EP4599710A1

EP4599710A1 - Devices, systems and articles for providing an aerosol

Info

Publication number: EP4599710A1
Application number: EP24157186.8A
Authority: EP
Inventors: Mark Potter; Joe MESNARD
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: WO2025172382A1

Abstract

A system for providing an aerosol from an aerosol generating material comprises an inlet (14), an outlet (16), a support structure (28) defining a channel extending along a longitudinal axis, an aerosol-generating material (30) configured to provide an aerosol including at least one volatilised component of the aerosol generating material upon heating, a heater arrangement (20) for heating the aerosol-generating material, wherein the heater arrangement is configured to heat a flow of air which, in use, flows into the system from the inlet (14), and a flow director (22) configured to direct the heated flow of air into the channel.

Description

TECHNICAL FIELD

The invention relates to devices, systems and articles for providing an aerosol and, more particularly, to articles for use with a non-combustible aerosol provision device.

BACKGROUND

Smoking consumables such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Alternatives to these types of consumables 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 consumables or aerosol generating assemblies.
One example of such a product is a heating device which releases compounds by heating, but not burning, a solid aerosol-generating material. This solid aerosol-generating material may, in some cases, comprise 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. Various different arrangements for volatilising at least one component of the solid aerosol-generating material are known.

SUMMARY

In an aspect, an article for providing an aerosol is provided (e.g., a non-combustible article). The article comprises an inlet (e.g., an article inlet), an outlet (e.g., an article outlet), a support structure defining a channel, and an aerosol-generating material. The aerosol-generating material is configured to provide an aerosol including at least one volatilised component of the aerosol generating material upon heating. The aerosol-generating material comprises two sides arranged to be exposed to a flow of air passing through the channel.
In another aspect, an article for providing an aerosol is provided (e.g., a non-combustible article). The article comprises an inlet (e.g., an article inlet), an outlet (e.g., an article outlet), a support structure defining a channel, and an aerosol-generating material. The aerosol-generating material is configured to provide an aerosol including at least one volatilised component of the aerosol generating material upon heating. At least a portion of the aerosol-generating material is suspended within the channel (e.g., as defined below), optionally such that two sides of said at least a portion of the aerosol generating material are arranged to be exposed to a flow of air passing through the channel.
In another aspect, a device for providing an aerosol from an aerosol generating article is provided (e.g., a non-combustible aerosol provision device). The device comprises an inlet (e.g., a device inlet), an area for receiving an aerosol-generating material or a volume of aerosol-generating material and a heater arrangement for heating the aerosol-generating material or volume of aerosol-generating material. The device may comprise a support structure arranged to support the aerosol-generating material (e.g., arranged to retain/suspend the aerosol-generating material within/across a channel). The heater arrangement may be configured to heat a flow of air which, in use, flows into the system from the inlet when a user draws on an outlet (e.g., a device outlet or an article outlet). The aerosol-generating material may be comprised in an article for providing an aerosol (e.g., an article comprising a channel having aerosol-generating material retained/suspended therein).
In another aspect, a system for providing an aerosol from an aerosol generating material is provided (e.g., non-combustible aerosol provision system). The system comprises an inlet (e.g., a device inlet), an outlet from which a user can draw (e.g., a device outlet or an article outlet), a support structure defining a channel (e.g., one or more internal walls defining a channel), an aerosol-generating material and a heater arrangement for heating the aerosol generating material. The aerosol-generating material is configured to provide an aerosol including at least one volatilised component of the aerosol generating material upon heating. The aerosol-generating material comprises two sides arranged to be exposed to a flow of air passing through the channel. The heater arrangement may be configured to heat a flow of air which, in use, flows into the system from the inlet when a user draws on the outlet. The aerosol-generating material may be comprised in an article for providing an aerosol (e.g., an article comprising the support structure and/or the channel).
In another aspect, an article for providing an aerosol is provided. The article comprises an inlet (e.g., an article inlet), an outlet (e.g., an article outlet), a support structure defining a channel extending from the inlet to the outlet along a channel axis (e.g., one or more walls defining a tubular channel), and a volume of aerosol generating material configured to provide an aerosol including at least one volatilised component of the aerosol generating material upon heating. The volume of aerosol generating material is arranged within the channel and comprises a spiral of aerosol-generating material. The spiral radially extends from a spiral axis. The spiral axis is parallel to the channel axis.
In another aspect, a system for providing an aerosol from an aerosol generating material is provided. The system comprises an inlet (e.g., a device inlet), an outlet (e.g., a device outlet or an article outlet), a support structure defining a channel extending from the inlet to the outlet along a channel axis (e.g., one or more internal walls defining a channel), a flow director arranged to direct the heated flow of air into the channel (e.g., a flow director comprised in a device or in an article containing aerosol generating material), a volume of aerosol generating material configured to provide an aerosol including at least one volatilised component of the aerosol generating material upon heating, and a heater arrangement for heating the volume of aerosol generating material. The volume of aerosol generating material is arranged within the channel and comprises a spiral of aerosol-generating material. The spiral radially extends from a spiral axis. The spiral axis is parallel to the channel axis. The heater arrangement is configured to heat a flow of air which, in use, flows into the system from the inlet when a user draws on the outlet. The spiral of aerosol-generating material may be comprised in an article for providing an aerosol (e.g., an article comprising the support structure and/or the channel).
The following optional features may be applied to any of the above aspects or embodiments, either alone or in any suitable combination.
Any reference herein to "aerosol-generating material" can be replaced by "aerosol-generating film" (whilst in some instances we have chosen to explicitly mention a film, that should not be interpreted as the material only being disclosed as a film in those instances).
The channel may extend along a longitudinal axis. At least a portion of the aerosol-generating material is, or may be suspended across the channel. The aerosol-generating material may be suspended across the channel such that two sides of at least a portion of the aerosol generating material are arranged to be exposed to a flow of air passing through the channel. The aerosol-generating material may be suspended across the channel such that a surface of the aerosol-generating material is arranged substantially parallel to the longitudinal axis.
The aerosol-generating material may have a longitudinal axis. The longitudinal axis may be along a major dimension of the aerosol-generating material (e.g., the aerosol-generating material may be substantially two-dimensional and have a major or longer dimension or length and a minor or shorter dimension or length, the longitudinal axis being defined along the longer dimension or length). The channel may have a longitudinal axis along a major dimension of the channel (e.g., along a length of the channel). The longitudinal axis of the aerosol-generating material may be parallel to the longitudinal axis of the channel.
The aerosol-generating material may be planar or substantially two-dimensional.
The aerosol-generating material may comprise or be provided as an aerosol-generating film.
The aerosol-generating material (e.g., film) may be a sheet material.
The channel may be substantially cylindrical.
The channel may be straight, or curved.
The aerosol-generating material may intersect a flow path from the inlet to the outlet. The flow path may be a flow of air as described above, namely which, in use, flows into the system from the inlet when a user draws on an outlet.
The two sides that are arranged to be exposed to a flow of air passing through the channel may comprise opposed surfaces (e.g., front and back surfaces, or upper and lower surfaces) of the aerosol-generating material. For example, the two opposed surfaces may correspond to opposed sides of a sheet of the aerosol-generating material (e.g., the aerosol-generating material may be a sheet material or film as described above and elsewhere herein).
A first airflow pathway may be provided within the channel on a first side of the aerosol-generating material and a second airflow pathway may be provided within the channel on a second side of the aerosol-generating material. The first and second airflow pathways may be fluidly separate, in that air may not pass from one to the other as it travels along the first or second pathway (e.g., at an intermediate location). Alternatively, the channel and material may be configured to allow air to pass from one to the other as it travels along the first or second airflow pathway, for example via apertures in the material or using a permeable material.
The aerosol-generating material may be provided on or in a substrate. The substrate may be porous. The aerosol-generating material may permeate (impregnate, infiltrate, interfuse or penetrate) the substrate. The aerosol-generating material may not permeate the substrate (e.g., aerosol-generating material may be provided with a substrate (e.g. paper) core).
The substrate may comprise paper. The substrate may comprise cardboard. The substrate may comprise tissue paper. The substrate may comprise a mesh (e.g., a metallic mesh). The mesh may comprise an inductive material (e.g., the mesh may act as a susceptor for inductive heating).
Alternatively, the aerosol-generating material may be substrateless (e.g., provided and/or suspended without a supporting substrate layer, e.g., a substrate as defined above). The article may include only the aerosol-generating material provided (e.g. suspended as defined above) across the channel.
The channel may have a width or diameter of less than 12 mm. The channel may have a width or diameter of less than 10 mm. The channel may have a width or diameter of between 4 and 10 mm. The channel may have a width or diameter of between 8 and 10 mm. The channel may have a width or diameter of between 6 and 8 mm. The channel may have a width or diameter of between 4 and 6 mm.
The channel may comprise an aerosol-generating section. The aerosol-generating section may comprise the aerosol-generating material. The aerosol-generating section may have a pressure drop of between 0 and 80 mm Wg (0 - 785 Pa). The aerosol generating section may have a pressure drop of less than 60 mm Wg (588 Pa). The aerosol generating section may have a pressure drop of between 20 and 60 mm Wg (196 - 588 Pa). The aerosol generating section may have a pressure drop of less than 20 mm Wg (196 Pa).
