EP3873254A1

EP3873254A1 - Smoking substitute consumable

Info

Publication number: EP3873254A1
Application number: EP19797609.5A
Authority: EP
Inventors: Kate FERRIE; Edward Ross SHENTON; Chris Lord
Original assignee: Nerudia Ltd
Current assignee: IMPERIAL TOBACCO Ltd
Priority date: 2018-10-29
Filing date: 2019-10-25
Publication date: 2021-09-08
Also published as: WO2020089056A1; GB201817539D0

Abstract

The present disclosure relates to an aerosol-forming article comprising an aerosol-forming substrate and a layer of non-combustible material (e.g. a metallic foil) comprising a flavourant (e.g. menthol). The layer of non-combustible material encloses at least a portion of the aerosol-forming substrate.

Description

Smoking substitute consumable

Field of the Disclosure

The present disclosure relates to a consumable for use in a smoking substitute system and particularly, although not exclusively, to a heat-not-burn (HNB) consumable.

Background

The smoking of tobacco is generally considered to expose a smoker to potentially harmful substances. It is generally thought that a significant amount of the potentially harmful substances are generated through the heat caused by the burning and/or combustion of the tobacco and the constituents of the burnt tobacco in the tobacco smoke itself.

Conventional combustible smoking articles, such as cigarettes, typically comprise a cylindrical rod of tobacco comprising shreds of tobacco which is surrounded by a wrapper, and usually also a cylindrical filter axially aligned in an abutting relationship with the wrapped tobacco rod. The filter typically comprises a filtration material which is circumscribed by a plug wrap. The wrapped tobacco rod and the filter are joined together by a wrapped band of tipping paperthat circumscribes the entire length of the filter and an adjacent portion of the wrapped tobacco rod. A conventional cigarette of this type is used by lighting the end opposite to the filter, and burning the tobacco rod. The smoker receives mainstream smoke into their mouth by drawing on the mouth end or filter end of the cigarette.

Combustion of organic material such as tobacco is known to produce tar and other potentially harmful byproducts. There have been proposed various smoking substitute systems (or“substitute smoking systems”) in order to avoid the smoking of tobacco.

Such smoking substitute systems can form part of nicotine replacement therapies aimed at people who wish to stop smoking and overcome a dependence on nicotine.

Smoking substitute systems include electronic systems that permit a user to simulate the act of smoking by producing an aerosol (also referred to as a“vapour”) that is drawn into the lungs through the mouth (inhaled) and then exhaled. The inhaled aerosol typically bears nicotine and/or flavourings without, or with fewer of, the odour and health risks associated with traditional smoking.

In general, smoking substitute systems are intended to provide a substitute for the rituals of smoking, whilst providing the user with a similar experience and satisfaction to those experienced with traditional smoking and with combustible tobacco products. Some smoking substitute systems use smoking substitute articles that are designed to resemble a traditional cigarette and are cylindrical in form with a mouthpiece at one end.

The popularity and use of smoking substitute systems has grown rapidly in the past few years. Although originally marketed as an aid to assist habitual smokers wishing to quit tobacco smoking, consumers are increasingly viewing smoking substitute systems as desirable lifestyle accessories.

There are a number of different categories of smoking substitute systems, each utilising a different smoking substitute approach.

One approach for a smoking substitute system is the so-called "heat not burn" (“HNB”) approach in which tobacco (rather than an“e-liquid”) is heated or warmed to release vapour. The tobacco may be leaf tobacco or reconstituted tobacco. The vapour may contain nicotine and/or flavourings. In the HNB approach the intention is that the tobacco is heated but not burned, i.e. the tobacco does not undergo combustion.

A typical HNB smoking substitute system may include a device and a consumable. The consumable may include the tobacco material. The device and consumable may be configured to be physically coupled together. In use, heat may be imparted to the tobacco material by a heating element of the device, wherein airflow through the tobacco material causes moisture in the tobacco material to be released as vapour. A vapour may also be formed from a carrier in the tobacco material (this carrier may for example include propylene glycol and/or vegetable glycerine) and additionally volatile compounds released from the tobacco. The released vapour may be entrained in the airflow drawn through the tobacco.

