TW202439995A - A consumable and a non-combustible aerosol provision system - Google Patents

Abstract

A consumable for use with an aerosol provision device. The consumable comprises an open airflow channel that extends between open ends of the consumable and an aerosol generating section configured to generate an aerosol in at least a portion of the open airflow channel during use. The pressure drop across the consumable is greater than about 50mmWg at a volumetric flow rate of about 17.5ml/s. Also disclosed is a non-combustible aerosol provision system comprising such a consumable.

Description

Consumables and non-flammable aerosol supply systems

The present disclosure relates to a component of an article for use or as an aerosol delivery system, a component for use or as an aerosol delivery system, and a method for forming a component of an article for use or as an aerosol delivery system.

Certain tobacco industry products generate an aerosol during use for inhalation by a user. For example, tobacco heating devices heat an aerosol generating substrate such as tobacco to form an aerosol by heating rather than burning the substrate. These tobacco industry products typically include consumables containing aerosol generating materials for use in a heating device.

In a first aspect of the present invention, a consumable is provided for use with an aerosol supply device, the consumable comprising: an open airflow channel extending between the open ends of the consumable; and an aerosol generating section configured to generate an aerosol in at least a portion of the open airflow channel during use; wherein the pressure drop across the consumable is greater than about 50 mmWg at a volume flow rate of about 17.5 ml/s.

In a second aspect of the present invention, a non-flammable aerosol supply system is provided, which includes: the consumable of the first aspect; and a non-flammable aerosol supply device, which is used to heat the aerosol generating material of the consumable to generate an aerosol, the device including an area for receiving the consumable, and an aerosol generator for causing the aerosol generating material to be heated when the consumable is located in the area.

As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user, and includes: non-flammable aerosol supply systems that release compounds from an aerosol generating material without burning the aerosol generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems that use a combination of aerosol generating materials to generate aerosols.

According to the present disclosure, a "non-flammable" aerosol delivery system is a system for facilitating delivery of at least one substance to a user without burning or combusting a component aerosol generating material of the aerosol delivery system (or its components).

In some embodiments, the delivery system is a non-flammable aerosol supply system, such as an electric non-flammable aerosol supply system.

In some embodiments, the non-flammable aerosol supply system is an aerosol generating material heating system, also referred to as a heat-not-burn system.

In some embodiments, the non-flammable aerosol supply system is a hybrid system that generates an aerosol using a combination of aerosol generating materials, one or more of which may be heated. Each of the aerosol generating materials may be in the form of a solid, liquid, or gel, for example, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol generating material and a solid aerosol generating material. The solid aerosol generating material may include, for example, tobacco or a non-tobacco product.

The non-flammable aerosol supply system described herein includes a non-flammable aerosol supply device and a consumable for use in the non-flammable aerosol supply device.

The present disclosure relates to consumables that contain aerosol generating materials and are configured to be used in non-flammable aerosol delivery devices. These consumables are sometimes referred to as articles in the present disclosure.

In some embodiments, a non-flammable aerosol supply system, such as a non-flammable aerosol supply device, may include a power source and a controller. The power source may be, for example, an electrical power source or an exothermic power source. In some embodiments, the exothermic power source includes a carbon matrix that can be charged to distribute energy in the form of heat to an aerosol generating material or to a heat transfer material near the exothermic power source.

In some embodiments, a non-flammable aerosol supply system may include an area for receiving consumables, an aerosol generator, an aerosol generating area, a housing, a nozzle, a filter and/or an aerosol modifier.

In some embodiments, a consumable for use in a non-flammable aerosol supply device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer assembly, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a nozzle, and/or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, which generates heat to cause the aerosol generating material to generate an aerosol during use. The heater may, for example, include a flammable material, a material that can be heated by electrical conduction, or a susceptor.

In some embodiments, the substance to be delivered may be an aerosol-generating material or a material not intended to be aerosolized. Where appropriate, any material may contain one or more active ingredients, one or more flavors, one or more aerosol former materials, and/or one or more other functional materials.

In some embodiments, the substance to be delivered comprises an active substance.

An active substance as used herein may be a physiologically active material, which is a material whose purpose is to achieve or enhance a physiological response. The active substance may be selected, for example, from a health supplement, a nootropic, or a psychoactive agent. The active substance may be naturally present or obtained synthetically. The active substance may include, for example, niacin, caffeine, taurine, theophylline, vitamins (e.g., B6 or B12 or C), melatonin, cannabinoids or components, derivatives or combinations thereof. The active substance may include one or more components, derivatives or extracts of tobacco, cannabis or another plant material.

