EP4604756A1

EP4604756A1 - A consumable

Info

Publication number: EP4604756A1
Application number: EP23800913.8A
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: WO2024084230A1; TW202421017A; GB202215604D0; JP2025535272A

Abstract

A consumable (100) for use with a non-combustible aerosol provision device (200), the consumable (100) comprising a core, wherein the core comprises a twisted rope-like structure of at least two strands (102) of material, wherein at least one of the strands (102) of material comprises aerosol generating material (105).

Description

A Consumable

Technical Field

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

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, the consumable comprising a core, wherein the core comprises a twisted rope-like structure of at least two strands of material, wherein at least one of the strands of material comprises aerosol generating material.

In a second aspect of the present invention, there is provided a method of manufacturing the consumable of the first aspect, the method comprising: providing at least two strands of material, wherein at least one of the strands of material comprises aerosol generating material; and forming a twisted rope-like structure of the at least two strands of material.

In a third aspect of the present invention, there is provided a non-combustible aerosol provision system comprising: the consumable of the first aspect; and a non-combustible aerosol provision device for heating the aerosol generating material of the consumable to generate an aerosol, the device comprising an area for receiving the consumable, and an aerosol generator for causing said heating of the aerosol generating material when the consumable is in said area. 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:

Fig. i shows an example consumable;

Fig. 2a shows an example of the consumable in cross-section; Fig. 2b shows another example of the consumable in cross-section;

Fig. 2c shows another example of the consumable in cross-section;

Fig. 2d shows another example of the consumable in cross-section;

Fig. 2e shows another example of the consumable in cross-section;

Fig. 3 is a schematic illustration of another example of the consumable; Fig. 4 schematically shows a system comprising the consumable and a non combustible aerosol provision device;

Fig. 5 shows another example of the consumable; Fig 6 schematically shows the steps of a method for manufacturing the consumable; and

Fig. 7 schematically illustrates a consumable in cross section in accordance with examples of the present disclosure.

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 throughout 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 aerosol - generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor. 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. 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, Memtha 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 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

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 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 aerosolgenerating 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 maybe continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, it may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosol - generating material. The aerosol-generating film may be discontinuous. For example, the aerosolgenerating 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 maybe 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 sluriy 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 an aerosol former, a binder, optionally a filler and optionally an active and/or a flavourant..

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.

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

The 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. 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. 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 aerosol- modifying 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.

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. Fig. 1 illustrates a consumable too for use with a non-combustible aerosol provision device, such as the non-combustible aerosol provision device 200 schematically illustrated by Fig. 4. The consumable too comprises a core 101 comprising a twisted rope-like structure of at least two strands 102 of material. At least one of the strands 102 of material comprises aerosol generating material 105. The non-combustible aerosol provision device 200 comprises an area 201 for receiving the consumable too and an aerosol generator 202. The aerosol generator 202 is configured to heat the aerosol generating material 105 of the consumable too when it is received in the area 201 to generate an aerosol for inhalation by a user, as will be explained further below.

Figs. 2a to 2e show example consumables too in cross section. Each cross section is projected onto a plane that bisects the consumable too perpendicular to its longitudinal axis. In each example, the core 101 of each consumable too comprises three strands 102, though it will be appreciated any of the examples may comprise only two strands 102 or more than two strands 102, such as four or five strands 102. It will also be appreciated that, while the illustrated strands 102 comprise a circular cross section, other cross sectional shapes may be used as long as the resulting strands can be twisted together to form a rope-like structure. In some examples described herein, the diameter of each strand 102 is between 0.1mm and 5mm, or between imm and 3mm. In one example, the diameter of each strand 102 is about 2mm.

In the example of Fig. 2a, each strand is formed from an absorbent material 104. The absorbent material 104 is provided with an aerosol generating material 105. For example, the aerosol generating material 105 may be provided as an additive to the absorbent material 104. In some examples, the absorbent material 104 may be doped with the aerosol generating material 105 in a liquid form so that the aerosol generating material 105 is absorbed by the absorbent material 104. The absorbent material 104 may be any material for suitable for absorbing aerosol generating materials 105 described herein. The absorbent material 104 may be a fibrous material and may be plant based. In one example the absorbent material 104 is a crimped and gathered paper. The aerosol generating material 105 may comprise an aerosol former material, as defined above. Therefore, when the consumable too is heated in use, the aerosol former material evaporates to form an aerosol for inhalation by a user. The aerosol generating material 105 may also comprise one or more active substances, one or more flavours and/ or one or more other functional materials, as defined above. In one example, the absorbent material 104 is provided with an aerosol generating material 105 that comprises an aerosol former material comprising glycerol, a flavour and an active substance comprising nicotine. Optionally, the absorbent material 104 is a reconstituted tobacco material that is formed as an absorbent tobacco paper. Therefore, the absorbent material 104 additionally provides flavour to the aerosol former material when the consumable is heated during use.

