EP4599708A1

EP4599708A1 - A consumable for use with a non-combustible aerosol provision device and a system for heating aerosol-generating material

Info

Publication number: EP4599708A1
Application number: EP24157161.1A
Authority: EP
Inventors: Walid Abi Aoun; Fahim AHSRAF
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2024-02-12
Filing date: 2024-02-12
Publication date: 2025-08-13
Also published as: WO2025172360A1

Abstract

A consumable (101) for use with a non-combustible aerosol provision device (1). The consumable comprises a first section (102) and a second section (112) upstream of the first section. At least one of the first section and the second section comprises aerosol generating material. The second section comprises a continuously changing density along its length, increasing towards an upstream most end of the consumable. The pressure drop across the second section is higher than the pressure drop across the first section.

Description

Technical Field

The present invention relates to a consumable for use with a non-combustible aerosol provision device and to a system for heating aerosol-generating material.

Background

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Alternatives to these types of articles release an inhalable aerosol or vapour by releasing compounds from a substrate material by heating without burning. These may be referred to as non-combustible smoking articles, aerosol generating assemblies or non-combustible aerosol provision systems.
One example of such a product is a heating device which release compounds by heating, but not burning, a solid aerosolisable material. This solid aerosolisable material may, in some cases, contain a tobacco material. The heating volatilises at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as heat-not-burn devices, tobacco heating devices or tobacco heating products (THP). Various different arrangements for volatilising at least one component of the solid aerosolisable material are known.
As another example, there are e-cigarette / tobacco heating product hybrid devices, also known as electronic tobacco hybrid devices. These hybrid devices contain a liquid source (which may or may not contain nicotine) which is vaporised by heating to produce an inhalable vapour or aerosol. The device additionally contains a solid aerosolisable material (which may or may not contain a tobacco material) and components of this material are entrained in the inhalable vapour or aerosol to produce the inhaled medium.

Summary

According to a first aspect of the present invention, there is provided a consumable for use with a non-combustible aerosol provision device, wherein the consumable comprises:

a first section, and
a second section upstream of the first section;
wherein at least one of the first section and the second section comprises aerosol-generating material;
wherein the second section comprises a continuously changing density along its length, the density continuously increasing towards an upstream most end of the consumable; and
wherein the pressure drop across the second section is higher than the pressure drop across the first section.

Optionally, the second section comprises a third and a fourth section upstream of the third section, wherein the pressure drop across the fourth section is higher than the pressure drop across the third section.
Optionally, the first and second sections each comprise a continuously changing density along their length, the density increasing towards an upstream most end of the consumable. Optionally, the density of the first and second sections increases continuously across a combined longitudinal length of the first and second sections.
Optionally, the first section comprises aerosol-generating material. Optionally, the first section comprises a body of aerosol-generating material. Optionally, the second section comprises aerosol-generating material. Optionally, the second section comprises a body of aerosol-generating material. Optionally, the aerosol generating material of the first and/or second sections each comprise a continuously changing density along its length, increasing towards an upstream most end of the consumable. Optionally, the density of aerosol generating material of the first and second sections increases continuously across a combined longitudinal length of the first and second sections.
Optionally, the aerosol generating material of the first section comprises an aerosol generating film, optionally the aerosol generating film comprises an amorphous solid.
Optionally, both of the first section and the second section comprise aerosol generating material, wherein the aerosol generating material of the first section and of the second section are different to each other. Optionally, the aerosol generating material of either the first section or the second section comprises tobacco, e.g. cut rag tobacco. Optionally, the first section comprises an aerosol generating film, optionally the aerosol generating film comprises an amorphous solid and wherein the second section comprises tobacco, e.g. cut rag tobacco.
Optionally, the mass ratio of the aerosol generating material of the second section to the aerosol generating material of the first section is more than 1, optionally from 1 to 5, for example 1.1, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, or 5.0, or within a range defined by any two of these values.
Optionally, the aerosol generating material of the first section is arranged to comprise at least one longitudinally-extending air channel extending through the first section. Optionally, the aerosol-generating film of the aerosol generating material of the first section is arranged to comprise at least one longitudinally-extending air channel extending through the first section. Optionally, the at least one longitudinally-extending air channel extends entirely through the first section.
Optionally, the aerosol generating material of the first section is provided on or as a sheet material, optionally arranged to comprise at least one substantially spiral shaped cross section so as to define the at least one longitudinally-extending air channel extending through the first section. Optionally, the substantially spiral shaped cross section defines at least one longitudinally extending air channel through the first section between each layer of the spiral. Optionally, the sheet material is rolled so as to provide the substantially spiral shaped cross section.
Optionally, the aerosol generating material of the first section is provided on or as a sheet material gathered to comprise a plurality of folds defining at least one longitudinally-extending air channel between each fold.
Optionally, the aerosol generating material of the first section is provided on a carrier, optionally the carrier is paper or card. Optionally, the aerosol generating material is provided as or within an aerosol-generating film, optionally wherein the aerosol-generating film comprises an amorphous solid. Optionally, the aerosol-generating film is attached to or cast onto the carrier. Optionally, the carrier comprises a carrier material onto which the aerosol-generating film is cast. Optionally, the aerosol-generating film may be laminated onto the carrier.
Optionally, the aerosol generating material of the first section is provided as a layer, for example as a film, on the carrier. The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. In some embodiments, the aerosol-generating film may have a thickness of about 0.11 mm to 0.17 mm, for example of about 0.12 mm to 0.13 mm.
Optionally, the aerosol generating material is provided on a tubular member, e.g. the carrier comprises a tubular member upon or within which the aerosol generating material is provided.
Optionally, the aerosol generating material of the first section is arranged to provide at least one air gap or void defining the least one longitudinally-extending air channel extending through the first section of aerosol generating material.
Optionally, the aerosol generating material of the first section comprises a plurality of discrete bodies of aerosol generating material. Optionally, the plurality of discrete bodies comprise aerosol generating material provided on a carrier, or carrier material, and optionally the carrier is a sheet material such as paper or cardboard. Optionally, the aerosol generating material of the first section comprises a first aerosol generating material and wherein the plurality of discrete bodies comprise a second aerosol generating material different from the first aerosol generating material. Optionally, the plurality of discrete bodies of aerosol generating material are distributed, interspersed or mixed throughout the body of aerosol generating material of the first section. Optionally, the aerosol generating material is provided as a layer, for example as a film, on the carrier. Optionally, the plurality of discrete bodies of aerosol generating material each comprise an aerosol generating film which may optionally comprise an amorphous solid. Optionally, the plurality of discrete bodies are provided as strips of aerosol generating material, optionally provided on a carrier, such as paper or cardboard.
Optionally, the pressure drop across the second section of aerosol generating material is from 35 to 54 mm wg, such as 40 to 45 mm wg, 36 to 40 mm wg, 10 to 20mm wg, or 10 to 15mm wg.
Optionally, a body of the consumable comprises the first and second sections and wherein the body comprises a continuously decreasing circumference along at least a portion of the length of the body, decreasing towards an upstream most end of the consumable. Optionally, the body comprises a continuously decreasing circumference along at least a portion of the length of only the first section. Optionally, the body comprises a continuously decreasing circumference along at least a portion of the length of only the second section. Optionally, the body comprises a continuously decreasing circumference along the entire length of the second section and along a portion of the length of the first section.
According to a second aspect of the present invention, there is provided a consumable for a non-combustible aerosol provision device, wherein the consumable comprises:

a body comprising a first section and a second section upstream of the first section, wherein at least one of the first section and the second section comprises aerosol generating material, and
wherein the body comprises a continuously decreasing circumference along at least a portion of the length of the body, decreasing towards an upstream most end of the consumable; and
wherein the pressure drop across the second section is higher than the pressure drop across the first section.

