A CONSUMABLE FOR USE WITH AN AEROSOL PROVISION DEVICE

A consumable (2) for use with a non-combustible aerosol provision device is disclosed. The consumable (2) comprises a support (4), aerosol generating material, a cover (12), and an absorbent or adsorbent material (10). The cover (12) and the support (4) at least partially define a passage along which one of an aerosol, atmospheric gas, or a mixture of aerosol and atmospheric gas may travel. The aerosol generating material is supported on the support (4), and the aerosol generating material is so located that vaporisation of the aerosol generating material causes the vapour to enter the passage.

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Description
TECHNICAL FIELD

This disclosure relates to the field of non-combustible aerosol-provision systems, in particular to a method of manufacturing a product comprising aerosol generating material for use as a consumable for use with an aerosol provision device, a method for manufacturing consumables for use with an aerosol provision device, and an aerosol provision system including a consumable and an aerosol provision device.

BACKGROUND

Aerosol-generating articles release an inhalable aerosol or vapour by releasing compounds from a substrate material by heating without burning. These may be referred to as non-combustible articles, aerosol generating assemblies, or aerosol provision devices.

One example of such a product is a heating device which release compounds by heating an aerosolisable material, which may be referred to as a solid aerosol-generating 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.

As another example, there are hybrid devices. These hybrid devices contain a liquid source (which may or may not contain an active) which is vaporised by heating to produce an inhalable vapour or aerosol. The device additionally contains a solid aerosol-generating material (which may or may not contain a botanical material) and components of this material are entrained in the inhalable vapour or aerosol to produce the inhaled medium.

SUMMARY

According to a first aspect of the present disclosure there is provided a consumable for use with a non-combustible aerosol provision device, in which the consumable comprises a support, aerosol generating material, a cover, and an absorbent or adsorbent material, in which the cover and the support at least partially define a passage along which one of an aerosol, atmospheric gas, or a mixture of aerosol and atmospheric gas may travel,

    • the aerosol generating material is supported on the support,
    • the aerosol generating material is so located that vaporisation of the aerosol
    • generating material causes the vapour to enter the passage, and
    • the absorbent or adsorbent material at least partially fills the passage and spaces the cover from the support.

According to a second aspect of the present disclosure there is provided a consumable for use with a non-combustible aerosol provision device, in which the consumable comprises a support, aerosol generating material, a cover, and an absorbent or adsorbent material, in which

    • the cover and the support partially define a passage along which one of an aerosol, atmospheric gas, or a mixture of aerosol and atmospheric gas may travel,
    • the aerosol generating material is supported on the support,
    • the aerosol generating material is so located that vaporisation of the aerosol generating material causes the vapour to enter the passage, and
    • the absorbent or adsorbent material partially defines the passage and spaces the cover from the support

According to a third aspect of the present disclosure there is provided a method of making a consumable for use with a non-combustible aerosol provision device, in which the consumable comprises a support, aerosol generating material, a cover, and an absorbent or adsorbent material, in which the method comprises

    • providing a support on which aerosol generating material is supported,
    • attaching the cover to the support to at least partially define a passage along which one or more of a vapour, an aerosol, and atmospheric gas may travel, and
    • positioning the absorbent or adsorbent material in the passage,
    • in which the aerosol generating material is located on the support in a position that results in vapour generated by vaporisation of the aerosol generating material entering the passage.

According to a fourth aspect of the present disclosure there is provided a method of making a consumable for use with a non-combustible aerosol provision device, in which the consumable comprises a support, aerosol generating material, a cover, and an absorbent or adsorbent material, in which the method comprises

    • providing a support on which aerosol generating material is supported,
    • attaching the cover to the support to partially define a passage along which one or more of a vapour, an aerosol, and atmospheric gas, may travel,
    • in which the aerosol generating material is located on the support in a position that results in vapour generated by vaporisation of the aerosol generating material entering the passage, and
    • the absorbent or adsorbent material partially defines the passage and spaces the cover from the support.

According to a fifth aspect of the present invention there is provided a method of making a consumable for use with a non-combustible aerosol provision device, in which the consumable comprises a support, aerosol generating material, a cover, and a body of absorbent or adsorbent material, in which the method comprises

    • providing a support on which aerosol generating material is supported;
    • one or more of fixing the support to the body of absorbent or adsorbent material using a fixing means, fixing the cover to the body of absorbent or adsorbent material using a fixing means, and fixing a portion of the support to a portion of the cover; in which the aerosol generating material located on the support is located between the support and the body of absorbent or adsorbent material.

According to a sixth aspect of the present disclosure there is provided a

According to a seventh aspect of the present disclosure there is provided an aerosol provision device for use with a consumable according to the first or second aspect of the present disclosure, in which the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable.

According to an eighth aspect of the present disclosure there is provided an aerosol provision system comprising an aerosol provision device and a consumable according to the first or second aspect of the present disclosure.

According to a ninth aspect of the present disclosure there is provided a method of generating aerosol from a consumable according to the first or second aspect of the present disclosure using an aerosol-generating device with at least one aerosol generator disposed to heat, but not burn, the consumable in use; wherein at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.

Further features and advantages of the present disclosure will become apparent from the following description of embodiments of the disclosure given by way of example and with reference to the accompanying drawings.

DRAWINGS

FIG. 1 shows a perspective view of a first embodiment of a consumable according to the present disclosure;

FIG. 2 shows a section of the consumable of FIG. 1 along the line A-A′;

FIG. 3 shows an exploded view of the consumable of FIG. 1;

FIG. 4 shows a perspective view of a second embodiment of a consumable according to the present disclosure;

FIG. 5 shows an exploded view of the consumable of FIG. 4;

FIG. 6 shows a schematic view of a part of the consumable of FIG. 4 with an aerosol provision device;

FIG. 7 shows a perspective view of a third embodiment of a consumable according to the present disclosure; and

FIG. 8 shows an exploded view of the consumable of FIG. 7.

 DETAILED DESCRIPTION

The consumable of the present description may be alternatively referred to as an article.

In some embodiments, the consumable comprises aerosol-generating material. The consumable may comprise an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, an aerosol-modifying agent, one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.

The apparatus for heating the aerosol-generating material with which the consumable is to be used is a part of a non-combustible aerosol provision system. Non-combustible aerosol provision systems 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.

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 consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

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.

According to a first aspect of the present disclosure there is provided a consumable for use with a non-combustible aerosol provision device, in which the consumable comprises a support, aerosol generating material, a cover, and an absorbent or adsorbent material, in which

    • the cover and the support at least partially define a passage along which one of an aerosol, atmospheric gas, or a mixture of aerosol and atmospheric gas may travel, the aerosol generating material is supported on the support,
    • the aerosol generating material is so located that vaporisation of the aerosol generating material causes the vapour to enter the passage, and
    • the absorbent or adsorbent material at least partially fills the passage and spaces the cover from the support.

According to a second aspect of the present disclosure there is provided a consumable for use with a non-combustible aerosol provision device, in which the consumable comprises a support, aerosol generating material, a cover, and an absorbent or adsorbent material, in which

    • the cover and the support partially define a passage along which one of an aerosol, atmospheric gas, or a mixture of aerosol and atmospheric gas may travel,
    • the aerosol generating material is supported on the support,
    • the aerosol generating material is so located that vaporisation of the aerosol generating material causes the vapour to enter the passage, and
    • the absorbent or adsorbent material partially defines the passage and spaces the cover from the support.

The vaporisation of the aerosol generating material is caused by heating but not burning the aerosol generating material. When the vapour enters the passage it also enters the absorbent or adsorbent material. It is an advantage of the consumable of the present disclosure that the absorbent or adsorbent material is such that it provides a seed surface which causes the vapour (which comprises one or more substances from the aerosol generating material in the gas phase) to transition from the gas phase to the liquid or solid phase in the form of an aerosol (a suspension of tiny particles of liquid, solid or both within a gas).

It is a further advantage of the consumable of the present disclosure that the absorbent or adsorbent material will absorb or adsorb any condensate that forms within the passage. This is advantageous because the absorbent or adsorbent material captures the condensate and prevents that condensate from flowing within the passage, and potentially out of the passage.