As the vapour passes through the consumable (entrained in the airflow) from an inlet to a mouthpiece (outlet), the vapour cools and condenses to form an aerosol for inhalation by the user. The aerosol will normally contain the volatile compounds.

In HNB smoking substitute systems, heating as opposed to burning the tobacco material is believed to cause fewer, or smaller quantities, of the more harmful compounds ordinarily produced during smoking. Consequently, the HNB approach may reduce the odour and/or health risks that can arise through the burning, combustion and pyrolytic degradation of tobacco.

There is a need for improved design of HNB consumables to enhance the user experience and improve the function of the HNB smoking substitute system.

The present disclosure has been devised in the light of the above considerations. Summary of the Invention

At its most general, the present disclosure relates to an aerosol-forming article e.g. a smoking substitute article such as an HNB consumable. The invention provides an aerosol-forming article comprising a means to prevent ignition of the article and provide flavour, thereby offering an improved user experience, including improved safety during use.

According to a first aspect, the present invention provides an aerosol-forming article (e.g. a smoking substitute article such as a heat-not-burn consumable) comprising an aerosol-forming substrate and a layer of non-combustible material comprising a flavourant, wherein the layer of non-combustible material encloses at least a portion of the aerosol-forming substrate.

The layer of non-combustible material in the article acts as a carrier or substrate for the flavourant, releasing the flavourant into the aerosol in response to heating. When heated, the flavourant volatilises into the main aerosol stream which is inhaled by the user. Furthermore, prior to use (for example, during storage and/or shipping), a portion of the flavourant may diffuse from the non-combustible material into the aerosol-forming substrate, improving the flavour of the aerosol released from the aerosol-forming substrate itself and creating a smoother flavour experience. The layer of non-combustible material also prevent mis-use of the article by preventing ignition of the aerosol-forming substrate.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

The aerosol-forming article is preferably a smoking substitute article, more preferably a heat-not-burn (HNB) consumable.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

As used herein, the terms’’upstream” and“downstream” are intended to refer to the flow direction of the vapour/aerosol i.e. with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include those selected from the group consisting of: nicotine, cocaine, caffeine, opiates and opioids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise at least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Oestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia califomica (California Poppy), Fittonia albivenis, Hippobroma longi flora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombi folia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g. slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g. paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g. greater than or equal to 1 10 g/m² such as greater than or equal to 120 g/m². The sheet may have a grammage of less than or equal to 300 g/m² e.g. less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt% plant material, e.g. at least 60 wt% plant material e.g. around 65 wt% plant material. The aerosol-forming substrate may comprise 80 wt% or less plant material e.g. 75 or 70 wt% or less plant material. The aerosol-forming substrate may comprise from 50 to 80 wt% plant material, for example from 50 to 75 wt%, from 55 to 80 wt%, from 55 to 75 wt%, from 50 to 70 wt%, from 55 to 70 wt%, from 60 to 75 wt% or from 60 to 70 wt%.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators - the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g. propylene glycol (PG), triethylene glycol, 1 ,2-butane diol and vegetable glycerine (VG)) and their esters (e.g. glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt%.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1 % by weight of the plant material, such as at least 2 wt%, such as at least 5 wt%, such as at least 10 wt%, such as at least 20 wt%, such as at least 30 wt%, or such as least 40 wt%.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50 % by weight of the plant material, such as at most 40 wt%, such as at most 30 wt%, or such as at most 20 wt%.

Preferably, the humectant content is 1 to 40 wt% of the aerosol-forming substrate, such as 1 to 20 wt%

Suitable binders are known in the art and may act to bind together the components forming the aerosolforming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/ sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt% of the aerosol-forming substrate e.g. around 6 to 8 wt%.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g. wood fibres), jute fibres and combinations thereof. Preferably, the filler content is 5 to 10 wt% of the aerosol-forming substrate e.g. around 6 to 9 wt%.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the solvent is water. In some embodiments, the aerosol forming substrate has a solvent content of between 5 and 10 wt% e.g. between 6-9 wt% such as between 7-9 wt%.