A pressure drop from an area for receiving the aerosol-generating material to the outlet (e.g., the pressure drop across an article from an article inlet to an article outlet) may be between 30 and 95 mm Wg (294 - 932 Pa). The pressure drop from the area for receiving the aerosol-generating material to the outlet (e.g., from the article inlet to the article outlet 46) may be between 40 and 70 mm Wg (392 - 686 Pa).
The channel or aerosol-generating section may have a length (e.g., an axial length along the direction of airflow) of less than 100 mm. The channel or aerosol-generating section may have a length of less than 80 mm. The channel or aerosol-generating section may have a length of between 20 and 80 mm. The channel or aerosol-generating section may have a length of between 20 and 60 mm. The channel or aerosol-generating section may have a length of between 30 and 40 mm.
The article may comprise a filter plug.
The article may comprise a tubular region (e.g., a first tubular region, a vacant or hollow tubular region or a heat displacement tube or collar). The tubular region may be disposed between the channel (e.g., having the aerosol-generating material) and the filter plug.
The article may comprise a second tubular region or a mouth end tube.
The article may have the same width or diameter as the channel (e.g., the channel may be defined by a wall or wrapper of the consumable article). The article may have a width or diameter of less than 12 mm. The article may have a width or diameter of less than 10 mm. The article may have a width or diameter of between 4 and 10 mm. The article may have a width or diameter of between 8 and 10 mm. The article may have a width or diameter of between 6 and 8 mm. The article may have a width or diameter of between 4 and 6 mm.
A length of the article (e.g., a length including the channel/aerosol-generating section and each of the filter plug (if present), the tubular region (if present) and the mouth end tube (if present)) may be less than 100 mm. The length of the article may be less than 80 mm. The length of the article may be between 50 and 80 mm. The length of the article may be between 70 and 80 mm.
A circumference of the article may be less than 30 mm. A circumference of the article may be between 23 and 25 mm. A circumference of the article may be 25 mm. A circumference of the article may be between 22 and 23 mm. A circumference of the article may be between 19 to 22 mm A circumference of the article may be between 16 and 19 mm. A circumference of the article may be less than 16 mm.
The aerosol-generating material may have a thickness of less than 2 mm. The aerosol-generating material may have a thickness of less than 1 mm. The aerosol-generating material may have a thickness of less than 0.5 mm. The aerosol-generating material may have a thickness of less than 0.1 mm.
One or more structures for directing the flow of heated air (e.g., having or formed by flow director such as a nozzle or a plurality of nozzles) may be provided (e.g., the article or system may comprise the structure). The flow director may be configured to direct the heated flow of air into the channel.
The flow director may be configured to selectively direct the heated flow of air at a plurality of different directions into or positions within the channel (e.g., a plurality of different positions along the width or circumference of the channel).
The flow director may be movable (e.g., tiltable or rotatable).
A movable shutter may be provided (e.g., forming or comprised as part of the directing structure). The movable shutter may be configured to selectively block or direct the heated flow of air into the channel to one or more of a plurality of different positions along the width or circumference of the channel.
A sensor may be provided and configured to detect when a user has drawn on the outlet. The sensor may be a flow or pressure sensor (e.g., a microphone or puff sensor).
A temperature sensor may be provided and may be configured to measure a temperature of the heated flow of air.
The system may be configured to increase a temperature of the heater arrangement after detecting that a user has drawn on the outlet. The system may be configured to increase a temperature of the heater arrangement from a first temperature to a second temperature after detecting that a user has drawn on the outlet. The system may, subsequently to the first increase, be configured to further increase the temperature of the heater arrangement from the second temperature to a third temperature after detecting that the user has further drawn on the outlet.
The aerosol-generating material (e.g., film) may comprise perforations. A size of the perforations may vary. The perforations may progressively increase in size, for example along a length of the article. The length may be a direction parallel with the longitudinal axis of the channel.
A plurality of layers of aerosol-generating material (e.g., film layers) may be provided (e.g., film layers, which may each be a separate aerosol-generating film). Each layer may be spaced from an adjacent layer. A surface of each layer may be arranged parallel to the longitudinal axis.
The aerosol-generating material may include a first layer (e.g., film) of the plurality of layers. Each layer (e.g., each aerosol-generating film) may be provided (e.g. suspended as defined above) across the channel such that it axially intersects or is axially parallel with the channel (e.g., the longitudinal axis of the channel).
The spacing between layers may be between 10 microns and 10 mm. The spacing between layers may be between 10 microns and 1.5 mm. The spacing between layers may be between 0.1 mm and 1 mm. The spacing between layers may be between 1 mm and 3 mm. The spacing between layers may be between 1 mm and 2 mm. The spacing between layers may be between 0.5 mm and 1.5 mm. The spacing may be less than 0.5 mm.
Each layer (e.g., each aerosol-generating film) may have a thickness of less than 2 mm. Each layer (e.g., each aerosol-generating film) may have a thickness of less than 1 mm. Each layer (e.g., each aerosol-generating film) may have a thickness of less than 0.5 mm. Each layer (e.g., each aerosol-generating film) may have a thickness of less than 0.1 mm.
Alternatively, the aerosol-generating material may consist of only one layer (e.g., a single aerosol-generating film).
Each layer (e.g., film) of aerosol-generating material (or a sub-set of layers/films of aerosol-generating material) may be aligned with a respective flow director or respective position of a variable flow director (e.g., a flow director as described above).
One layer (e.g., film) of the aerosol-generating material may be separated from an adjacent layer (e.g., film) of the aerosol-generating material, for example by a divider. The divider may be permeable to air. The divider may be perforated.
Alternatively, the divider may be impermeable to air.
The plurality of layers (e.g., films) may be axially staggered (e.g., with respect to the longitudinal axis of the channel) such that some of the layers (e.g., films) are positioned closer (e.g., fluidly closer/upstream) to the inlet than others.
The channel may comprise a width perpendicular to the axis (e.g., the longitudinal axis) defined between two sides of the channel. The plurality of layers (e.g., films) may be distributed along the width. The plurality of layers (e.g., films) may be positioned closer to the inlet (may be proximate the middle of the width).
A portion of a first layer of the plurality of layers (e.g., a portion of a first film) may be axially offset from a portion of a second layer of the plurality of layers (e.g., a portion of a second film).
The channel may be a first channel and the aerosol-generating material may be a first aerosol-generating material (e.g. a first plurality of layers/films thereof). A second channel may be provided, and a second aerosol-generating material or a second plurality of layers thereof (e.g., films) may be suspended across the second channel (e.g., as defined above). The second aerosol-generating material or layers thereof may be provided in the same manner (within the second channel) as described above in relation to the first aerosol-generating material or layers thereof.
The aerosol-generating material (e.g., film) may be a spiral. Stated slightly differently, the aerosol-generating material (e.g., film) may be configured as or otherwise form a spiral of aerosol-generating material (e.g., film).
The spiral may be supported on a frame. The frame may be configured to maintain the aerosol-generating material (e.g., film) as a spiral, and/or configured to maintain a shape of the spiral.
The spiral may be supported or suspended between a pair of supports located at opposed ends of the spiral (e.g. axial ends). Each of the pair of supports may be porous. One of the pair of supports may comprise a mesh material. The aerosol-generating material (e.g., film) may be provided on a spiral mesh (e.g., coated on or suspended on a mesh (e.g., a metallic mesh) arranged or formed in a spiral).
A volume of aerosol generating material (e.g., film) may be provided comprising a plurality of spirals of aerosol-generating material (e.g., film).
The support structure may define a plurality of channels, and wherein a respective aerosol-generating material (e.g., film) is arranged within each respective channel. Each respective aerosol-generating material (e.g., film) may comprise a respective spiral of aerosol-generating material (e.g., film). An airflow director (e.g., as described above) may be configured to selectively direct a heated flow of air into one or more of the channels.
Embodiments will now be described, by way of example only, with reference to the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 shows a schematic of an example non-combustible aerosol provision system.
Figure 2 shows a schematic of an example non-combustible aerosol provision system.
Figure 3 shows an example variable airflow director arrangement.
Figure 4 shows an example variable airflow director arrangement.
Figure 5 shows an example variable airflow director arrangement.
Figure 6A shows a schematic arrangement of a consumable comprising aerosol-generating material arranged within an area for receiving aerosol-generating material.
Figure 6B shows a schematic arrangement of a consumable comprising aerosol-generating material arranged within an area for receiving aerosol-generating material.
Figure 7A shows an example consumable comprising aerosol-generating material.
Figure 7B shows an example consumable comprising aerosol-generating material.
Figure 8A shows a perspective view of an example consumable article comprising aerosol-generating material.
Figure 8B shows a side view of the example consumable article comprising aerosol-generating material of Figure 8A.
Figure 9 shows a side view of an example consumable article comprising aerosol-generating material.
Figure 10 shows a sectional view of an example consumable article comprising aerosol-generating material.
Figure 11 shows a sectional view of an example consumable article comprising aerosol-generating material.
Figure 12A shows a sectional view of an example consumable article comprising aerosol-generating material.
Figure 12B shows a sectional view of an example consumable article comprising aerosol-generating material.
Figure 13A shows a sectional view of an example consumable article comprising aerosol-generating material.
Figure 13B shows a sectional view of an example consumable article comprising aerosol-generating material.
Figure 13C shows a sectional view of an example consumable article comprising aerosol-generating material.
Figures 14A-14D show sectional views of an example consumable article comprising aerosol-generating material before and during use.
Figure 15 shows a perspective view of an example aerosol-generating material.
Figure 16 shows a chart of Puff-to-Puff performance of aerosol-generating material for a constant operational temperature and an increasing operational temperature profile.