In an embodiment of the above embodiment, the cover is deformable and the absorbent or adsorbent material prevents the cover ceasing to be spaced from the support when the consumable is in use.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material is not damaged or substantially altered by the use of the consumable. In some embodiments this is because the absorbent or adsorbent material is substantially unaffected by the temperatures to which the aerosol generating material is heated to generate vapour.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material comprises a unitary mass and the mass of absorbent or adsorbent material substantially fills the passage. In some embodiments, the unitary mass is a matrix of intertwined longitudinally extending elements of one or more materials.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material comprises a plurality of separate masses, and each mass of absorbent or adsorbent material is located in the passage. In some embodiments, at least one of the masses of absorbent or adsorbent material is a matrix of intertwined longitudinally extending elements of one or more materials.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material is resiliently deformable. In some embodiments that deformation comprises decreasing the size or changing the shape of the pores or voids within the absorbent or adsorbent material, and the parous material is elastically deformed on compression and returns to substantially it's original configuration after the cause for compression is removed.

In an embodiment of any of the above embodiments, the cover has a predetermined configuration, and the absorbent or adsorbent material is configured resist the cover being deformed to a different configuration. In some embodiments the shape of the mass of the absorbent or adsorbent material and shape of the passage defined by the support and cover are substantially the same.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material comprises at least one three dimensional matrix of intertwined threads, fibres, or shredded material between which there are voids.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material comprises one of cellulose acetate, air-laid paper, cotton based material, shredded paper, or cut rag tobacco, or a mixture of two or more of these materials.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material comprises one or more sensory substances, and at least one sensory substance is a substance that will enhance a consumer's sensory experience when the consumable is in use.

In an embodiment of any of the above embodiments, the aerosol generating material is adapted to generate vapour when heated to a first temperature, and the temperature at which at least one of the at least one sensory substances will start to enhance a consumer's sensory experience is lower than the first temperature.

In an embodiment of any of the above embodiments, the aerosol generating material is heated to cause vapour generation, and the absorbent or adsorbent material is spaced from locations on the support that are heated when the consumable is in use.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material comprises a plurality of surfaces that act as seed surfaces for the formation of aerosol from vapour generated by the aerosol generating material.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material is configured to absorb and retain one or both of water vapour and condensate.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material is configured to cause a pressure drop in one or more of a vapour, aerosol, or atmospheric gas, as the one or more of vapour, aerosol or atmospheric gas are sucked along the passage by a user.

In an embodiment of any of the above embodiments, the cover is formed of a material that is absorbent or adsorbent.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material and cover are formed from different materials.

In an embodiment of any of the above embodiments, the support comprises one of a metallic foil, a metallic film, or a plastics film.

In an embodiment of any of the above embodiments, the support comprises aluminium foil.

In an embodiment of any of the above embodiments, the support is a laminate material.

In an embodiment of any of the above embodiments, one or both of the support and cover are fixed to the porous material using a fixing means.

In an embodiment of any of the above embodiments, the fixing means comprises an adhesive.

In an embodiment of any of the above embodiments, the adhesive is an aerosol generating material slurry. The aerosol generating material slurry is sticky and forms an adhesive when it sets. This is advantageous because the components of the aerosol generating material are known and acceptable for use in the manufacture of consumables.

In an embodiment of any of the above embodiments, the fixing means comprises ultrasonic welding or stitching. Other methods of fixing can be used and fall within the scope of the present disclosure.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material is configured to define one or more flow paths through the absorbent or adsorbent material. The flow paths are dimensioned so as to allow sufficient flow of a gas and aerosol mixture to flow along the or each flow path for a user of the consumable to draw a puff of a desired volume within a desired period of time.

In an embodiment of any of the above embodiments, at least one flow path includes one or more narrowings or restrictions to the flow of a gas and aerosol mixture. The narrowings or restrictions cause a desired pressure drop along the flow path.

In an embodiment of any of the above embodiments, there are a plurality of flow paths and at least two of the flow paths are in fluid communication with each other. In some embodiments, the flow paths may form a network of interlinked flow paths.

In an embodiment of any of the above embodiments, at least part of at least one of the flow paths is partially defined by a surface of one or both of the support and the cover. In some embodiments at least one flow path is partially defined by the support and the cover.

In an embodiment of any of the above embodiments, at least part of at least one of the flow paths is partially defined by a surface of aerosol generating material supported on the surface of the support. In such embodiments the aerosol generating material is supported on the support. This is advantageous because the aerosol generating material releases aerosol directly into the flow path when it is heated.

In an embodiment of any of the above embodiments, the surface of the cover that faces the support supports one or more discrete portions of aerosol generating material.

In an embodiment of any of the above embodiments, at least part of at least one of the flow paths is partially defined by a surface of aerosol generating material supported on the cover.

In an embodiment of any of the above embodiments, at least one flow path includes at least one chamber that is dimensionally larger than flow paths adjacent to the chamber. Such chambers allow the build up of aerosol within the flow path before the user draws a puff.

In an embodiment of any of the above embodiments, at part of at least one chamber is defined by aerosol generating material. This maximises the amount of aerosol that may build up in the or each chamber.

In an embodiment of any of the above embodiments, the number of discrete portions of aerosol generating material on the support corresponds to the number of chambers, and the positioning of the discrete portions on the support and the chambers is such that each discrete portion is so located that it corresponds with a chamber.

In an embodiment of any of the above embodiments, the support and the cover both support a plurality of discrete portions of aerosol generating material, the absorbent or adsorbent material is configured to define one or more flow paths through the absorbent or adsorbent material, at least one flow path includes at least two chambers, each chamber is dimensionally larger than the flow paths adjacent to that chamber, and the discrete portions of aerosol generating material are arranged on the support and cover in an arrangement that matches the arrangement of the at least two chambers.

In an embodiment of any of the above embodiments, one of the flow paths has an end that opens through a portion of the absorbent or adsorbent material that is accessible to a user, and that end is adapted to engage with a mouthpiece, or comprises a mouthpiece. In some embodiments, the end of the flow path is at an edge of the consumable and an edge of the support and cover are either side of the absorbent or adsorbent material.

In an embodiment of any of the above embodiments, the support and cover are formed from a single item of a flexible sheet material. In such an embodiment the support and cover are continuous with each other.

In an embodiment of any of the above embodiments, the support and cover are joined to form a single item of a flexible sheet material. The joining may be by using an adhesive or other known joining means.

In an embodiment of any of the above embodiments, the single item of a flexible sheet material supports one or more discrete portions of aerosol generating material on one surface of the single item of a flexible sheet material.

In an embodiment of any of the above embodiments, the single item of a flexible sheet material supports at least four discrete portions of aerosol generating material, and the discrete portions of aerosol generating material are arranged in a regular pattern on the surface of the single item of a flexible sheet material. In some embodiments the regular pattern has discrete portions of aerosol generating material at the intersections of a rectangular grid.

In an embodiment of any of the above embodiments, the single item of a flexible sheet material is wrapped around a core formed from the absorbent or adsorbent material. In some embodiments the single item of a flexible sheet material is wrapped around the whole of a core.

In an embodiment of any of the above embodiments, the core is longitudinally extending, and the single item of a flexible sheet material is wrapped around some or all of the longitudinally extending surfaces of the core.

In an embodiment of any of the above embodiments, the aerosol generating material is between the core and the single item of a flexible sheet material.

In an embodiment of any of the above embodiments, the core is substantially cylindrical. In other embodiments the core may have cross section with is polygonal in shape, for example, but without limitation, triangular, rectangular, square, pentagonal, or hexagonal.

In an embodiment of any of the above embodiments, one face of the core not covered by the single item of a flexible sheet material is adapted to engage with a mouthpiece, or comprises a mouthpiece. In some examples the core is longitudinally extending and the face is one end of the core.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material comprises one of a porous material, a fibrous material, or a mixture of a porous and a fibrous material.

According to a third aspect of the present disclosure there is provided a method of making a consumable for use with a non-combustible aerosol provision device, in which the consumable comprises a support, aerosol generating material, a cover, and an absorbent or adsorbent material, in which the method comprises

    • providing a support on which aerosol generating material is supported,
    • attaching the cover to the support to at least partially define a passage along which one or more of a vapour, an aerosol and atmospheric gas, may travel, and
    • positioning the absorbent or adsorbent material in the passage,
    • in which the aerosol generating material is located on the support in a position that results in vapour generated by vaporisation of the aerosol generating material entering the passage.

