises a spiral configuration so as to define a plurality of layers.

[0110] Figure 7A is an end-on schematic view of a third tubular element suitable for use with the aerosol delivery system of any one of Figures 1 to 5, viewed along a longitudinal axis of the tubular element. The tubular element of Figure 7A comprises a curved sheet of material having abutting opposed seams or edges.

[0111] Figure 7B is an end-on schematic view of a fourth tubular element suitable for use with the aerosol delivery system of any one of Figures 1 to 5, viewed along a longitudinal axis of the tubular element. The tubular element of Figure 7B comprises a curved sheet of material having spaced apart opposed seams or edges.

[0112] Figure 7C is an end-on schematic view of a fifth tubular element suitable for use with the aerosol delivery system of any one of Figures 1 to 5, viewed along a longitudinal axis of the tubular element. The tubular element of Figure 7C comprises a curved sheet of material having overlapping opposed seams or edges.

[0113] Figure 7D is an end-on schematic view of a sixth tubular element suitable for use with the aerosol delivery system of any one of Figures 1 to 5, viewed along a longitudinal axis of the tubular element. The tubular element of Figure 7D comprises a layered curved sheet of material having abutting opposing seams or edges.

[0114] Figure 7E is an end-on schematic view of a seventh tubular element suitable for use with the aerosol delivery system of any one of Figures 1 to 5, viewed along a longitudinal axis of the tubular element. The tubular element of Figure 7E comprises a layered curved sheet of material having spaced apart opposed seams or edges.P10024595

[0115] 131247GB1 - 10 -

[0116] Figure 7F is an end-on schematic view of an eighth tubular element suitable for use with the aerosol delivery system of any one of Figures 1 to 5, viewed along a longitudinal axis of the tubular element. The tubular element of Figure 7F comprises a layered curved sheet of material having overlapping opposed seams or edges.

[0117] Figure 8 is an end-on schematic view of a ninth tubular element suitable for use with the aerosol delivery system of any one of Figures 1 to 5, viewed along a longitudinal axis of the tubular axis. The tubular element of Figure 8 comprises crimped or corrugated layers.

[0118] Figure 9 is a schematic diagram of an embodiment of an apparatus for manufacturing a component for use in a delivery system.

[0119] Figure 10 is a schematic side elevation partial cross-sectional view of an embodiment of a device for use in the apparatus of Figure 9.

[0120] Detailed Description

[0121] 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.

[0122] As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes:

[0123] 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); andP10024595

[0124] 131247GB1 - 11 - 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.

[0125] As used herein, the term “tobacco” or “tobacco material” refers to any material comprising tobacco or derivatives or substitutes thereof. 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.

[0126] In the tobacco material described herein, the tobacco component preferably contains paper reconstituted tobacco. The tobacco component may also contain leaf tobacco, extruded tobacco, and / or bandcast tobacco.

[0127] 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. The tobacco material may be provided in the form of cut rag tobacco. The cut rag tobacco can be formed from a mixture of forms of tobacco material, for instance a mixture of one or more of paper reconstituted tobacco, leaf tobacco, extruded tobacco and bandcast tobacco. Preferably the tobacco material comprises paper reconstituted tobacco or a mixture of paper reconstituted tobacco and leaf tobacco. In the tobacco material described herein, the tobacco material may contain a filler component. The filler component is generally a non-tobacco component, that is, a component that does not include ingredients originating from tobacco. The filler component may be a non-tobacco fibre such as wood fibre or pulp or wheat fibre. The filler component may also be an inorganic material such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material.

[0128] 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.P10024595

[0129] 131247GB1 - 12 - 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, or a tobacco rod.

[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.

[0132] 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.

[0133] 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.

[0134] 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.

[0135] 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.

[0136] 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 sometimes referred to as articles throughout the disclosure.P10024595

[0137] 131247GB1 - 13 - In some embodiments, the non-combustible aerosol provision system, such as a noncombustible 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.

[0138] 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.

[0139] 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.

[0140] In some embodiments, 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.

[0141] In some embodiments, the substance to be delivered comprises an active substance or the tubular element comprises an active substance.

[0142] 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.

[0143] In one embodiment the active substance is a legally permissible recreational drug.P10024595

[0144] 131247GB1 - 14 - In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

[0145] 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.

[0146] The active substance may be CBD or a derivative thereof.

[0147] 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.

[0148] 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.

[0149] 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.

[0150] 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.P10024595

[0151] 131247GB1 - 15 - 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.

[0152] In some embodiments, the substance to be delivered comprises a flavour.

[0153] 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.

[0154] 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. InP10024595

[0155] 131247GB1 - 16 -some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.

[0156] 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.

[0157] 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.

[0158] 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 materials.

[0159] The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former. 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 particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

[0160] The aerosol-generating material may comprise or be in the form of an aerosol-generating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former. 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.

[0161] 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. TheP10024595

[0162] 131247GB1 - 17 -shredded sheet may comprise one or more strands or strips of aerosol-generating material.

[0163] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may comprise one or more discrete portions or regions of aerosol-generating 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.

[0164] 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 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.

[0165] The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.

[0166] 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.

[0167] The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free.

[0168] 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.P10024595

[0169] 131247GB1 - 18 - 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.

[0170] 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 aerosol-modifying 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.

[0171] 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.

[0172] The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosolmodifying 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.

[0173] Figure 1 is a side-on cross-sectional schematic view of an article 1 according to a first embodiment of the present invention for use with a non-combustible aerosol provision system.

[0174] The article 1 comprises a mouthpiece 19 and a body of aerosol generating material 15 which in this embodiment is provided as a cylindrical rod 15. In the present case, the aerosol generating material comprises tobacco material. The aerosol generating material is connected to the mouthpiece 19. The aerosol generating material 15 provides an aerosol when heated, for instance within a non-combustible aerosol provision device as described herein, for instance a non-combustible aerosol provision device comprising aP10024595

[0175] 131247GB1 >ig>

[0176] coil, forming a system. In other embodiments the article 1 can include its own heat source, forming an aerosol provision system without requiring a separate aerosol provision device.

[0177] The aerosol generating material 15, also referred to herein as an aerosol generating substrate 15, comprises at least one aerosol-former material. In the present example, the aerosol-former material is glycerol. In alternative examples, the aerosol-former material can be another material as described herein or a combination thereof. The aerosol-former material has been found to improve the sensory performance of the article, by helping to transfer compounds such as flavour compounds from the aerosol generating material to the consumer. However, an issue with adding such aerosol-former materials to the aerosol generating material within an article for use in a non-combustible aerosol provision system can be that, when the aerosol-former material is aerosolised upon heating, it can increase the mass of aerosol which is delivered by the article, and this increased mass can maintain a higher temperature as it passes through the mouthpiece. As it passes through the mouthpiece, the aerosol transfers heat into the mouthpiece and this warms the outer surface of the mouthpiece, including the area which comes into contact with the consumers lips during use. The mouthpiece temperature can be significantly higher than consumers may be accustomed to when smoking, for instance, conventional cigarettes, and this can be an undesirable effect caused by the use of such aerosol-former materials.

[0178] In the present example, the mouthpiece 19 comprises a component 2 comprising a body of fibrous material 3. In some embodiments, the body 3 may be of any suitable material and may not be of a fibrous material. In some embodiments the component 2 may be a filter 20 or filter element. The body of fibrous material 3 comprises a first, distal, end 7 and a second, proximal, end 10. The first end 7 is arranged in abutting relationship with the cylindrical rod of aerosol generating material 15. The second end 10 is opposed and spaced apart along a longitudinal axis 5 of the article 1 from the first end 7 and forms a proximal end 21 of the article 1. The closed pressure drop through the component 2 is between 5 mmWG and 30 mmWG. The ISO standard ISO 6565:2015 can be used to measure closed pressure drop, as known to those skilled in the art.

