EP4646946A1

EP4646946A1 - Heat-not-burn consumable and heat-not-burn device

Info

Publication number: EP4646946A1
Application number: EP24174975.3A
Authority: EP
Inventors: designation of the inventor has not yet been filed The
Original assignee: Imperial Tobacco Ltd United Kingdom
Current assignee: Imperial Tobacco Ltd United Kingdom
Priority date: 2024-05-08
Filing date: 2024-05-08
Publication date: 2025-11-12
Also published as: WO2025233077A1

Abstract

Heat-not-burn (HNB) consumable (70) containing an aerosol-forming precursor (6) at one end (74) thereof which is wider than an opposite end (76) of the consumable (70). There is also provided a method of manufacturing the HNB consumable. By increasing the width of the precursor end relative to the opposite end of the consumable the precursor may be compressed by inserting the consumable into a cavity (102) of an HNB device (10) and clamping an outer surface (80) of the consumable by a cylindrical wall (104) of the cavity. Therefore, an HNB consumable is provided which reduces the risk or likelihood of the precursor falling out or being pulled out from the HNB consumable into the cavity of the HNB device. An HNB device comprising a substantially cylindrical cavity for receiving an HNB consumable is also disclosed.

Description

FIELD

The present disclosure relates to a heat-not burn (HNB) consumable and a method of manufacture thereof and particularly, although not exclusively, to a smoking substitute system comprising a heat-not-burn device and an insertable HNB consumable, wherein the consumable is heated to generate an inhalable aerosol.

BACKGROUND

Smoking substitute systems include electronic aerosol generation systems that permit a user to simulate the act of smoking by producing an aerosol (also referred to as a "vapour") that is drawn into the lungs through the mouth (inhaled) and then exhaled.
One technology platform for a smoking substitute system is a class of products that use the "heat-not-burn" ("HNB") approach, also called the "Heated Tobacco" ("HT") approach, in which tobacco is heated or warmed to release vapour. In the HNB approach the tobacco is heated but not burned, i.e. the tobacco does not undergo combustion. The HNB approach recognises that burning tobacco is not necessary to release constituents from the tobacco leaf. Rather, release is achieved at temperatures of around 350°C or less. Because HNB systems do not combust the tobacco, the lower temperatures of HNB systems are expected to expose the user to emissions that have fewer chemicals and / or in smaller amounts than the smoke from a combustible cigarette. HNB systems are well known in the industry. And although referred herein as HNB systems, they may also be known as heated tobacco products (HTP), Heated Tobacco (HT) and smokeless systems.
The HNB class of products are easily distinguishable over e-cigarettes (or vapes), which are an alternative class of smoking substitute system based on a technology platform that uses a device to heat a pod or cartridge filled with a liquid (also termed e-liquid). Here, a primary difference is that HNB systems produce an aerosol from tobacco leaf, whereas in e-cigarettes, the aerosol is provided from a liquid suspension.
A typical HNB system includes an HNB device and an HNB consumable comprising the tobacco, which is replaced at the end of a smoking session. It will be appreciated that the HNB system can, herein, be interchangeably referred to as a 'system' and likewise, the HNB device can be interchangeably referred to as a device, and also the HNB consumable can be interchangeably referred to as a consumable. At a basic level, the consumable is inserted into the device to form a system, such that the user can operate the system to heat the consumable in a controlled manner to release flavours, aromas and other constituents whilst volatising the nicotine in the tobacco (without burning). A user can then draw on a mouthpiece of the system to draw air through the tobacco. The released constituents and volatised nicotine is entrained in the airflow to create an aerosol as it mixes and cools. The aerosol is then inhaled by the user. A known HNB device is sold under the brand name Pulze ^™ for use in combination with an HNB consumable sold under the brand name iD ^™.
Known HNB devices comprise a cavity for receiving the HNB consumable, where a heater is arranged in or about the cavity. The device therefore further comprises a power source (e.g. a battery) and control electronics for connecting the power source and heater, suitably via a user interface. Of course, the device also typically includes a charging port and the control electronics, as well as controlling the discharge of the power source to the heater (i.e. to activate the heater), also controls the recharging of the power source.
Various heaters are known for HNB systems. The Pulze ^™ device utilises a resistive heating rod as the heating element wherein resistive heating wires are arranged on the heating rod and the wires generate heat when supplied with power from the power source. The resistive heating wires transfer the heat by conduction to the tobacco which is in close proximity or in contact to the heating wires. Here, the heating rod is arranged coaxially in the cavity and insertion of the consumable into the cavity causes the heating rod to penetrate into the tobacco such that the heating rod heats the tobacco from the inside out. Flat blades have also been used for inside out heating. During use, the penetration of the heater into the tobacco portion exerts forces on the tobacco, which may cause the tobacco portion to be undesirably moved or shifted by the relative motion between the heating element and the consumable. Moreover, this penetration may disturb the tobacco material such that the tobacco material falls into the cavity of the device upon removal of the consumable from the device. For instance, the tobacco can be pulled out of the consumable as the heater element is withdrawn.
Known HNB consumables comprise three portions positioned sequentially end-to-end to form a rod, including but not limited to: a tobacco portion, a cooling portion, and a mouthpiece (or mouthpiece filter). Here, the tobacco portion forms an upstream end portion of the consumable and the mouthpiece filter the downstream end portion of the consumable. In the iD ^™ stick, the cooling portion comprises a bore filter and a paper tube positioned sequentially such that the rod comprises: a tobacco portion, a bore filter, a paper tube, and a mouthpiece filter positioned sequentially from the upstream end to the downstream end and end-to-end to form the rod. In such consumables, the rod is held together by a combination of a combining paper and a tipping paper. The combining paper circumscribes (where circumscribes includes a substantially single wrap as well as any gluing overlap) the tobacco portion, the hollow bore filter and part of the paper tube, and the tipping paper circumscribes the mouth filter and part of the paper tube.
Accordingly, in existing consumables, the mouthpiece end (also the mouthpiece or mouth end) is defined by an end surface of the mouthpiece filter and the tobacco end is defined by an end surface of the tobacco portion. Moreover, the mouthpiece end is flush with an end of the tipping paper and the tobacco end is flush with an end of the combining paper. Tobacco material is therefore exposed at the end of the consumable. Those skilled in the art will recognise that tobacco material is therefore prone to falling or being pulled out of the consumable in use (e.g. into a cavity of the device used to heat the consumable). If the device is not cleaned, this tobacco material may stick to the heater and increase odour or decreased performance. The tobacco material left in the cavity is also undesirable from a user point of view due to the tobacco particles then contaminating a user's pocket or bag or the like in which the HNB device is typically carried.
In spite of the effort already invested in the development of heat-not-burn devices/systems and consumables, further improvements are desirable to enhance the user experience of such products. Aspects and embodiments have been devised with the foregoing in mind.

SUMMARY

At its most general there is provided a compression means that is configured to cause a wall of a cavity to compress a precursor of a consumable.
In a first aspect, there is therefore provided an aerosol-generating apparatus comprising a heat-not-burn consumable and a heat-not-burn device. The consumable is a rod containing an aerosol-forming precursor. The device is configured to heat the precursor. Here, the device comprises a cavity for receiving the consumable. The cavity comprises an opening. The consumable is able to be inserted into the cavity via the opening. When inserted, the precursor is received within a wall of the cavity.
By providing a compression means, the precursor is caused to be compressed when the consumable is inserted into the cavity of the device. It has been found that compressing the precursor can act to reduce lateral movement of the consumable within the cavity. In the exemplary embodiments, the compression means is provided by appropriate configuration of the size and shape of the cavity and rod. For instance, the compression means is suitably provided by configuring the wall of the cavity to have an internal dimension specifically adapted to be less than an external dimension of an outer surface of the rod of the consumable. Of course, in the alternative, or in addition, the external dimension of the consumable can be specifically adapted to be greater than an internal dimension of the cavity. But in either case, the appropriate sizing of the wall relative to the rod causes the precursor to be compressed by the wall when the consumable is inserted into the cavity.
In exemplary embodiments, the compression means includes a shoulder. Here, the shoulder transitions between two sizes. That is, the shoulder transitions between a first dimension and a second, different dimension. As explained further below, the shoulder can be formed in the cavity, or in the alternative, the shoulder can be formed on the consumable, or in a further alternative, a shoulder can be formed in both the consumable and the cavity.
Consequently, presented below are alternative solutions for the compression means, identified as Developments A and B. Each of these includes different aspects and different optional features. These developments, aspects and optional features are combinable in any combination unless the context demands otherwise. That is, in development A, the compression means is provided in whole or in part by the consumable being configured to comprise a shoulder. Whereas in development B, the compression means is provided in whole or in part by the cavity being configured to comprise a shoulder.
When the consumable comprises a shoulder, suitably the shoulder is formed in an outer surface of the rod at a distance from a precursor end. Here, the rod comprises a first external dimension between the precursor end and the shoulder and a second external dimension between the shoulder and an end of the rod opposite the precursor end. The second external dimension is smaller than the first external dimension.
When the cavity comprises a shoulder, suitably the shoulder is formed in the wall of the cavity at a distance from the opening. Here, the cavity comprises a first internal dimension between the shoulder and an end of the cavity opposite to the opening and a second internal dimension between the shoulder and the opening. The second external dimension is greater than the first internal dimension.
The alternative solutions, which can be used ion combination, are explained in further detail below with reference to an independent consumable and an independent device. That is, when the compression means of the apparatus is provided wholly by the consumable, the device is optional, and the consumable is claimed in isolation to the device. And when the compression means of the apparatus is provided wholly by the device, the consumable is optional, and the device is claimed in isolation to the consumable.