DETAILED DESCRIPTION

As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user, and includes:

combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material);
non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials; and
aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

According to the present disclosure, a "non-combustible" aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user. In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system. In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.
In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.
In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.
Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.
In some embodiments, the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as "articles" throughout the disclosure.
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 may comprise an area for receiving the aerosol-generating material (e.g., as or comprised in a consumable article), an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.
An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol.
In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.
Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants.
The aerosol-generating material may comprise one or more active substances and/or flavourants, one or more aerosol-former materials, and optionally one or more other functional 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 provided as an aerosol-generating film. As noted above, any reference herein to "aerosol-generating material" can be replaced by "aerosol-generating film" (whilst in some instances we have chosen to explicitly mention a film, that should not be interpreted as the material only being disclosed as a film in those instances).
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. The aerosol-generating material may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.
The aerosol-generating material 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.
The aerosol-generating material may comprise more than one layer of aerosol-generating material (e.g., film), and the thickness described herein may refer to the aggregate thickness of those layers (e.g., films).
The aerosol-generating material may be continuous. For example, the aerosol-generating material may comprise or be a continuous sheet of material (e.g., a continuous sheet of film). The sheet may be in the form of a wrapper, it 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 material may be discontinuous. For example, the aerosol-generating material may comprise one or more discrete portions or regions of aerosol-generating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.
The aerosol-generating material may comprise or be an "amorphous solid". In some embodiments, the aerosol-generating material is provided as an aerosol-generating film that is 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.
The one or more other functional materials may comprise one or more of a pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.
The material 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.
A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.
The aerosol-generating material 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 material.
In some embodiments, the aerosol generating material comprises:

1-80 wt% of a binder; and/or
5-80 wt% of an aerosol-former; and
optionally, an active substance and/or a flavourant;

