A COMPONENT FOR A DELIVERY SYSTEM AND A METHOD AND APPARATUS FOR MANUFACTURING A COMPONENT FOR A DELIVERY SYSTEM

TECHNICAL FIELD

The present disclosure relates to a component for a delivery system and to a delivery system comprising the same. The present disclosure also relates to a method and apparatus for manufacturing a component for a delivery system.

BACKGROUND

It is known in the art to provide a cigarette with a capsule containing flavorant. During use, the user may break the capsule to release flavorant into smoke flowing through the cigarette. Therefore, the user is able to selectively add flavorant to the smoke.

SUMMARY

In accordance with some embodiments described herein, there is provided a component for a delivery system, the component comprising a body formed from a sheet of material and at least one object held in a space within the body, wherein the sheet material comprises a first internal edge at least partially defining a boundary of the space.

In some embodiments, the first internal edge is a cut edge of the sheet material.

In some embodiments, the sheet material comprises a slit that forms the first internal edge.

In some embodiments, the sheet material comprises an aperture in the sheet material and wherein an edge of the aperture comprises the first internal edge of the sheet material and, in some embodiments in some embodiments, the aperture is substantially rectangular.

In some embodiments, the aperture is a cut-out in the sheet material.

In some embodiments, the first internal edge is continuous. In other embodiments, the first internal edge is intermittent, being interspersed by one or more intermediate portions of the sheet material.

In some embodiments, the sheet material comprises first and second external edges at axial ends of the sheet material, wherein the first internal edge is substantially parallel to the first and/or second external edges.

In some embodiments, the first internal edge is configured to resist the at least one object from moving out of the space.

In some embodiments, the component comprises first and second ends, wherein the first end is a mouth end of the component and the second end is opposite to the first end, wherein the first internal edge is located between the at least one object and the first end of the component or is located between the at least one object and the second end of the component.

In some embodiments, the first internal edge forms a first wall portion.

In some embodiments, the sheet material further comprises a second internal edge at least partially defining a boundary of the space.

In some embodiments, the second end is opposite to the first end of the space.

In some embodiments, the second internal edge has any of the features of the first internal edge described herein.

In some embodiments, the sheet material comprises a slit that forms one of the first and second internal edges and the sheet material comprises an aperture in the sheet material and wherein an edge of the aperture comprises the other one of the first and second internal edges.

In some embodiments, the first and second internal edges are axially spaced by a distance in the range of 3 mm to 50 mm.

In some embodiments, the first and second edges are axially spaced by a distance in the range of 4 to 6 mm.

In some embodiments, the first and second internal edges are spaced by a distance of at least 3 mm and, in some embodiments, at least 5, 10, 15, 20, 25, 30, 35, 40, 45 or 50 mm.

In some embodiments, the first and second internal edges are spaced by a distance of at most 50 mm and, in some embodiments, at most 45, 40, 35, 30, 25, 20, 15, 10, 5 or 3 mm.

In some embodiments, the second internal edge forms a second wall portion.

In some embodiments, the first wall portion faces in a first axial direction and the second wall portion faces in a second axial direction.

In some embodiments, the or each wall portion extends to the central axis of the component.

In some embodiments, the first wall portion extends to the central axis of the component.

Alternatively, or additionally, the second wall portion extends to the central axis of the component.

In some embodiment, the or each wall portion subtends about the entire central axis of the component. In some embodiments, the first wall portion subtends about the entire central axis of the component. Alternatively, or additionally, the second wall portion subtends about the entire central axis of the component.

In some embodiments, the or each wall portion is porous.

In some embodiments, the first wall portion is porous. Alternatively, or additionally, the second wall portion is porous.

In some embodiments, the component comprises at least one further object and, in some embodiments, the at least one further object is axially spaced from the at least one object.

In some embodiments, the at least one further object is received in the space. In another embodiment, the sheet material comprises a second portion that is arranged to define a second space that receives the at least one further object, and wherein the sheet material comprises a third internal edge that forms a third wall portion that at least partially covers a first end of the second space.

In some embodiments, the at least one further object is held in a second space within the body, wherein the sheet material comprises a third internal edge at least partially defining a boundary of the second space.

In some embodiments, the sheet material further comprises a fourth internal edge at least partially defining a boundary of the second space.

In some embodiments, the third internal edge and/or the fourth internal edge has any of the features of the first internal edge described herein.

In some embodiments, the second and third internal edges are separated by a distance in the range of 3 to 50 mm.

In some embodiments, the second and third internal edges are spaced by a distance in the range of 4 to 45 mm, in the range of 4 to 25 mm, or in the range of 4 to 10 mm.

In some embodiments, the second and third internal edges are spaced by a distance of at least 3 mm and, in some embodiments, at least 4, 5, 10, 15, 20, 25, 30, 35, 40, 45 or 50 mm.

In some embodiments, the second and third internal edges are spaced by a distance of at most 50 mm and, in some embodiments, at most 45, 40, 35, 30, 25, 20, 15, 10, 5, 4 or 3 mm.

In some embodiments, the third internal edge forms a third wall portion and/or the fourth internal edge forms a fourth wall portion.

In some embodiments, the second end is opposite to the first end of the second space.

In some embodiments, the first and second internal edges are located at opposite ends of the space.

In some embodiments, the third and fourth internal edges are located at opposite ends of the second space.

In some embodiments, a first portion of the sheet material circumscribes the at least one object. The first and second internal edges may be provided at opposite sides of the first portion. The first portion may be generally cylindrical.

In some embodiments, a second portion of the sheet material circumscribes the at least one further object. The third and fourth internal edges may be provided at opposite sides of the second portion. The second portion may be generally cylindrical.

According to the present disclosure, there is also provided a method of manufacturing a component for a delivery system, the method comprising: providing an assembly comprising at least one object and a sheet material comprising a first internal edge; and, arranging the sheet material into a body such that the body comprises a space that receives the at least one object, wherein the first internal edge at least partially defines a boundary of the space.

In some embodiments, providing the assembly comprises forming the first internal edge in the sheet material.

In some embodiments, forming the first internal edge in the sheet material comprises cutting the sheet material to form the first internal edge and, in some embodiments, cutting through the entire thickness of the sheet material to form the first internal edge.

In some embodiments, forming the first internal edge comprises cutting the sheet material using a knife and/or laser.

In some embodiments, forming the first internal edge comprises forming a slit in the sheet material.

In some embodiments, forming the first internal edge comprises forming an aperture in the sheet material such that an edge of the aperture comprises the first internal edge of the sheet material and, in some embodiments, the aperture is substantially rectangular.

In some embodiments, forming the aperture comprises forming a cut-out in the sheet material.

In some embodiments, providing the assembly comprises providing the sheet material comprising the first internal edge, and then providing the at least one object on the sheet material and, in some embodiments, wherein providing the assembly comprises forming the first internal edge in the sheet material, and then providing the at least one object on the sheet material.

In some embodiments, providing the assembly comprises providing the sheet material, providing the at least one object on the sheet material, and then forming the first internal edge in the sheet material.

In some embodiments, the method comprises crimping the sheet material and, in some embodiments, in some embodiments crimping the sheet material to a crimp depth in the range of 0.1 to 2 mm and, in some embodiments, in the range of 0.1 to 1.5 mm or in the range of 0.2 to 0.7 mm.

In some embodiments, the method comprises crimping the sheet material after the first internal edge has been formed.

In some embodiments, the method comprises crimping the sheet material before the first internal edge is formed.

In some embodiments, the method comprises providing the at least one objects on the sheet material using an object delivery wheel.

In some embodiments, the sheet material of the assembly comprises a second internal edge, and wherein arranging the sheet material into the body comprises arranging the sheet material such that the second internal edge at least partially forms a boundary of the space.

In some embodiments, providing the assembly comprises forming the second internal edge in the sheet material.

In some embodiments, the second internal edge is formed in the same manner as the first internal edge as described herein.

In some embodiments, providing the assembly comprises proving a continuous web of sheet material.

In some embodiments, the method comprises cutting the continuous web of sheet material after arranging the sheet material into a body. In some embodiments, cutting the continuous web of sheet material forms one or more discrete components.

In some embodiments, the method comprises forming a plurality of internal edges in the continuous web at regularly spaced intervals.

The method may comprise forming first, second, third and/or fourth internal edges in the continuous web at regularly spaced intervals.

In some embodiments, the method comprises moving the continuous web along a conveyance path and providing the at least one object at regular intervals as the continuous web moves along the conveyance path.

In some embodiments, the web has a width in the range of 30 to 400 mm, and, in some embodiments, in the range of 40 to 300 mm, in the range of 50 to 280 mm, in the range of 75 to 225 mm, or in the range of 100 to 200 mm.

In some embodiments, the web has a width of at least 30 mm and, in some embodiments, at least 40, 50, 75, 100, 125, 150, 175 or 190 mm.

In some embodiments, the web has a width of at most 400 mm and, in some embodiments, at most 300, 280, 225, 200, 175, 150, 125 or 100 mm.

In some embodiments, arranging the sheet material into the body comprises gathering the sheet material together to form the body.

In some embodiments, the assembly comprises at least one further object.

In some embodiments, the sheet material of the assembly further comprises a third internal edge, wherein arranging the sheet material into the body comprises arranging the sheet material such that the body comprises a second space that receives the at least one further object wherein the third internal edge at least partially defines a boundary of the second space and, in some embodiments, providing the assembly comprises forming the third internal edge in the sheet material.

In some embodiments, the first end of the second space is on the opposite side of the at least one object and at least one further object to the first end of the space.

In some embodiments, the sheet material of the assembly further comprises a fourth internal edge, wherein arranging the sheet material into the body comprises arranging the sheet material such that the fourth internal edge at least partially defines a boundary of the second space and, in some embodiments, providing the assembly comprises forming the fourth internal edge in the sheet material.

In some embodiments, the third internal edge and/or fourth internal edge is formed in the same manner as the first internal edge as described herein.

In some embodiments, a third wall portion is defined by gathering the third internal edge of the sheet material and/or a fourth wall portion is defined by gathering the fourth internal edge of the sheet material.

In some embodiments, the method comprises detecting information indicative of at least one internal edge of the sheet material.

In some embodiments, the method comprises controlling the position that the at least one object is supplied relative to the sheet material based on the information indicative of the at least one internal edge detected by the sensor.

In some embodiments, the method comprises controlling the object supply device based on the on the information indicative of the position of the at least one internal edge detected by the sensor in order to control the position that the at least one object is supplied relative to the sheet material and, in some embodiments, controlling the timing and/or frequency of when the at least one objects are dispensed onto the sheet material.

According to the present disclosure, there is also provided an apparatus for manufacturing a component for a delivery system, the apparatus comprising: an edge forming device configured to form a first internal edge in a sheet material; an object supply device configured to position at least one object on the sheet material; and, a body forming device configured to arrange the sheet material into a body such that the body comprises a space that receives the at least one object, wherein the first internal edge at least partially defines a boundary of the space.

In some embodiments, the edge forming device is configured to form the first internal edge in the sheet material by cutting the sheet material to form the first internal edge and, in some embodiments, is configured to cut through the entire thickness of the sheet material to form the first internal edge.

In some embodiments, the edge forming device comprises one or more knives and/or one or more lasers configured to cut the sheet material.

In some embodiments, the edge forming device is configured to form an aperture in the sheet material such that an edge of the aperture comprises the first internal edge of the sheet material and, in some embodiments, the aperture is substantially rectangular.

In some embodiments, the edge forming device is configured to form a cut-out in the sheet material to form the aperture.

In some embodiments, the edge forming device is configured to form the first internal edge prior to the object supply device positioning the at least one object on the first portion of the sheet material.

In some embodiments, the edge forming device is configured to form the first internal edge after the object supply device has positioned the at least one object on the first portion of the sheet material.

In some embodiments, the apparatus further comprises a crimping device configured to crimp the sheet material and, in some embodiments, the crimping device is configured to crimp the sheet material to a crimp depth in the range of 0.1 to 2 mm and, in some embodiments, in the range of 0.1 to 1.5 mm or in the range of 0.2 to 0.7 mm.

In some embodiments, the crimping device is configured to crimp the sheet material prior to the edge forming device forming the first internal edge or is configured to crimp the sheet material after the edge forming device has formed the first internal edge.

In some embodiments, the object supply device comprises an object delivery wheel.

In some embodiments, the edge forming apparatus is configured to form a second internal edge in the sheet material, and wherein the body forming device is configured to arrange the sheet material into the body such that the second internal edge at least partially defines a boundary of the space.

In some embodiments, the edge forming apparatus is configured to form the second internal edge in the same manner as the first internal edge as described herein.

In some embodiments, the apparatus is configured to feed a continuous web of sheet material along a conveyance path.

In some embodiments, the cutting device is configured to cut the continuous web of sheet material after arranging the sheet material into a body.

In some embodiments, the edge forming device is configured to form a plurality of first internal edges in the continuous web at regularly spaced intervals and/or is configured to form a plurality of second internal edges in the continuous web at regularly spaced intervals.