Development A

At its most general, development A relates to an HNB consumable rod containing an aerosol-forming precursor at one end thereof which is wider than an opposite end of the consumable.
According to a first aspect of development A, there is provided a heat-not-burn consumable for use in a heat-not-burn device, the consumable being a rod containing an aerosol-forming precursor at one end thereof, and having a shoulder in its outer surface at a distance from the precursor end such that a first dimension of the rod from the precursor end to the shoulder is greater than a second dimension of the rod at its opposite end.
Known HNB consumables are typically cylindrical and have a substantially uniform diameter. Thus, it is envisaged in a particularly suitable embodiment that the rod is a substantially cylindrical rod. As will be appreciated, when the rod is cylindrical, the first and second external dimensions are first and second diameters. Here, dimension and diameter become interchangeable dependent on whether the rod is defined or restricted to being cylindrical or not. As described in the background section, the iD ^™ stick comprises: a tobacco portion, a bore filter, a paper tube, and a mouthpiece filter positioned sequentially and end-to-end, and held together by a tipping paper and a combining paper to form a rod. The iD ^™ stick has an increased diameter of 0.08 mm along an overlap region of the tipping paper and the combining paper adjacent the paper tube, but otherwise the diameter of the rod is constant. As such, the diameter of the iD ^™ stick along the tobacco portion is its minimum diameter.
By providing the HNB consumable rod with a shoulder in its outer surface at a distance from the precursor end such that a first diameter of the rod from the precursor end to the shoulder is greater than a second diameter of the rod at its opposite end (which is typically a mouth end, e.g. having a mouthpiece filter), the precursor may be compressed due to clamping of the outer surface of the rod between its precursor end and the shoulder by a wall defining a cavity of a heat-not-burn device, when the rod is inserted into such a cavity.
Accordingly, in a second aspect of development A, there is provided an aerosol-generating apparatus comprising the heat-not-burn consumable according to the first aspect of development A, and a heat-not-burn device for heating the aerosol-forming precursor, wherein the heat-not-burn device comprises: a cavity in which the rod is inserted via an opening at an end of the cavity. As above, when the rod is cylindrical, it will be appreciated that the cavity is suitably also substantially cylindrical. When the consumable is inserted in the cavity and end of the precursor (herein the precursor end) is received within the wall of the cavity. Again, it will be appreciated that the wall of the cavity may be formed of a single, cylindrical wall when the cavity is cylindrical. The precursor end is spaced from the opening when inserted. In exemplary embodiments the cavity includes a base opposite the opening. When the cavity includes a base, the shoulder may be spaced from the base additionally or alternatively to the shoulder being spaced from the opening. Here, the precursor end may be received at or around the base of the cavity. Suitably, a heating element is provided at or around the base of the cavity for heating the precursor of the inserted rod. As explained, in development A, the compression means is provided on the consumable via the cavity being sized relative to the rod, and in particular, relative to the first and second dimensions such that the outer surface of the rod between the precursor end and the shoulder is clamped by the wall of the cavity to compress the precursor.
The precursor may be exposed at the precursor end of the consumable. By clamping the outer surface of the HNB consumable rod using the wall of the cavity, it is possible to reduce lateral movement of the consumable within the cavity, which avoids dislodging the precursor and prevents the precursor falling into the cavity. For example, the precursor may be susceptible to flaking and tearing when in direct contact with components of the heat-not-burn device. Advantageously, a consumable is provided that reduces the risk or likelihood of the precursor falling out or being pulled or pushed out of the consumable in use.
As the first diameter of the consumable from the precursor end to the shoulder is greater than the second diameter of the consumable at its opposite end, the outer surface of the consumable can be clamped by the cylindrical wall of the cavity only between the precursor end and the shoulder. As a result, the total clamping force between the consumable and the wall of the cavity can be reduced as compared with clamping the consumable along its full length. This reduces the surface frictional sliding resistance between the outer surface of the consumable and the wall of the cavity, making insertion of the consumable into the cavity and withdrawal of the consumable from the cavity easier for the user while providing sufficient clamping to hold the consumable in place.
Radial compressive stress applied along the full length of the consumable, including its opposite end, can cause elongation of an inner portion of the consumable. In the iD ^™ stick, for example, such elongation of the bore filter, the paper tube, and/or the mouthpiece filter could push the tobacco portion out of the combining paper. However, in the present consumable the outer surface of the consumable can be clamped only between the precursor end and the shoulder. As such, radial compression of the consumable caused by the clamping can be concentrated at the precursor end rather than the opposite end, which may prevent the precursor from being squeezed out of the consumable.
Optional features of the first and second aspects of development A are set out below.
The precursor may fill a first portion of the consumable rod which extends from the precursor end by at least the distance of the shoulder from the precursor end. The first portion may extend from the precursor end beyond the shoulder. For example, the distance of the shoulder from the precursor end may be 25% to 75%, e.g. 40% to 60%, e.g. approximately 50% of the length of the first portion. By providing the first portion at least up to the shoulder, the clamping of the rod can compress only the precursor.
The consumable may comprise an aerosol flow path from the precursor end to the opposite end.
An axial length of the consumable may be between 40 and 60 mm, e.g. between 45 and 55 mm, e.g. approximately 48 mm.
The consumable rod may have a uniform diameter from its precursor end to the shoulder. As a result, the clamping force may be more evenly distributed along the outer surface of the rod between the precursor end and the shoulder.
The consumable rod may have a uniform diameter or a substantially uniform diameter between the shoulder and its opposite end. Here, substantially uniform includes any presence of an overlap region between a combining paper and a tipping paper, as described below. As such, differences in diameter of less than 0.1 mm between the shoulder and the opposite end can be considered to be negligible.
The second diameter may be not more than 98% of the first diameter. The second diameter may be not more than 97%, e.g. not more than 96%, e.g. not more than 95% of the first diameter. By ensuring a minimum difference between the first and second diameters, clamping of the outer surface of the consumable between the shoulder and the opposite end can be avoided, even when the outer surface between the shoulder and the precursor end is compressed by the cavity wall to effectively reduce the first diameter when in use.
The second diameter may be not less than 80% of the first diameter. The second diameter may be not less than 85%, e.g. not less than 90% of the first diameter. By ensuring a maximum difference between the first and second diameters, less material is required to form the shoulder in the outer surface. Moreover, a gap between the outer surface of the consumable and the cavity wall above the shoulder can be made smaller, which reduces the possibility of the consumable rod, in use, experiencing damaging amounts of bending between the shoulder and its opposite end.
The aerosol-forming precursor (e.g., tobacco rod) is suitably formed into a substantially cylindrical shape. The aerosol-forming precursor may have a diameter in the range 5 to 10 mm, e.g. in the range 6 to 9 mm or 6 to 8 mm, e.g. approximately 7 mm. The aerosol-forming precursor may have an axial length of between 10 and 25 mm, e.g. in the range 11 to 14 mm, e.g. in the range 12 to 13 mm.
As described above, the precursor may fill a first portion of the consumable which extends from the precursor end by at least the distance of the shoulder from the precursor end. Therefore, one or more dimensions of the first portion may correspond to the respective dimensions of the precursor. For example, an axial length of the first portion may be equal to the axial length of the precursor.
The first diameter may be in the range 6 to 16 mm, e.g. in the range 7 to 14 mm or 7 to 12 mm, e.g. approximately 8 mm.
The aerosol-forming precursor is a solid (as opposed to liquid) precursor capable of being heated to release at least one volatile compound that can form an aerosol. It will be appreciated that tobacco leaf is one such precursor, wherein an aerosol is generated by inhaling through the heated precursor. However, those skilled in the art will be aware that HNB systems might also be configured to heat non-tobacco organic material such as other plant material (e.g., cannabis leaf). Consequently, an HNB consumable is intended at its broadest to include an aerosol-forming precursor comprising at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, THC, CBD, opiates and opoids, cathine and cathinone, cannaboids, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A, together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.
Consequently, in the exemplary aspects and embodiments of the HNB consumable described and claimed herein, the aerosol-forming precursor of the consumable suitably comprises a plant material. The plant material may comprise at least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Amica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia califomica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.
It will however be appreciated that in particularly suitable exemplary embodiments, the plant material is tobacco. Here, in the exemplary aspects and embodiments of the HNB consumable described and claimed herein, any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above-mentioned tobaccos.
The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon). In each case, the aerosol-forming precursor is formed into a rod of material. For instance, as termed herein, a tobacco rod.
