EP4680052A1

EP4680052A1 - A consumable and a non-combustible aerosol provision system

Info

Publication number: EP4680052A1
Application number: EP24704884.6A
Authority: EP
Inventors: John Richardson; Walid Abi Aoun
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2023-03-13
Filing date: 2024-01-31
Publication date: 2026-01-21
Also published as: GB202303666D0; WO2024189303A1; JP2026508982A; CN121419688A; TW202439995A

Abstract

A consumable (100) for use with an aerosol provision device (200). The consumable comprises an open airflow channel (111) that extends between open ends (112, 113) of the consumable and an aerosol generating section configured to generate an aerosol in at least a portion of the open airflow channel during use. The pressure drop across the consumable is greater than about 50 mmWg at a volumetric flow rate of about 17.5 ml/s. Also disclosed is a non-combustible aerosol provision system comprising such a consumable..

Description

A Consumable and A Non-Combustible Aerosol Provision System

Technical Field

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

Background

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

In a first aspect of the present invention, there is provided a consumable for use with an aerosol provision device, the consumable comprising: an open airflow channel that extends between open ends of the consumable; and an aerosol generating section configured to generate an aerosol in at least a portion of the open airflow channel during use; wherein the pressure drop across the consumable is greater than about 50mm Wg at a volumetric flow rate of about i7.5ml/s.

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

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

Fig. 1 schematically illustrates a system comprising a consumable and a non- combustible aerosol provision device; Fig. 2 illustrates a cross section of a consumable projected onto a plane parallel to the longitudinal axis of the consumable; Fig. 3 illustrates a cross section of a consumable, projected onto a plane perpendicular to the longitudinal axis of the consumable;

Fig. 4 illustrates a cross section a consumable, projected onto a plane perpendicular to the longitudinal axis of the consumable; and Fig. 5 illustrates a cross section of a consumable projected onto a plane parallel to the longitudinal axis of the consumable;

Fig. 6 illustrates a crimped sheet material; and

Fig. 7 is a flow diagram showing an example of a method of manufacturing a consumable.

Detailed Description

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

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

In some embodiments, the non-combustible aerosol provision system is an aerosolgenerating material heating system, also known as a heat-not-burn system. In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol- generating material and a solid aerosol-generating material. The solid aerosolgenerating material may comprise, for example, tobacco or a non-tobacco product. The non-combustible aerosol provision systems described herein comprise a noncombustible aerosol provision device and a consumable for use with the noncombustible aerosol provision device.

The disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure. In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/ or an aerosol-modifying agent.

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosolgenerating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

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

The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

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

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

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

As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens

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

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

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

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

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

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

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

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

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

The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In particular, in some embodiments, the aerosolgenerating material is substantially tobacco free.

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

The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm.

The aerosol-generating film may be up to 0.5mm thick, preferably 0.05mm to 0.5mm microns thick. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

The aerosol-generating film maybe continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, it may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosolgenerating material.

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

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

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

The aerosol-generating material may comprise or be an “amorphous solid”. In some embodiments, the aerosol-generating material comprises an aerosol-generating film that is an amorphous solid. The amorphous solid may be a “monolithic solid”. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 6owt% or owt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid.

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

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

The one or more other functional materials may comprise one or more of a pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants. The aerosol generating material may be present on or in a support, the support forming a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.

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

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

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

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

Fig. 1 illustrates a non-combustible aerosol provision system comprising a consumable too and a non-combustible aerosol provision device 200. The device comprises an area 201 for receiving the consumable too and an aerosol generator 202.

Fig. 2 illustrates the consumable too in cross section. The cross section is projected onto a plane that bisects the consumable in a longitudinal direction. The consumable too comprises an aerosol generating section 101. The aerosol generating section 101 comprises a wall 102 surrounding an air gap 103 that forms part of an open airflow channel 111 that extends between open ends 112, 113 of the consumable too. The aerosol generating section 101 is configured to generate an aerosol in the air gap 103 when heated by the non-combustible aerosol provision device for inhalation by a user.