In some embodiments, the object supply device is configured to provide the at least one object at regular intervals as the continuous web moves along the conveyance path.

In some embodiments, the apparatus comprises a supply of sheet material and, in some embodiments, the supply of sheet material comprises a reel of sheet material.

In some embodiments, the object supply device configured to position at least one further object on the sheet material.

In some embodiments, the edge forming device is configured to form a third internal edge in the sheet material, and wherein the body forming device is configured to arrange the sheet material into the body such that the body comprises a second space that receives the at least one further object, wherein the third internal edge at least partially forms a boundary of the second space.

In some embodiments, the first end of the second space is on the opposite side of the at least one object and at least one further object to the first end of the space.

In some embodiments, the edge forming device is configured to form a fourth internal edge in the sheet material, and wherein the body forming device configured to arrange the sheet material into the body such that the fourth internal edge at least partially defines a boundary of the second space.

In some embodiments, the edge forming apparatus is configured to form the third internal edge and/or fourth internal edge in the same manner as the first internal edge as described herein.

In some embodiments, the body forming device is configured to gather the sheet material to form the body.

In some embodiments, the body forming device is configured to gather the first internal edge of the sheet material to form a first wall portion. In some embodiments, the body forming device is configured to gather the second internal edge of the sheet material to form a second wall portion. In some embodiments, the body forming device is configured to gather the third internal edge of the sheet material to form a third wall portion. In some embodiments, the body forming device is configured to gather the fourth internal edge of the sheet material to form a fourth wall portion.

In some embodiments, the apparatus comprises at least one sensor configured to detect information indicative of at least one internal edge of the sheet material.

In some embodiments, the apparatus further comprises a controller configured to control the position that the at least one object is supplied relative to the sheet material based on the information indicative of the at least one internal edge detected by the sensor.

In some embodiments, the controller controls the object supply device based on the information indicative of the position of the at least one internal edge detected by the sensor in order to control the position that the at least one object is supplied relative to the sheet material and, in some embodiments, is configured to control the timing and/or frequency of when the at least one objects are dispensed onto the sheet material.

In some embodiments, the first internal edge of the component, or the component produced by the method or apparatus, is substantially linear.

In some embodiments, the first internal edge extends substantially perpendicular to a central axis of the component.

In some embodiments, the first internal edge extends in the range of 10% to 95% across the width of the sheet material.

In some embodiments, the first internal edge extends at least 10% across the width of the sheet material and, in some embodiments, at least 20, 30, 40, 50, 60, 70, 80, 90 or 95% across the width of the sheet material.

In some embodiments, the first internal edge extends at most 95% across the width of the sheet material and, optionally, at most 90, 80, 70, 60, 50, 40, 30, 20 or 10% across the width of the sheet material.

In some embodiments, the or each internal edge has a length in the range of 5 mm to 360 mm and in some embodiments, in the range of 5 mm to 270 mm.

In some embodiments, the or each internal edge has a length of at least 5 mm and, in some embodiments, at least 10, 20, 30, 40, 50, 60, 70, 80, 100, 120, 140, 160, 180, 200, 250 or 300 mm. In some embodiments, the first, second, third and/or fourth internal edge has a length of at least 5 mm and, in some embodiments, at least 10, 20, 30, 40, 50, 60, 70, 80, 100, 120, 140, 160, 180, 200, 250 or 300 mm.

In some embodiments, the sheet material comprises first and second external edges that extend substantially parallel to the central axis of the component, wherein the first internal edge is spaced from at least one of the first and second external edges and, in some embodiments, is spaced from both of the first and second external edges.

In some embodiments, the first internal edge is substantially perpendicular to the first and/or second external edges.

In some embodiments, the first internal edge is spaced from the first and/or second external edge by at least 3 mm and, in some embodiments, at least 4, 5, 6, 7, 8 9 or 10 mm.

In some embodiments, the sheet material subtends about the central axis of the component and, in some embodiments, is wrapped around the at least one object.

In some embodiments, the sheet material is crimped and, in some embodiments, the sheet material has a crimp depth in the range of 0.1 to 2 mm and, in some embodiments, in the range of 0.1 to 1 mm or in the range of 0.2 to 0.7 mm.

In some embodiments, the sheet material comprises cellulose.

In some embodiments, the sheet material comprises, consists of, or essentially consists of at least one of: paper; cotton; tobacco, lyocell; polyvinyl alcohol (PVOH), polylactic acid (PLA), poly(ε-caprolactone)(PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT), starch based materials, aliphatic polyester materials, polysaccharide polymers, non-woven material; and/or, biodegradable material.

In some embodiments, the sheet material can comprise shredded sheet material selected from at least one of polyvinyl alcohol (PVOH), polylactic acid (PLA), poly(ε-caprolactone)(PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT), starch based materials, paper, aliphatic polyester materials and polysaccharide polymers.

In some embodiments, the sheet material is a crimped PLA, tobacco or paper sheet material.

In some embodiments, the sheet material does not comprise cellulose acetate.

In some embodiments, the sheet material has a density of at least 0.1 gms/cm3, and, in some embodiments, at least 0.15 gms/cm3.

In some embodiments, the sheet material has a density of at most 1.5 gms/cm3 and, in some embodiments, at most 1.2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.45 or 0.4 gms/cm3.

In some embodiments, the sheet material of the component has a length in the range of 5 to 50 mm and, in some embodiments, in the range of 10 to 30 mm.

In some embodiments, the sheet material of the component has a length of at least 5 mm, and, optionally, at least 10, 15, 20, 25, 30, 35, 40 or 45 mm.

In some embodiments, the sheet material of the component has a length of at most 50 mm, and, optionally, at most 45, 40, 35, 30, 25, 20, 15, 10 or 5 mm.

In some embodiments, the sheet material of the component has a width in the range of 30 to 400 mm and, in some embodiments, in the range of 40 to 300 mm, in the range of 50 to 280 mm, in the range of 75 to 225 mm, or in the range of 100 to 200 mm.

In some embodiments, the sheet material has a width of at least 30 mm and, in some embodiments, at least 40, 50, 75, 100, 125, 150, 175 or 190 mm.

In some embodiments, the sheet material has a width of at most 400 mm and, in some embodiments, at most 300, 280, 225, 200, 175, 150, 125 or 100 mm.

In some embodiments, the sheet material of the component has a thickness in the range of 20 microns to 1000 microns.

In some embodiments, the sheet material has a thickness of at least 20 microns and, in some embodiments, at least 50, 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 microns.

In some embodiments, the sheet material has a thickness of at most 1000 microns and, in some embodiments, at most 900, 800, 700, 600, 500, 400, 300, 200, 100 or 50 microns.

In some embodiments, the sheet material of the component has a basis weight in the range of 20 to 200 gsm and, in some embodiments, in the range of 25 to 70 gsm or in the range of 35 to 65 gsm.

In some embodiments, the body has an axial length in the range of 5 to 50 mm and in some embodiments, in the range of 10 to 30 mm.

In some embodiments, the body has an axial length of at least 5 mm, and, optionally, at least 10, 15, 20, 25, 30, 35, 40 or 45 mm.

In some embodiments, the apparatus comprises a sensor configured to detect information indicative of the at least one internal edge of the sheet material (for example, one or more of the first, second, third and/or fourth internal edges). In some embodiments, the apparatus further comprises a controller configured to control the position of the at least one object based on the information indicative of the at least one internal edge detected by the sensor. In some embodiments, the controller controls the object supply device based on the information indicative of the position of the at least one internal edge detected by the sensor in order to control the position of the at least one object. Additionally, or alternatively, the controller is configured to control the speed that the sheet material is conveyed along the conveyance path in order to control the position of the at least one object.

The sensor may comprise a camera that is configured to detect each integral edge as it passes the camera. Alternatively, or in addition, the sensor may comprise a different type of sensor for example, a light gate, capacitive sensor, magnetic or Hall effect sensor, or ultrasound sensor. In some embodiments, the sensor or one or more further sensors additionally or alternatively detects the second, third and/or fourth internal edges.

The controller may comprise a memory and a processor. The controller may be configured to controls the object supply device based on the on the information indicative of the position of the at least one internal edge detected by the sensor in order to control the position of the at least one object by, for example, controlling the timing and/or frequency of when the at least one objects are dispensed onto the sheet material in order to align each at least one object into a space between adjacent first and second internal edges. For example, in embodiments wherein the object supply device comprises an object insertion wheel, the controller may control the speed that the when rotates by, for example, controlling the speed of a motor of the object insertion wheel. Additionally, or alternatively, the controller may be configured to control the speed that the sheet material is conveyed along the conveyance path in order to control the position of the at least one object, for example, controlling the speed of a belt, drum and/or roller that feeds the sheet material along the conveyance path. Again, this helps to align each at least one object into a space between adjacent first and second internal edges (and/or align each at least one further object into a second space between adjacent third and fourth internal edges).

Controlling the position of the at least one object/at least one further object supplied to the sheet material based on the information indicative of the at least one first, second, third and/or fourth internal edge detected by the sensor helps to ensure that the at least one object/further object does not become misaligned with the sheet material, for example, due to the sheet material stretching or slipping on the conveyance path. However, it should be recognized that in other embodiments the sensor(s) are omitted.

In some embodiments, the body has an axial length of at most 50 mm, and, optionally, at most 45, 40, 35, 30, 25, 20, 15, 10 or 5 mm.

In some embodiments, the at least one object comprises one or more capsules and, in some embodiments, comprises one or more additive capsules.

In some embodiments, the at least one object is breakable upon the application of a force to the body by a user.

In some embodiments, the at least one object comprises a plurality of objects and, in some embodiments, comprises a plurality of capsules, beads or granules.

In some embodiments, the at least one object has a diameter in the range of 0.1 to 8 mm and, in some embodiments, in the range of 0.2 to 4 mm.

In some embodiments, the at least one further object comprises one or more capsules and, in some embodiments, comprises one or more additive capsules.

In some embodiments, the sheet material comprises a coating, and in some embodiments, the coating comprises an aerosol-modifying agent.

The aerosol-modifying agent may comprise a flavorant.

According to the present disclosure, there is also provided a component manufactured according to the method described herein and/or manufactured by the apparatus described herein.

According to the present disclosure, there is provided a rod configured to be cut at least once to form a plurality of components as described herein. Each component may be incorporated into a separate delivery system.

In some embodiments, the rod is at least two, three, four, five, six, seven, eight, nine or ten times the length of the individual component such that the rod is configured to be cut to form at least two, three, four, five, six, seven, eight, nine or ten components. That is, the rod is a multi-length base rod. In some embodiments, the rod comprises at least two, three, four, five, six, seven, eight, nine or ten objects each in a respective space. In some embodiments, the rod further comprises at least two, three, four, five, six, seven, eight, nine or ten further objects each in a respective second space. In some embodiments, the rod is between 60 to 180 mm in length and comprises at least six spaces that each receives a respective at least one object.

According to the present disclosure, there is also provided a delivery system comprising the component described herein. In some embodiments, the delivery system comprises an aerosol provision system and, in some embodiments, the aerosol provision system is a combustible aerosol provision system or a non-combustible aerosol provision system.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a delivery system comprising a component according to an embodiment.

FIG. 2 is a cross-sectional side view of the delivery system of FIG. 1.

FIG. 3 is a cross-sectional side view of the component of FIG. 1.

FIG. 4 is an end view of the component of FIG. 1.

FIG. 5 is a top view of a sheet material of the component of FIG. 1, with the sheet material laid flat and prior to the sheet material being formed into a body of the component.

FIG. 6 is a cross-sectional side view of a capsule of the delivery system of FIG. 1.

FIG. 7 is a cross sectional side view of a component for a delivery system, shown for information purposes.

FIG. 8 is a top view of a sheet material of another embodiment of a component for a delivery system, prior to the sheet material being formed into a body of the component.

FIG. 9 is a cross-sectional side view of a component for a delivery system of another embodiment.

FIG. 10 is a top view of a sheet material of the component of FIG. 9, prior to the sheet material being formed into a body of the component.

FIG. 11 is a block diagram showing an embodiment of a method of manufacturing a component for a delivery system.

FIG. 12 shows an embodiment of a continuous web of sheet material with capsules thereon, wherein the web is being passed along a conveyance path.

FIG. 13 shows an embodiment of an apparatus for manufacturing a component for a delivery system.

FIG. 14 is a schematic view of a controller connected to a sensor and object supply device of an apparatus of an embodiment.

FIG. 15 is a schematic side view of a base rod of an embodiment.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring now to FIGS. 1 to 6, an embodiment of a delivery system 1 is shown.

In the present embodiment, the delivery system 1 is a combustible aerosol provision system 1. The combustible aerosol provision system 1 comprises a tobacco rod 2 and a component 3 for a delivery system which, in the present example, is a component 3 for a combustible aerosol provision system 1. However, in alternative embodiments (not shown), the delivery system 1 is of an arrangement other than a combustible aerosol provision system 1. For example, the delivery system 1 may be a non-combustible aerosol provision system (not shown) or an aerosol-free delivery system (not shown).

