EP4604745A1

EP4604745A1 - An aerosol generating consumable

Info

Publication number: EP4604745A1
Application number: EP23800515.1A
Authority: EP
Inventors: John Richardson; Richard LEBBON
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2022-10-21
Filing date: 2023-10-20
Publication date: 2025-08-27
Also published as: JP2025534076A; GB202215609D0; KR20250071256A; WO2024084224A1; TW202434121A

Abstract

A consumable (10) is disclosed which is formed from a crimped and gathered sheet of material (20) having an aerosol generating section (30) and one or two filter sections (40). The aerosol generating section (30) is formed by aerosol generating material (31). The aerosol generating material may comprise a film of aerosol generating material provided, e.g. by printing, on a surface of a portion of the crimped and gathered sheet of material (20). Crimping may be applied to the filter sections (40) only, or to both the filter sections (40) and the aerosol generating section (30). The same level of crimping may be applied to all sections or different levels of crimping may be applied to each section.

Description

AN AEROSOL GENERATING CONSUMABLE

Technical Field

The present disclosure relates to a consumable for use with an aerosol provision system, an aerosol provision system comprising the consumable and a method for forming the consumable.

Background

Certain tobacco industry products produce an aerosol during use, which is inhaled by a user. For example, tobacco heating devices heat an aerosol generating substrate such as tobacco to form an aerosol by heating, but not burning, the substrate. Such tobacco industry products commonly include consumables containing aerosol generating material for use in a heating device.

Summary

In a first aspect of the present invention, there is provided a consumable for use with a non-combustible aerosol provision device, wherein the consumable comprises an aerosol generating section and a filter section, the aerosol generating section and filter section being collectively formed from a crimped and gathered sheet of material, wherein the aerosol generating section comprises an aerosol generating material and wherein the filter section is substantially free of aerosol generating material.

In some embodiments, the aerosol generating section comprises a portion of the crimped and gathered sheet of material that is laced with aerosol generating material.

In some embodiments, the aerosol generating section comprises a film of aerosol generating material provided on a surface of a portion of the crimped and gathered sheet of material. The aerosol generating material maybe printed onto the crimped and gathered sheet of material.

In some embodiments, the aerosol generating section comprises no crimping. The aerosol generating section may be substantially free of crimping. In some embodiments, the filter and aerosol generating sections of the crimped and gathered sheet of material comprise the same the level of crimping. In other embodiments, the filter and aerosol generating sections of the crimped and gathered sheet of material comprise different levels of crimping. The level of crimping may comprise the crimp amplitude and/or crimp spacing.

The crimp spacing may comprise the average spacing between adjacent ridges of the crimped and gathered sheet of material. In some embodiments, the average spacing of the crimping of both the filter and aerosol generating sections is between about 0.1 mm to about 3 mm. In some embodiments, adjacent grooves of the crimped sheet material are spaced by a distance of at most 3 mm, and preferably, at most, 2.5, 2, 1, 1.5, 0.7, 0.5, 0.2 or 0.1 mm.

In some embodiments, the average spacing of the crimping of the aerosol generating section is less than the average spacing of the crimping of the filter section. In other embodiments, the average spacing of the crimping of the aerosol generating section is greater than the average spacing of the crimping of the filter section.

The crimp amplitude may comprise the average height of a ridge of the crimped and gathered sheet of material. In some embodiments, the crimp amplitude of the both the filter and aerosol generating sections is between about 0.1 mm and about 1 mm. In some embodiments, the sheet material is crimped to a crimp amplitude of at least 0.1 mm and, preferably, at least 0.3 mm, 0.4 mm or 0.5 mm. In some embodiments, the sheet material is crimped to a crimp amplitude of at most 1 mm, and preferably, at most, 0.8 mm, 0.6 mm, or 0.5 mm.

In some embodiments, the sheet material can have a crimp with a crimp amplitude of less than 500 μm and spacing between peaks (or troughs) of at least 300 μm, at least 400 μm or at least 500 μm.

In some embodiments, the crimp amplitude of the aerosol generating section is less than the crimp amplitude of the filter section. In other embodiments, the crimp amplitude of the aerosol generating section is greater than the crimp amplitude of the filter section. In some embodiments, the crimped and gathered sheet material is circumscribed by a first wrapping material. The first wrapping material preferably comprises a basis weight of between about 30 and about 75 gsm, or between about 40 and about 65 gsm. Such basis weights can assist with improving the circularity of the cross section of the aerosol-generating section.