[0179] The body of fibrous material 3 may be made from a cellulose-based material. In certain embodiments the cellulose based material may be carboard, paper mache or paper, for example paper made from wood-pulp. In other embodiments the cellulose-based material may be a reconstituted tobacco sheet or a regenerated cellulose material such as lyocell or viscose.P10024595

[0180] 131247GB1 - 20 -

[0181] In some embodiments, the body of fibrous material 3 may be provided as loose fibres of fibrous material, such as cellulose acetate fibres. In other embodiments, the body of fibrous material 3 may comprise cellulose. In some embodiments, the body of fibrous material may be provided as a sheet. In the present example, the sheet material is paper. The sheet material may additionally or alternatively comprise cardboard, paper-mache or any other cellulose-based material or any other fibrous material. For example, in some embodiments the sheet material comprises reconstituted tobacco, i.e. the reconstituted tobacco may be formed into a sheet material, the sheet material being arranged to form the body 3. The reconstituted tobacco comprises cellulose. In another embodiment, the reconstituted tobacco is manufactured into a uniform plug of material that forms the body 3. The reconstituted tobacco may optionally be paper reconstituted tobacco.

[0182] The sheet material arranged to form the body 3 may be folded or gathered, e.g. around the tubular element 4, to form the body 3. In some embodiments, the sheet material is folded or gathered so as to provide a plurality of longitudinally extending (i.e. parallel to longitudinal axis 5 of the article 1) air channels extending therethrough.

[0183] In some embodiments, an aerosol-former material is applied to the body of fibrous material 3. For example, the aerosol-former material may be applied to the sheet material prior to the sheet material being folded or gathered to form the body of fibrous material 3. The aerosol-former material may be sprayed on to the sheet material or applied by a brush or by dipping the sheet material in aerosol-former material.

[0184] In some embodiments, the aerosol-former material may comprise 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. At least some of the aerosol-former material is combined with the aerosol as it passes through the body of material 3 and helps to make the aerosol feel less dry within the user’s mouth.

[0185] In some embodiments, the sheet material is crimped, for example to a crimp depth of at most 0.8 mm and, preferably, at most 0.6 mm, or 0.5 mm. In some embodiments, the sheet material is crimped to a crimp depth of at least 0.2, 0.3, 0.4, 0.5 or 0.6 mm.P10024595

[0186] 131247GB1 - 21 - The crimping factor (also known as “crimp depth”) refers to the depth of the grooves the crimping forms in the sheet material. That is, crimping the sheet material produces a plurality of troughs in the sheet material when viewed from a first side of the sheet material, wherein the crimp depth is the depth of the troughs. The crimping may form a Zig-Zag formation.

[0187] In some embodiments, the sheet material has a basis weight in the range of 15 to 80 gsm and, preferably, in the range of 20 to 50 gsm.

[0188] The body of fibrous material 3 comprises an aperture 26 which extends from the proximal end 21 of the article 1, entirely through the body of fibrous material 3, to the cylindrical rod of aerosol generating material 15. In this embodiment, the aperture 26 is cylindrical.

[0189] The component 2 comprises a tubular element 4 arranged coaxially within the aperture 26 of the body of fibrous material 3. In some embodiments the tubular element 4 may be secured within the body of fibrous material 3 via adhesive, for example the tubular element 4 may be bonded to the body of fibrous material 3 by adhesive. The tubular element 4 is hollow in that it comprises a longitudinally extending aperture 22 passing entirely therethrough. The tubular element 4 extends from the proximal end 21 of the article 1 such that the body of fibrous material 3 surrounds the tubular element 4 and such that a proximal end 9 of the tubular element 4 is axially aligned, or substantially axially aligned, with a proximal end 10 of the body of fibrous material 3. The tubular element 4 supports the tubular shape of the body 3. In other embodiments, the proximal end 9 of the tubular element 4 may not be so aligned with the proximal end 10 of the body of fibrous material 3. In some embodiments a distal end 8 of the tubular element may be aligned with a distal end 7 of the body of fibrous material 3.

[0190] In this embodiment the tubular element 4 extends through the body of fibrous material 3 but the tubular element 4 only extends part-way along the axial length of the body of fibrous material 3 (or part-way along the aperture 23 of the body of fibrous material 3) such that a distal end 8 of the tubular element 4 is spaced away from the cylindrical rod of aerosol generating material 15 so as to define a cavity 6 between, or defined by, the distal end 8 of tubular element 4 and the distal end 7 of the body of fibrous material 3. In some embodiments, the cavity 6 may also be defined by a proximal end of the body of aerosol generating material 15, or by a surface thereof. In some embodiments, the tubular element 4 may comprise an active substance such as an active substance as described herein.P10024595

[0191] 131247GB1 - 22 - In some embodiments, the cavity 6 may have an axial length (i.e. along a longitudinal axis 5 of the article 1 , the axial length of the cavity 6 being illustrated by reference A in Fig. 1) of from 0.5mm to 6mm, for example axial length of the cavity 6 may be 0.5, 1 , 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5 or 6mm. In some embodiments the axial length of the cavity 6 may be defined by a range from and to any two of 0.5, 1 , 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5 and 6mm. In other words, the distal end 7 of the body of fibrous material 3 may extend in an axial direction beyond the distal end 8 of the tubular element 4 by from 0.5mm to 6mm, for example by 0.5, 1 , 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5 or 6mm or by a range from and to any two of 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5 and 6mm. The selection of the axial length of the cavity 6 allows the mass of the article 1 to be reduced, with a cavity 6 having an axial length of from 1mm to 5mm being particularly advantageous in this regard.

[0192] In some embodiments, the tubular element 4 may have an axial length (i.e. along a longitudinal axis 5 of the article 1, the axial length of the tubular element 4 being illustrated by reference B in Fig. 1) of from 2mm to 20mm, for example 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20mm. In some embodiments the axial length of the tubular element 4 may be defined by a range from and to any two of 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 and 20mm. The selection of the axial length of the tubular element 4 provides sufficient strength to maintain the tubular shape of the body 3 while not adding unnecessary mass to the article 1 , with a tubular element 4 having an axial length of from 3mm to 7mm being particularly advantageous in this regard.

[0193] In some embodiments, the ratio of the axial length of the tubular element 4 (B) to the axial length of the cavity 6 (A) to may be 1:1, 1.1:1, 1.2:1, 1.3:1, 1.4:1, 1.5:1, 1.6:1. 1.7:1, 1.8:1, 1.9:1, 2:1, 2.1:1. 2.2:1, 2.3:1, 2.4:1, 2.5:1, 2.6:1, 2.7:1, 2.8:1, 2.9:1, 3:1, 3.1:1, 3.2:1, 3.3:1, 3.4:1, 3.5:1, 3.6:1, 3.7:1, 3.8:1, 3.9:1 or 4:1. In some embodiments the ratio of the axial length of the tubular element 4 (B) to the axial length of the cavity 6 (A) to may be a range defined by any two of 1:1, 1.1:1, 1.2:1, 1.3:1, 1.4:1, 1.5:1, 1.6:1. 1.7:1, 1.8:1, 1.9:1, 2:1, 2.1:1. 2.2:1, 2.3:1, 2.4:1, 2.5:1, 2.6:1, 2.7:1, 2.8:1, 2.9:1, 3:1, 3.1:1, 3.2:1, 3.3:1, 3.4:1, 3.5:1, 3.6: 1 , 3.7: 1 , 3.8: 1 , 3.9: 1 or 4: 1. The selection of the ratio of the axial length of the tubular element 4 (B) to the axial length of the cavity 6 (A) provides sufficient strength to maintain the tubular shape of the body 3 while not adding unnecessary mass to the article 1.