An outer wrap 4 circumscribes the component 3 and a portion of the tobacco rod 2. The outer wrap 4 comprises a tipping paper 4 that attaches the tobacco rod 2 to the component 3. The tobacco rod 2 comprises a column of smokeable material 5 circumscribed by a rod wrapper 6.

The component 3 comprises a sheet material 10 that is arranged into a body 7 such that the body 7 comprises a space 8 within the body 7 that receives at least one object 11. In the present example, the at least one object 11 is an aerosol-modifying agent release component 11 and, in particular, is a breakable capsule 11. In another embodiment (not shown), the at least one object may comprise a plurality of capsules or one or more other objects.

The body 7 is generally cylindrical. However, a skilled person will recognize that other shapes are possible. In the present example, the body 7 forms a plug 7.

In the present embodiment, the component 3 is a filter 3. However, it should be recognized that in other embodiments the component 3 may be provided merely to act as a carrier or support for the at least one object without substantially filtering the inhalant of the delivery system 1.

In the present embodiment, the sheet material 10 comprises paper. However, it should be recognized that in other embodiments the sheet material 10 comprises a different material, for example, cotton; tobacco, lyocell; polyvinyl alcohol (PVOH), polylactic acid (PLA), poly(ε-caprolactone)(PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT), starch based materials, aliphatic polyester materials, polysaccharide polymers, and/or woven or non-woven material. The sheet material 10 may be biodegradable. In some embodiments, the sheet material comprises cellulose. In one embodiment, the sheet material 10 may be non-plastic or may be plastic. In some embodiments, the sheet material 10 does not comprise cellulose acetate.

In some embodiments, the sheet material 10 comprises shredded sheet material selected from at least one of tobacco, polyvinyl alcohol (PVOH), polylactic acid (PLA), poly(ε-caprolactone)(PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT), starch based materials, paper, aliphatic polyester materials and polysaccharide polymers.

In some embodiments, the sheet material 10 comprises a fiber that is woven, or otherwise formed, into a sheet.

In some embodiments, the sheet material 10 is a crimped PLA, tobacco or paper sheet material.

In some embodiments, the sheet material 10 does not comprise cellulose acetate.

In some embodiments, the sheet material 10 has a density of at least 0.1 gms/cm3, and, in some embodiments, at least 0.15 gms/cm3.

In some embodiments, the sheet material 10 has a density of at most 1.5 gms/cm3 and, in some embodiments, at most 1.2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.45 or 0.4 gms/cm3.

The sheet material 10, for example, paper, may have a thickness of at least 20 micrometers (μm). In some embodiments, the sheet material 10 has a thickness of at least 50, 100, 200, 300, 400, 500, 600, 700, 800, 900 or 1000 microns.

The sheet material 10, for example, paper, may have a thickness of at most 1000 micrometers (μm). In some embodiments, the sheet material 10 has a thickness of at most 900, 800, 700, 600, 500, 400, 300, 200, 100 or 50 microns.

In some embodiments, the sheet material 10 has a thickness in the range of 20 to 1000 micrometers.

The sheet material 10, for example, paper, may have a basis weight of at least 20 GSM. In some embodiments, the sheet material 10 has a basis weight of at least 20, 25, 30 or 35 GSM.

The sheet material 10, for example, paper, may have a basis weight of at most 200 GSM. In some embodiments, the sheet material 10 has a basis weight of at most 150, 100, 70, 65 or 50 GSM.

The sheet material 10, for example, paper, may have a basis weight in the range of 20 to 200 GSM. In some embodiments, the sheet material 10 has a basis weight in the range of 25 to 70 GSM or in the range of 35 to 65 gsm.

The sheet material 10 comprises first and second external edges 10A, 10B that are at opposite ends of the sheet material 10. The first and second external edges 10A, 10B form first and second axial ends 7A, 7B of the body 7 when the sheet material 10 is arranged to form the body 7.

The sheet material 10 has a length (shown by arrow ‘X’ in FIGS. 2 and 5) that is measured between the first and second ends 10A, 10B. The length X of the sheet material 10 corresponds to the axial length X of the body 7.

The sheet material 10 may have a length X of in the range of 5 to 50 mm and, in some embodiments, in the range of 10 to 30 mm. However, in other embodiments the sheet material 10 has a different length X.

In some embodiments, the sheet material 10 of the component 3 has a length X of at least 5 mm, and, optionally, at least 10, 15, 20, 25, 30, 35, 40 or 45 mm.

In some embodiments, the sheet material 10 of the component 3 has a length X of at most 50 mm, and, optionally, at most 45, 40, 35, 30, 25, 20, 15, 10 or 5 mm.

In the present embodiment, the sheet material 10 is gathered together such that the body 7 is of a ‘crepe filter’ configuration. The sheet material 10 may filter gas flow as it passes through the body 7. In some embodiments, the sheet material 10 comprises pager that is gathered together such that the body 7 is a ‘paper filter’.

In some embodiments (not shown), the component 3 further comprises one or more segments (not shown) upstream and/or downstream of the body 7. For example, a plug of filtration material (not shown), for example, cellulose acetate, upstream and/or downstream of the body 7. In some embodiments, the component 3 comprises a tube filter (not shown) downstream of the body 7. The tube filter may form an end of the component 3 and may comprise an annular portion of filtration material, for example, an annular portion of cellulose acetate.

The body 7 has an axial length (depicted by arrow ‘X’ in FIG. 2) in the range of 5 to 50 mm and, in some embodiments, in the range of 10 to 30 mm. However, in other embodiments the body 7 has a different axial length X.

In some embodiments, the component 3 has an axial length X of at least 5 mm, and, optionally, at least 10, 15, 20, 25, 30, 35, 40 or 45 mm.

In some embodiments, the component 3 has an axial length X of at most 50 mm, and, optionally, at most 45, 40, 35, 30, 25, 20, 15, 10 or 5 mm.

In some embodiments, the sheet material 10 is gathered and/or folded to form the body 7 such that the at least one object 11 is retained within a space 8 within the body 7. In some embodiments, the sheet material 10 may be formed into the body 7 using a CU-20 machine manufactured by Decouflé™. However, a skilled person will recognize that other apparatus may be used to arrange the sheet material 10 into a plug, for example, apparatus that are known for the manufacture of ‘paper filters’ and ‘crepe filters’.

In the present example, the sheet material 10 is crimped prior to being arranged into the body 7. For instance, the sheet material 10 may be passed through a pair of crimping rollers. The crimping may make it easier to gather the sheet material 10 to form the body 7. The crimping may also increase the length of sheet material 10 that can be used to form a body 7 of a particular volume. Increasing the amount of sheet material 10 in the body 7 may increase the surface area of sheet material 10 that is in contact with aerosol passing through the body 7 and thus increase the amount of moisture absorbed from the aerosol by the sheet material 10.

In some embodiments, the sheet material 10 is crimped to a crimp depth of at least 0.1 mm and, in some embodiments, at least 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.5 mm, or 2 mm.

In some embodiments, the sheet material is crimped to a crimp depth of at most 2 mm and, in some embodiments, at most 1.5 mm, 1 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, 0.4 mm, 0.3 mm, 0.2 mm or 0.1 mm.

In some embodiments, the sheet material 10 is crimped to a crimp depth in the range of 0.1 mm to 2 mm and, in some embodiments, in the range of 0.1 to 1 mm or in the range of 0.2 mm to 0.7 mm.

The crimp depth (also known as “crimping factor”) refers to the depth of the grooves the crimping forms in the sheet material 10. That is, crimping the sheet material 10 produces a plurality of troughs in the sheet material 10 when viewed from a first side of the sheet material 10, wherein the crimp depth is the depth of the troughs. The crimping may form a Zig-Zag formation or another shape. In some embodiments, adjacent grooves of the crimped sheet material 10 are spaced by a distance in the range of 0.1 to 3 mm and, in some embodiments, in the range of 0.2 to 2 mm. In some embodiments, adjacent grooves of the crimped sheet material 10 are spaced by a distance of at least 0.1 mm and, in some embodiments, at least, 0.2, 0.5, 0.7, 1, 1.5, 2, 2.5 or 3 mm. In some embodiments, adjacent grooves of the crimped sheet material 10 are spaced by a distance of at most 3 mm, and in some embodiments, at most, 2.5, 2, 1, 1.5, 0.7, 0.5, 0.2 or 0.1 mm.

In some embodiments, the sheet material 10 is heated as it is crimped. For example, the sheet material 10 may be passed between crimping rollers, wherein one or both of the crimping rollers is heated.

The at least one object 11, for example one or more capsules 11, may be applied to the sheet material 10 prior to, or at the same time as, the sheet material 10 being formed into the body 7. In some embodiments, the at least one object 11 is attached to the sheet material 10, for example, by an adhesive (not shown) that may be sprayed on to the sheet material 10 and/or the at least one objects 11 or may be applied to the sheet material 10 or object(s) 11 using a brush or roller. In another embodiment (not shown), the at least one object 11 is attached to the sheet material 10 using static electricity, by statically charging the sheet material 10 and/or at least one object 11. However, it should be recognized that in other embodiments, the at least one object 11 is not attached to the sheet material 10.

In some embodiments, the at least one object 11 comprises one or more aerosol-modifying agent release components 11, which may be capsules 11.

A cross-sectional side view of one of the plurality of capsules 11 is shown in FIG. 6. Each capsule 11 comprises an outer shell 13 and an inner core 14.

The shell 13 of each capsule 11 may be solid at room temperature. The shell 13 may comprise, consist of, or essentially consist of, alginate. However, it should be recognized that in alternative embodiments the shell 13 is formed from a different material. For example, the shell 13 may alternatively comprise, consist of, or essentially consist of, gelatin, carrageenans or pectins. The shell 13 may comprise, consist of, or essentially consist of, one or more of alginate, gelatin, carrageenans or pectins.

The inner core 14 of each capsule 11 comprises, consist of, or essentially consists of, an aerosol-modifying agent, for example, an additive such as a flavorant configured to impart a flavor to gas flowing through the body 7 when the agent is exposed to the gas. However, it should be recognized that in other embodiments, the aerosol-modifying agent may alternatively or additionally comprise a different type of additive such as a humectant. In the present embodiment, the inner core 14 is a liquid. However, in other embodiments (not shown) the inner core 14 may comprise a solid, for example, a powder.

The shell 13 of each capsule 11 may be impermeable, or substantially impermeable, to the aerosol-modifying agent of the core 14. Therefore, the shell 13 initially prevents the aerosol-modifying agent of the core 14 from escaping from the capsule 11 and being entrained in gas flowing through the body 7. When the user desires to entrain the aerosol-modifying agent in the gas, for example, to flavor the gas in embodiments wherein the agent is a flavorant, the shells 13 of the capsules 11 are ruptured such that the agent can be entrained in the gas.

In some embodiments (not shown), the capsule 11 further comprises a carrier material. The carrier material may comprise, for example, gelatin.

The object 11 may instead or additionally comprise a different kind of object, for example, a filtration material such as beads or granules.

The aerosol-modifying agent component 11 allows for the user to control whether aerosol-modifying agent is introduced into the gas flow passing through the body 7. Initially, the shell 13 of each capsule 11 is intact and therefore no agent from the core 14 is introduced into the gas flow. When the user desires to introduce aerosol-modifying agent, he or she applies an external force to the component 3 to rupture the shells 13 of the capsules 11. In one example, the user holds the component 3 firmly and rolls the component 3 between his or her fingers.

In some embodiments the body 7 is circumscribed by a wrapper 16, for example, a paper wrapper, that forms a plug wrap 16. The plug wrap 16 may help to retain the sheet material 10 in the form of the body 7, for example, by preventing the sheet material 10 from unfolding.

The tipping paper 4 comprises one or more indicators 19 that provide a visual indication to the user of where the external force should be applied to the component 3 to release the aerosol-modifying agent. For example, the indicators 19 may indicate where the component 3 should be held and rolled between the fingers to release the agent. The indicators 19 may, for example, be printed onto the tipping paper 4 or may comprise a label that is adhered to the tipping paper 4. The indicators 19 may overlie the body 10 of filter material.

Optionally, the plug wrap 16 and tipping paper 4 are deformable such that, in use, the user applies an external force to deform the tipping paper 4 and body 7 radially inwardly to break the aerosol-modifying agent release component 11. In the example described above, the user grips the wall and rolls the component 3 between the fingers such that capsules 11 to release the aerosol-modifying agent therefrom. In embodiments wherein the plug wrap 16 is omitted, the tipping paper 4 is deformed. In embodiments wherein the tipping paper 4 is omitted, the plug wrap 16 is deformed. In some embodiments, the wall comprises a further sheet of material (not shown) in addition to the tipping paper 4 and/or plug wrap 16. In other embodiments (not shown), neither a tipping paper 4 or plug wrap 16 circumscribe the body 7 (or the whole of the body 7) and so the user applies a force directly to the body 7.