Optionally, the body comprises a continuously decreasing circumference along at least a portion of the length of only the first section. Optionally, the body comprises a continuously decreasing circumference along at least a portion of the length of only the second section. Optionally, the body comprises a continuously decreasing circumference along the entire length of the second section and along at least a portion, optionally the entirety, of the length of the first section. Optionally, the circumference is an outer circumference of the consumable. Optionally, the circumference is a circumference of a first of aerosol generating material section and/or of a second section of aerosol generating material. Optionally, the body comprises a continuously decreasing circumference along at least a portion of the length of the body, decreasing towards an upstream most end of the consumable, so as to define a tapered portion of the body and optionally the tapered end comprises a distal-most end of the consumable.
Optionally, the second section comprises a continuously decreasing circumference along at least a portion of the length of the second section. Optionally, the first and second sections each comprise a continuously decreasing circumference along their length, decreasing towards an upstream most end of the consumable. Optionally, the circumference of the first and second sections decreases continuously across a combined length of the first and second sections. Optionally, the body comprises a continuously decreasing circumference along at least a portion of the length of only the first section. Optionally, the body comprises a continuously decreasing circumference along at least a portion of the length of only the second section. Optionally, the body comprises a continuously decreasing circumference along the entire length of the second section and along a portion of the length of the first section.
Optionally, the first section comprises aerosol-generating material. Optionally, the first section comprises a body of aerosol-generating material. Optionally, the second section comprises aerosol-generating material. Optionally, the second section comprises a body of aerosol-generating material. Optionally, the aerosol generating material of the first and/or second sections each comprise a continuously changing density along its length, increasing towards an upstream most end of the consumable. Optionally, the density of aerosol generating material of the first and second sections increases continuously across a combined length of the first and second sections.
Optionally, the aerosol generating material of the first section comprises an aerosol generating film, optionally the aerosol generating film comprises an amorphous solid.
Optionally, both the first section and the second section each comprise aerosol generating material, optionally wherein the aerosol generating material of the first section and of the second section are different to each other. Optionally, the aerosol generating material of either the first section or the second section comprises tobacco, e.g. cut rag tobacco. Optionally, the aerosol generating material of the first section comprises an aerosol generating film (optionally the aerosol generating film comprises an amorphous solid) and wherein the second section comprises tobacco, e.g. cut rag tobacco.
Optionally, both the first and second sections each comprise aerosol generating material and wherein the mass ratio of the aerosol generating material of the second section to the aerosol generating material of the first section is more than 1, optionally from 1 to 5, for example 1.1, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, or 5.0, or within a range defined by any two of these values, for example from 1.4 to 1.9.
Optionally, the aerosol generating material of the first section is arranged to comprise at least one longitudinally-extending air channel extending through the first section. Optionally, the aerosol-generating film of the aerosol generating material of the first section is arranged to comprise at least one longitudinally-extending air channel extending through the first section.
Optionally, the aerosol generating material of the first section is provided on or as a sheet material arranged to comprise at least one substantially spiral shaped cross section so as to define the at least one longitudinally-extending air channel extending through the first section. Optionally, the substantially spiral shaped cross section defines at least one longitudinally-extending air channel through the first section between each layer of the spiral. Optionally, the at least one longitudinally-extending air channel extends entirely through the first section.
Optionally, the aerosol generating material of the first section is provided on or as a sheet material gathered to comprise a plurality of folds defining at least one longitudinally-extending air channel between each fold. Optionally, the one or more longitudinally-extending air channels extend entirely through the first section.
Optionally, the aerosol generating material of the first section is provided on a carrier, optionally the carrier is paper or card. Optionally, the aerosol generating material is provided as or within an aerosol-generating film. Optionally, the aerosol-generating film is attached to or cast onto the carrier. Optionally, the carrier comprises a carrier material onto which the aerosol-generating film is cast. Optionally, the aerosol-generating film may be laminated onto the carrier.
Optionally, the aerosol generating material is provided as a layer, for example as a film, on the carrier. The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. In some embodiments, the aerosol-generating film may have a thickness of about 0.11 mm to 0.17 mm, for example of about 0.12 mm to 0.13 mm.
Optionally, the aerosol generating material is provided on a tubular member, optionally comprising a sheet material. Optionally, the tubular member defines an axially extending air channel extending therethrough.
Optionally, the aerosol generating material of the first section is arranged to provide at least one air gap or void defining the least one longitudinally-extending air channel extending through the first section of aerosol generating material.
Optionally, the aerosol generating material of the first section comprises a plurality of discrete bodies of aerosol generating material. Optionally, the plurality of discrete bodies comprise aerosol generating material provided on a carrier, or carrier material, and optionally the carrier is a sheet material such as paper or cardboard. Optionally, the aerosol generating material of the first section comprises a first aerosol generating material and wherein the plurality of discrete bodies comprise a second aerosol generating material different from the first aerosol generating material. Optionally, the plurality of discrete bodies of aerosol generating material are distributed, interspersed or mixed throughout the body of aerosol generating material of the first section. Optionally, the aerosol generating material is provided as a layer, for example as a film, on the carrier. Optionally, the plurality of discrete bodies of aerosol generating material each comprise an aerosol-generating film. Optionally, the plurality of discrete bodies are provided as strips of aerosol generating material, optionally provided on a carrier, such as paper or cardboard.
Optionally, the second section comprises a continuously changing density along its length, increasing towards an upstream most end of the consumable. Optionally, the first and second sections each comprise a continuously changing density along their length, increasing towards an upstream most end of the consumable. Optionally, the density of the first and second sections increases continuously across a combined longitudinal length of the first and second sections.
Optionally, the pressure drop across the second section of aerosol generating material is from 35 to 54 mm wg, such as 40 to 45 mm wg, 36 to 40 mm wg, 10 to 20mm wg, or 10 to 15mm wg.
According to a third aspect of the present invention, there is provided a non-combustible aerosol provision device for heating a consumable of the non-combustible aerosol provision device, the non-combustible aerosol provision device comprising a tapered receiving portion for receiving the consumable. Optionally, the consumable is any one of the consumables described herein. Optionally, the receiving portion comprises a tapered base so as to impart a tapered section into a distal (i.e. upstream) end of the consumable upon receipt (e.g. insertion) of the consumable into the receiving portion.
According to a fourth aspect of the present invention, there is provided a system for heating aerosol-generating material to volatilise at least one component of the aerosol generating material, the system comprising:

the consumable of any one of the preceding claims, and
a non-combustible aerosol provision device for heating the first section and/or the second section of aerosol generating material to volatilise at least one component of the aerosol-generating material thereof, the non-combustible aerosol provision device comprising a tapered receiving portion for receiving the consumable of any one of the preceding claims.

Optionally, the tapered receiving portion comprises a tapered wall and/or a tapered base and optionally the tapered wall and/or base is configured to provide the consumable with (e.g. to form) a tapered portion at a distal end of the consumable when the consumable is received within the tapered receiving portion such that the tapered portion of the consumable is correspondingly shaped with the tapered receiving portion e.g. so as to provide the continuously decreasing circumference or continuously increasing density. Optionally, the second section comprises aerosol generating material and the non-combustible aerosol provision device is configured to heat the first section of aerosol generating material and the second section of aerosol generating material.

Brief Description of the Drawings

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

Figure 1 shows a schematic side part-cross-sectional view of a first embodiment of a consumable according to a first aspect of the present invention.
Figure 2 shows a schematic cross-sectional axial view of a first section of aerosol generating material of the embodiment of Figure 4 arranged in a spiral.
Figure 3 shows a schematic cross-sectional axial view of the first section of aerosol generating material of the embodiment of Figure 4 wherein the first section of aerosol generating material is gathered to form to a plurality of folds defining one or more longitudinally-extending air channels between each fold.
Figure 4 shows a schematic side part-cross-sectional view of a second embodiment of a consumable according a first aspect of the present invention.
Figure 5 shows a schematic perspective view of an embodiment of a non-combustible aerosol provision system according to a second aspect of the present invention.
Figure 6 shows a schematic cross-sectional view of the embodiment of Figure 5.
Figure 7 shows a schematic perspective view of the embodiment of Figures 5 and 6 showing a consumable according to the first or second embodiment of the first aspect arranged therein.

Detailed description

A consumable for use with a non-combustible aerosol provision device is provided comprising a first section and a second section upstream of the first section. At least one of the first section and the second section comprises aerosol-generating material. The second section comprises a continuously changing density along its length, increasing towards an upstream most end of the consumable. The pressure drop across the second section is higher than the pressure drop across the first section.
According to the disclosure, the continuously changing density of the second section may contribute to the pressure drop across the second section being higher than the pressure drop across the first section of aerosol generating material. In some embodiments, the continuously changing density may be provided by crushing or compressing the second section to an increasing extent toward the upstream end of the second section. The increased pressure drop provided by the continuously changing density of the second section allows for less aerosol-generating material to be provided, for example within the first or second sections of aerosol-generating material, as the reduction in pressure drop associated with the provision of less aerosol-generation material is compensated for by the continuously increasing density of the second section. Thus, the overall pressure drop may be maintained or otherwise increase.

Aerosol-generating material

The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.
The aerosol-generating material may comprise or be in the form of an aerosol-generating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.
The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. In some embodiments, the aerosol-generating film may have a thickness of about 0.11 mm to 0.17 mm, for example of about 0.12 mm to 0.13 mm.
The aerosol-generating material may comprise more than one film, and the thickness described herein may refer to the aggregate thickness of those films.
The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper. The sheet may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosol-generating material.
The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may comprise one or more discrete portions or regions of aerosol-generating material, such as dots, stripes, strips or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar. Each of the one or more discrete portions or regions of aerosol-generating material may comprise a combination of two or more aerosol-generating materials. Discrete portions of different aerosol-generating materials may be heated separately.
The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film.
The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.
The aerosol-generating material may comprise or be an "amorphous solid". In some embodiments, the aerosol-generating material is or comprises an aerosol-generating film that is or comprises an amorphous solid. The amorphous solid may be a "monolithic solid". The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.
The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free.