A second wrapping material may be provided, only around the filter section. The second wrapping material preferably comprises a basis weight of between about 70 gsm and about 120 gsm, more preferably between about 80 gsm and about 110 gsm. Such basis weights are desirable to achieve an acceptable overall level of rigidity.

In some embodiments, the consumable is substantially cylindrical.

The length of the aerosol generating section may be in the range of about 25 mm to about 50 mm, and more preferably in the range of about 30 mm to 45 mm, and still more preferably in the range of about 30 mm to 40 mm. The length of the filter section may be in the range of about 5 mm and about 50 mm.

In some embodiments, the closed pressure drop across the consumable is between 30 and 90 mm WG, and preferably between 35 and 70 mm WG.

The closed pressure drop across the filter section may be between about 0.5 to about 20 mm WG. The closed pressure drop across the filter section may be between about 1.5 and about 8.6 mm WG per mm of length of the filter section, or between about 3 and about 6 mm WG per mm of length of the filter section.

The closed pressure drop across the aerosol generating section may be between about 29 to about 70 mm WG.

In some embodiments, the aerosol-generating material comprises an aerosol former, a binder, optionally a filler, and optionally an active and/ or a flavourant.

In some embodiments, the consumable comprises an aerosol generating section and one filter section. In other embodiments, the consumable comprises an aerosol generating section and two filter sections, one each side of the aerosol generating section. In a second aspect of the present invention, there is provided a method of forming a consumable for use with a non-combustible aerosol provision device, the method comprising: providing a sheet of material; applying an aerosol generating material to the sheet of material in discrete sections to form alternating aerosol generating sections and filter sections substantially free of aerosol generating material; crimping the sheet of material; gathering the sheet of material to form a substantially cylindrical rod; and separating the rod into individual consumables, each consumable having an aerosol generating section and a filter section.

In some embodiments of the second aspect, different levels of crimping are applied to the aerosol generating sections and filter sections. In some embodiments of the second aspect, no crimping is applied to the aerosol generating section.

In a third aspect of the present invention, there is provided a method of forming a consumable for use with a non-combustible aerosol provision device, the method comprising: providing a continuous sheet of material having discrete sections comprising aerosol generating material, said discrete sections being arranged at evenly spaced intervals along the length of the continuous sheet of material; applying a crimp pattern to the continuous sheet of material; gathering the continuous sheet of material comprising the crimp pattern; and wrapping the gathered continuous sheet of material in at least one wrapping material to form the consumable.

In some embodiments of the third aspect, the step of applying the crimp pattern comprises applying a first level of crimping to the discrete sections and a second level of crimping to sections between the discrete sections.

In a fourth aspect of the present invention, there is provided a non-combustible aerosol provision system for heating aerosol generating material to volatilise at least one component of the aerosol generating material, the system comprising: the consumable in accordance with the first aspect; and a non-combustible aerosol provision device comprising an aerosol generator configured to heat the consumable to generate an aerosol when, in use, the consumable and the device are combined.

In a fifth aspect of the present invention, there is provided a consumable for use with a non-combustible aerosol provision device, wherein the consumable comprises a first end and a second end, the consumable comprising: a mouthpiece downstream of the first end, an aerosol generating section downstream of the first end and upstream of the mouthpiece, and a blocking member (or plug) arranged upstream of the aerosol generating section, wherein the aerosol generating section and blocking member are collectively formed from a crimped and/ or slit and gathered sheet of material, and wherein the aerosol generating section comprises an aerosol generating material.

In some embodiments of the fifth aspect, the blocking member permits air flow but prevents egress of aerosol generating material from the consumable. Therefore, in some embodiments, the blocking member is air permeable.

In a sixth aspect of the present invention, there is provided a consumable for use with a non-combustible aerosol provision device, wherein the consumable comprises an aerosol generating section and a filter section, the aerosol generating section and filter section being collectively formed from a crimped and/ or slit and gathered sheet of material, wherein the aerosol generating section comprises an aerosol generating material and wherein the filter section is substantially free of aerosol generating material.