In exemplary embodiments comprising reconstituted tobacco, the aerosol-forming precursor may comprise a gathered sheet of homogenised reconstituted tobacco or gathered shreds/strips formed from such a sheet. Here, the plurality of strips may be substantially aligned. Moreover, the plurality of strips, parallel to one another, may be substantially parallel to a longitudinal axis of the rod. In addition to this, the plurality of strips may be tightly packed together. The skilled person will recognise that the plurality of strips of reconstituted tobacco are prone to fracture and thus may fall out of the consumable during and after use. Therefore, even when the precursor comprises reconstituted tobacco, the problems associated with tobacco falling out of the consumable still exists and, moreover, the risk is increased when using other types such as cut rag tobacco. Consequently, compression of the precursor by clamping the outer surface of the rod between the shoulder and its precursor end is beneficial to HNB consumables including reconstituted tobacco as the aerosol-forming precursor and may be particularly beneficial to HNB consumables formed with a precursor comprising non-reconstituted tobacco.
In exemplary aspects and embodiments described and claimed herein, the aerosol-forming precursor may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/nonaqueous solvents and binders. Here, the flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming precursor or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming precursor.
HNB consumables are specifically adapted for use with an HNB device (either known devices or the heat-not-burn device described and claimed herein). In particular, a combustible cigarette is not specifically adapted for use with an HNB device. Primarily, this is because insertion of a combustible cigarette into an HNB device and subsequent operation of the HNB device, would not generate an acceptable vapour for consumption by the user. In particular, an insufficient aerosol vapour would be generated. Consequently, in the exemplary embodiments of HNB consumables described and claimed herein, one specific adaption for use with an HNB device is the incorporation of a carrier in the precursor. Here, during use, a first vapour is produced from an active substance (e.g. tobacco material volatising the nicotine or other active substance as described above) and a second vapour is produced from vaporisation of the carrier. Any known or suitable carrier is considered. For instance, the carrier added to the aerosol-forming precursor (e.g., added to the plant material such as tobacco) suitably comprises polyglycol (PG), propylene glycol, and/or vegetable glycerine (VG).
In addition to an aerosol-forming precursor, the HNB consumable may comprise further components or elements combined with the precursor as is known in the art as well as described and claimed herein. Thus, the consumable may contain the precursor combined with one or more further components or elements by a combining paper. Here, the combining paper circumscribes the precursor and further components and is glued or adhered to form a homogenous component or rod as is known in the art and as explained in the background section above. Therefore, except where incompatible, the addition or combination of features of the described and claimed aspects and embodiments of the consumables is expressly considered. Furthermore, as used herein, combining paper in its broadest is intended to include any suitable substrate that can be used to circumscribe the components of the consumable to join or wrap one or more of the components. It is envisaged that suitable substrates are thin and flexible, e.g. paper. Thus, as used herein, wrapping substrate is used interchangeably to reference combining paper in its broadest form even for instance when the combining paper is not combining components.
As used herein, the terms "upstream" and "downstream" are intended to refer to the flow direction of the vapour/aerosol i.e. with the upstream end of the consumable typically the precursor end which provides an inlet for air to enter the consumable rod, e.g. from the base of the cavity. The downstream end of the consumable is the opposite end or mouth end which provides an outlet where the aerosol exits the consumable for inhalation by the user.
As will become apparent, the described or claimed aspects and embodiments of the HNB consumable are suitable for use with an aerosol-generating apparatus wherein the HNB consumable is intended to be used as described in the background section above. That is, with the consumable inserted into the cavity at a downstream end of the heat-not-burn device (i.e. the opening at the end of the cavity). Or stated alternatively, wherein the consumable is insertable into the cavity in a downstream to upstream direction. Herein, such arrangements can be termed 'downstream' consumable. Here, the precursor end is an upstream end and the opposite end is a distal, downstream end which comprises a mouthpiece. For instance, a mouthpiece filter (e.g., a terminal filter arrangement). Here, suitably, the mouthpiece filter may comprise a monoacetate filter or a hollow bore filter. In some arrangements, the hollow bore filter may be a triple bore filter e.g., with three bores arranged in an equilateral triangle around a central axis. Alternatively, the mouthpiece filter may be comprised of cellulose acetate or polypropylene tow. Further alternatively, the mouthpiece filter element (e.g., the terminal filter element) may be comprised of activated charcoal or may be comprised of paper. In each case, the mouthpiece filter element is suitably at least partly (e.g., preferably, but not necessarily entirely) circumscribed with a plug wrap e.g., a paper plug wrap. In some arrangements of the downstream consumable, the mouthpiece filter may include flavourant. For instance, the mouthpiece filter may be formed with a capsule that is fracturable (able to be fractured) by the user to release a vapour or liquid (e.g., provided with a crush ball) as is known in the art.
The mouthpiece filter (at the downstream end of the consumable) is suitably joined to the upstream elements forming the consumable and including at least the aerosol-generating substrate by a circumscribing tipping layer e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.
The HNB consumable may comprise further components and elements, e.g. arranged between the precursor (or first portion) and the mouthpiece filter. Whereas in non-downstream embodiments which might not necessarily comprise a mouthpiece filter, the further elements may be provided to one side of the precursor. For instance, in some embodiments, the consumable comprises an aerosol-cooling element which is adapted to cool (by heat exchange) the aerosol generated from the precursor before being inhaled by the user. That is, in such consumables, the cooling element regulates the temperature of vapour. In some exemplary arrangements, wherein the cooling element may suitably comprise a bore filter and a paper tube, each of the bore filter and the paper tube regulate the temperature of the vapour in use. In some arrangements, the bore filter may be a hollow bore filter. In some arrangements, the paper tube may be a spiral paper tube. In other words, the paper tube may be a continuous paper tube wound in a spiral or the paper tube may be a cardboard tube. In the exemplary embodiments, the paper tube itself may be impermeable to air but comprise a plurality of perforations e.g., formed by a laser. The plurality of perforations may be distributed circumferentially about the paper tube and correspond in number and location with the plurality of perforations of the tipping paper to provide ventilation into an internal cavity of the paper tube.
The HNB consumable may comprise a metal foil or lacquered foil-paper laminate circumscribing the first portion. Wrapping the precursor with a metal foil prevents misuse of the HNB consumable through use of the consumable as a combustible cigarette (i.e. because the metal foil prevents or inhibits or supresses ignition).
Suitably, the heat-not-burn device may comprise an elongate housing (also referred to as a body). An end of the elongate body may be configured for engagement with the consumable. The cavity may be provided in the end of the elongate body. As described above, the consumable rod can be inserted via the opening at the end of the cavity such that the precursor end is received at the base of the cavity opposite the opening.
An internal diameter of the cavity may be less than the first diameter to clamp the outer surface of the consumable rod. The internal diameter of the cavity may be greater than the second diameter of the consumable rod.
The opening at the end of the cavity may be flared outwardly to guide the insertion of the precursor end of the consumable into the cavity. For example, the wall of the cavity may comprise a tapered portion, e.g. a tapered rim which decreases in diameter towards the opening, i.e. in the direction of insertion. This reduces a risk of the precursor end of the consumable rod being snagged on or damaged by an end of the cylindrical wall at the opening if there is any misalignment of the rod and the cavity as the rod is inserted into the cavity.
The heat-not-burn device comprises a heater including the heating element for heating the aerosol-forming precursor. In exemplary embodiments, the heater (and thus the heating element) is rigidly mounted to the body. The heating element may be elongate so as to define a longitudinal axis and may, for example, have a transverse profile (i.e., transverse to a longitudinal axis of the heating element) that is substantially circular (i.e., the heating element may be generally cylindrical). Alternatively, the heating element may have a transverse profile that is rectangular (i.e., the heater may be a "blade heater"). The heating element may alternatively be in the shape of a tube (i.e., the heater may be a "tube heater"). The heating element may take other forms (e.g., the heating element may have an elliptical transverse profile). The shape and/or size (e.g., diameter) of the transverse profile of the heating element may be generally consistent for the entire length (or substantially the entire length) of the heating element.
In exemplary embodiments, the heating element is between 8 mm and 25 mm long, e.g., between 8 mm and 20 mm long, e.g., around 10 mm long. The heating element may have a diameter of between 1.5 mm and 2.5 mm, e.g., a diameter between 2 mm and 2.3 mm, e.g., a diameter of around 2.15 mm.
The heating element may be formed of ceramic. The heating element may comprise a core (e.g., a ceramic core) comprising Al2O3. The core of the heating element may have a diameter of 1.8 mm to 2.1 mm, e.g., between 1.9 mm and 2 mm. The heating element may comprise an outer layer (e.g., an outer ceramic layer) comprising AI2O3. The thickness of the outer layer may be between 160 µm and 220 µm, e.g., between 170 µm and 190 µm, e.g., around 180 µm. The heating element may comprise a heating track, which may extend longitudinally along the heating element. The heating track may be sandwiched between the outer layer and the core of the heating element. The heating track may comprise tungsten and/or rhenium. The heating track may have a thickness of around 20 µm.
In exemplary embodiments, the heating element is located in the cavity (of the device), and may extend (e.g., along a longitudinal axis) from the base of the cavity towards the opening at the end of the cavity. The length of the heating element (i.e., along the longitudinal axis of the heater) may be less than the depth of the cavity. Hence, the heating element may extend for only a portion of the length of the cavity. That is, the heating element may not extend through (or beyond) the opening.