Binder

Suitably, the aerosol-generating film may comprise from about 15 wt% to about 60 wt% binder, such as a gelling agent, for example from about 25 wt%, 30 wt%, or 35 wt% to about 40 wt%, 45 wt% or 50 wt% of a binder (all calculated on a dry weight basis). For example, the aerosol-generating material may comprise about 25 to 50 wt%, 30 to 45 wt% or 35 to 40 wt% of the binder. In some embodiments, the binder comprises a hydrocolloid.
In some embodiments, the gelling agent comprises (or is) one or more compounds selected from polysaccharide gelling agents, such as alginate, pectin, starch or a derivative thereof, cellulose or a derivative thereof, pullulan, carrageenan, agar and agarose; gelatin; gums, such as xanthan gum, guar gum and acacia gum; silica or silicone compounds, such as PDMS and sodium silicate; clays, such as kaolin; and polyvinyl alcohol.
In some embodiments the gelling agent comprises (or is) one or more polysaccharide gelling agents.
In some embodiments, the polysaccharide gelling agent is selected from alginate, pectin, starch or a derivative thereof, or cellulose or a derivative thereof. In some embodiments the polysaccharide gelling agent is selected from alginate and a cellulose derivative.
In some embodiments, the gelling agent is a polysaccharide gelling agent, optionally the polysaccharide gelling agent is selected from alginate and a cellulose derivative.
In some embodiments, the alginate is sodium alginate.
In some embodiments, the polysaccharide gelling agent is a cellulose derivative. Without wishing to be bound by theory, the inventors believe that such gelling agents do not react with calcium ions to form crosslinks.
In some embodiments, the polysaccharide gelling agent is alginate.
In some embodiments the binder is not crosslinked. The absence of crosslinks in the binder may facilitate quicker delivery of the constituent, derivative or extract of active substances and/or flavours) from the aerosol-generating material.
Examples of cellulosic gelling agents (also referred to herein as cellulose derivatives) include, but are not limited to, hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), and cellulose acetate propionate (CAP). In some embodiments the cellulose or derivative thereof is selected from hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), and cellulose acetate propionate (CAP). In some embodiments, the cellulose derivative is CMC.
For example, in some embodiments, the gelling agent comprises (or is) one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol.
In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, guar gum, acacia gum, alginate and/or pectin.
In some cases, the gelling agent comprises (or is) alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during formation of the aerosol-generating material. In some cases, the aerosol-generating material may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.
In some embodiments, the gelling agent comprises (or is) alginate, optionally the alginate is present in the aerosol-generating material in an amount of from about 15 to 40 wt%, for example about 15 to 25 wt%, of the aerosol-generating material (calculated on a dry weight basis).
In some embodiments, the gelling agent comprises (or is) alginate, optionally the alginate is present in the aerosol-generating material in an amount of from about 15 to 40 wt%, for example about 30 to 40 wt%, of the aerosol-generating material (calculated on a dry weight basis).
In some embodiments, alginate is the only gelling agent present in the aerosol-generating material.
In other embodiments, the gelling agent comprises alginate and at least one further gelling agent, such as pectin.
In particular embodiments, the gelling agent is carboxymethylcellulose, optionally the carboxymethylcellulose (CMC) is present in an amount of about 15 to 50 wt%, for example about 20 to 40 wt% or about 30 wt%. In some embodiments, CMC is the only gelling agent present in the aerosol-generating material.
In some embodiments, the weight ratio of the total amount of gelling agent to the total amount of constituents, derivatives or extracts of cannabis is from about 2:1 to 1:2, such as about 1.5:1 to 1:1.5 or 1.2:1 to 1:1.2.

Aerosol-former material

The aerosol-former material may comprise one or more constituents capable of forming an aerosol.
Suitably, the aerosol-generating film may comprise from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt% or 10 wt% to about 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt% or 25 wt% of an aerosol-former material (all calculated on a dry weight basis). For example, the aerosol-generating film may comprise 0.5 to 40 wt%, 3 to 35 wt% or 10 to 25 wt% of an aerosol-former material.
In some embodiments, the aerosol-former material may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
In some embodiments, the aerosol-former material may comprise one or more of erythritol, propylene glycol, glycerol, and triacetin. In some cases, the aerosol-former material comprises, consists essentially of or consists of glycerol, or a mixture of glycerol and propylene glycol.
In some embodiments, the aerosol-former material comprises a mixture of glycerol and propylene glycol in a weight ratio of glycerol to propylene glycol of about 3:1 to 1:3, about 2:1 to 1:2, about 1.5:1 to 1:1.5, about 55:45 to 45:55, or about 45:55.
The aerosol-former material may act as a plasticiser. If the content of the plasticiser is too high, the aerosol-generating material may absorb water resulting in a material that does not create an appropriate consumption experience in use. If the plasticiser content is too low, the aerosol-generating material may be brittle and easily broken. The plasticiser content specified herein provides an aerosol-generating material flexibility which allows a sheet of the aerosol-generating material to be wound onto a bobbin, which is useful in manufacture of aerosol generating articles (consumables).

Filler

The aerosol-generating material may further comprise a filler. Use of a filler may help to reduce tackiness of the aerosol-generating material, for example if high levels of aerosol-former material are present.
In some embodiments, the aerosol-generating material may comprise less than about 50 wt% of a filler, such as from about 1 wt% to 50 wt%, or 5 wt% to 40 wt%, or 5 wt% to 30 wt%, or 10 wt% to 20 wt%.
In other embodiments, the aerosol-generating material comprises less than 20 wt%, suitably less than 10 wt% or less than 5 wt% of a filler. In some cases, the aerosol-generating material comprises less than 1 wt% of a filler, and in some cases the aerosol-generating material comprises no filler.
The filler, if present, may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp; tobacco pulp; hemp fibre; starch and starch derivatives, such as maltodextrin; chitosan; and cellulose and cellulose derivatives, such as microcrystalline cellulose and nanocrystalline cellulose. In particular cases, the aerosol-generating material comprises no calcium carbonate such as chalk.

Flavour

The aerosol-generating material may optionally comprise a flavour. For example, the aerosol-generating material may comprise up to about 60 wt%, 55 wt%, 50 wt% or 45 wt% of a flavour. In some cases, the aerosol-generating material may comprise at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt% or 40 wt% of a flavour (all calculated on a dry weight basis). For example, the aerosol-generating material may comprise 1 to 60 wt%, 10 to 60 wt%, 20 to 50 wt%, or 30 to 40 wt% a flavour.
The various aerosol-generating materials of the consumable include the same or different flavours, and/or flavours in different amounts.
As used herein, the terms "flavour" and "flavourant" 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 flavour 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 flavour comprises menthol, spearmint and/or peppermint.
In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry.
In some embodiments, the flavour comprises eugenol.
In some embodiments, the flavour comprises flavour components extracted from tobacco.
In some embodiments, the flavour comprises flavour components extracted from cannabis.
In some embodiments, the flavour 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 or WS-3 (N-ethyl-2-isopropyl-5-methylcyclohexanecarboxamide).
In some cases, the aerosol-generating material may additionally comprise an emulsifying agent, which emulsified molten flavour during manufacture. For example, the aerosol-generating material may comprise from about 5 wt% to about 15 wt% of an emulsifying agent (calculated on a dry weight basis), suitably about 10 wt%. The emulsifying agent may comprise acacia gum.
In particular embodiments which include filler, the filler may be fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, tobacco pulp, hemp fibre, cellulose or cellulose derivatives. In some embodiments, the fibrous organic filler material may be wood pulp, hemp fibre, cellulose or cellulose derivatives. In some embodiments, the fibrous filler is wood pulp. Without wishing to be bound by theory, it is believed that including fibrous filler in an aerosol-generating material may increase the tensile strength of the material. This may be particularly advantageous in examples wherein the aerosol-generating material is provided as a sheet, such as when an aerosol-generating material sheet circumscribes a rod of aerosolisable material.
In some embodiments the gelling agent is CMC and is used together with wood pulp as a filler.

Solvent

The aerosol-generating film may be made from a gel, and this gel may additionally comprise a solvent, included at 0.1-50 wt%. However, it has been established that the inclusion of a solvent in which the flavour is soluble may reduce the gel stability and the flavour may crystallise out of the gel. As such, in some cases, the gel does not include a solvent in which the flavour is soluble.

Other functional material

In some embodiments, one or more aerosol-generating material may further comprise one or more other functional material(s).
In some embodiments, the aerosol-generating material may further comprise one or more additional active substances and/or flavours, and optionally one or more other functional material. The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, stabilizers, and/or antioxidants.

