An article for use in an aerosol provision system and a method of manufacturing an article

Abstract

The present disclosure relates to an article ( 1 ) for use in an aerosol provision system ( 200 ). The article ( 1 ) comprises a storage area ( 2 ) and a first blocking member ( 4 ). The storage area ( 2 ) contains an aerosol-generating material ( 3 ) configured to be heated within the storage area ( 2 ) to generate an aerosol. The first blocking member ( 4 ) comprises a body of material ( 6 ) arranged to resist the aerosol-generating material ( 3 ) from moving out of the storage area ( 2 ) through a first end ( 6 A) of the storage area ( 2 ). The present disclosure also relates to a method of manufacturing an article ( 1 ) for use in an aerosol provision system ( 200 ). The present disclosure also relates to kit of parts comprising an article ( 1 ) and an aerosol provision device ( 200 ), and to a package of articles ( 1 ).

1 . An article for use in an aerosol provision system, the article comprising:
 a storage area containing an aerosol-generating material configured to be heated within the storage area to generate an aerosol; and,   a first blocking member comprising a body of material arranged to resist the aerosol-generating material from moving out of the storage area through a first end of the storage area.   
     
     
         2 . An article according to  claim 1 , further comprising a wall that surrounds the storage area. 
     
     
         3 . An article according to  claim 2 , wherein the wall comprises a sheet material and, preferably, wherein the sheet material comprises paper and/or foil. 
     
     
         4 . An article according to any one of  claims 1 to 3 , wherein the first blocking member comprises a first wrapper that circumscribes the body of material of the first blocking member and, preferably, the first wrapper comprises paper or cardboard. 
     
     
         5 . An article according to any one of  claims 1 to 4 , wherein the first blocking member does not comprise plastic. 
     
     
         6 . An article according to  any one of the preceding claims , wherein the first blocking member comprises the end of a rod of aerosol generating material and, preferably, said end of the rod has a higher density than another portion of the rod and, preferably, the rod is a tobacco rod. 
     
     
         7 . An article according to  any one of the preceding claims , wherein the body of material comprises a plug of material. 
     
     
         8 . An article according to  any one of the preceding claims , wherein the body of material is disposed adjacent to a first end of the storage area. 
     
     
         9 . An article according to  any one of the preceding claims , wherein the body of material has an axial length in the range of 3 to 20 mm and, preferably in the range of 4 to 15 mm, 5 to 12 mm or 7 to 10 mm. 
     
     
         10 . An article according to  any one of the preceding claims , wherein the body of material comprises an aerosol-generating material. 
     
     
         11 . An article according to  claim 10 , wherein the aerosol-generating material of the body of material comprises tobacco material. 
     
     
         12 . An article according to  claim 11 , wherein the tobacco material is only tobacco lamina and no other types of tobacco material and/or the tobacco material has a nicotine level in the range of 0.5% to 2.5% by weight of the tobacco and, preferably, in the range of 1% to 2.1%. 
     
     
         13 . An article according to  any one of the preceding claims , wherein the aerosol-generating material in the storage area has a density in the range of about 0.4 g/cm 3  to about 2 g/cm 3 . 
     
     
         14 . An article according to  any one of the preceding claims , wherein the body of material comprises aerosol-generating material with a density in the range of about 0.1 g/cm 3  to about 1 g/cm 3 . 
     
     
         15 . An article according to  any one of the preceding claims , wherein the density of the aerosol-generating material in the storage area is at least 25% higher than the density of the body of material. 
     
     
         16 . An article according to  any one of the preceding claims , wherein the body of material comprises an aerosol-former material. 
     
     
         17 . An article according to  any one of the preceding claims , wherein the blocking member comprises an aerosol-generating material comprising: from about 10 to about 50 wt % aerosol-former material; from about 15 to about 60 wt % gelling agent; and optionally filler; wherein the wt % values are calculated on a dry weight basis and, preferably, wherein the aerosol-generating material of the blocking member comprises a flavourant. 
     