The plug wrap 16 comprises a paper layer 17 and a sealing layer 18. The sealing layer 18 is impermeable, or substantially impermeable, to the aerosol-modifying agent of the capsules 11. Therefore, when the capsules 11 are broken to entrain aerosol-modifying agent in the gas flow, the sealing layer 18 prevents the aerosol-modifying agent from seeping through the plug wrap 16. This is advantageous because the combustible aerosol provision system 1 is usually held between the user's fingers in the region of the component 3 and thus the sealing layer 18 helps to prevent the aerosol-modifying agent from coming into contact with the user's fingers.

In the present embodiment, the sealing layer 18 is in the form of a coating 18 provided on the paper layer 17. For example, the coating 18 may comprise Ethyl cellulose. In an alternative embodiment (not shown), the sealing layer 18 comprises a layer of material, for example, plastic sheet or foil, that is bonded to the paper layer 17 by an adhesive. In some embodiments, the sealing layer 18 is an oil repellent.

In one embodiment, the sealing layer 18 is provided on the inner surface of the paper layer 17 such that the paper layer 17 is disposed between the sealing layer 18 and the tipping paper 4. Alternatively, the sealing layer 18 may be provided on the outer surface of the paper layer 17 such that the sealing layer 18 is disposed between the paper layer 17 and the tipping paper 4.

In one embodiment, the sealing layer 18 is provided over the entire inner and/or outer surface of the paper layer 17. However, in an alternative embodiment, the sealing layer 18 is only provided over a portion of the inner and/or outer surface of the paper layer 17, for instance, only over the portion of the paper layer 17 that circumscribes the body 7.

The plug wrap 16 is configured to provide structural support to the component 3 to help maintain the structural integrity of the component 3 during rolling of the component 3 to release the aerosol-modifying agent. In some embodiments, the plug wrap 16 has a basis weight of at least 20 gsm, and, in some embodiments, at least 60 gsm, and in some embodiments of at least 80 gsm. This basis weight provides the plug wrap 16 with increased rigidity in order to help maintain the structural integrity of the component 3 during rolling of the component 3. In some embodiments the basis weight of the plug wrap 16 is in the range of 20 to 110 gsm, 60 to 110 gsm and, in some embodiments, is in the range of 80 to 110 gsm. The basis weight of the plug wrap 16 may be in the range of 20 to 100 gsm, in the range of 60 to 100 gsm, or in the range of 80 to 100 gsm.

In one embodiment, the rigidity of the plug wrap 16 is achieved by manufacturing the paper layer 17 from paper having a thickness of at least 30 micrometers, and, in some embodiments, at least 35 micrometers, and in some embodiments, at least 50, 60, 70, 80, 90 or 100 micrometers. In some embodiments, the paper layer 17 has a thickness in the range of 30 to 137 micrometers and, in some embodiments, in the range of 35 to 137 micrometers. The rigidity of the plug wrap 16 helps the component 3 to return to its original shape once the user has finished rolling the component 3 to release the aerosol-modifying agent.

In one embodiment (not shown), the component 3 is a cavity filter. The tipping paper 4, plug wrap 16, or a further wrap (not shown) may extend past the mouth end of the body 7 to form a space that comprises a void (not shown).

In some embodiments, the at least one object 11, for example, the capsule 11, has a diameter in the range of 0.1 to 8 mm and, in some embodiments, in the range of 0.2 to 4 mm.

In some embodiments, the at least one object 11, for example, the capsule 11, has a diameter of at least 0.1 mm and, in some embodiments, at least 0.2, 0.4, 0.6, 0.8, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5 or 8 mm.

In some embodiments, the at least one object, 11 for example, the capsule 11, has a particle size of at least 0.1 mm and, in some embodiments, at least 0.2, 0.4, 0.6, 0.8, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5 or 8 mm. The term ‘particle size’ refers to particle size when measured by sieving.

In some embodiments, the at least one object 11 comprises a plurality of objects, for example, a plurality of capsules, beads and/or granules. In other embodiments, a single object 11, for example, a single capsule 11, is provided in the space 8.

In the above described embodiment, the or each capsule 11 comprises an outer shell 13 and an inner core 14. However, in alternative embodiments (not shown), the outer shell 13 is omitted.

In one embodiment (not shown), the or each capsule 11 comprises a body of material that comprises the aerosol-modifying agent, wherein no shell surrounds the body. In one embodiment (not shown), the or each capsule 11 comprises a solid material that breaks down, for example, forming a powder, when an external force is applied to the component 3 to allow the aerosol-modifying agent to be entrained in gas flowing through the body 7.

The sheet material 10 comprises the first and second external edges 10A, 10B and further comprises third and fourth external edges 10C, 10D that are substantially parallel to each other and substantially perpendicular to the first and second external edges 10A, 10B. The third and fourth external edges 10C, 10D are substantially parallel to the central axis A-A of the component 3 when the sheet material 10 is arranged to form the body 7. The sheet material 10 may be generally rectangular.

The sheet material 10 comprises first and second slits 20, 21.

The first slit 20 extends in a direction generally perpendicular to the third and fourth external edges 10C, 10D of the sheet material 10. The first slit 20 extends in a direction generally parallel to the first and second external edges 10A, 10B.

The sheet material 10 has a width (shown by arrow ‘W’ in FIG. 5) that is measured between the third and fourth external edges 10C, 10D of the sheet material 10.

In some embodiments, the sheet material 10 has a width W in the range of 30 to 400 mm and, in some embodiments, in the range of 40 to 300 mm, in the range of 50 to 280 mm, in the range of 75 to 225 mm or in the range of 100 to 200 mm, when measured with the sheet material 10 laid flat.

In some embodiments, the sheet material 10 has a width W of at least 30 mm and, in some embodiments, at least 40, 50, 75, 100, 125, 150, 175 or 190 mm, when measured with the sheet material 10 laid flat.

In some embodiments, the sheet material 10 has a width W of at most 400 mm and, in some embodiments, at most 300, 280, 250, 225, 200, 175, 150, 125 or 100 mm, when measured with the sheet material 10 laid flat.

In some embodiments, the first slit 20 is spaced from the third and fourth external edges 10C, 10D, in other words the first slit 20 does not extend across the entire width W of the sheet material 10.

The second slit 21 extends in a direction generally perpendicular to third and fourth external edges 10C, 10D of the sheet material 10. The second slit 21 extends in a direction generally parallel to the first and second external edges 10A, 10B.

In some embodiments, the second slit 21 is spaced from the third and fourth external edges 10C, 10D, in other words the second slit 21 does not extend across the entire width (shown by arrow ‘W’ in FIG. 5) of the sheet material 10.

The first slit 20 forms a first internal edge 22 of the sheet material 10 and the second slit 21 forms a second internal edge 23 of the sheet material 10. That is, when the sheet material 10 is gathered to form the body 7, the first slit 20 allows for the sheet material 10 on a first side (for example, a downstream side) of the at least one object 11 to be gathered together such that the first internal edge 22 at least partially defines a boundary of the space 8 that contains the at least one object 11. The first internal edge may thus form a first wall portion 22A. Similarly, when the sheet material 10 is gathered to form the body 7, the second slit 21 allows for the sheet material 10 on a second side (for example, a upstream side) of the at least one object 11 to be gathered together such that the second internal edge 23 at least partially defines a boundary of the space 8 that contains the at least one object 11. The second internal edge 23 may thus form a second wall portion 23A.

The first internal edge 22 therefore allows for the sheet material 10 to be gathered together on one side of the space 8 to at least partially, or fully, define a boundary of the space 8 to prevent the at least one object 11 from moving out of a first end of the space 8. This improves the positioning of the at least one object 11 within the component 3. In addition, since the sheet material 10 is gathered together, it helps to obscure the at least one object 11 in the space 8, when viewed from a first end 3A of the component 3, which may improve the aesthetics of the component 3. Advantageously, the first internal edge 22 achieves these benefits without require a separate component, for example, a cellulose acetate plug, to be provided downstream of the object 11 or downstream of the body 7.

The second internal edge 23 allows for the sheet material 10 to be gathered together on one side of the space 8 to at least partially, or fully, define a boundary of the space 8 to prevent the at least one object 11 from moving out of a second end of the space 8, which also improves the positioning of the at least one object 11 within the component 3. In addition, since the sheet material 10 is gathered together, it helps to obscure the at least one object 11 in the space 8, when viewed from a second end 3B of the component 3, to improve the aesthetics of the component 3. Advantageously, the second internal edge 23 achieves these benefits without require a separate component, for example, a cellulose acetate plug, to be provided upstream of the object 11 or upstream of the body 7.

A component 303 that comprises a body 307 formed from a sheet of material 310 and at least one object 311 held in a space 308 within the body 307, wherein the sheet material 310 does not comprise first or second internal edges is shown in FIG. 7, for information purposes. It has been found that the space 308 tends to form a continuous cylinder that extends all of the way from the first end 303A to the second end 303B of the component 303 when the sheet material 10 is wrapped or gathered around the object 11. This is due to the inherent stiffness of the sheet material 310 and because the sheet material 310 does not comprise any internal edges that facilitate the sheet material 310 gathering together to at least partially form a boundary of the space 308. Thus, the object 311 within the space 308 may move along the continuous cylindrical space 308 towards the first or second end 303A, 303B of the component 303, or may require excessive adhesive to keep the object 311 in position during transport and use of the component 303. Moreover, the entire object 311 will be visible when viewed from the first or second end 303A, 303B of the component 303. In contrast, the first and second internal edges 22, 23 of the sheet material 10 of the embodiment of FIGS. 1 to 6 promotes the sheet material 10 around the space being gathered together to at least partially define a boundary of the space 8.

In some embodiments, for example, the embodiment of FIGS. 1 to 6, the first and second internal edges 22, 23 are axially spaced by a distance in the range of 3 mm to 50 mm. In some embodiments, the first and second internal edges 22, 23 are spaced by a distance of at least 3 mm and, in some embodiments, at least 5, 10, 15, 20, 25, 30, 35, 40, 45 or 50 mm. In some embodiments, the first and second internal edges 22, 23 are spaced by a distance of at most 50 mm and, in some embodiments, at most 45, 40, 35, 30, 25, 20, 15, 10, 5 or 3 mm.

In some embodiments, at least a portion of the first and second slits 20, 21 extends linearly and, in some embodiments, the entire first and/or second slit 20, 21 extends linearly. However, it should be recognized that in other embodiments the first and/or second slit 20, 21 may be at least partially or entirely non-linear, for example, being curved. In one embodiment (not shown), the first and/or second external edges follow a zig-zag path.

In some embodiments, the first internal edge 22 is continuous. In other embodiments, the first internal edge 23 is intermittent, being interspersed by one or more intermediate portions of the sheet material 10 that connect adjacent portions of the first internal edge 23. Similarly, the second internal edge 23 may be continuous or intermittent.

The first and second internal edges 22, 23 may be provided on opposite sides of the at least one object 11 and may face in opposite directions.

In the present example, the second internal edge 23 is located between the at least one object 11 and the first end 3B of the component 3. In other embodiments, the second internal edge 23 is located between the at least one object 11 and the first end 3A of the component 3.

In some embodiments, the first or second internal edge 22, 23 may be omitted. The remaining internal edge 22, 23 will still at least partially define a boundary of the space 8 and thus help to improve positioning of the at least one object 11 within the component 3 and help to at least partially obscure the component 3.

In some embodiments, the first internal edge 22 is configured such that when the sheet material 10 is gathered together to form the body 7, the sheet material 10 on the opposite side of the first internal edge 22 to the at least one object 11 will extend all of the way to the central axis A-A of the component 3 (as shown in FIG. 4). Similarly, the second internal edge 23 is configured such that when the sheet material 10 is gathered together to form the body 7, the sheet material 10 on the opposite side of the second internal edge 23 to the at least one object 11 will extend all of the way to the central axis A-A of the component 3. However, it should be recognized that in other embodiments, the first and/or second internal edge 22, 23 is configured such that the sheet material 10 does not extend all of the way to the central axis A-A and instead may form an annular wall portion (not shown). The annular wall portion will still at least partially define a boundary of the space 8 and thus help to improve positioning of the at least one object 11 within the component 3 and the aesthetics of the component 3, providing that the space within the annular portion is of smaller diameter than the space 8 containing the at least one object 11.

In some embodiment, the first and/or second wall portion 22A, 23A subtends about the entire central axis A-A of the component 3. In some embodiments, the first wall portion 22A subtends about the entire central axis A-A of the component 3. Alternatively, or additionally, the second wall portion 23A subtends about the entire central axis A-A of the component 3.

In some embodiments, the first and/or second wall portion 22A, 22B is porous. In the present example, the inhalant is able to flow through the layers of gathered sheet material 10 of the first wall portion 22A and through the layers of gathered sheet material 10 of the second wall portion 23A.

In some embodiments, a first portion 9 of the sheet material 10 circumscribes the at least one object 11. The first and second internal edges 22, 23 may be provided at opposite sides of the first portion 9 of the sheet material 10. The first portion 9 may be generally tubular and may be cylindrical. The space 8 is formed within the first portion 9 of the sheet material 10.