Optionally, the heater comprises a heating element in the form of a rod or blade that extends from the body and into the cavity. That is, the heating element extends from an end of the body that is configured for engagement with the consumable. Here, the heating element is configured for insertion into the consumable when the consumable is inserted into the cavity. In that respect, a distal end (i.e., distal from a base of the heating element where it is mounted to the device) of the heating element may comprise a tapered portion, which may facilitate insertion of the heating element into the precursor end of the consumable rod. The heating element may fully penetrate the consumable when the consumable is fully inserted into the cavity. That is, the entire length, or substantially the entire length, of the heating element may be received in the consumable.
The heating element may have a length that is less than, or substantially the same as, the axial length of the precursor (i.e. the first portion of the consumable). Thus, when the consumable is engaged with the device, the heating element may only penetrate the precursor, rather than other components of the consumable. The heating element may penetrate the consumable for substantially the entire axial length of the precursor (the first portion). Thus, heat may be transferred from (e.g., an outer circumferential surface of) the heating element to the surrounding precursor, when penetrated by the heating element. That is, heat may be transferred radially outwardly (in the case of a cylindrical heating element).
By clamping the outer surface of the HNB consumable rod using the wall of the cavity, it is possible to reduce lateral movement of the consumable within the cavity. The heating rod may be prevented from tearing through the precursor after insertion by reducing lateral movement of the precursor end of the consumable rod relative to the heating rod.
The heating rod may be centrally disposed within the cavity such that its longitudinal axis may be coaxial with the cavity. Hence, by clamping the consumable centrally within the cavity it is possible to achieve better alignment of the heating rod to the longitudinal axis of the consumable. This, in turn, allows heat generated by the heating element to be more evenly distributed throughout the precursor.
Alternatively, the heater can be configured to transfer heat radially inwardly (in the case of a tube heater). In exemplary embodiments where the heater is a tube heater, the heating element of the tube heater may surround at least a portion of the cavity. When the consumable is inserted in the cavity, the heating element may surround a portion of the consumable (i.e., so as to heat that portion of the consumable, for instance the aerosol-forming precursor). In particular, the heating element may surround the first portion of the consumable. That is, when the consumable is engaged with the device, the precursor may be located adjacent an inner surface of the (tubular) heating element. When the heating element is activated (by applying an electrical current though the heater), heat may be transferred radially inwardly from the inner surface of the heating element to heat the aerosol-forming precursor.
In exemplary embodiments where the heater is a tube heater, the (tubular) heating element extends around at least a portion of the cylindrical wall. In this way, the wall of the cavity may be located between the inner surface of the heating element and the outer surface of the consumable. The wall of the cavity may be formed from a thermally conductive material (e.g., a metal) to allow heat conduction from the heating element to the consumable. Thus, heat may be conducted from the heating element, through the cavity wall, to the precursor of the consumable received in the cavity. Alternatively, here, the heating element may be an infrared (IR) heating element. A tubular IR heating element may be configured to emit more IR radiation across the cavity wall than is transmitted by conduction. The cavity wall is therefore suitably transmissive of the emitted IR radiation. The combination of the wall with the tubular IR heating element may be referred to as an IR heating tube. That is, in exemplary embodiments, the cavity may be formed from an IR heating tube.
In some exemplary embodiments, the device comprises a cap disposed at the end of the body that is configured for engagement with the consumable. Where the device comprises a heating element configured to be inserted into the consumable, the cap may at least partially enclose the heating element. The cap may be moveable between an open position in which access is provided to the heating element, and a closed position in which the cap at least partially encloses the heating element by covering the opening at the end of the cavity. The cap may be slideably engaged (i.e., slid to engage) with the body of the device, and may be slideable (i.e., able to slide) between the open and closed positions. In the alternative, rather than or additional to opening and closing the cavity, the sliding between the open and closed position may act to lift the consumable from heating element.
In exemplary embodiments, the cap is configured such that when a consumable is engaged with the device (e.g., inserted in the cavity), only a portion of the consumable is inserted in the cavity. That is, a portion of the consumable (not inserted in the cavity) may protrude from (i.e., extend beyond) the opening. In embodiments wherein the cavity is an upstream cavity, this (protruding) portion of the consumable is a terminal (e.g., mouth) end of the consumable, which is received in a user's mouth for the purpose of inhaling aerosol formed by the system.
In exemplary embodiments, the device comprises a power source or may be connectable to a power source (e.g., a power source separate to the device). Here, the power source is electrically connectable to the heater. In that respect, altering (e.g., toggling) the electrical connection of the power source to the heater may affect a state of the heater. For example, toggling the electrical connection of the power source to the heater may toggle the heater between an on state and an off state (e.g., PWM control). The power source may be a power store. For example, the power source may be a battery or rechargeable battery (e.g., a lithium-ion battery).
According to a third aspect of development A, there is provided a method of manufacturing a heat-not-burn consumable, the method including steps of: providing a heat-not-burn consumable containing an aerosol-forming precursor; and applying a material to a surface of the consumable circumscribing the precursor such that a first dimension of the consumable at one end thereof containing the precursor is greater than a second dimension of the consumable at its opposite end. As explained herein, suitably, the consumable may be substantially cylindrical. Here, the surface to which the material is applied is a circumferential surface and the first and second dimensions are first and second diameters respectively.
In this way, the material which is applied to the circumferential surface can provide a shim for increasing the diameter of the consumable over a distance from the precursor end and thereby form the shoulder in the outer surface of the consumable at that distance from the precursor end along an annular edge of the shim. That is, the first diameter of the consumable forms the first diameter. Moreover, suitably, the difference between the first diameter and the second diameter is suitably the material.
The material may comprise a wrapping substrate, e.g. a rectangular sheet.
The applying step may include wrapping one or more layers of the material circumferentially around the consumable. For example, a length of the material may be wound around the consumable over a plurality of turns. The number of layers may be selected based on a thickness of the material to determine the first diameter of the consumable. Specifically, the first diameter of the consumable is increased by twice the thickness of the material for each layer that is wrapped around the circumferential surface of the consumable.
A width of the wrapping substrate may define the distance of the shoulder from the precursor end. For example, the wrapping substrate may comprise a rectangular sheet. A length of the rectangular sheet (i.e. perpendicular to the width) may be selected based on the number of layers to be applied to the circumferential surface of the consumable and the diameter of the consumable at the precursor end.
In some embodiments, applying the material may include aligning an edge of the wrapping substrate to the precursor end as the length of the wrapping substrate is wrapped circumferentially around the consumable.
In other embodiments, the method may include a cutting step of cutting through the applied material such that a planar face of the precursor is flush with an edge of the applied material. For example, the cutting step may include cutting through the precursor to form the precursor end. Alternatively, the cutting step may include cutting through only the applied material at a location of the precursor end to remove an excess portion of the material.
The thickness of the/each layer of the material may not more than 1.5 mm, e.g. not more than 1.2 mm, e.g. not more than 1.0 mm, e.g. not more than 0.8 mm, e.g. not more than 0.5 mm, e.g. not more than 0.2 mm, e.g. not more than 0.1 mm, e.g. not more than 0.08 mm, e.g. not more than 0.05 mm, e.g. approximately 0.04 mm.
The thickness of the/each layer of the material may not less than 0.04 mm, e.g. not less than 0.05 mm, e.g. not less than 0.08 mm, e.g. not less than 0.1 mm, e.g. not less than 0.2 mm, e.g. not less than 0.5 mm, e.g. not less than 0.8 mm, e.g. not less than 1.0 mm, e.g. not less than 1.2 mm, e.g. not less than 1.5 mm.
The number of layers may be not more than 35 layers, e.g. not more than 30 layers, e.g. not more than 25 layers, e.g. not more than 20 layers, e.g. not more than 15 layers, e.g. not more than 10 layers.
The number of layers may be not less than 5 layers, e.g. not less than 10 layers, e.g. not less than 15 layers, e.g. not less than 20 layers, e.g. not less than 25 layers, e.g. not less than 30 layers.
When the material is wound circumferentially around the consumable, the first diameter may vary by up to a thickness of a single layer. Therefore, it may be beneficial to use thinner layers of the material as slight differences in the first diameter at different circumferential positions of the outer surface become negligible. Similarly, by applying more layers, slight differences in the first diameter become negligible relative to the first diameter. As a result, the first diameter may be more consistent in the circumferential direction and the outer surface between the shoulder and the precursor end may be more cylindrical.
One or both longitudinal ends of the material may be tapered, respectively, such that the thickness of the material decreases towards each end. Therefore, when a length of the material is wound circumferentially around the consumable to form a plurality of layers, differences in the first diameter where the ends of the material are disposed can be reduced.
The material may comprise paper or card. For example, the material may have identical properties to a combining paper used to hold components of the consumable together.
Adhesive may be applied to the material and/or the consumable before the material is applied. Subsequently, the material may be applied to the circumferential surface of the consumable with the adhesive being disposed therebetween.