The open airflow channel 111 (hereinafter simply referred to as ‘channel 111’), is free of obstruction, by which it is meant that a straight airflow path 114 is provided through the channel 111 between open ends 112, 113 of the consumable too. Because the airflow path 114 is straight, fewer components of aerosol generated during heating of the consumable too are deposited when a user draws on the consumable too than if the path were non-straight. For example, if the consumable were instead provided with an air permeable material closing one end of the consumable, then when a user draws on the consumable the resultant air stream through the consumable is required to take a tortuous path through the air permeable material, causing components of the aerosol to be blocked by the material. This is, of course, the principle of a cigarette style filter.

However, in the examples described herein, such obstructions are foregone to allow more components of aerosol generated during heating of the consumable too reaching the user. The consumable too is configured to provide a pressure drop across the consumable too of greater than about sommWg. Having a pressure drop across the consumable too of greater than about sommWg. ensures a satisfactory draw resistance. By ‘satisfactory draw resistance’, it is meant that when a user draws on the consumable too, the draw resistance is similar to that of a cigarette. The pressure drop is measured using an industry standard technique that will be familiar to the skilled person. In short, the pressure drop is measured by sealing one of the open ends 112, 113 to a pressure drop measuring device (for example, a Borgwaldt An) configured to draw a set volumetric flow rate of about i7.5ml/s through the consumable too. The open end 112, 113 selected for attachment to the pressure drop measuring device is the end of the consumable 100 on which a user will draw during use of the consumable 100 and is hereinafter referred to as the mouth end. ME. In the example of Fig. 2, the mouth end ME is at the same end of the consumable as open end 112.

In order to deliver the required pressure drop the dimensions of the channel are selected accordingly. As the air gap 103 forms part of the channel 111, and as aerosol is generated in the air gap 103 during use, that part of the channel 111 comprising the air gap 103 must be of adequate volume to accommodate a satisfactory quantity of the generated aerosol. Too small an air gap 103, and insufficient aerosol will form during heating of the consumable 100. Therefore, the channel 111 comprises a first region 115 having a first cross sectional area and a second region 116 having a second cross sectional area, the second cross sectional area being less than the first cross sectional area. When a user draws on the consumable too, the second cross sectional area 116 causes a restriction which increases the pressure drop of the consumable too. The first region 115 forms the part of the channel 111 comprising the air gap 103 and has a cross sectional area optimal for aerosol generation.

The first cross-sectional area may be between about 5 mm² and about 20 mm² and the second cross-sectional area between about 0.5 mm² and about 3.5 mm².

In one example, the first cross sectional area is about 7.1mm² and the second cross sectional area is about 1.8 mm². In such an example, the length of the first region 115 may be about 60 mm and the length of the second region 116 may be about 20 mm. The pressure drop across the combined first and second regions 115, 116 according to this example would be about yommWg, with about 40 mm Wg being contributed by the second region 116 and about 30mm Wg being contributed by the first region 115.

In another example, the first cross sectional area is about 19.6 mm² and the second cross sectional area is about 0.8 mm². In this example, the length of the first region 115 may be about 60 mm and the length of the second region 116 may be about 20 mm. The pressure drop across the combined first and second regions 115, 116 according to this example would be about 72mmWg, with about 6ommWg being contributed by the second region 116 and about i2mmWg being contributed by the first region 115. The ratio of the first cross-sectional area to the second cross-sectional area may be between 20:1 and 7:3, and in one example between about 20:1 and 3.5:1. The length of the first region 115 may be between 40 mm and 80 mm and the length of the second region 116 between 15 mm and 25 mm. In one example, the length of the first region 115 is about 60 mm and the length of the second region 116 is about 20 mm.