[0194] As discussed hereinbelow, in some embodiments in which the component 4 is arranged downstream of a filter element 220 (see for example Figs. 3 and 5), the ratio of the axialP10024595

[0195] 131247GB1 - 23 -length of the tubular element 4 (B) to the axial length of the cavity 6 (A) to may preferably be from 1.5:1 to 2.5:1, for example 1.5:1, 1.6:1. 1.7:1, 1.8:1, 1.9:1, 2:1, 2.1:1. 2.2:1, 2.3:1, 2.4:1, or 2.5:1, or a range defined by any two of 1.5: 1 , 1.6:1. 1.7:1, 1.8:1, 1.9: 1 , 2: 1 , 2.1 : 1.

[0196] 2.2: 1 , 2.3: 1 , 2.4: 1 , or 2.5: 1. A ratio of B:A of about 2: 1 for embodiments in which the component 4 is arranged downstream of a filter element 220 is particularly advantageous for providing sufficient strength to maintain the tubular shape of the body 3 while not adding unnecessary mass to the article 1.

[0197] As discussed hereinbelow, in some embodiments in which the component 4 is arranged upstream of a filter element 220 (see for example Figs. 4 and 5), ), the ratio of the axial length of the tubular element 4 (B) to the axial length of the cavity 6 (A) to may preferably be from 2:1 to 3:1, for example 2:1, 2.1:1. 2.2:1, 2.3:1, 2.4:1, 2.5:1, 2.6:1, 2.7:1, 2.8:1, 2.9:1, or 3: 1 , or a range defined by any two of 2: 1 , 2.1 : 1. 2.2: 1 , 2.3: 1 , 2.4: 1 , 2.5: 1 , 2.6: 1 , 2.7:1, 2.8:1, 2.9:1, 3:1. A ratio of B:A of about 2.5:1 for embodiments in which the component 4 is arranged upstream of a filter element 220 is particularly advantageous for providing sufficient strength to maintain the tubular shape of the body 3 while not adding unnecessary mass to the article 1.

[0198] The tubular element 4 comprises, in certain embodiments, at least one radial perforation 14 or hole for facilitating the flow of gas, such as aerosol, therethrough. In some embodiments the tubular element 4 may comprise a plurality of such holes 14 arranged circumferentially around the tubular element, for example equiangularly spaced. The tubular element 4 may also be made of a permeable material, such as paper or other such cellulose-based material, for example so as to allow, at least to a certain extent, gas or aerosol to pass therethrough. The permeable material may be selected to provide a predetermined pressure drop across the article 1 or through the component 2. The article 1 has a ventilation level of about 75% of the aerosol drawn through the article 1. In alternative embodiments, the article 1 can have a ventilation level of between 50% and 80% of aerosol drawn through the article, for instance between 65% and 75%. Ventilation at these levels helps to slow down the flow of aerosol drawn through the mouthpiece 19 and thereby enable the aerosol to cool sufficiently. The ventilation provided by the radial perforation 14 has been found to be particularly beneficial in assisting with the aerosol generation process.

[0199] In some embodiments, the tubular element 4 may itself comprise aerosol generating material, for example an aerosol generating material different to the aerosol generating material of the body of aerosol generating material 15. Providing a second aerosolP10024595

[0200] 131247GB1 - 24 -generating material on the tubular element 4 can result in generation of a second aerosol which boosts or complements the flavour or visual appearance of the aerosol of the cylindrical rod of aerosol generating material 15.

[0201] The outer circumference of the body of fibrous material 3 is substantially the same as the outer circumference of the rod of aerosol generating material 15, such that there is a smooth or continuous transition between these components.

[0202] The tubular element 4 may be made in any suitable fashion. In the embodiments of Figs.1 to 5, as shown in Fig. 6A the tubular element 4 may comprise a plurality, such as two or more, such as three, four, five, six or seven or more, concentric layers 23 of material. In some embodiments, the tubular element 4 may comprise between 4 and 25 layers. In this way, the tubular element 4 may be considered to be formed from a plurality of concentric tubes.

[0203] As shown in Fig. 6B, the tubular element 4 may comprise a sheet 24 of material arranged (for example rolled) in a spiral configuration so as to define a plurality of layers 23. The material of the tubular element 4 may be a sheet material, for example formed from cellulose-based material such as paper, cardboard or paper mache, or from a plastic material such as an extruded plastic or similar. In other embodiments the cellulose-based material may be a reconstituted tobacco sheet or a regenerated cellulose material such as lyocell or viscose. In some embodiments, the sheet 24 may comprise a plurality of layers together arranged in a spiral configuration or the tubular element may comprise a plurality of stacked sheets 24 together arranged in a spiral configuration. In some embodiments, the tubular element 4 may comprise between 4 and 25 layers arranged in a spiral configuration.

[0204] Turning back now to Fig. 1, a plug wrap 16 circumscribes the body of fibrous material 3 and a wrapper 17 circumscribes the body of aerosol generating material 15. The body of fibrous material 3 and the body of aerosol generating material 15 are combined by a circumferential extending second plug wrap 18, or tipping paper 18, which is wrapped around and circumscribes both sections. The body of aerosol generating material 15 and the body of fibrous material 3 each define a substantially cylindrical overall outer shape of the article 1 and are both aligned with a longitudinal axis 5 of the article 1.

[0205] The wrapper 17 can, for instance, be a paper or paper-backed foil wrapper. In the present example, the wrapper 17 is substantially impermeable to air. In alternative embodiments,P10024595

[0206] 131247GB1 - 25 -the wrapper 17 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, results in an improvement in the aerosol formation in the rod of aerosol generating material 15. Without wishing to be bound by theory, it is hypothesised that this is due to reduced loss of aerosol compounds through the wrapper 17. The permeability of the wrapper 10 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 some embodiments, the wrapper 17 comprises aluminium foil. Aluminium foil has been found to be particularly effective at enhancing the formation of aerosol within the aerosol generating material 15. In some embodiments, the aluminium foil has a metal layer having a thickness of about 6 pm. In some embodiments, the aluminium foil has a paper backing. However, in alternative arrangements, the aluminium foil can be other thicknesses, for instance between 4 pm and 16 pm in thickness. The aluminium foil also need not have a paper backing, but could have a backing formed from other materials, for instance to help provide an appropriate tensile strength to the foil, or it could have no backing material. Metallic layers or foils other than aluminium can also be used.

[0207] Figure 2 is a side-on cross-sectional schematic view of a second embodiment of an article 101 according to the present invention. Features of the second embodiment corresponding with those of the first embodiment are provided with corresponding reference numerals, increased by 100 as compared to the first embodiment.