Where strands 102 of reconstituted tobacco material are used, the strands 102 may be provided in strips of reconstituted tobacco material. The reconstituted tobacco strands can be longitudinal strips. The reconstituted tobacco material can be, for example, band cast reconstituted tobacco material or paper reconstituted tobacco material. In some embodiments, the strands are provided as flat strips of reconstituted tobacco. The strips may have a width of between 0.25 mm and 2 mm; a thickness of 30 to 1000 pm, or 30 to 300 pm; and a density in the range of about 20 to 250 grams per square metre. The strips may have a ratio of the width to the thickness of between 0.25 and 70, or between 1 and 10.

To form the core 101, the strips are arranged in parallel and collected in a bundle before being twisted into a rope like structure in accordance with the method 60 described below with reference to Fig. 6. Any number of strands may be used, but in some examples, between too and 300 number of strands may be used to form the core. In some examples, the core may have a density of between 0.1 g/cm3 _and 0.9 g/cm3.

An advantage of twisting strips of reconstituted tobacco material into a rope like structure is that the strips become interlocked, making them less easily displaced. This is particularly beneficial when the consumable is used with a non-combustible aerosol provision device 200 comprising a pin or blade-like heater that extends into the area 201 for receiving the consumable too. A pin or blade-like heater is configured to penetrate the consumable too along its axis to heat the aerosol generating material 105. It has been found that consumables comprising strands of reconstituted tobacco material that are not formed into a twisted rope like structure tend to be displaced by such heaters, leaving debris with the area 201 for receiving the consumable. During longer term use of the device, this debris can accumulate to the detriment of heater efficiency and hygiene. In another example illustrated by Fig. 2b, each strand comprises a homogenized structure 106 of aerosol generating material 105, wherein the aerosol generating material 105 comprises an aerosol former, a binder, optionally a filler, and optionally an active and/ or a flavourant. In the illustrated example, each strand 102 is a monolithic solid. That is to say, each strand is cast as single piece. For example, each strand 102 may be an extruded section of the aerosol generating material 105. When the consumable too is heated in use, volatile constituents of the aerosol generating material 105 evaporate to form an aerosol for inhalation by a user.

The example consumable too illustrated by Fig. 2c is the same as the example of Fig. 2b with the exception that each strand 102 further comprises a material 107 heatable by penetration with a varying magnetic field, herein referred to as a susceptor 107. In the illustrated example, a susceptor 107 is embedded in each strand 102 of the consumable too. Such example consumables too are configured for use with a device 200 comprising an aerosol generator 202 configured to generate a varying magnetic field that penetrates the area 201 for receiving the consumable too, as explained further below. Therefore, when the consumable too is used with such a device 200, the susceptor 107 of each strand 102 is heated by the varying magnetic field to heat the aerosol generating material 105 and form an aerosol for inhalation by the user. In the illustrated example, the susceptor 107 of each strand 102 comprises a twisted rope-like structure. However, it will be appreciated that the susceptors 207 may take any form suitable for their integration into the strands 102. Therefore, the susceptors 207 are preferably formed of a resiliently flexible material that allows them to follow the helical path of the strands 102 in which they are embedded. In the illustrated example, each susceptor 107 is embedded substantially centrally within a strand 102. Such example consumables too maybe formed by extruding a strand 102 of aerosol generating material 105 around a continuous length of susceptor 107. Each strand 102 is then cut to length and twisted about at least one other such strand 102 to form the rope-like structure of the core 101, as will be explained further below.