Development B

At its most general, development B relates to a heat-not-burn device comprising a cavity for receiving a heat-not-burn consumable, the cavity having an opening and a portion spaced from the opening, wherein the position spaced from the opening is narrower than the opening.
According to a first aspect of development B, there is provided an heat-not-burn device for use with a heat-not-burn consumable rod containing an aerosol-forming precursor at one end thereof, the device comprising: a cavity defined by a wall and having an opening at an end thereof through which the rod is insertable into the cavity such that the precursor end is within the wall; wherein the wall of the cavity has a shoulder in its wall at a distance from the opening such that a first internal dimension of the cavity between the shoulder and an end of the cavity opposite the opening is narrower than a second internal dimension of the cavity between the shoulder and the opening, whereby an outer surface of the inserted rod between the end of the cavity and the shoulder is clampable by the wall of the cavity to compress the precursor.
Known HNB devices typically have cylindrical cavities with a substantially uniform diameter. Thus, it is envisaged in a particularly suitable embodiment that the cavity is substantially cylindrical. As will be appreciated, when the cavity is cylindrical, the first and second internal dimensions are first and second diameters. Here, dimension and diameter become interchangeable dependent on whether the cavity is defined or restricted to being cylindrical or not. As described in the background section, in the Pulze ^™ device a housing is provided to define a cavity. The housing has a generally longitudinal shape, having a longitudinal axis that is aligned with the cavity such that when the consumable is inserted, the consumable and device have a common axis. The Pulze ^™ device and the iD ^™ stick are physically coupled together by inserting the iD ^™ stick into the cavity, with the upstream tobacco portion inserted first. When the iD ^™ stick is fully inserted into the cavity, the mouthpiece filter protrudes from the cavity and the tobacco portion end abuts the base of the cavity.
By providing the heat-not-burn device with a shoulder in its cavity-defining wall at a distance from the opening such that a first diameter of the cavity at its end is narrower than a second diameter of the cavity at its opening, the precursor may be compressed due to clamping of the outer surface of the consumable rod by the cavity-defining wall between the base and the shoulder.
Accordingly, in a second aspect of development B, there is provided an aerosol-generating apparatus comprising: a cylindrical heat-not-burn consumable rod containing an aerosol-forming precursor at one end thereof; and the heat-not-burn device according to the first aspect of development B. when the consumable is inserted in the cavity an end of the precursor (herein the precursor end) is received within the wall of the cavity. Again, it will be appreciated that the wall of the cavity may be formed of a single, cylindrical wall when the cavity is cylindrical. The precursor end is spaced from the opening when inserted. In exemplary embodiments the cavity end comprises a base opposite the opening. Here, the precursor end may be received at or around the base of the cavity. When the cavity includes a base, the shoulder may be spaced from the base additionally or alternatively to the shoulder being spaced from the opening. Suitably, a heating element is provided at or around the base of the cavity for heating the precursor of the inserted rod. As explained, in development B, the compression means is provided on the device via the cavity being sized relative to the rod, and in particular, relative to the first and second dimensions such that the outer surface of the inserted rod between the base (or in the alternative, the end) and the shoulder is clamped by the wall of the cavity to compress the precursor.
By clamping the outer surface of the HNB consumable rod using the wall of the cavity, it is possible to reduce lateral movement of the consumable within the cavity, which helps to avoid dislodging the precursor and to prevent the precursor falling into the cavity. For example, the precursor may be susceptible to flaking and tearing when in direct contact with components of heat-not-burn device. Advantageously, a heat-not-burn device is provided that reduces the risk or likelihood of the precursor falling out or being pulled or pushed out of the consumable in use.
As the first diameter of the cavity at base is greater than the second diameter of the consumable at its opening, the outer surface of the consumable can be clamped by the wall of the cavity up to a maximum distance from the precursor end which corresponds to the distance of the shoulder from the base of the cavity. As a result, the total clamping force between the consumable and the wall of the cavity can be reduced as compared with clamping the consumable along its full length. This reduces the surface frictional sliding resistance between the outer surface of the consumable and the wall of the cavity, making insertion of the consumable into the cavity and withdrawal of the consumable from the cavity easier for the user while providing sufficient clamping to hold the consumable in place.
Radial compressive stress applied along the full length of the consumable, i.e. from the precursor end to its opposite end (which is typically a mouth end, e.g. having a mouthpiece filter), can cause elongation of an inner portion of the consumable. In the iD TM stick, for example, such elongation of the bore filter, the paper tube, and/or the mouthpiece filter could push the tobacco portion out of the combining paper. However, the present heat-not-burn device can clamp the outer surface of the received consumable using the wall of the cavity only between the base and the shoulder. As such, radial compression of the consumable caused by the clamping can be concentrated at the precursor end rather than the opposite end, which may prevent the precursor from being squeezed out into the cavity.
Optional features of the first and second aspects of development B are set out below.
Suitably, the heat-not-burn device may comprise an elongate housing (also referred to as a body). An end of the elongate body may be configured for engagement with the consumable. The cavity may be provided in the end of the elongate body. As described above, the consumable rod can be inserted via the opening at the end of the cavity such that the precursor end is received at the base of the cavity opposite the opening.
The first diameter of the cavity may be less than a diameter of the consumable rod to clamp the outer surface of the consumable rod. The second diameter of the cavity may be greater than the diameter of the consumable rod.
The precursor may fill a first portion of the consumable rod which extends from the precursor end by at least the distance of the shoulder from the base of the cavity. Therefore, the clamping of the rod can compress only the precursor. The first portion may extend from the precursor end by a distance greater than the distance of the shoulder from the base of the cavity. For example, the distance of the shoulder from the base of the cavity may be 25% to 75%, e.g. 40% to 60%, e.g. approximately 50% of the length of the first portion.
The distance of the shoulder from the base of the cavity may be between 5 and 20 mm, e.g. in the range 6 to 12 mm, e.g. in the range 7 to 8 mm.
An axial length of the cavity from the base to the opening may be between 25 and 55 mm, e.g. between 30 and 45 mm, e.g. approximately 35 mm.
The cavity may have a uniform diameter from its base to the shoulder. As a result, the clamping force may be more evenly distributed along the substantially cylindrical wall between the base and the shoulder.
The cavity may have a uniform diameter or a substantially uniform diameter between the shoulder and the opening.
The shoulder may be formed by machining a narrower bored cavity to the depth of the shoulder. Alternatively, the shoulder may be formed by a moulding process.
The first diameter may be not more than 98% of the second diameter. The first diameter may be not more than 97%, e.g. not more than 96%, e.g. not more than 95% of the second diameter. By ensuring a minimum difference between the first and second diameters, clamping of the outer surface of the consumable by the cavity wall between the shoulder and the opening can be avoided, even when the outer surface of the consumable is compressed by the cavity wall between the shoulder and the base to effectively reduce the diameter of the consumable at the precursor end when in use.
The first diameter may be not less than 80% of the second diameter. The first diameter may be not less than 85%, e.g. not less than 90% of the second diameter. By ensuring a maximum difference between the first and second diameters, a gap between the outer surface of the consumable and the cavity wall above the shoulder can be made smaller, which reduces the possibility of the consumable rod, in use, experiencing damaging amounts of bending between the shoulder and its opposite end.
The second diameter may be in the range 6 to 16 mm, e.g. in the range 7 to 14 mm or 7 to 12 mm, e.g. approximately 8 mm.
The substantially cylindrical wall may taper smoothly at the shoulder to transition from the second diameter to the first diameter to guide the precursor end of the rod past the shoulder on insertion into the cavity. For example, the shoulder may comprise a tapered portion which decreases in diameter towards the base of the cavity, i.e. in the direction of insertion. This reduces a risk of the precursor end of the consumable rod being snagged on or damaged by the shoulder if there is any misalignment of the consumable rod and the cavity as the rod is inserted into the cavity.
The heat-not-burn device comprises a heater including the heating element for heating the aerosol-forming precursor. The heating element may have identical features to those described under development A. In particular, the heating element may comprise a heating rod. By clamping the outer surface of the consumable rod using the wall of the cavity, it is possible to reduce lateral movement of the consumable within the cavity. The heating rod may be prevented from tearing through the precursor after insertion by reducing lateral movement of the precursor end of the consumable rod relative to the heating rod.
The heating rod may be centrally disposed within the cavity such that its longitudinal axis may be coaxial with the cavity. Hence, by clamping the consumable centrally within the cavity it is possible to achieve better alignment of the heating rod to the longitudinal axis of the consumable. This, in turn, allows heat generated by the heating element to be more evenly distributed throughout the precursor.
The heat-not-burn device may comprise a cap disposed at the end of the body that is configured for engagement with the consumable. The cap may have identical features to those described under development A.
The heat-not-burn device may comprise a power source or may be connectable to a power source (e.g., a power source separate to the device). The power source may have identical features to those described under development A.
The preceding summary is provided for purposes of summarizing some examples to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the above-described features should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and/or proceeding examples may be combined in any suitable combination to provide further examples, except where such a combination is clearly impermissible or expressly avoided. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following text and the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

Aspects, features and advantages of the present disclosure will become apparent from the following description of examples in reference to the appended drawings in which like numerals denote like elements.

