Classifications

• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
  • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
  • A24B15/10—Chemical features of tobacco products or tobacco substitutes
  • A24B15/16—Chemical features of tobacco products or tobacco substitutes of tobacco substitutes
  • A24B15/167—Chemical features of tobacco products or tobacco substitutes of tobacco substitutes in liquid or vaporisable form, e.g. liquid compositions for electronic cigarettes
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
  • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
  • A24B15/10—Chemical features of tobacco products or tobacco substitutes
  • A24B15/12—Chemical features of tobacco products or tobacco substitutes of reconstituted tobacco
  • A24B15/14—Chemical features of tobacco products or tobacco substitutes of reconstituted tobacco made of tobacco and a binding agent not derived from tobacco
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
  • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
  • A24B15/18—Treatment of tobacco products or tobacco substitutes
  • A24B15/186—Treatment of tobacco products or tobacco substitutes by coating with a coating composition, encapsulation of tobacco particles
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
  • A24B15/00—Chemical features or treatment of tobacco; Tobacco substitutes, e.g. in liquid form
  • A24B15/18—Treatment of tobacco products or tobacco substitutes
  • A24B15/28—Treatment of tobacco products or tobacco substitutes by chemical substances
  • A24B15/30—Treatment of tobacco products or tobacco substitutes by chemical substances by organic substances
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24C—MACHINES FOR MAKING CIGARS OR CIGARETTES
  • A24C5/00—Making cigarettes; Making tipping materials for, or attaching filters or mouthpieces to, cigars or cigarettes
  • A24C5/01—Making cigarettes for simulated smoking devices
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24C—MACHINES FOR MAKING CIGARS OR CIGARETTES
  • A24C5/00—Making cigarettes; Making tipping materials for, or attaching filters or mouthpieces to, cigars or cigarettes
  • A24C5/14—Machines of the continuous-rod type
  • A24C5/18—Forming the rod
  • A24C5/1885—Forming the rod for cigarettes with an axial air duct
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
  • A24D1/00—Cigars; Cigarettes
  • A24D1/002—Cigars; Cigarettes with additives, e.g. for flavouring
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
  • A24D1/00—Cigars; Cigarettes
  • A24D1/20—Cigarettes specially adapted for simulated smoking devices
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
  • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
  • A24F40/20—Devices using solid inhalable precursors
• • A—HUMAN NECESSITIES
  • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
  • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
  • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
  • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
  • A24F40/46—Shape or structure of electric heating means
  • A24F40/465—Shape or structure of electric heating means specially adapted for induction heating

Definitions

• the present invention relates to consumables for use with apparatus for heating aerosolisable material, to systems comprising such a consumable and an apparatus for heating aerosolisable material of the consumable to volatilise at least one component of the aerosolisable material, and to methods of manufacturing consumables for use with apparatus for heating aerosolisable material.
• Smoking articles such as cigarettes, cigars and the like bum tobacco during use to create tobacco smoke. Attempts have been made to provide alternatives to these articles by creating products that release compounds without combusting. Examples of such products are so-called“heat not bum” products or tobacco heating devices or products, which release compounds by heating, but not burning, material.
• the material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine.
• a first aspect of the present invention provides a consumable for use with apparatus for heating aerosolisable material to volatilise at least one component of the aerosolisable material, the consumable comprising a hollow tube comprising a wound structure comprising aerosolisable material.
• the consumable is non-combustible.
• the wound structure is a helically wound structure.
• the aerosolisable material comprises tobacco.
• the aerosolisable material comprises reconstituted aerosolisable material.
• the aerosolisable material comprises an amorphous solid.
• the structure comprising aerosolisable material comprises a carrier, and the aerosolisable material is on a surface of the carrier or impregnated in the carrier.
• the structure comprising aerosolisable material consists of the aerosolisable material.
• the aerosolisable material may be cast or otherwise shaped.
• the wound structure comprising aerosolisable material defines at least part of a surface of the consumable. In an exemplary embodiment, the wound structure comprising aerosolisable material defines the surface of the consumable. In an exemplary embodiment, the surface is an innermost surface of the consumable.
• the wound structure comprising aerosolisable material comprises corrugations, embossing or debossing.
• the wound structure forms a layer of the hollow tube, and the hollow tube comprises one or more further layers.
• at least one of the further layer is a wound layer, such as a helically wound layer.
• the aerosolisable material adheres the wound structure comprising aerosolisable material to at least one of the one or more further layers.
• the wound structure comprising aerosolisable material comprises corrugations, embossing or debossing
• the hollow tube comprises one or more aerosol flow paths defined by and between the corrugations, embossing or debossing of the structure comprising aerosolisable material and at least one of the one or more further layers.
• the hollow tube comprises a barrier layer that defines at least part of a surface of the consumable.
• the barrier layer is impermeable to aerosol released from the aerosolisable material during heating of the aerosolisable material in use.
• the barrier layer is a wound layer, such as a helically wound layer.
• the barrier layer defines the surface of the consumable.
• the surface is an outermost surface of the consumable.
• the consumable is free from heating material that is heatable by penetration with a varying magnetic field.
• the consumable comprises heating material that is heatable by penetration with a varying magnetic field.
• the hollow tube comprises a layer comprising the heating material.
• the heating material comprises one or more materials selected from the group consisting of: an electrically-conductive material, a magnetic material, and a magnetic electrically-conductive material.
• the heating material comprises a metal or a metal alloy.
• the heating material comprises one or more materials selected from the group consisting of: aluminium, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain-carbon steel, mild steel, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper, and bronze.
• the layer comprising the heating material comprises a metal foil or a metal alloy foil.
• the layer comprising the heating material is a wound layer, such as a helically wound layer.
• the hollow tube comprises a barrier layer that defines at least part of a surface of the consumable, and the layer comprising the heating material is located between the barrier layer and the wound structure comprising aerosolisable material. In an exemplary embodiment, the layer comprising the heating material is located radially outwards of the wound structure comprising aerosolisable material.
• the one or more further layers comprise one or more further wound layers, such as helically wound layers.
• the hollow tube comprises one or more further layers, and at least one of the one or more further layers comprises aerosolisable material.
• the hollow tube comprises a layer comprising heating material, wherein the layer comprising heating material is located between the wound structure comprising aerosolisable material and the at least one further layer comprising aerosolisable material.
• the hollow tube comprises one or more further layers, and at least one of the one or more further layers comprises a flavourant or a sensate.
• the aerosolisable material of the wound structure comprises an amorphous solid.
• a second aspect of the present invention provides a system for heating aerosolisable material to volatilise at least one component of the aerosolisable material, the system comprising: the consumable of the first aspect of the present invention; and apparatus for heating the aerosolisable material of the consumable to volatilise at least one component of the aerosolisable material, the apparatus comprising a heating zone for receiving the consumable, and a device for causing heating of the aerosolisable material when the consumable is in the heating zone.
• the device comprises a magnetic field generator for generating a varying magnetic field for penetrating the heating zone when the consumable is in the heating zone.
• the device for causing heating of the aerosolisable material when the consumable is in the heating zone is configured for heating different sections of the heating zone independently of each other.
• a third aspect of the present invention provides a method of manufacturing a hollow tube for use in or as a consumable for use with apparatus for heating aerosolisable material to volatilise at least one component of the aerosolisable material, the method comprising: winding a structure comprising aerosolisable material.
• the aerosolisable material comprises tobacco. In an exemplary embodiment, the aerosolisable material is reconstituted aerosolisable material. In an exemplary embodiment, the aerosolisable material comprises an amorphous solid.
• the structure comprising aerosolisable material comprises a carrier, and the aerosolisable material is on a surface of the carrier or impregnated in the carrier.
• the structure comprising aerosolisable material consists of the aerosolisable material.
• the aerosolisable material may be cast or otherwise shaped.
• the winding comprises helically winding the structure comprising aerosolisable material.
• the winding comprises winding the structure comprising aerosolisable material around a mandrel.
• the method comprises applying the aerosolisable material to a material using the mandrel to form the structure.
• the method comprises winding a material while drawing the material from a supply, and applying the aerosolisable material to the material downstream of the supply.
• the material is porous to the aerosolisable material.
• the method comprises drying the aerosolisable material during or after the winding of the structure comprising aerosolisable material.
• the wound structure forms a layer of the hollow tube, and the method comprises winding one or more further layers. In an exemplary embodiment, the method comprises winding one or more further layers around the structure comprising aerosolisable material. In an exemplary embodiment, the method comprises winding the structure comprising aerosolisable material around one or more layers.
• the method comprises helically winding the one or more further layers.
• the method comprises winding the structure comprising aerosolisable material around a mandrel, and winding the one or more layers around the mandrel.
• At least one of the one or more layers comprises heating material that is heatable by penetration with a varying magnetic field.
• the winding the structure comprising aerosolisable material comprises winding the structure comprising aerosolisable material to form an innermost surface of the hollow tube.
• the structure comprising aerosolisable material consists of the aerosolisable material, or comprises a carrier with the aerosolisable material on a surface of the carrier or impregnated in the carrier.
• the aerosolisable material of the structure comprises an amorphous solid.
• a further aspect of the present invention may provide the use of the consumable of the first aspect of the present invention in the generation of an inhalable aerosol.