[0208] The article 101 of the second embodiment is identical to that of the first embodiment, and so the discussion above relating to the first embodiment applies equally to the second embodiment, with the exception that the aperture 126 of the body of fibrous material 103 of the second embodiment does not extend entirely through the body of fibrous material 103, from the proximal end 21 of the article 1, through the body of fibrous material 3, to the cylindrical rod of aerosol generating material 15 as it does in the first embodiment, but instead the aperture 122 of the second embodiment extends through the body of fibrous material 103, from the proximal end 121 of the article 101 to part-way along the body of fibrous material 103. Thus, the article 101 of the second embodiment does not comprise the cavity 6 of the article 1 of the first embodiment and the aperture 122 of the second embodiment defines a base 125 of the aperture 122 which is longitudinally spaced away from the body of aerosol generating material 115.P10024595

[0209] 131247GB1 - 26 - In the second embodiment, the body of fibrous material 103 comprises a first longitudinal region 111 which circumferentially surrounds the tubular element 104, the tubular element 104 being provided within the aperture 123 of the fibrous body 103. The tubular element 104 extends the length of the first longitudinal region 111 and extends from the proximal end 109 of the body of fibrous material 103 (i.e. from the proximal end 121 of the article 101) to the base 125 of the aperture 122, although embodiments are envisaged where the tubular element 104 does not extend all the way to the base 125, or is spaced from the proximal end 121 of the article 101. The body of fibrous material 103 comprises a second longitudinal region 112 upstream of the first longitudinal region 111 and in this embodiment the second longitudinal region 112 extends from the base 125 of the aperture 122, or from the distal end 108 of the tubular element 104, to the rod of aerosol generating material 115.

[0210] The bulk density of the first longitudinal region 111 (e.g. of the material thereof) is greater than the bulk density of the second longitudinal region 112 (e.g. of the material thereof). The closed pressure drop per unit cross-sectional area of the component 102 is larger across the first longitudinal region 111 than the second longitudinal region 112. In some embodiments, the closed pressure drop per unit cross-sectional area of the component in the first longitudinal region is between 0.03 mmWG / mm2and 7 mmWG / mm2and / or the closed pressure drop per unit cross-sectional area of the component in the second longitudinal region is between 0.015 mmWG / mm2and 4 mmWG / mm2.

[0211] The increased pressure drop of the first longitudinal region 111 may be provided in numerous ways as will be appreciated by a person skilled in the art, but in this embodiment it is provided by compressing the fibrous material within the first longitudinal region 111 , for example during wrapping of the plug wrap 116 around the body of fibrous material 103 and the tubular element 104, or it may be provided by pressing the tubular element 104 into the aperture 122 from the proximal end 121 of the article 101, thereby compressing the fibrous material in the first longitudinal region 111. Pressing the tubular element 104 into the proximal end 121 may form the aperture 126 of the body of fibrous material 103.

[0212] Alternatively, the fibrous material of the first longitudinal region 111 may differ from the fibrous material of the second longitudinal region 112, for example it may be more or less dense or be made from a different material. In other embodiments, the fibrous material of the second longitudinal region 112 could be provided as a gathered or folded sheet ofP10024595

[0213] 131247GB1 - 27 -fibrous material whereas the fibrous material of the first longitudinal region 112 could be provided as a concentrically layered or rolled sheet of fibrous material, for example.

[0214] In some embodiments, the first 111 and / or second 112 longitudinal regions may comprise a common, or alternatively a respective, sheet of fibrous material. The sheet of fibrous material may comprise a crimp pattern comprising a series of substantially parallel ridges and grooves, which may in certain embodiments extend longitudinally along the article 101 or component 102. The sheet of the fibrous material of the first longitudinal region 111 may in certain embodiments comprise a first crimp pattern and the sheet of fibrous material of the second longitudinal region 112 may comprise a second crimp pattern different from the first crimp pattern, for example the spacing of the parallel ridges and grooves may be increased in the second longitudinal region 112 as compared to the first 111.

[0215] The sheet of the first longitudinal region 111 may comprise a first crimping factor and the sheet of the second longitudinal region 112 may comprise a second crimping factor, different to the first. For example, the sheet of the first longitudinal region 111 may have a crimping depth of 0.5mm whereas the sheet of the second longitudinal region 112 may have a crimping depth of 0.6mm.

[0216] In some embodiments, the axial length of the first longitudinal region 111 may be from 2 to 20mm for example 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20mm. In some embodiments, the axial length of the first longitudinal region 111 may be defined by a range from and to any two of 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 and 20mm.

[0217] In some embodiments, the axial length of the second longitudinal region 112 may be from 2 to 20mm for example 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20mm. In some embodiments, the axial length of the second longitudinal region 112 may be defined by a range from and to any two of 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 and 20mm.

[0218] Figure 3 is a side-on cross-sectional schematic view of a third embodiment of an article 201 according to the present invention. Features of the third embodiment corresponding with those of the first embodiment are provided with corresponding reference numerals, increased by 200 as compared to the first embodiment.P10024595

[0219] 131247GB1 - 28 - In the third embodiment, the component 202 may be either the component 2 of the first embodiment or the component 102 of the second embodiment and so discussion relating to the specific features of the component 202 is omitted as it will be understood that discussion herein relating to the component 2, 102 of the first and second components relates equally to the component 202 of the third embodiment. The only differences of the third embodiment compared to the first and second embodiments is the provision of a filter 220 and a cooling element 228 arranged between the component 202 and the body of aerosol generating material 215. In some embodiments, the filter 220 may be omitted and, in such embodiments for example, the end 207 of the component 202 may be in abutting relationship with the cooling element 228. In other embodiments, the cooling element 228 may be omitted and, in such embodiments for example, the end 207 of the component 202 may be in abutting relationship with the body of aerosol generating material 215 or the component 202 may be spaced away from the body of aerosol generating material 215.

[0220] Whereas in the first and second embodiments the first end 7, 107 of the component 2, 102 is arranged in abutting relationship with the cylindrical rod of aerosol generating material 15, 115, in the third embodiment the component 202 is instead arranged such that the first end 207 thereof is in abutting relationship with a filter 220, which may comprise a body of filter material which, in some embodiments, may be formed from cellulose acetate fibers or any other suitable filter material. In this embodiment, the filter 220 is provided upstream of the component 202 and downstream of the body of aerosol generating material 215. Furthermore, in this embodiment, a cooling element 228 is provided which is arranged between the body of aerosol generating material 215 and the filter 220. Thus, the cooling element 228 is provided downstream of the body of aerosol generating material 215 and upstream of the filter 220. The cooling element 228 allows vapour components to condense to form an aerosol and / or spaces the very hot parts of the apparatus from the user. The filter 220 may remove components from the fluid flow, affecting the chemical composition of the inhaled aerosol.

[0221] In some embodiments, the cooling element 228 may comprise a monolithic rod having first and second ends and comprising plural through holes extending between the first and second ends. The through holes may extend substantially parallel to the central longitudinal axis of the rod. The through holes of the cooling element 228 may be arranged generally radially of the element when viewed in lateral cross-section. That is, in an example, the element has internal walls which define the through holes and which have two main configurations, namely radial walls and central walls. The radial wallsP10024595

[0222] 131247GB1 - 29 -extend along radii of the cross-section of the element and the central walls are centred on the centre of the cross-section of the element. The central walls in one example are circular, though other regular or irregular cross-sectional shapes may be used. Likewise, the cross-section of the element in one example is circular, though other regular or irregular cross-sectional shapes may be used. In an example, the majority of the through holes have a hexagonal or generally hexagonal cross-sectional shape. In this example, the element has what might be termed a “honeycomb” structure when viewed from one end.

[0223] In some embodiments, the cooling element 228 may comprise a hollow tube which spaces the filter 220 from the very hot part(s) of the main apparatus that heats the aerosolisable material. The cooling element 228 may be formed of for example paper, for example in the form of a spirally wound paper tube, cellulose acetate, cardboard, crimped paper, such as crimped heat resistant paper or crimped parchment paper, and polymeric materials, such as low density polyethylene (LDPE), or some other suitable material. The cooling element 228 may be substantially incompressible. It may be formed of a ceramic material, or of a polymer, for example a thermoplastic polymer, which may be an extrudable plastics material. In an example, the porosity of the element is in the range 60% to 75%. The porosity in this sense may be a measure of the percentage of the lateral cross-sectional area of the element occupied by the through holes. In an example, the porosity of the element is around 69% to 70%.