Herein, the term“flavourant” encompasses any natural or artificial substance or composition which imparts a pleasant or desirable flavour to the aerosol. The flavourant may comprise a natural extract from a plant source (e.g. fruit extract). The flavourant may comprise a derivative of a natural extract, for example a purified form thereof. In some embodiments, the flavourant is added to the article in purified or substantially purified form. In some embodiments, the flavourant comprises a flavoured compound or mixture of compounds. In some embodiments, the flavourant comprises a compound which does not occur naturally in tobacco, for example menthol or other organic aromatic compound.

In addition to the non-combustible material comprising flavourant, there may also be flavourant provided at other locations within the article, including but not limited to the aerosol-forming substrate and the filter. The flavourant(s) used elsewhere may be the same or different from the flavourant provided on the noncombustible material layer.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g. citrus, cherry etc.), vanilla, spice (e.g. ginger, cinnamon) or tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical rod-shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10mm e.g. between 6 and 9mm or 6 and 8mm e.g. around 7 mm. It may have an axial length of between 10 and 15mm e.g. between 1 1 and 14mm such as around 12 or 13mm.

In some embodiments, the layer of non-combustible material at least partially (e.g. fully) circumscribes the axially-extending curved surface of the cylindrical rod of plant material. It may have an axial length substantially matching the axial length of the aerosol-forming substrate. The axial, upstream end face of the tobacco rod may not be covered by the layer of non-combustible material. This may allow for inter alia the penetration of a heating element directly into the aerosol-forming substrate without the need to pass through the non-combustible material.

Herein, the term“non-combustible material” pertains to a material which offers increased resistance to ignition and/or combustion relative to standard materials used in smoking articles such as cigarettes. In some embodiments, the term“non-combustible material” pertains to a material which does not burn when exposed to fire. For example, the non-combustible material may comprise or consist of a material which is inherently incombustible under the conditions experienced by a HNB consumable, such as a metal or alloy with a suitably high melting point (e.g. aluminium). The non-combustible material may alternatively comprise a composite material or a material which comprises an additive which imparts non-combustibility to the material. In some embodiments, the non-combustible material has a relatively high thermal conductivity. In some embodiments, the non-combustible material has a thermal conductivity of at least 100 Wm^_1K ¹ , for example at least 120 Wnr¹K ¹ , for example at least 140 Wnr¹K ¹ , for example at least 150 Wnr¹K^~1 , for example at least 160 Wnr¹K ¹ , for example at least 170 Wrrr¹K^~1 , for example at least 200 Wnrr ¹K^~1. In some embodiments, the non-combustible material has a relatively high melting point, i.e. a melting point higher than the temperatures to which a HNB consumable is exposed during use. In some embodiments, the non-combustible material has a melting point of at least 300 °C, for example at least 350 °C, for example at least 400 °C, for example at least 450 °C, for example at least 500 °C, for example at least 550 °C, for example at least 600 °C.

Herein, the term“metal” or“metallic” encompasses traditional single-element metals but also mixtures of metals, including alloys. The term“foil” has its usual meaning, referring to a thin flexible sheet or layer of material, such as metal.

Herein, the term“laminate” or“laminar structure” refers in the traditional sense to an assembly of two or more thin layer structures such as films, foils, papers or wrappers lying in a laminar arrangement, one on top ofthe other. Individual layers ofthe laminate may be loosely associated (i.e. not strongly or permanently attached or bonded to one another), or may be partially or fully adhered to one another. For example, a layer of foil may encompass an aerosol-forming substrate and a layer of paper may be wrapped around the layer of foil to form a laminate structure, and the two layers may or may not be adhered to one another (for example, the layers may be held in place merely by friction between the layers rather than adhesive).

The aerosol-forming substrate may be circumscribed by a wrapping layer e.g. a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

In some embodiments, the aerosol-forming article comprises a wrapping layer with a laminate structure comprising a first layer and a second layer, the first layer being an inner layer adjacent the aerosol-forming substrate and the second layer lying radially outside the first layer, wherein the inner layer comprises the non-combustible material and the outer layer comprises a cellulosic material.

In this way, the layer of non-combustible material is located adjacent the aerosol-forming substrate which facilitates the diffusion of flavourant into the aerosol-forming substrate, both prior to use (e.g., during storage) and during use, upon heating. The laminate structure provides an outer layer of cellulosic material for easier handling of the aerosol-forming article. Other layers may be present in addition to the first and second layers. For example, one or more additional layers may be present between the first and second layers, and/or outside the second layer. In some embodiments, the wrapping layer consists of the first and second layers, i.e. no other layers are present.