In one embodiment, the active substance is a legal recreational drug.

In some embodiments, the active substance comprises niacin. In some embodiments, the active substance comprises caffeine, melatonin, or vitamin B12.

As described herein, an active substance may comprise one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

The active substance can be CBD or a derivative thereof

As described herein, active substances may comprise or be derived from one or more plant materials or components, derivatives or extracts thereof. As used herein, the term "plant" includes any material derived from a plant, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, shells, or the like. Alternatively, the material may comprise an active compound naturally present in a plant material that is obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, flakes, or the like. Examples of botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay, licorice, matcha, mate, orange peel, papaya, rose, sage, teas such as green or black tea, thyme, cloves, cinnamon, coffee, aniseed (aniseed), basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, cinnamon, thyme, cloves, cinnamon, cumin ... Rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, basil, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, black currant, valerian, bell pepper, nutmeg, damien, marjoram, olive, lemongrass, lemon basil, scallion, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theanine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following mint species: wild mint (Mentha arventis), peppermint (Mentha c.v.), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), lemon peppermint (Mentha piperita citrata c.v.), chocolate mint (Mentha piperita c.v.), wrinkled mint (Mentha spicata crispa), heart mint (Mentha cardifolia), European peppermint (Mentha longifolia), pineapple mint (Mentha suaveolens variegate), lip calyx mint (Mentha pulegium), spearmint (Mentha spicata c.v.), and apple mint (Mentha suaveolens).

In some embodiments, the active substance comprises or is derived from one or more plant materials or components, derivatives or extracts thereof, and the plant material is tobacco.

In some embodiments, the active ingredient comprises or is derived from one or more plant materials or components, derivatives or extracts thereof, and the plant material is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active ingredient comprises or is derived from one or more plant materials, or components, derivatives or extracts thereof, and the plant material is selected from rooibos tea and fennel.

In some embodiments, the substance to be delivered includes a flavor.

As used herein, the terms "flavor" and "flavoring agent" refer to materials that can be used to create a desired taste, aroma or other sensory sensation in a product for adult consumers, where permitted by local regulations. They can include naturally occurring flavoring materials, plant materials, extracts of plant materials, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme, thyme , matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herbs, 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 fruit, Drambuie, bourbon, Scotch whisky, whiskey, gin , tequila, rum, spearmint, mint, lavender, aloe, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cinnamon, caraway, cognac, jasmine, ylang-ylang, sage, fennel, mustard, chili peppers, ginger, coriander, coffee, hemp, mint oil from any species of the mint family, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, laurel, mate, orange peel, rose, tea (e.g., green or black), thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, basil, turmeric (curcuma), cilantro, myrtle, black currant, valerian, bell pepper, and celery Cope, damian, marjoram, olive, lemongrass, lemon basil, shrimp onion, carvi, verbena, tarragon, limonene, daphneol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, potassium sultone, aspartame, saccharin, cyclohexane sulfonate, lactose, sucrose, glucose, fructose, sorbitol or mannitol), and other additives such as charcoal, chlorophyll, minerals, plant materials or breath fresheners. They can be simulated, synthetic or natural ingredients or blends thereof. It may be in any suitable form, for example a liquid (such as an oil), a solid (such as a powder) or a gas.

In some embodiments, the flavor comprises menthol, green mint and/or mint. In some embodiments, the flavor comprises a flavor component of cucumber, blueberry, citrus fruit and/or cranberry. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises a flavor component extracted from tobacco. In some embodiments, the flavor comprises a flavor component extracted from cannabis.

In some embodiments, the flavor may include a sensory agent that is intended to achieve a somatosensory sensation that is typically chemically induced and sensed by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or in place of the aroma or taste nerves, and these sensory agents may include preparations that provide heating, cooling, tingling, numbing effects. Suitable thermal effect agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucalyptol, WS-3.

An aerosol generating material is a material that is capable of generating an aerosol, for example when heated, irradiated or energized in any other way. The aerosol generating material may, for example, be in the form of a solid, liquid or semi-solid (e.g., a gel), which may or may not contain an active substance and/or flavoring agent.

The aerosol generating material may comprise one or more active substances and/or flavors, one or more aerosol former materials, and optionally one or more other functional materials.

The aerosol generating material may include a binder, such as a gelling agent and an aerosol former. Optionally, a substance to be delivered and/or a 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 of plant material. In particular, in some embodiments, the aerosol generating material is substantially free of tobacco.