In another unillustrated example, each strand 102 comprises a susceptor 107 embedded in a strand 102 formed from a material other than a homogenized structure 106 of aerosol generating material 105. It will be appreciated that a susceptor 207 may be embedded in any of the strands 102 described herein. For example, a susceptor 207 may be embedded in strands 102 of absorbent material, such as the strands 102 described in connection with Fig. 2a. Such example strands 102 may be formed by gathering absorbent material 104 around a continuous length of susceptor 107. Each resulting strand 102 is then cut to length and twisted about at least one other such strand 102 to form the rope-like structure of the core 101, as will be explained further below with reference to the method of Fig. 6.

The example consumable illustrated by Fig. 2d further comprises an outer wrapping material 108 that circumscribes the core 101. The illustrated strands 102 are representative of any of the strands 102 described above, including strands 102 of absorbent material 104 and strands of comprising a homogenized structure 106 of aerosol generating material 105. In such examples the consumable too is provided with a smooth, generally cylindrical appearance. The outer wrapper 108 forms an outer surface of the consumable too. Therefore, wrapping the core 101 in an outer wrapper 108 prevents the user from having to handle the core 101 directly. This maybe beneficial to stop the user getting any of the aerosol generating material 105 on them where they touch the consumable too. A further advantage of the outer wrapper 108 is that air flow channels 109 are formed between the outer wrapper 108 and the core 101. The air flow channels 109 follow the helical groove formed between strands 102 of the rope-like structure. The air flow channels 209 form a helical air flow pathway that extends from a distal end too” of the consumable to a mouth end too’. On account of their helical shape, the length of the helical air flow pathway formed by the air flow channels 209 is greater than if the air flow pathway were straight. That is to say, the length of the helical air flow pathway is greater than a straight air flow pathway that extends over the same axial length of the consumable too. Therefore, the residence time of air drawn through the consumable too is greater than if the air flow pathway were straight. This allows more of the constituent parts of the aerosol formed during use to be entrained into the air drawn along the air flow pathway. Another effect of the helical airflow pathway is that the pressure drop across the consumable is greater than if the airflow pathway were straight.

It will be appreciated that the length of the airflow pathway can be affected by the pitch P of the helix formed by each strand 102 of the core 101. The pitch P of the helix formed by each strand 102 of the core is defined as the length of one complete turn of the strand 102, measured parallel to the longitudinal axis X-X of the consumable too. Fig. 1 illustrates the pitch P of a three strand 102 core 101. Increasing the pitch P will reduce theisressuree drop of the consumable too and the residence time of air drawn through the consumable. In one example, the pitch P is between 0.2 and 1.5 times the diameter D of the helix formed by each strand 102. The outer wrapper 108 may extend along the entire length of the core 101 or may extend only partially along the length of the core 101, as illustrated in Fig. 5. In the example of Fig. 5, the outer wrapper extends 108 from the mouth end too’ of the consumable too over a portion of the length of the core 101. The mouth end 101’ of the consumable too is herein defined as the part of the consumable too placed between the lips of a user to allow the user to draw on the consumable too. Therefore, the user’s lips do not come into contact with the aerosol generating material 105 during use. Alternatively, the device 200 may be provided with a mouthpiece (not shown) which moveably encloses the area 201 for receiving the consumable too. In such examples, when a consumable too is inserted into said area 201, the mouthpiece is moved to enclose said area 201 and can be placed between the lips of the user to allow the user to draw on the mouthpiece and inhale the aerosol generated during use of the device 200. Advantageously, the outer wrapper 108 may be omitted completely from consumables too configured for use with a device 200 comprising a mouthpiece. The consumable too may be sized to tightly abut a wall 207 of the area for receiving the consumable too so that airflow channels are instead formed between the core 101 of the consumable too and the wall 207 when the consumable is inserted into said area 201.

The outer wrapper 108 may be made of any suitable wrapping material, such as cigarette paper.

The example consumable too illustrated by Fig. 2e is the same as the example of Fig. 2d with the exception that the outer wrapper 108 is a laminate comprising first and second layers 110, 111. The first layer is an outer layer 110 and comprises paper, such as cigarette paper. The second layer 111 is an inner layer and comprises a material heatable by penetration with a varying magnetic field. The inner layer is herein referred to as a susceptor 111. Such example consumables too are configured for use with devices 200 comprising an aerosol generator 202 configured to generate a varying magnetic field that penetrates the area 201 for receiving the consumable too, as explained further below. Therefore, when the consumable too is used with such a device 200, the susceptor 111 is heated by the varying magnetic field to heat the aerosol generating material 105 of the adjacent strands 102 and form an aerosol for inhalation by the user. In examples described herein, the pitch circle diameter PCD of the strands 102 is between about 4mm and 12mm, or between about 5mm and 11mm, or between about 6mm and 9mm. In one example, the pitch circle diameter PCD of the strands 102 is about 7mm, or about 8mm, or about 9mm, or about 10mm.