According to a fourth aspect of the present disclosure there is provided a method of making a consumable for use with a non-combustible aerosol provision device, in which the consumable comprises a support, aerosol generating material, a cover, and an absorbent or adsorbent material, in which the method comprises

    • providing a support on which aerosol generating material is supported,
    • attaching the cover to the support to partially define a passage along which one or more of a vapour, an aerosol, and atmospheric gas, may travel,
    • in which the aerosol generating material is located on the support in a position that results in vapour generated by vaporisation of the aerosol generating material entering the passage, and
    • the absorbent or adsorbent material partially defines the passage and spaces the cover from the support.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material is selected to be resiliently deformable.

In an embodiment of any of the above embodiments, the cover is attached to the support followed by placing the absorbent or adsorbent material in the passage.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material is compressed before being placed in the passage. Once the absorbent or adsorbent material is in the passage the absorbent or adsorbent material will then expand due to is resilient nature.

In an embodiment of any of the above embodiments, placing the absorbent or adsorbent material in the passage comprises locating the absorbent or adsorbent material on the support followed by attaching the cover to the support so that the absorbent or adsorbent material is between the cover and the support.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material is configured to cause the cover to have a predetermined configuration when the absorbent or adsorbent material is positioned in the passage. That is, the cover is shaped around the absorbent or adsorbent material.

In an embodiment of any of the above embodiments, the cover has a predetermined configuration, and the absorbent or adsorbent material is configured resist the cover being deformed to a different configuration.

In an embodiment of any of the above embodiments, the cover is deformable and the absorbent or adsorbent material prevents the cover ceasing to be spaced from the support when the consumable is in use.

According to a fifth aspect of the present invention there is provided a method of making a consumable for use with a non-combustible aerosol provision device, in which the consumable comprises a support, aerosol generating material, a cover, and a body of absorbent or adsorbent material, in which the method comprises

    • providing a support on which aerosol generating material is supported;
    • one or more of fixing the support to the body of absorbent or adsorbent material using a fixing means, fixing the cover to the body of absorbent or adsorbent material using a fixing means, and fixing a portion of the support to a portion of the cover; in which the aerosol generating material located on the support is located between the support and the body of absorbent or adsorbent material.

According to a sixth aspect of the present disclosure there is provided a method of making a consumable for use with a non-combustible aerosol provision device, in which the consumable comprises a support, aerosol generating material, a cover, and a body of absorbent or adsorbent material, in which the method comprises

    • providing a support on which aerosol generating material is supported;
    • one or more of fixing the support to the body of absorbent or adsorbent material using a fixing means, fixing the cover to the body of absorbent or adsorbent material using a fixing means, and fixing a portion of the support to a portion of the cover;
    • in which the body of absorbent or adsorbent material at least partially defines a passage.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material is selected to cause a pressure drop to one or more of vapour, aerosol, or atmospheric gas, travelling through the passage as a result of a user sucking on the device in which the consumable is located when the consumable is in use. In some embodiments, the pressure drop is within a predetermined range.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material is configured to cause a pressure drop to one or more of vapour, aerosol, or atmospheric gas, travelling through the passage as a result of a user sucking on the device in which the consumable is located when the consumable is in use. In some embodiments, the pressure drop is within a predetermined range.

In an embodiment of any of the above embodiments, the method further comprises providing a support on which aerosol generating material is supported, and in which the aerosol generating material located on the cover is located between the cover and the body of absorbent or adsorbent material.

In an embodiment of any of the above embodiments, the method further comprises providing a cover on which aerosol generating material is supported, and in which the cover has a surface that faces the support, and the aerosol generating material located on the surface of the cover that faces the support.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material is selected to cause a pressure drop to one or more of vapour, aerosol, or atmospheric gas, travelling through the passage as a result of a user sucking on the device in which the consumable is located when the consumable is in use. In some embodiments, the pressure drop is within a predetermined range.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material comprises a plurality of separate masses, and each mass is located in the passage.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material is selected not to be substantially altered by the use of the consumable.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material comprises a unitary mass and the mass of absorbent or adsorbent material substantially fills the passage.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material comprises a three dimensional matrix of intertwined threads, fibres, or shredded material between which there are voids.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material comprises cellulose acetate, air-laid paper, cotton based material, shredded paper, or cut rag tobacco, or a mixture of two or more of these materials.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material comprises one or more sensory substances, and the sensory substances are substances that will enhance a consumer's sensory experience when the consumable is in use.

In an embodiment of any of the above embodiments, the aerosol generating material is adapted to be heated to a first temperature to cause vapour generation by the aerosol generating material, at least one of the sensory substances are selected to have a second temperature at which they will start to enhance a consumers sensory experience, and the second temperature is lower than the first temperature.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material is selected to comprises a plurality of surfaces that act as seed surfaces for the formation of aerosol from the vapour generated by the aerosol generating material.

In an embodiment of any of the above embodiments, the absorbent or adsorbent material is selected to comprise material which will absorb and retain one or both of water vapour and condensate.

Aerosol-generating material is a material that is capable of generating vapour or 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 flavours, 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 in the form of an aerosol-generating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

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

The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film.

The slurry may be heated to remove at least about 60 wt %, 70 wt %, 80 wt %, 85 wt % or 90 wt % of the solvent.

The aerosol-generating material may comprise or be an “amorphous solid”. In some embodiments, the aerosol-generating material comprises 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 50 wt %, 60 wt % or 70 wt % of amorphous solid, to about 90 wt %, 95 wt % or 100 wt % of amorphous solid.

The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free.

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the susceptor by resistive heating as a result of electric eddy currents. The susceptor may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the susceptor. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator.

The susceptor may comprise a ferromagnetic metal such as iron or an iron alloy such as steel or an iron nickel alloy. Some example ferromagnetic metals are a 400 series stainless steel such as grade 410 stainless steel, or grade 420 stainless steel, or grade 430 stainless steel, or stainless steel of similar grades. Alternatively, the susceptor may comprise a suitable non-magnetic, in particular paramagnetic, conductive material, such as aluminium. In a paramagnetic conductive material inductive heating occurs solely by resistive heating due to eddy currents. Alternatively, the susceptor may comprise a non-conductive ferrimagnetic material, such as a non-conductive ferrimagnetic ceramic. In that case, heat is only generated by hysteresis losses. The susceptor may comprise a commercial alloy like Phytherm 230 (with a composition (in % by weight=wt %) with 50 wt % Ni, 10 wt % Cr and the rest Fe) or Phytherm 260 (with a composition with 50 wt % Ni, 9 wt % Cr and the rest Fe).

In an embodiment of any of the above embodiments the aerosol-generating material comprises an active substance.

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, terpenes of non-cannabinoid origin, 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.

The active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

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

The active substance 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 Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens

In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

In some embodiments, the aerosol-generating material comprises a flavour or flavourant.

As used herein, the terms “flavour” and “flavourant” refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, Ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.

In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

The aerosol generating material comprises an aerosol generating agent. In some embodiments the aerosol generating agent may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol generating agent 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 particular examples, the aerosol generating agent comprises glycerol.

In some embodiments, the aerosol generating agent comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and/or aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

In some embodiments, the aerosol generating material may comprise from about 0.1 wt %, 0.5 wt %, 1 wt %, 3 wt %, 5 wt %, 7 wt % or 10% to about 50 wt %, 45 wt %, 40 wt %, 35 wt %, 30 wt % or 25 wt % of an aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticiser. For example, the aerosol generating material may comprise 0.5-40 wt %, 3-35 wt % or 10-25 wt % of an aerosol generating agent.

In some embodiments, the aerosol generating material may comprise from about 5 wt %, 10 wt %, 20 wt %, 25 wt %, 27 wt % or 30 wt % to about 60 wt %, 55 wt %, 50 wt %, 45 wt %, 40 wt %, or 35 wt % of an aerosol generating agent (DWB). For example, the aerosol generating material may comprise 10-60 wt %, 20-50 wt %, 25-40 wt % or 30-35 wt % of an aerosol generating agent.

In some embodiments, the aerosol generating material may comprise up to about 80 wt %, such as about 40 to 80 wt %, 40 to 75 wt %, 50 to 70 wt %, or 55 to 65 wt % of an aerosol generating agent (DWB).

The aerosol generating material may also comprise a gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent 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 gelling agent 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 gelling agent 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 gelling agent comprises one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum and mixtures thereof.

In some embodiments, the cellulosic gelling agent is selected from the group consisting of: hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP) and combinations thereof.