Making the aerosol generating material may in some cases comprise (a) forming a slurry comprising components of the aerosol generating material, (b) forming a layer of the slurry, (c) optionally setting the slurry to form a gel, and (d) drying the gel to form the aerosol-generating material.
The step (b) of forming a layer of slurry may comprise spraying, casting or extruding the slurry, for example. In some cases, the slurry layer is formed by electrospraying the slurry. In some cases, the slurry layer is formed by casting the slurry.
In some cases, the steps (b) and/or (c) and/or (d) may, at least partially, occur simultaneously (for example, during electrospraying). In some cases, these steps may occur sequentially.
The step (b) may comprise forming a layer of the slurry on a carrier.
The step (c) of setting the gel may comprise the addition of a setting agent to the slurry. For example, the slurry may comprise sodium, potassium or ammonium alginate as a binder, and a setting agent comprising a calcium source (such as calcium chloride), may be added to the slurry to form a calcium alginate gel.
During step (d) the slurry may be heated to remove the solvent, for example to remove at least about 60 wt%, 70 wt %, 80 wt%, 85 wt% or 90 wt% of the solvent.
In some cases, the slurry solvent may consist essentially of or consist of water. In some cases, the slurry may comprise from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% of solvent (WWB).
In some embodiments, the binder comprises a hydrocolloid. In some embodiments, the binder comprises one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, the binder comprises one or more of alginates, pectins, 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 cases, the binder comprises 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 binder comprises alginate, and the alginate is present in the amorphous solid in an amount of from 10-30wt% of the amorphous solid (calculated on a dry weight basis). In some embodiments, alginate is the only binder present in the amorphous solid. In other embodiments, the binder comprises alginate and at least one further binder, such as pectin.
In some embodiments the binder comprises a mixture of alginate and carboxymethylcellulose (CMC). Suitably the binder comprises a greater quantity of CMC than alginate; for example in some cases the ratio of CMC to alginate is about 5 : 1, about 3 : 1, about 2 : 1, or about 1.5 : 1; for example is in the range of 5 : 1 - 1.5 : 1.
In some embodiments the amorphous solid may include a binder comprising carrageenan.
As used herein, the term "aerosol-former" or "aerosol generating agent" refers to an agent that promotes the generation of an aerosol. An aerosol-former may promote the generation of an aerosol by promoting an initial vaporisation and/or the condensation of a gas to an inhalable solid and/or liquid aerosol.
In some embodiments, the aerosol-former 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 embodiments in which the amorphous solid comprises a flavourant, suitably, the amorphous solid comprises up to about 60wt%, 50wt%, 40wt%, 30wt%, 20wt%, 10wt% or 5wt% of the flavourant. In some cases, the amorphous solid may comprise at least about 0.5wt%, 1wt%, 2wt%, 5wt% 10wt%, 20wt% or 30wt% of the flavourant (all calculated on a dry weight basis). For example, the amorphous solid may comprise 0.1-60wt%, 1-60wt%, 5-60wt%, 10-60wt%, 20-50wt% or 30-40wt% of the flavourant. In some cases, the flavourant (if present) comprises, consists essentially of or consists of menthol. In some cases, the amorphous solid is free from flavourant.
The "active substance" as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.
In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.
As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.
Cannabinoids are a class of natural or synthetic chemical compounds which act on cannabinoid receptors (i.e., CB1 and CB2) in cells that repress neurotransmitter release in the brain. Cannabinoids may be naturally occurring (phytocannabinoids) from plants such as cannabis, from animals (endocannabinoids), or artificially manufactured (synthetic cannabinoids). Cannabis species express at least 85 different phytocannabinoids, and are divided into subclasses, including cannabigerols, cannabichromenes, cannabidiols, tetrahydrocannabinols, cannabinols and cannabinodiols, and other cannabinoids. Cannabinoids found in cannabis include, without limitation: cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), Cannabinol propyl variant (CBNV), cannabitriol (CBO), tetrahydrocannabmolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).
As used herein, the terms "flavourant" and "flavour" 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.
The flavourant may suitably comprise one or more mint-flavours suitably a mint oil from any species of the genus Mentha. The flavourant may suitably comprise, consist essentially of or consist of menthol. In some embodiments, the flavourant comprises menthol, spearmint and/or peppermint. In some embodiments, the flavourant comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavourant comprises eugenol. In some embodiments, the flavourant comprises flavour components extracted from tobacco. In some embodiments, the flavourant comprises flavour components extracted from cannabis.
In some embodiments, the flavourant 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 eucalyptol, WS-3.
The active substance and/or flavourant may comprise a tobacco material.
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.
The active substance and/or flavourant may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof.
As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha arvensis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.
In some embodiments, the botanical is selected from eucalyptus, star anise, cocoa and hemp. In some embodiments, the botanical is selected from rooibos and fennel.
Referring to Figs. 1 and 2, the non-combustible aerosol provision system, or a non-combustible aerosol provision device 1 thereof, typically comprises electronics 12 such as a power source and a controller. The electronics 12 may comprise a sensor configured to detect when a user has drawn on the outlet. The electronics 12 may comprise a puff sensor (e.g., a microphone or a pressure sensor). The power source may be an electric power source such as a battery. The non-combustible aerosol provision system or non-combustible aerosol provision device comprises a housing 10, an inlet 14, an aerosol generator 20, an area for receiving the aerosol-generating material 24 and an outlet 16. Of course, the provision and layout of these features may differ between different systems, of which Fig. 1 is merely an example. For example, the outlet 16 may be formed in a mouthpiece 18, or the mouthpiece 18 may be omitted. For example, the outlet 16 may be formed in a consumable article 34.
As noted above, any reference herein to "aerosol-generating material" can be replaced by "aerosol-generating film" (whilst in some instances we have chosen to explicitly mention a film, that should not be interpreted as the material only being disclosed as a film in those instances).
An airflow pathway is provided from the inlet 14 to the outlet 16. The airflow pathway is typically arranged so as to pass through the area for receiving the aerosol-generating material 24, which is between the inlet 14 and the outlet 16. The outlet 16 may be arranged to allow a user to draw thereon such that air is drawn in through the inlet 14 and the area for receiving the aerosol-generating material 24.
The aerosol generator 20 may comprise a heater arrangement such as a convection heating system, e.g., including a heater or heater component. The heater arrangement may be configured or arranged to heat a flow of air drawn in through the inlet 14. For example, a heater could be arranged in the airflow pathway in between the inlet 14 and the area for receiving the aerosol-generating material 24. The heater may heat a flow of air drawn into the device 1such that a hot or heated flow of air is passed to (e.g., drawn into by a user) the area for receiving the aerosol-generating material 24. Providing a hot or heated flow of air to the area for receiving the aerosol-generating material 24 may generally be referred to as providing convection heating to the area for receiving the aerosol-generating material 24.
The heater or heater component may comprise any suitable heater. For example, the heater may comprise an induction heating system (e.g., including a coil and a susceptor) or a resistive heating system (e.g., a resistive coil or a film heater).
For example, such an induction heating system could comprise a coil arranged within the device 1 and a susceptor arranged within the device 1 (e.g., with or along the airflow pathway). The induction heating system may alternatively comprise a coil arranged within the device 1 and a susceptor arranged within a consumable article 34.