The second region 116 may contribute at least 40% of the total pressure drop of the combined first and second regions 115, 116 - which in embodiments may be the total pressure drop across the consumable 100. For example, the second region 116 may contribute at least 50%, or at least 60%, or at least 70% or at least 80% of the total pressure across the consumable 100. Fig- 3 illustrates an aerosol generating section 101 of consumables 100 described herein in a section projected onto a plane that bisects the aerosol generating section 101 perpendicular to the longitudinal direction. Fig. 3 shows further details of the wall 102 of the aerosol generating section 101. In the present example, the wall 102 further comprises a support 104 and a film of aerosol generating material 105 provided on the support 104. The film of aerosol generating material 105 forms an inner surface of the wall 102. The support 104 forms an outer surface of the wall 102 which, in the present example, is overwrapped by a wrapping material 110 for attachment of the aerosol generating section 101 to further components of the consumable. In other examples, the outer surface of the wall 2 may be an outermost surface of the consumable 100- such as the example of Fig. 5, illustrated and described below. The support may be made from any suitable material such as paper or paperboard.

Fig. 4 illustrates another example aerosol generating section 101, wherein like features retain the same reference numbers. Like Fig. 3, Fig. 4 is a section projected onto a plane that bisects the aerosol generating section 101 perpendicular to the longitudinal direction. In the example of Fig. 4, the support 104 further comprises a first layer 106 and a second layer 107, the first layer 106 being located between the aerosol generating material 105 and the second layer 107. The first layer 106 is a susceptor 106 and is heatable by penetration with a varying magnetic field. The second layer 107 is not heatable by penetration with a varying magnetic field and may be any suitable material falling within this criteria, such as paper or paperboard. The aerosol generating material 105 is provided directly on the susceptor 106. However, in other examples, further materials may be provided between the aerosol generating material 105 and the susceptor 106. In the example of Fig. 2, the first region 115 is provided by the aerosol generating section 101 and the second region 116 is provided by a separate component 109, herein referred to as a restrictor 109. The restrictor 109 is arranged coaxially with the aerosol generating section 101 and is attached thereto by the wrapping material 110 which circumscribes both the restrictor 109 and the aerosol generating section 101. The restrictor 109 has an opening 117 that forms the second region of the airflow channel 111.

Fig. 5 illustrates another example consumable 100 in which like features retain the same reference numbers. The example of Fig. 5 is substantially the same as the example of Fig. 2, but with the difference that the wrapping material 110 is omitted and a restrictor 109’ is instead attached to the aerosol generating section 101 by insertion into an end of the aerosol generating section 101. In the illustrated example, said end is the mouth end ME of the consumable 100. The restrictor 109’ is provided with overall dimensions substantially the same, or slightly less than, internal dimensions of the aerosol generating section 101 so that the restrictor 109’ fits tightly within the aerosol generating section 101. As above, the restrictor 109’ has an opening that forms the second cross sectional area of the airflow channel 111

In the illustrated examples, the aerosol generating section 101 is tubular, that is to say, comprises an annular cross-section. However, it shall be appreciated that other cross- sectional shapes maybe used. For example, the wall 102 maybe a prism having a polygonal cross section. Example polygonal cross sections can include, but are not limited to, octagons, hexagons, heptagons or squares. In the illustrated examples, the restrictor 109, 109’ is provided at the mouth end ME of the consumable too. However, in other examples the restrictor 109, 109’ maybe provided at a distal end, i.e. an end opposite the mouth end ME. As airflow leaving the restrictor 109, 109’ is provided with turbulent energy, the position of the restrictor can have effect on the user’s sensory experience. For example, placing the restrictor 109, 109’ at the distal end of the consumable too encourages more mixing of the aerosol generated in the air gap 103 which can increase the flavour intensity of the aerosol delivered to the user. Alternatively, placing the restrictor 109, 109’ at the mouth end ME causes the aerosol to be delivered into the mouth of a user at a higher velocity, causing more mixing within the user’s mouth and a different sensory experience. In the illustrated examples, the second region 116 of the channel 111 is provided by a single component 109, 109’ with a constant cross-sectional area. However, it will be appreciated that invention may be achieved by a second region 116 formed of multiple components having different cross-sectional areas or a single component having a varying cross-sectional area. Regardless of the arrangement of the second region 116, it is important that the consumable too is provided with the channel 111 having a straight airflow path 114 between open ends of the consumable too and that the pressure drop across the consumable is as defined herein.