In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose, guar gum, or acacia gum.

In some embodiments, the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum Arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In preferred embodiments, the non-cellulose based gelling agent is alginate or agar.

In some embodiments, the gelling agent comprises alginate, and the alginate is present in the aerosol generating material in an amount of from 10-30 wt % of the aerosol generating material (calculated on a dry weight basis). In some embodiments, alginate is the only gelling agent present in the aerosol generating material. In other embodiments, the gelling agent comprises alginate and at least one further gelling agent, such as pectin.

In some embodiments, the aerosol generating material comprises from about 1 wt %, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 60 wt %, 50 wt %, 45 wt %, 40 wt % or 35 wt % of a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 1-50 wt %, 5-45 wt %, 10-40 wt % or 20-35 wt % of a gelling agent.

In some embodiments, the aerosol generating material comprises from about 20 wt % 22 wt %, 24 wt % or 25 wt % to about 30 wt %, 32 wt % or 35 wt % of a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 20-35 wt % or 25-30 wt % of a gelling agent.

In some cases, the aerosol generating material may comprise from about 1 wt %, 5 wt %, 10 wt %, 15 wt % or 20 wt % to about 60 wt %, 50 wt %, 40 wt %, 30 wt % or 25 wt % of a gelling agent (DWB). For example, the aerosol generating material may comprise 10-40 wt %, 15-30 wt % or 20-25 wt % of a gelling agent (DWB).

In examples, the aerosol generating material comprises gelling agent and filler, taken together, in an amount of from about 10 wt %, 20 wt %, 25 wt %, 30 wt %, or 35 wt % to about 60 wt %, 55 wt %, 50 wt %, or 45 wt % of the aerosol generating material. In examples, the aerosol generating material comprises gelling agent and filler, taken together, in an amount of from about 20 to 60 wt %, 25 to 55 wt %, 30 to 50 wt %, or 35 to 45 wt % of the aerosol generating material.

In examples, the aerosol generating material comprises gelling agent (i.e. without taking into account the amount of filler) in an amount of from about 5 wt %, 10 wt %, 15 wt %, 20 wt %, 25 wt %, 30 wt %, or 35 wt % to about 60 wt %, 55 wt %, 50 wt %, or 45 wt % of the aerosol generating material. In examples, the aerosol generating material comprises gelling agent (i.e. without taking into account the amount of filler) in an amount of from about 5 to 60 wt %, 20 to 60 wt %, 25 to 55 wt %, 30 to 50 wt %, or 35 to 45 wt % of the aerosol generating material.

In some examples, alginate is comprised in the gelling agent in an amount of from about 5 to 40 wt % of the aerosol generating material, or 15 to 40 wt %. That is, the aerosol generating material comprises alginate in an amount of about 5 to 40 wt % by dry weight of the aerosol generating material, or 15 to 40 wt %. In some examples, the aerosol generating material comprises alginate in an amount of from about 20 to 40 wt %, or about 15 wt % to 35 wt % of the aerosol generating material.

In some examples, pectin is comprised in the gelling agent in an amount of from about 3 to 15 wt % of the aerosol generating material. That is, the aerosol generating material comprises pectin in an amount of from about 3 to 15 wt % by dry weight of the aerosol generating material. In some examples, the aerosol generating material comprises pectin in an amount of from about 5 to 10 wt % of the aerosol generating material.

In some examples, guar gum is comprised in the gelling agent in an amount of from about 3 to 40 wt % of the aerosol generating material. That is, the aerosol generating material comprises guar gum in an amount of from about 3 to 40 wt % by dry weight of the aerosol generating material. In some examples, the aerosol generating material comprises guar gum in an amount of from about 5 to 10 wt % of the aerosol generating material. In some examples, the aerosol generating material comprises guar gum in an amount of from about 15 to 40 wt % of the aerosol generating material, or from about 20 to 40 wt %, or from about 15 to 35 wt %.

In examples, the alginate is present in an amount of at least about 50 wt % of the gelling agent. In examples, the aerosol generating material comprises alginate and pectin, and the ratio of the alginate to the pectin is from 1:1 to 10:1. The ratio of the alginate to the pectin is typically >1:1, i.e. the alginate is present in an amount greater than the amount of pectin. In examples, the ratio of alginate to pectin is from about 2:1 to 8:1, or about 3:1 to 6:1, or is approximately 4:1.

The aerosol generating material may be formed by (a) forming a slurry comprising components of the aerosol generating material or precursors thereof, (b) forming a layer of the slurry, (c) setting the slurry to form a gel, and (d) drying to form an aerosol generating material.

The (b) forming a layer of the slurry typically comprises spraying, casting or extruding the slurry. In examples, the slurry layer is formed by electrospraying the slurry. In examples, the slurry layer is formed by casting the slurry.

In some examples, (b) and/or (c) and/or (d), at least partially, occur simultaneously (for example, during electrospraying). In some examples, (b), (c) and (d) occur sequentially.

In some examples, the slurry is applied to a support. The layer may be formed on a support.

In examples, the slurry comprises gelling agent, aerosol-former material and active substance. The slurry may comprise these components in any of the proportions given herein in relation to the composition of the aerosol generating material. For example, the slurry may comprise (on a dry weight basis):

    • gelling agent and, optionally, filler, wherein the amount of gelling agent and filler taken together is about 10 to 60 wt % of the slurry;
    • aerosol-former material in an amount of about 40 to 80 wt % of the slurry;
    • and
    • optionally, active substance in an amount of up to about 20 wt % of the slurry.

The setting the gel (c) may comprise supplying a setting agent to the slurry. For example, the slurry may comprise sodium, potassium or ammonium alginate as a gel-precursor, and a setting agent comprising a calcium source (such as calcium chloride), may be added to the slurry to form a calcium alginate gel.

In examples, the setting agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the setting agent comprises or consists of calcium formate and/or calcium lactate. In particular examples, the setting agent comprises or consists of calcium formate. The inventors have identified that, typically, employing calcium formate as a setting agent results in an aerosol generating material having a greater tensile strength and greater resistance to elongation.

The total amount of the setting agent, such as a calcium source, may be 0.5-5 wt % (calculated on a dry weight basis). Suitably, the total amount may be from about 1 wt %, 2.5 wt % or 4 wt % to about 4.8 wt % or 4.5 wt %. The inventors have found that the addition of too little setting agent may result in an aerosol generating material which does not stabilise the aerosol generating material components and results in these components dropping out of the aerosol generating material. The inventors have found that the addition of too much setting agent results in an aerosol generating material that is very tacky and consequently has poor handleability.

When the aerosol generating material does not contain tobacco, a higher amount of setting agent may need to be applied. In some cases the total amount of setting agent may therefore be from 0.5-12 wt % such as 5-10 wt %, calculated on a dry weight basis. Suitably, the total amount may be from about 5 wt %, 6 wt % or 7 wt % to about 12 wt % or 10 wt %. In this case the aerosol generating material will not generally contain any tobacco.

In examples, supplying the setting agent to the slurry comprises spraying the setting agent on the slurry, such as a top surface of the slurry.

Alginate salts are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic (M) and α-L-guluronic acid (G) units (blocks) linked together with (1,4)-glycosidic bonds to form a polysaccharide. On addition of calcium cations, the alginate crosslinks to form a gel. It has been found that alginate salts with a high G monomer content more readily form a gel on addition of the calcium source. In some cases therefore, the gel-precursor may comprise an alginate salt in which at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginate copolymer are α-L-guluronic acid (G) units.

In examples, the drying (d) removes from about 50 wt %, 60 wt %, 70 wt %, 80 wt % or 90 wt % to about 80 wt %, 90 wt % or 95 wt % (WWB) of water in the slurry. In examples, the drying (d) reduces the cast material thickness by at least 80%, suitably 85% or 87%. For instance, the slurry is cast at a thickness of 2 mm, and the resulting dried aerosol generating material has a thickness of 0.2 mm.

In some examples, the slurry solvent consists essentially of or consists of water. In some examples, the slurry comprises from about 50 wt %, 60 wt %, 70 wt %, 80 wt % or 90 wt % of solvent (WWB).

In examples where the solvent consists of water, the dry weight content of the slurry may match the dry weight content of the aerosol generating material. Thus, the discussion herein relating to the solid composition is explicitly disclosed in combination with the slurry aspect of the invention.