• Figure 1 shows a schematic cross-sectional side view of an example of a consumable for use with apparatus for heating aerosolisable material to volatilise at least one component of the aerosolisable material;
• Figure 2 shows a schematic cross-sectional end view of the consumable of Figure 1 taken along the line II-II in Figure 1;
• Figure 3 shows a schematic cross-sectional side view of an example of another consumable for use with apparatus for heating aerosolisable material to volatilise at least one component of the aerosolisable material;
• Figure 4 shows a schematic cross-sectional end view of the consumable of Figure 3 taken along the line IV-IV in Figure 3;
• Figure 5 shows a schematic cross-sectional side view of an example of a system comprising a consumable and apparatus for heating aerosolisable material of the consumable to volatilise at least one component of the aerosolisable material;
• Figure 6 shows a flow diagram showing an example of a method of manufacturing a hollow tube for use in or as a consumable for use with apparatus for heating aerosolisable material to volatilise at least one component of the aerosolisable material;
• Figure 7 shows a flow diagram showing an example of another method of manufacturing a hollow tube for use in or as a consumable for use with apparatus for heating aerosolisable material to volatilise at least one component of the aerosolisable material.
• the term“aerosolisable material” includes materials that provide volatilised components upon heating, typically in the form of vapour or an aerosol.
• “Aerosolisable material” may be a non-tobacco-containing material or a tobacco-containing material.
• “Aerosolisable material” may, for example, include one or more of tobacco per se, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco extract, homogenised tobacco or tobacco substitutes.
• the aerosolisable material can be in the form of ground tobacco, cut rag tobacco, extruded tobacco, reconstituted tobacco, reconstituted aerosolisable material, liquid, gel, gelled sheet, powder, or agglomerates, or the like.
• “Aerosolisable material” also may include other, non-tobacco, products, which, depending on the product, may or may not contain nicotine. “Aerosolisable material” may comprise one or more humectants, such as glycerol or propylene glycol.
• the aerosolisable material comprises an“amorphous solid”, which may alternatively be referred to as a“monolithic solid” (i.e. non- fibrous), or as a“dried gel”.
• the amorphous solid is a solid material that may retain some fluid, such as liquid, within it.
• the aerosolisable material comprises from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or l00wt% of amorphous solid.
• the aerosolisable material consists of amorphous solid.
• the amorphous solid may be formed as a sheet. It may be incorporated into the consumable in sheet form.
• the aerosolisable material may be included as a planar sheet, as a bunched or gathered sheet, as a crimped sheet, or as a rolled sheet (i.e. in the form of a tube).
• the amorphous solid of these embodiments may be included in a consumable or system as a sheet, such as a sheet circumscribing a rod of aerosolisable material (e.g. tobacco).
• the aerosolisable material may be formed as a sheet and then shredded and incorporated into the consumable. In some cases, the shredded sheet may be mixed with cut rag tobacco and incorporated into the consumable.
• the amorphous solid takes the form of a foam, such as an open celled foam.
• “Aerosolisable material” also may include other, non-tobacco, products, which, depending on the product, may or may not contain nicotine. “Aerosolisable material” may comprise one or more humectants, such as glycerol or propylene glycol.
• the amorphous solid may comprise l-60wt% of a gelling agent wherein these weights are calculated on a dry weight basis.
• the amorphous solid may comprise from about lwt%, 5wt%, l0wt%, l5wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, 30wt% or 27wt% of a gelling agent (all calculated on a dry weight basis).
• the amorphous solid may comprise l-50wt%, 5-40wt%, l0-30wt% or l5-27wt% of a gelling agent.
• the gelling agent comprises a hydrocolloid.
• the gelling agent comprises one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof.
• the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol.
• the gelling agent comprises alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during formation of the amorphous solid.
• a setting agent such as a calcium source
• the amorphous solid may comprise a calcium- crosslinked alginate and/or a calcium-crosslinked pectin.
• the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of from l0-30wt% of the amorphous solid (calculated on a dry weight basis).
• alginate is the only gelling agent present in the amorphous solid.
• the gelling agent comprises alginate and at least one further gelling agent, such as pectin.
• the amorphous solid may include gelling agent comprising carrageenan.
• the amorphous solid may comprise from about 5wt%, l0wt%, l5wt%, or 20wt% to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt%, 45wt% 40wt%, or 35wt% of an aerosol generating agent (all calculated on a dry weight basis).
• the aerosol generating agent may act as a plasticiser.
• the amorphous solid may comprise l0-60wt%, l5-50wt% or 20-40wt% of an aerosol generating agent.
• the aerosol generating agent comprises one or more compound selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol. In some cases, the aerosol generating agent comprises, consists essentially of or consists of glycerol.
• the inventors have established that if the content of the plasticiser is too high, the amorphous solid may absorb water resulting in a material that does not create an appropriate consumption experience in use. The inventors have established that if the plasticiser content is too low, the amorphous solid may be brittle and easily broken.
• the plasticiser content specified herein provides an amorphous solid flexibility which allows the amorphous solid sheet to be wound onto a bobbin, which is useful in manufacture of aerosol generating articles.
• the amorphous solid may comprise a flavour.
• the amorphous solid may comprise up to about 60wt%, 50wt%, 40wt%, 30wt%, 20wt%, l0wt% or 5wt% of a flavour.
• the amorphous solid may comprise at least about 0.1 wt%, 0.5wt%, lwt%, 2wt%, 5wt% l0wt%, 20wt% or 30wt% of a flavour (all calculated on a dry weight basis).
• the amorphous solid may comprise 0.l-60wt%, l-60wt%, 5-60wt%, l0-60wt%, 20-50wt% or 30-40wt% of a flavour.
• the flavour (if present) comprises, consists essentially of or consists of menthol.
• the amorphous solid does not comprise a flavour.
• the amorphous solid comprises an active substance.
• the amorphous solid comprises a tobacco material and/or nicotine.
• the amorphous solid may comprise powdered tobacco and/or nicotine and/or a tobacco extract.
• the amorphous solid may comprise from about lwt%, 5wt%, l0wt%, l5wt%, 20wt% or 25wt% to about 70wt%, 50wt%, 45wt% or 40wt% (calculated on a dry weight basis) of active substance.
• the amorphous solid may comprise from about lwt%, 5wt%, l0wt%, l5wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt% or 40wt% (calculated on a dry weight basis) of a tobacco material and/or nicotine.
• the amorphous solid comprises an active substance such as tobacco extract.
• the amorphous solid may comprise 5-60wt% (calculated on a dry weight basis) of tobacco extract.
• the amorphous solid may comprise from about 5wt%, l0wt%, l5wt%, 20wt% or 25wt% to about 55wt%, 50wt%, 45wt% or 40wt% (calculated on a dry weight basis) tobacco extract.
• the amorphous solid may comprise 5-60wt%, l0-55wt% or 25-55wt% of tobacco extract.
• the tobacco extract may contain nicotine at a concentration such that the amorphous solid comprises lwt% l.5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%, 4.5wt% or 4wt% (calculated on a dry weight basis) of nicotine. In some cases, there may be no nicotine in the amorphous solid other than that which results from the tobacco extract.
• the amorphous solid comprises no tobacco material but does comprise nicotine.
• the amorphous solid may comprise from about lwt%, 2wt%, 3wt% or 4wt% to about 20wt%, l5wt%, l0wt% or 5wt% (calculated on a dry weight basis) of nicotine.
• the amorphous solid may comprise l-20wt% or 2-5 wt% of nicotine.
• the total content of active substance and/or flavour may be at least about 0.1 wt%, lwt%, 5wt%, l0wt%, 20wt%, 25wt% or 30wt%.
• the total content of active substance and/or flavour may be less than about 80wt%, 70wt%, 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis).
• the total content of tobacco material, nicotine and flavour may be at least about lwt%, 5wt%, l0wt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of tobacco material, nicotine and flavour may be less than about 70wt%, 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis).
• the amorphous solid comprises from about lwt% to about l5wt% water, or from about 5wt% to about l5wt% calculated on a wet weight basis.
• the water content of the amorphous solid may be from about 5wt%, 7wt% or 9wt% to about l5wt%, l3wt% or 1 lwt% (WWB), most suitably about l0wt%.
• the amorphous solid is a hydrogel and comprises less than about 20wt% of water calculated on a wet weight basis.
• the hydrogel may comprise less than about l5wt%, l2wt% or 10 wt% of water calculated on a wet weight basis (WWB).
• WWB wet weight basis
• the hydrogel may comprise at least about 2wt% or at least about 5wt% of water (WWB).
• the amorphous solid may be made from a gel, and this gel may additionally comprise a solvent, included at 0.l-50wt%.
• a solvent in which the flavour is soluble may reduce the gel stability and the flavour may crystallise out of the gel.
• the gel does not include a solvent in which the flavour is soluble.
• the amorphous solid comprises less than 60wt% of a filler, such as from lwt% to 60wt%, or 5wt% to 50wt%, or 5wt% to 30wt%, or l0wt% to 20wt%. In other embodiments, theamorphous solid comprises less than 20wt%, suitably less than l0wt% or less than 5wt% of a filler. In some cases, the amorphous solid comprises less than lwt% of a filler, and in some cases, comprises no filler.
• the filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves.
• the filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivativesln particular cases, the amorphous solid comprises no calcium carbonate such as chalk.
• the filler is fibrous.
• the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives.
• fibrous filler in an amorphous solid may increase the tensile strength of the material. This may be particularly advantageous in examples wherein the amorphous solid is provided as a sheet, such as when an amorphous solid sheet circumscribes a rod of aerosolisable material.
• the amorphous solid does not comprise tobacco fibres. In particular embodiments, the amorphous solid does not comprise fibrous material.
• the aerosolisable material does not comprise tobacco fibres. In particular embodiments, the aerosolisable material does not comprise fibrous material.
• the aerosol generating substrate does not comprise tobacco fibres. In particular embodiments, the aerosol generating substrate does not comprise fibrous material.