     
         18 . An article according to  any one of the preceding claims , wherein the body of material comprises a sheet material that is arranged to form the body of material and, preferably, the sheet material is gathered to form the body of material. 
     
     
         19 . An article according to  claim 18 , wherein the sheet material is crimped. 
     
     
         20 . An article according to  claim 18 or claim 19 , wherein the sheet material of the body of material comprises one or more of: paper and/or aerosol-generating material and, preferably, comprises tobacco. 
     
     
         21 . An article according to  any one of the preceding claims , wherein the first blocking member comprises an end that contacts the aerosol-generating material. 
     
     
         22 . An article according to  any one of the preceding claims , further comprising a second blocking member arranged to resist the aerosol-generating material from moving out of the storage area through a second end of the storage area. 
     
     
         23 . An article according to  claim 22 , wherein the second blocking member comprises a second body of material. 
     
     
         24 . An article according to  claim 22 or claim 23 , wherein the second blocking member has any of the features of the first blocking member of any one of  claims 5 to 21 . 
     
     
         25 . An article according to any one of  claims 22 to 24 , wherein the second blocking member comprises a second wrapper that circumscribes the body of material of the second blocking member and, preferably, the second wrapper comprises paper or cardboard. 
     
     
         26 . An article according to any one of  claims 22 to 25 , wherein the first and second blocking members each at least partially define a boundary of the storage area. 
     
     
         27 . An article according to any one of  claims 22 to 26 , wherein the first and second blocking members are the same. 
     
     
         28 . An article according to any one of  claims 22 to 27 , wherein the first and second blocking members each comprise, consist of, or essentially consist of tobacco and, preferably, each comprise a plug of tobacco. 
     
     
         29 . An article according to any one of  claims 22 to 28 , wherein the first blocking member comprises a first end of the consumable and the second blocking member comprises a second end of the consumable. 
     
     
         30 . An article according to  any one of the preceding claims , wherein the aerosol-generating material in the storage area is a solid material. 
     
     
         31 . An article according to  any one of the preceding claims , wherein the aerosol-generating material in the storage area is a loose material. 
     
     
         32 . An article according to  any one of the preceding claims , wherein the aerosol-generating material in the storage area comprises a plurality of compressed or extruded bodies of aerosol generating material and, preferably, a plurality of compressed or extruded bodies of tobacco material. 
     
     
         33 . An article according to  any one of the preceding claims , wherein the aerosol-generating material in the storage area comprises, consists of, or essentially consists of, tobacco material. 
     
     
         34 . An article according to  claim 33 , wherein the tobacco material is only tobacco lamina and no other types of tobacco material. 
     
     
         35 . An article according to  claim 33 or claim 34 , wherein the tobacco material has a nicotine level in the range of 0.5% to 2.5% by weight of the tobacco and, preferably, in the range of 1% to 2.1%. 
     
     
         36 . An article according to  any one of the preceding claims , further comprising a cooling section and, preferably, wherein the cooling section is arranged such that, in use of the consumable, the cooling section is downstream of the aerosol-generating material. 
     
     
         37 . An article according to  claim 36 , wherein the cooling section comprises aerosol generating material and, preferably, comprises aerosol generating material in the form of a plug. 
     
     
         38 . An article according to  claim 37 , wherein the cooling section comprises a flavourant. 
     
     
         39 . An article according to  any one of the preceding claims , further comprising a plug of material provided on the other side of the first and/or second blocking member to the storage area. 
     
     
         40 . An article according to  any one of the preceding claims , wherein the article has an axial length in the range of 10 to 36 mm and, preferably, in the range of 14 to 32 mm, in the range of 20 to 26 mm, or in the range of 22 to 24 mm. 
     
     
         41 . An article according to  any one of the preceding claims , wherein the article comprises aerosol-generating material along at least 90% of the length of the article and, preferably, along at least 92%, 94%, 96%, 98% or 99% of the length of the article and, preferably, along the entire length of the article. 
     