The aerosol generating material may comprises a flavour. Suitably, the aerosol generating material may comprise up to about 80 wt %, 70 wt %, 60 wt %, 55 wt %, 50 wt % or 45 wt % of a flavour. In some cases, the aerosol generating material may comprise at least about 0.1 wt %, 1 wt %, 10 wt %, 20 wt %, 30 wt %, 35 wt % or 40 wt % of a flavour (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 1-80 wt %, 10-80 wt %, 20-70 wt %, 30-60 wt %, 35-55 wt % or 30-45 wt % of a flavour. In some cases, the flavour comprises, consists essentially of or consists of menthol.

The aerosol generating material may comprise a filler.

In some embodiments, the aerosol generating material comprises less than 60 wt % of a filler, such as from 1 wt % to 60 wt %, or 5 wt % to 50 wt %, or 5 wt % to 30 wt %, or 10 wt % to 20 wt %.

In other embodiments, the aerosol generating material comprises less than 20 wt %, suitably less than 10 wt % or less than 5 wt % of a filler. In some cases, the aerosol generating material comprises less than 1 wt % of a filler, and in some cases, comprises no filler.

In some such cases the aerosol generating material comprises at least 1 wt % of the filler, for example, at least 5 wt %, at least 10 wt %, at least 20 wt % at least 30 wt %, at least 40 wt %, or at least 50 wt % of the filler. In some embodiments, the aerosol generating material comprises 5-25 wt % of the filler.

The filler, if present, may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)). In particular cases, the aerosol generating material comprises no calcium carbonate such as chalk.

In particular embodiments which include filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)).

Without wishing to be bound by theory, it is believed that including fibrous filler in an aerosol generating material may increase the tensile strength of the material. This may be particularly advantageous in examples wherein the aerosol generating material is provided as a sheet, such as when an aerosol generating material sheet circumscribes a rod of aerosolisable material.

In some embodiments, the aerosol generating material does not comprise tobacco fibres. In particular embodiments, the aerosol generating material does not comprise fibrous material.

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

In some embodiments, the aerosol generating material additionally comprises an active substance. For example, in some cases, the aerosol generating material additionally comprises a tobacco material and/or nicotine. In some embodiments, the aerosol generating material comprises powdered tobacco and/or nicotine and/or a tobacco extract.

In some cases, the aerosol generating material may comprise 5-60 wt % (calculated on a dry weight basis) of a tobacco material and/or nicotine. In some cases, the aerosol generating material may comprise from about 1 wt %, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 70 wt %, 60 wt %, 50 wt %, 45 wt %, 40 wt %, 35 wt %, or 30 wt % (calculated on a dry weight basis) of an active substance. In some cases, the aerosol generating material may comprise from about 1 wt %, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 70 wt %, 60 wt %, 50 wt %, 45 wt %, 40 wt %, 35 wt %, or 30 wt % (calculated on a dry weight basis) of a tobacco material. For example, the aerosol generating material may comprise 10-50 wt %, 15-40 wt % or 20-35 wt % of a tobacco material. In some cases, the aerosol generating material may comprise from about 1 wt %, 2 wt %, 3 wt % or 4 wt % to about 20 wt %, 18 wt %, 15 wt % or 12 wt % (calculated on a dry weight basis) of nicotine. For example, the aerosol generating material may comprise 1-20 wt %, 2-18 wt % or 3-12 wt % of nicotine.

In some cases, the aerosol generating material comprises an active substance such as tobacco extract. In some cases, the aerosol generating material may comprise 5-60 wt % (calculated on a dry weight basis) of tobacco extract. In some cases, the aerosol generating material may comprise from about 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 60 wt %, 50 wt %, 45 wt %, 40 wt %, 35 wt %, or 30 wt % (calculated on a dry weight basis) tobacco extract. For example, the aerosol generating material may comprise 10-50 wt %, 15-40 wt % or 20-35 wt % of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the aerosol generating material comprises 1 wt % 1.5 wt %, 2 wt % or 2.5 wt % to about 6 wt %, 5 wt %, 4.5 wt % or 4 wt % (calculated on a dry weight basis) of nicotine. In some cases, there may be no nicotine in the aerosol generating material other than that which results from the tobacco extract.

In some embodiments the aerosol generating material comprises no tobacco material but does comprise nicotine. In some such cases, the aerosol generating material may comprise from about 1 wt %, 2 wt %, 3 wt % or 4 wt % to about 20 wt %, 18 wt %, 15 wt % or 12 wt % (calculated on a dry weight basis) of nicotine. For example, the aerosol generating material may comprise 1-20 wt %, 2-18 wt % or 3-12 wt % of nicotine.

In some cases, the total content of active substance and/or flavour may be at least about 0.1 wt %, 1 wt %, 5 wt %, 10 wt %, 20 wt %, 25 wt % or 30 wt %. In some cases, the total content of active substance and/or flavour may be less than about 90 wt %, 80 wt %, 70 wt %, 60 wt %, 50 wt % or 40 wt % (all calculated on a dry weight basis). In some cases, the total content of tobacco material, nicotine and flavour may be at least about 0.1 wt %, 1 wt %, 5 wt %, 10 wt %, 20 wt %, 25 wt % or 30 wt %. In some cases, the total content of active substance and/or flavour may be less than about 90 wt %, 80 wt %, 70 wt %, 60 wt %, 50 wt % or 40 wt % (all calculated on a dry weight basis).

The aerosol-generating composition may comprise one or more active substances. In examples, the aerosol generating material comprises one or more active substances, e.g. up to about 20 wt % of the aerosol generating material. In examples, the aerosol generating material comprises active substance in an amount of from about 1 wt %, 5 wt %, 10 wt %, or 15 wt % to about 20 wt %, 15 wt %, 15 wt % or 5 wt % of the aerosol generating material.

The active substance may comprise a physiologically and/or olfactory active substance which is included in the aerosol-generating composition in order to achieve a physiological and/or olfactory response.

Tobacco material may be present in the aerosol-generating composition in an amount of from about 50 to 95 wt %, or about 60 to 90 wt %, or about 70 to 90 wt %, or about 75 to 85 wt %.

The tobacco material may be present in any format, but is typically fine-cut (e.g. cut into narrow shreds). Fine-cut tobacco material may advantageously be blended with the aerosol generating material to provide an aerosol-generating composition which has an even dispersion of tobacco material and aerosol generating material throughout the aerosol-generating composition.

In examples, the tobacco material comprises one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract. Surprisingly, the inventors have identified that it is possible to use a relatively large amount of lamina tobacco in the aerosol-generating composition and still provide an acceptable aerosol when heated by a non-combustible aerosol provision system. Lamina tobacco typically provides superior sensory characteristics. In examples, the tobacco material comprises lamina tobacco in an amount of at least about 50 wt %, 60 wt %, 70 wt %, 80 wt %, 85 wt %, 90 wt %, or 95 wt % of the tobacco material. In particular examples, the tobacco material comprises cut tobacco in an amount of at least about 50 wt %, 60 wt %, 70 wt %, 80 wt %, 85 wt %, 90 wt %, or 95 wt % of the tobacco material.

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.

In some embodiments the one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

In some cases, the aerosol generating material may additionally comprise an emulsifying agent, which emulsified molten flavour during manufacture. For example, the aerosol generating material may comprise from about 5 wt % to about 15 wt % of an emulsifying agent (calculated on a dry weight basis), suitably about 10 wt %. The emulsifying agent may comprise acacia gum.

In some embodiments, the aerosol generating material is a hydrogel and comprises less than about 20 wt % of water calculated on a wet weight basis. In some cases, the hydrogel may comprise less than about 15 wt %, 12 wt % or 10 wt % of water calculated on a wet weight basis. In some cases, the hydrogel may comprise at least about 1 wt %, 2 wt % or at least about 5 wt % of water (WWB).

The aerosol generating material may have any suitable water content, such as from 1 wt % to 15 wt %. Suitably, the water content of the aerosol generating material is from about 5 wt %, 7 wt % or 9 wt % to about 15 wt %, 13 wt % or 11 wt % (WWB), most suitably about 10 wt %. The water content of the aerosol generating material may, for example, be determined by Karl-Fischer-titration or Gas Chromatography with Thermal Conductivity Detector (GC-TCD).

In some cases, the aerosol generating material may consist essentially of, or consist of a gelling agent, water, an aerosol generating agent, a flavour, and optionally an active substance.