Sheets

In some embodiments, one or more of the aerosol-generating materials are each formed as a sheet.
In some cases, the aerosol-generating material sheet may be incorporated into the system or consumable of the present invention in sheet form. The aerosol-generating material sheet may be incorporated as a planar sheet, as a gathered or bunched sheet, as a crimped sheet, or as a rolled sheet (i.e. in the form of a tube). A rolled sheet may be arranged in a spiral configuration (see Figure 2) in the consumable so as to provide one or more longitudinally-extending air channels. In some such cases, the aerosol-generating material may be included in the system/consumable as a sheet, such as a sheet circumscribing a rod of aerosolisable material (e.g. tobacco). For example, the aerosol-generating material sheet may be formed on a wrapping paper which circumscribes an aerosolisable material such as tobacco. In other cases, the sheet may be shredded and then incorporated into the assembly, optionally mixed into an aerosolisable material such as cut rag tobacco or a non-tobacco plant material.
Where the aerosol-generating material comprises two or more aerosol-generating materials in sheet form, the sheets may be incorporated into the non-combustible aerosol provision system or consumable in the same manner or in different manners.
The "thickness" of the aerosol-generating material describes the shortest distance between a first surface and a second surface. In embodiments where the aerosol-generating material is in the form of a sheet, the thickness of the aerosol-generating material is the shortest distance between a first planar surface of the sheet and a second planar surface of the sheet which opposes the first planar surface of the sheet. In some cases, the aerosol-generating material may be in the form of a sheet or layer having a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm, for example 0.1-3 mm or 0.15-3 mm. A material having a thickness of 0.2 mm may be particularly suitable. In some embodiments, the aerosol-generating film may have a thickness of about 0.11 mm to 0.17 mm, for example of about 0.12 mm to 0.13 mm. The aerosol-generating material may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers. Where the aerosol-generating material comprises two or more aerosol-generating materials in sheet form, the sheets may have the same thickness or different thicknesses.
If the aerosol-generating material is too thick, then heating efficiency may be compromised. This adversely affects the power consumption in use. Conversely, if the aerosol-generating material is too thin, it may be difficult to manufacture and handle; a very thin material is harder to cast and may be fragile, compromising aerosol formation in use.
The thickness stipulated herein is a mean thickness for the material. In some cases, the aerosol-generating material thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%.
In some examples, the aerosol-generating material in sheet form may have a tensile strength of from around 200 N/m to around 2000 N/m. In some examples, the aerosol-generating material in sheet form may have a tensile strength of from around 200 N/m to around 900 N/m. In some examples, such as where the aerosol-generating material does not comprise a filler, the aerosol-generating material in sheet form may have a tensile strength of from around 200 N/m to around 400 N/m, or around 200 N/m to around 300 N/m, or about 250 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosol-generating material and/or the aerosol-generating material is formed as a sheet and then shredded and incorporated into a consumable. In some examples, such as where the aerosol-generating material comprises a filler, the aerosol-generating material may have a tensile strength of from around 600 N/m to around 900 N/m, or from around 700 N/m to around 900 N/m, or around 800 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosol-generating material and/or the aerosol-generating material is included in a consumable/non-combustible aerosol provision system as a rolled sheet, suitably in the form of a tube.
Where the aerosol-generating material comprises two or more aerosol-generating materials in sheet form, the sheets may have the same tensile strength or different tensile strengths.
The aerosol-generating material may have any suitable area density, such as from 30 g/m2 to 120 g/m2. In some cases, the aerosol-generating material may have a mass per unit area of 80-120 g/m2, or from about 70 to 110 g/m2, or particularly from about 90 to 110 g/m2, or suitably about 100 g/m2 (so that it has a similar density to cut rag tobacco and a mixture of these substances will not readily separate). Such area densities may be particularly suitable where the aerosol-generating material is included in assembly consumable/system in sheet form, or as a shredded sheet (described further hereinbelow). In some cases, the aerosol-generating material may have a mass per unit area of about 30 to 70 g/m2, 40 to 60 g/m2, or 25 to 60 g/m2 and may be used to wrap an aerosolisable material such as tobacco.
Where the aerosol-generating material comprises two or more aerosol-generating materials in sheet form, the sheets may have the same area density or different area densities.
In some embodiments, the aerosol-generating material is formed as a film on a support. The aerosol-generating film may be a continuous film or a discontinuous film, such as an arrangement of discrete portions of film on a support. In some cases, the aerosol-generating film does not comprise a filler.
The aerosol-generating material for use in aerosol generation may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.
The aerosol-generating material may comprise a carrier on which the aerosol-generating material is provided. The carrier functions as a support on which the aerosol-generating material layer forms, easing manufacture. The carrier may provide tensile strength to the aerosol-generating material layer, easing handling. In some embodiments, a carrier may not be provided and in these embodiments the aerosol generating material may comprise an aerosol generating film which is not provided on a carrier. The omission of a carrier provides for an aerosol generating material/film having a reduced thermal mass, which may provide faster aerosolization of the aerosol generating material/film. Furthermore, the omission of the carrier increases the surface area of the aerosol generating material/film which provides for faster and improved aerosolisation as aerosol can be released from a greater surface area of the aerosol generating material/film.
In some cases, the carrier may be formed from materials selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes such as graphite and graphene, plastic, cardboard, wood or combinations thereof. In some cases, the carrier may comprise or consist of a tobacco material, such as a sheet of reconstituted tobacco. In some cases, the carrier may be formed from materials selected from metal foil, paper, cardboard, wood or combinations thereof. In some cases, the carrier itself be a laminate structure comprising layers of materials selected from the preceding lists. In some cases, the carrier may also function as a flavour carrier. For example, the carrier may be impregnated with a flavour or with tobacco extract.
In some cases, the carrier may be magnetic. This functionality may be used to fasten the carrier to the device (e.g. non-combustible aerosol provision device) in use, or may be used to generate particular aerosol-generating material shapes. In some cases, the aerosol-generating material may comprise one or more magnets which can be used to fasten the material to an induction heater in use.
In some cases, the carrier may be substantially or wholly impermeable to gas and/or aerosol. This prevents aerosol or gas passage through the carrier layer, thereby controlling the flow and ensuring it is delivered to the user. This can also be used to prevent condensation or other deposition of the gas/aerosol in use on, for example, the surface of a heater provided in an aerosol generating assembly. Thus, consumption efficiency and hygiene can be improved in some cases.
In some cases, the surface of the carrier that abuts the aerosol-generating material may be porous. For example, in one case, the carrier comprises paper. A porous carrier such as paper has been found to be particularly suitable; the porous (e.g. paper) layer abuts the aerosol-generating material layer and forms a strong bond. The aerosol-generating material may be formed by drying a gel and, without being limited by theory, it is thought that the slurry from which the gel is formed partially impregnates the porous carrier (e.g. paper) so that when the gel sets, the carrier is partially bound into the gel. This provides a strong binding between the gel and the carrier (and between the dried gel and the carrier).
In some embodiments, the aerosol-generating material may be laminated to a carrier, such as a paper sheet.
In some embodiments, when the aerosol-generating material is formed from a slurry as described herein, the layer of slurry may be formed on a carrier, such as a paper sheet.
Additionally, surface roughness may contribute to the strength of bond between the aerosol-generating material and the carrier. The paper roughness (for the surface abutting the carrier) may suitably be in the range of 50-1000 Bekk seconds, suitably 50-150 Bekk seconds, suitably 100 Bekk seconds (measured over an air pressure interval of 50.66-48.00 kPa). (A Bekk smoothness tester is an instrument used to determine the smoothness of a paper surface, in which air at a specified pressure is leaked between a smooth glass surface and a paper sample, and the time (in seconds) for a fixed volume of air to seep between these surfaces is the "Bekk smoothness".)
Conversely, the surface of the carrier facing away from the aerosol-generating material may be arranged in contact with the heater, and a smoother surface may provide more efficient heat transfer. Thus, in some cases, the carrier is disposed so as to have a rougher side abutting the aerosol-generating material and a smoother side facing away from the aerosol-generating material.
In one particular case, the carrier may be a paper-backed foil; the paper layer abuts the aerosol-generating material layer and the properties discussed in the previous paragraphs are afforded by this abutment. The foil backing is substantially impermeable, providing control of the aerosol flow path. A metal foil backing may also serve to conduct heat to the aerosol-generating material.
In another case, the foil layer of the paper-backed foil abuts the aerosol-generating material. The foil is substantially impermeable, thereby preventing water provided in the aerosol-generating material from being absorbed into the paper which could weaken its structural integrity.
In some cases, the carrier is formed from or comprises metal foil, such as aluminium foil. A metallic carrier may allow for better conduction of thermal energy to the aerosol-generating material. Additionally, or alternatively, a metal foil may function as a susceptor in an induction heating system. In particular embodiments, the carrier comprises a metal foil layer and a support layer, such as cardboard. In these embodiments, the metal foil layer may have a thickness of less than 20 µm, such as from about 1 µm to about 10 µm, suitably about 5 µm.
In some cases, the carrier may have a thickness of between about 0.010 mm and about 2.0 mm, suitably from about 0.015 mm, 0.02 mm, 0.05 mm or 0.1 mm to about 1.5 mm, 1.0 mm, or 0.5 mm.
Where the aerosol-generating material comprises two or more aerosol-generating materials in sheet form, the sheets may be formed on the same carrier, may be formed on the same type of carrier, or may be formed on different carrier.
The two or more aerosol-generating materials are included in the aerosol-generating material. These aerosol-generating materials include different active substances. The aerosol-generating materials may, otherwise, be the same. Alternatively the materials may differ in one or more further ways.
For example, the aerosol-generating materials may have different thicknesses and/or that may be provided in otherwise different sizes, such as cut to different dimensions or average particle sizes.
The density of the aerosol-generating materials may be different.
In some embodiments, the aerosol-generating materials include different components or the same components in different amounts.
The two or more aerosol-generating materials may be included in the aerosol-generating material in different amounts.
In some embodiments, the different aerosol-generating materials may be mixed to form a largely homogenous blend. In other embodiments, the distribution of the different aerosol-generating materials is controlled to provide a desired distribution within the material, optionally with the materials being unmixed or substantially unmixed. Where the aerosol-generating material comprises a blend of two or more different aerosol-generating materials this may control the release of the active agents. For example, the blend may provide a consistent release throughout use of the consumable, and may be configured/formulated to provide either a rapid release or a slow release.