The aerosol generating material may comprise an aerosol generating film or may 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 forming agent. Optionally, a substance to be delivered and/or a filler may also be present. The aerosol generating film may be substantially free of plant material. In particular, in some embodiments, the aerosol generating material is substantially free of tobacco.

The aerosol generating film may have a thickness of about 0.015 mm to about 1 mm. The aerosol generating film may be up to 0.5 mm thick, preferably 0.05 mm to 0.5 mm thick. For example, the thickness may range from about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

The aerosol generating film may be continuous. For example, the film may comprise or may be a continuous sheet of material. The sheet may be in the form of a wrap, 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 film may be discontinuous. For example, the aerosol-generating film may include one or more discrete portions or regions of aerosol-generating material, such as points, strips, or lines that may be supported on a support. In such embodiments, the support may be planar or non-planar.

The aerosol-generated film may be formed by combining a binder (e.g., a gelling agent) with a solvent (e.g., water, an aerosol-forming agent) and one or more other components (e.g., one or more substances to be delivered) to form a slurry and then heating the slurry to volatilize at least some of the solvent to form the aerosol-generated 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 include or be an "amorphous solid". In some embodiments, the aerosol generating material includes an aerosol generating film, which 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 xerogel. The amorphous solid is a solid material that can retain some fluid such as a liquid inside. In some embodiments, the amorphous solid may, for example, include about 50wt%, 60wt% or 70wt% amorphous solid to about 90wt%, 95wt% or 100wt% amorphous solid.

The amorphous solid may be substantially free of plant material. The amorphous solid may be substantially free of tobacco.

The aerosol former material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol former material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, tetratetrol, meso-tetratetrol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, glyceryl triacetate, diacetate glyceryl mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer and/or an antioxidant.

The aerosol generating material may be present on or in a support member, which forms a substrate. The support member may be or include, for example, paper, card, paperboard, cardboard, reconstructed material, plastic material, ceramic material, composite material, glass, metal or metal alloy. In some embodiments, the support member includes a receptor. In some embodiments, the receptor is embedded in the material. In some alternative embodiments, the receptor is located on one or either side of the material.

A susceptor is a material that can be heated by passing through a varying magnetic field (e.g., an alternating magnetic field). The susceptor can be a conductive material such that its passage through the varying magnetic field causes inductive heating of the heating material. The heating material can be a magnetic material such that penetration of the varying magnetic field into the heating material causes hysteresis heating of the heating material. The susceptor can be both conductive and magnetic such that the susceptor can be heated by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

An aerosol modifier is a substance, typically located downstream of an aerosol generation zone, that is configured to modify the generated aerosol, for example by changing the taste, flavor, acidity or other properties of the aerosol. The aerosol modifier may be provided in an aerosol modifier release element that is operable to selectively release the aerosol modifier.

The aerosol modifier may be, for example, an additive or an absorbent. The aerosol modifier may, for example, include one or more of a flavoring agent, a coloring agent, water, and a carbon absorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a string, or a granule. The aerosol modifier may not contain a filter material.

An aerosol generator is a device configured to cause an aerosol to be generated from an aerosol generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol generating material to thermal energy to release one or more volatiles from the aerosol generating material to form an aerosol.

FIG1 illustrates a non-flammable aerosol supply system, which includes a consumable 100 and a non-flammable aerosol supply device 200. The device includes an area 201 for receiving the consumable 100 and an aerosol generator 202.

FIG2 illustrates a consumable 100 in cross section. The cross section is projected onto a plane that bisects the consumable in a longitudinal direction. The consumable 100 comprises an aerosol generating section 101. The aerosol generating section 101 comprises a wall 102 that surrounds an air gap 103 that forms part of an open air flow channel 111 extending between open ends 112, 113 of the consumable 100. The aerosol generating section 101 is configured to generate an aerosol in the air gap 103 for inhalation by a user when heated by a non-flammable aerosol supply device.

The open airflow channel 111 (hereinafter simply referred to as "channel 111") is free of obstructions, which means that a straight airflow path 114 is provided through the channel 111 between the open ends 112, 113 of the consumable 100. Because the airflow path 114 is straight, when a user inhales the consumable 100, less aerosol components generated during the heating of the consumable 100 are deposited compared to when the path is non-straight. For example, if the consumable is instead provided with a breathable material that closes one end of the consumable, when a user inhales the consumable, the airflow generated through the consumable needs to pass through the breathable material in a tortuous path, causing the aerosol components to be blocked by the material. This is, of course, the principle of a cigarette type filter. However, in the examples described herein, these obstacles are eliminated to allow more of the aerosol produced during heating of the consumable 100 to reach the user.