In some cases, the aerosol generating material may consist essentially of, or consist of a gelling agent, water, an aerosol generating agent, a flavour, and optionally a tobacco material and/or a nicotine source.

In examples, the aerosol generating material consists essentially of, or consists of a gelling agent, aerosol generating agent, active substance, and water. In examples, the aerosol generating material consists essentially of, or consists of a gelling agent, aerosol generating agent, and water.

In examples, the aerosol generating material does not comprise a flavourant; in particular examples, the aerosol generating material does not comprise an active substance.

In some embodiments the aerosol generating material comprises an aerosol generating material, the aerosol generating material comprising:

    • 1-60 wt % of a gelling agent;
    • 0.1-50 wt % of an aerosol generating agent; and
    • 0.1-80 wt % of a flavour;
      wherein these weights are calculated on a dry weight basis

In some embodiments, the aerosol generating material comprises 1-80 wt % of a flavour (dry weight basis).

In some embodiments, the aerosol generating material comprising:

    • 1-50 wt % of a gelling agent;
    • 0.1-50 wt % of an aerosol generating agent; and
    • 30-60 wt % of a flavour;
      wherein these weights are calculated on a dry weight basis.

In alternative embodiments of the aerosol generating material, the aerosol generating material comprises an aerosol generating material, the aerosol generating material comprising:

    • 1-60 wt % of a gelling agent;
    • 5-60 wt % of an aerosol generating agent; and
    • 10-60 wt % of a tobacco extract;
      wherein these weights are calculated on a dry weight basis.

In some embodiments, the aerosol generating material comprises:

    • 1-60 wt % of a gelling agent;
    • 20-60 wt % of an aerosol generating agent; and
    • 10-60 wt % of a tobacco extract;
      wherein these weights are calculated on a dry weight basis.

In some embodiments, the aerosol generating material comprises 20-35 wt % of the gelling agent; 10-25 wt % of the aerosol-former material; 5-25 wt % of the filler comprising fibres; and 35-50 wt % of the flavourant and/or active substance. In some cases, the aerosol generating material may consist essentially of, or consist of a gelling agent, an aerosol generating agent a tobacco extract, water, and optionally a flavour. In some cases, the aerosol generating material may consist essentially of, or consist of glycerol, alginates and/or pectins, a tobacco extract and water.

In some embodiments, the aerosol generating material may have the following composition (DWB): gelling agent (preferably comprising alginate) in an amount of from about 5 wt % to about 40 wt %, or about 10 wt % to 30 wt %, or about 15 wt % to about 25 wt %; tobacco extract in an amount of from about 30 wt % to about 60 wt %, or from about 40 wt % to 55 wt %, or from about 45 wt % to about 50 wt %; aerosol generating agent (preferably comprising glycerol) in an amount of from about 10 wt % to about 50 wt %, or from about 20 wt % to about 40 wt %, or from about 25 wt % to about 35 wt % (DWB).

In one embodiment, the aerosol generating material comprises about 20 wt % alginate gelling agent, about 48 wt % Virginia tobacco extract and about 32 wt % glycerol (DWB).

The “thickness” of the aerosol generating material describes the shortest distance between a first surface and a second surface. In embodiments where the aerosol generating material is in the form of a sheet, the thickness of the aerosol generating material is the shortest distance between a first planar surface of the sheet and a second planar surface of the sheet which opposes the first planar surface of the sheet.

In some cases, the aerosol-forming aerosol generating material layer has a thickness of about 0.015 mm to about 1.5 mm, suitably about 0.05 mm to about 1.5 mm or 0.05 mm to about 1.0 mm. Suitably, the thickness may be in the range of from about 0.1 mm or 0.15 mm to about 1.0 mm, 0.5 mm or 0.3 mm.

In some cases, the aerosol generating material may have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

A material having a thickness of 0.2 mm is particularly suitable. The aerosol generating material may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.

It has been found that if the aerosol-generating material is too thick, then heating efficiency is compromised. This adversely affects the power consumption in use. Conversely, if the aerosol-generating material is too thin, it is difficult to manufacture and handle; a very thin material is harder to cast and may be fragile, compromising aerosol formation in use.

The thickness stipulated herein is a mean thickness for the material. In some cases, the aerosol generating material thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%.

In some examples, the aerosol generating material in sheet form may have a tensile strength of from around 200 N/m to around 900 N/m. In some examples, such as where the aerosol generating material does not comprise a filler, the aerosol generating material may have a tensile strength of from 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m.

Such tensile strengths may be particularly suitable for embodiments wherein the aerosol generating material is formed as a sheet and then shredded and incorporated into an aerosol generating article. In some examples, such as where the aerosol generating material comprises a filler, the aerosol generating material may have a tensile strength of from 600 N/m to 900 N/m, or from 700 N/m to 900 N/m, or around 800 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosol generating material is included in an aerosol generating article/assembly as a rolled sheet, suitably in the form of a tube.

In some examples, the aerosol generating material in sheet form may have a tensile strength of from around 200 N/m to around 2600 N/m. In some examples, the aerosol generating material may have a tensile strength of from 600 N/m to 2000 N/m, or from 700 N/m to 1500 N/m, or around 1000 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosol-generating material comprising the aerosol generating material is formed and incorporated into an aerosol-generating consumable as a sheet.

The aerosol generating material comprising the aerosol generating material may have any suitable area density, such as from 30 g/m2 to 350 g/m2. In some cases, the sheet may have a mass per unit area of 50-250 g/m2, or from about 70 to 210 g/m2, or from about 90 to 190 g/m2, or suitably about 100 g/m2 (so that it has a similar density to cut rag tobacco and a mixture of these substances will not readily separate). In some cases, the sheet may have a mass per unit area of about 30 to 70 g/m2, 40 to 60 g/m2, or 25-60 g/m2 and may be used to wrap an aerosolisable material such as tobacco.

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.

As used herein, the term “sheet” denotes an element having a width and length substantially greater than a thickness thereof. A major surface of the sheet is a surface which extends in both width and length dimensions when the sheet is flat. The sheet may be a strip, for example.

The aerosol generating material may comprise a colourant. The addition of a colourant may alter the visual appearance of the aerosol generating material. The presence of colourant in the aerosol generating material may enhance the visual appearance of the aerosol generating material and the aerosol-generating material. By adding a colourant to the aerosol generating material, the aerosol generating material may be colour-matched to other components of the aerosol-generating material or to other components of an article comprising the aerosol generating material.

A variety of colourants may be used depending on the desired colour of the aerosol generating material. The colour of aerosol generating material may be, for example, white, green, red, purple, blue, brown or black. Other colours are also envisaged. Natural or synthetic colourants, such as natural or synthetic dyes, food-grade colourants and pharmaceutical-grade colourants may be used. In certain embodiments, the colourant is caramel, which may confer the aerosol generating material with a brown appearance. In such embodiments, the colour of the aerosol generating material may be similar to the colour of other components (such as tobacco material). In some embodiments, the addition of a colourant to the aerosol generating material renders it visually indistinguishable from other components in the aerosol-generating material.

The colourant may be incorporated during the formation of the aerosol generating material (e.g. when forming a slurry comprising the materials that form the aerosol generating material) or it may be applied to the aerosol generating material after its formation (e.g. by spraying it onto the aerosol generating material).

In some embodiments of any of the above embodiments, talcum powder, calcium carbonate powder or other powder is applied to the exposed surface of at least one discrete portion of aerosol-generating material. This may reduce the level of tackiness or adhesion of the aerosol-generating material.

In the following discussions of the accompanying drawings, where the same element is present in a more than one embodiment the same reference numeral is used for that element throughout, where there are similar elements similar reference numerals (the same numeral plus a multiple of 100) are used.

With reference to FIGS. 1 to 3, a consumable 2 comprises a support 4 with a first surface 6. On first surface 6 are supported a plurality of discrete portions 8 of aerosol generating material. The discrete portions 8 of aerosol generating material are located on the first surface 6 in a grid pattern. The number of discrete portions 8 and their positioning on the first surface 6 of the support 4 are exemplary and different (non-zero) numbers of discrete portions 8 and different layouts of those discrete portions 8 fall within the scope of the present disclosure.

Overlying the discrete portions 8 of aerosol generating material and a portion of the first surface 6 is an absorbent or adsorbent material 10. Overlying the remainder of the first surface 6 and the absorbent or adsorbent material 10 is a cover 12.