The consumable

The consumable may alternatively be referred to herein as a cartridge or article. The consumable may be adapted for use in a THP, an electronic tobacco hybrid device or another aerosol generating device such as a non-combustible aerosol provision device. In some cases, the consumable may additionally comprise a filter and/or cooling element (or cooling segment). In some cases, the consumable may be circumscribed by a wrapping material such as paper.
The consumable may additionally comprise ventilation apertures. These may be provided in the sidewall of the article. In some cases, the ventilation apertures may be provided in the filter and/or cooling element/segment. These apertures may allow cool air to be drawn into the article during use, which can mix with the heated volatilised components thereby cooling the aerosol.
The ventilation enhances the generation of visible heated volatilised components from the article when it is heated in use. The heated volatilised components are made visible by the process of cooling the heated volatilised components such that supersaturation of the heated volatilised components occurs. The heated volatilised components then undergo droplet formation, otherwise known as nucleation, and eventually the size of the aerosol particles of the heated volatilised components increases by further condensation of the heated volatilised components and by coagulation of newly formed droplets from the heated volatilised components.
In some cases, the ratio of the cool air to the sum of the heated volatilised components and the cool air, known as the ventilation ratio, is at least 15%. A ventilation ratio of 15% enables the heated volatilised components to be made visible by the method described above. The visibility of the heated volatilised components enables the user to identify that the volatilised components have been generated and adds to the sensory experience of the smoking experience.
In another example, the ventilation ratio is between 50% and 85% to provide additional cooling to the heated volatilised components. In some cases, the ventilation ratio may be at least 60% or 65%.
In some embodiments, the disclosure relates to consumables configured to be used with non-combustible aerosol provision devices.
Articles of the present invention may be provided in any suitable shape or configuration. In some examples, the article is provided as a rod (e.g. substantially cylindrical). An article provided as a rod may comprise the aerosol-generating material as shredded sheets of aerosol-generating material, for example in the first section of the consumable. Optionally these shredded sheets are blended with another aerosol-generating material, such as cut tobacco or another botanical material.
Alternatively, or additionally, the article provided as a rod may include one or more sheets of aerosol-generating material circumscribing a rod of aerosol-generating material (e.g. tobacco, an aerosol-generating material such as described herein or a combination thereof).
Alternatively, or additionally, the one or more sheets of aerosol-generating material may be arranged in a spiral configuration (for example the first section of aerosol-generating material of the consumable may comprise such one or more spiral sheets), for example the one or more sheets of aerosol-generating material may be arranged in substantially spiral configuration, or having a substantially spiral-shaped cross-section. One or more longitudinally-extending air channels may be provided between each layer of the spiral. The one or more sheets may be rolled or wound into a spiral configuration.
Alternatively, or additionally, the one or more sheets of aerosol-generating material may be gathered so as to provide a plurality of folds (for example the first section of aerosol-generating material of the consumable may comprise such one or more gathered sheets). One or more longitudinally-extending air channels may be provided between, or defined by layers of, each fold.
Figure 1 shows a cross-sectional view of a consumable (or "article") 101 according to a first embodiment of the present invention. Figure 4 shows a cross-sectional view of a consumable 301 according to a second embodiment of the present invention. The reference signs shown in Figure 4 are equivalent to the reference signs shown in Figure 1, but with an increment of 200.
With reference to Figure 1, the consumable 101 is adapted for use with a device having a power source and a heater. The consumable 101 of this embodiment is particularly suitable for use with the device 51 shown in Figures 5 to 7, described below. In use, the consumable 101 may be removably inserted into the device shown in Figure 5 at an insertion point 20 of the device 51.
In one embodiment, the total length of the article 101 is between 71 mm and 95 mm, suitably between 79 mm and 87 mm, suitably 83 mm. The overall mass of the consumable 101 may be 390mg or less, for example 340mg or less, 300mg or less, or 290mg or less.
The consumable 101 of one example is in the form of a substantially cylindrical rod.
The consumable of all embodiments of the present invention comprises a first section 102 and a second section 112 upstream of the first section 102. At least one of the first 102 and/or second sections 112 comprise aerosol generating material. The second section 112 comprises a continuously increasing density, continuously increasing towards an upstream-most end 115 (or distal-most end 115) most end of the consumable 101. The continuously increasing density causes the pressure drop of the second section 112 to continuously increase correspondingly. This increased pressure drop allows for less aerosol generating material to be provided, either in the first section 102 or the second section 112, without affecting the overall pressure drop of the consumable 101. As less aerosol generating material may be used, the overall weight of the consumable may be reduced.
In some embodiments, for example in the embodiments of Figs. 1 and 4, the first section 102 comprises aerosol-generating material described herein, although the first section 102 of other embodiments may be made of any other suitable material such as cellulose acetate tow.
In some embodiments in which the first section 302 comprises aerosol-generating material, the aerosol generating of the first section 302 may be provided in sheet form 306, as shown in the embodiment of Fig. 4. The first section 302 comprises at least one longitudinally extending air channel 304, in this embodiment defined by the sheet, extending therethrough. The provision of one or more longitudinally-extending air channels allows the overall weight of the consumable to be reduced as less aerosol generating material may be provided in the first section of aerosol-generating material and so less aerosol generating may be provided in the consumable overall, thereby reducing the weight of the consumable.
In some embodiments for example in the embodiment of Fig. 4, the sheet of aerosol generating material of the first section 302 may be provided in the form of a spiral 303 (see Fig. 2) and, as such, in some embodiments the aerosol generating material of the first section 302 may have a substantially spiral shaped cross section with one or more longitudinally-extending air channels 304 between, or defined by, each layer of the spiral of sheet 306 of aerosol-generating material, for example defined by opposing, or spaced-apart, surfaces of the sheet 306, or between points where opposing parts or points of the sheet 306 may touch in the spiral. The sheet 306 may be rolled into the spiral 303 and the spiral 303 may in some embodiments be formed by a loosely rolled sheet 306 of aerosol generating material. In some embodiments, the spiral 303 may be arranged to revolve around an axis which is parallel to or collinear with a longitudinal axis of the consumable.
In some embodiments, the first section of aerosol generating-material 302 may be provided as one or more (e.g. loosely rolled) sheets of, or comprising, aerosol-generating material each arranged in a spiral 303, for example wherein a spiral 303 of a first sheet 306 is nestled within a spiral 303 of a second sheet 306 of aerosol-generating material so that the two spirals spiral together, for example wherein the spirals 303 of the first and second sheets are arranged to revolve around a common axis, which in some embodiments may be parallel to or collinear with a longitudinal axis of the consumable. Where two or more sheets 303 of aerosol generating material are provided, the aerosol-generating material, for example the aerosol-generating film thereof, of each sheet 306 may be different from each other, for example the composition of the aerosol-generating material or aerosol-generating film of each sheet 303 may be different from each other, for example each sheet may comprise a different concentration of aerosol-generating material.
It has advantageously been found that a spiral configuration of the one or more sheets 306 may increase the pressure drop across the first section of aerosol-generating material 302 and thus may contribute to increasing the overall pressure drop across the consumable, which is particularly advantageous as less aerosol generating material may then be used in the first 302 or second 312 sections and so the overall weight of the consumable may be reduced.
In some embodiments, one or more longitudinally extending air channels 304 through the first section 302 may instead be provided by alternative means, for example the first section 302 may instead be provided in other embodiments by gathering one or more sheets 306 of aerosol-generating material so as to provide a plurality of folds 316 (see Fig. 3) and one or more longitudinally-extending air channels 304 may be provided between each fold 316. The provision of a gathered sheet of aerosol generating material has also been advantageously found to increase the pressure drop across the first section of aerosol-generating material 302 and thus less aerosol generating material may be used in the first 302 or second 303 sections and so the overall weight of the consumable may be reduced.
In some embodiments the at least one longitudinally-extending air channel 304 may be provided by a longitudinally extending tubular element (not shown) arranged within the first section 302, for example surrounded by the sheet 306.
In embodiments comprising at least one longitudinally-extending air channel extending through the first section 302, the aerosol generating material of the first section 302 may be arranged to provide at least one air gap or void 321 defining the at least one longitudinally-extending air channel 304.
In some embodiments, for example in the embodiments of Figs. 1 and 4, the first section 302 of aerosol generating material is in the form of an aerosol-generating film, for example provided on the sheet 306. The aerosol-generating film may be, or comprise, an amorphous solid, for example such as an amorphous solid as described above. The first section 102 of aerosol generating material is provided on a carrier which in the embodiment of Figures 1 and 4 is paper although any suitable carrier may instead be used as described hereinabove. The aerosol generating material of the first section 102 may be provided as a layer, for example as a film, on or in the carrier. The one or more sheets 306 may therefore comprise aerosol-generating material as an aerosol-generating layer or film (which in some embodiments may be or comprise an amorphous solid) provided on the carrier.
As the consumable of the present invention may have a reduced overall weight due to a reduction in some embodiments of the mass of aerosol-generating material in the first section 102 of aerosol generating material, the aerosol-generating material of the first section 102 comprising an aerosol-generating film, for example on the sheet 106, allows for any sensory reduction of the consumable resulting from the reduced mass of aerosol-generation material of the portion 102 to be compensated for. This is because the aerosol-generating material of the aerosol-generating film may in some embodiments be particularly concentrated per unit weight as compared to, for example, cut rag tobacco and this may compensate for any reduction in sensory performance of the consumable resulting from the reduction of mass of the section of aerosol-generating material. For example, in some embodiments, the aerosol generating material may comprise tobacco extract which may be particularly concentrated as compared to, for example, cut-rag tobacco, and so, even though less aerosol generating material by weight may be used in the section of aerosol-generating material, the overall sensory performance of the consumable may be improved.
In some embodiments, the mass ratio of the second section 112 to the aerosol generating material of the first section 102 may be more than 1, for example the mass ratio of the second section to the aerosol generating material of the first section 102 may be from 1 to 5, for example 1.1, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, or 5.0, or may be within a range defined by any two of these values, for example from 1.5 to 1.9.
The continuously increasing density of the second section 112 provides a pressure drop member 119 having an overall increased pressure drop. Thus, the section second 112 compensates in overall pressure drop across the consumable 101 in embodiments in which the pressure drop across first section 102 is particularly low. The second section 112 in the embodiments of Figures 1 and 4 extends from an upstream-most end 110 of the first section 102 to an upstream-most end 115 of the consumable 101. Thus, the continuously increasing density of the second section 112 provides a pressure drop which is greater than the pressure drop across the first section 102 aerosol generating material 102. The continuously increasing density of the second section 112 (and optionally the first section 102) may be provided by any suitable means, for example the second section 112 may be crushed to a tapered shape in which the circumference continuously decreases towards an upstream-most end 115 of the consumable. In some embodiments, the pressure drop across the second section 112 is between 35 to 54 mm wg, such as 40 to 45 mm wg, 36 to 40 mm wg, 10 to 20mm wg, or 10 to 15mm wg.
The second section 112 may comprise any suitable material for providing a pressure drop there across and, in the embodiment of Figure 1, the second section 112 comprises cellulose acetate tow.
In contrast, in the second embodiment of Figure 4, the second section 312 comprises a body 318 of aerosol generating material, which in some embodiments may be or comprise tobacco. The body 318 extends from an upstream-most end 310 of the first section 302 to an upstream-most end 315 of the consumable 301. In the embodiment of Figure 4, the body 318 of aerosol generating material is provided as cut rag tobacco, however in other embodiments the body 318 aerosol generating material may be provided as discrete bodies 122, or strips 122, of aerosol generating material provided as a film (which in certain embodiments may be or comprise an amorphous solid) provided on a carrier 124, mixed or otherwise distributed within the body 318 and in some embodiments the bodies may be mixed or otherwise distributed within a body 318 of a second aerosol generating material such as tobacco, such as cut rag tobacco. In some embodiments, the carrier may be omitted.
In the embodiment of Figure 1, the second section 112 of the consumable 101 comprises cellulose acetate tow (and so the second section 112 is absent of aerosol generating material) and the first section 102 comprises a body of aerosol generating material which, in this specific embodiment, comprises tobacco such as cut rag tobacco, although any other aerosol generating material could instead be used. Mixed, or dispersed, within the aerosol generating material of the first section 102 are a plurality of discrete bodies 122 of aerosol generating material, which may in some embodiments be strips 122 of shredded aerosol generating material. In other embodiments, the body of aerosol generating material may be substituted for a body of non-aerosol generating material (such as cellulose acetate tow) and a plurality of discrete bodies 122 (such as strips) of aerosol generating material may be dispersed within the body of non-aerosol generating material - in such embodiments, the second section 112 may comprise aerosol generating material, for example provided as a body of aerosol generating material.