The consumable 100 is configured to provide a pressure drop greater than about 50 mmWg across the consumable 100. Providing a pressure drop greater than about 50 mmWg across the consumable 100 ensures a satisfactory resistance to draw. "Satisfactory resistance to draw" means that when a user draws on the consumable 100, the resistance to draw is similar to the resistance to draw of a cigarette. The pressure drop is measured using an industry standard technique that will be familiar to those of ordinary skill in the art. In short, the pressure drop is measured by sealing one of the open ends 112, 113 to a pressure drop measuring device (e.g., Borgwaldt A11), which is configured to draw at a set volume flow rate of about 17.5 ml/s through the consumable 100. The open end 112, 113 selected to be attached to the pressure drop measuring device is the end of the consumable 100 on which the user will draw during use of the consumable 100 and is hereinafter referred to as the mouth end ME. In the example of Figure 2, the mouth end ME and the open end 112 are at the same end of the consumable.

In order to deliver the required pressure drop, the size of the channel is selected accordingly. Since the air gap 103 forms part of the channel 111, and since aerosol is generated in the air gap 103 during use, the part of the channel 111 containing the air gap 103 must have sufficient volume to accommodate a satisfactory amount of aerosol generated. If the air gap 103 is too small, insufficient aerosol will be formed during the heating of the consumable 100. Therefore, the channel 111 includes a first region 115 having a first cross-sectional area, and a second region 116 having a second cross-sectional area, which is smaller than the first cross-sectional area. When a user inhales the consumable 100, the second cross-sectional area 116 leads to a limitation that increases the pressure drop of the consumable 100. The first region 115 forms a portion of the channel 111 including the air gap 103 and has a cross-sectional area that is optimal for aerosol generation.

The first cross-sectional area may be between about 5 mm ² and about 20 mm ² , and the second cross-sectional area may be between about 0.5 mm ² and about 3.5 mm ² .

In one example, the first cross-sectional area is about 7.1 mm ² and the second cross-sectional area is about 1.8 mm ² . In this example, the length of the first region 115 may be about 60 mm and the length of the second region 116 may be about 20 mm. According to this example, the pressure drop across the combined first and second regions 115, 116 will be about 70 mmWg, of which about 40 mmWg is contributed by the second region 116 and about 30 mmWg is contributed by the first region 115.

In another example, the first cross-sectional area is about 19.6 mm ² and the second cross-sectional area is about 0.8 mm ² . In this example, the length of the first region 115 may be about 60 mm and the length of the second region 116 may be about 20 mm. According to this example, the pressure drop across the combined first and second regions 115, 116 will be about 72 mmWg, of which about 60 mmWg is contributed by the second region 116 and about 12 mmWg is contributed by the first region 115.

The ratio of the first cross-sectional area to the second cross-sectional area may be between 20:1 and 7:3, and in one example between approximately 20:1 and 3.5:1.

The length of the first region 115 may be between 40 mm and 80 mm, and the length of the second region 116 may be between 15 mm and 25 mm. In one example, the length of the first region 115 is about 60 mm and the length of the second region 116 is about 20 mm.

The second zone 116 may contribute at least 40% of the total pressure drop of the combined first and second zones 115, 116 - which in embodiments may be the total pressure drop across the consumable 100. For example, the second zone 116 may contribute at least 50%, or at least 60%, or at least 70%, or at least 80% of the total pressure across the consumable 100.

FIG3 illustrates an aerosol generating section 101 of a consumable 100, which is illustrated herein as a cross section projected onto a plane perpendicular to the longitudinal direction bisecting the aerosol generating section 101. FIG3 shows further details of a wall 102 of the aerosol generating section 101. In the present example, the wall 102 further comprises a support 104 and a film of an aerosol generating material 105 disposed on the support 104. The film of aerosol generating material 105 forms an inner surface of the wall 102. The support 104 forms an outer surface of the wall 102, which in the present example is coated with a coating material 110 for attaching the aerosol generating section 101 to another component of the consumable. In other examples, the outer surface of the wall 2 may be an outermost surface of the consumable 100, such as the example of Figure 5 as illustrated and described below. The support member may be made of any suitable material, such as paper or cardboard.