In some embodiments, the first layer consists of the non-combustible material. In this way, protection of the aerosol-forming substrate is increased.

In some embodiments, the second layer consists of the cellulosic material. In some embodiments, the cellulosic material comprises paper.

In some embodiments, the first layer and second layer are adhered to one another. In other words, the two layers are bound together by strong forces which does not permit easy separation of the layers. In this way, the structural integrity of the aerosol-forming article is increased.

In some embodiments, the non-combustible material comprises a metallic foil. In some embodiments, the metal in the metallic foil is aluminium. A metallic non-combustible material provides advantageous properties of resistance to ignition and/or combustion but also ductility, ease of availability and manufacture, good heat dissipation to the aerosol-forming substrate and a good substrate for applied flavourant. Importantly, the high thermal conductivity of metallic material means that a larger quantity of flavourant will be volatilised in circumstances when an aerosol-forming article is heated during use, thereby providing a more intense flavour experience for the user.

In some embodiments, an inner surface of the layer of non-combustible material adjacent to the aerosolforming substrate carries the flavourant. In this way, flavourant is better placed to diffuse into and through the aerosol-forming substrate prior to and during use of the aerosol-forming article. For example, after manufacture and prior to use (e.g. during storage and shipment), flavourant will begin to diffuse into the aerosol-forming substrate thereby improving flavour during subsequent use. In addition, flavourant will diffuse directly into the aerosol forming substrate when heat is applied to the aerosol-forming article during use.

In some embodiments, the entire inner surface of the layer of non-combustible material adjacent to the aerosol-forming substrate carries flavourant. In some embodiments, the flavourant is evenly applied across the surface of the layer of non-combustible material. In this way, a smooth flavour experience can be provided for the user.

The flavourant may be applied to the layer of non-combustible material by any suitable coating method. In some embodiments, the flavourant (e.g. provided as a solution) is applied to a surface of the layer of non-combustible material by spraying. This provides an even coat and a means to more accurately control the quantity of flavourant applied in the coating and thereby the intensity of flavour delivered. This also provides a means to provide a varied concentration of flavourant across the surface of the non-combustible material layer. For example, it may be desirable to decrease the concentration of flavourant at a downstream location to prevent excessive flavour intensity, but to retain a higher concentration at an upstream location to ensure sufficient flavour.

The article/consumable may comprise at least one filter element. There may be a terminal filter element at the downstream/mouth end of the article/consumable.

The or at least one of the filter element(s) (e.g. the terminal filter element) may be comprised of cellulose acetate or polypropylene tow. The at least one filter element (e.g. the terminal filter element) may be comprised of activated charcoal. The at least one filter element (e.g. the terminal element) may be comprised of paper. The or each filter element may be circumscribed with a plug wrap e.g. a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length ofthe or each filter element may be less than 20mm, e.g. between 8 and 15mm, for example between 9 and 13 mm e.g. between 10 and 12mm.

The or at least one of the filter element(s) may be a solid filter element. The or at least one of the filter element(s) may be a hollow bore filter element. The or each hollow bore filter may have a bore diameter of between 1 and 5 mm, e.g. between 2 and 4 mm or between 2 and 3 mm.

There may be a plurality of e.g. two filter elements which may be adjacent one another or which may be spaced apart. Any filter element(s) upstream of the terminal filter element may be at least partly (e.g. entirely) circumscribed by the (paper) wrapping layer.

The terminal filter element (at the downstream end ofthe article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer e.g. a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The or at least one of the filter elements e.g. the terminal filter element may include a capsule e.g. a crushable capsule (crush-ball) containing a liquid flavourant e.g. any of the flavourants listed above. The capsule can be crushed by the user during smoking of the article/consumable to release the flavourant. The capsule may be located at the axial centre of the terminal filter element. In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and a/the filter element and/or between two filter elements. The aerosol cooling element may be at least partly (e.g. completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximise heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may comprise a cardboard tube. The spacer element may be at least partly (e.g. entirely) circumscribed by the wrapping layer. In some embodiments, the non-combustible material also covers at least a portion of the surface of the spacer element.