By ‘pitch circle diameter PCD’ it is meant the diameter of a circle that passes through the centre C of each strand 102. This is illustrated schematically in Fig. 7. By ‘centre C of each strand’, it is meant a centreline C that follows the helical path of each strand 102. By selecting a pitch circle diameter PCD in accordance with the above examples, it can be ensured that the consumable provides an appropriate draw resistance during use and that the above discussed helical airflow pathway is sized to allow the generation of an appropriate quantity of aerosol therein when the consumable is heated.

The consumable too may comprise any number of additional components 90 for attachment to any of the cores 101 of twisted rope-like structure described above. Alternatively, the consumable too may consist of only the core 101 (for example, where the consumable too is configured for use with a device 200 comprising a mouthpiece).

Where the consumable too comprises an additional component 90, the additional component 90 maybe, for example, a filter component 91, as shown in the example consumable too of Fig. 3. Other components 90 may comprise cooling sections or other sections containing aerosol generating material, as is known in the field. The filter component 91 may be a paper filter component or a cellulose filter component. Preferably, any additional component 90 comprises an outside diameter substantially the same as the core 101 to which it is to be attached. Therefore, the additional component 90 maybe attached by an overlapping layer of wrapping material, such as the outer wrapping material 108.

Including a filter component 91 advantageously allows for finer control of the closed pressure drop - or draw resistance - of the consumable too. 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 91. The filter component 91 may be attached to either the mouth end too’, as illustrated in Fig. 3, or to the distal end too”.

In one example, the closed pressure drop of the consumable too is in the range of about 30 to 90 mmWg. In another example, the closed pressure drop of the consumable too is in the range of about 40 to 60 mmWg. Fig. 6 schematically illustrates a method 60 of forming the consumables too of the examples discussed herein. The method comprises providing 61 at least two strands 102 of material, at least one of the strands comprising aerosol generating material 105; and forming 62 a twisted rope-like structure of the at least two strands of material 102. In some examples, the method further comprises wrapping 63 the twisted rope-like structure 101 in a wrapping material 108.

In some examples, providing 61 the at least two strands 102 of material comprises providing at least two strands of absorbent material 104 and doping 64 each strand of the absorbent material with aerosol generating material. The doping 64 may comprise doping 64 with a liquid aerosol generating material so that the absorbent material 104 absorbs the liquid aerosol generating material 105.

In some examples, providing 61 the at least two strands 102 comprises extruding 65 strands 102 of aerosol generating material 105 comprising an aerosol former, a binder, optionally a filler and optionally an active and/or a flavourant. In such examples, the aerosol generating material 105 may be a homogenized structure 106 of aerosol generating material 105. In some examples, forming 62 the twisted rope-like structure comprises laying the strands 102 alongside each other in a bundle and twisting ends of the bundle to form helical strands 102 that extend around each other. It shall be appreciated that such twisted rope-like structures are distinct from other common rope like structures such as braided structures. A braided structure is distinct from a twisted structure in that the individual strands are woven in a braided structure, but not woven in a twisted structure. It would be further appreciated that a braided structure would not provide the helical flow path discussed above. Any such flow path would be broken up by the weave of such a braided structure. Fig. 4 illustrates a system comprising the consumable too and a non-combustible aerosol provision device 200. The device comprises a power source 203, a controller 204 and a puff sensor 205. In use, a user inserts a consumable too into the area 201 for receiving the consumable and activates the aerosol generator 202 to generate an aerosol for inhalation. The user may then draw on the consumable too 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 mouth end too’ of the consumable too protrudes from the area 201 for receiving the consumable too when fully inserted into the device 200. Therefore, the consumable too is available for placing between the lips of the user while the user holds the device 200. The puff sensor 205 is configured to detect when a user is drawing on the consumable too 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 too. Alternatively, the device 200 maybe provided with a user interface - such as a button (not shown) - that the user may interact with 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 201 for passing through the consumable too when a user inhales on the mouth end too’ of the consumable too. Therefore, a flow of air is directed through the consumable too when a user draws on the consumable too. More particularly, the flow of air is directed along the airflow pathway of the consumable too. The flow of air entrains the aerosol generated by the aerosol generating material 105 of the consumable too when heated by the aerosol generator 202. The aerosol generator 202 comprises any suitable means for heating the aerosol generating material 105 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 107, 111 that is placed within the area 201 for the receiving the consumable too by magnetic hysteresis. This example may be used, therefore, with a consumable too comprising a material heatable by a varying magnetic field, as described above. Therefore, when such a consumable too is placed within the device 200 and the aerosol generator 202 is activated, a varying magnetic field penetrates said material of the consumable too and causes heating of aerosol generating material 105 in thermal contact with said material, 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 105 of the consumable too, generating an aerosol for inhalation by the user. In such embodiments, the susceptor may be the wall 207 of the area 201 for receiving the consumable too and the consumable too may be configured for direct contact with the wall 207 for efficient heat transfer.