FIG4 illustrates another example aerosol generating section 101 in which similar features retain the same reference numerals. Similar to FIG3 , FIG4 is a cross section projected onto a plane perpendicular to the longitudinal direction bisecting the aerosol generating section 101. In the example of FIG4 , the support 104 further comprises a first layer 106 and a second layer 107, the first layer 106 being located between the aerosol generating material 105 and the second layer 107. The first layer 106 is a receptor 106 and can be heated by penetration with a varying magnetic field. The second layer 107 can be heated by penetration with a varying magnetic field and can be any suitable material falling within this criterion, such as paper or paperboard. The aerosol generating material 105 is disposed directly on the receptor 106. However, in other examples, additional materials may be disposed between the aerosol generating material 105 and the susceptor 106 .

In the example of Figure 2, the first region 115 is provided by the aerosol generating segment 101 and the second region 116 is provided by a separate component 109, which is referred to herein as a restriction 109. The restriction 109 is arranged coaxially with the aerosol generating segment 101 and is attached to the aerosol generating segment 101 by a wrapping material 110 surrounding the restriction 109 and the aerosol generating segment 101. The restriction 109 has an opening 117 that forms the second region of the airflow channel 111.

FIG5 illustrates another example consumable 100 in which similar features retain the same reference numerals. The example of FIG5 is substantially the same as the example of FIG2, but the difference is that the covering material 110 is omitted and a restriction 109' is instead attached to the aerosol generating section 101 by being inserted into one end of the aerosol generating section 101. In the illustrated example, the end is the mouth end ME of the consumable 100. The restriction 109' is provided with an overall size that is substantially the same as or slightly smaller than the internal size of the aerosol generating section 101, so that the restriction 109' fits tightly within the aerosol generating section 101. As described above, the restriction 109' has an opening that forms a second cross-sectional area of the airflow channel 111.

In the illustrated example, the aerosol generating section 101 is tubular, i.e., comprises a ring-shaped cross section. However, it should be understood that other cross-sectional shapes may be used. For example, the wall 102 may be a prism having a polygonal cross section. Example polygonal cross sections may include, but are not limited to, octagonal, hexagonal, heptagonal, or square.

In the illustrated example, the restriction 109, 109' is disposed at the mouth end ME of the consumable 100. However, in other examples, the restriction 109, 109' may be disposed at a distal end, i.e., an end relative to the mouth end ME. Since the airflow leaving the restriction 109, 109' has turbulent energy, the position of the restriction may have an impact on the sensory experience of the user. For example, placing the restriction 109, 109' at the distal end of the consumable 100 promotes more mixing of the aerosol generated in the air gap 103, which may increase the flavor intensity of the aerosol delivered to the user. Alternatively, placing the restriction 109, 109' at the mouth end ME causes the aerosol to be delivered to a user's mouth at a higher velocity, resulting in more mixing and a different sensory experience within the user's mouth.

In the illustrated example, the second region 116 of the channel 111 is provided by a single component 109, 109' having a constant cross-sectional area. However, it will be appreciated that the present invention may be achieved by a second region 116 formed by multiple components having different cross-sectional areas or a single component having a varying cross-sectional area. Regardless of the configuration of the second region 116, it is important that the consumable 100 is provided with a channel 111 having a straight airflow path 114 between the open ends of the consumable 100 and the pressure drop across the consumable is as defined herein.

The consumable 100 may be provided with any of a variety of additional components for attachment to the aerosol generating section 101 described above. However, it is important that any additional components have an opening that does not obstruct the straight airflow path 114.

The limiting members 109, 109' described herein may be formed from a sheet of gathered material. "Formed from a sheet of gathered material" means that a sheet of material is gathered into the shape of the limiting members 109, 109'. Similarly, the support member 104 of the example consumables described herein may be formed from a sheet of gathered material. In the example, the sheet is a fiber sheet, such as paper. In the example, the sheet is rolled up before being gathered into the shape of the limiting members 109, 109' or the support member 104. Therefore, the limiting members 109, 109' or the support member 104 may be formed from a gathered sheet of rolled material.