The support 4 is a laminate material having a first layer 14 formed from aluminium foil, and a second layer 16 formed from paper. The surface of first layer 14 that faces away from layer 16 of the support 4 is first surface 6 of the support 4. The support 4 being a laminate of layers 14 and 16 results in a support that is sufficiently stiff to be self supporting and to be handleable without damage. In an unillustrated embodiment of the consumable 2 the support 4 is formed from a layer of aluminium foil only. In such an embodiment the cover 12 and absorbent or adsorbent material 10 provide support 4 with the required level of stiffness.

The discrete portions 8 of the aerosol generating material are applied to the first surface 6 of the support 4 in any appropriate fashion, for example by application as a aerosol generating material slurry which subsequently sets.

The cover 12 is formed of a sheet material and includes fold lines 18 and 20 as shown in FIG. 3. The fold lines 18, 20 allow the cover 12 to be configured so as to include a pair of contact panels 22, a pair of leg panels 24, and a main panel 26. The contact panels are adapted to be adhered to portions of the first surface 6 of the support 4 using an adhesive (not shown). The contact panels are so dimensioned, and the discrete portions 8 of aerosol generating material so positioned, that when one or more of the discrete portions 8 are heated, for example as a result of inductive heating causing the aluminium foil overlain by at least one discrete portion 8 to heat up, the vapour emitted from the aerosol generating material is emitted into the passage. That vapour enters the absorbent or adsorbent material 10.

The leg panels 24 serve to hold the main panel 26 of the cover 12 at a distance from and substantially parallel to the first surface 6 of the support 4. The leg panels 24 and main panel 26 of cover 12 and the first surface 6 of support 4 together define a passage between them. As illustrated in FIGS. 1 to 3, that passage is filed or at least substantially filled with the absorbent or adsorbent material 10. The absorbent or adsorbent material 10 has the effect that there is a pressure loss as vapour, aerosol or air or a mixture thereof are drawn along the passage by a user (as a result of the user sucking the device) when the consumable 2 is in use.

The absorbent or adsorbent material 10 is a mass of an absorbent or adsorbent material, the material having a surface that causes vapour emitted by one or more of the discrete portions 8 to seed and thus causes the vapour to transition to an aerosol. The absorbent or adsorbent material 10 may, for example and without limitation, be formed from one of cellulose acetate, air-laid paper, cotton based material, shredded paper, or cut rag tobacco, or a mixture of two or more of these materials. Those materials may be in the form of a matrix of intertwined longitudinally extending elements of those materials. Those elements may be threads, fibres, or shreds.

The absorbent or adsorbent material 10 will also absorb or adsorb any condensate that forms within the passage.

The material of which the cover 12 is formed is sufficiently thin that the cover 12 is readily deformable if, for example, the main panel 26 of the cover 12 is subject to a force towards the support 4. The absorbent or adsorbent material 10 prevents the cover ceasing to be spaced from the support. This spacing is maintained both before use of the consumable 2 and when the consumable 2 is in use.

The absorbent or adsorbent material 10 is not substantially altered by the use of the consumable 2 because the absorbent or adsorbent material 10 is substantially unaffected by the temperature to which the discrete portions 8 of aerosol generating material are heated to generate vapour.

In some unillustrated embodiments of the present disclosure the absorbent or adsorbent material 10 is formed from two or more separate portions of absorbent or adsorbent material. In such embodiments the separate portions of material may be different absorbent or adsorbent materials. The separate portions of absorbent or adsorbent material 10 do, however, collectively fill or substantially fill the passage.

The absorbent or adsorbent material 10 is resiliently deformable. That deformation may comprise decreasing the size or changing the shape of the pores or voids within the absorbent or adsorbent material 10, and the parous material 10 being elastically deformed on compression and returning to substantially it's original configuration after the cause for compression is removed.

The absorbent or adsorbent material 10 may further comprise one or more sensory substances, and at least one sensory substance is a substance (not illustrated) that will enhance a consumer's sensory experience when the consumable is in use. At least one of the at least one sensory substance will start to enhance a consumer's sensory experience at a temperature X degrees centigrade. The temperature X is lower than the temperature Y degrees centigrade at which one or more of the discrete portions 8 of aerosol generating material start to vaporise.

In some, non-illustrated embodiments of the present disclosure, the absorbent or adsorbent material 10 is so configured, for example by the inclusion of recesses in the surface of the absorbent or adsorbent material 10 adjacent to the discrete portions 8 of aerosol generating material, that the absorbent or adsorbent material 10 is spaced from the discrete portions 8. This has the effect of lessening the heating of the absorbent or adsorbent material 10 when the consumable is in use.

A method of making a consumable 2 as described above starts with the provision of a support 4. One or more discrete portions 8 of aerosol generating material are applied to a first surface 6 of the support as an aerosol generating material slurry using an appropriate application technique. The aerosol generating material slurry is then allowed to or caused to set.

Next, a cover 12 is formed by folding the cover 12 around the fold lines 18, 20. Adhesive is applied to the surfaces of contact panels 22, that will be in contact with the first face 6 of the support 4. The adhesive coated faces of the contact panels 22 are pressed against the first surface 6 and a passage is formed between the support 4 and the cover 12. The discrete portions 8 of aerosol generating material are on the portion of the first surface 6 of the support 4 that defines the passage. Next, the absorbent or adsorbent material 10 is compressed and then fed into the passage. The absorbent or adsorbent material 10 subsequently expands and fills the passage.

The consumable 2 is now ready for use.

In an alternative method of making the consumable 2, the method starts with the provision of a support 4. One or more discrete portions 8 of aerosol generating material are applied to a first surface 6 of the support as an aerosol generating material slurry using an appropriate application technique. The aerosol generating material slurry is then allowed to or caused to set.

Next, an element of absorbent or adsorbent material 10 of a predetermined shape and size is placed over the over the discrete portions 8 of aerosol generating material and a portion of the first surface 6 of the support 4.

A cover 12 is next formed by folding the cover 12 around the fold lines 18, 20 and adhesive is applied to the surfaces of contact panels 22, that will be in contact with the first face 6 of the support 4. The cover 12 is then placed over the absorbent or adsorbent material 10 and the adhesive coated faces of the contact panels 22 pressed against the first surface 6. This forms a passage between the support 4 and the cover 12 which is filled by the absorbent or adsorbent material 10.

The consumable 2 is now ready for use.

With reference to FIGS. 4, 5 and 6, a consumable 102 comprises a support 104 with a first surface 106 and a cover 112 which has a first surface 128. On the first surface 106 of the support 104 are supported a plurality of discrete portions 108 of aerosol generating material. The discrete portions 108 of aerosol generating material are located on the first surface 106 in a repeating pattern.

The first surface 128 of the cover 112 faces towards the support 104. Supported on the first surface 128 of the cover 112 are a plurality of discrete portions of aerosol generating material (not shown). The discrete portions of aerosol generating material on the first surface 128 are equal in number to the discrete portions 108 on the first surface 106 and they are located on the first surface 128 in the same repeating pattern.

The number of discrete portions of aerosol generating material and their positioning on the first surface 106 of the support 104 and first surface 128 of the support 112 are exemplary and different (non-zero) numbers of discrete portions of aerosol generating material and different layouts of those discrete portions fall within the scope of the present disclosure.

Located between the support 104 and cover 112 is an absorbent or adsorbent material 110. The absorbent or adsorbent material 110 partially defines first, second and third flow paths 130, 132, 134. The remainder of those flow paths is defined by the support 106/portions 108 of aerosol generating material and cover 112/the portions of aerosol generating material supported thereon.

The absorbent or adsorbent material 110 includes a main body 146 and a mouthpiece 148. The main body 146 includes the first and third flow paths 130, 134, and a portion of the second flow path 132. The remainder of the second flow path 132 is wholly defined by the mouthpiece 148 and terminates at the mouth 150 in a portion of the mouthpiece 148 most remote from the main body 146.

Each of the first and third flow paths 130, 134 include three chambers 152 (for clarity not all of the chambers 152 are labelled), and the second flow path 132 includes four chambers 152. The chambers are connected by channels 154 (again, for clarity not all of the channels 154 are labelled), and at the ends of each flow path there are first and second end channels 156, 158. The first end channel mouths out of the edge of the absorbent or adsorbent material 110 adjacent the mouthpiece 148 for the first and third flow paths 130, 134 and through the mouth 156 for the second flow path 132. The second end channels 158 all mouth through the edge of the absorbent or adsorbent material 110 furthest from the mouthpiece 148.