With reference to Figures 1-5, the non-combustible aerosol provision system, or a non-combustible aerosol provision device 1 thereof, may comprise one or more flow directors 22 (e.g., airflow directors) that are configured to direct and/or funnel the hot or heated flow of air to the area for receiving the aerosol-generating material 24. A flow director 22 may take any suitable form for directing a flow of air. For example, each flow director 22 may be a tube or frustoconical shape through which hot or heated air flows and may include a nozzle configured to control the rate of flow, speed, direction, mass, shape, and/or the pressure of the stream that emerges from them. The one or more flow directors 22 may be configured to direct the hot or heated flow of air to a portion of a consumable or consumable article 34 received within the area for receiving the aerosol-generating material 24. In some embodiments, the consumable article 34 may comprise the one or more flow directors 22.
The non-combustible aerosol provision system, or a non-combustible aerosol provision device 1 thereof, may comprise a variable or indexed flow director system. The variable or indexed flow director system may comprise one or more flow directors 22 and a movable shutter or shutter system 26. The shutter system 26 may act as a gate that is configured to selectively direct the hot or heated flow of air to different portions of the area for receiving the aerosol-generating material 24 or of a consumable or consumable article 34 received within the area for receiving the aerosol-generating material 24. In some embodiments, the device 1 may comprise the shutter system 26 and the consumable article 34 may comprise the one or more flow directors 22.
With reference to Figure 3, the shutter system 26 may comprise a rotating shutter arranged to selectively block or obstruct one or more of a plurality of flow directors 22. The airflow pathway may be directed to one or a subset of a plurality of flow directors 22 (as indicated by an arrow in Figure 3). Alternatively, the shutter system 26 may comprise a rotating shutter arranged to selectively block or obstruct one or more of portions of a single flow director 22. Any suitable mechanism may be used to rotate the shutter, for example a stepper motor.
With reference to Figure 4, the shutter system 26 may comprise a leaf shutter arranged to selectively block or obstruct one or more of a plurality of flow directors 22. The airflow pathway may be directed to one or a subset of a plurality of flow directors 22 (as indicated by an arrow in Figure 4). Alternatively, the shutter system 26 may comprise a leaf shutter arranged to selectively block or obstruct one or more of portions of a single of flow director 22.
With reference to Figure 5, the one or more flow directors 22 may comprise one or more variable flow directors 22. The one or more variable flow directors 22 may be configured to vary the direction into which an airflow is directed. For example, a variable flow director may be configured to rotate or tilt so as to direct an airflow to different portions (e.g., portions distributed along a width or circumference) or sectors of the area for receiving the aerosol-generating material 24 (as indicated by the arrows in Figure 5). Similar to the shutter system 26 of Figure 3, any suitable mechanism may be used to operate the variable flow director(s) 22.
In any of the aspects and embodiments described herein, the consumable for use with the non-combustible aerosol provision system or device 1 may comprise aerosol-generating material 30. The consumable comprising aerosol-generating material 30 may be or comprise an aerosol-generating film.
The area for receiving the aerosol-generating material 24 may be configured (e.g., shaped, sized and dimensioned) to receive an aerosol-generating film 30. The area for receiving the aerosol-generating material 24 may be configured (e.g., shaped, sized and dimensioned) to receive a consumable article 34. The area for receiving the aerosol-generating material 24 may comprise a longitudinal axis along which the airflow pathway extends.
The area for receiving the aerosol-generating material 24 may comprise a channel (e.g., an elongate channel) defined by a support structure 28. The support structure 28 may comprise or be formed by an inner chamber in the device 1.
The channel may be a substantially linear channel, for example the channel may extend along the longitudinal axis of the area for receiving the aerosol-generating material 24. The airflow pathway may pass along the longitudinal axis. In some embodiments, the channel may be substantially cylindrical, and/or the channel may have a circular or elliptical cross-section (e.g., as measured in a plane perpendicular to the longitudinal axis). In some embodiments, the channel may have polygonal cross-section (e.g., triangular, square or rectangular).
The channel may have a width or diameter of less than 12 mm. The channel may have a width or diameter of less than 10 mm. The channel may have a width or diameter of between 4 and 10 mm. The channel may have a width or diameter of between 8 and 10 mm. The channel may have a width or diameter of between 6 and 8 mm. The channel may have a width or diameter of between 4 and 6 mm.
The channel defines an aerosol-generating section (e.g., a section comprising aerosol-generating material 30 such as a part of an consumable article 34 containing the aerosol-generating material 30). Aerosol-generating material 30 may be arranged within the aerosol-generating section to provide a controlled pressure drop across the aerosol-generating section (e.g., from an inlet or upstream end to an outlet or downstream end of the aerosol-generating section). The pressure drop across the aerosol-generating section may be controlled based on a packing density of the aerosol-generating material 30. For example, providing a plurality of films of aerosol generating material 30 in a channel (e.g. a higher packing density) may increase the pressure drop. The aerosol generating section may have a pressure drop of between 0 and 80 mm Wg (0 - 785 Pa). The aerosol generating section may have a pressure drop of less than 60 mm Wg (588 Pa). The aerosol generating section may have a pressure drop of between 20 and 60 mm Wg (196 - 588 Pa). The aerosol generating section may have a pressure drop of less than 20 mm Wg (196 Pa).
The pressure drop from the area for receiving the consumable 24 to the outlet 16 (e.g., the pressure drop across a whole of a consumable article 34 from an article inlet 44 to an article outlet 46 - as discussed further below) may be controlled. For example, it may be desired to include a low pressure drop aerosol-generating section (e.g. a single layer of aerosol generating material or a lose-packed spiral of aerosol generating material) whilst maintaining a relatively higher pressure drop across a whole of a consumable article 34. This may improve the sensation or mouth feel to a user. Other sections or parts of the consumable article 34 through which the air flows (e.g. a filter or end plug, if present) may be made to have a relatively higher pressure drop to compensate for the low pressure drop of the aerosol-generating section and provide the desired overall pressure drop. The overall pressure drop from the area for receiving the consumable 24 to the outlet 16 (e.g., from an article inlet 44 to an article outlet 46) may be between 30 and 95 mm Wg (294 - 932 Pa). The overall pressure drop from the area for receiving the consumable 24 to the outlet 16 (e.g., from an article inlet 44 to an article outlet 46) may be between 40 and 70 mm Wg (392 - 686 Pa).
The channel or aerosol-generating section may have a length (e.g., an axial length along the direction of airflow) of less than 100 mm. The channel or aerosol-generating section may have a length of less than 80 mm. The channel or aerosol-generating section may have a length of between 20 and 80 mm. The channel or aerosol-generating section may have a length of between 20 and 60 mm. The channel or aerosol-generating section may have a length of between 30 and 40 mm.
With reference to Figure 6A, the aerosol-generating material 30 may be arranged to intersect the area for receiving the aerosol-generating material 24 along the airflow pathway. Here, the aerosol-generating material 30 intersects the channel along a plane extending parallel to the longitudinal axis. The aerosol-generating material 30 may be suspended across the channel by the support structure 28. The aerosol-generating material 30 may have a surface area running parallel to the longitudinal axis.
A first airflow pathway may be provided on a first side of the aerosol-generating material 30 and a second airflow pathway may be provided on a second side of the aerosol-generating material 30 (e.g., the aerosol-generating material 30 may bisect at least part of the airflow pathway from the inlet 14 to the outlet 16). Suspending the aerosol-generating material 30 within or across the channel increases the exposed surface area of the aerosol-generating material 30 (e.g., the surface area which is exposed to, or brought into contact with, the hot or heated flow of air). Suspending the aerosol-generating material 30 within or across the channel may provide for a taut surface of aerosol-generating material 30 (the aerosol-generating material 30 may be pulled taut within or across the channel), which would allow for consistent flow dynamics through the channel and/or a consistent user experience.