Fig. 1 is a block system diagram showing an aerosol-generating apparatus.
Fig. 2 is a block system diagram showing an example implementation of the apparatus of Fig. 1, where the aerosol-generating apparatus is configured to generate aerosol from a solid precursor.
Fig. 3 is a schematic diagram showing an example implementation of the apparatus of Fig. 2.
Fig. 4 is a schematic diagram showing an example heat-not-burn consumable rod.
Fig. 5 shows an end view of a first portion at a precursor end of the consumable rod of Fig. 4.
Fig. 6 is a schematic diagram showing part of an example heat-not-burn device.
Figs. 7A-C are schematic diagrams of a cross-section of an aerosol-generating apparatus showing the insertion of the consumable rod of Fig. 4 into the device of Fig. 6.
Fig. 8 is a flow chart diagram showing a method of manufacturing the consumable rod of Fig. 4.
Fig. 9 is a schematic diagram showing another example heat-not-burn consumable rod.
Fig. 10 is a schematic diagram showing part of another example heat-not-burn device.
Figs. 11A-C are schematic diagrams of a cross-section of an aerosol-generating apparatus showing the insertion of the consumable rod of Fig. 9 into the device of Fig. 10.

DETAILED DESCRIPTION OF EMBODIMENTS

Before describing several examples implementing the present disclosure, it is to be understood that the present disclosure is not limited by specific construction details or process steps set forth in the following description and accompanying drawings. Rather, it will be apparent to those skilled in the art having the benefit of the present disclosure that the systems, apparatuses and/or methods described herein could be embodied differently and/or be practiced or carried out in various alternative ways.
Unless otherwise defined herein, scientific and technical terms used in connection with the presently disclosed inventive concept(s) shall have the meanings that are commonly understood by those of ordinary skill in the art, and known techniques and procedures may be performed according to conventional methods well known in the art and as described in various general and more specific references that may be cited and discussed in the present specification.
Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.
All examples implementing the present disclosure can be made and executed without undue experimentation in light of the present disclosure. While particular examples have been described, it will be apparent to those of skill in the art that variations may be applied to the systems, apparatus, and/or methods and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit, and scope of the inventive concept(s). All such similar substitutions and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the inventive concept(s) as defined by the appended claims.
The use of the term "a" or "an" in the claims and/or the specification may mean "one," as well as "one or more," "at least one," and "one or more than one." As such, the terms "a," "an," and "the," as well as all singular terms, include plural referents unless the context clearly indicates otherwise. Likewise, plural terms shall include the singular unless otherwise required by context.
The use of the term "or" in the present disclosure (including the claims) is used to mean an inclusive "and/or" unless explicitly indicated to refer to alternatives only or unless the alternatives are mutually exclusive. For example, a condition "A or B" is satisfied by any of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
As used in this specification and claim(s), the words "comprising, "having," "including," or "containing" (and any forms thereof, such as "comprise" and "comprises," "have" and "has," "includes" and "include," or "contains" and "contain," respectively) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.
Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, examples, or claims prevent such a combination, the features of examples disclosed herein, and of the claims, may be integrated together in any suitable arrangement, especially ones where there is a beneficial effect in doing so. This is not limited to only any specified benefit, and instead may arise from an "ex post facto" benefit. This is to say that the combination of features is not limited by the described forms, particularly the form (e.g. numbering) of example(s), embodiment(s), or dependency of claim(s). Moreover, this also applies to the phrase "in one embodiment," "according to an embodiment," and the like, which are merely a stylistic form of wording and are not to be construed as limiting the following features to a separate embodiment to all other instances of the same or similar wording. This is to say, a reference to 'an,' 'one,' or 'some' embodiment(s) may be a reference to any one or more, and/or all embodiments, or combination(s) thereof, disclosed. Also, similarly, the reference to "the" embodiment may not be limited to the immediately preceding embodiment. Further, all references to one or more embodiments or examples are to be construed as non-limiting to the claims.
The present disclosure may be better understood in view of the following explanations, wherein the terms used that are separated by "or" may be used interchangeably:
As used herein, an "aerosol generating apparatus" may be an apparatus configured to deliver an aerosol to a user for inhalation by the user. The apparatus may additionally/alternatively be referred to as a "smoking substitute apparatus", if it is intended to be used instead of a conventional combustible smoking article. As used herein a combustible "smoking article" may refer to a cigarette, cigar, pipe or other article, that produces smoke (an aerosol comprising solid particulates and gas) via heating above the thermal decomposition temperature (typically by combustion and/or pyrolysis). An aerosol generated by the apparatus may comprise an aerosol with particle sizes of 0.2 - 7 microns, or less than 10 microns, or less than 7 microns. This particle size may be achieved by control of one or more of: heater temperature; cooling rate as the vapour condenses to an aerosol; flow properties including turbulence and velocity. The generation of aerosol by the aerosol generating apparatus may be controlled by an input device. The input device may be configured to be user-activated, and may for example include or take the form of an actuator (e.g. actuation button) and/or an airflow sensor.
Each occurrence of the aerosol generating apparatus being caused to generate aerosol for a period of time (which may be variable) may be referred to as an "activation" of the aerosol generating apparatus. The aerosol generating apparatus may be arranged to allow an amount of aerosol delivered to a user to be varied per activation (as opposed to delivering a fixed dose of aerosol), e.g. by activating an aerosol generating unit of the apparatus for a variable amount of time, e.g. based on the strength/duration of a draw of a user through a flow path of the apparatus (to replicate an effect of smoking a conventional combustible smoking article).
The aerosol generating apparatus may be portable. As used herein, the term "portable" may refer to the apparatus being for use when held by a user.
As used herein, an "aerosol" may include a suspension of precursor, including as one or more of: solid particles; liquid droplets; gas. Said suspension may be in a gas including air. An aerosol herein may generally refer to/include a vapour. An aerosol may include one or more components of the precursor.
As used herein, a "precursor" may include one or more of a: liquid; solid; gel; loose leaf material; other substance. The precursor may be processed by an aerosol generating unit of an aerosol generating apparatus to generate an aerosol. The precursor may include one or more of: an active component; a carrier; a flavouring. The active component may include one or more of nicotine; caffeine; a cannabidiol oil; a non-pharmaceutical formulation, e.g. a formulation which is not for treatment of a disease or physiological malfunction of the human body. The active component may be carried by the carrier, which may be a liquid, including propylene glycol and/or glycerine. The term "flavouring" may refer to a component that provides a taste and/or a smell to the user. The flavouring may include one or more of: Ethylvanillin (vanilla); menthol, Isoamyl acetate (banana oil); or other. The precursor may include a substrate, e.g. reconstituted tobacco to carry one or more of the active component; a carrier; a flavouring.
As used herein, a "flow path" may refer to a path or enclosed passageway through an aerosol generating apparatus, e.g. for delivery of an aerosol to a user. The flow path may be arranged to receive aerosol from an aerosol generating unit. When referring to the flow path, upstream and downstream may be defined in respect of a direction of flow in the flow path, e.g. with an outlet being downstream of an inlet.
As used herein, a "delivery system" may be a system operative to deliver an aerosol to a user. The delivery system may include a mouthpiece and a flow path.
As used herein, a "flow" may refer to a flow in a flow path. A flow may include aerosol generated from the precursor. The flow may include air, which may be induced into the flow path via a puff by a user.
As used herein, a "puff" (or "inhale" or "draw") by a user may refer to expansion of lungs and/or oral cavity of a user to create a pressure reduction that induces flow through the flow path.
As used herein, an "aerosol generating unit" may refer to a device configured to generate an aerosol from a precursor.
As used herein, a "heating system" may refer to an arrangement of at least one heating element, which is operable to aerosolise a precursor once heated. The at least one heating element may be electrically resistive to produce heat from the flow of electrical current therethrough. The at least one heating element may be arranged as a susceptor to produce heat when penetrated by an alternating magnetic field. The heating system may be configured to heat a precursor to below 300 or 350 degrees C, including without combustion.
As used herein, a "consumable" may refer to a unit that includes a precursor. The consumable may include a mouthpiece. With solid material implementations of the precursor, e.g. tobacco or reconstituted tobacco formulation, the consumable may be referred to as a "stick" or "package" or "heat-not-burn consumable". In a heat-not-burn consumable, the mouthpiece may be implemented as a filter and the consumable may be arranged to carry the precursor. The consumable may be implemented as a dosage or pre-portioned amount of material, including a loose-leaf product.
As used herein "heat-not-burn" (or "HNB" or "heated precursor") may refer to the heating of a precursor, typically tobacco, without combustion, or without substantial combustion (i.e. localised combustion may be experienced of limited portions of the precursor, including of less than 5% of the total volume).
Referring to Fig. 1, an example aerosol generating apparatus 1 includes a power supply 2, for supply of electrical energy. The apparatus 1 includes an aerosol generating unit 4 that is driven by the power supply 2. The power supply 2 may include an electric power supply in the form of a battery and/or an electrical connection to an external power source. The apparatus 1 includes a precursor 6, which in use is aerosolised by the aerosol generating unit 4 to generate an aerosol. The apparatus 1 includes a delivery system 8 for delivery of the aerosol to a user.
Electrical circuitry (not shown in Fig. 1) may be implemented to control the interoperability of the power supply 4 and aerosol generating unit 6.
Fig. 2 shows an implementation of the apparatus 1 of Fig. 1, where the aerosol generating apparatus 1 is configured to generate aerosol by a-heat not-burn process.
In this example, the apparatus 1 includes an HNB device 10 and an HNB consumable 70.
In this example, the HNB device 10 comprises a device body 50 which includes the power supply 4 and a heating system 52. The heating system 52 includes at least one heating element 54. The body may additionally include any one or more of electrical circuitry 56, a memory 58, a wireless interface 60, one or more other components 62.
The electrical circuitry 56 may include a processing resource for controlling one or more operations of the body 50, e.g. based on instructions stored in the memory 58.
The wireless interface 60 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.
The other component(s) 62 may include an actuator, one or more user interface devices configured to convey information to a user and/or a charging port, for example (see e.g. Fig. 3).
The body 50 is configured to engage with the consumable 70 such that the heating element 54 of the heating system 52 penetrates into the solid precursor 6 of the consumable. In use, a user may activate the aerosol generating apparatus 1 to cause the heating system 52 of the body 50 to cause the heating element 54 to heat the solid precursor 6 of the consumable (without combusting it) by conductive heat transfer, to generate an aerosol which is inhaled by the user.
Fig. 3 shows an example implementation of the heat-not-burn device 10 of Fig. 2.
As depicted in Fig. 3, the consumable 70 is implemented as a rod, which is engaged with the body 50 by inserting the rod into an opening at a top end 53 of the body 50, which causes the at least one heating element 54 of the heating system 52 to penetrate into the solid precursor 6 (further details are discussed below).
The consumable 70 includes the solid precursor 6 proximal to the body 50, and a filter distal to the body 50 when the consumable 70 is inserted. The filter serves as the mouthpiece of the consumable 70 and thus the apparatus 1 as a whole.
In this example, the body 50 includes a cap 51. In use the cap 51 is engaged at a top end 53 of the body 50. Although not apparent from Fig. 3, the cap 51 is moveable relative to the body 50. In particular, the cap 51 is slidable and can slide along a longitudinal axis of the body 50.
The body 50 also includes an actuator 55 on an outer surface of the body 50. In this example, the actuator 55 has the form of a button.
The body 50 also includes a user interface device configured to convey information to a user. Here, the user interface device is implemented as a plurality of lights 57, which may e.g. be configured to illuminate when the apparatus 1 is activated and/or to indicate a charging state of the power supply 4. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.