[0224] In further examples, the cooling element 228 may be formed from a sheet material that is folded, crimped or pleated to form through holes. The sheet material may be made, for example, from metal such as aluminium; polymeric plastics material such as polyethylene, polypropylene, polyethylene terephthalate, or polyvinyl chloride; or paper.

[0225] Other than the presence of a filter 220 and a cooling element 228, the article 201 of the third embodiment is substantially identical to the first and second embodiments and so it will be understood that discussion relating to specific features of the first and second embodiments also applies equally to the third embodiment.

[0226] Figure 4 is a side-on cross-sectional schematic view of a fourth embodiment of an article 301 according to the present invention. Features of the fourth embodiment corresponding with those of the first embodiment are provided with corresponding reference numerals, increased by 300 as compared to the first embodiment.P10024595

[0227] 131247GB1 - 30 - In the fourth embodiment, the component 302 may be either the component 2 of the first embodiment or the component 102 of the second embodiment and so discussion relating to the specific features of the component 302 is omitted as it will be understood that discussion herein relating to the component 2, 102 of the first and second components relates equally to the component 302 of the fourth embodiment. The only difference of the fourth embodiment compared to the first and second embodiments, is the provision of a filter 320 and a cooling element 328 arranged downstream of the component 302, the component 302 being arranged downstream of the body of aerosol generating material 315.

[0228] In the fourth embodiment, the component 302 is arranged between a body of aerosol generating material 315 and a cooling element 328. The discussion above relating to the cooling element 228 of the third embodiment applies equally to the cooling element 328 of the fourth embodiment. Thus, the component 302 is arranged downstream of the body of aerosol generating material 315 and upstream of the cooling element 328, the cooling element 228 being arranged upstream of a filter 320, the filter 320 forming the mouthpiece 319 of the article 301. Thus, the end 307 of component 302 is in abutting relationship with the body of aerosol generating material 315 and the end 310 is in abutting relationship with the cooling element 328. In some embodiments, the cooling element 328 may be omitted and, in such embodiments for example, the end 310 of the component 302 may be in abutting relationship with the filter 320 rather than with the cooling element 328.

[0229] Other than the arrangement of the component within the article 301, the article 301 of the fourth embodiment is substantially identical to the first and second embodiments and so it will be understood that discussion relating to specific features of the first and second embodiments also applies equally to the fourth embodiment.

[0230] Figure 5 is a side-on cross-sectional schematic view of a fifth embodiment of an article 401 according to the present invention. Features of the fifth embodiment corresponding with those of the first embodiment are provided with corresponding reference numerals, increased by 400 as compared to the first embodiment.

[0231] In the fifth embodiment, the article comprises two components 402A and 402B. Each component 402A and 402B may be either the component 2 of the first embodiment or the component 102 of the second embodiment (for example component 402A may be the component 2 of the first embodiment or the component 102 of the second embodiment; and component 402B may be the component 2 of the first embodiment or the componentP10024595

[0232] 131247GB1 - 31 - 102 of the second embodiment) and so discussion relating to the specific features of the components 402A and 402B is omitted as it will be understood that discussion herein relating to the component 2, 102 of the first and second components relates equally to each of the component 402A and 402B of the fifth embodiment.

[0233] In the fourth embodiment, a first component 402A is arranged in the same way as of the third embodiment in that the first component 402A is arranged downstream of a filter 420 and an end 407A of the component 402A is in abutting relationship with a filter 420 and a second component 402B is arranged in the same way as of the fourth embodiment in that the second component 402B is arranged upstream of the filter 420 between a body of aerosol generating material 415 and a cooling element 428. The discussion above relating to the cooling element 228 of the third embodiment applies equally to the cooling element 428 of the fourth embodiment. Thus, the second component 402B is arranged downstream of the body of aerosol generating material 415 and upstream of the cooling element 428, the cooling element 428 being arranged upstream of the filter 420. Thus, the end 407B of component 402B is in abutting relationship with the body of aerosol generating material 415 and the end 410B is in abutting relationship with the cooling element 428. In some embodiments, the cooling element 428 may be omitted and, in such embodiments for example, the end 410B of the component 402B may be in abutting relationship with the filter 420 rather than with the cooling element 428. In other embodiments, the filter 420 may be omitted and, in such embodiments for example, the end 407A of the first component 402A may be in abutting relationship with the cooling element 428. In still other embodiments, the second component 402B may be arranged upstream of the filter 420 but downstream of the cooling element 428.

[0234] As shown in Fig. 7A, the tubular element 4, 104, 204, 304, 404 may in some embodiments be provided as a curved sheet 24 of material having abutting opposing seams or edges 27. The opposing seams 27 may be affixed together, for example by a suitable adhesive. The curved sheet 24 may be initially provided within the article 1, 101, 201, 301, 401 such that the opposing seams 27 are spaced-apart, for example the curved sheet 24 could initially be provided as a flat sheet, and when the component 2, 102, 202, 302, 402A, 402B is wrapped with a wrapper, such as plug wrap 16, 116, 216, 316, 416 or wrapper 17, 117, 217, 317, 417, the spaced-apart seams 27 are caused to be brought together in abutting relationship as the wrapper, e.g. plug wrap 16, 116, 216, 316, 416, or wrapper 17, 117, 217, 317, 417 is wrapped around component 2, 102, 202, 302, 402A, 402B. Thus, the tubular element 4, 104, 204, 304, 404 could initially be provided “open” and mayP10024595

[0235] 131247GB1 - 32 -be “closed” as the wrapper, e.g. plug wrap 16, 116, 216, 316, 416 or wrapper 17, 117, 217, 317, 417, is applied.

[0236] As shown in Fig. 7B, in some embodiments the tubular element 4, 104, 204, 304, 404 may be provided as a curved sheet 24 of material having spaced apart and opposed opposing seams or edges 27. Thus, the tubular element 4, 104, 204, 304, 404 may be an “open” tubular element 4, 104, 204, 304, 404 in that it may have two opposing longitudinal edges or seams 27 which are spaced apart from each other and which are substantially opposed to one another. The curved sheet 24 may be initially provided within the article 1, 101, 201, 301, 401 in a first configuration in which the opposing seams 27 are spaced-apart from each other by a first distance, and when the component 2, 102, 202, 302, 402A, 402B is wrapped with a wrapper, such as plug wrap 16, 116, 216, 316, 416 or wrapper 17, 117, 217, 317, 417, the spaced-apart seams 27 are caused to be brought closer together but remaining spaced apart from each other in a second configuration such that the seams 27 are spaced-apart from each other by a second distance, less than the first distance, as the wrapper, e.g. plug wrap 16, 116, 216, 316, 416 or wrapper 17, 117, 217, 317, 417 is wrapped around the component 2, 102, 202, 302, 402A, 402B.

[0237] As shown in Fig. 7C, in some embodiments the tubular element 4, 104, 204, 304, 404 may be provided as a curved sheet 24 of material having overlapping opposed seams 27 (or longitudinal edges 27). The overlapping seams 27 may be affixed together, for example by a suitable adhesive. The curved sheet 24 may be initially provided within the article 1, 101, 201, 301, 401 such that the opposed seams 27 are spaced-apart, for example the curved sheet 24 could initially be provided as a flat sheet, and when the component 2, 102, 202, 302, 402A, 402B is wrapped with a wrapper, such as plug wrap 16, 116, 216, 316, 416 or wrapper 17, 117, 217, 317, 417, the spaced-apart seams 27 are caused to be brought together in overlapping relationship as the wrapper, e.g. plug wrap 16, 116, 216, 316, 416 or wrapper 17, 117, 217, 317, 417 is wrapped around component 2, 102, 202, 302, 402A, 402B. Thus, the tubular element 4, 104, 204, 304, 404 could initially be provided “open” and may be “closed” as the wrapper, e.g. plug wrap 16, 116, 216, 316, 416 or wrapper 17, 117, 217, 317, 417, is applied.