With reference to Figure 6B, the housing 10 may be configured with a cover 10A to allow access to the area for receiving the aerosol-generating material 24. The cover 10A may be arranged at area for receiving the aerosol-generating material 24, for example at the channel, and optionally such that the cover 10A provides access to an entire length of the channel. This is shown in Fig. 6B, in which the cover 10A bisects the channel along a plane extending parallel to its longitudinal axis. The cover 10A may be removed in order to replace the aerosol-generating material 30 (e.g., after a portion of the aerosol-generating material 30 is expended). The channel may be opened so that aerosol-generating material 30 may be placed in or across channel (e.g., a strip of aerosol-generating material 30 may be placed into the channel).
With reference to Figure 7A, the aerosol-generating material 30 may be unsupported (e.g., the aerosol-generating material 30 may be substrateless). For example, the aerosol-generating material 30 may be self-supporting and may be replaced within the system or device 1 by, e.g., opening the cover 10A. In some embodiments, the aerosol-generating material 30 may be supported on a substrate (not shown). The substrate may comprise a porous substrate (e.g., cardboard, paper, tissue paper, mesh or the like) or a non-porous substrate (e.g., a plastic film or a metal foil). With reference to Figure 7B, the aerosol-generating material 30 may be supported on a frame 32. The frame 32 may comprise cardboard, paper, mesh, plastic or metal. The frame 32 may be configured to provide rigidity to the aerosol-generating material 30. The frame 32 may suspend the aerosol-generating material 30, for example holding it taut (as discussed above).
The aerosol-generating material 30 may comprise a plurality of aerosol-generating films 30 or layers of aerosol-generating material 30. Each aerosol-generating film 30 or layer of aerosol-generating material 30 may be spaced from an adjacent aerosol-generating film 30 or layer of aerosol-generating material 30.
In embodiments that include one or more flow directors 22, each layer or film of aerosol-generating material 30 or sub-set of layers or films of aerosol-generating material 30 may be aligned with a respective flow director 22. A divider 36, 38 may be provided between each layer of aerosol-generating material or film 30 or sub-set of layers of aerosol-generating material or films 30 (see Figures 9 and 11, discussed below). The divider 36 may be porous/permeable (e.g., air permeable). The divider 36 may support and provide alignment to each layer of aerosol-generating material or film 30. The divider 36 may comprise a mesh. Alternatively, the divider 38 may be impermeable (e.g., a substantially air impermeable barrier) so as to create a plurality of separate air channels in the area for receiving the aerosol-generating material 24 and/or the support structure 28.
With reference to Figures 8A-14D, the consumable comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices may comprise a consumable article 34 for use with the non-combustible aerosol provision system or device 1. The consumable articles 34 are considered inventive in their own right and each may be claimed independently.
Each consumable article 34 comprises an inlet (e.g., an article inlet 44) and an outlet (e.g., an article outlet 46). The outlet of the consumable article 34 may comprise or otherwise form the outlet 16 of the non-combustible aerosol provision system. The support structure 28 may form part of the consumable article 34. For example, the consumable article 34 may define the channel and/or aerosol generating section which may be removably received in the area for receiving the aerosol-generating material 24, as described above. The support structure 28 may be a substantially tubular support structure, although other shapes may be used.
The consumable article 34 may include a filter plug. The consumable article 34 may include a tubular region (e.g., a first tubular region, a vacant or hollow tubular region or a heat displacement tube or collar). The tubular region may be disposed between the channel (e.g., having the aerosol-generating material 30) and the filter plug. The consumable article 34 may include a second tubular region or a mouth end tube.
The consumable article 34 may have the same width or diameter as the channel (e.g., the channel may be defined by a wall or wrapper of the consumable article 34). The consumable article 34 may have a width or diameter of less than 12 mm. The consumable article 34 may have a width or diameter of less than 10 mm. The consumable article 34 may have a width or diameter of between 4 and 10 mm. The consumable article 34 may have a width or diameter of between 8 and 10 mm. The consumable article 34 may have a width or diameter of between 6 and 8 mm. The consumable article 34 may have a width or diameter of between 4 and 6 mm.
An overall length of the consumable article 34 (e.g., a length including the channel/aerosol-generating section and each of the filter plug (if present), the tubular region (if present) and the mouth end tube (if present)) may be less than 100 mm. The overall length of the consumable article 34 may be less than 80 mm. The overall length of the consumable article 34 may be between 50 and 80 mm. The overall length of the consumable article 34 may be between 70 and 80 mm.
A circumference of the consumable article 34 may be less than 30 mm. A circumference of the consumable article 34 may be between 23 and 25 mm. A circumference of the consumable article 34 may be 25 mm. A circumference of the consumable article 34 may be between 22 and 23 mm. A circumference of the consumable article 34 may be between 19 to 22 mm A circumference of the consumable article 34 may be between 16 and 19 mm. A circumference of the consumable article 34 may be less than 16 mm.
With reference to Figures 8A and 8B, the aerosol-generating material 30 may comprise multiple aerosol-generating films 30 or layers of aerosol-generating material 30 (which may generally be referred to as aerosol-generating films 30). Each aerosol-generating film 30 or layer of aerosol-generating material 30 may be spaced within the support structure from an adjacent aerosol-generating film 30 or layer of aerosol-generating material 30 (e.g., each layer of aerosol-generating material or aerosol-generating film 30 may have a surface area running parallel to the longitudinal axis at a different diametric position across a width of the support structure or channel). The film(s) 30 could be pulled taut across the support structure. The spacing between layers of aerosol-generating film 30 may be between 10 microns and 10 mm. The spacing may be 0.5 mm, 1.0 mm or 1.5 mm. Each aerosol-generating film 30 or sub-set of aerosol-generating films 30 may configured to be aligned with a respective flow director 22. For example, the consumable article 34 and the area for receiving the aerosol-generating material 24 may comprise respective alignment features to allow for alignment with the one or more flow directors (not shown).
With reference to Figures 9-11, a divider 36, 38 may be provided between each aerosol-generating film 30 or sub-set of aerosol-generating films 30. Each divider 36, 38 may separate a first volume within the article 34 and/or support structure 28 (containing a first aerosol-generating film 30 or sub-set of aerosol-generating films 30) from an adjacent second volume (containing a second aerosol-generating film 30 or sub-set of aerosol-generating films 30). The separation could be spatial, for example with airflow possible between the separate volumes as with the embodiment of Figure 9. Alternatively the separation could be fluidly separate, such that airflow directly between the adjacent volumes is not possible as shown for example in Figures 10-11 (although noting that the fluid passing through the volumes will typically originate from a common source).
Each aerosol-generating film 30 may have a surface area running parallel to the longitudinal axis and each divider may have a surface area running parallel to the longitudinal axis. The divider 36 may be porous or permeable (e.g., a permeable support 36). The divider 36 may support and provide alignment to each aerosol-generating film 30.
With reference to Figure 9, the divider 36 may comprise a mesh (e.g., a porous mesh material). The mesh may support the aerosol-generating material 30 and allow for the passage of air (e.g., the hot or heated flow of air generated by the aerosol generator 20). A plurality of mesh dividers 36 may be provided. Each layer of aerosol-generating material or film 30 may be stacked on a respective mesh divider or layer 36 (e.g., a stack of alternating layers of aerosol-generating material or film 30 and mesh dividers or layers 36 may be provided). The mesh (or plurality of mesh dividers or layers) may allow flow axially through the mesh (e.g., traverse to a plane in which the mesh is arranged). The hot or heated flow of air may heat the mesh and the mesh may transfer heat to the aerosol-generating material 30. Where the consumable article 34 comprises the aerosol generator 20, the mesh may be in contact with, or form part of, the aerosol generator 20. For example, the mesh may be a heated mesh (e.g., comprising a heater) and could be inductively heated. The mesh may be a susceptor arranged to be heated by a coil arranged in the device 1.