In some embodiments, the first and/or second internal edge 22, 23 extends in the range of 10% to 95% across the width W of the sheet material 10. For instance, if the sheet material 10 has a width W of 150 mm, when laid flat, then the first internal edge 22 extends in the range of 15 to 142.5 mm across the width W of the sheet material 10 and/or the second internal edge 23 extends in the range of 15 to 142.5 mm across the width W of the sheet material 10.

In some embodiments, the first and/or second internal edge 22, 23 extends at least 10% across the width W of the sheet material 10 and, in some embodiments, at least 20, 30, 40, 50, 60, 70, 80, 90 or 95% across the width W of the sheet material 10.

In some embodiments, the first and/or second internal edge 22, 23 extends at most 95% across the width W of the sheet material 10 and, optionally, at most 90, 80, 70, 60, 50, 40, 30, 20 or 10% across the width W of the sheet material 10.

In some embodiments, the first internal edge 22 has a length L1 in the range of 5 mm to 360 mm and, in some embodiments, in the range of 5 mm to 270 mm, when the sheet material 10 is laid flat.

In some embodiments, the first internal edge 22 has a length L1 of at least 5 mm and, in some embodiments, at least 10, 20, 30, 40, 50, 60, 70, 80, 100, 120, 140, 160, 180, 200, 250, 270 or 300 mm, when the sheet material 10 is laid flat.

In some embodiments, the second internal edge 23 has a length L2 in the range of 5 mm to 360 mm, when the sheet material 10 is laid flat, and, in some embodiments, in the range of 5 to 270 mm.

In some embodiments, the second internal edge 23 has a length L2 of at least 5 mm and, in some embodiments, at least 10, 20, 30, 40, 50, 60, 70, 80, 100, 120, 140, 160, 180, 200, 250, 270 or 300 mm, when the sheet material 10 is laid flat.

In some embodiments, the first and/or second internal edge 22, 23 is spaced from at least one of the third and fourth external edges 10C, 10D of the sheet material 10. In the present example, the first and/or second internal edge 22, 23 is spaced from both of the third and fourth external edges 10C, 10D of the sheet material 10. This makes the sheet material 10 easier to handle during manufacture of the component 3 because otherwise if the first and/or second internal edge 22, 23 extended to the third or fourth external edge 10C, 10D then a flap of sheet material 10 would be created that would be more difficult to maintain in correct alignment. However, it should be recognized that in other embodiments the first and/or second internal edge 22, 23 extends to the third and/or fourth external edge 10C, 10D.

In some embodiments, the first and/or second internal edge 22, 23 is substantially perpendicular to the third and/or fourth external edges 10C, 10D of the sheet material 10.

In some embodiments, the first and/or second internal edge 22, 23 is spaced from the third and/or fourth external edge 10C, 10D by at least 3 mm and, in some embodiments, at least 4, 5, 6, 7, 8, 9 or 10 mm, measured when the sheet material 10 is laid flat.

In some embodiments, the first and/or second internal edge 22, 23 is spaced from the third and/or fourth external edge 10C, 10D by at least 2.5% of the width W of the sheet material 10 and, in some embodiments, at least 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10%, measured when the sheet material 10 is laid flat.

In some embodiments, the sheet material 10 subtends about the central axis A-A of the component 3 and, in some embodiments, subtends about the entire central axis A-A of the sheet material 10. The sheet material 10 may be gathered or wrapped around the at least one object 11.

In some embodiments, the sheet material 10 comprises a coating, and in some embodiments, the coating comprises an aerosol-modifying agent. The aerosol-modifying agent may optionally comprise a flavorant.

The first and second slits 20, 21 may be the same shape or may be different shapes. The first and second slits 20, 21 may be the same size or may be different sizes.

Referring now to FIG. 8, a sheet material 10 of an alternative embodiment of component is shown. The sheet material 10 of FIG. 8 it similar to the sheet material 10 of the component 3 of FIGS. 1 to 6, with like features retaining the same reference numerals, except that the first and second slits 20, 21 are omitted and are replaced by first and second apertures 120, 121.

An edge 122 of the first aperture 120 forms a first internal edge 122 of the sheet material 10 and an edge 123 of the second aperture 121 forms a second internal edge 123 of the sheet material 10.

In the present example, the first and second apertures 120, 121 are formed as cut-outs in the sheet material 10, for example, by cutting portions of the sheet material 10 out of the remainder of the sheet material 10 to form the first and second apertures 120, 121. For example, the first and second apertures 120, 121 may be formed by stamping said portions out of the sheet material 10.

In other embodiments, the first and/or second apertures 120, 121 may be formed by a different method, for example, by cutting the sheet material 10 using one or more lasers. In yet another embodiment, the sheet material 10 may be cast in a mold such that the first and/second apertures 120, 121 are formed in the sheet as the sheet material 10 is cast.

In the present example, the first and second apertures 120, 121 are rectangular. However, in other embodiments, the first and/or second aperture 120, 121 may be a different shape, for example, circular, oval, triangular, hexagonal or D-shaped.

The first aperture 120 is nearer to the first external edge 10A of the sheet material 10 and the second aperture 121 is nearer to the second external edge 10B of the sheet material. The at least one object (not shown) is located on the portion of the sheet material 10 between the first and second apertures 120, 121 and then the sheet material 10 is gathered to form a body (not shown) with a space (not shown) that contains the at least one object.

The first internal edge 122 is the edge 122 of the first aperture 120 that is nearest to the first external edge 10A of the sheet material 10 and furthest form the portion of the sheet material 10 that receives the at least one object (not shown). The second internal edge 123 is the edge 123 of the second aperture 121 that is nearest to the second external edge 10B of the sheet material 10 and furthest from the portion of the sheet material 10 that receives the at least one object (not shown).

When the sheet material 10 is gathered to form the body (not shown), the first aperture 120 allows for the sheet material 10 on the a first side of the at least one object to be gathered together such that the first internal edge 122 at least partially, or fully, defines a boundary of the space (not shown) that contains the at least one object. The first internal edge 122 may thus form a first wall portion (not shown). Similarly, when the sheet material 10 is gathered to form the body, the second aperture 121 allows for the sheet material 10 on a second side of the at least one object to be gathered together such that the second internal edge 123 at least partially, or fully, defines a boundary of the space that contains the at least one object. The second internal edge 123 may thus form a second wall portion.

Similarly to the embodiment of FIGS. 1 to 6, the first internal edge 122 of the embodiment of FIG. 8 allows for the sheet material 10 to be gathered together on one side of the space to at least partially define the boundary of the space to prevent the at least one object from moving out of a first end of the space. This improves the positioning of the at least one object within the component. In addition, since the sheet material 10 is gathered together, it helps to obscure the at least one object in the space, when viewed from a first end of the component. Moreover, the second internal edge 123 allows for the sheet material 10 to be gathered together on one side of the space to at least partially define the boundary of the space to prevent the at least one object from moving out of a second end of the space, which also improves the positioning of the at least one object within the component. In addition, since the sheet material 10 is gathered together, it helps to obscure the at least one object in the space, when viewed from a second end of the component.

The first and second apertures 120, 121 may be the same shape or may be different shapes. The first and second apertures 120, 121 may be the same size or may be different sizes.

In the present example, the first and second internal edges 122, 123 are each linear. This facilitates a more uniform gathering of the sheet material 10 when the sheet material is formed into a body. However, in some embodiments (not shown), the first and/or second internal edges 122, 123 are partially or entirely non-linear. For example, the first and/or second internal edges 122, 123 may be curved. In one embodiment (not shown), the first and/or second external edges follow a zig-zag path.

In some embodiments, the first and/or second internal edges 122, 123 extend substantially perpendicular to the central axis A-A of the component 3. When the sheet material 10 is laid flat, the first and second internal edges 122, 123 are parallel to the first and second external edges 10A, 10B and/or are perpendicular to the third and fourth external edges 10C, 10D. However, in alternative embodiments the first and/or second internal edges 122, 123 may be at an angle to first, second, third and fourth external edges 10A, 10B, 10C, 10D.

It should be recognized that any of the features or variations of the embodiment of FIGS. 1 to 6 may be applied to the embodiment of FIG. 8.

In some embodiments (not shown), one of the first and second internal edges may be formed by a slit and the other one of the first and second internal edges may be formed by an aperture.

In some embodiments (not shown), one of the first and second internal edges 22, 23, 122, 123 is omitted. For example, the first or second slit 20, 21 of the embodiment of FIGS. 1 to 6 may be omitted or the first or second aperture 120, 121 of the embodiment of FIG. 8 may be omitted.

Referring now to FIGS. 9 and 10, another embodiment of a component 3 is shown. The component 3 of the embodiment of FIGS. 9 and 10 is similar to the embodiment of FIGS. 1 to 6, with like features retaining the same reference numerals. A difference is that the component 3 is formed into a body 7 that further comprises a second space 208 that receives at least one further object 211. Furthermore, in addition to the first and second slits 20, 21 of the embodiment of FIGS. 1 to 6, the sheet material 10 of the embodiment of FIGS. 9 and 10 further comprises a third slit 220 on one side of the further object 211 and a fourth slit 221 on the other side of the further object 211, wherein the third slit 220 forms a third internal edge 222 and the fourth slit 221 forms a fourth internal edge 223 of the sheet material 10.

The at least one object 11, for example one or more capsules 11, and at least one further object 211, for example one or more further capsules 211, may be applied to the sheet material 10 prior to, or at the same time as, the sheet material 10 being formed into the body 7. In some embodiments, the at least one object 11 and/or at least one further object 211 is attached to the sheet material 10, for example, by an adhesive (not shown) or using static electricity. However, it should be recognized that in other embodiments, the at least one object 11 and/or at least one further object 211 is not attached to the sheet material 10. Indeed, an advantage of the internal edges 22, 23, 222, 223 is improved positioning of the object 11/further object 211 within the component 3 and thus in some embodiments such adhesive may be omitted whilst still maintaining correct positioning of the object 11/further object 211.

In some embodiments, the at least one further object 211 comprises one or more aerosol-modifying agent release components 211, which may be capsules 211. The at least one further object 211 may be different to the at least one object 11, for example, comprising a different aerosol-modifying agent or being configured to release a different amount or concentration of agent. Alternatively, the at least one object 11 and at least one further object 211 may of the same configuration.

The at least one further object 211 may have any of the features of the at least one object 11 described above in relation to FIGS. 1 to 6. Additionally, or alternatively, the at least one further object 211 may have any of the features of the at least one object 11 described above in relation to FIGS. 1 to 6 and, for example, may be an aerosol-modifying agent release component 211 and may be a capsule 211 comprising an outer shell (not shown) and an inner core (not shown). The at least one further object 211 may instead or additionally comprise a different kind of object, for example, a filtration material such as beads or granules.

The aerosol-modifying agent component 11 allows for the user to control whether aerosol-modifying agent is introduced into the gas flow passing through the body 7 and the further aerosol-modifying component 211 also allows for the user to control whether aerosol-modifying agent is introduced into the gas flow passing through the body 7 (whether this is a different kind of aerosol-modifying agent to the component 11, or to permit an increased delivery of the same type of aerosol-modifying agent as the component 11). When the user desires to introduce agent, he or she applies an external force to the component 3 to rupture one or both of the aerosol-modifying agent release components 11, 211, depending on the position of the user's fingers and/or the amount of force applied.

The first, second, third and fourth slits 20, 21, 220, 221 each extend in a direction generally perpendicular to third and fourth external edges 10C, 10D of the sheet material 10. The first, second, third and fourth slits 20, 21, 220, 221 each extend in a direction generally parallel to the first and second external edges 10A, 10B. However, it should be recognized that in other embodiments, one or more of the first, second, third and fourth slits 20, 21, 220, 221 extend at an angle to the first, second, third and fourth external edges 10A, 10B, 10C, 10D.

In some embodiments, first, second, third and fourth slits 20, 21, 220, 221 are each spaced from the third and fourth external edges 10C, 10D, in other words the first, second, third and fourth slits 20, 21, 220, 221 each do not extend across the entire width (shown by arrow W in FIG. 10) of the sheet material 10.

Similarly to the embodiment of FIGS. 1 to 6, the first slit 20 forms a first internal edge 22 of the sheet material 10 and the second slit 21 forms a second internal edge 23 of the sheet material 10. That is, when the sheet material 10 is gathered to form the body 7, the first slit 20 allows for the sheet material 10 on a first side (e.g. downstream side) of the at least one object 11 to be gathered together such that the first internal edge 22 at least partially, or fully, defines a boundary of the space 8 that contains the at least one object 11. The first internal edge may thus form a first wall portion 22A. Similarly, when the sheet material 10 is gathered to form the body 7, the second slit 21 allows for the sheet material 10 on a second side (e.g. upstream side) of the at least one object 11, but on a first (e.g. downstream) side of the at least one further object 211, to be gathered together such that the second internal edge 23 at least partially, or fully, defines a boundary of the space 8 that contains the at least one object 11. The second internal edge 23 may thus form a second wall portion 23A.

