AN ARTICLE FOR USE IN A NON-COMBUSTIBLE AEROSOL PROVISION SYSTEM

TECHNICAL FIELD

The present invention relates to an article for use in a non-combustible aerosol provision system, a non-combustible aerosol provision system including an article, and a method of manufacturing an article for use in a non-combustible aerosol provision system.

BACKGROUND

Certain tobacco industry products produce an aerosol during use, which is inhaled by a user. For example, tobacco heating devices heat an aerosol generating substrate such as tobacco to form an aerosol by heating, but not burning, the substrate. Such tobacco industry products commonly include one or more hollow tubes, in a mouthpiece for example, through which the aerosol passes to reach the user's mouth.

SUMMARY

In accordance with a first aspect, the specification provides an article for use with a non-combustible aerosol provision system, the article comprising a rod of aerosol generating material, and a hollow tube in axial alignment with the rod of aerosol generating material, wherein the hollow tube has a weight less than 8.5 mg/mm in an axial direction.

In accordance with a second aspect, the specification provides an article for use with an aerosol provision system, the article comprising a rod of aerosol generating material, and a hollow tube in axial alignment with the rod of aerosol generating material, wherein the hollow tube comprises a plurality of layers of a sheet material having a basis weight of less than 90 GSM.

In accordance with a third aspect, the specification provides an article for use with a non-combustible aerosol provision system, the article comprising a rod of aerosol generating material, and a hollow tube in axial alignment with the rod of aerosol generating material, wherein the hollow tube comprises a plurality of layers of a sheet material and wherein the weight per unit length of the hollow tube is less than 4 mg/mm in an axial direction.

In accordance with a fourth aspect, the specification provides an article for use with a non-combustible aerosol provision system, the article comprising: a rod of aerosol generating material configured to generate an aerosol when heated during use, and a hollow tube in axial alignment with the rod of aerosol generating material, and provided adjacent to and in abutment with the rod of aerosol generating material, wherein the hollow tube has a length in an axial direction of 5 mm or less.

In accordance with a fifth aspect the specification provides an article for use in a non-combustible aerosol provision system, the article comprising a mouthpiece comprising a filter plug, and a hollow tube at a mouth end of the mouthpiece, and a tubular cooling section upstream of the filter segment, the filter plug being circumscribed by a layer of sheet material forming a wrapped cylinder, the layer of sheet material extending longitudinally beyond a downstream edge of the filter plug, thereby forming the hollow tube at the mouth end of the mouthpiece, and the sheet material extending longitudinally beyond an upstream edge of the filter plug, thereby forming the tubular cooling section upstream of the filter segment and a rod of aerosol generating material connected to mouthpiece by a tipping paper circumscribing the cooling section and the rod of aerosol generating material.

In accordance with a sixth aspect, the specification provides a method of manufacturing an article for use in a non-combustible aerosol provision system, the method comprising: forming a mouthpiece by wrapping a filter plug with a layer of sheet material to form a wrapped cylinder, the layer of sheet material extending longitudinally beyond a downstream edge of the filter plug, thereby forming a first hollow tube at a mouth end of the mouthpiece, and the layer of sheet material extending longitudinally beyond an upstream edge of the filter segment thereby forming a tubular cooling section upstream of the filter segment, and connecting the mouthpiece to a rod of aerosol generating material by a tipping paper circumscribing the cooling section and the rod of aerosol generating material.

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 1a is a side-on cross sectional view of an article for use with a non-combustible aerosol provision system according to aspects of the specification, the article including a hollow tube at a mouth end of the article and a cooling section;

FIG. 1b illustrates the article of FIG. 1a additionally including a capsule;

FIG. 2 is a side on cross sectional view of an article for use with a non-combustible aerosol provision system according to aspects of the specification, the article including a cellulose acetate tube in a cooling section;

FIG. 3 is a side on cross section view of an article for use with a non-combustible aerosol provision system according to aspects of the specification, the article including a cooling section which includes a hollow tube;

FIG. 4a is a side on cross sectional view of an article for use with a non-combustible aerosol provision system according to aspects of the specification, the article including a recessed mouthpiece and a cooling section formed of plug wrap;

FIG. 4b is a side on cross sectional view of an article for use with a non-combustible aerosol provision system according to aspects of the specification, the article including a recessed mouthpiece formed of plug wrap, and a hollow tube located within a cooling section;

FIG. 4c is a side on cross sectional view of an article for use with a non-combustible aerosol provision system according to aspects of the specification, the article including a recessed mouthpiece formed of plug wrap, and a hollow tube located within a cooling section;

FIG. 5a is a schematic illustration of a manufacturing method for manufacturing an article according to FIG. 4a;

FIG. 5b is a schematic illustration of a manufacturing method for manufacturing an article according to FIG. 4b;

FIG. 6 is a flow chart illustrating steps of a method for manufacturing an article for use with a non-combustible aerosol provision system;

FIG. 7a is a schematic illustration for manufacturing an article for use with a non-combustible aerosol provision system;

FIG. 7b is a schematic illustration for manufacturing an article for use with a non-combustible aerosol provision system;

FIG. 8 is a table illustrating properties of a tube suitable for use in an article of FIG. 1, 2, or 3.

DETAILED DESCRIPTION

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 “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.

The terms ‘upstream’ and ‘downstream’ used herein are relative terms defined in relation to the direction of mainstream aerosol drawn through an article or device in use.

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

In some embodiments, the non-combustible aerosol provision system comprises an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

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

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

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), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

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 flavour components extracted from tobacco. In some embodiments, the flavor comprises flavour 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.

An aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. An aerosol-generating material may be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavorants. The aerosol-generating material may be incorporated into an article for use in the aerosol-generating system.

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

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

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a 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 filamentary tow material described herein can comprise cellulose acetate fibre tow. The filamentary tow can also be formed using other materials used to form fibres, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT), starch based materials, cotton, aliphatic polyester materials and polysaccharide polymers or a combination thereof. The filamentary tow may be plasticized with a suitable plasticizer for the tow, such as triacetin where the material is cellulose acetate tow, or the tow may be non-plasticised. The tow can have any suitable specification, such as fibers having a ‘Y’ shaped or other cross section such as ‘X’ shaped, filamentary denier values between 2.5 and 15 denier per filament, for example between 8.0 and 11.0 denier per filament and total denier values of 5,000 to 50,000, for example between 10,000 and 40,000.

In the figures described herein, like reference numerals are used to illustrate equivalent features, articles or components.

In accordance with aspects of the specification, FIGS. 1 to 4 illustrate articles for use in a system, such as non-combustible aerosol provision system, which include components having a reduced weight compared to conventional articles for use in non-combustible aerosol provision systems. Reducing the weight of components may reduce the overall waste leftover after use of the article. The biodegradability of the article may therefore be improved by reducing the amount of waste material leftover after use of the article.

Certain aspects of the specification relate to an article for use with a non-combustible aerosol provision device, wherein the article comprises a rod of aerosol generating material, and a hollow tube in axial alignment with the rod of aerosol generating material, wherein the hollow tube has a weight less than 8.5 mg/mm in an axial direction. Certain other aspects of the specification relate to a hollow tube having a weight of less than 8.5 mg/mm in an axial direction for use in an article for use with a non-combustible aerosol provision system. Certain other aspects of the specification relate to use of a hollow tube having a weight less than 8.5 mg/mm in an article for use with a non-combustible aerosol provision system.