The body 50 may also include an airflow sensor which detects airflow in the aerosol generating apparatus 1 (e.g. caused by a user inhaling through the consumable 70). This may be used to count puffs, for example.
In this example, the consumable 70 includes a flow path which transmits aerosol generated by the heating element 54 to the mouthpiece of the consumable 70.
In this example, the aerosol generating unit 4 is provided by the above-described heating system 52 and the delivery system 8 is provided by the above-described flow path and mouthpiece of the consumable 70.
Fig. 4 shows the consumable 70 which takes the form of a substantially cylindrical rod having a longitudinal axis. The rod 70 contains the aerosol-forming precursor 6 which fills a first portion 72 of the rod 70 extending from a precursor end 74 part-way towards an opposite (mouth) end 76. Specifically, the axial length L of the consumable 70 is approximately 48 mm and the first portion 72 has an axial length P of around 12 mm. The precursor 6 is exposed at the precursor end 74.
The consumable rod 70 has a shoulder 78 in its outer surface 80 at a distance S from the precursor end 74 such that a first diameter of the rod 70 from the precursor end 74 to the shoulder 78 is greater than a second diameter of the rod at its opposite end 76. As shown in Fig. 4, the first portion 72 extends from the precursor end 74 beyond the shoulder 78 such that the distance S of the shoulder 78 from the precursor end 74 is approximately 50% of the length of the first portion 72. The first diameter is substantially uniform from its precursor end 74 to the shoulder 78 and the second diameter is substantially uniform between the shoulder 78 and the opposite end 76. The first and second diameters are approximately 8 mm and 7.5 mm, respectively.
The consumable 70 comprises an aerosol flow path (not shown) from the precursor end 74 to the opposite end 76. Accordingly, the precursor end 74 is an upstream end of the consumable 70 which provides an inlet for air to enter the first portion 70. The opposite end 76 is therefore a downstream end of the consumable 70 providing an outlet from which the aerosol exits the consumable 70 for inhalation by the user.
In the exemplary embodiments, the precursor 6 is suitably a reconstituted tobacco, and although herein the precursor will be referred to as a tobacco, references to tobacco equally apply to the encompassing generic term aerosol-forming precursor. As such, the first portion 72 is also referred to herein as a tobacco portion 72. The processing of tobacco in the preparation of reconstituted tobacco (recon) by means of a paper-making process is well known in the art as exemplified by Canadian Pat. No. 862,497 which has been incorporated herein by reference. The processes therein described are particularly advantageous with the paper-making process for preparing reconstituted tobacco material ("recon") sheets. A carrier is added to the recon to assist in the aerosol formation to allow the consumable to be specifically adapted to operate as an HNB consumable.
Fig. 5 illustrates an end view of the first portion 72 at the precursor end 74. The recon is prepared in a strip maker and gathered into a rod corresponding to the first portion 72. The first portion 72 therefore comprises multiple parallel strips 82 of the cut recon running parallel to the longitudinal axis. Consequently, in Fig. 5, only the cut tips of the strips 82 are seen. Although the strips can be tightly packed, voids 84 are left between adjacent strips. As will be appreciated, the voids provide air flow passages through the first portion 72 to provide the inlet.
Fig. 6 shows the cavity of the heat-not-burn device 10. The device 10 comprises a cavity 102 defined by a cylindrical wall 104 and configured to receive the consumable rod 70. The cavity 102 has a base 106 and an opening 108 opposite the base 106. The opening 108 is provided by the aperture in the top end 53 of the body 50 of the device 10. The rod 70 is insertable into the cavity 102 via the opening 106 of the cavity 102 as shown in Fig. 7A. When the rod 70 is fully inserted, its precursor end 74 is received at the base 106 as shown in Fig. 7C. As shown in Figs. 7B and 7C, the cavity 102 is sized such that the outer surface 80 of the consumable rod 70 from the shoulder 78 to the precursor end 74 is clamped by the wall 104 of the cavity 102 to compress the tobacco 6. This is because the cavity 102 has an internal diameter which is less than the first diameter from the precursor end 74 to the shoulder 78. Also, the internal diameter of the cavity 102 is greater than the second diameter of the consumable rod 70 at its opposite end 76.
The opening 108 is flared outwardly to guide the insertion of the precursor end 74 of the rod 70 into the cavity 102. Specifically, the cylindrical wall 104 comprises a tapered rim 110 that decreases in diameter towards the opening 108 of the cavity 102. This reduces a risk of the precursor end 74 being caught by the cylindrical wall 104 at the opening 108 due to misalignment of the rod 70 with the cavity 102.
The device 10 has a heating rod 112 which forms part of the heating element 54 at the base 106 of the cavity for heating the tobacco 6 in the first portion 72.
The heating rod 112 is rigidly mounted to the base 106 and extends along a longitudinal axis from the base 106 towards the opening 108 of the cavity 102. The heating rod 112 is shorter than the depth of the cavity 102 as shown in Fig. 6. Specifically, the heating rod 112 is approximately 10 mm long. A diameter of the heating rod 112 is around 2.15 mm. A distal end 114 (i.e., distal from a base 106) of the heating rod 112 comprises a tapered portion to facilitate insertion of the heating rod 112 through the precursor end 74 of the consumable 70. As shown in Fig. 7C, the heating rod 112 fully penetrates the consumable 70 when the consumable 70 is fully inserted into the cavity 102. The length of the heating rod 112 is substantially the same as the axial length of the first portion 72 of the consumable 70, such that its entire length is embedded in the tobacco 6. Thus, heat is transferred radially outwardly from an outer circumferential surface 116 of the heating rod 112 to the surrounding tobacco 6, when penetrated by the heating rod 112.
The heating rod 112 is centrally disposed within the cavity 102 with respect to the cylindrical wall 104 such that its longitudinal axis is coaxial with the cavity 102. Therefore, clamping the consumable 70 within the cavity 104 achieves better alignment of the heating rod 112 to the longitudinal axis of the consumable 70, which enables the heat generated by the heating rod 112 to be more evenly distributed throughout the tobacco 6. Additionally, by clamping the outer surface 80 of the consumable rod 70 using the cavity wall 104, lateral movement of the consumable 70 within the cavity is restricted. This helps to prevent the heating rod 112 from tearing through the tobacco 6 after insertion, which could otherwise lead to the tobacco 6 falling into the cavity 102.
Fig. 8 shows the steps of a method of manufacturing the consumable rod 70.
At step S1, a substantially cylindrical heat-not-burn consumable containing an aerosol-forming precursor is provided. Such a consumable may be the consumable rod 170 illustrated in Fig. 9. The same reference numbers are used to identify features of the consumable rod 170 in Fig. 9 which are identical to those of the consumable rod 70 in Fig. 4. However, unlike the consumable rod 70, the consumable rod 170 does not have a shoulder in its outer surface 180 and therefore it has a uniform diameter from its precursor end 74 to the opposite end 76. The precursor 6 is nonetheless exposed at the precursor end 74 of the consumable 170.
At step S2, a length of wrapping substrate (not shown) having a constant width is provided. The wrapping substrate is suitably a rectangular sheet of paper having a thickness of approximately 0.04 mm. The width of the rectangular sheet is around 12 mm, and its length is around 135 mm. An adhesive may be applied to one side of the wrapping substrate, for example, at each of its longitudinal ends.
At step S3, the wrapping substrate is wrapped circumferentially around the consumable 170 to circumscribe the precursor 6, i.e. the tobacco portion 72. This involves winding the entire length of the substrate around the rod 170 (i.e. forming about 6 layers). Hence, the length of the wrapping substrate perpendicular to its width is selected based on a first diameter of the consumable 70 required to form an interference fit within the cavity 102 of the device 10. The number of layers therefore depends on the original diameter of the consumable 170 and the wrapping substrate thickness. The first diameter of the consumable 70 is increased by twice the thickness of the wrapping substrate for each layer applied. More layers and/or an increased thickness may be used to obtain a larger first diameter, thereby increasing the compression of the tobacco by increasing the clamping force. Conversely, fewer layers and/or a decreased thickness may be used to obtain a smaller first diameter, thereby decreasing the compression of the tobacco by decreasing the clamping force. In other words, the wrapping substrate forms a shim for increasing the diameter of the consumable 170 at its precursor end 174.
In the consumable rod 70, the distance of the shoulder 78 from the precursor end 74 is determined by the width of the wrapping substrate. Accordingly, the shoulder 78 in the outer surface 80 of the consumable 70 is defined by an annular edge of the shim formed by the wrapping substrate.
In order to achieve the fast-processing times, cylindrical rods of tobacco may be cut to form a double length tobacco portion. In other words, the tobacco material is formed into rods sufficiently long so as to form two consumables when cut in half. In some arrangements, double lengths of each of a tobacco portion, a bore filter, a paper tube and a mouthpiece filter are stored in buffers for supplying to a combiner when required. Within the combiner, a double length paper tube may be cut in half to form a single length paper tube. The double length bore filter may subsequently be sandwiched between each single length paper tube to form a first unit. The first unit may subsequently be cut in half (through the centre of the double length bore filter) to form two second units (each comprising a single length bore filter abutting a single length paper tube). The double length tobacco portion is subsequently sandwiched between each second unit to form a third unit.
A double width (here the width is formed along the length or longitudinal axis of the consumable) of combining paper may then be fed into the combiner. Within the combiner, adhesive may be applied to the combining paper. Subsequently, the combining paper with adhesive may be wrapped around the third unit. The adhesive may be consolidated before the wrapped third unit is cut into two fourth units (through the centre of the double length tobacco portion). That is, the cut forms the precursor end of the HNB consumable. The precursor end has a planar face that is flush with the tobacco and combining paper to expose the tobacco because the cut is made through the combining paper and tobacco portion.
Accordingly, at step S1 in Fig. 8, a double-length consumable may be provided in which the double length tobacco portion wrapped in the combining paper has not been cut through its centre. At step S2, a wrapping substrate having a double width may be provided. Therefore, at step S3, a length of the double width wrapping substrate is wrapped circumferentially around the double length consumable circumscribing the double-length tobacco portion and the combining paper. After the wrapping substrate has been applied, the double length consumable is cut through the centre of its double length tobacco portion. This cut forms the precursor end of the HNB consumable, and because the cut is made through the wrapping substrate, the combining paper and the tobacco portion, the precursor end has a planar face that is flush with the tobacco, the combining paper and the wrapping substrate.
Fig. 10 shows the cavity of another example heat-not-burn device 200. The device 200 comprises a cavity 202 defined by a substantially cylindrical wall 204 and configured to receive the consumable rod 170. The cavity 202 has a base 206 and an opening 208 opposite the base 206. The base 206 and the opening 208 of the device 10 are different to those of the device 10 in Fig. 6 because the wall 204 of the cavity has a shoulder 220 at a distance S' from the base 206 such that a first diameter of the cavity 202 at its base 206 is narrower than a second diameter of the cavity 202 at its opening 208.
The consumable rod 170 is insertable into the cavity 202 via the opening 206 of the cavity 202 as shown in Fig. 11A. When the rod 170 is fully inserted, its precursor end 74 is received at the base 206 as shown in Fig. 11C. As shown in Figs. 11B and 11C, the cavity 202 is sized such that the outer surface 180 of the consumable rod 170 is clamped by the wall 204 of the cavity 202 from the shoulder 220 to the base 206 to compress the tobacco 6. This is because the first diameter of the cavity 202 at the base 206 is less than the diameter of the consumable rod 170 to clamp the outer surface 180 of the consumable rod 170. Also, the second diameter of the cavity 202 at the opening 208 is greater than the diameter of the consumable rod 170.
As shown in Fig. 10, the cavity wall 204 smoothly tapers at the shoulder 220 to transition from the second diameter to the first diameter to guide the precursor end 74 of the consumable 170 past the shoulder 220 and towards the base 206 of the cavity 202. This reduces a risk of the precursor end 74 being caught on the shoulder 220 as the consumable rod 170 is inserted into the cavity 202 due to any misalignment of the rod 170 and the cavity 202.
The same reference numbers are used to identify features of the consumable rod 170 in Fig. 9 which are identical to those of the consumable rod 70 in Fig. 4. For example, the arrangement of the heating element 54 and its associated features in the device 200 is the same as the heating element 54 in the device 10.