In some embodiments of the sixth aspect, the slits may replace the crimps of the other embodiments. The material maybe slit by means of a plurality of discrete slits or perforations.

In some embodiments of the sixth aspect, the aerosol generating section is slit and the filter section is crimped. The crimped filter section may help to retain the aerosol generating material in the consumable.

In some embodiments, the crimps and/or slits extend longitudinally along the consumable. Brief Description of the Drawings

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

Figs. 1A and 1B show schematic representations of example consumables formed from a crimped and gathered sheet of material having an aerosol generating section and one or two filter sections;

Figs. 2A, 2B and 2C show schematic representations of the consumable of Fig. 1B with crimping on the filter sections only, crimping on the filter sections and the aerosol generating section, and different levels of crimping on the filter sections and the aerosol generating section;

Figs. 3A and 3B show the amplitude and spacing of two different crimp forms;

Figs. 4A and 4B show schematic representations of the consumables of Figs. 1A and 1B with additional wrapping materials;

Fig. 5 shows a schematic process arrangement for crimping the sheet of material during the manufacture of the consumable; and

Fig. 6 schematically shows a system comprising a consumable and a non-combustible aerosol provision device.

Detailed Description

As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes: non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

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 aerosolgenerating material heating system, also known as a heat-not-burn 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 aerosolgenerating material and a solid aerosol-generating material. The solid aerosolgenerating material may comprise, for example, tobacco or a non-tobacco product.

The non-combustible aerosol provision systems described herein comprise a non- combustible aerosol provision device and a consumable for use with the non- combustible aerosol provision device.

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 in the disclosure.

In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device, 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. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosolgenerating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

In some embodiments, the substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolised. As appropriate, either material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.

Active Substance

In some embodiments, the substance to be delivered 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, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

In one embodiment the active substance is a legally permissible recreational drug.

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

As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes. The active substance may be CBD or a derivative thereof.

As noted herein, 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.

Flavours

In some embodiments, the substance to be delivered comprises a flavour. 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.

Aerosol-generating material

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

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

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 aerosolgenerating material is substantially tobacco free.

The aerosol-generating material may comprise or be in the form of an aerosolgenerating 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 maybe 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 0.3 mm or 0.5 mm.

In some embodiments, the aerosol-generating film may be discontinuous. For example, the aerosol-generating film may comprise one or more discrete portions or regions of aerosol-generating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non- planar.

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 aerosolgenerating 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 50wt%, 6owt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid.

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

The aerosol-generating material may comprise or be in the form of granules or beads. The granules or beads may be trapped in the consumable when the sheet of material is gathered and the consumable is formed.

Aerosol-former material The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

Functional material

The one or more other functional materials may comprise one or more of a pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

Substrate

The aerosol generating material may be present on or in a support, the support forming a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.

Susceptor

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 heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. 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, herein.

Aerosol-modifying agent

An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosolmodifying agent

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol-modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent maybe in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

Aerosol generator

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

Figs. 1A and 1B show schematic representations of example consumables io formed from a crimped and gathered sheet of material 20 having an aerosol generating section 30 and one or two filter sections 40. The aerosol generating section 30 is formed by aerosol generating material 31. In Fig. 1A, the aerosol generating section 30 is placed at one end of the consumable so that one filter section 40 is provided. In Fig. 1B, the aerosol generating section 30 is placed in the middle of the consumable so that two filter sections 40 are provided. The sheet of material 20 maybe formed from or comprise paper, card, paperboard, cardboard or reconstituted material. Other materials for the sheet 20 may be as described above in relation to the substrate/support.

The aerosol generating material 31 is configured to generate an aerosol when heated by an aerosol generator of a non-combustible aerosol provision device, as will be explained further below. The aerosol generating material 31 may be formed from or comprise any of the materials discussed above. The consumable may additionally comprise a metallic material to serve as a susceptor to heat the aerosol generating material 31.

Figs. 2A, 2B and 2C show schematic representations of the consumable of Fig. 1B with different configurations of crimping 50. The skilled person will understand that the different configurations of crimping are equally applicable to the consumable of Fig. 1A.

In Fig. 2A, crimping 50 is applied to the filter sections 40 only.