In addition, the third slit 220 forms the third internal edge 222 of the sheet material 10 and the fourth slit 221 forms the fourth internal edge 223 of the sheet material 10. That is, when the sheet material 10 is gathered to form the body 7, the third slit 220 allows for the sheet material 10 on a first side (e.g. the downstream side) of the at least one further object 211, but on a second (e.g. upstream) side of the at least one object 11, to be gathered together such that the third internal edge 222 at least partially, or fully, defines a boundary of the second space 208 that contains the at least one further object 211. The third internal edge 222 may thus form a third wall portion 222A. Similarly, when the sheet material 10 is gathered to form the body 7, the fourth slit 221 allows for the sheet material 10 on a second side (e.g. the upstream side) of the at least one further object 211 to be gathered together such that the fourth internal edge 223 at least partially defines a boundary of the second space 208 that contains the at least one further object 211. The fourth internal edge 223 may thus form a fourth wall portion 223A.

The first internal edge 22 therefore allows for the sheet material 10 to be gathered together on one side of the space 8 to at least partially define the boundary of the space 8 to prevent the at least one object 11 from moving out of a first end of the space 8. This improves the positioning of the at least one object 11 within the component 3. In addition, since the sheet material 10 is gathered together, it helps to obscure the at least one object 11 in the space 8, when viewed from a first (e.g. downstream) end of the component 3. In addition, the second internal edge 23 allows for the sheet material 10 to be gathered together on another side of the space 8 to at least partially define the boundary of the space 8 to prevent the at least one object 11 from moving out of a second end of the space 8, which also improves the positioning of the at least one object 11 within the component 3. In addition, since the sheet material 10 is gathered together, it helps to obscure the at least one object 11 in the space 8, when viewed from a second (e.g. upstream) end of the component 3.

The third internal edge 222 allows for the sheet material 10 to be gathered together on one side of the second space 208 to at least partially define the boundary of the second space 208 to prevent the at least one further object 211 from moving out of a first end of the second space 208. This improves the positioning of the at least one further object 211 within the component 3. In addition, since the sheet material 10 is gathered together, it helps to obscure the at least one further object 211 in the second space 208, when viewed from the a first (e.g. downstream) end of the component 3. In addition, the fourth internal edge 223 allows for the sheet material 10 to be gathered together on another side of the second space 208 to at least partially define the boundary of the second space 208 to prevent the at least one further object 211 from moving out of a second end of the second space 208, which also improves the positioning of the at least one further object 211 within the component 3. In addition, since the sheet material 10 is gathered together, it helps to obscure the at least one further object 211 in the second space 208, when viewed from a second (e.g. upstream) end of the component 3.

In some embodiments, the first and second internal edges 22, 23 are axially spaced by a distance in the range of 3 mm to 50 mm. In some embodiments, the first and second internal edges 22, 23 are spaced by a distance of at least 3 mm and, in some embodiments, at least 5, 10, 15, 20, 25, 30, 35, 40, 45 or 50 mm. In some embodiments, the first and second internal edges 22, 23 are spaced by a distance of at most 50 mm and, in some embodiments, at most 45, 40, 35, 30, 25, 20, 15, 10, 5 or 3 mm.

In some embodiments, the third and fourth internal edges 222, 223 are axially spaced by a distance in the range of 3 mm to 50 mm. In some embodiments, the third and fourth internal edges 222, 223 are spaced by a distance of at least 3 mm and, in some embodiments, at least 5, 10, 15, 20, 25, 30, 35, 40, 45 or 50 mm. In some embodiments, the third and fourth internal edges 222, 223 are spaced by a distance of at most 50 mm and, in some embodiments, at most 45, 40, 35, 30, 25, 20, 15, 10, 5 or 3 mm.

In some embodiments, at least a portion of the first, second, third and fourth slits 20, 21, 220, 221 (and thus respective internal edges of the sheet material) extends linearly and, in some embodiments, the entire first, second, third and/or fourth slit 20, 21, 220, 221 extends linearly. However, it should be recognized that in other embodiments the first, second, third and/or fourth slit 20, 21, 220, 221 (and thus respective internal edges of the sheet material) may be at least partially non-linear, for example, being curved. In some embodiments, one of the first, second, third and/or fourth slits 20, 21, 220, 221 may follow a zig-zag path.

In some embodiments, the first, second, third and fourth internal edges 22, 23, 222, 223 are continuous. In other embodiments, one or more of the first, second, third and/or fourth internal edges 22, 23, 222, 223 may be intermittent, being interspersed by one or more intermediate portions of the sheet material 10.

The first and second internal edges 22, 23 may be provided on opposite sides of the at least one object 11 and may face in opposite directions.

The third and fourth internal edges 222, 223 may be provided on opposite sides of the at least one further object 211 and may face in opposite directions.

The component 3 comprises first and second ends 3A, 3B, wherein the first end 3A is a mouth end of the component 3 and the second end 3B is opposite to the first end 3A. In the present example, the first internal edge 22 is located between the at least one object 11 and the first end 3A of the component 3, the second internal edge 23 is located between the at least one object 11 and the second end 3B of the component 3, the third internal edge 222 is located between the at least one further object 211 and the first end 3A of the component 3, and the fourth internal edge 223 is located between the at least one further object 211 and the second end 3B of the component 3.

In the present example, the first, second, third and fourth internal edges 22, 23, 222, 223 are arranged sequentially.

In some embodiments, one or more of the first, second, third or fourth internal edges 22, 23, 222, 223 may be omitted. The remaining internal edge(s) 22, 23, 222, 223 will still at least partially define a boundary of the space 8 and/or second space 208 and thus help to improve positioning of the at least one object 11 and/or at least one further object 211 within the component 3 and improve the aesthetics of the component 3.

In one such embodiment, one of the second or third internal edges 23, 222 is omitted, wherein the other one of the second or third internal edges 23, 222 will still facilitate the sheet material 10 gathering together between the at least one object 11 and at least one further object 211 to aid separation thereof within the component 3. In yet another embodiment, both of the second and third internal edges 23, 222 are omitted.

In some embodiments, the first internal edge 22 is configured such that when the sheet material 10 is gathered together to form the body 7, the sheet material 10 on the opposite side of the first internal edge 22 to the at least one object 11 will extend all of the way to the central axis A-A of the component 3. Similarly, the second and/or third internal edge 23, 222 may be configured such that when the sheet material 10 is gathered together to form the body 7, the sheet material 10 between the second and third internal edges 23, 222 will extend all of the way to the central axis A-A of the component 3. Moreover, the fourth internal edge 223 may be configured such that the sheet material 10 on the opposite side of the fourth internal edge 223 to the at least one further object 211 will extend all of the way to the central axis A-A of the component 3. However, it should be recognized that in other embodiments, the first, second, third and/or fourth internal edge 22, 23, 222, 223 is configured such that the sheet material 10 does not extend all of the way to the central axis A-A and instead may form an annular wall portion (not shown).

In some embodiment, the first, second, third and/or fourth wall portion 22A, 23A, 222A, 223A subtends about the entire central axis A-A of the component 3.

In some embodiments, the first, second, third and/or fourth wall portion 22A, 23A, 222A, 223A is porous. In the present example, the inhalant is able to flow through the layers of gathered sheet material 10 of the first, second, third and fourth wall portions 22A, 23A, 222A, 223A.

In some embodiments, a first portion 9 of the sheet material 10 circumscribes the at least one object 11. The first and second internal edges 22, 23 may be provided at opposite ends of the first portion 9 of the sheet material 10. The first portion 9 may be generally tubular and may be cylindrical. The space 8 is formed within the first portion 9 of the sheet material 10.

In some embodiments, a second portion 209 of the sheet material 10 circumscribes the at least one further object 211. The third and fourth internal edges 222, 223 may be provided at opposite ends of the second portion 209 of the sheet material 10. The second portion 209 may be generally tubular and may be cylindrical. The second space 208 is formed within the second portion 209 of the sheet material 10.

In some embodiments, the first, second, third and/or fourth internal edge 22, 23, 222, 223 each extends in the range of 10% to 95% across the width W of the sheet material 10. For instance, if the sheet material 10 has a width W of 150 mm, when laid flat, then the first internal edge 22 extends in the range of 15 to 142.5 mm across the width W of the sheet material 10 and/or the second internal edge 23 extends in the range of 15 to 142.5 mm across the width W of the sheet material 10 and/or the third internal edge 222 extends in the range of 15 to 142.5 mm across the width W of the sheet material 10 and/or fourth internal edge 223 extends in the range of 15 to 142.5 mm across the width W of the sheet material 10.

In some embodiments, the first, second, third and/or fourth internal edge 22, 23, 222, 223 each extends at least 10% across the width W of the sheet material 10 and, in some embodiments, at least 20, 30, 40, 50, 60, 70, 80, 90 or 95% across the width W of the sheet material 10.

In some embodiments, the first, second, third and/or fourth internal edge 22, 23, 222, 223 each extends at most 95% across the width W of the sheet material 10 and, optionally, at most 90, 80, 70, 60, 50, 40, 30, 20 or 10% across the width W of the sheet material 10.

In some embodiments, the first, second, third and/or fourth internal edge 22, 23, 222, 223 each have a length in the range of 5 mm to 360 mm and, in some embodiments, in the range of 5 to 270 mm, when the sheet material 10 is laid flat.

In some embodiments, the first, second, third and/or fourth internal edge 22, 23, 222, 223 each have a length of at least 5 mm and, in some embodiments, at least 10, 20, 30, 40, 50, 60, 70, 80, 100, 120, 140, 160,180, 200, 250, 270 or 300 mm, when the sheet material 10 is laid flat.

In some embodiments, the first, second, third and/or fourth internal edge 22, 23, 222, 223 is spaced from at least one of the third and fourth external edges 10C, 10D of the sheet material 10. In the present example, the first, second, third and/or fourth internal edge 22, 23, 222, 223 is spaced from both of the third and fourth external edges 10C, 10D of the sheet material 10. This makes the sheet material 10 easier to handle during manufacture of the component 3 because otherwise if the first, second, third and/or fourth internal edge 22, 23, 222, 223 extended to the third or fourth external edge 10C, 10D then a flap of sheet material 10 would be created that would be more difficult to maintain in correct alignment. However, it should be recognized that in other embodiments the first, second, third and/or fourth internal edge 22, 23, 222, 223 extends to the third and/or fourth external edge 10C, 10D.

In some embodiments, the first, second, third and/or fourth internal edge 22, 23, 222, 223 is substantially perpendicular to the third and/or fourth external edges 10C, 10D of the sheet material 10.

In some embodiments, the first, second, third and/or fourth internal edge 22, 23, 222, 223 is spaced from the third and/or fourth external edge 10C, 10D by at least 3 mm and, in some embodiments, at least 4, 5, 6, 7, 8 9 or 10 mm, measured when the sheet material 10 is laid flat.

In some embodiments, the first, second, third and/or fourth internal edge 22, 23, 222, 223 is spaced from the third and/or fourth external edge 10C, 10D by at least 2.5% of the width W of the sheet material 10 and, in some embodiments, at least 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10%, measured when the sheet material 10 is laid flat.

In some embodiments, the sheet material 10 subtends about the central axis A-A of the component 3 and, in some embodiments, subtends about the entire central axis A-A of the sheet material 10. The sheet material 10 may be wrapped or gathered around the at least one object 11 and/or further object 211.

In some embodiments, the second and third internal edges 23, 222 are separated by a distance (shown by arrow ‘D’ in FIG. 10) in the range of 3 to 50 mm. In some embodiments, the second and third internal edges 23, 222 are separated by a distance D in the range of 4 to 45 mm, in the range of 4 to 25 mm, or in the range of 4 to 10 mm.

In some embodiments, the second and third internal edges 23, 222 are spaced by a distance D of at least 3 mm and, in some embodiments, at least 4, 5, 10, 15, 20, 25, 30, 35, 40, 45 or 50 mm.

In some embodiments, the second and third internal edges 23, 222 are spaced by a distance D of at most 50 mm and, in some embodiments, at most 45, 40, 35, 30, 25, 20, 15, 10, 5, 4 or 3 mm.

The sheet material 10 of the embodiment of FIG. 8 or the embodiment of FIGS. 9 and 10 may have any of the features of the sheet material 10 of the embodiment of FIGS. 1 to 6, including, but not limited to, any or all of the same dimensions, shape, basis weight, thickness, length, width or material.

The first, second, third and fourth slits 20, 21, 220, 221 may be the same shape or may be different shapes. The first, second, third and fourth slits 20, 21, 220, 221 may be the same size or may be different sizes.

It should be recognized that any of the features or variations of the embodiment of FIGS. 1 to 6 may be applied to the embodiment of FIG. 8 or FIGS. 9 and 10. For example, in one embodiment (not shown) a component is provided that comprises a sheet material having first, second, third and fourth apertures of the configuration described above in relation to FIG. 8 that form the first, second, third and fourth internal edges respectively. In another embodiment (not shown), one or more of the first, second, third and fourth internal edges are formed by a respective slit and the other ones of the first, second, third and fourth internal edges are formed by a respective aperture.