• the consumable does not comprise tobacco fibres.
• the consumable does not comprise fibrous material.
• the amorphous solid may consist essentially of, or consist of a gelling agent, an aerosol generating agent, a tobacco material and/or a nicotine source, water, and optionally a flavour.
• a method of making an aerosolisable material may comprise (a) forming a slurry comprising components of the amorphous solid or precursors thereof, (b) forming a layer of the slurry, and (c) setting the slurry to form a gel and (d) drying to form an amorphous solid.
• the step (b) of forming a layer of the slurry may comprise spraying, casting or extruding the slurry, for example.
• the layer is formed by electro- spraying the slurry.
• the layer is formed by casting the slurry.
• the slurry is applied to a carrier.
• the steps (b) and/or (c) and/or (d) may, at least partially, occur simultaneously (for example, during electro-spraying). In some cases, these steps may occur sequentially.
• the step (c) of setting the gel may comprise the addition of a setting agent to the slurry.
• the slurry may comprise sodium, potassium or ammonium alginate as a gel-precursor, and a setting agent comprising a calcium source (such as calcium chloride), may be added to the slurry to form a calcium alginate gel.
• the total amount of the setting agent such as a calcium source, may be 0.5- 5wt% (calculated on a dry weight basis).
• the inventors have found that the addition of too little setting agent may result in an amorphous solid which does not stabilise the amorphous solid components and results in these components dropping out of the amorphous solid.
• the inventors have found that the addition of too much setting agent results in an amorphous solid that is very tacky and consequently has poor handleability.
• Alginate salts are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa).
• Alginic acid is a copolymer of b-D-mannuronic (M) and a-L-guluronic acid (G) units (blocks) linked together with (l,4)-glycosidic bonds to form a polysaccharide.
• M b-D-mannuronic
• G a-L-guluronic acid
• the alginate crosslinks to form a gel.
• the inventors have determined that alginate salts with a high G monomer content more readily form a gel on addition of the calcium source.
• the gel-precursor pay comprise an alginate salt in which at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginate copolymer are a- L-guluronic acid (G) units.
• the drying step may cause the cast material thickness to reduce by at least 80%, suitably 85% or 87%.
• the slurry may be cast at a thickness of 2mm, and the resulting dried amorphous solid material may have a thickness of 0.2mm.
• the amorphous solid may have a thickness of about 0.015mm to about 1.0mm.
• the thickness may be in the range of about 0.05mm, 0. lmm or 0. l5mm to about 0.5mm or 0.3mm.
• the inventors have found that a material having a thickness of 0.2mm is particularly suitable.
• the amorphous solid may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.
• the slurry solvent may consist essentially of or consist of water. In some cases, the slurry may comprise from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% of solvent (WWB).
• the dry weight content of the slurry may match the dry weight content of the amorphous solid.
• the discussion herein relating to the solid composition is explicitly disclosed in combination with the slurry aspect of the invention.
• the slurry has a viscosity of from about 10 to about 20 Pa-s at 46.5 °C, such as from about 14 to about 16 Pa-s at 46.5 °C.
• the aerosolisable material comprising the amorphous solid may have any suitable area density, such as from 30 g/m 2 to 120 g/m 2 . In some embodiments, aerosolisable material may have an area density of from about 30 to 70 g/m 2 , or about 40 to 60 g/m 2 . In some embodiments, the amorphous solid may have an area density of from about 80 to 120 g/m 2 , or from about 70 to 110 g/m 2 , or particularly from about 90 to 110 g/m 2 . Such area densities may be particularly suitable where the aerosol- generating material is included in a consumable or system in sheet form, or as a shredded sheet (described further hereinbelow).
• the amorphous solid in sheet form may have a tensile strength of from around 200 N/m to around 900 N/m. In some examples, such as where the amorphous solid does not comprise a filler, the amorphous solid may have a tensile strength of from 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosolisable material is formed as a sheet and then shredded and incorporated into a consumable.
• the amorphous solid may have a tensile strength of from 600 N/m to 900 N/m, or from 700 N/m to 900 N/m, or around 800 N/m.
• tensile strengths may be particularly suitable for embodiments wherein the aerosolisable material is included in a consumable or system as a rolled sheet, suitably in the form of a tube
• the carrier may be a paper-backed foil; the paper layer abuts the amorphous solid layer and the properties discussed in the previous paragraphs are afforded by this abutment.
• the foil backing is substantially impermeable, providing control of the aerosol flow path.
• a metal foil backing may also serve to conduct heat to the amorphous solid.
• the foil layer of the paper-backed foil abuts the amorphous solid.
• the foil is substantially impermeable, thereby preventing water provided in the amorphous solid to be absorbed into the paper which could weaken its structural integrity.
• the carrier is formed from or comprises metal foil, such as aluminium foil.
• a metallic carrier may allow for better conduction of thermal energy to the amorphous solid.
• a metal foil may function as a susceptor in an induction heating system.
• the carrier comprises a metal foil layer and a support layer, such as cardboard.
• the metal foil layer may have a thickness of less than 20pm, such as from about 1 pm to about lOpm, suitably about 5pm.
• 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.
• the active substance comprises nicotine.
• the active substance comprises caffeine, melatonin or vitamin B12.
• the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.
• Cannabinoids are a class of natural or synthetic chemical compounds which act on cannabinoid receptors (i.e., CB1 and CB2) in cells that repress neurotransmitter release in the brain.
• Cannabinoids may be naturally occurring (phytocannabinoids) from plants such as cannabis, from animals (endocannabinoids), or artificially manufactured (synthetic cannabinoids).
• Cannabis species express at least 85 different phytocannabinoids, and are divided into subclasses, including cannabigerols, cannabichromenes, cannabidiols, tetrahydrocannabinols, cannabinols and cannabinodiols, and other cannabinoids.
• Cannabinoids found in cannabis include, without limitation: cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol mono methyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), Cannabinol propyl variant (CBNV), cannabitriol (CBO), tetrahydrocannabmolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).
• CBD cannabigerol
• the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof.
• 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.
• 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, maqoram, olive,
• the mint may be chosen from the following mint varieties: Mentha arvensis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens.
• the botanical is selected from eucalyptus, star anise, cocoa and hemp. In some embodiments, the botanical is selected from rooibos and fennel.
• 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.
• flavour materials 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,
• flavours may suitably comprise one or more mint-flavours suitably a mint oil from any species of the genus Mentha.
• the flavour may suitably comprise, consist essentially of or consist of menthol.
• the flavour comprises menthol, spearmint and/or peppermint.
• the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry.
• the flavour comprises eugenol.
• the flavour comprises flavour components extracted from tobacco.
• the flavour comprises flavour components extracted from cannabis.
• the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect.
• a suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucalyptol, WS-3.
• an aerosol generating agent refers to an agent that promotes the generation of an aerosol.
• An aerosol generating agent may promote the generation of an aerosol by promoting an initial vaporisation and/or the condensation of a gas to an inhalable solid and/or liquid aerosol.
• Suitable aerosol generating agents include, but are not limited to: a polyol such as erythritol, sorbitol, glycerol, and glycols like propylene glycol or triethylene glycol; a non-polyol such as monohydric alcohols, high boiling point hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate or myristates including ethyl myristate and isopropyl myristate and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate and dimethyl tetradecanedioate.
• the aerosol generating agent may suitably have a composition that does not dissolve menthol.
• the aerosol generating agent may suitably comprise, consist essentially of or consist of glycerol.
• tobacco material refers to any material comprising tobacco or derivatives therefore.
• tobacco material may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes.
• the tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract.
• the tobacco used to produce tobacco material may be any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental. It may also be tobacco particle‘fines’ or dust, expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut rolled stems.
• the tobacco material may be a ground tobacco or a reconstituted tobacco material.
• the reconstituted tobacco material may comprise tobacco fibres, and may be formed by casting, a Fourdrinier-based paper making-type approach with back addition of tobacco extract, or by extrusion.
• the amorphous solid comprises menthol.
• the amorphous solid may have the following composition (DWB): gelling agent (preferably comprising alginate, more preferably comprising a combination of alginate and pectin) in an amount of from about 20wt% to about 40wt%, or about 25wt% to 35wt%; menthol in an amount of from about 35wt% to about 60wt%, or from about 40wt% to 55wt%; aerosol generating agent (preferably comprising glycerol) in an amount of from about l0wt% to about 30wt%, or from about l5wt% to about 25wt% (DWB).
• gelling agent preferably comprising alginate, more preferably comprising a combination of alginate and pectin
• menthol in an amount of from about 35wt% to about 60wt%, or from about 40wt% to 55wt%
• aerosol generating agent preferably comprising glycerol
• the amorphous solid comprises about 32-33wt% of an alginate/pectin gelling agent blend; about 47-48wt% menthol flavourant; and about l9-20wt% glycerol aerosol generating agent (DWB).
• DWB glycerol aerosol generating agent
• the amorphous solid of these embodiments may be included in a consumable or system as a shredded sheet.
• the shredded sheet may be provided in the consumable or system blended with cut tobacco.
• the amorphous solid may be provided as a non-shredded sheet.
• the shredded or non- shredded sheet has a thickness of from about 0.015mm to about lmm, preferably from about 0.02mm to about 0.07mm.
• the menthol-containing amorphous solid may be particularly suitable for including in a consumable or system as a sheet, such as a sheet circumscribing a rod of aerosolisable material (e.g. tobacco).