     
         42 . A method of manufacturing an article for use in an aerosol provision system, the method comprising:
 providing an aerosol-generating material and a first blocking member comprising a body of material, wherein the aerosol-generating material and first blocking member are arranged such that the aerosol-generating material is contained in a storage area and the first blocking member resists the aerosol-generating material from moving out of the storage area through a first end of the storage area.   
     
     
         43 . A method according to  claim 42 , wherein the first blocking member has any of the features of the first blocking member of any one of  claims 5 to 21 . 
     
     
         44 . A method according to  claim 42 or claim 43 , comprising wrapping a first wrapper about the body of material of the first blocking member. 
     
     
         45 . A method according to any one of  claims 42 to 44 , wherein providing the aerosol-generating material and first blocking member comprises locating the aerosol-generating material and first blocking member on a sheet material and, preferably, wherein the sheet material comprises paper and/or foil. 
     
     
         46 . A method according to  claim 45 , comprising wrapping the sheet material about the aerosol-generating material and first blocking member. 
     
     
         47 . A method according to any one of  claims 42 to 46 , further comprising providing a second blocking member arranged such that the second blocking member resists the aerosol-generating material from moving out of the storage area through a second end of the storage area and, preferably, the second blocking member comprises a body of material. 
     
     
         48 . A method according to  claim 47 , wherein the second blocking member has any of the features of the first blocking member of any one of  claims 5 to 21 . 
     
     
         49 . A method according to  claim 47 or claim 48 , comprising wrapping a second wrapper about the body of material of the second blocking member. 
     
     
         50 . A method according to any one of claims  47  to  50 , when dependent on  claim 45 or claim 46 , comprising positioning the first and second blocking members on the sheet material such that a gap is formed therebetween, and at least partially filling the gap with the aerosol-generating material. 
     
     
         51 . A method according to  claim 50 , wherein the sheet material with the first and second blocking members thereon is conveyed along a conveyance path. 
     
     
         52 . A method according to  claim 51 , wherein the gap is at least partially filled with the aerosol-generating material as the sheet material with the first and second blocking members passes a filling apparatus. 
     
     
         53 . A method according to  claim 51 or claim 52 , comprising providing a plurality of first blocking members and second blocking members arranged sequentially on a web of the sheet material, and filling gaps between adjacent first and second blocking members with aerosol-generating material. 
     
     
         54 . A method according to  claim 53 , comprising wrapping the first and second blocking members and aerosol-generating material with the sheet material to form a rod, and then cutting the rod to form an article. 
     
     
         55 . A method according to any one of  claims 47 to 54 , wherein providing the first blocking member comprises providing a double-length first blocking member and providing the second blocking member comprises providing a double-length second blocking member. 
     
     
         56 . A method according to any one of  claims 42 to 55 , wherein the aerosol-generating material in the storage area is a solid material. 
     
     
         57 . A method according to any one of  claims 42 to 56 , wherein the aerosol-generating material in the storage area is a loose material. 
     
     
         58 . A method according to any one of  claims 42 to 57 , wherein the aerosol-generating material in the storage area comprises, consists of, or essentially consists of, tobacco material. 
     
     
         59 . A method according to any one of  claims 42 to 58 , wherein the tobacco material is only tobacco lamina and no other types of tobacco material. 
     
     
         60 . A method according to any one of  claims 42 to 59 , wherein the tobacco material has a nicotine level in the range of 0.5% to 2.5% by weight of the tobacco and, preferably, in the range of 1% to 2.1%. 
     
     
         61 . A method according to any one of  claims 42 to 60 , further comprising providing a cooling section and, preferably, arranging the cooling section such that, in use of the consumable, the cooling section is downstream of the aerosol-generating material. 
     
     
         62 . An article for use in an aerosol provision system, the article comprising aerosol-generating material along at least 90% of the length of the article. 
     
     
         63 . An article according to  claim 62 , wherein the article comprises aerosol-generating material along at least 92% of the length of the article and, preferably, at least 94%, 96%, 98% or 99% of the length of the article. 
     
     
         64 . An article according to  claim 62 or claim 63 , wherein the article comprises aerosol-generating material along substantially the entire length of the article. 
     