In some embodiments, for example in the embodiments shown in both Figures 1 and 4, the consumable further comprises a filter assembly 105 downstream of the first section 102. The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109 and a mouth end segment 111. However, other embodiments are envisaged wherein only a filter segment 109 is provided and the cooling segment 107 and mouth end segment 111 are omitted. The article 101 has a first end 113, also known as a mouth end or a proximal end and a second end 115, also known as a distal end. The first section 102 and second section 112 are located towards the distal end 115 of the article 101. In one example, the cooling segment 107 is located adjacent the first section 102 of aerosol-generating material between the first section 102 of aerosol-generating material and the filter segment 109, such that the cooling segment 107 is in an abutting relationship with the first section 102 of aerosol-generating material and the filter segment 109. In other examples, there may be a separation between the first section 102 of aerosol-generating material and the cooling segment 107 and between the first section 102 of aerosol-generating material and the filter segment 109. The filter segment 109 is located in between the cooling segment 107 and the mouth end segment 111. The mouth end segment 111 is located towards the proximal end 113 of the consumable 101, adjacent the filter segment 109. In one example, the filter segment 109 is in an abutting relationship with the mouth end segment 111. In one embodiment, the total length of the filter assembly 105 is between 37 mm and 45 mm, more preferably, the total length of the filter assembly 105 is 41 mm. In another embodiment, the total length of the filter assembly 105 is between 30 mm to 40 mm, such as 34 mm or 35 mm.
The filter segment 109 may be formed of any filter material sufficient to remove one or more volatilised compounds from heated volatilised components from the aerosol-generating material. In one example the filter segment 109 is made of a mono-acetate material, such as cellulose acetate. The filter segment 109 provides cooling and irritation-reduction from the heated volatilised components without depleting the quantity of the heated volatilised components to an unsatisfactory level for a user.
In some embodiments, a capsule (not illustrated) may be provided in filter segment 109. It may be disposed substantially centrally in the filter segment 109, both across the filter segment 109 diameter and along the filter segment 109 length. In other cases, it may be offset in one or more dimension. The capsule may in some cases, where present, contain a volatile component such as a flavour or aerosol-former material.
The density of the cellulose acetate tow material of the filter segment 109 controls the pressure drop across the filter segment 109, which in turn controls the draw resistance of the article 101. Therefore the selection of the material of the filter segment 109 is important in controlling the resistance to draw of the article 101. In addition, the filter segment performs a filtration function in the article 101.
In one example, the filter segment 109 is made of a 8Y15 grade of filter tow material, which provides a filtration effect on the heated volatilised material, whilst also reducing the size of condensed aerosol droplets which result from the heated volatilised material.
The presence of the filter segment 109 provides an insulating effect by providing further cooling to the heated volatilised components that exit the cooling segment 107. This further cooling effect reduces the contact temperature of the user's lips on the surface of the filter segment 109.
In one example, the filter segment 109 is between 6 mm to 10 mm in length, suitably 8 mm. In another example, the length of the filter assembly 105 is between 30 mm to 40 mm, such as 34 mm or 35 mm.
The first section 102 of aerosol-generating material may in some embodiments be joined to the second section 112 by annular tipping paper (not shown), which is located substantially around the circumference of the second section 112 to surround the filter assembly 105 and extends partially along the length of the first section 102 of aerosol-generating material. In one example, the tipping paper is made of 58 GSM standard tipping base paper. In one example the tipping paper has a length of between 42 mm and 50 mm, suitably of 46 mm. The first section 102 of aerosol-generating material may in some embodiments be provided within or extend at least partially within the cooling segment 107 - advantageously this may improve the firmness of the section of the consumable 101 containing the first section 102.
In one example, the cooling segment 107 is an annular tube and is located around and defines an air gap within the cooling segment. The air gap provides a chamber for heated volatilised components generated from the first section 102 of aerosol-generating material to flow. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article 101 is in use during insertion into the device 51. In one example, the thickness of the wall of the cooling segment 107 is approximately 0.29 mm.
The cooling segment 107 provides a physical displacement between the first section 102 of aerosol-generating material and the filter segment 109. The physical displacement provided by the cooling segment 107 will provide a thermal gradient across the length of the cooling segment 107. In one example the cooling segment 107 is configured to provide a temperature differential of at least 40°C between a heated volatilised component entering a first end of the cooling segment 107 and a heated volatilised component exiting a second end of the cooling segment 107. In one example the cooling segment 107 is configured to provide a temperature differential of at least 60 °C between a heated volatilised component entering a first end of the cooling segment 107 and a heated volatilised component exiting a second end of the cooling segment 107. This temperature differential across the length of the cooling element 107 protects the temperature sensitive filter segment 109 from the high temperatures of the aerosol-generating material when it is heated by the device 51. If the physical displacement was not provided between the filter segment 109 and the first section 102 of aerosol-generating material and the heating elements of the device 51, then the temperature sensitive filter segment 109 may become damaged in use, so it would not perform its required functions as effectively.
In one example the length of the cooling segment 107 is at least 15 mm. In one example, the length of the cooling segment 107 is between 20 mm and 30 mm, more particularly 23 mm to 27 mm, more particularly 25 mm to 27 mm, suitably 25 mm. In another embodiment, the length of the cooling segment 107 is between 30 mm to 40 mm, such as 34 mm or 35 mm.
The cooling segment 107 is made of paper, which means that it is comprised of a material that does not generate compounds of concern, for example, toxic compounds when in use adjacent to the heater of the device 51. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube which provides a hollow internal chamber yet maintains mechanical rigidity. Spirally wound paper tubes are able to meet the tight dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness and straightness.
In another example, the cooling segment 107 is a recess created from stiff plug wrap or tipping paper. The stiff plug wrap or tipping paper is manufactured to have a rigidity that is sufficient to withstand the axial compressive forces and bending moments that might arise during manufacture and whilst the article 101 is in use during insertion into the device 51.
The mouth end segment 111 is an annular tube and is located around and defines an air gap within the mouth end segment 111. The air gap provides a chamber for heated volatilised components that flow from the filter segment 109. The mouth end segment 111 is hollow to provide a chamber for aerosol accumulation yet rigid enough to withstand axial compressive forces and bending moments that might arise during manufacture and whilst the article is in use during insertion into the device 51. In one example, the thickness of the wall of the mouth end segment 111 is approximately 0.29 mm. In one example, the length of the mouth end segment 111 is between 6 mm to 10 mm, suitably 8 mm.
The mouth end segment 111 may be manufactured from a spirally wound paper tube which provides a hollow internal chamber yet maintains critical mechanical rigidity. Spirally wound paper tubes are able to meet the tight dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness and straightness.
The mouth end segment 111 provides the function of preventing any liquid condensate that accumulates at the exit of the filter segment 109 from coming into direct contact with a user.
It should be appreciated that, in one example, the mouth end segment 111 and the cooling segment 107 may be formed of a single tube and the filter segment 109 is located within that tube separating the mouth end segment 111 and the cooling segment 107.
A ventilation region 117 is provided in the article 101 to enable air to flow into the interior of the article 101 from the exterior of the article 101. In one example the ventilation region 117 takes the form of one or more ventilation holes 117 formed through the outer layer of the article 101. The ventilation holes may be located in the cooling segment 107 to aid with the cooling of the article 101 or, as in the embodiment shown, in the filter segment 109. In one example, the ventilation region 117 comprises one or more rows of holes, and preferably, each row of holes is arranged circumferentially around the article 101 in a cross-section that is substantially perpendicular to a longitudinal axis of the article 101.
In one example, there are between one to four rows of ventilation holes to provide ventilation for the article 101. Each row of ventilation holes may have between 12 to 36 ventilation holes 117. The ventilation holes 117 may, for example, be between 100 to 500 µm in diameter. In one example, an axial separation between rows of ventilation holes 117 is between 0.25 mm and 0.75 mm, suitably 0.5 mm.
In one example, the ventilation holes 117 are of uniform size. In another example, the ventilation holes 117 vary in size. The ventilation holes can be made using any suitable technique, for example, one or more of the following techniques: laser technology, mechanical perforation of the cooling segment 107 or pre-perforation of the cooling segment 107 before it is formed into the article 101. The ventilation holes 117 are positioned so as to provide effective cooling to the article 101.
In one example, the rows of ventilation holes 117 are located at least 11mm from the proximal end 113 of the article, suitably between 17 mm and 20 mm from the proximal end 113 of the article 101. The location of the ventilation holes 117 is positioned such that user does not block the ventilation holes 117 when the article 101 is in use.
Providing the rows of ventilation holes between 17 mm and 20 mm from the proximal end 113 of the article 101 enables the ventilation holes 117 to be located outside of the device 51, when the article 101 is fully inserted in the device 51, as can be seen in Figures 6 and 7. By locating the ventilation holes outside of the device, non-heated air is able to enter the article 101 through the ventilation holes from outside the device 51 to aid with the cooling of the article 101.
The length of the cooling segment 107 is such that the cooling segment 107 will be partially inserted into the device 51, when the article 101 is fully inserted into the device 51. The length of the cooling segment 107 provides a first function of providing a physical gap between the heater arrangement of the device 51 and the heat sensitive filter arrangement 109, and a second function of enabling the ventilation holes 117 to be located in the cooling segment, whilst also being located outside of the device 51, when the article 101 is fully inserted into the device 51. As can be seen from Figures 6 and 7, the majority of the cooling element 107 is located within the device 51. However, there is a portion of the cooling element 107 that extends out of the device 51. It is in this portion of the cooling element 107 that extends out of the device 51 in which the ventilation holes 117 may be located.
The second embodiment shown in Fig. 4 is substantially the same as the first embodiment discussed above with the exception that, in addition to the first section 302, the second section 312 also comprises aerosol-generating material which may be or comprise tobacco such as cut-rag tobacco. The aerosol-generating material of the second embodiment is provided as a body of aerosol generating material. The aerosol-generating material of the second section 312 may extend from an upstream-most end of the first section 302 of aerosol generating material to an upstream-most end of the consumable 301. The first and second embodiments may also comprise a further component such as an end cap or plug provided at (for example at an extremity of) the distal-most end 315 of the article 301. Thus, the end cap or plug may be configured to prevent the material of the first section 208, for example aerosol generating material, from escaping the article 301.
While in the second embodiment shown in Fig. 4 only the second section 312 (and not also the first section 302) has a continuously increasing density, continuously increasing towards the upstream end 315 of the consumable 301, in contrast in the embodiment of Fig. 1 both the first 102 and second 112 sections have a continuously increasing density, increasing towards the upstream end 115 of the consumable 101. In the first embodiment, the first 102 and second 112 sections together define a body having a continuously increasing density across both the first 102 and second sections 112 combined (that is, there is no discrete step change in density between the first 102 and second sections 112).
Similarly, while in the second embodiment shown in Fig. 4 only the second section 312 (and not also the first section 302) has a continuously decreasing circumference, continuously decreasing towards the upstream end 315 of the consumable 301, in contrast, in the embodiment of Fig. 1, both the first 102 and second 112 sections have a continuously decreasing circumference, decreasing towards the upstream end 115 of the consumable 101. In the first embodiment, the first 102 and second 112 sections together define a body having a continuously decreasing circumference across both the first 102 and second sections 112 combined (that is, there is no discrete step change in circumference between the first 102 and second sections 112). Thus, in the second embodiment of Fig. 4, only the second section 312 is tapered, whereas in the first embodiment of Fig. 1, both the first section 102 and the second section 112 are tapered. In some embodiments, only a portion of the axial length of second section 112 is tapered whereas in other embodiments the entire axial length of the second section 112 is tapered and a portion of the axial length of the first section 102 is tapered. In still other embodiments, the entire axial length of both the first 102 and second 112 sections is tapered and in some embodiments the tapered portion may extend downstream of the first section 102 such that, for example, at least a portion of the filter assembly 305 may be tapered. In certain embodiments the second section 112 may taper all the way to the distal-most end 115 of the consumable 101, that is the circumference of the second section 112 may continuously reduce all the way to the distal-most end 115 of the consumable 101. In all embodiments, rather than a material of the first 102; 302 and/or second sections 112; 312 being tapered (or having a continuously reducing circumference), a wrapper of the first 102; 302 and/or second sections 112;312 may be continuously tapered such as to have a continuously reducing circumference (or increasing thickness).