• the amorphous solid may have the following composition (DWB): gelling agent (preferably comprising alginate, more preferably comprising a combination of alginate and pectin) in an amount of from about 5wt% to about 40wt%, or about l0wt% to 30wt%; menthol in an amount of from about l0wt% to about 50wt%, or from about l5wt% to 40wt%; aerosol generating agent (preferably comprising glycerol) in an amount of from about 5wt% to about 40wt%, or from about l0wt% to about 35wt%; and optionally filler in an amount of up to 60wt% - for example, in an amount of from 5wt% to
• DWB composition
• the amorphous solid comprises about 1 lwt% of an alginate/pectin gelling agent blend, about 56wt% woodpulp filler, about 18% menthol flavourant and about l5wt% glycerol (DWB). In another of these embodiments, the amorphous solid comprises about 22wt% of an alginate/pectin gelling agent blend, about l2wt% woodpulp filler, about 36% menthol flavourant and about 30wt% glycerol (DWB).
• the amorphous solid of these embodiments may be included as a sheet.
• the sheet is provided on a carrier comprising paper.
• the sheet is provided on a carrier comprising metal foil, suitably aluminium metal foil.
• the amorphous solid may abut the metal foil.
• the sheet forms part of a laminate material with a layer (preferably comprising paper) attached to a top and bottom surface of the sheet.
• a layer preferably comprising paper
• the sheet of amorphous solid has a thickness of from about 0.0l5mm to about lmm.
• the amorphous solid comprises a flavourant which does not comprise menthol.
• the amorphous solid may have the following composition (DWB): gelling agent (preferably comprising alginate) in an amount of from about 5 to about 40wt%, or from about l0wt% to about 35wt%, or from about 20wt% to about 35wt%; flavourant in an amount of from about 0.1 wt% to about 40wt%, of from about lwt% to about 30wt%, or from about lwt% to about 20wt%, or from about 5wt% to about 20wt%; aerosol generating agent (preferably comprising glycerol) in an amount of from l5wt% to 75wt%, or from about 30wt% to about 70wt%, or from about 50wt% to about 65wt%; and optionally filler (suitably woodpulp) in an amount of less than about 60wt%, or about 20wt%
• gelling agent preferably
• the amorphous solid comprises about 27wt% alginate gelling agent, about l4wt% flavourant and about 57wt% glycerol aerosol generating agent (DWB).
• the amorphous solid comprises about 29wt% alginate gelling agent, about 9wt% flavourant and about 60wt% glycerol (DWB).
• the amorphous solid of these embodiments may be included in a consumable or system as a shredded sheet, optionally blended with cut tobacco.
• the amorphous solid of these embodiments may be included in a consumable or system as a sheet, such as a sheet circumscribing a rod of aerosolisable material (e.g. tobacco).
• the amorphous solid of these embodiments may be included in a consumable or system as a layer portion disposed on a carrier.
• the amorphous solid comprises tobacco extract.
• the amorphous solid may have the following composition (DWB): gelling agent (preferably comprising alginate) in an amount of from about 5wt% to about 40wt%, or about l0wt% to 30wt%, or about l5wt% to about 25wt%; tobacco extract in an amount of from about 30wt% to about 60wt%, or from about 40wt% to 55wt%, or from about 45wt% to about 50wt%; aerosol generating agent (preferably comprising glycerol) in an amount of from about l0wt% to about 50wt%, or from about 20wt% to about 40wt%, or from about 25wt% to about 35wt% (DWB).
• gelling agent preferably comprising alginate
• tobacco extract in an amount of from about 30wt% to about 60wt%, or from about 40wt% to 55wt%, or from about 45wt% to about 50wt
• the amorphous solid comprises about 20wt% alginate gelling agent, about 48wt% Virginia tobacco extract and about 32wt% glycerol (DWB).
• the amorphous solid of these embodiments may have any suitable water content.
• the amorphous solid may have a water content of from about 5wt% to about l5wt%, or from about 7wt% to about l3wt%, or about l0wt%.
• the amorphous solid of these embodiments may be included in a consumable or system as a shredded sheet, optionally blended with cut tobacco.
• the amorphous solid of these embodiments may be included in a consumable or system as a sheet, such as a sheet circumscribing a rod of aerosolisable material (e.g. tobacco).
• the amorphous solid of these embodiments may be included in a consumable or system as a layer portion disposed on a carrier.
• the amorphous solid has a thickness of from about 50 pm to about 200 mih, or about 50 mih to about 100 mih, or about 60 mih to about 90 mih, suitably about 77 mih.
• the slurry for forming this amorphous solid may also form part of the invention.
• the slurry may have an elastic modulus of from about 5 to 1200 Pa (also referred to as storage modulus); in some cases, the slurry may have a viscous modulus of about 5 to 600 Pa (also referred to as loss modulus).
• weight percentages by weight described herein are calculated on a dry weight basis, unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis.
• a weight quoted on a dry weight basis refers to the whole of the extract or slurry or material, other than the water, and may include components which by themselves are liquid at room temperature and pressure, such as glycerol.
• a weight percentage quoted on a wet weight basis refers to all components, including water.
• the term“sheet” denotes an element having a width and length substantially greater than a thickness thereof.
• the sheet may be a strip, for example.
• heating material or“heater material” refers to material that is heatable by penetration with a varying magnetic field.
• Induction heating is a process in which an electrically-conductive object is heated by penetrating the object with a varying magnetic field.
• An induction heater may comprise an electromagnet and a device for passing a varying electrical current, such as an alternating current, through the electromagnet.
• a varying electrical current such as an alternating current
• the electromagnet and the object to be heated are suitably relatively positioned so that the resultant varying magnetic field produced by the electromagnet penetrates the object, one or more eddy currents are generated inside the object.
• the object has a resistance to the flow of electrical currents. Therefore, when such eddy currents are generated in the object, their flow against the electrical resistance of the object causes the object to be heated. This process is called Joule, ohmic, or resistive heating.
• An object that is capable of being inductively heated is known as a susceptor.
• Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by penetrating the object with a varying magnetic field.
• a magnetic material can be considered to comprise many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such material, the magnetic dipoles align with the magnetic field. Therefore, when a varying magnetic field, such as an alternating magnetic field, for example as produced by an electromagnet, penetrates the magnetic material, the orientation of the magnetic dipoles changes with the varying applied magnetic field. Such magnetic dipole reorientation causes heat to be generated in the magnetic material.
• the consumable 1 is for use with apparatus for heating aerosolisable material to volatilise at least one component of the aerosolisable material, such as the apparatus 100 shown in Figure 5 and described below.
• the apparatus may be a tobacco heating product (also known in the art as a tobacco heating device or a heat- not-bum device).
• the consumable 1 comprises a hollow tube la.
• the hollow tube la defines a passageway 20 therein.
• the hollow tube la comprises a wound structure 10 comprising aerosolisable material.
• the wound structure 10 is a helically wound structure comprising aerosolisable material.
• the wound structure may be non-helically wound.
• the structure comprising aerosolisable material may be non-helically spirally wound.
• the aerosolisable material of the structure 10 comprises tobacco.
• the aerosolisable material comprises reconstituted aerosolisable material, such as reconstituted tobacco.
• the aerosolisable material comprises an amorphous solid, which may, for example, be carried by a carrier such as paper or card.
• the aerosolisable material may be in any of the other forms discussed herein.
• the structure comprising aerosolisable material may comprise a carrier such as paper or card, and the aerosolisable material may be on a surface of the carrier or impregnated in the carrier.
• the aerosolisable material may comprise tobacco extract.
• the structure comprising aerosolisable material consists of the aerosolisable material.
• the aerosolisable material may be cast or otherwise shaped.
• the wound structure 10 comprising aerosolisable material defines both an innermost surface lb of the hollow tube la and an outermost surface lc of the hollow tube la.
• the hollow tube la consists of, or substantially consists of, the wound structure 10 comprising aerosolisable material.
• the innermost surface lb of the hollow tube la and/or the outermost surface lc of the hollow tube la may be defined by a part of the consumable other than the wound structure 10 comprising aerosolisable material. The part may be another layer of the hollow tube la or of the consumable.
• the wound structure 10 comprising aerosolisable material defines only part of the innermost surface lb of the hollow tube la and/or only part of the outermost surface lc of the hollow tube la, as a result of another part of the hollow tube la or consumable defining some or all of the rest of the innermost and/or outermost surface, respectively.
• the structure 10 comprising aerosolisable material is circular.
• the wound structure 10 comprising aerosolisable material comprises corrugations, embossing or debossing. Such an arrangement may increase the surface area over which an aerosol is able to form from the aerosolisable material in use.
• FIGS 3 and 4 there are shown schematic cross-sectional side and end views of an example of another consumable according to an embodiment of the invention.
• the consumable 2 of Figures 3 and 4 is for use with apparatus for heating aerosolisable material to volatilise at least one component of the aerosolisable material, such as the apparatus 100 shown in Figure 5 and described below.
• the apparatus may be a tobacco heating product (also known in the art as a tobacco heating device or a heat-not-bum device).
• the consumable 2 comprises a hollow tube 2a.
• the hollow tube 2a defines a passageway 20 therein.
• the hollow tube 2a comprises plural layers 10, 11, 12, 13. In some embodiments, two or some or all of the plural layers 10, 11, 12, 13 are bonded together such that the plural layers form a laminate.
• the wound structure 10 is a helically wound structure comprising aerosolisable material.
• the wound structure may be non-helically wound.
• the structure comprising aerosolisable material may be non-helically spirally wound.
• the aerosolisable material of the structure 10 comprises tobacco.
• the aerosolisable material is reconstituted aerosolisable material, such as reconstituted tobacco.
• the aerosolisable material comprises an amorphous solid, which may, for example, be carried by a carrier such as paper or card.