FIG6 illustrates a cross section of a curling pattern of an example rolled sheet 6 that may be used to form a limiter 109, 109' or support 104. The curling pattern includes a plurality of peaks and troughs in the sheet 6, wherein the curling amplitude "A" is the depth of the trough, measured from its peak. The curling may form a "zig-zag" formation or another shape. Adjacent grooves of the rolled sheet may be spaced a distance apart, or have a pitch "P", in the range of 0.3 to 2 mm, and preferably in the range of 0.4 to 1 mm. In an example, adjacent grooves of the rolled sheet 6 are spaced at least 0.4 mm or at least 0.5, 0.6, 0.7 or 0.8 mm apart. In other examples, adjacent grooves of the rolled sheet 6 are spaced at most 1.5 mm apart, and preferably at most 1.4, 1.3, 1.2, 1.1 or 1.0 mm apart. The rolled sheet 6 may have a rolling amplitude of less than 0.5 mm.

The extended width of the rolled sheet can be selected to provide a gathered sheet having a density of about 0.1 mg/mm ³ to 0.3 mg/mm ³ .

Referring again to FIG. 1 , the aerosol generator 202 is configured to heat the aerosol generating material 105 of the consumable 100 when the consumable 100 is received in the area 201 for receiving the consumable. The device further includes a power supply 203, a controller 204, and an inhalation sensor 205. In use, a user inserts the consumable 100 into the area 201 for receiving the consumable and activates the aerosol generator 202 to generate an aerosol for inhalation. The user can then inhale the aerosol by sucking the mouth end ME of the consumable 100 or alternatively the mouthpiece (not shown) of the device 200. In the illustrated example, the consumable 100 and the device 200 are assembled so that the mouth end ME is a portion of the consumable 100 that protrudes from the area 201 when the consumable 100 is fully inserted into the device 200. Thus, the mouth end ME is available for the user to suck on while the user holds the device 200.

The puff sensor 205 is configured to detect when a user draws on the mouth end of the consumable in the device 200, and sends a signal to the controller 204 to activate the aerosol generator 202. Therefore, the aerosol is generated at the same time as the user inhales on the consumable. Alternatively, the device 200 can be provided with a user interface, such as a button (not shown), which the user can press to cause the actuation of the aerosol generator 202.

The area 201 for receiving the consumable 100 is provided with an inlet (not shown) to allow air to enter the area 201 before passing through the consumable 100 when a user draws on the mouth end 101 of the consumable 100. Thus, an airflow is directed through the consumable 100 when a user draws on the consumable 100. Specifically, air is directed through the airflow channel 111 of the consumable 100. The airflow entrains the aerosol generated by the aerosol generating material 105 of the consumable for inhalation by the user.

The aerosol generator 202 includes any suitable means for heating the aerosol generating material 105 of a consumable 100 received in the region 201 of the device 200. Power for the aerosol generator 202 is provided by a power source 203, which in the illustrated example is an electrical energy source 203, such as a battery pack 203.

In one example, the aerosol generator 202 includes a magnetic field generator configured to generate a changing magnetic field that penetrates an area 201 for receiving a consumable 100. Thus, the device 200 is configured for use with a consumable 100 that includes a receptor (such as the receptor 106 illustrated in FIG. 4 ). The changing magnetic field heats the receptor 106 by magnetic hysteresis. When the consumable 100 is placed in the device 200 and the aerosol generator 202 is activated, a changing magnetic field penetrates the receptor 106 of the consumable 100 and causes heating of the aerosol generating material 105 in thermal contact with the receptor, thereby generating an aerosol for inhalation by a user.

In another example, the aerosol generator 202 includes: a receptor that is in thermal contact with the area 201 for receiving the consumable 100; and a magnetic field generator that is used to generate a changing magnetic field that penetrates the receptor. The changing magnetic field heats the receptor by magnetic hysteresis. The receptor in turn heats the area 201 for receiving the consumable. Therefore, when a consumable 100 is placed in the device 200 and the aerosol generator 202 is activated, a changing magnetic field penetrates the receptor and causes the area 201 in which the consumable 100 is received to be heated. The heat is transferred to the aerosol generating material 105 of the consumable 100, thereby generating an aerosol for the user to inhale. In these examples, the wall 207 of the area 201 for receiving the consumable 100 may include the receptor. The consumable 100 may be configured to directly contact the wall 207 for efficient heat transfer. Alternatively or additionally, the protrusion 206 may include a susceptor. For example, either or both of the wall 207 and the protrusion 206 may be made of a material that can be heated by penetrating with a varying magnetic field.