System for heating aerosol-generating material

In another aspect of the disclosure, there is provided a system for heating aerosol-generating material to volatilise at least one component of the aerosol generating material, the system comprising: the consumable as described herein; and a non-combustible aerosol provision device for heating the first section and/or the second section to volatilise at least one component of the aerosol-generating material thereof, the non-combustible aerosol provision device comprising a tapered receiving portion for receiving the consumable as described herein.
The system may be a non-combustible aerosol provision system comprising the consumable described herein and a non-combustible aerosol provision device.
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 powered non-combustible aerosol provision system.
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 device is a heat-not-burn device.
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. In some embodiments, the hybrid system comprises the aerosol-generating material described herein comprising or consisting of the aerosol-generating material and an additional liquid or gel aerosol-generating material.
In some embodiments, the non-combustible aerosol provision device is an electronic tobacco hybrid device.
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 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, such as a non-combustible aerosol provision device thereof, may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.
The non-combustible aerosol provision system or device may comprise a heater configured to heat but not burn the aerosol generating substrate. The heater may be, in some cases, a thin film, electrically resistive heater. In other cases, the heater may comprise an induction heater or the like. In yet further cases, the heater may be a combustible heat source or a chemical heat source which undergoes an exothermic reaction to produce heat in use.
In some cases, the heater may heat but not burn the aerosolisable material(s) to between 120°C and 350°C in use. In some cases, the heater may heat but not burn the aerosolisable material(s) to between 140°C and 250°C in use. In some cases in use, substantially all of the aerosol-generating material is less than about 4 mm, 3 mm, 2 mm or 1 mm from the heater. In some cases, the solid is disposed between about 0.017 mm and 2.0 mm from the heater, suitably between about 0.1 mm and 1.0 mm. These minimum distances may, in some cases, reflect the thickness of a carrier that supports the aerosol-generating material. In some cases, a surface of the aerosol-generating material may directly abut the heater.
In some cases, the heater may be embedded in the aerosol-generating material. In some such cases, the heater may be an electrically resistive heater (with exposed contacts for connection to an electrical circuit). In other such cases, the heater may be a susceptor embedded in the aerosol-generating material, which is heated by induction.
The non-combustible aerosol provision system may additionally comprise a cooling element and/or a filter. The cooling element, if present, may act or function to cool gaseous or aerosol components. In some cases, it may act to cool gaseous components such that they condense to form an aerosol. It may also act to space the very hot parts of the apparatus from the user. The filter, if present, may comprise any suitable filter known in the art such as a cellulose acetate plug.
In some cases, the non-combustible aerosol provision system may be a heat-not-burn system. That is, it may contain a solid material (and no liquid aerosolisable material). A heat-not-burn device is disclosed in WO 2015/062983 A2 , which is incorporated by reference in its entirety.
Referring now to Figures 5 to 7 in more detail, there is shown an example of a device 51 arranged to heat aerosol-generating material to volatilise at least one component of said aerosol-generating material, typically to form an aerosol which can be inhaled. The device 51 is a heating device which releases compounds by heating, but not burning, the aerosol-generating material.
A first end 53 is sometimes referred to herein as the mouth or proximal end 53 of the device 51 and a second end 55 is sometimes referred to herein as the distal end 55 of the device 51. The device 51 has an on/off button 57 to allow the device 51 as a whole to be switched on and off as desired by a user.
The device 51 comprises a housing 59 for locating and protecting various internal components of the device 51. In the example shown, the housing 59 comprises a uni-body sleeve 11 that encompasses the perimeter of the device 51, capped with a top panel 17 which defines generally the 'top' of the device 51 and a bottom panel 19 which defines generally the 'bottom' of the device 51. In another example the housing comprises a front panel, a rear panel and a pair of opposite side panels in addition to the top panel 17 and the bottom panel 19.
The top panel 17 and/or the bottom panel 19 may be removably fixed to the uni-body sleeve 11, to permit easy access to the interior of the device 51, or may be "permanently" fixed to the uni-body sleeve 11, for example to deter a user from accessing the interior of the device 51. In an example, the panels 17 and 19 are made of a plastics material, including for example glass-filled nylon formed by injection moulding, and the uni-body sleeve 11 is made of aluminium, though other materials and other manufacturing processes may be used.
The top panel 17 of the device 51 has an opening 20 at the mouth end 53 of the device 51 through which, in use, the article 101, 301 including the aerosol-generating material may be inserted into the device 51 and removed from the device 51 by a user.
The housing 59 has located or fixed therein a heater arrangement 23, control circuitry 25 and a power source 27. In this example, the heater arrangement 23, the control circuitry 25 and the power source 27 are laterally adjacent (that is, adjacent when viewed from an end), with the control circuitry 25 being located generally between the heater arrangement 23 and the power source 27, though other locations are possible.
The control circuitry 25 may include a controller, such as a microprocessor arrangement, configured and arranged to control the heating of the aerosol-generating material in the article 101, 301 as discussed further below.
The power source 27 may be for example a battery, which may be a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include for example a lithium-ion battery, a nickel battery (such as a nickel-cadmium battery), an alkaline battery and/ or the like. The battery 27 is electrically coupled to the heater arrangement 23 to supply electrical power when required and under control of the control circuitry 25 to heat the aerosol-generating material in the article (as discussed, to volatilise the aerosol-generating material without causing the aerosol-generating material to burn).
An advantage of locating the power source 27 laterally adjacent to the heater arrangement 23 is that a physically large power source 25 may be used without causing the device 51 as a whole to be unduly lengthy. As will be understood, in general a physically large power source 25 has a higher capacity (that is, the total electrical energy that can be supplied, often measured in Amp-hours or the like) and thus the battery life for the device 51 can be longer.
In one example, the heater arrangement 23 is generally in the form of a hollow cylindrical tube, having a hollow interior heating chamber 29 into which the article 101, 301 comprising the aerosol-generating material is inserted for heating in use. Different arrangements for the heater arrangement 23 are possible. For example, the heater arrangement 23 may comprise a single heating element or may be formed of plural heating elements aligned along the longitudinal axis of the heater arrangement 23. The or each heating element may be annular or tubular, or at least part-annular or part-tubular around its circumference. In an example, the or each heating element may be a thin film heater. In another example, the or each heating element may be made of a ceramics material. Examples of suitable ceramics materials include alumina and aluminium nitride and silicon nitride ceramics, which may be laminated and sintered. Other heating arrangements are possible, including for example inductive heating, infrared heater elements, which heat by emitting infrared radiation, or resistive heating elements formed by for example a resistive electrical winding.
In one particular example, the heater arrangement 23 is supported by a stainless steel support tube and comprises a polyimide heating element. The heater arrangement 23 is dimensioned so that substantially the whole of the portion 102 of aerosol-generating material of the article 101, 301 is inserted into the heater arrangement 23 when the article 101, 301 is inserted into the device 51.
The or each heating element may be arranged so that selected zones of the aerosol-generating material can be independently heated, for example in turn (over time, as discussed above) or together (simultaneously) as desired.
The heater arrangement 23 in this example is surrounded along at least part of its length by a thermal insulator 31. The insulator 31 helps to reduce heat passing from the heater arrangement 23 to the exterior of the device 51. This helps to keep down the power requirements for the heater arrangement 23 as it reduces heat losses generally. The insulator 31 also helps to keep the exterior of the device 51 cool during operation of the heater arrangement 23. In one example, the insulator 31 may be a double-walled sleeve which provides a low pressure region between the two walls of the sleeve. That is, the insulator 31 may be for example a "vacuum" tube, i.e. a tube that has been at least partially evacuated so as to minimise heat transfer by conduction and/or convection. Other arrangements for the insulator 31 are possible, including using heat insulating materials, including for example a suitable foam-type material, in addition to or instead of a double-walled sleeve.
The housing 59 may further comprises various internal support structures 37 for supporting all internal components, as well as the heating arrangement 23.
The device 51 further comprises a collar 33 which extends around and projects from the opening 20 into the interior of the housing 59 and a generally tubular chamber 35 which is located between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further comprises a cooling structure 35f, which in this example, comprises a plurality of cooling fins 35f spaced apart along the outer surface of the chamber 35, and each arranged circumferentially around outer surface of the chamber 35. There is an air gap 36 between the hollow chamber 35 and the article 101, 301 when it is inserted in the device 51 over at least part of the length of the hollow chamber 35. The air gap 36 is around all of the circumference of the article 101, 301 over at least part of the cooling segment 307.
The collar 33 comprises a plurality of ridges 60 arranged circumferentially around the periphery of the opening 20 and which project into the opening 20. The ridges 60 take up space within the opening 20 such that the open span of the opening 20 at the locations of the ridges 60 is less than the open span of the opening 20 at the locations without the ridges 60. The ridges 60 are configured to engage with an article 101, 301 inserted into the device to assist in securing it within the device 51. Open spaces (not shown in the Figures) defined by adjacent pairs of ridges 60 and the article 101, 301 form ventilation paths around the exterior of the article 101, 301. These ventilation paths allow hot vapours that have escaped from the article 101, 301 to exit the device 51 and allow cooling air to flow into the device 51 around the article 101, 301 in the air gap 36.
In operation, the article 101, 301 is removably inserted into an insertion point 20 of the device 51, as shown in Figures 5 to 7. Referring particularly to Figure 6, in one example, the portion 102; 302 of aerosol-generating material, which may be located towards the distal end 115, 315 of the article 101, 301, is entirely received within the heater arrangement 23 of the device 51. The proximal end 113, 313 of the article 101, 301 extends from the device 51 and acts as a mouthpiece assembly for a user.
In operation, the heater arrangement 23 will heat the article 101, 301 to volatilise at least one component of the aerosol-generating material from the portion 102 of aerosol-generating material.
The primary flow path for the heated volatilised components from the portion 102 of aerosol-generating material is axially through the article 101, 301, through the chamber inside the cooling segment 107, 307, through the filter segment 109, 309, through the mouth end segment 111, 313 to the user. In one example, the temperature of the heated volatilised components that are generated from the portion 102 of aerosol-generating material is between 60°C and 250°C, which may be above the acceptable inhalation temperature for a user. As the heated volatilised component travels through the cooling segment 107, 307, it will cool and some volatilised components will condense on the inner surface of the cooling segment 107, 307.
In the examples of the article 301 shown in Figures 1 and 4, cool air will be able to enter the cooling segment 307 via the ventilation holes 117; 317 formed in the cooling segment 107; 307 or filter segment 109; 309. This cool air will mix with the heated volatilised components to provide additional cooling to the heated volatilised components.