In some embodiments, the first, second, third and/or fourth aperture is modified to be a cut-out that extends to the third or fourth external edge 10C, 10D of the sheet material and, for example, may be U-shaped.

In one embodiment (not shown), the second and third internal edges are omitted such that one space is formed in the body between the first and fourth internal edges, wherein the at least one object and at least one further object are both received in said space.

Referring now to FIG. 11, a block diagram is shown depicting an embodiment of a method 400 of manufacturing a component for a delivery system. The method comprises: providing an assembly comprising at least one object and a sheet material comprising a first internal edge (S1); and, arranging the sheet material into a body such that the body comprises a space that receives the at least one object, wherein the first internal edge at least partially, or fully, defines a boundary of the space (S2).

In some embodiments, providing the assembly (S1) comprises forming the first internal edge in the sheet material. Alternatively, the sheet material may be provided with the first internal edge pre-formed into the sheet material.

In some embodiments, forming the first internal edge comprises cutting the sheet material using a suitable cutting device, for example, using a knife and/or laser.

In some embodiments, forming the first internal edge comprises forming a slit in the sheet material.

In some embodiments, forming the first internal edge comprises forming an aperture in the sheet material such that an edge of the aperture comprises the first internal edge of the sheet material. The aperture may be substantially rectangular or may be another shape, for example, circular, oval, triangular, hexagonal or D-shaped.

In some embodiments, forming the aperture comprises forming a cut-out in the sheet material. For example, the method may comprise cutting portions of the sheet material out of the remainder of the sheet material to form the first and second apertures. In some embodiments, the first and second apertures may be formed by stamping said portions out of the sheet material.

In other embodiments, the first and/or second apertures may be formed in a different manner, for example, by cutting the sheet material using one or more lasers. In yet another embodiment, the sheet material may be cast in a mold such that the first and/second apertures are formed in the sheet as the sheet material is cast.

In some embodiments, providing the assembly (S1) comprises providing the sheet material comprising the first internal edge, and then providing the at least one object on the sheet material and, in some embodiments, wherein providing the assembly comprises forming the first internal edge in the sheet material, and then providing the at least one object on the sheet material.

In other embodiments, providing the assembly (S1) comprises providing the sheet material, providing the at least one object on the sheet material, and then forming the first internal edge in the sheet material.

In some embodiments, the method comprising crimping the sheet material and, in some embodiments crimping the sheet material to a crimp depth as previously described, for example, in the range of 0.1 to 2 mm and, in some embodiments, in the range of 0.1 to 1 mm or in the range of 0.2 to 0.7 mm. In some embodiments, the method comprises heating the sheet material as it is crimped.

The method may comprise crimping the sheet material after the or each internal edge has been formed, or crimping the sheet material before the or each internal edge is formed.

In some embodiments, the method comprises providing the at least one objects on the sheet material using an object supply device, for example, an object delivery wheel.

In some embodiments, providing the assembly (S1) comprises forming the second internal edge in the sheet material. In some embodiments, the second internal edge is formed in the same manner as the first internal edge as described above.

In some embodiments, providing the assembly (S1) comprises proving a continuous web of sheet material.

In some embodiments, the method comprises cutting the continuous web of sheet material (and any surrounding wrappers) after arranging the sheet material into a body. In some embodiments, cutting the continuous web of sheet material forms one or more discrete components. In some embodiments cutting the continuous web of sheet material after arranging the sheet material into a body comprises cutting the web such that single-length components are formed (i.e. of the final length for use in the delivery system). In other embodiments, cutting the continuous web of sheet material after arranging the sheet material into a body comprises cutting the web such that multi-length components are formed, that may subsequently be cut to form single-length components (before or after attachment to a further component such as a tobacco rod).

An example of a continuous web 500 of sheet material is shown in FIG. 12.

In the present example, the continuous web 500 is intermittently cut in a region (along dashed line ‘Z-Z’ in FIG. 12) between adjacent first and second internal edges 22, 23 in order to separate portions of the sheet material 10 from the remainder of the continuous web 500. In the present example, the continuous web 500 and the overlying plug wrap (not shown) is cut at said region once the sheet material has been gathered into a body and wrapped with the plug wrap. That is, the web 500 is cut after it has been formed into a rod that contains the at least one object 11. In some embodiments, the rod is cut such that each separated portion of the sheet material 10 corresponds to the final length of the component (i.e. the cut rod is a single-length of the component). In other embodiments, the rod is cut such that each separated portion of the sheet material 10 corresponds to a multiple of the final length of the component (for example, the cut rod is a double-length component that is subsequently cut to form single-length components, or is three, four, five, six, seven, eight or more times the final length of the component). In some embodiments, each separated portion of sheet material comprises one or more pairs of first and second internal edges and/or one or more pairs of third and fourth internal edges.

In some embodiments, the method comprises forming a plurality of internal edges in the continuous web at regularly spaced intervals. For example, the method may comprise forming first, second, third and/or fourth internal edges in the continuous web at regularly spaced intervals. In the example of FIG. 12, a plurality of first internal edges 22 are formed at regularly spaced intervals (see arrow ‘D2’ in FIG. 12) on the web 500 and a plurality of second internal edges 23 are formed at regularly spaced intervals (shown by arrow ‘D3’ in FIG. 12) on the web 500.

The distance D2 between each first internal edge 22 and/or the distance D3 between each second internal edge 23 may be in the range of 5 to 50 mm and, in some embodiments, in the range of 10 to 30 mm. In some embodiments, distance D2 and/or D3 is at least 5 mm and, optionally, at least 10, 15, 20, 25, 30, 35, 40 or 45 mm. In some embodiments, distance D2 and/or D3 is at most 50 mm and, in some embodiments, at most 45, 40, 35, 30, 25, 20, 15, 10 or 5 mm.

Each first internal edge 22 is spaced from a respective second internal edge 23 by a distance (shown by arrow ‘D1’ in FIG. 12), wherein at least one object 11 is disposed between each pair of first and second internal edges 22, 23. When the sheet material of the web 500 is gathered to form the body, the first and second internal edges 22, 23 allow for the sheet material to be gathered together such that the first and second internal edges 22, 23 at least partially define a boundary of a space that contains the at least one object 11. In other embodiments, one of the first and second internal edges 22, 23 may be omitted. In yet further embodiments, third and/or fourth internal edges (not shown) may be formed on the continuous web 500 and, optionally, at least one further object (not shown) may be positioned on the web 500 in proximity to the third and/or fourth internal edges.

In some embodiments, the distance D1 between the first and second internal edges 22, 23 is in the range of 3 to 50 mm. In some embodiments, the first and second internal edges 22, 23 are spaced by a distance D1 of at least 3 mm and, in some embodiments, at least 5, 10, 15, 20, 25, 30, 35, 40, 45 or 50 mm. In some embodiments, the first and second internal edges 22, 23 are spaced by a distance D1 of at most 50 mm and, in some embodiments, at most 45, 40, 35, 30, 25, 20, 15, 10, 5 or 3 mm.

In some embodiments (not shown), the web comprises third and fourth internal edges, and wherein the distance between the third and fourth internal edges is in the range of 3 to 50 mm. In some embodiments, the third and fourth internal edges are spaced by a distance of at least 3 mm and, in some embodiments, at least 5, 10, 15, 20, 25, 30, 35, 40, 45 or 50 mm. In some embodiments, the third and fourth internal edges are spaced by a distance of at most 50 mm and, in some embodiments, at most 45, 40, 35, 30, 25, 20, 15, 10, 5 or 3 mm.

In some embodiments, the method comprises moving the continuous web 500 along a conveyance path (shown by arrow ‘Y’ in FIG. 12) and providing the at least one object 11 (and/or at least one further object) at regular intervals as the continuous web 500 moves along the conveyance path Y. The at least one object 11 may be located between first and second internal edges 22, 23, or in proximity to one of the first or second internal edges 22, 23 if the other one of the first and second internal edges 22, 23 is omitted.

In some embodiments, the web 500 has a width (shown by arrow ‘W1’ in FIG. 12) in the range of 30 to 400 mm and, in some embodiments, in the range of 40 to 300 mm, in the range of 50 to 280 mm, in the range of 75 to 225 mm or in the range of 100 to 200 mm.

In some embodiments, the web 500 has a width W1 of at least 30 mm and, in some embodiments, at least 40, 50, 75, 100, 125, 150, 175, 190, 250, 280, 300 or 400 mm.

In some embodiments, the web 500 has a width W1 of at most 400 mm and, in some embodiments, at most 300, 280, 250, 225, 200, 175, 150, 125 or 100 mm.

Although in the above described example the internal edges 22, 23 are provided in a web 500 of continuous sheet material, which is then gathered and formed into a body that is subsequently cut to form individual components (or multi-length components), in an alternative embodiment (not shown) the web is cut into individual sheets and thereafter the internal edges are provided in the sheet material and the at least one object is provided on the sheet.

In some embodiments, arranging the sheet material into the body (S2) comprises gathering the sheet material together to form the body.

In some embodiments, a first wall portion is defined by gathering the first internal edge of the sheet material and/or a second wall portion is defined by gathering the second internal edge of the sheet material. In embodiments, wherein the sheet material further comprises a third and/or fourth internal edge, the method may comprise gathering the third and/or fourth internal edge of the sheet material to define a respective third and/or fourth wall portion. In some embodiments, the assembly comprises at least one further object. Arranging the sheet material into the body (S2) may comprise arranging the sheet material such that the body comprises a second space that receives the at least one further object, wherein the third internal edge at least partially defines a boundary of the second space. In some embodiments, arranging the sheet material into the body (S2) comprises arranging the sheet material such that the fourth internal edge at least partially defines a boundary of the second space.

The third internal edge and/or fourth internal edge may be formed in the same manner as previously described in reference to the first and/or second internal edge.

In some embodiments, the method further comprises connecting the component to a further component of a delivery system, for example, a further component of a combustible or non-combustible aerosol provision device. In one embodiment, the further component is a tobacco rod and may be connected to the component by a wrapper such as a tipping paper.

The method 400 may be used to manufacture the component of the embodiment described above in reference to FIGS. 1 to 6, FIG. 8, or FIGS. 9 and 10, including a component comprising any of the variations described therein. For example, the sheet material may have any of the features described above in relation to any of the embodiments, the first, second, third and/or fourth internal edges may have any of the features described above in relation to any of the embodiments, and/or the object and/or further object may have any of the features of the object/further object described above in relation to any of the embodiments.

Referring now to FIG. 13, an embodiment of an apparatus 600 for manufacturing a component for a delivery system is shown.

The apparatus 600 comprises a supply 601 of sheet material 10, a crimping device 602 and an edge forming device 603 comprising a first pair of cutting drums 604 and a second pair of cutting drums 605. The apparatus 600 further comprises an adhesive applicator 606, an object supply device 607, and a body forming device 608.

In the present example, the supply 601 is a reel 601 of sheet material 10 that is fed along a conveyance path (shown by arrow ‘Y’ in FIG. 13). The sheet material 10 may be fed along the conveyance path Y by, for example, rollers and/or a belt, as will be apparent to a skilled person. In the present example, the sheet material 10 is fed as a continuous web 500 to the body forming device 608.

In the present example, the crimping device 602 comprises first and second crimping rollers 602A, 602B. However, in other embodiments the crimping device 602 may be omitted or may have a different configuration, for example, alternatively or additionally comprising an embossing device such as embossing rollers.

The crimping device 602 is configured to crimp the sheet material 10 as it passes between the rollers 602A, 602B. In some embodiments, the crimping device 602 is configured to crimp the sheet material 10 to a crimp depth as previously described, for example, in the range of 0.1 to 2 mm and, in some embodiments, in the range of 0.1 to 1 mm or in the range of 0.2 to 0.7 mm. In some embodiments, the crimping device 602 is configured to heat the sheet material, for example, one or both of the rollers 602A, 602B may be heated. In one such embodiment, one or both of the crimping rollers 602A, 602B comprises one or more heating elements, for example, resistive heating elements.

In the present example, the crimping device 602 is configured to crimp the sheet material 10 prior to the edge forming device 603 forming the internal edge(s). In an alternative embodiment (not shown), the crimping device 602 is configured to crimp the sheet material 10 after the edge forming device 603 has formed the internal edge(s).

The first pair of cutting drums 604 comprises a scissor drum 604A and a support drum 604B. The scissor drum 604A comprises a plurality of knives 604C that are configured to sequentially meet the sheet material 10 as the sheet material 10 passes between the scissor drum 604A and the support drum 604B in order to form a first slit in the sheet material 10 of the web 500. The knives 604C are regularly spaced about the central axis of the scissor drum 604A such that knives 604C form first slits at regularly spaced intervals in the sheet material 10. The distance between each first slit can be selected by adjusting the distance between adjacent knives 604C and/or the number of knives 604C on the scissor drum 604A.

