Article for use in a non-combustible aerosol provision system

Abstract

An article for use in a non-combustible aerosol provision system that includes an aerosol provision device. The article includes a rod of aerosol-generating material having a distal end for insertion into the non-combustible aerosol provision device such that a heating element of the device extends into the rod of aerosol-generating material through said distal end. The article includes a cavity extending in a longitudinal direction into the rod of aerosol-generating material from said distal end to receive the heating element. A system including a non-combustible aerosol provision device having a heating element, and an article according to the invention, together with a method of manufacturing an article according to the invention is also disclosed.

1 . An article for use in a non-combustible aerosol provision system that includes an aerosol provision device, the article comprising a rod of aerosol-generating material having a distal end for insertion into the non-combustible aerosol provision device such that a heating element of the device extends into the rod of aerosol-generating material through said distal end, wherein the article comprises a cavity extending in a longitudinal direction into the rod of aerosol-generating material from said distal end to receive the heating element. 
     
     
         2 . An article according to  claim 1 , comprising a mouth end opposite to said distal end, said mouth end being configured to be placed between the lips of a user when the distal end is inserted into a non-combustible aerosol provision device. 
     
     
         3 . An article according to  claim 2 , wherein a cooling segment is located between the aerosol-generating material and the mouth end. 
     
     
         4 . An article according to  claim 3 , wherein a filtration segment is located between the cooling segment and the mouth end. 
     
     
         5 . An article according to  any preceding claim , wherein the cavity extends the full length of the aerosol-generating material. 
     
     
         6 . An article according to any of  claims 1 to 4 , wherein the cavity is coaxial with a longitudinal axis of the article. 
     
     
         7 . An article according to  claim 6 , wherein the aerosol-generating material comprises a tube. 
     
     
         8 . An article according to  claim 7 , wherein the tube comprises an inner surface, and a profile is formed in said surface that extends in a longitudinal direction. 
     
     
         9 . An article according to  claim 8 , wherein said profile comprises a helical groove or recess. 
     
     
         10 . An article according to  claim 8 , wherein said profile comprises a linear groove or recess. 
     
     
         11 . An article according to any of  claims 1 to 4 , wherein a plurality of cavities extend into the aerosol-generating material from said distal end. 
     
     
         12 . An article according to  claim 11 , wherein one or more of said cavities are arranged about said longitudinal axis. 
     
     
         13 . An article according to  claim 11 , wherein one of said cavities is coaxial with said longitudinal axis of the aerosol-generating material. 
     
     
         14 . An article according to any of  claims 1 to 4 , wherein the or each cavity has a non-circular cross-section. 
     
     
         15 . An article according to any of  claims 1 to 4 , wherein the or each cavity has a non-uniform cross section in a longitudinal direction. 
     
     
         16 . An article according to  claim 15 , wherein the or each cavity is tapered in a longitudinal direction. 
     
     
         17 . An article according to  claim 16 , wherein the or each cavity is tapered so that it narrows in a direction away from the distal end. 
     
     
         18 . An article according to any of  claims 1 to 4 , comprising a plug at said distal end. 
     
     
         19 . An article according to  claim 18 , wherein said plug abuts the aerosol-generating material. 
     
     
         20 . An article according to  claim 18 , comprising a passage in the plug positioned to correspond with the cavity extending in the aerosol-generating material. 
     
     
         21 . An article according to  claim 20 , wherein the passage is a slit or slot in the plug. 
     
     
         22 . An article according to  claim 18 , wherein the plug is formed from gathered, and optionally, crimped, paper. 
     
     
         23 . An article according to any of  claims 1 to 4 , comprising a material layer on an inner wall of the cavity. 
     
     
         24 . An article according to  claim 23 , wherein the material layer is a gel, an amorphous solid, or a sheet material layer such as paper. 
     
     
         25 . An article according to  claim 24 , wherein the material layer is another layer of aerosol-generating material different to the aerosol-generating material  3 . 
     
     
         26 . An article according to  claim 23 , wherein the material layer comprises a heat-conductive material. 
     
     
         27 . An article according to  claim 26 , wherein the material layer comprises a metal or metal alloy, polymer ceramic or graphite. 
     
     
         28 . A system comprising a non-combustible aerosol provision device having a heating element; and an article comprising a rod of aerosol-generating material having a distal end for insertion into a non-combustible aerosol provision device such that the heating element of the device extends into the aerosol-generating material through said distal end, wherein a cavity extends into the rod of aerosol-generating material in a longitudinal direction from said distal end to receive the heating element. 
     
     
         29 . A system according to  claim 28 , wherein the heating element and the cavity each have the same cross-sectional shape. 
     
     
         30 . A system according to  claim 28 or 29 , wherein the heating element is a snug or interference fit in the cavity. 
     
     
         31 . A system according to  claim 28 , wherein the heating element and the cavity each have a different cross-sectional shape such that, when the heating element is received in the cavity, a passage remains between the heating element and an inner wall of the aerosol generating material. 
     
     
         32 . A system according to  claim 31 , wherein the cavity has a portion with a cross-section that compliments the cross-section of the heating element, such that the heating element is received within said portion, the cavity further comprising at least one lobe extending from said portion to form said passage. 
     
     
         33 . A system according to  claim 28 or 29 , wherein the aerosol-generating material has a longitudinal axis and said cavity to receive the heating element is a central cavity extending along said longitudinal axis. 
     
     
         34 . A system according to  claim 33 , comprising a plurality of additional cavities extending into said aerosol-generating material from said distal end, wherein said additional cavities surround said central cavity and form open passages through the aerosol-generating material when the heating element is received in said central cavity. 
     
     
         35 . A method of manufacturing an article comprising a rod of aerosol-generating material having a distal end for insertion into a non-combustible aerosol provision device, the method comprising extruding the aerosol-generating material through a die head and over a mandrel to form a cavity extending through the aerosol-generating material. 
     
     
         36 . A method according to  claim 35 , wherein the mandrel is shaped to provide a correspondingly shaped cavity in the aerosol-generating material. 
     
     
         37 . A method of manufacturing an article comprising aerosol-generating material having a distal end for insertion into a non-combustible aerosol provision device, comprising molding the aerosol-generating material around a former. 
     
     
         38 . A method according to  claim 37 , wherein the former is shaped to provide a correspondingly shaped cavity in the aerosol-generating material.