In Fig. 2B, crimping 50 is applied to the filter sections 40 and the aerosol generating section 30. The same level of crimping is applied to all sections.

In Fig. 2C, different levels of crimping are applied to the filter sections 40 and the aerosol generating section 30. The filter sections 40 are provided with a first level of crimping 51 and the aerosol generating section 30 is provided with a second level of crimping 52. The “level” of crimping maybe defined as amplitude and/or spacing, as discussed further below in relation to Fig. 4.

The spacing of the crimping 51 applied to the filter sections 40 may be greater than or less than the spacing of the crimping 52 applied to the aerosol generating section 30.

The amplitude of the crimping 51 applied to the filter sections 40 may be greater than or less than the amplitude of the crimping 52 applied to the aerosol generating section 30. Both the spacing and the amplitude may differ between the filter sections 40 and the aerosol generating section 30.

Figs. 3A and 3B show the amplitude A and spacing S of two different crimp forms, comprising a sine wave and a triangular wave respectively. Other shapes of crimp may be employed, such as square for example. Figs. 4A and 4B show schematic representations of the consumables of Figs. 1A and 1B with additional wrapping materials. A first wrapping material 60 is provided around the entire consumable 10, which serves to retain the crimped and gathered material 20 in a cylindrical form. A second wrapping material 70 is provided around the one or two filter sections 40. In Fig. 4B, the second wrapping material 70 may be provided around one or both filter sections 40. The first and second wrapping materials may be formed from a tipping paper.

A filter component may be included in the filter section 40, or in one or both filter sections 40 where two are present. A filter component advantageously allows for finer control of the closed pressure drop - or draw resistance - of the consumable 10. For example, the closed pressure drop may be controlled by setting the density of filter material in the filter component, or by increasing or decreasing the axial length of the filter component. The filter component may comprise additional filter material. The filter component may include a capsule.

Fig. 5 shows a schematic process arrangement for crimping the sheet of material during the manufacture of the consumable. Bobbin 90 comprises a roll (which may be regarded as substantially continuous) of sheet material 20 which is to be crimped and gathered to form the consumable. The sheet material 20 in bobbin 90 is pre-printed with sections of aerosol generating material 31. Alternatively, aerosol generating material 31 may be printed or otherwise applied to the sheet material 20 in-line, after unwinding from bobbin 90.

Crimp rollers 91 apply a crimp to the sheet material. This may be a continuous crimp or a discontinuous crimp, depending on the required crimp configuration. The crimp configuration may be one of those shown in Fig. 2. After the crimp is applied, the crimped sheet 20 with aerosol generating material 31 is fed to a rod maker in which the sheet is gathered by conventional means to form a rod. The rod may also be wrapped with one or more wrapping materials, for example as shown in Fig. 4 or in another configuration as maybe required. The rod is then separated, e.g. by cutting, into individual consumables.

Fig. 6 illustrates a system comprising a consumable too, which maybe one of the consumables 10 in accordance with the invention discussed above, and a non- combustible aerosol provision device 200. The device comprises an area 201 for receiving the consumable 100 and an aerosol generator 202. The aerosol generator is configured to heat the aerosol generating material 31 of the consumable 100 when it is received in the area 201 to generate an aerosol for inhalation by a user. The device further comprises a power source 203, a controller 204 and a puff sensor 205. In use, a user inserts a consumable 100 distal end 102 first into the area for receiving the consumable 201 and activates the aerosol generator 202 to generate an aerosol for inhalation. The user may then draw on the mouth end 101 of the consumable or, alternatively, on a mouthpiece (not shown) of the device 200 to inhale the aerosol. In the illustrated example, the consumable too and device 200 are configured so that the mouth end 101 protrudes from the area 201 for receiving the consumable too when fully inserted into the device 200. Therefore, the mouth end 101 is available for placing between the lips of the user while the user holds the device.

The puff sensor 205 is configured to detect when a user is drawing on the mouth end 101 of the consumable within the device 200 and to send a signal to the controller 204 to activate the aerosol generator 202. Therefore, aerosol is generated concurrently with the user inhaling on the consumable. Alternatively, the device 200 may be provided with a user interface - such as a button (not shown) - that the user may press to cause activation of the aerosol generator 202.