Certain other aspects of the specification relate to an article for use with a non-combustible aerosol provision system, wherein the article comprises a rod of aerosol generating material, and a hollow tube in axial alignment with the rod of aerosol generating material. The hollow tube comprises a plurality of layers of a sheet material having a basis weight of less than 90 GSM. Certain other aspects of the specification relate to a hollow tube comprising a plurality of layer of a sheet material having a basis weight of less than 90 GSM for use in an article for use with a non-combustible aerosol provision system.

Certain other aspects of the present specification relate to an article for use with an aerosol provision system, wherein the article comprises a rod of aerosol generating material, and a hollow tube in axial alignment with the rod of aerosol generating material. The weight of the hollow tube is less than 4 mg/mm in an axial direction. Certain other aspects of the specification relate to a hollow tube comprising a plurality of layers of sheet material for use in an article for use with a non-combustible aerosol provision system.

Certain other aspects of the specification relate to an article for use in a non-combustible aerosol provision system, the article comprising a mouthpiece comprising a filter plug, and a hollow tube at a mouth end of the mouthpiece, and a tubular cooling section upstream of the filter segment, the filter plug being circumscribed by a layer of sheet material forming a wrapped cylinder, the layer of sheet material extending longitudinally beyond a downstream edge of the filter plug, thereby forming the hollow tube at the mouth end of the mouthpiece, and the sheet material extending longitudinally beyond an upstream edge of the filter plug, thereby forming a tubular cooling section upstream of the filter segment, and a rod of aerosol generating material connected to mouthpiece by a tipping paper circumscribing the cooling section and the rod of aerosol generating material.

Certain other aspects of the specification relate to the use of any of the articles described herein in a non-combustible aerosol provision system.

Certain other aspects of the specification relate to a method of generating an aerosol using a system comprising any article as described herein and a non-combustible aerosol provision device.

Certain other aspects of the specification relate to a mouthpiece comprising a filter plug, and a hollow tube at a mouth end of the mouthpiece, and a tubular cooling section upstream of the filter segment, the filter plug being circumscribed by a layer of sheet material, the layer of sheet material extending longitudinally beyond a downstream edge of the filter plug, thereby forming the hollow tube at the mouth end of the mouthpiece, and the sheet material extending longitudinally beyond an upstream edge of the filter plug, thereby forming the tubular cooling section upstream of the filter segment. Certain other aspects of the specification relate to use of the above described mouthpiece in an article for use with a non-combustible aerosol provision system.

Certain other aspects of the present specification relate to a method of manufacturing an article for use in a non-combustible aerosol provision system. The method comprises forming a mouthpiece by wrapping a filter plug with a layer of sheet material to form a wrapped cylinder, the layer of sheet material extending longitudinally beyond a downstream edge of the filter plug, thereby forming a first hollow tube at a mouth end of the mouthpiece, and the layer of sheet material extending longitudinally beyond an upstream edge of the filter segment thereby forming a tubular cooling section upstream of the filter segment. The method further comprises connecting the mouthpiece to a rod of aerosol generating material by a tipping paper circumscribing the cooling section and the rod of aerosol generating material. Certain other aspects of the specification relate to an article manufactured according to the above described method.

Examples of articles for use with a non-combustible aerosol provision system in accordance with the above aspects of the specification will be described in more detail below. A system such a non-combustible aerosol provision system as described herein may comprise an article and an aerosol provision device. The aerosol provision device may be a heater for heating the aerosol.

FIG. 1a is a side on cross-sectional view of an article 1 for use in an aerosol provision system according to an aspect of the present specification. The example of FIG. 1a is an article 1 for use together in a system with an aerosol generator, such as a heater. The article 1 comprises a mouthpiece 14 connected to an aerosol generating section. In the example of FIG. 1a, the aerosol generating section is a rod of aerosol generating material 10. However in alternative examples, the article 1 may comprise an aerosol generating section comprising a cavity for receiving a source of aerosol generating material connected to the mouthpiece 14.

The article 1 illustrated in FIG. 1a comprises the rod of aerosol generating material 10, and one or more hollow tubes in axial alignment with the rod of aerosol generating material. In the example of FIG. 1a, a hollow tube 12 is provided at the mouthpiece 14, at a mouth end of the article 1. The hollow tube 12 provides a recessed mouthpiece filter segment configured to be inserted into a user's mouth for receiving aerosols generated by the aerosol generating material during use. However, a hollow tube may additionally or alternatively be provided at any other location. In the example of FIG. 1a, the mouthpiece 14 also comprises a hollow tube 16 adjacent to and in abutment with the rod of aerosol generating material 10, at a downstream end of the rod of aerosol generating material 10. The hollow tube 16 in the example of FIG. 1a is a cooling section 16. The cooling section 16 is configured to cool aerosols which are generated when the rod of aerosol generating material 10 is heated during use.

The hollow tube 12 and/or hollow tube 16 as described herein may be provided for use with any suitable article for use with a non-combustible aerosol provision system. For example, the outer diameter of the hollow tube may substantially correspond to the outer diameter of a rod of aerosol generating material of an article for use with a non-combustible aerosol provision system. In some examples, the outer diameter of the hollow tube may substantially correspond to the outer diameter of a filter plug segment of an article for use with a non-combustible aerosol provision system. The inner diameter of the hollow tube may be configured to receive an aerosol generated during heating of a rod of aerosol generating material during use of an article for use with a non-combustible aerosol provision system.

In the example of FIG. 1a, the hollow tube 12 is approximately 6 mm in length, the filter segment 18 is approximately 10 mm in length, and the cooling section is approximately 25 mm in length. The skilled person will recognise other suitable lengths for the segments. For example the hollow tube 12 may be between 5 and 15 mm in length. The filter segment 18 may be between 5 and 20 mm in length. The cooling section 16 may be between 5 and 30 mm in length.

The mouthpiece 1 illustrated in FIG. 1a may also comprise a filter segment 18, which may be, for example, a filter plug of cellulose acetate tow. In other examples, the filter segment may be formed from paper. Alternatively the filter segment may be formed from polylactic acid (PLA), or other filamentary tow or similar materials.

The filter segment 18 may be provided between the hollow tube 12 at the mouth end of the article 1 and the cooling section 16. In some examples, the filter plug 18 may comprise an aerosol modifying material, to modify the aerosol as it passes through. FIG. 1b illustrates the article 1 of FIG. 1a with a capsule 18a additionally included in the filter plug 18. The remaining features of the article 1 of FIG. 1b otherwise correspond to the features of the article 1 of FIG. 1a. In the example of FIG. 1b, the capsule is a breakable capsule comprising a shell and an aerosol modifying agent enclosed within the shell. For example, the aerosol modifying agent may be a flavorant for providing a flavour to the aerosol as it passes through the mouthpiece. Examples of aerosol modifying agents and flavorants are set out in more detail above. The capsule may be any suitable size. For example the capsule may be between 2 and 5 mm, more preferably between 2.5 and 4.5 mm, more preferably between 3 and 4 mm, for example 3.5 mm.