• the structure comprising aerosolisable material may comprise a carrier such as paper or card, and the aerosolisable material may be on a surface of the carrier or impregnated in the carrier.
• the aerosolisable material may comprise tobacco extract.
• the structure comprising aerosolisable material consists of the aerosolisable material.
• the aerosolisable material may be cast or otherwise shaped.
• the wound structure 10 comprising aerosolisable material defines a surface of the hollow tube 2a, and more specifically an innermost surface 2b of the hollow tube 2a.
• the wound structure 10 comprising aerosolisable material defines only part of the innermost surface 2b hollow tube 2a, as a result of another part of the hollow tube 2a or of the consumable defining some or all of the rest of the innermost surface 2b.
• the wound structure 10 comprising aerosolisable material comprises corrugations in this embodiment.
• the structure 10 additionally or alternatively comprises embossing or debossing, so as to be embossed or debossed, respectively.
• embossing or debossing so as to be embossed or debossed, respectively.
• such an arrangement may increase the surface area over which an aerosol is able to form from the aerosolisable material in use.
• the wound structure 10 comprising aerosolisable material is free from corrugations, embossings or debossings.
• the hollow tube 2a comprises further layers 11, 12, 13. It is to be noted that not all of these further layers 11, 12, 13 may be present in all embodiments.
• each of the further layers 11, 12, 13 is a wound layer, such as a helically wound layer, but in other embodiments one or more of the further layers 11, 12, 13 may be a non- wound layer, such as a cast or extruded layer.
• the consumable 2 comprises heating material that is heatable by penetration with a varying magnetic field. The heating material may be any of those discussed herein. The heating material is heatable to heat the aerosolisable material of the wound structure 10.
• the hollow tube 2a comprises a layer 11 comprising the heating material.
• the layer 11 comprising heating material is radially adjacent and abuts the wound structure 10 comprising aerosolisable material, so that heat energy generated in the heating material in use is able efficiently to pass to the aerosolisable material.
• the layer 11 comprising heating material is located radially outwards of the wound structure 10 comprising aerosolisable material, but in other embodiments the layer 11 comprising heating material may be located radially inwards of the wound structure 10 comprising aerosolisable material.
• the layer 11 comprising heating material is a wound layer, such as a helically wound layer, and the layer 11 comprising heating material has been wound around the structure 10 comprising aerosolisable material.
• the layer 11 comprising heating material may be non- wound.
• the layer 11 comprising heating material comprises a carrier, such as paper, carrying the heating material.
• the layer 11 comprising heating material comprises a foil, such as a metal or metal alloy foil, such as aluminium foil.
• the layer 11 comprising heating material may be omitted. Indeed, in some embodiments, the consumable 2 may be free from heating material that is heatable by penetration with a varying magnetic field.
• the aerosolisable material of the wound structure 10 adheres the wound structure 10 to the layer 11 comprising heating material. In other embodiments, this may not be the case and/or the aerosolisable material of the wound structure 10 may adhere the wound structure 10 to a different layer or part of the hollow tube 2a. In some embodiments, a separate adhesive may be used to adhere layers to each other.
• the structure 10 comprising aerosolisable material comprises corrugations, and in some other embodiments the structure 10 additionally or alternatively comprises embossing or debossing.
• the hollow tube 2a of this embodiment comprises one or more aerosol flow paths 17 defined by and between the corrugations, embossing or debossing of the structure 10 comprising aerosolisable material and the layer 11 comprising heating material.
• the aerosol flow path(s) extend in the axial direction of the hollow tube 2a and provide a route via which aerosol generated in or from the aerosolisable material is able to leave the hollow tube 2a.
• the one or more aerosol flow paths may be defined by and between the corrugations, embossing or debossing of the structure 10 comprising aerosolisable material and another layer or part of the hollow tube 2a, such as the other layer 12 or the barrier layer 13 described below.
• the hollow tube 2a comprises a barrier layer 13 that defines a surface of the hollow tube 2a.
• the surface is an outermost surface 2c of the hollow tube 2a. Therefore, the barrier layer 13 is located radially outwards of the wound structure 10 of aerosolisable material. Moreover, the layer 11 comprising heating material is located between the barrier layer 13 and the structure 10 comprising aerosolisable material, and abuts the structure 10 comprising aerosolisable material.
• the barrier layer 13 defines only part of the outermost surface 2c of the hollow tube 2a, as a result of another part of the hollow tube 2a or consumable defining some or all of the rest of the outermost surface 2c.
• the barrier layer 13 is a wound layer, such as a helically wound layer, but in other embodiments the barrier layer 13 may be a non- wound layer.
• the barrier layer 13 may, for example, comprise one or more materials selected from the group consisting of: paper, card, paperboard, cardboard, reconstituted tobacco, a plastics material, and heating material.
• the barrier layer 13 may help to provide the hollow tube 2a with rigidity.
• the barrier layer 13 is impermeable to aerosol generated in or from the structure 10 in use. This may help to prevent or discourage the generated aerosol from contacting the apparatus, or depositing in the apparatus, with which the consumable 2 is usable. It may also help to channel the aerosol generated in or from the aerosolisable material along and out of the hollow tube 2a.
• the barrier layer 13 is omitted.
• the consumable 2 of this embodiment comprises another layer 12, which is radially adjacent and abuts the layer 11 comprising heating material, so that heat energy generated in the heating material in use is able efficiently to pass to the other layer 12.
• the layer 11 comprising heating material is located radially inwards of the other layer 12, but in other embodiments the layer 11 comprising heating material may be located radially outwards of the other layer 12.
• the other layer 12 is thus located between the barrier layer 13 and the layer 11 comprising heating material.
• the other layer 12 also abuts the barrier layer 13, in this embodiment.
• the other layer 12 comprises aerosolisable material.
• the hollow tube 2a thus comprises a layer 11 comprising heating material that is located between the wound structure 10 comprising aerosolisable material and the other layer 12 comprising aerosolisable material.
• the aerosolisable material of the other layer 12 may adhere the other layer 12 to the barrier layer 13 and/or to the layer 11 comprising heating material.
• the aerosolisable material of the other layer 12 comprises tobacco.
• the aerosolisable material is reconstituted aerosolisable material, such as reconstituted tobacco.
• the aerosolisable material comprises an amorphous solid, which may, for example, be carried by a carrier such as paper or card.
• the other layer 12 may comprise a flavourant or a sensate, for example.
• the other layer 12 is omitted.
• the other layer 12 is a wound layer, such as a helically wound layer, but in other embodiments the other layer 12 may be a non- wound layer. In some embodiments, the other layer 12 has been wound around the layer 11 comprising heating material or whatever other layer is radially inwards of the other layer 12. Similarly, in some embodiments, the barrier layer 13 has been wound around the other layer 12.
• the aerosolisable material of the other layer 12 has a different form or chemical composition to the aerosolisable material of the structure 10.
• the difference in form may comprise a difference in mean particle size of the aerosolisable material.
• particles of aerosolisable material having a smaller mean particle size are heatable more quickly, for example to volatilise at least one component of the aerosolisable material, by a given heat source than are particles of the aerosolisable material having a greater mean particle size.
• the difference in form may comprise the aerosolisable material of one of the structure 10 and layer 12 being in the form of reconstituted aerosolisable material (such as reconstituted tobacco) and the aerosolisable material of the other of the structure 10 and layer 12 comprising an amorphous solid.
• the difference in chemical composition may comprise a difference in the ingredient or ingredients of the aerosolisable material, such as a difference in chemical compositions of respective amorphous solids.
• the difference in chemical composition may comprise a difference in the type or density of aerosol forming agent, such as glycerol, in the aerosolisable material.
• the difference in chemical composition may comprise a difference in quantities by weight of a smoke modifying agent, such as a flavourant as a percentage of a total weight of aerosolisable material.
• the layer 12 (when provided) and/or the wound structure 10 comprising aerosolisable material may comprise plural, spaced apart discrete regions of aerosolisable material.
• such discrete regions of aerosolisable material may be heatable independently by respective heaters of an apparatus with which the consumable 2 is usable.
• the plurality of layers 10, 11, 12, 13 of the hollow consumable 2a may be wound layers, wherein outward ones of the layers 11, 12, 13 have been wound around inward ones of the layers 10, 11, 12. Example methods for manufacturing such hollow tubes 2a are discussed below.
• an order of the layers 10, 11, 12, 13 of the hollow consumable 2a may be other than that shown in Figures 3 and 4.
• the consumable may have a wound structure comprising aerosolisable material that forms at least part of an outermost surface of the hollow tube, and a layer comprising heating material that is located radially inwards of the structure comprising aerosolisable material.
• the hollow tube 2a may comprise at least one additional layer, which may or may not be a wound layer, such as a helically wound layer.
• the hollow tube la, 2a has circular inner and outer cross-sectional shapes.
• one or each of the inner and outer cross-sectional shapes of the hollow tube may be non-circular, such as elliptical, polygonal, rectangular, square, triangular, or star-shaped.
• the hollow tube la, 2a extends along an axis A-A.
• the axis A-A is a central axis that extends along the passageway 20, but in other embodiments the configuration of the consumable 1, 2 may be such that the axis A-A is offset from the passageway 20.
• the consumable 1, 2 is elongate in the direction of the axis A-A, but in other embodiments a width or diameter of the consumable 1, 2 may be greater than or equal to a dimension of the consumable 1, 2 in the direction of the axis A-A, so that the consumable 1, 2 is not elongate.