Definitions

As used herein, the term "tobacco material" refers to any material comprising tobacco or derivatives therefore. 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, reconstituted tobacco and/or tobacco extract.
The tobacco used to produce tobacco material may be any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental. It may also be tobacco particle 'fines' or dust, expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut rolled stems. The tobacco material may be a ground tobacco or a reconstituted tobacco material. The reconstituted tobacco material may comprise tobacco fibres, and may be formed by casting, a Fourdrinier-based paper making-type approach with back addition of tobacco extract, or by extrusion.
All percentages by weight described herein (denoted wt%) are calculated on a dry weight basis (DWB), unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis. A weight quoted on a dry weight basis refers to the whole of the extract or slurry or material, other than the water or other solvent, and may include components which by themselves are liquid at room temperature and pressure, such as glycerol. Conversely, a weight percentage quoted on a wet weight basis (WWB) refers to all components, including water or other solvent.
For the avoidance of doubt, where in this specification the term "comprises" is used in defining the invention or features of the invention, embodiments are also disclosed in which the invention or feature can be defined using the terms "consists essentially of" or "consists of" in place of "comprises". Reference to a material "comprising" certain features means that those features are included in, contained in, or held within the material.
The above embodiments are to be understood as illustrative examples of the invention. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims.
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.

Claims

A consumable for use with a non-combustible aerosol provision device, wherein the consumable comprises:
a first section, and

a second section upstream of the first section;

wherein at least one of the first section and the second section comprises aerosol-generating material;

wherein the second section comprises a continuously changing density along its length, the density continuously increasing towards an upstream most end of the consumable; and

wherein the pressure drop across the second section is higher than the pressure drop across the first section.
The consumable of any preceding claim, wherein the first and second sections each comprise a continuously changing density along their length, the density continuously increasing towards an upstream most end of the consumable.
The consumable of Claim 1 or 2, wherein the first section comprises aerosol-generating material, optionally wherein the aerosol generating material comprises an aerosol generating film, optionally wherein the aerosol generating film comprises an amorphous solid.
The consumable of any preceding claim, wherein both of the first section and the second section comprise aerosol generating material, wherein the aerosol generating material of the first section and of the second section are different to each other.
The consumable of Claim 3, or Claim 4 when dependent on Claim 3, wherein the aerosol generating material of the first section is arranged to comprise at least one longitudinally-extending air channel extending through the first section.
The consumable of Claim 5, wherein the aerosol generating material of the first section is provided on or as a sheet material arranged to comprise at least one substantially spiral shaped cross section so as to define the at least one longitudinally-extending air channel extending through the first section.
The consumable of Claim 5, wherein the aerosol generating material of the first section is provided on or as a sheet material gathered to comprise a plurality of folds defining at least one longitudinally-extending air channel between each fold.
The consumable of any preceding claim, wherein a body of the consumable comprises the first and second sections and wherein the body comprises a continuously decreasing circumference along at least a portion of the length of the body, decreasing towards an upstream most end of the consumable.
A consumable for use with a non-combustible aerosol provision device, wherein the consumable comprises:
a body comprising a first section and a second section upstream of the first section, wherein at least one of the first section and the second section comprises aerosol generating material, and

wherein the body comprises a continuously decreasing circumference along at least a portion of the length of the body, decreasing towards an upstream most end of the consumable; and

wherein the pressure drop across the second section is higher than the pressure drop across the first section.
The consumable of Claim 9, wherein the first section comprises aerosol-generating material, optionally wherein the aerosol generating material comprises an aerosol generating film, optionally wherein the aerosol generating film comprises an amorphous solid.
The consumable of Claim 9 or 10, wherein both the first section and the second section each comprise aerosol generating material, wherein the aerosol generating material of the first section and of the second section are different to each other.
The consumable of any one of Claims 9 to 11, wherein the aerosol generating material of the first section is arranged to comprise at least one longitudinally-extending air channel extending through the first section, optionally wherein the aerosol generating material of the first section is provided on or as a sheet material arranged to comprise at least one substantially spiral shaped cross section so as to define the at least one longitudinally-extending air channel extending through the first section, or optionally wherein the aerosol generating material of the first section is provided on or as a sheet material gathered to comprise a plurality of folds defining at least one longitudinally-extending air channel between each fold.
The consumable of any one of Claims 9 to 12, wherein the second section comprises a continuously changing density along its length, increasing towards an upstream most end of the consumable.
A non-combustible aerosol provision device for heating a consumable of the non-combustible aerosol provision device, the non-combustible aerosol provision device comprising a tapered receiving portion for receiving the consumable.
A system for heating aerosol-generating material to volatilise at least one component of the aerosol generating material, the system comprising:
the consumable of any one of the preceding claims, and

a non-combustible aerosol provision device for heating the first section and/or the second section to volatilise at least one component of the aerosol-generating material thereof, the non-combustible aerosol provision device comprising a tapered receiving portion for receiving the consumable of any one of Claims 1 to 13.