The rod of aerosol generating material 10 may comprise strands or strips of aerosol generating material. In some examples, the aerosol generating material comprises tobacco. However, the rod 10 may comprise any suitable aerosol generating material, which may include, but is not limited to, any of the examples listed above. The rod of aerosol generating material 10 may be a cylindrical rod.

The rod of aerosol generating material 10 may be circumscribed by a wrapper 11. The wrapper 11 may be a moisture impermeable wrapper.

The rod of aerosol generating material 10 in the example of FIG. 1a has a circumference of about 20.5 mm, or more particularly 20.45 mm. However, in other examples, the rod of aerosol generating material 10 may have any suitable circumference, for example between about 20 mm and about 26 mm.

The hollow tube 12 may have a low weight. For example, the hollow tube 12 may be reduced in weight compared to standard tubular segments used in aerosol delivery systems. In the aerosol delivery system 1 according to the present specification the hollow tube 12 has a weight less than 8.5 mg/mm in an axial direction. A reduced weight has been found to improve biodegradability of the consumable and to reduce the waste generated through use of aerosol delivery systems.

The hollow tube may be formed from any suitable material provided the weight in an axial direction is less than 8.5 mg/mm in an axial direction.

For example, the hollow tube 12 may comprise a cellulose acetate tube. The cellulose acetate tube may be formed from cellulose acetate tow.

In particular, the cellulose acetate tube may be formed of cellulose acetate tow having a total fiber denier of between 25000 and 40000. More preferably, the total fiber denier may be between 28000 and 36000. The cellulose acetate tow forming the cellulose acetate tube may have a fiber denier per filament (dpf) value of between 3 and 10 dpf, more preferably between 5 and 8 dpf.

The hollow tube 12 in the example of FIG. 1a may have a circumference of about 20.5 mm, a wall thickness of about 1.3 mm, and an internal diameter of about 3.9 mm. The hollow tube may comprise cellulose acetate tow having a denier per filament value of 7.3 and a total fibre denier of 36,000. Alternatively, the cellulose acetate tube may comprise cellulose acetate tow having a denier per filament value of 5.8, and a total fibre denier of 28,000. These examples have been found to have a weight of less than 8.5 mg/mm and therefore provide a reduced weight tube to help in reducing the weight of the overall consumable. However, the skilled person will appreciate that any suitable combination of total fiber denier and denier per filament value having a weight of less than 8.5 mm/mg may be used.

It is desirable to maintain relatively high levels of hardness of the hollow tube 12 in order that the tube can withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article 1 is in use. For example, it is desirable that a cellulose acetate tube provided at the mouth end of the mouthpiece for insertion into a user's mouth retains its shape and is not easily deformed by pressure of the user's mouth on the tube.

It has been found that high levels of hardness can be maintained for a cellulose acetate tube having parameters as described herein. The hollow tube according to aspects of the present specification has a hardness of at least 70%. Preferably, the hardness of the hollow tube is at least 80%. More preferably, the hardness of the hollow tube is at least 90%.

The hardness of any of the tubes as described throughout the specification may be measured according to the following protocol. Where the hardness of a tube or tubular section is referred to throughout the specification, the hardness is that as determined by the following measurement process. Any suitable device may be used for performing the measurement, such as the Borgwaldt Hardness Tester H10.

Hardness is defined as the ratio between the height h0 of a body and the height h1 of the body under a defined load, state as a percentage of h0. Hardness may be expressed as:

Hardness=(h1/h0)×100

For an individual tube, or a tube contained in a multi-section article, the hardness measurement is performed at the longitudinal center point of the body.

A load bar is used to apply the defined load to the tube. The length of the load bar should be significantly higher than that of the specimen to be measured. Prior to the hardness measurement, the tube to be measured is conditioned according to ISO 3402 for a minimum of 48 hours, and is maintained in environmental conditions according to ISO 3402 during the measurement.

To perform the hardness measurement, a tube is placed into the Hardness Tester H10, a pre-load of 2 g is applied to the tube, and after 1s the initial height ho of the tube under the 2 g pre-load is recorded. The pre-load is then removed and a load bar bearing a load of 150 g is lowered onto the sample at a rate of 0.6 mm/s, after 5 s the height h1 of the tube under the 150 g load is measured.

The hardness is determined as the average hardness of at least 20 tube sections measured according to this protocol.

According to other examples according to the present specification, the circumference of the hollow tube 12 may be any suitable value, for example between about 20 mm and 26 mm. In particular, the circumference of the hollow tube may be 20.45 mm.

The wall thickness of the hollow tube 12 may be between about 1.0 mm and 1.5 mm, and may preferably be between 1.25 mm and 1.4 mm. The internal diameter may be between about 3.5 mm and 4.2 mm.

The hollow tube 12 may comprise less than 15% by weight of plasticizer. The plasticizer may be triacetin, for example, although any suitable plasticizer may be used.

The mouthpiece in the example according to FIG. 1a includes the cooling section. The cooling section is positioned downstream of and immediately adjacent to the rod of aerosol generating material 10. The cooling section 16 in this example is also in an abutting relationship with the rod of aerosol generating material 10. The cooling section 16 comprises a hollow channel. The hollow channel can provide a space into which aerosol drawn into the cooling section 16 can expand and cool down.

It is desirable that the cooling section 16 has a hardness that is sufficient to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article is in use. However, it also desirable to reduce the weight of the cooling section to reduce the overall waste of the article remaining after use, to improve the overall biodegradability of the article 1.

The cooling section 16 may include a hollow tube 161 formed of a plurality of layers of a sheet material. The hollow tube 161 may be formed from a plurality of layers of paper which are parallel wound, with butted seams, to form a hollow tube. In the present example, first and second paper layers are provided in a two-ply tube, although in other examples 3, 4 or more paper layers can be used forming 3, 4 or more ply tubes. Other constructions can be used, such as spirally wound layers of paper, cardboard tubes, tubes formed using a papier-mâché type process, moulded or extruded plastic tubes or similar.

The paper may be a plug wrap paper and/or tipping paper. In some examples, the plug wrap paper forming the hollow tube 161 of the cooling section 16 is an impermeable, or substantially non-porous plug wrap.

The sheet material making up the hollow tube 161 of the cooling section 16 preferably has a basis weight below 90 GSM. In some examples, the basis weight of the sheet material forming the cooling section 16 has a basis weight below 80 GSM. In some examples, the basis weight of the sheet material forming the hollow tube 161 of the cooling section 16 has a basis weight below 70 GSM. In the example of FIG. 1a, the sheet material is a plug wrap having a basis weight of 82 GSM.

Preferably, the weight of the hollow tube 161 forming the cooling section 16 is 4 mg/mm or less. In other examples, the weight of the cooling section 16 is 3.5 mg/mm or less. In yet other examples, the weight of the cooling section 16 is 3.0 mg/mm or less, or 2.5 mg/mm or less. In the example of FIG. 1a, the cooling section has a weight of 3.2 mg/mm.