Claims

An aerosol-generating apparatus comprising a heat-not-burn consumable being a rod, containing an aerosol-forming precursor at one end thereof, and a heat-not-burn device for heating the aerosol-forming precursor,
wherein the heat-not-burn device comprises a cavity in which the rod is inserted via an opening at an end of the cavity such that the precursor is received within a wall of the cavity, and characterised in that:
the apparatus comprises a compression means, and the compression means is configured to cause the wall of the cavity to compress the precursor.
The aerosol-generating apparatus according to claim 1, wherein the compression means comprises an internal dimension of the cavity's wall being specifically adapted to be less than an external dimension of an outer surface of the rod of the consumable.
The aerosol-generating apparatus according to claim 2, wherein the consumable comprises a shoulder in the outer surface of the rod at a distance from the precursor end such that a first external dimension of the rod between the precursor end and the shoulder is greater than a second external dimension of the rod between the shoulder and an end of the rod opposite the precursor end.
The aerosol-generating apparatus according to claim 2 or claim 3, wherein the compression means comprises a shoulder in the wall of the cavity at a distance from the opening such that a first internal dimension of the cavity between the shoulder and an end of the cavity opposite the opening is narrower than a second internal dimension of the cavity between the shoulder and the opening.
The aerosol-generating apparatus according to any preceding claim, wherein the opening is flared outwardly to guide the insertion of the precursor end of the rod into a portion of the cavity having the first internal dimension.
A heat-not-burn consumable for use in the aerosol-generating apparatus of claim 1, the consumable being a rod, containing an aerosol-forming precursor at one end thereof, and having a shoulder in an outer surface of the rod at a distance from the precursor end such that a first external dimension of the rod between the precursor end to the shoulder is greater than a second external dimension between the shoulder and an end of the rod opposite the precursor end.
The consumable according to claim 6 or the apparatus according to claim 3, wherein the precursor is exposed at the precursor end of the consumable, and wherein the precursor fills a first portion of the rod which extends from the precursor end by at least the distance of the shoulder from the precursor end.
The consumable according to claims 6 or 7 or the apparatus according to claims 3 or 7, wherein the rod has a uniform external dimension from the precursor end to the shoulder.
The consumable according to any of claims 6 to 8 or the apparatus according to any of claims 3, 7 or 8, wherein the second external dimension is not more than 98% of the first external dimension.
The consumable according to any of claims 6 to 9 or the apparatus according to any of claims 3, 7, 8 or 9, wherein the second external dimension is not less than 80% of the first external dimension.
A heat-not-burn device for use in the aerosol-generating apparatus of claim 1, the device comprising:
a cavity defined by a wall and having an opening at an end thereof through which a rod is insertable into the cavity such that a precursor end of the rod is received within the wall; and

wherein the wall of the cavity has a shoulder at a distance from the opening such that a first internal dimension of the cavity between the shoulder and an end of the cavity opposite the opening is narrower than a second internal dimension of the cavity between the shoulder and the opening, whereby an outer surface of the inserted rod is clampable by the wall of the cavity to compress the precursor.
The heat-not-burn device according to claim 11 or the apparatus according to claim 4, wherein the wall of the cavity tapers smoothly at the shoulder to transition from the second diameter to the first diameter to guide the precursor end of the rod past the shoulder on insertion into the cavity.
A method of manufacturing a heat-not-burn consumable, the method including steps of:
providing a heat-not-burn consumable containing an aerosol-forming precursor; and

applying a material to a surface of the consumable circumscribing the precursor such that a first dimension of the consumable at one end thereof containing the precursor is greater than a second dimension of the consumable at its opposite end.
The method of claim 13, wherein the applying step includes wrapping one or more layers of the material around the consumable.
The method of claims 13 or 14, wherein the material comprises paper or card.