• the hollow tube la, 2a of the consumable 1, 2 is elongate in the direction of the axis A-A, but in other embodiments a width or diameter of the hollow tube la, 2a may be greater than or equal to a dimension of the hollow tube la, 2a in the direction of the axis A-A, so that the hollow tube la, 2a is not itself elongate.
• the passageway 20 opens at an axial end 15 of the hollow tube la, 2a, and indeed the consumable 1, 2.
• a heating element of the apparatus may be insertable into the passageway 20 in use, as will be discussed in more detail below.
• the passageway 20 extends fully through the hollow tube la, 2a from one axial end 15 of the hollow tube la, 2a to an opposite axial end 16 of the hollow tube la, 2a. Moreover, in each of these embodiments, the passageway 20 extends fully through the consumable 1, 2 from a first axial end 15 of the consumable 1, 2 to an opposite second axial end 16 of the consumable 1, 2. However, in some embodiments, the passageway 20 may extend only partially along a length or axial dimension of the consumable 1, 2, such as for a majority of the length or axial dimension of the consumable 1, 2 or for a minority of a length or axial dimension of the consumable 1, 2.
• the hollow tube la, 2a extends for a full length or axial dimension of the consumable 1, 2.
• the consumable 1, 2 may comprise one or more elements (not shown) at one or each axial end of the hollow tube la, 2a, so that the hollow tube la, 2a extends for only part of the length or axial dimension of the consumable 1, 2.
• the consumable 1, 2 comprises a porous body (not shown).
• the porous body may be for filtering aerosol or vapour released from the aerosolisable material in use.
• the porous body may be for controlling the pressure drop over a length or axial dimension of the consumable 1 , 2.
• the porous body could be of any type used in the tobacco industry.
• the porous body may be made of cellulose acetate.
• the porous body is substantially cylindrical with a substantially circular cross section and a longitudinal axis.
• the filter may have a different cross section or not be elongate.
• the porous body abuts an axial end 15, 16 of the hollow tube la, 2a and is axially aligned with the hollow tube la, 2a.
• the porous body may be spaced from the hollow tube la, 2a, such as by a gap and/or by one or more further components of the consumable 1, 2.
• Example further component(s) are an additive or flavour source (such as an additive- or flavour- containing capsule or thread), which may be held by a body of filtration material or between two bodies of filtration material, for example.
• the consumable 1, 2 may also comprise a wrap that is wrapped around the hollow tube la, 2a and the porous body to retain the porous body relative to the hollow tube la, 2a.
• the wrap may encircle the hollow tube la, 2a and the porous body.
• the wrap may be wrapped around the hollow tube la, 2a and the porous body so that free ends of the wrap overlap each other.
• the wrap may form part of, or all of, a circumferential outer surface of the consumable 1, 2.
• the wrap could be made of any suitable material, such as paper, card, or reconstituted aerosolisable material (e.g. reconstituted tobacco).
• the wrap may also comprise an adhesive that adheres the overlapped free ends of the wrap to each other. The adhesive helps prevent the overlapped free ends of the wrap from separating. In other embodiments, the adhesive may be omitted or the wrap may take a different from to that described.
• the porous body may be retained relative to the hollow tube la, 2a by a connector other than a wrap, such as
• the consumable 1 , 2 has a length or an axial dimension of between 30 millimetres and 150 millimetres, such as between 70 millimetres and 120 millimetres.
• the consumable 1, 2 has an inner dimension (e.g. an inner diameter) in a direction perpendicular to the axial direction of between 2 millimetres and 10 millimetres, such as between 4 millimetres and 8 millimetres.
• an inner dimension e.g. an inner diameter
• the consumable 1, 2 has an outer dimension (e.g. an outer diameter) in a direction perpendicular to the axial direction of between 4 millimetres and 10 millimetres, such as between 4.5 millimetres and 8 millimetres.
• the aerosolisable material, wherever provided in the consumable 1, 2 has a thickness of between 0.05 millimetres and 2 millimetres, such as between 0.05 millimetres and 1 millimetre, or such as between 0.1 millimetres and 1 millimetre, or such as between 0.15 millimetres and 0.5 millimetres.
• the thickness may be less than or equal to 1 millimetre, such as less than or equal to 0.5 millimetres, or less than or equal to 0.25 millimetres, or less than or equal to 0.2 millimetres, or less than or equal to 0.1 millimetres, or less than or equal to 0.05 millimetres.
• the wound structure may comprising aerosolisable material may comprise corrugations, embossing or debossing.
• the corrugations, embossing or debossing define a plurality of troughs or depressions, and aerosolisable material (such as an amorphous solid described herein) is disposed in at least one of the troughs or depressions, such as a plurality of the troughs or depressions.
• Example methods of manufacturing a hollow tube for use in or as a consumable for use with apparatus for heating aerosolisable material to volatilise at least one component of the aerosolisable material will now be described. Any of the following methods may be used in the manufacture of any of the hollow tubes described herein, for example.
• Figure 6 shows a flow diagram showing an example of a method of manufacturing such a hollow tube.
• the method 600 comprises winding 601 a structure comprising aerosolisable material.
• the aerosolisable material may, for example, be any of those discussed herein.
• the aerosolisable material comprises tobacco.
• the aerosolisable material is reconstituted aerosolisable material, such as reconstituted tobacco.
• the aerosolisable material comprises an amorphous solid, which may, for example, be carried by a carrier such as paper or card.
• the structure comprising aerosolisable material may comprises a carrier such as paper or card, and the aerosolisable material may be on a surface of the carrier or impregnated in the carrier.
• the aerosolisable material may comprise tobacco extract.
• the structure comprising aerosolisable material consists of the aerosolisable material.
• the aerosolisable material may be cast or otherwise shaped.
• the winding 601 comprises helically winding the structure comprising aerosolisable material. In some embodiments, the winding 601 comprises spirally winding the structure comprising aerosolisable material. In some embodiments, the winding 601 comprises helically-spirally winding the structure comprising aerosolisable material so that the structure adopts a helical spiral form.
• the winding 601 may comprise winding the structure comprising aerosolisable material around a mandrel.
• the mandrel may be made of any suitable material, such as a metal, metal alloy, or a plastics material such as polyether ether ketone (PEEK). Alternatively, a mandrel may not be used.
• the structure comprising aerosolisable material may be wound using a garniture.
• a surface of the mandrel may be correspondingly shaped so as to engage with the corrugations, embossings or debossings.
• the winding 601 comprises winding the structure comprising aerosolisable material to form an innermost surface of the hollow tube.
• the structure comprising aerosolisable material may be wound around one or more other elements of the hollow tube being manufactured, such as one or more helically-wound layers, so that the structure comprising aerosolisable material does not form an innermost surface of the hollow tube.
• the structure comprising aerosolisable material comprises aerosolisable material on a surface of a carrier, such as paper.
• the method comprises winding the carrier and the aerosolisable material around a mandrel with the carrier in contact with the mandrel and the aerosolisable material outermost, and then winding a layer, such as of paper, onto the aerosolisable material. This forms an arrangement in which the aerosolisable material is sandwiched between the carrier and the layer.
• Figure 7 shows a flow diagram showing an example of another method of manufacturing a hollow tube for use in or as a consumable.
• the method 700 comprises drawing 701 material from a supply, such as a bobbin or spool.
• the material may, for example, be paper or card.
• the method also comprises winding 702 the material while drawing it from the supply.
• the winding 702 may be helical winding, for example.
• the winding 702 may comprise winding the material around a mandrel.
• the mandrel may be made of any of the mandrel materials discussed herein, for example.
• the method comprises applying 703 aerosolisable material to the material downstream of the supply.
• the aerosolisable material may be any of those discussed herein.
• the applying 703 may be performed upstream of the point at which the winding 702 of the material is performed.
• the winding 702 comprises winding the material around a mandrel
• the applying 703 may be performed using the mandrel.
• the aerosolisable material may be passed, such as pumped, in fluid form through the mandrel and into contact with the material while the material is on the mandrel.
• the mandrel may include a first portion around which the material is wound or wrapped, and a second portion downstream of the first portion and including aerosolisable material supply holes thorough which the aerosolisable material passes into contact with the material.
• the first portion of the mandrel may be free from aerosolisable material supply holes.
• the material may be porous, or non-porous, to the aerosolisable material. Following the application 703 of the aerosolisable material to the material, the material carrying the aerosolisable material continues to be wrapped around the mandrel.
• the aerosolisable material may be applied to an external surface of the mandrel, or to the material on the mandrel or upstream of the mandrel, without first passing through the mandrel.
• the aerosolisable material may take the form of a slurry, when so applied.
• the method may further comprise drying 704 the aerosolisable material during, or after, the winding 702 of the structure.
• the structure comprising aerosolisable material consists of the aerosolisable material.
• the aerosolisable material may be cast or otherwise shaped.
• the aerosolisable material may be cast as a block, and then rolled or otherwise pressed into a thinner form, such as a layer or sheet.
• the structure comprising aerosolisable material may, for example, include corrugations or embossings or debossings when in the supply, or the structure may be passed through a station at which the corrugations or embossings or debossings are made in the structure after it has been drawn from the supply.
• the method may also comprise winding 705 one or more layers, for example helically.
• the one or more layers may be wound around the mandrel, when used.
• the one or more layers may be wound around the structure comprising aerosolisable material.
• the structure comprising aerosolisable material may be wound around the one or more layers.
• the structure comprising aerosolisable material may be wound around one or more layers, and then one or more further layers may be wound around the structure comprising aerosolisable material.
• At least one of the layers may comprise heating material that is heatable by penetration with a varying magnetic field.
• the heating material may be any one of those discussed herein, for example.
• At least one of the layers may comprise a flavourant or sensate.