The layers of sheet material forming the hollow tube of the cooling section 16 are secured together with an adhesive. In the example of FIG. 1a, the adhesive is applied at the seams of the layers of sheet material, and an anchorage line of adhesive is additionally applied to further secure the layers together.

The hardness of the hollow tube 161 forming the cooling section 16 is preferably at least 70%. In some examples, the hardness of the cooling section 16 is at least 80%. In yet other examples, the hardness of the cooling section 16 is at least 90%. In the example of FIG. 1a, the hardness of the cooling section is 94%.

In some examples, the cooling section 16 may be alternatively be formed using a layer of sheet material such as a stiff plug wrap and/or tipping paper meaning that a separate tubular element is not required. The stiff plug wrap is manufactured to have a rigidity that is sufficient to withstand the axial and compressive forces and bending moments that might arise during manufacture and while the article 1 is in use. The stiff plug wrap and/or tipping paper can have a basis weight between 70 GSM and 120 GSM, more preferably between 80 GSM and 110 GSM. Additionally or alternatively, the stiff plug wrap and/or tipping paper can have a thickness between 80 μm and 200 μm, more preferably between 100 μm and 160 μm, or from 120 μm to 150 μm. It can be desirable for both the plug wrap and tipping paper to have values in these ranges, to achieve an acceptable overall level of rigidity for the hollow tube of the cooling section 16.

The cooling section 16 may be formed by wrapping the hollow tube 12 and filter segment 18 with plug wrap 13, wherein the plug wrap extends in an axial direction beyond the upstream end of the filter plug 18, forming a hollow tube adjacent to and in axial alignment with the filter segment 18. The hollow tube may be joined to the rod of aerosol generating material 10 by tipping paper 11 for example, with a cavity formed between the filter plug 18 and the rod of aerosol generating material 10, thus forming the cooling section 16. By forming the cooling section 16 from a stiff plug wrap 13 which also wraps the remaining segments of the mouthpiece, this removes the need to provide an additional tubular segment as the cooling section 16.

In other examples, the cooling section may comprise a cellulose acetate tube. The cellulose acetate tube may be a reduced weight cellulose acetate tube having substantially similar properties to those described in relation to the hollow tube 12, and an article comprising such a cooling section will now be described in more detail with respect to FIG. 2.

FIG. 2 is a side cross sectional view of an alternative example of an article 2 aerosol provision system according to an aspect of the present specification in which the cooling section comprises a cellulose acetate tube. The article 2 largely corresponds to the article 1 of FIG. 1, and comprises a rod of aerosol generating material 10, and a mouthpiece 24 comprising a hollow cellulose acetate tube 12, and a filter material segment 18, as described in relation to FIG. 1a. The filter material segment 18 may additionally include an aerosol modifying material, such as a breakable capsule as described in relation to FIG. 1b.

The mouthpiece 24 further comprises cooling section 26 provided adjacent to and abutting the rod of aerosol generating material 10. Similarly to the example of FIG. 1a, the cooling section 26 may be configured to cool aerosols which are generated when the rod of aerosol generating material 10 is heated during use. In the example of FIG. 2, the cooling section comprises a cellulose acetate tube 261. The cellulose acetate tube may be a cellulose acetate tube substantially similar to the cellulose acetate tube 12 described in relation to FIG. 1a. For example, the hollow tube 261 may have a low weight to improve the biodegradability of the article 2 and to reduce the waste generated through use of aerosol delivery systems. In particular, the hollow tube 261 may have a weight per unit length of less than 8.5 mg/mm in an axial direction.

The hollow tube 261 may be formed from any suitable material provided the weight in an axial direction is less than 8.5 mg/mm in an axial direction.

The hollow tube 12 may be approximately 6 mm in length. The filter segment 18 may be 10 mm in length. The hollow tube 261 may be approximately 6 mm in length.

The hollow tube 261 may be formed from cellulose acetate tow. In particular, the hollow tube 261 may be formed of cellulose acetate tow having a total fibre denier of between 28000 and 36000. The cellulose acetate tow forming the cellulose acetate tube may have a fibre denier per filament value of between 5.8 and 7.3. For example the hollow tube may comprise cellulose acetate tow having a denier per filament value of 7.3 and a total fibre denier of 36,000. Alternatively, the cellulose acetate tube may comprise cellulose acetate tow having a denier per filament value of 5.8, and a total fibre denier of 28,000. However, the skilled person will appreciate that any suitable combination of total fibre denier and denier per filament value having a weight of less than 8.5 mm/mg may be used.

The circumference, wall thickness and internal diameter of the hollow tube 261 may be substantially the same as the hollow tube 12. However, any suitable values may be used. In some examples, the circumference of the hollow tube 261 may be between about 20 mm and 26 mm. The wall thickness of the hollow tube 261 may be between about 1.0 mm and 1.5 mm, and may preferably be between 1.3 mm and 1.4 mm. The internal diameter may be between about 3.5 mm and 4.0 mm.

It is desirable to maintain relatively high levels of hardness of the hollow tube 261 in order that the tube can withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article 2 is in use. The hollow tube 261 according to aspects of the present specification has a hardness of at least 70%. Preferably, the hardness of the hollow tube is at least 80%. More preferably, the hardness of the hollow tube is at least 90%.

The hollow tube 261 may comprise less than 15% by weight of plasticizer. The plasticizer may be triacetin, for example, although any suitable plasticizer may be used.

The cooling section 26 may additionally or alternatively comprise at least one hollow tubular section formed of sheet material. In the example of FIG. 2, the cooling section 26 further comprises hollow tubular sections 262, 263 provided at each end of the cellulose acetate tube 261. The hollow tubular sections 262, 263 are provided adjacent to and in abutment with the cellulose acetate tube 261. The hollow tubular section 262 may be provided adjacent to and in abutment with the upstream end of the filter segment 18. The hollow tubular section 263 may be provided adjacent to and in abutment with the downstream end of the rod of aerosol generating material 10. Hollow tubular section 262 may be between 6 mm and 15 mm, for example 13 mm. Hollow tubular section 263 may be between 4 and 10 mm, for example 6 mm.

The hollow tubular sections 262, 263 may be formed by at least one layer of sheet material, such as paper, for example. The paper may be plug wrap and/or tipping paper. In the example of FIG. 2, the hollow tubular sections 262, 273 are formed of a plug wrap paper. The plug wrap paper may be, for example, an impermeable plug wrap. In one example according to the present specification, the plug wrap paper may be a tube formed from a single layer of a stiff plug wrap or tipping paper joined by butted seams. In the example of FIG. 2, the mouthpiece of the article is wrapped in a plug wrap paper having a basis weight of about 100 GSM. Forming the mouthpiece using a stiff plug wrap and/or tipping paper means that a separate tubular element is not required for the hollow tubular sections 262, 263, and the hollow tubular sections 262, 263 are cavities formed between the filter plug 18 and the hollow tubular section 261, defined by the outer plug wrap. The stiff plug wrap and/or tipping paper can have a basis weight between 70 GSM and 120 GSM, more preferably between 80 GSM and 110 GSM. Additionally or alternatively, the stiff plug wrap and/or tipping paper can have a thickness between 80 μm and 200 μm, more preferably between 100 μm and 160 μm, or from 120 μm to 150 μm. It can be desirable for both the plug wrap and tipping paper to have values in these ranges, to achieve an acceptable overall level of rigidity for the hollow tube of the cooling section 16.