The consumable too may be provided with any number of additional components for attachment to the aerosol generating section 101 described above. Importantly however, any additional components must have an opening that does not obstruct the straight airflow path 114.

The restrictors 109, 109’ described herein may be formed from a gathered sheet of material. By ‘formed from a gathered sheet material’, it is meant a sheet material is gathered into the shape of the restrictor 109, 109’. Similarly, the support 104 may of example consumables described herein may be formed from a gathered sheet of material. In examples, the sheet material is a fibrous sheet material such as paper. In examples, the sheet material is crimped prior to being gathered into the shape of the restrictor 109, 109’ or support 104. Therefore, the restrictor 109, 109’ or support 104 maybe formed from a gathered sheet of crimped material.

Fig. 6 illustrates a cross section of the crimp pattern of an example crimped sheet material 6 that maybe used to form the restrictor 109, 109’ or support 104. The crimp pattern comprises a plurality of peaks and troughs in the sheet material 6, wherein the crimp amplitude ‘A’ is the depth of the troughs, measured from their peak. The crimping may form a ‘Zig-Zag’ formation or another shape. Adjacent grooves of the crimped sheet material may be spaced by a distance, or have a pitch ‘P’, in the range of 0.3 to 2 mm and, preferably, in the range of 0.4 to 1 mm. In examples, adjacent grooves of the crimped sheet material 6 are spaced by a distance of at least 0.4 mm or at least

0.5, 0.6, 0.7 or 0.8 mm. In other examples, adjacent grooves of the crimped sheet material 6 are spaced by a distance of at most 1.5 mm, and preferably, at most, 1.4, 1.3, 1.2, 1.1 or 1.0 mm. The crimped sheet material 6 may have a crimp amplitude of less than 0.5 mm. The extended width of the crimped sheet material may be selected to provide the gathered sheet material with a density of about 0.1 mg/mm3to 0.3 mg/mms.

With reference again to Fig. 1, the aerosol generator 202 is configured to heat the aerosol generating material 105 of the consumable too when the consumable too is received in the area 201 for receiving the consumable. The device further comprises a power source 203, a controller 204 and a puff sensor 205. In use, a user inserts the consumable too into the area 201 for receiving the consumable and activates the aerosol generator 202 to generate an aerosol for inhalation. The user may then draw on the mouth end ME of the consumable too or, alternatively, on a mouthpiece (not shown) of the device 200 to inhale the aerosol. In the illustrated example, the consumable too and device 200 are configured so that the mouth end ME is a part of the consumable too that protrudes from the area 201 when the consumable too is fully inserted into the device 200. Therefore, the mouth end ME is available for a user to draw on the mouth-end while the user holds the device 200.

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

The area 201 for receiving the consumable too is provided with an inlet (not shown) to allow air into area 201 before passing through the consumable too when a user draws on the mouth end 101 of the consumable too. Therefore, a flow of air is directed through the consumable too when a user draws on the consumable too. Specifically, air is directed through the airflow channel 111 of the consumable too. The flow of air entrains the aerosol generated by the aerosol generating material 105 of the consumable for inhalation by the user. The aerosol generator 202 comprises any suitable means for heating the aerosol generating material 105 of a consumable too received in said area 201 of the device 200. Power for the aerosol generator 202 is provided by the power source 203, which in the illustrated example is an electrical power source 203, such as a battery 203.