     
         65 . An article according to any one of  claims 62 to 64 , wherein the article comprises one or more bodies of material, and wherein the or each body of material of the article comprises aerosol-generating material. 
     
     
         66 . An article according to any one of  claims 62 to 65 , wherein the aerosol generating material comprises first and second aerosol generating materials. 
     
     
         67 . An article according to  claim 66 , wherein the first and second aerosol generating materials are mixed together over at least a portion of the axial length of the article and, preferably, over the entire axial length of the article. 
     
     
         68 . An article according to  claim 66 , comprising a first region that comprises the first aerosol generating material and a second region that comprises the second aerosol generating material and, preferably, wherein the first region is disposed along a first portion of the axial length of the article and the second region is disposed along a second portion of the axial length of the article. 
     
     
         69 . An article according to any one of  claims 62 to 68 , wherein the aerosol generating material comprises one or more extruded or compressed bodies of aerosol generating material and, preferably, wherein the or each extruded or compressed body of aerosol generating material is a bead of aerosol generating material. 
     
     
         70 . An article according to  claim 69 , when dependent on any one of  claims 66 to 68 , wherein the first aerosol generating material comprises the one or more extruded or compressed bodies of aerosol generating material. 
     
     
         71 . An article according to any one of  claims 62 to 70 , wherein the aerosol generating material comprises a sheet of aerosol generating material and, preferably, wherein the sheet is shredded or cut into strips. 
     
     
         72 . An article according to  claim 71 , wherein the sheet of aerosol generating material comprises reconstituted tobacco. 
     
     
         73 . An article according to any one of  claims 62 to 72 , wherein the aerosol generating material comprises lamina tobacco and, preferably, shredded lamina tobacco. 
     
     
         74 . An article according to any one of  claims 71 to 73 , when dependent on any one of  claims 66 to 68 or 70 , wherein the second aerosol generating material comprises the sheet of aerosol generating material and/or the lamina tobacco. 
     
     
         75 . An article according to any one of  claims 62 to 74 , comprising first and second blocking members that each comprise aerosol generating material, wherein a storage area is disposed between the first and second blocking members and wherein the storage area contains aerosol generating material. 
     
     
         76 . An article according to  claim 75 , when dependent on any one of  claims 66 to 68, 70 or 74 , wherein the aerosol generating material in the storage area is the first aerosol generating material and wherein the aerosol generating material of the first and/or second blocking members is the second aerosol generating material. 
     
     
         77 . An article according to any one of  claims 62 to 76 , wherein the aerosol-generating material comprises, consists of, or essentially consists of, tobacco material. 
     
     
         78 . An article according to  claim 77 , wherein tobacco material is provided along at least 90% of the axial length of the article and, preferably, at least 92%, 94%, 96%, 98% or 99% of the length of the article and, preferably, the entire axial length of the article. 
     
     
         79 . An article according to  claim 77 or claim 78 , wherein the tobacco material is manufactured from only tobacco lamina and no other types of tobacco material. 
     
     
         80 . An article according to any one of  claims 77 to 79 , wherein the tobacco material has a nicotine level in the range of 0.5% to 2.5% by weight of the tobacco and, preferably, in the range of 1% to 2.1%. 
     
     
         81 . An article according to any one of  claims 62 to 80  wherein the aerosol generating material is in the form of a rod. 
     
     
         82 . An article according to any one of  claims 62 to 81 , comprising first and second ends, wherein at least one of the first and second ends comprises aerosol generating material and, preferably, both of the first and second ends comprise aerosol generating material. 
     
     
         83 . An article according to any one of  claims 62 to 82 , wherein the article has an axial length in the range of 10 to 36 mm and, preferably, in the range of 14 to 32 mm, in the range of 20 to 26 mm, or in the range of 22 to 24 mm. 
     
     
         84 . A kit of parts comprising: the article of any one  claims 1 to 41 or 62 to 83 ; and, an aerosol provision device. 
     
     
         85 . A package comprising a plurality of articles according to any one of  claims 1 to 41 or 62 to 83  and, preferably, wherein the package is hermetically sealed.