• At least one of the layers may comprise aerosolisable material.
• the aerosolisable material may be any one of those discussed herein, for example.
• the mandrel when a mandrel is used, in some embodiments the mandrel may be considered to have different zones: one in which aerosolisable material is applied to the material to form the structure comprising aerosolisable material, one in which the structure is wound, one in which the aerosolisable material is dried or allowed to dry, and optionally one or more zones in which the one or more layers may be wound around the structure comprising aerosolisable material.
• different materials or layers may be wrapped around the mandrel from diametrically opposite sides of the mandrel. These different materials may be wrapped around the mandrel at a certain common region in the length direction of the mandrel. Each of the materials or layers may be of any type discussed herein, for example.
• the aerosolisable material in order to reduce sticking of the aerosolisable material to the mandrel, may be coated with, or comprise, a release agent.
• the mandrel may be coated with a release agent, or may be heated or tapered or include a gas blower or ultrasonic vibrator to discourage sticking of the aerosolisable material to the mandrel, or to encourage release of the aerosolisable material from the mandrel if sticking were to occur.
• the gas blower may comprise one or more apertures in the surface of the mandrel on which the aerosolisable material or material is wound in use, and a source of gas, such as air, for supplying gas to the one or more apertures in the surface of the mandrel.
• the mandrel could be made of porous material, and the gas could be supplied from the gas source to a surface of the mandrel via pores in the mandrel.
• the method may result in the formation of a continuous hollow tube.
• the continuous hollow tube may be drawn from the mandrel while or after the winding takes place.
• the method may then comprise separating 706, such as by cutting, the continuous hollow tube to form discrete hollow tubes that can be incorporated into, or form, a consumable for use with apparatus for heating aerosolisable material to volatilise at least one component of the aerosolisable material.
• the winding 702 may comprise winding the material to form an innermost surface of the hollow tube, and the winding 705 of layers may comprise winding a layer comprising heating material around the structure comprising aerosolisable material, winding another layer comprising aerosolisable material around the layer comprising heating material, and winding a barrier layer around the other layer comprising aerosolisable material.
• the method may comprise providing aerosolisable material, such as comprising an amorphous solid, on a carrier, such as paper so as to provide the structure comprising aerosolisable material.
• the aerosolisable material may be coated, such as cast, band-cast, sprayed or electro-sprayed, on the carrier.
• the structure may be stored as a supply, on a bobbin for example.
• the structure may be drawn, from the supply for example, and wound, either around a mandrel or not, so that free ends of the structure are circumferentially adjacent or abutting, but not overlapping, thereby to create a tube or a near-tubular form with a substantially uniform diameter.
• the tube may thus have a seamless join between the free ends.
• the aerosolisable material may face an inner hollow space of the tube or near-tubular form.
• a layer, such as of paper, may be wound around the outside of the tube or near tubular form, and optionally adhered thereto, so as to help maintain the shape of the tube or near-tubular form.
• This layer similarly may have free ends that are adjacent or abut, but do not overlap.
• the adhesive when used, may be band casted onto the structure.
• the free ends of the structure do not overlap, such a method is usable to form a hollow tube that is purely, or at least closer to, circular or regular in cross- section, than a comparative hollow tube that includes overlapping free ends of material.
• the free ends of the combination may overlap.
• a surface of the carrier that abuts the aerosolisable material may be porous.
• the carrier comprises paper.
• the carrier comprises or consists of a tobacco material, such as a sheet of reconstituted tobacco, which may be porous. The inventors have found that a porous carrier such as paper is particularly suitable for some embodiments of the present invention; the porous layer abuts the aerosolisable material and forms a strong bond.
• the amorphous solid of the aerosolisable material of some embodiments is formed by drying a gel and, without being limited by theory, it is thought that the slurry from which the gel is formed partially impregnates the porous carrier (e.g. paper) so that when the gel sets and forms cross-links, the carrier is partially bound into the gel. This provides a strong binding between the gel and the carrier (and between the dried gel and the carrier).
• the porous layer e.g. paper
• the porous layer may also be used to carry flavours.
• the porous layer may comprise paper, suitably having a porosity of 0- 300 Coresta Units (CU), suitably 5-100 CU or 25-75 CU.
• surface roughness may contribute to the strength of bond between the aerosolisable material and the carrier.
• the inventors have found that the paper roughness (for the surface abutting the aerosolisable material) may suitably be in the range of 50-1000 Bekk seconds, suitably 50-150 Bekk seconds, suitably 100 Bekk seconds (measured over an air pressure interval of 50.66-48.00 kPa).
• a Bekk smoothness tester is an instrument used to determine the smoothness of a paper surface, in which air at a specified pressure is leaked between a smooth glass surface and a paper sample, and the time (in seconds) for a fixed volume of air to seep between these surfaces is the "Bekk smoothness”.
• the consumable 1, 2 is suitable for insertion into a heating zone of an apparatus, such as the heating zone 110 of the apparatus 100 shown in Figure 5, wherein the apparatus has a device for causing heating of the aerosolisable material of the consumable 1, 2 when the consumable 1, 2 is in the heating zone.
• the device of the apparatus causes heating of the aerosolisable material to volatilise at least one component of the aerosolisable material.
• the device is configured to apply heat energy to the consumable 1, 2, and specifically to the aerosolisable material thereof.
• the device comprises a resistive heater that is heated by electrically connecting the resistive heater to a supply of electricity, and heat energy passes from the resistive heater to the consumable 1, 2.
• the device may comprise a magnetic field generator for generating a varying magnetic field for penetrating the heating zone when the consumable 1, 2 is in the heating zone 110, and the consumable 1, 2 comprises heating material that is heatable by penetration with the varying magnetic field to thereby heat the aerosolisable material.
• the device is configured to cause electromagnetic energy to be applied to the heating material of the consumable 1, 2 to create heat in the heating material, and then heat energy is applied from the heating material to the aerosolisable material.
• the consumable 1 , 2 may comprise heating material that is partially or fully embedded in the aerosolisable material.
• the apparatus 100 has a heatable element comprising heating material, wherein the heatable element is in thermal contact with the heating zone, and wherein the magnetic field generator is for generating a varying magnetic field for penetrating the heatable element of the apparatus, so as to cause heating of the heatable element and thus the heating zone. Heat energy is thus applied to any consumable present in the heating zone.
• volatilised component(s) of the aerosolisable material pass from the aerosolisable material and out of the consumable 1, 2, such as by a user drawing on the consumable 1, 2 or a mouthpiece (when provided) of the apparatus.
• FIG. 5 there is shown a schematic cross-sectional side view of an example of a system comprising a consumable and apparatus for heating aerosolisable material of the consumable to volatilise at least one component of the aerosolisable material, according to an embodiment of the invention.
• the system 1000 comprises the consumable 1 of Figures 1 and 2 and apparatus 100 for heating the aerosolisable material of the consumable 1 to volatilise at least one component of the aerosolisable material.
• the consumable may be replaced by any of the other consumables described herein, such as the consumable 2 shown in Figures 3 and 4.
• the apparatus 100 is a tobacco heating product (also known in the art as a tobacco heating device or a heat-not-bum device).
• the apparatus comprises a heating zone 110 for receiving the consumable 1, 2, and a device 112 for causing heating of the aerosolisable material when the consumable 1, 2 is in the heating zone 110.
• the apparatus 100 may define at least one air inlet (not shown) that fluidly connects the heating zone 110 with the exterior of the apparatus 100.
• a user may be able to inhale the volatilised component(s) of the aerosolisable material by drawing the volatilised component(s) from the heating zone 110.
• air may be drawn into the heating zone 110 via the air inlet(s) of the apparatus 100.
• the heating zone 110 comprises a recess for receiving at least a portion of the consumable 1, 2.
• the heating zone 110 may be other than a recess, such as a shelf, a surface, or a projection, and may require mechanical mating with the consumable 1, 2 in order to co-operate with, or receive, the consumable 1, 2.
• the heating zone 110 is elongate, and is sized and shaped to accommodate the whole consumable 1, 2.
• the heating zone 110 may be dimensioned to receive only a portion of the consumable 1, 2.
• substantially all of the amorphous solid is less than about 4mm, 3mm, 2mm or lmm from the heater (i.e. the heatable element or the resistive heater).
• the solid is disposed between about 0.010mm and 2.0mm from the heater, suitably between about 0.02mm and l.Omm, suitably O.lmm to 0.5mm.
• These minimum distances may, in some cases, reflect the thickness of a carrier that supports the amorphous solid.
• a surface of the amorphous solid may directly abut the heater.
• the device 112 comprises an electrical power source, a resistive heater that is heated by passing electricity through the resistive heater, and a controller for controlling the passage of electricity through the resistive heater.
• the resistive heater is configured to apply heat energy to the heating zone 110, and thus to the consumable 1, 2 when the consumable is in the heating zone 110.
• the resistive heater may cause the heat energy to be applied to the aerosolisable material of the consumable 1, 2.
• the resistive heater may project into the heating zone 110 so as to be located in the passageway 20 of the consumable 1, 2 when the consumable 1, 2 is in the heating zone 110.
• the resistive heater may be located radially outwards of the consumable 1, 2 when the consumable is in the heating zone 110.
• the resistive heater may at least partially define the heating zone 110.
• the device may comprise a first resistive heater that is in the passageway 20 of the consumable 1, 2 when the consumable 1, 2 is in the heating zone 110, and a second resistive heater that is located radially outwards of the consumable 1, 2 when the consumable 1, 2 is in the heating zone 110.