In other examples according to the present specification, the hollow tubular sections may be formed of paper tubes formed of a plurality of layers of sheet material. Weight reduction may be provided by reducing the basis weight of the sheet material. For example, the cooling section 26 may comprise one or more hollow tubes 262, 263 formed of a plurality of layers of paper having a basis weight of 90 GSM or below. In some examples, the basis weight of the sheet material is below 80 GSM. In some examples, the basis weight of the sheet material is below 70 GSM.

In some examples, the weight per unit length of the hollow tubular sections 262, 263 is 4 mg/mm or less. In other examples, the weight of the hollow tubular sections 262, 263 is 3.5 mg/mm or less. In yet other examples, the weight of hollow tubular sections 262, 263 is 3.0 mg/mm or less, or 2.5 mg/mm or less.

The sheet material forming the hollow tubular sections 262, 263 is secured together with an adhesive at the seam. If a plurality of layers of sheet material are used, then the plurality of layers are secured together at the seams with adhesive, and an anchorage line of adhesive may further be provided to secure the sheets together.

In the example of FIG. 2, the cooling section 26 may be formed by wrapping the cellulose acetate tube 261 with plug wrap, where the plug wrap extends in an axial direction beyond the ends of the cellulose acetate tube 261. The plug wrap forming the hollow tubular sections 262, 263 may further be provided around each of the segments in the mouthpiece 24, for example including the cellulose acetate tube 12 and filter segment 18, where a gap is provided between the filter segment 18 and the cellulose acetate tube 261, forming the hollow tubular section 262. Accordingly, the hollow tubular sections 262, 263 are formed by the plug wrap, and a separate tubular section is not required. A tipping wrapper may join the rod of aerosol generating material 10 to the mouthpiece 24.

The hardness of the hollow tubular sections 262, 263 is preferably at least 70%. In some examples, the hardness of the hollow tubular sections 262, 263 is at least 80%. In yet other examples, the hardness of the hollow tubular sections 262, 263 is at least 90%.

The hollow tubes 261, 262, 263 as described herein may be provided for use with any suitable article for use with a non-combustible aerosol provision system. For example, the outer diameter of the hollow tube may substantially correspond to the outer diameter of a rod of aerosol generating material of an article for use with a non-combustible aerosol provision system. In some examples, the outer diameter of the hollow tube may substantially correspond to the outer diameter of a filter plug segment of an article for use with a non-combustible aerosol provision system. The inner diameter of the hollow tube may be configured to receive an aerosol generated during heating of a rod of aerosol generating material during use of an article for use with a non-combustible aerosol provision system.

FIG. 3 is a side cross sectional view of an alternative example of an article 3 for use with an aerosol provision system according to an aspect of the present specification. The article 3 largely corresponds to the article 1 of FIG. 1, and comprises a rod of aerosol generating material 10, and a mouthpiece 34 comprising a hollow cellulose acetate tube 12, and a filter material segment 18, as described in relation to FIG. 1a. The filter material segment 18 may additionally comprise an aerosol modifying material, for example a breakable capsule containing an aerosol modifying material as described in relation to FIG. 1b. The mouthpiece 34 further comprises cooling section 36 provided adjacent to and abutting the rod of aerosol generating material 10. Similarly to the example of FIG. 1a, the cooling section 36 may be configured to cool aerosols which are generated when the rod of aerosol generating material 10 is heated during use.

In the example of FIG. 3, the cooling section comprises a hollow tube 361 formed of a plurality of layers of sheet material. The sheet material forming the hollow tube 361 may be plug wrap and/or tipping paper. For example the hollow tube may be formed of two or more layers of plug wrap which are parallel wound with butted seams. As described above in relation to cooling section 16, other constructions can be used, such as spirally wound layers of paper, cardboard tubes, tubes formed using a papier-mâché type process, molded or extruded plastic tubes or similar. In order to reduce the weight of the hollow tube 361 to reduce the waste from the article after use the hollow tube 361 may be formed from a plug wrap or other sheet material having a basis weight of 90 GSM or less, similarly to the cooling section 16 of FIG. 1. In some examples, the basis weight of the sheet material is below 80 GSM. In some examples, the basis weight of the sheet material is below 70 GSM. In the example of FIG. 3, the hollow tube 361 is shorter than the hollow tube forming the cooling section 16 in the example of FIG. 1a. By providing a shorter tube the weight of the tube may be reduced, thus reducing the weight of the cooling section 36. The tube 361 in the example of FIG. 3 may be 5 mm or less.

In some examples, the hollow tube 361 may be provided in axial alignment with, but spaced from the filter segment 18. The tube 361 may be connected to the filter segment 18 and the hollow tube 12 by means of a stiff plug wrap 13, thus providing a cavity between the hollow tube 361 and the filter segment 18. The cavity surrounded by the plug wrap 13 therefore provides hollow tubular segment 362 without requiring use of a separate hollow tubular element. The hollow tubular segment 362 may be 20 mm in length. The stiff plug wrap 13 and/or tipping paper 11 can have a basis weight between 70 GSM and 120 GSM, more preferably between 80 GSM and 110 GSM. Additionally or alternatively, the stiff plug wrap 13 and/or tipping paper 11 can have a thickness between 80 μm and 200 μm, more preferably between 100 μm and 160 μm, or from 120 μm to 150 μm. It can be desirable for both the plug wrap 13 and tipping paper 11 to have values in these ranges, to achieve an acceptable overall level of rigidity for the hollow tube of the cooling section 36.

By providing the hollow tube 362 between the hollow tube 361 and the filter segment 18, the distance of the cooling section can be increased, which may be of use in the case that the hollow segment 361 is substantially shorter than the cooling section 16 of the example of FIG. 1a. That is, a large volume may be provided in the mouthpiece through which the aerosols generated during heating of the aerosol generating material can expand and cool while passing through the cooling section 36, while keeping the weight of the cooling section low. The overall weight of the article 3 may be lower than the article of FIG. 1a, and therefore the overall waste of the article after use may be reduced, thus improving the biodegradability of the article.

In an alternative example, the cooling section 36 may be made entirely from a single layer of stiff plug wrap 13, without the tubular segment 361. However, the rigidity of the cooling section 36 may be improved through inclusion of the tubular section 361 which is formed of a plurality of layers of sheet material.

The hollow tubes 361, 362 as described herein may be provided for use with any suitable article for use with a non-combustible aerosol provision system. For example, the outer diameter of the hollow tube may substantially correspond to the outer diameter of a rod of aerosol generating material of an article for use with a non-combustible aerosol provision system. In some examples, the outer diameter of the hollow tube may substantially correspond to the outer diameter of a filter plug segment of an article for use with a non-combustible aerosol provision system. The inner diameter of the hollow tube may be configured to receive an aerosol generated during heating of a rod of aerosol generating material during use of an article for use with a non-combustible aerosol provision system.