In another example, the aerosol generator 202 includes a material that can be heated by electrical conduction, and the material is configured to be in thermal contact with the area 201 for receiving the consumable 100. Therefore, when the consumable 100 is placed in the device 200 and the aerosol generator 202 is activated, an electric current flows through the material to heat the area 201 in which the consumable 100 is received. The heat is transferred to the aerosol generating material 105 of the consumable 100, thereby generating an aerosol for the user to inhale. In these embodiments, the material can be a wall 207 of the area 201 for receiving the consumable 100, and the consumable 100 can be configured to be in direct contact with the wall 207 for efficient heat transfer.

In any of the above examples of the aerosol generator 202, the aerosol generator 202 can be configured for zoned or staged heating of the consumable 100. "Zoned or staged heating" means that the aerosol generator 202 is configured to heat discrete portions of the aerosol generating material 105 separately, i.e., at different points in time.

7, a flow chart is shown that illustrates an example of a method 80 of manufacturing a consumable 100 for use with the example systems described herein. The method 80 of FIG. 7 may be used to manufacture any of the consumables 100 described herein.

The method includes an act 81 of providing an aerosol generating section 101 including a support 104 and an aerosol generating material 105 added to the support 104, and optionally attaching any desired additional components thereto.

In some examples, the providing of act 81 includes act 82 of adding aerosol generating material 105 to support 104, and act 83 of forming aerosol generating section 101. Accordingly, in some examples, when aerosol generating material 105 is added to support 104, it may be flat or substantially flat. Thereafter, in some examples, support 104 and aerosol generating material 105 may be manipulated together during the formation of aerosol generating section 101. Such manipulations may include rolling or wrapping the combination of support 104 and aerosol generating material 105 into a section 101, which is typically tubular. However, it is to be understood that the combination of the support 104 and the aerosol generating material 105 may alternatively be folded into a section 101 having a non-circular cross-section. Such rolling, wrapping or folding may be around, for example, a mandrel. In other examples, the support 104 is provided in a tubular or substantially tubular form and the aerosol generating material 105 is thereafter added to the support 104.

In some examples, the method includes manufacturing a support 104. For example and as discussed by some examples herein, the support 104 can include a plurality of layers 106, 107, and the manufacturing of the support 104 can include assembling those layers to form the support 104, such as by bonding. At least one of the layers 106, 107 can be in the form of a sheet or a strip.

In some examples, the adding of act 82 is performed before the forming of act 83. In some of those examples, the adding of act 82 includes coating the aerosol-generating material 105 onto the support 104 to form a film of the aerosol-generating material 105. Such coating may include, for example, spraying, electric spraying, casting, or band casting. Such casting may involve providing a material in the form of a liquid or other fluid on a surface of the support 104 (or a material that will eventually form the support 104), and then allowing the material to at least partially solidify or cure on the surface of the support 104 to form the aerosol-generating material 105 comprising a film. Materials in liquid or other fluid form may be aerosol-generating while in that form, or may become aerosol-generating only once the material has solidified or cured.

In some examples, the adding of action 82 may include a technique other than coating. For example, the adding of action 82 includes using an adhesive to adhere the aerosol generating material 105 to the support 104.

If additional components are required, they can be attached to the aerosol generating section 101 by first arranging each of the components in axial alignment to form an assembly of components and then encasing the components in a coating material 110. In the example of FIG. 5 , the assembly includes, in sequence, the distal locator assembly 109, the aerosol generating section 101, the mouth end locator assembly 109 ′, and the filter plug 108. The assembly is then encased in the coating material 110 to form the consumable 100 of FIG. 5 .

The aerosol generating material 105 of any of the examples described herein may include an aerosol former, a binder, optionally a filler, and optionally an active and/or a flavoring agent.

In some examples described herein, the consumables are tobacco-free, eliminating tobacco-specific nitrosamine levels and thereby eliminating the need for a filter.

The various embodiments described herein are presented merely to assist in understanding and teach the claimed features. These embodiments are provided merely as a representative example of embodiments and are not exhaustive and/or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures and/or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the scope of the claims, or limitations on the equivalents of the scope of the claims, and other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. The various embodiments of the present invention may suitably include, consist of, or consist essentially of appropriate combinations of disclosed elements, components, features, parts, steps, members, etc., in addition to those combinations specifically described herein. In addition, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

6: sheet 80: method 81,82,83: action 100: consumables 101: aerosol generating section, section 102: wall 103: air gap 104: support 105: aerosol generating material 106: first layer, receptor, layer 107: second layer, layer 108: filter plug 109: distal locator assembly, separate assembly, restriction, assembly 109': oral locator assembly, restriction, assembly 110: covering material 111: open airflow channel, airflow channel, channel 112,113: open end 114: airflow path 115: first zone 116: second cross-sectional area, second zone 117: opening 200: non-flammable aerosol supply device, device 201: zone 202: aerosol generator 203: electrical energy, battery pack, power supply 204: controller 205: suction and exhalation sensor 206: protrusion 207: wall A: curling amplitude ME: mouth end P: pitch