In one example, the aerosol generator 202 comprises a magnetic field generator configured to generate a varying magnetic field that penetrates the area 201 for receiving the consumable too. Therefore, the device 200 is configured for use with the consumables too comprising a susceptor, such as the susceptor 106 exemplified by Fig. 4. The varying magnetic field heats the susceptor 106 by magnetic hysteresis. When the consumable too is placed within the device 200 and the aerosol generator 202 is activated, a varying magnetic field penetrates the susceptor 106 of the consumable too and causes heating of aerosol generating material 105 in thermal contact with the susceptor, generating an aerosol for inhalation by a user.

In another example, the aerosol generator 202 comprises a susceptor in thermal contact with the area 201 for receiving the consumable too; and a magnetic field generator for generating a varying magnetic field that penetrates the susceptor. The varying magnetic field heats the susceptor by magnetic hysteresis. The susceptor in turn heats the area 201 for receiving the consumable. Therefore, when a consumable too is placed within the device 200 and the aerosol generator 202 is activated, a varying magnetic field penetrates the susceptor and causes heating of area 201 in which the consumable too is received. The heat is transferred to the aerosol generating material 105 of the consumable too, generating an aerosol for inhalation by the user. In such examples, the wall 207 of the area 201 for receiving the consumable too may comprise the susceptor. The consumable too may be configured for direct contact with the wall 207 for efficient heat transfer. Alternatively, or additionally, the projection 206 may comprise the susceptor. For example, either or both of the wall 207 and the projection 206 may be made from a material that can be heated by penetration with a varying magnetic field.

In another example, the aerosol generator 202 comprises a material heatable by electrical conduction, the material being provided in thermal contact with the area 201 for receiving the consumable too. Therefore, when a consumable too is placed within the device 200 and the aerosol generator 202 is activated, a current is passed through the material to heat area 201 in which the consumable too is received. The heat is transferred to the aerosol generating material 105 of the consumable too, generating an aerosol for inhalation by the user. In such embodiments, the material may be the wall 207 of the area 201 for receiving the consumable too and the consumable too maybe configured for direct contact with the wall 207 for efficient heat transfer.

In any of the above examples of aerosol generator 202, the aerosol generator 202 may be configured for zonal or sectional heating of the consumable too. By ‘zonal or sectional heating’ it is meant that the aerosol generator 202 is configured to heat discreet portions of the aerosol generating material 105 separately, that is to say, at different points in time.

Referring to Fig. 7, there is shown a flow diagram showing an example of a method 80 of manufacturing a consumable too for use with the system of examples described herein. The method 80 of Fig. 7 is usable to manufacture any of the consumables too described herein.

The method comprises providing 81 the aerosol generating section 101 comprising the support 104 and aerosol generating material 105 affixed to the support 104 and, optionally, attaching thereto any desired additional components.

In some examples, the providing 81 comprises affixing 82 the aerosol generating material 105 to the support 104, and then forming 83 the aerosol generating section 101. Accordingly, in some examples, the support 104 maybe flat or substantially flat at the time the aerosol generating material 105 is affixed to it. Thereafter, in some examples, the support 104 and aerosol generating material 105 may be manipulated together during formation of the aerosol generating section 101. Such manipulation may comprise rolling or wrapping the combination of the support 104 and aerosol generating material 105 into a - typically tubular - section 101. However, it will be appreciated that the combination of the support 104 and aerosol generating material 105 may instead be folded into a section 101 having a non-circular cross section. Such rolling, wrapping or folding may be around a mandrel, for example. In other examples, the support 104 is provided in a tubular, or substantially tubular, form, and thereafter the aerosol generating material 105 is affixed to the support 104. In some examples, the method comprises manufacturing the support 104. For example, and as discussed byway of some examples herein, the support 104 may comprise a plurality of layers 106, 107, and the manufacture of the support 104 may comprise assembling those layers to form the support 104, such as by adhesion. At least one of the layers 106, 107 maybe in sheet or strip form. In some examples, such as some of those in which the affixing 82 is performed before the forming 83, the affixing 82 comprises coating the aerosol generating material 105 onto the support 104 to form a film of aerosol generating material 105. Such coating may comprise spraying, electro-spraying, casting or band casting, for example. Such casting may involve providing material in liquid or other fluid form on a surface of the support 104 (or material that ultimately will form the support 104), and then allowing the material to at least partially solidify or cure on the surface of the support 104 to form the aerosol generating material 105 comprising the film. The material in liquid or other fluid form may be aerosol generating in that form, or may only become aerosol generating once it has solidified or cured.