FIG. 4a is a side cross sectional view of an alternative example of an article 4 for use with an aerosol provision system according to an aspect of the present specification. The article 4 comprises a rod of aerosol generating material 10, and a mouthpiece 44. The mouthpiece comprises a cooling section 46 at a downstream end of the rod of aerosol generating material 10. The cooling section 46 is provided adjacent to and in abutment with the rod of aerosol generating material. A filter plug 18 is provided downstream of the cooling section. The filter plug 18 is provided adjacent to and in abutment with the cooling section 46. In addition, a recessed mouth end segment 42 is provided at the downstream end of the mouthpiece 44.

The mouth end segment may be, for example, between 5 and 15 mm in length, for example 12 mm in length. The filter segment 18 may be between 5 and 15 mm in length, for example 13 mm in length. The cooling section may be between 5 and 30 mm in length, for example 25 mm.

Similarly to the examples of FIGS. 1, 2, and 3, the cooling section 46 is provided to receive aerosols from the rod of aerosol generating material 10 when the rod of aerosol generating material 10 is heated during use. The generated aerosols expand within the cooling section 46 and are cooled during their passage through the cooling section 46 prior to the aerosols being transmitted to a user via the filter plug and the recessed mouth end segment 42.

In the example of FIG. 4a, the cooling section 46 is a hollow tube 461a formed by a layer of sheet material. In particular, the cooling section may comprise a channel having an inner surface defined by the layer of sheet material. For example, the cooling section may comprise a stiff plug wrap 13 formed into a tube shape. The stiff plug wrap 13 forming the cooling section 46 can have a basis weight between 70 GSM and 120 GSM, more preferably between 80 GSM and 110 GSM. Additionally or alternatively, the stiff plug wrap 13 can have a thickness between 80 μm and 200 μm, more preferably between 100 μm and 160 μm, or from 120 μm to 150 μm. It can be desirable for the plug wrap to have values in these ranges, to achieve an acceptable overall level of rigidity for the hollow tube of the cooling section 46.

In the example of FIG. 4a, the recessed mouthpiece 42 is also a hollow tube formed by a layer of sheet material, such as a stiff plug wrap 13 formed into a tube shape. In particular, the recessed mouthpiece may comprise a channel having an inner surface defined by the layer of sheet material. In a similar manner as the cooling section 46, the stiff plug wrap 13 forming the recessed mouthpiece 42 can have a basis weight between 70 GSM and 120 GSM, more preferably between 80 GSM and 110 GSM. Additionally or alternatively, the stiff plug wrap 13 can have a thickness between 80 μm and 200 μm, more preferably between 100 μm and 160 μm, or from 120 μm to 150 μm. It can be desirable for the plug wrap 13 to have values in these ranges, to achieve an acceptable overall level of rigidity for the hollow tube of the cooling section 46.

In the example of FIG. 4a, the cooling section 46 and recessed mouthpiece 42 are both formed by wrapping a single piece of stiff plug wrap 131 around the filter plug 18. The plug wrap 13 extends longitudinally beyond the edges of the filter plug 18 to form a hollow tube 42, 461a, on each side of the filter plug 18. In this way, the mouthpiece 44 can be formed simply without requiring any additional tubes.

However, the provision of an additional tube in the cooling section 46 may improve the overall rigidity of the article 4.

In the example of FIG. 4b, the cooling section 46 additionally comprises a hollow tubular segment 461b provided adjacent to and in abutment with the rod of aerosol generating material 10. For example, the hollow tube 461a formed by the plug wrap 13 may be provided around the hollow tubular segment 461b. The hollow tubular segment 461 may extend the entire length of the cooling section 46, or it may be a shorter section as illustrated in the example of FIG. 4c. The hollow tubular segment 461c in FIG. 4c may be similar to the hollow tubular segment 361 illustrated in FIG. 3.

Providing an additional hollow tubular segment 461 in the cooling section 46 may improve the overall rigidity of the article 4, however it may increase the overall weight and the waste generated after use of the article 4. Therefore, providing a shortened tubular segment 461c which does not extend along the entire length of the cooling section 46 may provide some additional rigidity compared to the example of FIG. 4a, while keeping the weight of the article low. Therefore, the waste generated after use of the article 4 and the overall biodegradability of the article 4 may be improved.

In the example of FIG. 4c, the hollow tubular segment 461 is 5 mm or less. In some examples, the hollow tubular segment 461c may be between 2.5 mm and 5 mm. In some examples, the hollow tubular segment 461c may be 4 mm or less, 3 mm or less, or 2.5 mm.

The hollow tubular segment 461b, 461c may be formed of a plurality of layers of sheet material. The sheet material forming the hollow tubular segment 461b, 461c may have any suitable basis weight. In the case a of shortened length tubular segment 461c, the basis weight may be between 60 GSM and 120 GSM. In some examples the basis weight may be between 90 GSM and 110 GSM. In some examples, the basis weight may be 100 GSM. In some examples, such as when the hollow tubular segment 461b extends over at least half the length of the cooling section 46, the hollow tubular segment 461b is formed of a sheet material having a basis weight of 90 GSM or below. In some examples, the basis weight of the sheet material is below 80 GSM. In some examples, the basis weight of the sheet material is below 70 GSM. In this case, a lighter plug wrap may be used to compensate for the length of the hollow tubular segment 461b being longer, and so the basis weight of the sheet material forming the hollow tubular segment 461b may be reduced in order to keep the overall weight of the cooling section 46 low.

The hollow tubes 461a, 461b as described herein may be provided for use with any suitable article for use with a non-combustible aerosol provision system. For example, the outer diameter of the hollow tube may substantially correspond to the outer diameter of a rod of aerosol generating material of an article for use with a non-combustible aerosol provision system. In some examples, the outer diameter of the hollow tube may substantially correspond to the outer diameter of a filter plug segment of an article for use with a non-combustible aerosol provision system. The inner diameter of the hollow tube may be configured to receive an aerosol generated during heating of a rod of aerosol generating material during use of an article for use with a non-combustible aerosol provision system.

The filter plug 18 in any of the examples of FIGS. 4a, 4b, and 4c may additionally comprise a breakable capsule. The capsule may comprise a shell containing an aerosol modifying material as described above with reference to FIG. 1b.

In the examples of FIGS. 4a, 4b, and 4c, the filter plug 18 is preferably formed of paper. The skilled person will recognise paper filter plugs which may be suitable for use in the article 4 for use with a non-combustible aerosol provision system. Alternatively, the filter plug 18 may be formed of cellulose acetate, such as cellulose acetate tow. The skilled person will recognize that any suitable filter material may be used to form the filter plug 18.

In accordance with an aspect of the specification, any of the articles described above with respect to FIGS. 1 to 4c may alternatively be provided without a mouth end recess segment. Accordingly the mouthpiece 14, 23, 34, 44 may have a further weight reduction by reducing the overall length of the mouthpiece through omission of the mouth end tube formed of either cellulose acetate or sheet material layers.