The spacer element may have an external diameter of between 5 and 10mm e.g. between 6 and 9mm or 6 and 8mm e.g. around 7 mm. It may have an axial length of between 10 and 15mm e.g. between 12 and 14 mm or 13 and 14mm e.g. around 14mm.

In a second aspect, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect and a device comprising a heating element.

The device may be a HNB device i.e. a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g. rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g. the main body) may further comprise an electrical power supply e.g. a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element. In a third aspect, there is provided a method of using a smoking substitute system according to the second aspect, the method comprising:

inserting the article/consumable into the device; and

heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects may be applied to any other aspect. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect and/or combined with any other feature or parameter described herein.

Summary of the Figures

So that the invention may be understood, and so that further aspects and features thereof may be appreciated, embodiments illustrating the principles of the invention will now be discussed in further detail with reference to the accompanying figures, in which:

Figure 1 shows a cross-sectional view of a first embodiment of an HNB consumable;

Figure 2 shows a cross-sectional view of a second embodiment of an HNB consumable Figure 3 shows a cross-sectional view of a third embodiment of an HNB consumable;

Figure 4 shows a cross-sectional view of a fourth embodiment of an HNB consumable;

Figure 5 shows a cross-sectional view of the first embodiment within a device forming an HNB system; Figure 6 shows a perspective view of the first embodiment with the paper wrapper layer cut away; and Figure 7 shows a close-up view of the upstream axial end of the first embodiment.

Detailed Description of the Figures

As shown in Figure 1 , the HNB consumable 1 comprises an aerosol-forming substrate 2 at the upstream end of the consumable 1 . The aerosol-forming substrate comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 comprises 65 wt% tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt% of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt%. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2 is circumscribed by a layer of aluminium foil 3a, which in turn is circumscribed by a paper wrapping layer 3b. The aerosol-forming substrate is therefore circumscribed by a laminate wrapper comprising two layers: the inner aluminium foil layer 3a and the outer paper layer 3b. The inner surface ofthe aluminium foil layer 3a carries menthol flavourant which is applied by spray coating prior to assembly of the consumable. The layer of aluminium foil 3a extends to cover the curved external surface of the aerosol-forming substrate 2 but does not cover any of the planar circular end face of the aerosol-forming substrate 2.

The consumable 1 comprises an upstream filter element 4 and a downstream (terminal) filter element 5. The two filter elements 4, 5 are spaced by a cardboard tube spacer 6. Both filter elements 4, 5 are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements have a substantially cylindrical shape. The diameter of the upstream filter 4 matches the diameter of the aerosol-forming substrate 2. The diameter of the terminal filter element 5 is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 and the wrapping layer 3. The upstream filter element is slightly shorter in axial length than the terminal filter element at an axial length of 10 mm compared to 12 mm for the terminal filer element.

The cardboard tube spacer is longer than each of the two filter elements having an axial length of around 14 mm.

Each filter element 4, 5 is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter is slightly larger than the diameter of the bore in the terminal filter having a diameter of 3 mm compared to 2 mm for the terminal filter element.

The cardboard tube spacer 6 and the upstream filter element 4 are circumscribed by the wrapping layer 3. The terminal filter element 5 is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7. The tipping layer 7 encircles the terminal filter element 5 and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6.

Figure 2 shows a second embodiment of a consumable T which is the same as that shown in Figure 1 except that the aluminium foil layer 3a extends to circumscribe not only the aerosol-forming substrate 2 but also the upstream filter element 4.

Figure 3 shows a third embodiment of a consumable 1” which is the same as that shown in Figure 1 except that the terminal filter element 5 is a solid filter element and comprises a crushable capsule 8 (crush-ball) having a shell wall containing a liquid menthol or cherry or vanilla flavourant. The capsule 8 is spherical and has a diameter of 3.5 mm. It is positioned within the axial centre of the terminal filter element 5.

Figure 4 shows a fourth embodiment of a consumable T” which is the same as the first embodiment except that the wrapping layer 3 does not completely circumscribe the cardboard tube spacer 6 such that there is an annular gap 9 between the tipping layer 7 and the cardboard tube spacer 6 downstream of the end of the wrapping layer 3.

Figure 5 shows the first embodiment inserted into an HNB device 10 comprising a rod-shaped heating element 20. The heating element 20 projects into a cavity 1 1 within the main body 12 of the device.