The second pair of cutting drums 605 comprises a scissor drum 605A and a support drum 604B. The scissor drum 605A comprises a plurality of knives 605C that are configured to sequentially meet the sheet material 10 as the sheet material 10 passes between the scissor drum 605A and the support drum 605B in order to form a second slit in the sheet material 10 of the web 500. The knives 605C are regularly spaced about the central axis of the scissor drum 605A such that knives 605C form second slits at regularly spaced intervals in the sheet material 10. The distance between each second slit can be selected by adjusting the distance between adjacent knives 605C and/or the number of knives 605C on the scissor drum 605A.

In some embodiments, the rotation of the first and second pairs of cutting drums 604, 605 may be synchronized.

The first slit forms a first internal edge of the sheet material 10 and the second slit forms a second internal edge of the sheet material 10. The first and second slits and/or first and second internal edges may have any of the features of the slits/internal edges described above in relation to the embodiments of FIGS. 1 to 6 and FIGS. 8 to 12, including a similar shape and/or dimensions.

In an alternative embodiment (not shown), one pair of cutting drums forms both the first and second internal edges. For example, one knife or set of knives forms the first internal edges and the second knife or set of knives forms the second internal edges. In other embodiments, the first or second internal edges are omitted.

In some embodiments, the first and/or second pair of cutting drums 604, 605 may be replaced with one or more cutting lasers that are configured to form slits or apertures in the sheet material that form the internal edges of the sheet material 10.

In the present example, the edge forming device 603 forms slits in the sheet material 10. In other embodiments, the edge forming device 603 forms apertures in the sheet material 10 that form the internal edges. For instance, the edge forming device 603 may be configured to form a cut-out in the sheet material 10 to form the or each aperture. In one such embodiment, the cutting device 603 comprises a punching drum comprising a plurality of protrusions that each punch a portion of the sheet material 10 out of the remainder of the sheet material 10 to form the apertures. The apertures may have any of the features of the apertures described above in relation to the embodiments of FIGS. 1 to 6 and FIGS. 8 to 12, including similar shape and/or dimensions.

In some embodiments, the edge forming device 603 is configured to form a first internal edge, wherein said first internal edge passes the object supply device which then positions the at least one object on the sheet material. In another embodiment, the edge forming device is configured to form the first internal edge after the object supply device has positioned the at least one object on the first portion of the sheet material.

The adhesive applicator 606 is configured to apply adhesive to the sheet material 10, for example, by spraying the adhesive or applying the adhesive with a roller or brush. Alternatively, the adhesive may be gravity fed to the sheet material 10. The adhesive is applied to the sheet material 10 as the sheet material 10 moves along the conveyance path Y and passes the adhesive applicator 606. The adhesive applicator 606 may supply the adhesive to the sheet material 10 through a nozzle 606A using compressed gas. It should be recognized that in some embodiments the adhesive applicator 606 may be omitted.

The object supply device 607 is configured to provide the at least one object at regular intervals on the continuous web. The object supply device 607 may be configured to position the at least one object on a first side of the first internal edge and on a second side of the second internal edge such that the at least one object is positioned on the sheet material between the first and second edges.

The object supply device 607 comprises a hopper 607A and a screw feeder 607B. The hopper 607A contains objects which, in the present example, are aerosol-modifying agent release components, such as capsules. The screw feeder 607B is configured to supply the objects from the hopper 607A to the sheet material 10 as the sheet material 10 moves along the conveyance path Y and passes the object supply device 607.

In an alternative embodiment (not shown), the screw feeder 607B is replaced by an alternative object supply device, for example, a belt that feeds the objects, for example capsules, to the sheet material. In some embodiments (not shown), the objects are stored in containers and supplied to the sheet material through a pipe using compressed gas.

In some embodiments, the object supply device 607 comprises an object delivery wheel.

The body forming device 608 comprises a tongue 608A. The sheet material 10 is fed into the tongue 608A. The tongue 608A reduces in cross-sectional area such that the sheet material 10 is gathered together to form a body as is passes through the tongue 608A. In one embodiment, the body forming device is a CU-20 paper filter maker manufactured by Decouflé™. However, a skilled person will recognize that other devices can be used to form the sheet material 10 into a body, for example, an apparatus for manufacturing a ‘crepe filter’ or ‘paper filter’.

The body forming device 608 may arrange the sheet material 10 into a body of material that is circumscribed by a wrapper (not shown). The body and wrapper may form a continuous rod that may then be cut into segments for inclusion in delivery systems, and in some embodiments the apparatus further comprises a component cutting device configured to cut the rod into components/segments of single length or a multiple thereof.

The body forming device 608 is configured to arrange the sheet material 10 into a body such that the body comprises a space that receives the at least one object. When the sheet material of the web is gathered to form the body, the first and second internal edges 22, 23 allow for the sheet material to be gathered together such that the first and second internal edges 22, 23 at least partially, or fully, define a boundary of a space that contains the at least one object 11.

In some embodiments, the edge forming device 603 is configured to provide third and/or fourth slits or apertures in the sheet material 10 in order to form third and/or fourth internal edges respectively in the sheet material 10. In one embodiment, the first pair of cutting drums 604 are configured to form the first and third internal edges in the sheet material 10 and the second pair of cutting drums 605 are configured to form the second and fourth internal edges in the sheet material 10. In another embodiment (not shown), the edge forming device 603 further comprises a third pair of cutting drums (not shown) that are configured to form the third internal edges (e.g. forming third slits/apertures in the sheet material) and/or comprises a fourth pair of cutting drums (not shown) that are configured to form the fourth internal edges (e.g. forming fourth slits/apertures in the sheet material). In yet another embodiment (not shown), a single pair of cutting drums forms all of the first, second, third and fourth internal edges. In another embodiment (not shown), one or more lasers may be used to form the first, second, third and fourth internal edges.

The third and fourth slits/apertures and/or third and fourth internal edges may have any of the features of the slits/internal edges described above in relation to the embodiments of FIGS. 1 to 6 and FIGS. 8 to 12, including a similar shape and/or dimensions.

The object supply device 607 is configured to position at least one further object on the sheet material 10. For example, the object supply device 607 may comprise a second hopper (not shown) and a second screw feeder (not shown). The second hopper contains further objects which, in the present example, are further aerosol-modifying agent release components, such as capsules. The second screw feeder is configured to supply the further objects from the second hopper to the sheet material 10 as the sheet material 10 moves along the conveyance path Y and passes the object supply device 607. In an alternative embodiment (not shown), the second screw feeder is replaced by an alternative object supply device, for example, a belt that feeds the further objects, for example capsules, to the sheet material. In some embodiments (not shown), the further objects are stored in containers and supplied to the sheet material through a pipe using compressed gas.

In such embodiments, the body forming device 608 is configured to arrange the sheet material 10 into the body such that the body comprises a second space that receives the at least one further object, wherein the third internal edge at least partially, or fully, forms a boundary of the second space and the fourth internal edge at least partially, or fully, forms a boundary of the second space.

In some embodiments, the body forming device 608 is configured to gather the first internal edge of the sheet material to form a first wall portion. In some embodiments, the body forming device 608 is configured to gather the second internal edge of the sheet material to form a second wall portion. In some embodiments, the body forming device 608 is configured to gather the third internal edge of the sheet material to form a third wall portion. In some embodiments, the body forming device 608 is configured to gather the fourth internal edge of the sheet material to form a fourth wall portion.

In some embodiments, the apparatus 600 comprises a sensor 650 (shown in FIG. 14) configured to detect information indicative of the at least one internal edge 22, 23, 222, 223 of the sheet material (for example, one or more of the first, second, third and/or fourth internal edges 22, 23, 222, 223).

In some embodiments, the apparatus 600 further comprises a controller 660 (shown in FIG. 14) configured to control the position of the at least one object based on the information indicative of the at least one internal edge detected by the sensor 650.

In some embodiments, the controller 660 controls the object supply device 607 based on the on the information indicative of the position of the at least one internal edge detected by the sensor 650 in order to control the position of the at least one object and/or further. Additionally, or alternatively, the controller 660 is configured to control the speed that the sheet material 10 is conveyed along the conveyance path Y in order to control the position of the at least one object and/or further object.

The sensor 650 may comprise a camera (not shown) that is configured to detect each first integral edge as is passes the camera. Alternatively, or in addition, the sensor may comprise a different type of sensor (not shown) for example, a light gate, capacitive sensor, magnetic or Hall effect sensor, or ultrasound sensor. In some embodiments, the sensor 650 or one or more further sensors additionally or alternatively detects the second, third and/or fourth internal edges.

The controller 60 may comprise a memory 661 and a processor 662. The memory 661 may be configured to store instructions and/or information and the processor 662 may be configured to carry out the instructions.

The controller 602 may be configured to control the object supply device 607 based on the information indicative of the position of the at least one internal edge 22, 23, 222, 223 detected by the sensor 650 in order to control the position of the at least one object by, for example, controlling the timing and/or frequency of when the at least one objects are dispensed onto the sheet material 10 in order to align each at least one object into a space between adjacent first and second internal edges. For example, in embodiments wherein the object supply device 607 comprises an object insertion wheel, the controller 660 may control the speed that the when rotates. Additionally, or alternatively, the controller 660 may be configured to control the speed that the sheet material 10 is conveyed along the conveyance path Y in order to control the position of the at least one object, for example, controlling the speed that of a belt, drum and/or roller that feeds the sheet material 10 along the conveyance path Y. Again, this helps to align each at least one object into a space between adjacent first and second internal edges (and/or align each at least one further object into a second space between adjacent third and fourth internal edges).

Controlling the position of the at least one object/at least one further object supplied to the sheet material 10 based on the information indicative of the at least one first, second, third and/or fourth internal edge 22, 23, 222, 223 detected by the sensor helps to ensure that the at least one object/further object does not become misaligned with the sheet material 10, for example, due to the sheet material stretching or slipping on the conveyance path. However, it should be recognized that in other embodiments the sensor(s) are omitted.

Referring now to FIG. 15, a base rod 700 is shown that is configured to be cut along lines Z-Z in order to form a plurality of components as described herein. In the present example, the rod 700 is six times the length of the individual component that is finally incorporated into the delivery system, such that the rod is configured to be but five times. The rod comprises five spaces 8 that each contains a respective at least one object 11 (and may optionally further comprise five second spaces that each comprise at least one further object).

In some embodiments, the rod 700 is at least two, three, four, five, six, seven, eight, nine or ten times the length of the individual component such that the rod is configured to be cut to form at least two, three, four, five, six, seven, eight, nine or ten components. That is, the rod 700 is a multi-length base rod. In some embodiments, the rod 700 comprises at least two, three, four, five, six, seven, eight, nine or ten objects each in a respective space. In some embodiments, the rod 700 further comprises at least two, three, four, five, six, seven, eight, nine or ten further objects each in a respective second space. In some embodiments, the rod 700 is between 60 to 180 mm in length and comprises at least six spaces that each receives a respective at least one object.

In the above described embodiments, the delivery system is a combustible aerosol provision system. However, in alternative embodiments (not shown), the delivery system is of an arrangement other than a combustible aerosol provision system. For example, the delivery system may be a non-combustible aerosol provision system or an aerosol-free delivery system.

Thus, the component may be a component for a non-combustible aerosol provision system or an aerosol-free delivery system.

In the above described embodiments, the component 3 is in the form of a filter 3. However, it should be recognized that in alternative embodiments (not shown) the component 3 is of a different configuration. For example, the component 3 could comprise part of an aerosol generation device such as an e-cigarette, which may not comprise a filter.

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

- 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);
- 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; and
- aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

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.

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.

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

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.

In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

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

In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.

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

In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energized so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system 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.

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.

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

In some embodiments, the delivery system is an aerosol-free delivery system that delivers at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

In some embodiments, the substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolized. As appropriate, either material may comprise one or more active constituents, one or more flavors, one or more aerosol-former materials, and/or one or more other functional materials.

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

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.

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

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.

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, fibers, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, Ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens

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.

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.

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.

In some embodiments, the substance to be delivered comprises a flavor.

As used herein, the terms “flavor” and “flavorant” 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 flavor 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), flavor 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.

In some embodiments, the flavor comprises menthol, spearmint and/or peppermint. In some embodiments, the flavor comprises flavor components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.

In some embodiments, the flavor 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.

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 gel which may or may not contain an active substance and/or flavorant. In some embodiments, the aerosol-generating material may comprise an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. 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 aerosol-generating material may for example comprise from about 50 wt %, 60 wt % or 70 wt % of amorphous solid, to about 90 wt %, 95 wt % or 100 wt % of amorphous solid.

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

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 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.

The one or more other functional materials may comprise one or more of pH regulators, coloring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.

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.

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

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, flavor, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent.

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavorant, a colorant, 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.

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

The delivery system described herein can be implemented as a combustible aerosol provision system, a non-combustible aerosol provision system or an aerosol-free delivery system.

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 disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claims. Various embodiments of the disclosure 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.

A COMPONENT FOR A DELIVERY SYSTEM AND A METHOD AND APPARATUS FOR MANUFACTURING A COMPONENT FOR A DELIVERY SYSTEM

Information

Publication Number

Date Filed

Date Published

Inventors

Original Assignees

CPC

International Classifications

Abstract

Description

Claims

Priority Claims (1)

PRIORITY CLAIM

PCT Information