For example, the filter plug segment 18 may be provided having a length of approximately 12 mm and this may be combined with any of the above described cooling sections 16, 26, 36, 46 having a length of approximately 25 mm. The total length of the mouthpiece may therefore be approximately 37 mm, in contrast to a mouthpiece including a mouth end recess having a length of approximately 41 mm. The overall amount of material forming the mouthpiece may therefore be reduced, improving the biodegradability of the article. The sensation experienced by the user may differ depending on whether the article includes a mouth end recess segment. For example, an article without a mouth end recess may have a warmer sensation on the lips of the user during use compared to a corresponding article including a mouth end recess. Therefore, a mouth end recess may be provided or omitted to suit different user preferences. The filter 18 may be provided with or without a capsule containing an aerosol modifying material.

In another example, an article provided without a mouth end filter segment may be provided with a filter segment 18 having a length of approximately 20 mm, and a cooling section 16, 26, 36, 46 having a length of approximately 17 mm. Accordingly, the corresponding length reduction and omission of a mouth end tube may result in an overall weight reduction of the article. The overall amount of material forming the mouthpiece may therefore be reduced, improving the overall biodegradability of the article. A filter segment 18 having a length of approximately 20 mm may be provided with two or more capsules containing an aerosol modifying material. In other examples, the 20 mm length filter segment 18 may be provided without a capsule, with a single capsule, or with more than two capsules.

FIG. 5a illustrates a method of manufacturing an article 4 as illustrated in FIG. 4a, according to an aspect of the specification, and FIG. 6 is a flow chart illustrating the steps of the method. FIG. 5a illustrates the elements of the article 4 prior to wrapping. In Step S601, filter plug 18 is wrapped with a layer of sheet material to form a wrapped cylinder. The layer of sheet material extends longitudinally beyond a downstream edge of the filter plug 18, thereby forming a first hollow tube 42 at a mouth end of the mouthpiece. In addition, the layer of sheet material extends longitudinally beyond an upstream edge of the filter plug, thereby forming a tubular cooling section 46 upstream of the filter segment. The wrapped cylinder comprises the filter plug 18, hollow tube 42, and hollow tube 461a form the mouthpiece 44 of the article.

The sheet material used for wrapping the filter plug 18 is, for example, a stiff plug wrap as described in relation to the articles of FIG. 4a.

Therefore, a recessed mouthpiece may be manufactured with a simple manufacturing process and at low cost, as the mouthpiece does not require additional tubes.

The filter plug 18 may be formed of paper. Alternatively, a cellulose acetate, PLA, or any other suitable filter material may be used to form the filter plug 18.

In step S602, the method further comprises connecting the mouthpiece 44 to a rod of aerosol generating material by a tipping paper circumscribing the cooling section 46 and the rod of aerosol generating material 10.

In some examples, the method at step S601 also comprises wrapping the layer of sheet material around a hollow tubular segment 461b or 461c. In the example FIG. 5b, the hollow tubular segment 461c is longitudinally spaced from the filter plug 18, and the layer of sheet material wraps the filter plug 18 and hollow tubular segment 461c, such that there is a gap between the filter plug 18 and the hollow tubular segment 461c. The filter plug may comprise a breakable capsule comprising a shell containing an aerosol modifying material.

In other examples, the method at step S601 comprises wrapping the layer of sheet material around the tubular segment 461b such that the hollow tubular segment 461b is provided in abutment with the upstream end of the filter plug 18. The filter plug 18 and hollow tubular segment 461b are wrapped with the layer of sheet material to form the article 4b illustrated in FIG. 4b.

FIG. 7 illustrates an example of forming a 2-up mouthpiece rod which can be cut to form two mouthpieces for subsequent combination with a rod of aerosol generating material.

In the example of FIG. 7, filter plugs 18 are separated by a gap of about 50 mm and wrapped by a plug wrap 11 of approximately 100 mm in length. For filter segments having a length of approximately 13 mm, the plug wrap extends approximately 12 mm beyond the edges of each of the filter segment. The filter plugs 18 are wrapped by the plug wrap 11, to form a hollow tube having a hollow cavity at each end of approximately 12 mm, and a cavity between the filter plugs 18 of approximately 50 mm. The hollow tube may then be cut by a cutter down the middle, to form two mouthpieces. Each mouthpiece includes a 12 mm mouth end cavity, a 13 mm filter plug, and a 25 mm upstream cavity which forms a cooling section. The mouthpiece may subsequently be combined with a rod of aerosol generating material to form an article for use with an aerosol provision system by circumscribing the cooling section and the rod of aerosol generating material with a tipping paper to secure them together.

In some examples, as illustrated in FIG. 7b, a hollow tube can be inserted into the cooling section. A hollow tubular segment may be provided between the filter plugs 18. The hollow tubular segment may be 10 mm long, for example. The filter plugs 18 may each be separated from the hollow tubular segment by a 15 mm gap. The filter plugs 18 and hollow tubular segment may be wrapped by the plug wrap to form a wrapped rod. The wrapped rod may be cut by a cutter down the middle, i.e. through the hollow tubular segment, to form two mouthpieces. Each mouthpiece includes a 12 mm mouth end cavity, a 13 mm filter plug, a 15 mm cavity, and a 5 mm hollow tubular segment. The hollow tubular segment may provide additional rigidity to the mouthpiece. For example, the hollow tubular segment may help to improve the roundness of the mouthpiece.

The hollow tube may be any suitable length. In some examples, the hollow tube may extend between the filter plugs 18. However, a reduced weight may be obtained by reducing the length of the hollow tube. Preferably, the hollow tube in the resulting mouthpiece is 5 mm or less in order to keep the total weight of the article low to reduce the waste leftover after the article is used.

It will be recognized by the skilled person that the method of manufacture can additionally be adapted for the inclusion of a mouth end tube such as the cellulose acetate tube 12 of FIGS. 1, 2, and 3, or the cellulose acetate tube 261 illustrated in FIG. 2. Alternatively or additionally, further filter segments or components may be included in the mouthpiece by being wrapped by the sheet material together with the filter segment 18 and a cooling section 16, 26, 36, 46.

The below examples describe in more detail hollow tubes which may be used in the mouthpieces 14, 24, 34, 44 of the articles 1, 2, 3, 4 described above in accordance with aspects of the specification.

Examples

FIG. 8 is a table illustrating some examples hollow tubes for use in articles in accordance with embodiments of the present specification, such as the articles 1, 2, and 3. The examples illustrated in FIG. 8 are hollow tubes formed of cellulose acetate tow. In the examples, the tubes are approximately 96.6 mm in length. The tubes are intended to be cut to a desired length prior to introducing into an aerosol generating article during manufacture.

The parameters given include the initial values of the parameters after production (i.e. the “operation” column in FIG. 8), and the subsequent values of the tubes after being subject to an ageing period of 5 days from production.

A comparative example of a cellulose acetate tube currently used in some aerosol provision systems is provided. In the comparative example, the initial length of the tube is 96.6 mm, the initial weight is 1028.4 mg, the initial wall thickness is 1.3 mm, and the circumference is 20.53 mm. The initial hardness of the comparative example tube is 96.1%. After the ageing period the length of the tube is 96.4 mm, the weight is 1020.7 mg, the wall thickness is 1.3 mm, and the circumference is 20.50 mm. The hardness after the ageing period has risen to 96.7%.