[0238] While Figs. 7A to 7C show a tubular element 4, 104, 204, 304, 404 having a single curved sheet 24, the tubular elements 4, 104, 204, 304, 404 of each of Figs. 7A to 7C could instead comprise a plurality of stacked curved sheets 24, or a single curved sheet 24 comprising a plurality of different layers 23. Two of such embodiments are shown in Fig.

[0239] 7D and 7E.P10024595

[0240] 131247GB1 - 33 -

[0241] In Fig. 7D the curved sheet 24 of the tubular element 4, 104, 204, 304, 404 comprises a plurality of layers 23 having abutting opposing seams or edges 27 of each layer 23. While in the embodiment shown, the abutting opposing seams 27 are shown radially aligned, in some embodiments, the abutting opposing seams 27 may be radially offset between one or more layers 23, for example the abutting opposing seam 27 of one layer may be radially offset from the abutting opposing seam 27 of another layer 23 (for example from an adjacent layer). In some embodiments, the abutting opposing seams 27 of all layers may be radially offset from each other. In some embodiments, the abutting opposing seams 27 may be radially staggered, and in some such embodiments, the abutting opposing seams 27 may be radially staggered by a constant circumferential distance or angle between layers 23. The opposing seams 27 may be affixed together, for example by a suitable adhesive. The curved sheet 24 may be initially provided within the article 1 , 101 , 201 , 301 , 401 such that the opposing seams 27 of each layer are spaced-apart, for example the curved sheet 24 could initially be provided as a flat sheet, and when the component 2, 102, 202, 302, 402A, 402B is wrapped with a wrapper, such as plug wrap 16, 116, 216, 316, 416 or wrapper 17, 117, 217, 317, 417, the spaced-apart seams 27 of each layer are caused to be brought together in abutting relationship as the wrapper, e.g. plug wrap 16, 116, 216, 316, 416 or wrapper 17, 117, 217, 317, 417 is wrapped around component 2, 102, 202, 302, 402A, 402B. Thus, the tubular element 4, 104, 204, 304, 404 could initially be provided “open” and may be “closed” as the wrapper, e.g. plug wrap 16, 116, 216, 316, 416 or wrapper 17, 117, 217, 317, 417, is applied.

[0242] In Fig. 7E, the curved sheet 24 of the tubular element 4, 104, 204, 304, 404 also comprises a plurality of layers 23 having spaced apart and opposed opposing seams or edges 27. Thus, the tubular element 4, 104, 204, 304, 404 may be an “open” tubular element 4, 104, 204, 304, 404 in that it may have two opposing longitudinal edges or seams 27 of each layer 23 which are spaced apart from each other and which are substantially opposed to one another. The curved sheet 24 may be initially provided within the article 1, 101, 201, 301, 404 in a first configuration in which the opposing seams 27 of each layer 23 are spaced-apart from each other by a first distance, and when the component 2, 102, 202, 302, 402A, 402B is wrapped with a wrapper, such as plug wrap 16, 116, 216, 316, 416 or wrapper 17, 117, 217, 317, 417, the spaced-apart seams 27 of each layer 23 are caused to be brought closer together but remaining spaced apart from each other in a second configuration such that the seams 27 of each layer 23 are spaced-apart from each other by a second distance, less than the first distance, as the wrapper,P10024595

[0243] 131247GB1 - 34 -e.g. plug wrap 16, 116, 216, 316, 416 or wrapper 17, 117, 217, 317, 417, is wrapped around the component 2, 102, 202, 302, 402A, 402B.

[0244] In Fig. 7F, corresponding to Fig. 7C, in a similar way as in Figs. 7D and 7E, the curved sheet 24 thereof could also comprise a plurality of layers 23, of the tubular element 4, 104, 204, 304, 404 thereof could comprise a plurality of stacked sheets 24, such that the curved sheet 24 has overlapping opposed seams or edges 27. The overlapping seams 27 may be affixed together, for example by a suitable adhesive. The curved sheet 24 may be initially provided within the article 1, 101, 201, 301, 401 such that the opposed seams 27 of each layer 23 are spaced-apart, for example the curved sheet 24 could initially be provided as a flat sheet, and when the component 2, 102, 202, 302, 402A, 402B is wrapped with a wrapper, such as plug wrap 16, 116, 216, 316, 416 or wrapper 17, 117, 217, 317, 417, the spaced-apart seams 27 of each layer are caused to be brought together in overlapping relationship as the wrapper, e.g. plug wrap 16, 116, 216, 316, 416 or wrapper 17, 117, 217, 317, 417, is wrapped around component 2, 102, 202, 302, 402A, 402B. Thus, the tubular element 4, 104 could initially be provided “open” and may be “closed” as the wrapper, e.g. plug wrap 16, 116, 216, 316, 416 or wrapper 17, 117, 217, 317, 417 is applied.

[0245] In each of the embodiments of Figs. 7C to 7F, the curved sheet 24 may comprise any number of layers 23 (or stacked sheets), such as two, three, four, five or six layers 23 (or sheets 24). Each layer 23 (or sheet 24) may be made from a cellulose-based material such as paper (such as paper made from wood pulp), cardboard or paper mache or from a reconstituted tobacco sheet or from a regenerated cellulose material such as lyocell or viscose, or from a plastic such as an extruded plastic.

[0246] The layers 23 or stacked sheets 24 may be the same as each other, for example they may have the same thickness or basis weight or be made from the same material, or they may be different to each other in these respects. For example, in embodiments having three layers 23 or stacked sheets 24, the inner sheet 23 or layer 24 may have a basis weight of 60gsm, the next may have a basis weight of 60gsm and the outer sheet 23 or layer 24 may have a basis weight of 80gsm. In other embodiments, one or more layers 24 or stacked sheets 23 may be made from a reconstituted tobacco sheet whereas one or more other layers 24 or stacked sheets 23 may be made from paper, such as from paper formed from wood-pulp.P10024595

[0247] 131247GB1 - 35 - In all embodiments disclosed herein in which the tubular element 4, 104, 204, 304, 404 comprises a plurality of layers, the tubular element 4, 104, 204, 304, 404 may comprise two or more, such as three, four, five, six or seven or more, layers 23 of material. In some embodiments, the tubular element 4, 104, 204, 304, 404 may comprise from 2 to 25 layers, for example from 4 to 25 layers. In particular, it has been found that providing 2 or more layers, for example from 4 to 25 layers, provides increased rigidity of the tubular element 4, 104, 204, 304, 404. Each layer 23 may have a thickness of 50, 60, 70, 80, 85, 90, 100, 200, 300, 400, 500 or 600 of may have a thickness defined by a range between defined by any two of these values. Such thicknesses provide increased rigidity of the tubular element.

[0248] In all embodiments disclosed herein, the tubular element 4, 104, 204, 304, 404 may comprise a mouth-end of the article 1, 101, 201, 301, 401 and in some such embodiments the tubular element 4, 104, 204, 304, 404 may extend to the mouth-end of the article 1, 101, 201, 301, 401. In some embodiments, the tubular element 4, 104, 204, 304, 404 may be, for example direly or indirectly, connected or coupled to an upstream or downstream component of the article 1, 101, 201, 301, 401, which may in some embodiments be a filter or cooling element or cooling tube of the article 1 , 101 , 201 , 301 , 401 , for example a combining plug wrap may connect or couple the tubular element 4, 104, 204, 304, 404 to the upstream or downstream component.