The consumable 1 is inserted into the cavity 1 1 of the main body 12 of the device 10 such that the heating rod 20 penetrates the aerosol-forming substrate 2. Heating of the reconstituted tobacco in the aerosolforming substrate 2 is effected by powering the heating element (e.g. with a rechargeable battery (not shown)).

As the tobacco is heated, moisture and volatile compound (e.g. nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5. Additionally, the menthol present within the coating applied to the inner surface of the aluminium foil layer 3a is volatilised and becomes entrained within the airflow to provide flavour to the user.

As the vapour cools within the upstream filer element 4 and the cardboard tube spacer 6, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Figure 6 shows a perspective view of the structure of the wrapping layer in the first embodiment. The wrapping layer consists of the inner aluminium foil layer 3a and the outer paper layer 3b. The layer of aluminium foil 3a extends to cover only the curved surface of the aerosol-forming substrate 2, without extending to cover the adjacent upstream filter element 4 or the planar circular end-surface of the aerosol- forming substrate 2. The paper wrapping layer 3b then lies over the entire length of the consumable 100, including the aluminium foil layer.

Figure 7 is a close-up view of the upstream end of the first embodiment shown in Figure 6.

The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the scope of the invention.

For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

Throughout this specification, including the claims which follow, unless the context requires otherwise, the words“have”,“comprise”, and“include”, and variations such as“having”,“comprises”,“comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

It must be noted that, as used in the specification and the appended claims, the singular forms“a,”“an,” and“the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from“about” one particular value, and/or to“about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent“about,” it will be understood that the particular value forms another embodiment. The term“about” in relation to a numerical value is optional and means, for example, +/- 10%.

The words "preferred" and "preferably" are used herein refer to embodiments of the invention that may provide certain benefits under some circumstances. It is to be appreciated, however, that other embodiments may also be preferred under the same or different circumstances. The recitation of one or more preferred embodiments therefore does not mean or imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure, or from the scope of the claims.

Claims

Claims:

1 . An aerosol-forming article comprising an aerosol-forming substrate and a layer of non-combustible material comprising a flavourant, wherein the layer of non-combustible material encloses at least a portion of the aerosol-forming substrate.

2. An aerosol-forming article according to claim 1 , comprising a wrapping layer with a laminate structure comprising a first layer and a second layer, the first layer being an inner layer adjacent the aerosolforming substrate and the second layer lying outside the first layer, wherein the first layer comprises the non-combustible material.

3. An aerosol-forming article according to claim 2 wherein the second layer consists of cellulosic

material.

4. An aerosol-forming article according to claim 3 wherein the cellulosic material comprises paper.

5. An aerosol-forming article according to any one of claims 1 to 4 wherein the non-combustible material comprises a metallic foil.

6. An aerosol-forming article according to claim 5 wherein the metallic foil is aluminium foil.

7. An aerosol-forming article according to any one of claims 1 to 6, wherein an inner surface of the layer of non-combustible material adjacent to the aerosol-forming substrate carries the flavourant.

8. An aerosol-forming article according to any one of claims 1 to 7, wherein the flavourant is applied to a surface of the layer of non-combustible material by spraying.

9. An aerosol-forming article according to any one of claims 1 to 8, wherein the flavourant comprises menthol.

10. An aerosol-forming article according to any one of claims 1 to 9, wherein the aerosol-forming

substrate comprises a cylindrical rod of plant material.

1 1 . An aerosol-forming article according to claim 10, wherein the layer of non-combustible material

circumscribes the axially extending curved surface of the cylindrical rod of plant material.

12. An aerosol-forming article according to any one of claims 1 to 1 1 wherein the aerosol-forming article is a heat-not-burn consumable.

13. A system comprising an aerosol-forming article according to any one of the preceding claims and a device comprising a heating element.

14. A system according to claim 13 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.

15. A method of using the system according to claim 13 or 14, the method comprising:

inserting the aerosol-forming article into the device; and

heating the aerosol-forming article using the heating element.

16. A method according to claim 15 comprising inserting the aerosol-forming article into a cavity within a main body of the device main body and penetrating the aerosol-forming article with the heating element upon insertion of the aerosol-forming article.