In example 1, which relates to hollow tubes 12 according to embodiments of the present specification, a tube is formed of cellulose acetate tow having a denier per filament value of 7.3 and has a total denier of 36000. The initial length of the tube is 96.44 mm, the initial weight is 933.18 mg, the initial wall thickness is 1.27 mm, and the circumference is 20.52 mm. The initial hardness is 95.68%.

After the ageing process, the hollow tube has a circumference of 20.45 mm and wall thickness of 1.3 mm. The length of the tube 12 is 96.35 mm. The weight of the tube is 925.72 mg. This weight has been found to be less than the weight of the cellulose acetate tube of the comparative example, corresponding to a weight reduction of 9.3%. It can therefore be seen that a substantial weight reduction can be obtained by reducing the denier per filament value and total denier of a cellulose acetate tube, while still retaining substantially the same physical size characteristics. As can be seen, the length, circumference, and wall thickness are substantially the same as those of the comparative example, while providing the weight reduction as described.

Furthermore, it has been found that the hardness of the hollow tube according to the first example is not substantially lower than the hardness of the hollow tube of the comparative example. As can be seen from FIG. 8, the hardness of the tube after the ageing process increases to 96.40%. Therefore, the hardness of the reduced weight tube of example 1 is substantially similar to the hardness of the comparative example.

In example 2, the tube is formed of cellulose acetate tow having a denier per filament value of 5.8 and has a total denier of 28000. The initial length of the tube is 96.43 mm, the initial weight is 839.6 mg, the initial wall thickness is 1.37 mm, and the circumference is 20.48 mm. The initial hardness is 95.51%.

After the ageing process, the hollow tube has a circumference of 20.39 mm and wall thickness of 1.3 mm. The length of the tube 12 is 96.5 mm. The weight of the tube is 834.76 mg. This weight has been found to be less than the weight of the cellulose acetate tube of the comparative example, corresponding to a weight reduction of 17.7%. It can therefore be seen that a substantial weight reduction can be obtained by reducing the denier per filament value and total denier of a cellulose acetate tube, while still retaining substantially the same physical size characteristics. As can be seen, the length, circumference, and wall thickness are substantially the same as those of the comparative example, while providing the weight reduction as described.

Furthermore, it has been found that the hardness of the hollow tube according to the first example is not substantially lower than the hardness of the hollow tube of the comparative example. As can be seen from FIG. 8, the hardness of the tube after the ageing process increases to 96.66%. Therefore, the hardness of the reduced weight tube of example 2 is substantially similar to the hardness of the comparative example.

Therefore, it can be seen that, a substantial weight reduction of an article can be achieved by reducing the fiber denier per filament and total denier of the cellulose acetate tow making up a hollow tube, while retaining a hardness of the tube of greater than 90%.

Therefore, the tubes of examples 1 and 2 may provide a base rod to be cut into a plurality of hollow tubes 12 for inclusion in an aerosol generating article.

Hollow tubes such as the hollow tubes 161, 362, 461b, 461c are formed of a plurality of layers of sheet material, such as plug wrap, as described in relation to FIGS. 1, 3, and 4. Such hollow tubes will be described in more detail herein. In the examples described below, the hollow tubes are approximately 100 mm in length, and may be cut to an appropriate size prior to being included in a mouthpiece of an article.

Example 3

In example 3, a hollow tube is formed of a plurality of layers of a plug wrap paper. The plug wrap paper has a basis weight of 82 GSM. The tube has a circumference of between about 20.15 mm and 20.51 mm, and preferably about 20.33 mm. The bore size of the hollow tube is about 19.56 mm.

The weight of the plug wrap paper for forming the 100 mm tube as described above is approximately 304 mg. The layers of plug wrap are secured together by an adhesive at the seams, and adjacent layers are secured together by an anchorage line of adhesive, such that the plug wrap forms a hollow tube. The seams are secured using an adhesive applied at a rate of approximately 0.08 mg/mm. The adhesive is applied to the seams of the 100 mm tube such that the total weight of adhesive at each seam is between approximately 6.4 mg and 9.6 mg in weight, for example 8 mg in weight. The anchorage line of adhesive is applied at a rate of approximately 0.2 mg/mm. The adhesive is applied at the anchorage line such that the total weight of adhesive at the anchorage line is between 16 mg and 24 mg, for example between 18 mg and 22 mg, and preferably 20 mg.

After application of the adhesive to the plug wrap to form the tube, the tube is left to cure for approximately 1 hour. The total weight of the tube after curing is between 300 mg and 340 mg, preferably between 310 mg and 330 mg, more preferably about 320 mg.

The hardness of the tube is at least 70% in order to retain suitable rigidity to withstand axial and compressive forces during manufacture of an article using the tube. Preferably, the hardness of the tube is at least 80%, or at least 90%. More preferably, the hardness of the tube is about 94%.

The roundness of the tube is at least 92%. Preferably, the roundness of the tube is 94%.

Example 4

In example 4, a hollow tube is formed of a plurality of layers of a plug wrap paper, similarly to as described in example 3, except using a plug wrap paper having a basis weight of 60 GSM. The tube has a circumference of between about 20.15 mm and 20.51 mm, and preferably about 20.33 mm. The bore size of the hollow tube is about 19.56 mm.

The weight of the plug wrap paper for forming the 100 mm tube as described above is approximately 324 mg. The layers of plug wrap are secured together by an adhesive at the seams, and adjacent layers are secured together by an anchorage line of adhesive, such that the plug wrap forms a hollow tube. The seams are secured using an adhesive applied at a rate of approximately 0.08 mg/mm. The adhesive is applied to the seams of the 100 mm tube such that the total weight of adhesive at each seam is between approximately 6.4 mg and 9.6 mg in weight, for example 8 mg in weight. The anchorage line of adhesive is applied at a rate of approximately 0.2 mg/mm. The adhesive is applied at the anchorage line such that the total weight of adhesive at the anchorage line is between 16 mg and 24 mg, for example between 18 mg and 22 mg, and preferably 20 mg.

After application of the adhesive to the plug wrap to form the tube, the tube is left to cure for approximately 1 hour. The total weight of the tube after curing is between 226 mg and 266 mg, preferably between 236 mg and 256 mg, more preferably about 246 mg.

The hardness of the tube measured using a H10 hardness method is at least 70% in order to retain suitable rigidity to withstand axial and compressive forces during manufacture of an article using the tube. Preferably, the hardness of the tube is at least 80%, or at least 90%. More preferably, the hardness of the tube is about 94%.

The roundness of the tube is at least 92%. Preferably, the roundness of the tube is 94%.

The tubes in examples 3 and 4 may be cut to an appropriate length and introduced to the cooling section and/or mouth end of any of the articles 1, 2, 3, and 4 as described above. The weight of the tubes may be lower than conventional paper tubes used in cooling sections of articles for use with non-combustible aerosol provision systems.

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

AN ARTICLE FOR USE IN A NON-COMBUSTIBLE AEROSOL PROVISION SYSTEM

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