[0249] In embodiments in which the tubular element 4, 104, 204, 304, 404 comprises a plurality of concentrically arranged layers 23, such as those described above in reference to Figures 6A, 7D, 7E and 7F, one or more of the layers 23 may be crimped or corrugated so as to provide longitudinally extending grooves 23A in the crimped or corrugated layer 23, the longitudinally extending grooves 23A being configured to extend longitudinally with respect to the longitudinal axis of the tubular element 4, 104, 204, 304, 404 so as to define a plurality of longitudinally extending air passages 23B. An example of such an embodiment is shown in Figure 8. In some embodiments, the tubular element 4, 104, 204, 304, 404 may comprise a first crimped or corrugated layer 23C and an adjacent inner layer 23D and / or an adjacent outer layer 23E. In some embodiments, the inner layer 23D and / or the outer layer 23E may crimped or corrugated. In other embodiments, at least one and optionally both of the inner 23D and outer layers 23E may be non-crimped or noncorrugated. In Figure 7, both the inner 23D and outer layers 23E are non-crimped or noncorrugated. In some embodiments the crimped or corrugated layer 23C may be arranged so as to be supported by one or both of the inner 23D and outer layers 23E, for example the crimped or corrugated layer 23C may be in abutting contact with at least one of theP10024595

[0250] 131247GB1 - 36 -inner 23D and / or outer layers 23E. In some embodiments, the longitudinally extending air passages 23B are defined by the longitudinally extending grooves 23A of the crimped or corrugated layer 23C and one or both of the inner 23C and outer layers 23E. In some embodiments, the tubular element 4, 104, 204, 304, 404 may comprise a plurality of layers 23 comprising a pattern of alternating crimped and non-crimped / non-corrugated layers 23, such as shown in Figure 8. For example the tubular element 4, 104, 204, 304, 404 may comprise a non-crimped or non-corrugated layer 23D arranged between (and optionally supported by or in abutting contact with) an inner crimped 23F or corrugated layer 23 and / or an outer crimped or corrugated layer 23C. With respect to this aspect, the terms “outer layer” and “inner layer” mean with respect to the layer 23 and are not necessarily an inner-most or outer-most layer of the tubular element 4, 104, 204, 304, 404 although in some embodiments the outer layer and the inner layer may be an outer-most layer or an inner-most layer of the tubular element 4, 104, 204, 304, 404 respectively.

[0251] In embodiments in which the tubular element 4, 104, 204, 304, 404 comprises a sheet of material arranged in a spiral, such as in the embodiment of Figure 6B, the sheet may comprise one or more crimped or corrugated sections so as to provide longitudinally extending grooves in the one or more crimped or corrugated sections, the longitudinally extending grooves being configured to extend longitudinally with respect to the longitudinal axis of the tubular element 4, 104, 204, 304, 404 so as to define a plurality of longitudinally extending air passages when the sheet is arranged in the spiral configuration. In some embodiments, the sheet may comprise a single crimped or corrugated section which may extend along the entire width of the sheet or, in other embodiments, along only a portion of the width of the sheet. In other embodiments, the sheet may comprise a plurality of corrugated or crimped sections and the sheet may further comprise one or more non-corrugated or non-crimped sections. The one or more non-corrugated or non-crimped sections may be arranged adjacent to a respective corrugated or crimped section of the sheet across the width of the sheet. For example, the sheet may comprise a pattern of alternating corrugated or crimped sections and noncrimped or non-corrugated sections so as to define a plurality of longitudinally extending air passages when the sheet is arranged in the spiral configuration.

[0252] Figure 9 illustrates a schematic diagram of an embodiment of an apparatus 50 for manufacturing a component that comprises a crimped sheet of material, the component being for use in a delivery system.P10024595

[0253] 131247GB1 - 37 - In the present example, the component is a body of fibrous material. However, it should be recognised that in alternative embodiments the component may have a different configuration.

[0254] The apparatus 50 comprises a crimping unit 51, which receives a sheet of material 52, such as a sheet of fibrous material 52, and is configured to crimp said sheet of material 52 to from a crimped sheet of material 52a. The crimping unit 51 comprises a pair of crimping rollers 53 through which the sheet of material 52 is fed. The pair of crimping rollers 53 are configured to form a series of crimps along the width of the sheet of material 52 which extend in a direction along the length of the crimped sheet of material 52a.

[0255] Downstream of the crimping unit 51, the apparatus 50 comprises a gathering unit 54, configured to gather the crimped sheet of material 52a to form a continuous rod of material 55. The term “downstream” refers to the direction of travel of the sheet of material 52 as the sheet of material 52 is fed towards the gathering unit 54. The gathering unit 54 may comprise a funnel or cone (not shown) that is configured to gather the crimped sheet of material 52a to form the continuous rod of material 55.

[0256] Additionally, the apparatus 50 comprises a device 56 located between the crimping unit 51 and the gathering unit 54. The device 50 is configured to shape the crimped sheet of material 52a prior to the crimped sheet of material 52a being gathered by the gathering apparatus 54. In the present example, the device 56 comprises a pair of rollers 57 configured to shape the crimped sheet of material 52a as the crimped sheet of material 52a is fed therebetween. The structure of the pair of rollers 57 is described below in relation to Figure 10.

[0257] In a conventional apparatus for forming a component for use in a delivery system from a crimped sheet of material, the sheet of material is gathered immediately after crimping of the sheet of material. In this situation, the gathering of the crimped sheet of material is completely random which results in non-uniform components. For example, when the crimped sheet of material is gathered, a higher percentage of the crimps may be gathered into one area of the component compared to another area which will inevitably comprise a lower percentage of crimps. In other words, the density of the crimped sheet of material in one area of the formed component may be different to another area of the component. This can lead to issues or a lack of performance when a user draws on a delivery system comprising the formed component. Presently, the crimped sheet of material is fed through the device 56 prior to being gathered by the gathering unit 54. The device 56 is configuredP10024595

[0258] 131247GB1 - 38 -to shape the crimped sheet of material 52a prior to gathering such that the gathering, and hence the uniformity of the formed components, can be controlled.

[0259] The apparatus 50 may comprise a feeding unit 58 which receives a supply of a sheet of material 52 and is configured to supply said sheet of material 52 along a conveyance path C. In the present example, the sheet of material 52 is formed from a fibrous material, such as paper. However, it is to be appreciated that in alternative embodiments, the sheet of material 52 may be formed from a different material. For example, in some embodiments the sheet of material 52 is a non-woven sheet of material, such as lyocell or viscose.

[0260] The feeding unit 58 comprises a receiving mechanism 59 which receives a supply of a sheet of material 52. In the present example, the receiving mechanism 59 is configured to receive a bobbin 60 of a paper material. The bobbin 60 supplies a continuous sheet of paper material along the conveyance path C. In an alternative embodiment (not shown) the feeding unit 58 supplies individual sheets of paper material along the conveyance path C. The sheet of material 52 may be fed along the conveyance path C by any suitable mechanism, for example, a plurality of rollers.

[0261] The structure of the pair of rollers 57 of the device 56 will now be described in relation to Figure 10 which illustrates a side elevation partial cross-sectional view of the device 56 according to the present disclosure along the line X-X.

[0262] As seen in Figure 10, there is a gap between the pair of rollers 57 through which the crimped sheet of material 52a is fed. The device 56 is configured such that the distance between the pair of rollers 57 is adjustable to alter the size of the gap. If the distance between the pair of rollers 57 is reduced, the effect of the gap on the shaping of the crimped sheet of material 52a passing through the gap is increased. Alternatively, if the distance between the pair of rollers 57 is increased, the effect of the gap on the shaping of the crimped sheet of material 52a passing through the gap is reduced. It is to be appreciated that the distance between the pair of rollers 57 is less than the height of the crimps formed in the crimped sheet of material 52a otherwise the crimped sheet of material 52a would not be shaped by the pair rollers 57.