The area 201 for receiving the consumable too is provided with an inlet (not shown) to allow air into the area for passing through the consumable when a user inhales on the mouth end 101 of the consumable too. Therefore, a flow of air is directed through the consumable too when a user draws on the consumable too. The flow of air entrains the aerosol generated by the aerosol generating material 31 of the consumable when heated by the aerosol generator 202.

The aerosol generator 202 comprises any suitable means for heating the aerosol generating material 31 of a consumable received in said area 201 of the device 200. Power for the aerosol generator 202 is provided by the power source 203, which in the illustrated example is an electrical power source 203, such as a battery 203.

In one example, the aerosol generator 202 comprises a magnetic field generator configured to generate a varying magnetic field that penetrates the area 201 for receiving the consumable too. The varying magnetic field heats a susceptor that is placed within the area for the receiving the consumable by magnetic hysteresis. This example is used where the consumable 100 comprises a susceptor in thermal contact with the aerosol generating material 31, such as the metallic material mentioned above. Therefore, when such a consumable 100 is placed within the device 200 and the aerosol generator 202 is activated, a varying magnetic field penetrates the susceptor of the consumable 100 and causes heating of aerosol generating material 31 in thermal contact with the susceptor, generating an aerosol for inhalation by a user.

In another example, the aerosol generator 202 comprises a susceptor in thermal contact with the area 201 for receiving the consumable; and a magnetic field generator for generating a varying magnetic field that penetrates the susceptor. The varying magnetic field heats the susceptor by magnetic hysteresis. The susceptor in turn heats the area 201 for receiving the consumable. Therefore, when a consumable too is placed within the device 200 and the aerosol generator 202 is activated, a varying magnetic field penetrates the susceptor and causes heating of area 201 in which the consumable too is received. The heat is transferred to the aerosol generating material 31 of the consumable too, generating an aerosol for inhalation by the user. In such embodiments, the susceptor may be a wall of the area 201 for receiving the consumable too and the consumable too may be configured for direct contact with the wall for efficient heat transfer. Alternatively, the susceptor may comprise one or more protrusions (not shown) that upstand within the area 201 for receiving the consumable too. Therefore, the susceptor maybe directly locatable within the consumable too.

In another example, the aerosol generator 202 comprises a material heatable by electrical conduction, the material being provided in thermal contact with the area 201 for receiving the consumable too. Therefore, when a consumable too is placed within the device 200 and the aerosol generator 202 is activated, a current is passed through the material to heat area 201 in which the consumable too is received. The heat is transferred to the aerosol generating material 31 of the consumable too, generating an aerosol for inhalation by the user. In such embodiments, the material may be a wall of the area 201 for receiving the consumable too and the consumable too may be configured for direct contact with the wall for efficient heat transfer. Alternatively, the aerosol generator 202 maybe in the form of a blade or pin which, when a consumable too is placed within the device, inserts into the aerosol generating material 31. When the aerosol generator 202 is activated, heat is transferred directly to the aerosol generating material 31, generating an aerosol for inhalation by the user.

Claims

1. A consumable for use with a non-combustible aerosol provision device, wherein the consumable comprises an aerosol generating section and a filter section, the aerosol generating section and filter section being collectively formed from a crimped and gathered sheet of material, wherein the aerosol generating section comprises an aerosol generating material and wherein the filter section is substantially free of aerosol generating material.

2. The consumable of claim i, wherein the aerosol generating section comprises a portion of the crimped and gathered sheet of material that is laced with aerosol generating material.

3. The consumable of claim 1, wherein the aerosol generating section comprises a film of aerosol generating material provided on a surface of a portion of the crimped and gathered sheet of material.

4. The consumable of any of claims 1 to 3, wherein the aerosol generating section comprises no crimping.

5. The consumable of any of claims 1 to 3, wherein the filter and aerosol generating sections of the crimped and gathered sheet of material comprise the same the level of crimping.

6. The consumable of any of claims 1 to 3, wherein the filter and aerosol generating sections of the crimped and gathered sheet of material comprise different levels of crimping.

7. The consumable of claim 5 or 6, wherein the level of crimping comprises the crimp amplitude and/ or crimp spacing.

8. The consumable of claim 7, wherein the crimp spacing comprises the average spacing between adjacent ridges of the crimped and gathered sheet of material.