With reference to Figures 10-11, the divider 38 may be impermeable so as to create a plurality of channels in the support structure 28 of the consumable article 34 (e.g., a substantially air impermeable barrier). As shown in Figure 10, the divider 38 may separate the consumable article 34 or support structure thereof into discrete channels. Each channel may comprise one or more layers or films of aerosol-generating material 30. Each channel may comprise a subset of a plurality of aerosol-generating films 30.
Each channel may be aligned with a respective flow director 22 or a respective indexed position of a variable flow director 22 (e.g., as shown in Figure 5), such that each channel provides a discrete session of aerosolising (e.g., a session of 5-10 puffs of aerosol). The system or device thereof may be configured to switch channels mid-session (e.g., using the variable flow director 22 described above). For example, the system may be configured to provide 3-5 puffs from a first channel (e.g., as determined by a puff sensor) before switching to a second channel for another 3-5 puffs. The system, device 1 or a controller thereof may be configured to automatically switch channels (e.g., automatically adjust a variable flow director 22, or automatically adjust a shutter system 26). The system or device 1 may be configured to manually switch between channels (e.g., by user intervention).
With reference to Figure 11, the consumable article 34 may comprise a plurality of dividers 38 and a plurality of layers or sheets of aerosol-generating material or aerosol-generating films 30 (which , again, may generally be referred to as aerosol-generating films 30), each divider 38 arranged adjacent to a respective aerosol-generating film 30. The plurality of dividers 38 may form a plurality of channels, each channel having aerosol-generating material 30. The system, device 1 or a controller thereof may be configured to automatically switch channels after each puff (e.g., using the variable flow director 22 described above). This may provide improved puff-to-puff consistency. For example, each puff may use a fresh or previously unused (or a less recently used) aerosol-generating material 30. The variable or indexed flow director system may be configured to direct the hot or heated flow of air into the next respective channel after each puff.
With reference to Figures 12A-12B, the consumable article 34 may comprise aerosol-generating material (e.g., one or more aerosol-generating films 30) rolled into spirals, which may be referred to as a spiral of aerosol-generating material 30 (e.g., an Archimedean spiral of aerosol-generating material 30) or, generally, as a spiral. The roll or spiral of aerosol-generating material 30 may radiate from a central, spiral axis (e.g., viewed end-on, the roll may be two-dimensional spiral projected along the spiral axis to form a three-dimensional spiral roll). The spiral axis may be parallel to the longitudinal axis of the area for receiving the aerosol-generating material 24, support structure 28 and/or consumable article 34. A surface area of the spiral may run parallel to the longitudinal axis.
The one or more spirals of aerosol-generating material 30 may be suspended, and optionally pulled taut across the channel. For example, with reference to Figure 12A, the one or more spirals of aerosol-generating material 30 may be supported by a frame 40 intersecting the support structure 28. Alternatively, the one or more spirals of aerosol-generating material 30 may be supported by a rod or other support (e.g., an elongate or axial support, or a rod) from which the spiral radiates (not shown). The rod or other support may be held in place by any suitable means (e.g., by a frame or end cap.
The one or more spirals of aerosol-generating material 30 may be axially suspended as shown for example in Figure 12A. Here, a first frame 40 or mesh is provided proximate the article inlet 44 and a second frame 40 or mesh is provided proximate the article outlet 46 and the one or more spirals of aerosol-generating material 30 may be suspended (e.g., held taut) between the first and second frames 40 or meshes. The aerosol-generating material 30 may be provided on a spiral mesh (not shown). For example, aerosol-generating material 30 may be coated on, impregnated into or suspended over a mesh (e.g., a metallic mesh) which may be arranged as or formed into a spiral shape (e.g., a mesh having the aerosol-generating material 30 may be rolled into a spiral shape). The mesh may comprise an inductive material (e.g., the mesh may act as a susceptor for inductive heating).
Alternatively, the one or more spirals of aerosol-generating material 30 may be provided and axially retained within the consumable article 34 or support structure 28. As shown in Figure 13A, the one or more spirals of aerosol-generating material 30 may be encapsulated in a consumable article. For example, the one or more spirals of aerosol-generating material 30 may be slotted into the consumable article 34 or support structure 28 and retained therein, for example by a cap 50 at each of the article inlet 44 and article outlet 46. Each cap 50 may comprise a mesh or any other suitable permeable structure (e.g., a filter medium) or combination of materials and structures that permits airflow through the consumable article 34 or support structure 28. For example, a mesh may be provided at the article inlet 44 end and a filter may be provided at the article outlet 46. The one or more spirals of aerosol-generating material 30 may be movable within the channel (e.g., loose or otherwise free to move within the channel, for example circumferentially and/or radially). With reference to Figure 13B, the spiral of aerosol-generating material 30 may be held within the channel by an interference fit (e.g., the spiral may be compressed/rolled up more tightly for insertion into the channel and allowed to unfurl into the space). This interference fit may be provided in addition, or as an alternative, to the encapsulation or suspension described above. With reference to Figure 13C, the spiral of aerosol-generating material 30 may be adhered to the channel at an outer end of the spiral (e.g., in addition, or as an alternative, to the encapsulation, suspension or interference fits described above). For example, a spot or strip of adhesive 52 may be applied to a surface of support structure 28 or the spiral of aerosol-generating material 30 to adhere the spiral within the consumable article 34.
With reference to Figure 12B, a plurality of spirals of aerosol-generating material 30 may be provided in a respective plurality of channels defined within the support structure 28. Each spiral of aerosol-generating material 30 may have a surface area running parallel to the longitudinal axis. Each spiral may be retained in each respective the channel in one or more of a number of different ways, as described above (e.g., by being suspended, encapsulated, unfurled into and/or adhered). Each channel may be aligned with a respective flow director 22 of a variable or indexed flow director system (e.g., as described above and shown in Figure 3) or a respective indexed position of a variable flow director 22 (e.g., as described above shown in Figure 5).
Tests have been conducted with an aerosol generator 20 comprising a heater arrangement configured to provide a flow of hot air (e.g., a convection heating system), and aerosol-generating material 30 suspended across a channel of a support structure 28. The tests used a cylindrical channel having an inner diameter of 8 mm and an axial length of 40 mm. Five layers of aerosol-generating material 30 were suspended across the centre of an 8mm diameter channel with a 40 mm length (in accordance with the arrangement shown in Fig. 8A) such that a 1417 mm² area of aerosol-generating material 30 was exposed to the channel (resulting in a total exposed surface area on both sides of the aerosol-generating material 30 of 2834 mm²). The channel was exposed to simulated puffing conditions by the use of controlled bursts of hot or heated air. The hot or heated air was temperature controlled to a set temperature and supplied at a flow rate of approximately 1 litre per minute (1 dm³/min) for the duration of each simulated puff. Each simulated puff lasted 3 seconds. The amount of aerosol produced by each simulated puff was determined by measuring the change in mass (the reduction in mass) of the aerosol-generating material 30 after each puff. Tables 1 and 2 and Figure 16 show the results of these tests. Table 1: Mass of aerosol produced from simulated puffs at a constant temperature