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 105 of the consumable too, generating an aerosol for inhalation by the user. In such embodiments, the material may be the wall 207 of the area 201 for receiving the consumable too and the consumable too maybe configured for direct contact with the wall 207 for efficient heat transfer.

Claims

1. A consumable for use with a non-combustible aerosol provision device, the consumable comprising a core, wherein the core comprises a twisted rope-like structure of at least two strands of material, wherein at least one of the strands of material comprises aerosol generating material.

2. A consumable according to claim 1, wherein the core comprises three or more strands of material.

3. A consumable according to claim 1 or claim 2, wherein each strand of material comprises an absorbent material.

4. A consumable according to claim 2, wherein the absorbent material is laced with aerosol generating material.

5. A consumable according to claim 1 or claim 2, wherein each strand of material comprises an aerosol generating material.

6. A consumable according to any of claim 5, wherein the aerosol-generating material comprises: an aerosol former a binder; optionally a filler; and - optionally an active and/or a flavourant.

7. A consumable according to claim 6, wherein each strand of material consists exclusively of aerosol generating material.

8. A consumable according to any preceding claim, wherein each strand of material comprises a substantially circular cross section.

9. A consumable according to claim 8, wherein the diameter of each strand of material is between 0.1mm and 5mm.

10. A consumable according to claim 9, wherein the diameter of each strand of material is about 2mm.

11. A consumable according to any of claims 1 to 5, wherein each strand comprises reconstituted tobacco material and, optionally, wherein the reconstituted tobacco material comprises a reconstituted tobacco paper and, optionally, wherein the reconstituted tobacco paper has a thickness of 30 to 300 pm.

12. A consumable according to claim 11, wherein each strand comprises a strip having a width of between 0.25 mm and 2 mm.

13. A consumable according to claim 11 or claim 12, wherein the core comprises a density of between 0.1 g/cm3 and 0.9 g/cm3.

14. A consumable according to any preceding claim, wherein the core is wrapped in an outer wrapper to form a rod shaped section comprising the core wrapped in the outer wrapper.

15. A consumable according to claim 14, wherein the outer wrapper comprises a material heatable by penetration with a varying magnetic field.

16. A consumable according to any preceding claim, wherein at least one of the strands comprises a material heatable by penetration with a varying magnetic field.

17. A consumable according to any preceding claim, wherein a pitch circle diameter of the strands 102 is between about 4mm and 12mm.

18. A method of manufacturing the consumable of any of claims 1 to 17, the method comprising: providing at least two strands of material, wherein at least one of the strands of material comprises aerosol generating material; and forming a twisted rope-like structure of the at least two strands of material.

19. A method according to claim 18, wherein the at least two strands of material are absorbent material and the method comprising doping each strand of material with aerosol generating material.

20. A method according to claim 18, wherein the at least one of the strands of material are formed by extruding an aerosol generating material comprising a binder, a gelling agent and an aerosol-former material.

21. A method according to any of claims 18 to 20, further comprising wrapping the twisted rope-like structure in an outer wrapper.

22. A non-combustible aerosol provision system comprising: the consumable of any one of claims i to 17; and a non-combustible aerosol provision device for heating the aerosol generating material of the consumable to generate an aerosol, the device comprising an area for receiving the consumable, and an aerosol generator for causing said heating of the aerosol generating material when the consumable is in said area.