Embodiments of the present invention will now be described by way of non-limiting examples only with reference to the accompanying drawings, wherein: FIG. 1 schematically illustrates a system comprising a consumable and a non-flammable aerosol supply device; FIG. 2 illustrates a cross section of a consumable projected onto a plane parallel to the longitudinal axis of the consumable; FIG. 3 illustrates a cross section of a consumable projected onto a plane perpendicular to the longitudinal axis of the consumable; FIG. 4 illustrates a cross section of a consumable projected onto a plane perpendicular to the longitudinal axis of the consumable; and FIG. 5 illustrates a cross section of a consumable projected onto a plane parallel to the longitudinal axis of the consumable; FIG. 6 illustrates a rolled sheet; and FIG. 7 is a flow chart showing an example of a method for manufacturing a consumable.

100:Consumables

102: Wall

103: Air gap

109: Remote positioner assembly, separate assembly, restraint, assembly

110: Coating material

111: Open airflow channel, airflow channel, channel

112,113: Open end

114: Airflow path

115: District 1

116: Second cross-sectional area, second zone

117: Open your mouth

ME: Mouth end

Claims (18)

A consumable for use with an aerosol supply device, the consumable comprising: an open airflow channel extending between the open ends of the consumable; and an aerosol generating section configured to generate an aerosol in at least a portion of the open airflow channel during use; wherein the pressure drop across the consumable is greater than about 50 mmWg at a volume flow rate of about 17.5 ml/s. A consumable as in claim 1, wherein the open airflow channel includes a first region having a first pressure drop and a second region having a second pressure drop. A consumable as claimed in claim 2, wherein the first region has a first cross-sectional area, and the second region has a second cross-sectional area, and the second cross-sectional area is smaller than the first cross-sectional area. A consumable as in claim 3, wherein the second zone is located downstream of the first zone along the open airflow channel. A consumable as in claim 3, wherein the first zone is located downstream of the second zone along the open airflow channel. A consumable as claimed in claim 4 or claim 5, wherein the ratio of the first cross-sectional area to the second cross-sectional area is between approximately 20:1 and 7:3. A consumable as in any of the preceding claims, wherein the aerosol generating section comprises a support and an aerosol generating material disposed on the support. A consumable as claimed in claim 7, wherein the support member is part of a wall of the aerosol generating section, which surrounds at least a portion of the open airflow channel, and the aerosol generating material forms an inner surface of the wall. A consumable as claimed in claim 8, wherein the support member forms at least a portion of a surface of the consumable, and optionally, wherein the surface of the consumable is an outermost surface of the consumable. A consumable as claimed in claim 9, wherein the aerosol generating material forms an interior surface of the aerosol generating section. A consumable as claimed in any one of claims 7 to 10, wherein the aerosol generating material comprises: an aerosol former a binder; optionally a filler; and optionally an active ingredient and/or a flavoring agent. A consumable as in any one of claims 7 to 11, wherein the aerosol generating material comprises an aerosol generating film, and wherein the aerosol generating film is up to about 1 mm thick, and optionally up to 500 microns thick, and optionally 50 to 500 microns thick. A consumable as in any of the preceding claims, wherein the aerosol generating section is tubular. A consumable as claimed in any one of claims 2 to 13, wherein the second region of the open airflow channel is formed by a component separate from the aerosol generating section, and wherein the separate component is attached to the aerosol generating section by a covering material surrounding both the aerosol generating section and the separated component. A consumable as in claim 14, wherein the separate component has an interior surface that surrounds at least a portion of the open airflow channel. A consumable as claimed in claim 14 or 15, wherein the separate component comprises a body of material surrounding the interior surface, and optionally wherein the body of material comprises a gathered sheet. A consumable as in any of claims 2 to 16, wherein the pressure drop across the second zone contributes at least 40% of the pressure drop across the consumable. A non-flammable aerosol supply system, comprising: The consumable of any one of claims 1 to 17; and A non-flammable aerosol supply device for heating the aerosol generating material of the consumable to generate an aerosol, the device comprising an area for receiving the consumable, and an aerosol generator for causing the heating of the aerosol generating material when the consumable is located in the area.