As may be seen in FIG. 5, the first, second and third flow paths 130, 132, 134 include narrowings 160 (for clarity not all of the chambers 152 are labelled) which restrict the flow of gas/aerosol along the flow paths 130, 132, 134.

With reference to FIG. 6, when the consumable 102 is placed in a heating chamber 138 of an aerosol provision device 140, the consumable is in sliding contact with side walls 142 of the heating chamber 138. The heating chamber 138 has a dimension longer in the direction D than the main portion 146 of the absorbent or adsorbent material 110 and a void 144 between the consumable 102 and the end wall 162 of the heating chamber 138 remains when the consumable is inserted to the position shown in FIG. 6. A stop 162 prevents the consumable being inserted any further into the heating chamber 138. The void 144 fluidly connects the second channel ends 158 and completes a composite flow path from the mouths of the first end channels 156 of the first and third flow paths 130, 134, along the first and third flow paths 130, 134, through the void 144, along the second flow path 132, through the first channel end 156 of the second flow path 132 and out through the mouth 150.

The chambers 152 are so located that the surfaces that define the chambers 152 that are not formed by the absorbent or adsorbent material 110 are wholly or partially formed by aerosol generating material portions 108 and the aerosol generating material portions supported by the cover 112.

When the consumable 102 is in use, one or more of the aerosol generating material portions 108 and the aerosol generating material portions supported by the cover 112 are heated to cause the generation of vapour which will transition to aerosol. That vapour/aerosol will build up mainly in the chambers 152 and the channels 154. A user drawing on the mouthpiece 148 will cause the flow of atmospheric gas to flow into the mouths of the first end channels 156 of the first and third flow paths 130, 134, along the first and third flow paths 130, 134, through the void 144, along the second flow path 132, through the first channel end 156 of the second flow path 132 and out through the mouth 150. The atmospheric gas will mix with the vapour/aerosol and an atmospheric gas/vapour/aerosol mixture will exit the mouth 150.

The absorbent or adsorbent material 110 is a mass of an absorbent or adsorbent material, the material having a high surface area that causes vapour emitted by one or more of the discrete portions 108 to seed and thus causes the vapour to transition to an aerosol. The absorbent or adsorbent material 110 may, for example and without limitation, be formed from one of cellulose acetate, air-laid paper, cotton based material, shredded paper, or cut rag tobacco, or a mixture of two or more of these materials. Those materials may be in the form of a matrix of intertwined longitudinally extending elements of those materials. Those elements may be threads, fibres, or shreds.

The absorbent or adsorbent material 110 will also absorb or adsorb any water vapour or condensate that forms within the consumable 102.

With reference to FIGS. 7 and 8, a consumable 202 comprises a support/cover 264 with a first surface 266. On the first surface 266 of the support/cover 264 are supported a plurality of discrete portions 208 of aerosol generating material. The discrete portions 208 of aerosol generating material are located on the first surface 266 in a repeating pattern.

The support/cover 264 is wrapped around a core 210 of absorbent or adsorbent material with the discrete portions 208 of aerosol generating material between the support/cover 264 and the core 210.

In use, one or more of the discrete portions 208 of aerosol generating material are heated and the vapour/aerosol generated by the aerosol generating material portions is held within the tube formed by the support/cover 264 around the core 210. A user would attach a mouthpiece (not shown) to the mouth 250 and can draw on the mouthpiece which will cause the aerosol/vapour in the core 210 and atmospheric gas from the end of the core not attached to the mouthpiece into their mouth.

The absorbent or adsorbent material of the core 210 is similar to that of the absorbent or adsorbent material 110 described above.

The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without departing from the scope of the invention disclosed. Still other modifications which fall within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure.

Various aspects of the method, product, and consumable disclosed in the various embodiments may be used alone, in combination, or in a variety of arrangements not specifically discussed in the embodiments described above. This disclosure is therefore not limited in its application to the details and arrangement of components set forth in the foregoing description or illustrated in the drawings. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments. Although particular embodiments have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from this invention in its broader aspects. The scope of the following claims should not be limited by the embodiments set forth in the examples, but should be given the broadest reasonable interpretation consistent with the description as a whole.

Claims

1. A consumable for use with a non-combustible aerosol provision device, in which the consumable comprises a support, aerosol generating material, a cover, and an absorbent or adsorbent material, in which

the cover and the support at least partially define a passage along which one of an aerosol, atmospheric gas, or a mixture of aerosol and atmospheric gas may travel,
the aerosol generating material is supported on the support,
the aerosol generating material is so located that vaporisation of the aerosol generating material causes the vapour to enter the passage, and
the absorbent or adsorbent material at least partially fills the passage and spaces the cover from the support.

2. The consumable according to claim 1 in which the absorbent or adsorbent material comprises a unitary mass and the mass of absorbent or adsorbent material substantially fills the passage.

3. The consumable according to claim 1 in which the absorbent or adsorbent material comprises a plurality of separate masses, and each mass of absorbent or adsorbent material is located in the passage.

4. A consumable for use with a non-combustible aerosol provision device, in which the consumable comprises a support, aerosol generating material, a cover, and an absorbent or adsorbent material, in which

the cover and the support partially define a passage along which one of an aerosol, atmospheric gas, or a mixture of aerosol and atmospheric gas may travel,
the aerosol generating material is supported on the support,
the aerosol generating material is so located that vaporisation of the aerosol generating material causes the vapour to enter the passage, and
the absorbent or adsorbent material partially defines the passage and spaces the cover from the support.

5. The consumable according to claim 4 in which the absorbent or adsorbent material comprises a unitary mass.

6. The consumable according to claim 1 in which the cover is deformable and the absorbent or adsorbent material prevents the cover ceasing to be spaced from the support when the consumable is in use.

7. The consumable according to claim 1 in which the absorbent or adsorbent material is not damaged or substantially altered by the use of the consumable.

8. The consumable according to claim 1 in which the absorbent or adsorbent material is resiliently deformable.

9. The consumable according to claim 1 in which the absorbent or adsorbent material comprises at least one three dimensional matrix of intertwined threads, fibres, or shredded material between which there are voids.

10. The consumable according to claim 1 in which the absorbent or adsorbent material comprises cellulose acetate, air-laid paper, cotton based material, shredded paper, or cut rag tobacco, or a mixture of two or more of these materials.

11. The consumable according to claim 1 in which the absorbent or adsorbent material comprises at least one sensory substance, and the at least one sensory substance is a substances that will enhance a consumer's sensory experience when the consumable is in use.

12. The consumable according to claim 11 in which the aerosol generating material is adapted to generate vapour when heated to a first temperature, and the temperature at which at least one of the at least one sensory substances will start to enhance a consumer's sensory experience is lower than the first temperature.

13. The consumable according to claim 1 in which the aerosol generating material is heated to cause vapour generation, and the absorbent or adsorbent material is spaced from locations on the support that are heated when the consumable is in use.

14. The consumable according to claim 1 in which the absorbent or adsorbent material comprises a plurality of surfaces that act as seed surfaces for the formation of aerosol from the vapour generated by the aerosol generating material.

15. The consumable according to claim 1 in which the absorbent or adsorbent material is configured to absorb and retain one or both of water vapour and condensate.

16. The consumable according to claim 1 in which the absorbent or adsorbent material is configured to cause a pressure drop in one or more of vapour, aerosol, or atmospheric gas, as that one or more of vapour, aerosol or atmospheric gas, are sucked along the passage by a user.

17. The consumable according to claim 1 in which the cover is formed of a material that is absorbent or adsorbent.

18. The consumable according to claim 17 in which the absorbent or adsorbent material and cover are formed from different materials.

19. The consumable according to claim 1 in which the support comprises one of a metallic foil, a metallic film, or a plastics film.

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69. An aerosol provision system comprising an aerosol provision device and a consumable according to claim 1.

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Patent History
Publication number: 20250049118
Type: Application
Filed: Dec 20, 2022
Publication Date: Feb 13, 2025
Inventors: Joanna SOFFE (London), John RICHARDSON (London), Thomas DE TINA (London)
Application Number: 18/720,777
Classifications
International Classification: A24F 40/42 (20060101); A24F 40/20 (20060101); A24F 40/48 (20060101);