[0263] Each roller of the pair of rollers 57 comprises a longitudinal axis A-A about which the pair of rollers 57 rotate. The pair of rollers 57 are positioned such that their respective axes are parallel to each other. Each roller of the pair of rollers 57 comprises a plurality of ridges 61 spaced from one another along the length of each roller, and which extend around theP10024595

[0264] 131247GB1 - 39 -circumference of the roller. Furthermore, each roller of the pair of rollers 57 comprises a plurality of grooves 62 located between each of the plurality of ridges 61 , and which extend around the circumference of the roller. The combination of said ridges 61 and grooves 62 is configured to shape the crimped sheet of material 52a as the crimped sheet of material 52a is fed through the gap. In other words, the pair of rollers 57 are configured to shape the crimped sheet of material 52a such that the crimps in the continuous rod of material 55, and therefore the resulting component, are uniformly distributed.

[0265] As explained above, the pair of crimping rollers 53 of the crimping unit 51 are configured to generate a plurality of crimps along the width of the sheet of material 52 and which extend longitudinally in a direction along the length of the sheet of material 52. By feeding the crimped sheet of material 52a through the pair of rollers 57 prior to gathering of the crimped sheet of material 52a, the uniformity of the crimps in the continuous rod of material 55, and therefore the resulting components, is controlled since the pair of rollers 57 are configured to shape the crimped sheet of material 52a such that a random gathering of the crimped sheet of material 52a is prevented. This may result in a more uniform density of the material in the formed component in any given cross section of said component.

[0266] Each roller of the pair of rollers 57 is configured to rotate about its own longitudinal axis A-A. In the present example, the pair of rollers 57 are configured to rotate due to friction with the crimped sheet of material 52a as the crimped sheet of material 52a is fed along the conveyance path C. However, it is to be appreciated that in other embodiments, one or both of the pair of rollers 57 may be driven by an external device such as a motor.

[0267] The pair of rollers 57 are orientated such that each ridge 61 of one roller is in alignment with a corresponding groove 62 of the other roller. In other words, the pair of rollers 57 are orientated in relation to each other such that the pair of rollers 57 mesh together. It is to be appreciated that the space between the pair of rollers 57 shown in Figure 10 (i.e. the gap) is exaggerated so that the structure of the pair of rollers 57 can be seen more clearly.

[0268] In the example shown in Figure 10, each roller comprises three ridges 61 and two grooves 62. However, it should be recognised that in alternative embodiments, each roller may comprise any number of ridges and grooves along the length of each roller.

[0269] The pair of rollers 57 are configured to shape the crimped sheet of material 52a such that the profile of the crimped sheet of material varies in a direction along the width of theP10024595

[0270] 131247GB1 - 40 -crimped sheet of material 52a. In particular, the pair of rollers 57 are configured to shape the crimped sheet of material 52a such that a plurality of peaks and troughs are formed along the width of the crimped sheet of material 52a. In particular, the plurality of peaks and troughs in the crimped sheet of material 52a form a substantially sinusoidal wave in the crimped sheet of material 52a such that the profile of the crimped sheet of material 52a is shaped without creases or folds in a continuously undulating manner. In other words, the plurality of peaks and troughs in the crimped sheet of material 52a provide the crimped sheet of material 52a with a corrugated form. It has been found that shaping the crimped sheet of material 52a in this manner prior to gathering of the crimped sheet of material 52a improves the uniformity of the gathered sheet of material 52a in the continuous rod of material 55.

[0271] It is envisaged that the person skilled in the art may make various changes to the embodiments specifically described above without departing from the scope of the invention.

Claims

P10024595131247GB1 - 41 - CLAIMS1. A component for an article for use in or as an aerosol delivery system, the component comprising:a body; anda tubular element extending through said body substantially along a common axis; wherein the component comprises a cavity between an end of the body and an end of the tubular element.

2. A component according to claim 1, wherein the cavity has a length between 1 mm and 6 mm.

3. A component according to claim 1 or 2, wherein a proximal end of the tubular element is aligned with a proximal end of the body.

4. A component according to any preceding claim, wherein the body has a wall thickness between 1 mm and 2 mm.

5. A component according to any preceding claim, wherein the tubular element comprises at least one layer of sheet material which is corrugated or crimped so as to provide a plurality of grooves configured to extend in a longitudinal direction of the tubular element, each of the plurality of grooves defining a longitudinally-extending air passage extending through the tubular element.

6. A component for an article for use in or as an aerosol delivery system, the component comprising:a body; anda tubular element extending through said body substantially along a common axis; wherein the body comprises a first longitudinal region circumferentially surrounding the tubular element and a second longitudinal region, andwherein the bulk density of the first longitudinal region is greater than the bulk density of second longitudinal region.

7. A component according to claim 6, wherein the closed pressure drop per unit cross-sectional area of the component is larger across the first longitudinal region than the second longitudinal region, optionally wherein the closed pressure drop per unit cross-P10024595131247GB1 - 42 -sectional area of the component in the first longitudinal region is between 0.03 mmWG / mm2and 7 mmWG / mm2.

8. A component according to claim 6 or 7, wherein the first longitudinal region comprises a first crimping factor and the second longitudinal region comprises a second crimping factor.

9. A component according to any preceding claim, wherein the tubular element is hollow.

10. A component according to any preceding claim, wherein the tubular element is a spiral tubular element.

11. A component according to any one of claims 1 to 9, wherein the tubular element is a coaxial tubular element.

12. A component according to any preceding claim, wherein the component forms a mouthpiece of a single article.

13. A component according to any preceding claim, wherein the tubular element is formed from a cellulose-based material.

14. A component according to any preceding claim, wherein the body is a body of fibrous material and wherein the fibrous material is formed from a cellulose-based material.

15. A component according to claim 13 or 14, wherein the cellulose-based material is paper.

16. A component according to claim 15, wherein said paper is formed from wood-pulp.

17. A component according to claim 13 or 14, wherein the cellulose-based material is a reconstituted tobacco sheet.

18. A component according to claim 13 or 14, wherein the cellulose-based material is a regenerated cellulose material.P10024595131247GB1 - 43 - 19. A component according to claim 18, wherein the regenerated cellulose material is lyocell or viscose.

20. A component according to any preceding claim, wherein the tubular element is secured within the body via adhesive.

21. An article for use in or as an aerosol delivery system, the article comprising a component according to any one of claims 1 to 20.

22. An aerosol delivery system comprising an article according to claim 21.

23. A method for forming a component for an article for use in or as an aerosol delivery system, the method comprising:providing a sheet of material;providing a tubular element; andgathering said sheet of material around said tubular element to form a body of material in which the tubular element extends through said body substantially along a common axis and is circumferentially surrounded by said material, and such that a cavity is formed between the end of the body of material and an end of the tubular element.

24. A method for forming a component for an article for use in or as an aerosol delivery system, the method comprising:providing a sheet of material;providing a tubular element; andgathering said sheet of material around said tubular element to form a body of material comprising a first longitudinal region, in which the tubular element extends through said body substantially along a common axis and is circumferentially surrounded by said material, and a second longitudinal region, and such that the bulk density of the first longitudinal region is greater than the bulk density of second longitudinal region.

25. A method according to claim 23 or 24, wherein the method comprises applying a crimp pattern to the sheet of material, the crimp pattern comprising a series of substantially parallel ridges and grooves.

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