Puff number Temperature Mass of aerosol produced (mg)

1 270°C 46.5

2 270°C 9.2

3 270°C 7

4 270°C 7.9

5 270°C 4.2

6 270°C 3.2
With reference to Table 1 and Figure 16, the tests showed that the mass of aerosol produced from puff to puff can be inconsistent. For example, when using a constant air temperature of 270°C, the first puff can result in a relatively larger volume and/or mass of aerosol than subsequent puffs. It is believed that such variations between puffs or inconsistencies in the volume and/or mass of aerosol produced can adversely affect user experience. With reference to Figures 3-5 and 9-11 consistency in the volume and/or mass of aerosol produced from puff to puff can be improved by providing one or more dividers 36, 38 between adjacent films in combination with a variable or indexed flow director system. For example, each puff may be indexed to a new (e.g., fresh or previously unused) aerosol-generating film 30 or portion of aerosol-generating material 30. In this way each puff can produce the same or similar "first puff" volume and/or mass of aerosol. There are, of course, various other advantages to the described arrangements as detailed elsewhere herein.
Figures 14A-14D show some examples that exhibit improved consistency in the volume and/or mass of aerosol produced from puff to puff. Broadly speaking, these advantages can be achieved when using a plurality of layers of aerosol-generating material 30 that include features that stagger the amount of material exposed to the hot or heated air in use. The layers may be respective layers of aerosol-generating film.
In the examples shown in Figures 14A-D, a plurality of layers of aerosol-generating material 30 are arranged in the support structure 28. The layers may be respective layers of aerosol-generating film.
Each of the layers 30 has a first end arranged proximate the inlet (e.g., proximate the article inlet 44, the aerosol generator 20 and/or flow director 22), and a second end proximate the outlet 16. The first end of a first layer 30 is axially offset from the first end of a second, adjacent (i.e., the next) layer 30 (with respect to the longitudinal axis). In the illustrated example, the end of the layer 30 proximate the centre of the channel is axially closer to the aerosol generator 20 than the adjacent (i.e., next) layer 30, the ends of which are axially farther from the aerosol generator 20. The plurality of layers may have a plurality of different axial lengths. The plurality of layers may each have the same axial length (some may be shifted further towards the aerosol generator), or their lengths may be different.
Offsetting or staggering the axial position of the respective first ends of the layers (in particular, in the direction of airflow) provides for tailoring of the puff-to-puff aerosol volume and/or mass. In this manner the layers 30 may be configured to provide a consistent puff-to-puff experience. As shown in Figures 14B-14D, each puff expenses portions of the plurality of layers in an advancing front created by a laminar flow regime of the hot or heated flow of air (the expended parts of the layers 30 is indicated as increasing from Figure 14B to Figure 14D). Staggering the layers 30 in the direction of the hot or heated flow of air allows for the portion of aerosol-generating material 30 expended in the first puff to be reduced thereby reducing the volume and/or mass of aerosol of the first puff.
In addition, or alternatively to their position within the article 34 or support structure 28, the aerosol-generating material 30 may include intrinsic features that improve consistency in the volume and/or mass of aerosol produced from puff to puff. For example, a plurality of perforations 42 may be provided in each of one or more aerosol-generating layers 30, wherein the number and/or size of the perforations 42 is configured to adjust the volume and/or mass of aerosol produced in consecutive puffs.
In the example of Figure 15, the aerosol-generating material 30 may comprise relatively larger perforations 42 proximate the aerosol generator 20 and/or the article inlet 44, and relatively smaller perforations 42 proximate the outlet 16, 46. The larger perforations 42 proximate the aerosol generator 20 and/or the article inlet 44 may reduce the volume of aerosol-generating material expended during the first puff thereby providing an improved consistency in the volume and/or mass of aerosol produced from puff to puff.
Tests have also been conducted with an aerosol generator 20 comprising a heater arrangement configured to provide a flow of hot air and aerosol-generating material 30 suspended across a channel of a support structure 28 with variable temperatures from puff to puff. The experimental setup was the same as indicated previously except that the temperature of each simulated puff was set to a different value. Table 2 show the results of one such test wherein the temperature was progressively increased after each puff. Table 2: Mass of aerosol produced from simulated puffs at progressively increasing temperatures

Puff number Temperature Mass of aerosol produced (mg)

1 175°C 12.4

2 190°C 6.3

3 200°C 5.7

4 230°C 7.4

5 240°C 7.6

6 250°C 5.5
With reference to Table 2 and Figure 16, the tests showed that the consistency in the volume and/or mass of aerosol produced from puff to puff can be improved by using a progressively increasing temperatures from puff to puff.
All percentages by weight described herein (denoted wt%) are calculated on a dry weight basis, 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, 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 refers to all components, including water.
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 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

An article (34) for providing an aerosol comprising:
an inlet (44);

an outlet (46);

a support structure (28) defining a channel extending along a longitudinal axis; and

an aerosol-generating material (30), the aerosol-generating material (30) configured to provide an aerosol including at least one volatilised component of the aerosol generating material upon heating;

wherein at least a portion of the aerosol-generating material (30) is suspended within the channel such that two sides of said at least a portion of the aerosol generating material are arranged to be exposed to a flow of air passing through the channel.
A system for providing an aerosol from an aerosol generating material, the system comprising:
an inlet (14);

an outlet (16) from which a user can draw;

a support structure (28) defining a channel extending along a longitudinal axis;

an aerosol-generating material (30) configured to provide an aerosol including at least one volatilised component of the aerosol generating material upon heating, wherein at least a portion of the aerosol-generating material (30) is suspended within the channel such that two sides of said at least a portion of the aerosol generating material are arranged to be exposed to a flow of air passing through the channel;

a heater arrangement (20) for heating the aerosol-generating material, wherein the heater arrangement is configured to heat a flow of air which, in use, flows into the system from the inlet (14) when a user draws on the outlet (16); and

a flow director (22) configured to direct the heated flow of air into the channel.
The system of claim 2, wherein the flow director (22) is configured to selectively direct the heated flow of air at a plurality of different directions into the channel.
The system of claim 2, comprising a movable shutter (26) configured to selectively block or direct the heated flow of air into the channel to one or more of a plurality of different positions along the width of the channel.
The system of claim 2, 3 or 4, comprising a sensor configured to detect when a user has drawn on the outlet.
The system of claim 5, wherein the system is configured to increase a temperature of the heater arrangement (20) after detecting by the sensor that the user has drawn on the outlet.
The system of claim 5 or 6, wherein the system is configured to increase a temperature of the heater arrangement (20) from a first temperature to a second temperature after detecting by the sensor that the user has drawn on the outlet (16), and wherein the system is, subsequently to the first increase, configured to further increase the temperature of the heater arrangement (20) from the second temperature to a third temperature after detecting by the sensor that the user has further drawn on the outlet (16).
The article of claim 1, or the system of any of claims 2-7, wherein the two sides comprise opposed surfaces of the aerosol-generating material.
The article of any of claims 1 or 8, or the system of any of claims 2-8, wherein the aerosol-generating material (30) comprises perforations (42).
The article of any of claims 1, 8 or 9, or the system of any of claims 2-9, wherein the aerosol-generating material (30) comprises a plurality of aerosol-generating films (30), each aerosol-generating film (30) spaced from an adjacent aerosol-generating film (30).
The article of claim 10, or the system of claim 10, wherein an aerosol-generating film (30) of the plurality of aerosol-generating films (30) is separated from an adjacent aerosol-generating film (30) of the plurality of aerosol-generating films (30) by a divider.
The article of claim 11, or the system of claim 11, wherein the divider is permeable to air.
The article of claim 11, or the system of claim 11, wherein the divider is substantially impermeable to air.
The article of claim 10, or the system of claim 10, wherein the plurality of aerosol-generating films (30) are axially staggered such that some of the plurality of aerosol-generating films (30) are positioned closer to the inlet (14) than others of the plurality of aerosol-generating films (30).
The article of any of claims 1, 8 or 9, or the system of any of claims 2-9, wherein the aerosol-generating material (30) is a spiral of aerosol-generating material (30).