9. The consumable of claim 8, wherein the average spacing of the crimping of both the filter and aerosol generating sections is between about 0.1mm to about 3mm.

10. The consumable of claim 8 or 9, wherein the average spacing of the crimping of the aerosol generating section is less than the average spacing of the crimping of the filter section, or wherein the average spacing of the crimping of the aerosol generating section is greater than the average spacing of the crimping of the filter section.

11. The consumable of any of claims 7 to 10, wherein the crimp amplitude comprises the average height of a ridge of the crimped and gathered sheet of material.

12. The consumable of claim 11, wherein the crimp amplitude of the both the filter and aerosol generating sections is between about 0.1 mm and about 1 mm.

13. The consumable of claim 11 or 12, wherein the crimp amplitude of the aerosol generating section is less than the crimp amplitude of the filter section, or wherein the crimp amplitude of the aerosol generating section is greater than the crimp amplitude of the filter section.

14. The consumable of any of claims 1 to 13, wherein the crimped and gathered sheet material is circumscribed by a first wrapping material.

15. The consumable of claim 14, wherein a second wrapping material is provided only around the filter section.

16. The consumable of any of claims 1 to 15, wherein the length of the aerosol generating section is between about 25 mm and about 50 mm and/ or wherein the length of the filter section is between about 5 mm and about 50 mm.

17. The consumable of any of claims 1 to 16, wherein the aerosol-generating material comprises: an aerosol former a binder; optionally a filler; and optionally an active and/ or a flavourant.

18. The consumable of any of claims 1 to 17, wherein the consumable comprises an aerosol generating section and one filter section.

19- The consumable of any of claims 1 to 17, wherein the consumable comprises an aerosol generating section and two filter sections, one each side of the aerosol generating section.

20. A method of forming a consumable for use with a non-combustible aerosol provision device, the method comprising: providing a sheet of material; applying an aerosol generating material to the sheet of material in discrete sections to form alternating aerosol generating sections and filter sections substantially free of aerosol generating material; crimping the sheet of material; gathering the sheet of material to form a substantially cylindrical rod; and separating the rod into individual consumables, each consumable having an aerosol generating section and a filter section.

21. The method of claim 20, wherein different levels of crimping are applied to the aerosol generating sections and filter sections.

22. The method of claim 20, wherein no crimping is applied to the aerosol generating section.

23. A method of forming a consumable for use with a non-combustible aerosol provision device, the method comprising: providing a continuous sheet of material having discrete sections comprising aerosol generating material, said discrete sections being arranged at evenly spaced intervals along the length of the continuous sheet of material; applying a crimp pattern to the continuous sheet of material; gathering the continuous sheet of material comprising the crimp pattern; and wrapping the gathered continuous sheet of material in at least one wrapping material to form the consumable.

24. The method of claim 23, wherein the step of applying the crimp pattern comprises applying a first level of crimping to the discrete sections and a second level of crimping to sections between the discrete sections.

25. A non-combustible aerosol provision system for heating aerosol generating material to volatilise at least one component of the aerosol generating material, the system comprising: the consumable of any one of claims i to 19; and a non-combustible aerosol provision device comprising an aerosol generator configured to heat the consumable to generate an aerosol when, in use, the consumable and the device are combined.

26. A consumable for use with a non-combustible aerosol provision device, wherein the consumable comprises a first end and a second end, the consumable comprising: a mouthpiece downstream of the first end, an aerosol generating section downstream of the first end and upstream of the mouthpiece, and a blocking member arranged upstream of the aerosol generating section, wherein the aerosol generating section and blocking member are collectively formed from a crimped and/ or slit and gathered sheet of material, and wherein the aerosol generating section comprises an aerosol generating material.

27. A consumable for use with a non-combustible aerosol provision device, wherein the consumable comprises an aerosol generating section and a filter section, the aerosol generating section and filter section being collectively formed from a crimped and/or slit and gathered sheet of material, wherein the aerosol generating section comprises an aerosol generating material and wherein the filter section is substantially free of aerosol generating material.

28. The consumable of claim 27, wherein the aerosol generating section is slit and the filter section is crimped.

29 The consumable of any of claims 1 to 19 or 26 to 28, wherein the crimps and/or slits extend longitudinally along the consumable.