In some examples, the affixing 82 may comprise a technique other than coating. For example, the affixing 82 comprises adhering the aerosol generating material 105 to the support 104 using an adhesive. Should additional components be required then said components may be attached to the aerosol generating section 101 by first arranging each of the components in axial alignment to form an assembly of components and then wrapping the components in a wrapping material 110. In the example of Fig. 5, said assembly comprises, in order, the distal end locator component 109, the aerosol generating section 101, the mouth end locator component 109’ and the filter plug 108. Said assembly is then wrapped in the wrapping material 110 to form the consumable too of Fig. 5.

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

In some examples described herein, the consumable is tobacco-free, eliminating the tobacco-specific nitrosamine levels and thereby negating the need for a filter. The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.”

Claims

Claims i. A consumable for use with an aerosol provision device, the consumable comprising: an open airflow channel that extends between open ends of the consumable; and an aerosol generating section configured to generate an aerosol in at least a portion of the open airflow channel during use; wherein the pressure drop across the consumable is greater than about sommWg at a volumetric flow rate of about I7.5ml/s. 2. A consumable according to claim 1, wherein the open airflow channel comprises a first region having a first pressure drop and second region having a second pressure drop.

3. A consumable according to claim 2, wherein the first region has first cross sectional area and the second region has a second cross sectional area, the second cross sectional area being less than the first cross sectional area.

4. A consumable according to claim 3, wherein the second region is downstream of the first region along the open airflow channel.

5. A consumable according to claim 3, wherein the first region is downstream of the second region along the open airflow channel.

6. A consumable according to claim 4 or claim 5, wherein the ratio of the first cross sectional area to the second cross sectional area is between about 20:1 and 7:3.

7. A consumable according to any preceding claim, wherein the aerosol generating section comprises a support and aerosol generating material provided on the support. 8. A consumable according to claim 7, wherein the support is part of a wall of the aerosol generating section that surrounds at least a portion of the open airflow channel and the aerosol generating material forms an inner surface of the wall.

9. A consumable according to claim 8, wherein the support forms at least part of a surface of the consumable and, optionally, wherein the surface of the consumable is an outermost surface of the consumable. io. A consumable according to claim 9, wherein the aerosol generating material forms an internal surface of the aerosol generating section. 11. A consumable according to any of claims 7 to 10, wherein the aerosol-generating material comprises:

- an aerosol former

- a binder;

- optionally a filler; and - optionally an active and/ or a flavourant.

12. A consumable according to any of claims 7 to 11, wherein the aerosol generating material comprises an aerosol generating film and wherein the aerosol generating film is up to about 1 mm thick and, optionally, up to 500 microns thick and, optionally, 50 to 500 microns thick.

13. A consumable according to any preceding claim wherein the aerosol generating section is tubular. 14. A consumable according to any one of claims 2 to 13, wherein the second region of the open airflow channel is formed of a separate component to the aerosol generating section and wherein the separate component is attached to the aerosol generating section by a wrapping material that circumscribes both the aerosol generating section and the separate component.

15. A consumable according to claim 14, wherein the separate component has an internal surface that surrounds at least a portion of the open airflow channel.

16. A consumable according to claim 14 or 15, wherein the separate component comprises a body of material that surrounds the internal surface and, optionally, wherein the body of material comprises a gathered sheet material.

17. A consumable according to any of claims 2 to 16, wherein the pressure drop across the second region contributes at least 40% of the pressure drop across the consumable.

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