• the device 112 comprises a magnetic field generator for generating a varying magnetic field for penetrating the heating zone 110 when the consumable 1, 2 is in the heating zone 110.
• the consumable comprises heating material for use in heating the aerosolisable material.
• the magnetic field generator of the apparatus may be configured to generate a varying magnetic field that penetrates the heating material of the consumable 1, 2 when the consumable 1, 2 is in the heating zone 110.
• the device 112 of the apparatus 100 comprises a heatable heating element 111, and the magnetic field generator is configured to generate a varying magnetic field that penetrates the heating element 111.
• the heating element is located radially outwards of the consumable 1, 2 when the consumable 1, 2 is in the heating zone 110.
• the heating element may at least partially define the heating zone 110.
• the heating element 111 projects into the heating zone 110.
• the heating element 111 may be insertable into the passageway 20 of the consumable 1, 2 in use.
• the heating element 111 enters the passageway 20 while the consumable 1, 2 is inserted into the heating zone 110.
• the apparatus may be configured so that the heating element 111 is movable relative to the heating zone 110 so as to project into the passageway 20 when the consumable 1, 2 is already located in the heating zone 110.
• the heating element 111 of the apparatus has an outer cross-sectional shape
• the innermost surface lb, 2b of the hollow tube la, 2a of the consumable 1, 2 has an inner cross-sectional shape that matches the outer cross- sectional shape of the heating element 111.
• the inner and outer cross- sectional shapes may be circular or may be non-circular, such as elliptical, polygonal, rectangular, square, triangular, corrugated, or star-shaped.
• the heating element 111 of the apparatus and the innermost surface lb, 2b of the hollow tube la, 2a of the consumable 1, 2 are relatively dimensioned so that the innermost surface abuts the heating element 111 in use, so as to increase the efficiency and effectiveness of heat energy transfer from the heating element 111 to the innermost surface.
• the innermost surface may be a close fit to, or a snug fit on, the heating element 111.
• the magnetic field generator comprises an electrical power source 113, a coil 114, a device 116 for passing a varying electrical current, such as an alternating current, through the coil 114, a controller 117, and a user interface 118 for user-operation of the controller 117.
• the electrical power source 113 of this embodiment is a rechargeable battery.
• the electrical power source 113 may be other than a rechargeable battery, such as a non-rechargeable battery, a capacitor, a battery- capacitor hybrid, or a connection to a mains electricity supply.
• the coil 114 may take any suitable form.
• the coil 114 is a helical coil of electrically-conductive material, such as copper.
• the coil is a flat coil. That is, the coil may be a two-dimensional spiral of electrically-conductive material, such as copper.
• the coil 114 encircles the heating zone 110.
• the coil 114 extends along a longitudinal axis that is substantially aligned with a longitudinal axis of the heating zone 110.
• the aligned axes may be coincident. Alternatively, the aligned axes may be parallel or oblique to each other.
• the device 116 for passing a varying current through the coil 114 is electrically connected between the electrical power source 113 and the coil 114.
• the controller 117 also is electrically connected to the electrical power source 113, and is communicatively connected to the device 116 to control the device 116. More specifically, in this embodiment, the controller 117 is for controlling the device 116, so as to control the supply of electrical power from the electrical power source 113 to the coil 114.
• the controller 117 comprises an integrated circuit (IC), such as an IC on a printed circuit board (PCB). In other embodiments, the controller 117 may take a different form.
• the apparatus 100 may have a single electrical or electronic component comprising the device 116 and the controller 117.
• the controller 117 is operated in this embodiment by user-operation of the user interface 118.
• the user interface 118 may comprise a push-button, a toggle switch, a dial, a touchscreen, or the like.
• the user interface 118 may be remote and connected to the rest of the apparatus 100 wirelessly, such as via Bluetooth.
• operation of the user interface 118 by a user causes the controller 117 to cause the device 116 to cause an alternating electrical current to pass through the coil 114.
• This causes the coil 114 to generate an alternating magnetic field.
• the coil 114 and the heating zone 110 of the apparatus 100 are suitably relatively positioned so that, when the consumable 1, 2, 3 is located in the heating zone 110, the varying magnetic field produced by the coil 114 penetrates the heating element 111 of the apparatus 100.
• the heating material of the heating element 111 is electrically-conductive, this penetration causes the generation of one or more eddy currents in the heating material.
• the flow of eddy currents in the heating material against the electrical resistance of the heating material causes the heating material to be heated by Joule heating.
• the heating material of the heating element 111 is a magnetic material
• the orientation of magnetic dipoles in the heating material changes with the changing applied magnetic field, which causes heat to be generated in the heating material.
• the consumable 1, 2 comprises heating material and the coil 114 and the heating zone 110 of the apparatus 100 are suitably relatively positioned so that, when the consumable 1, 2 is located in the heating zone 110, the varying magnetic field produced by the coil 114 penetrates the heating material of the consumable 1, 2.
• the apparatus 100 comprises the heating element 111, the heating element 111 comprises heating material, and the consumable 1, 2 also comprises heating material.
• the coil 114 and the heating zone 110 of the apparatus 100 may be suitably relatively positioned so that, when the consumable 1, 2 is located in the heating zone 110, the varying magnetic field produced by the coil 114 penetrates the heating material of the consumable 1, 2 and the heating material of the heating element 111.
• the apparatus 100 of this embodiment comprises a temperature sensor 119 for sensing a temperature of the heating zone 110.
• the temperature sensor 119 is communicatively connected to the controller 117, so that the controller 117 is able to monitor the temperature of the heating zone 110.
• the controller 117 may cause the device 112 to adjust a characteristic of the varying or alternating electrical current passed through the coil 114 as necessary, in order to ensure that the temperature of the heating zone 110 remains within a predetermined temperature range.
• the characteristic may be, for example, amplitude or frequency or duty cycle.
• the controller, and the apparatus 100 as a whole is arranged to heat the aerosolisable material to volatilise the at least one component of the aerosolisable material without combusting the aerosolisable material.
• the temperature range is about 50°C to about 350°C, such as between about l00°C and about 300°C, or between about l20°C and about 350°C, or between about l40°C and about 250°C, or between about 200°C and about 270°C.
• the temperature range may be other than one of these ranges.
• the upper limit of the temperature range could be greater than 350°C.
• the consumable may be non-combustible, for example in these ranges of temperatures.
• the temperature sensor 119 may be omitted.
• the device 112 for causing heating of the aerosolisable material when the consumable is in the heating zone 110 is configured for heating different sections of the heating zone 110 independently of each other, such as by way of comprising independently-controllable heatable elements 111.
• the heating material of the consumable 1, 2, or of the heatable heating element 111 of the apparatus 100 is aluminium.
• the heating material may comprise one or more materials selected from the group consisting of: an electrically-conductive material, a magnetic material, and a magnetic electrically-conductive material.
• the heating material may comprise a metal or a metal alloy.
• the heating material may comprise one or more materials selected from the group consisting of: aluminium, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain-carbon steel, mild steel, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper, and bronze. Other heating material(s) may be used in other embodiments.
• the heating material may be coated to help avoid corrosion or oxidation of the heating material in use.
• Such coating may, for example, comprise nickel plating, gold plating, or a coating of a ceramic or an inert polymer.
• the consumable 1 , 2 may comprise heating material that is partially or fully embedded in the aerosolisable material of the consumable 1, 2.
• the aerosolisable material may comprise heating material.
• the aerosolisable material may be free from heating material.
• the aerosolisable material comprises tobacco.
• the aerosolisable material may consist of tobacco, may consist substantially entirely of tobacco, may comprise tobacco and aerosolisable material other than tobacco, may comprise aerosolisable material other than tobacco, or may be free from tobacco.
• the aerosolisable material may comprise a vapour or aerosol forming agent or a humectant, such as glycerol, propylene glycol, triacetin, or diethylene glycol.
• the consumable is non-combustible. In some embodiments, the consumable is configured so as not to be combustible in use.
• the user may remove the consumable 1, 2 from the heating zone of the apparatus 100 and dispose of the consumable 1, 2. The user may subsequently re-use the apparatus 100 with another of the consumables 1, 2.
• the apparatus 100 and the consumable 1, 2 may be disposed of together once the volatilisable component(s) of the aerosolisable material has/have been spent.
• the consumable 1, 2 is sold, supplied or otherwise provided separately from the apparatus 100 with which the consumable 1, 2 is usable.
• the apparatus 100 and one or more of the consumables 1, 2 may be provided together as a system, such as a kit or an assembly, possibly with additional components, such as cleaning utensils.
• the entirety of this disclosure shows by way of illustration and example various embodiments in which the claimed invention may be practised and which provide for superior consumables for use with apparatus for heating aerosolisable material to volatilise at least one component of the aerosolisable material, systems comprising such a consumable and such apparatus, and methods of manufacturing a hollow tube for use in or as such a consumable.
• the advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed and otherwise disclosed features.

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• General Chemical & Material Sciences (AREA)
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• Manufacture Of Tobacco Products (AREA)
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• 2018
  • 2018-07-31 GB GBGB1812492.5A patent/GB201812492D0/en not_active Ceased
• 2019
  • 2019-07-31 JP JP2021504516A patent/JP7294700B2/ja active Active
  • 2019-07-31 KR KR1020217005919A patent/KR102627441B1/ko active IP Right Grant
  • 2019-07-31 EP EP19752975.3A patent/EP3829364A1/en active Pending
  • 2019-07-31 US US17/264,054 patent/US20210368851A1/en active Pending
  • 2019-07-31 KR KR1020247001763A patent/KR20240013277A/ko active Application Filing
  • 2019-07-31 WO PCT/EP2019/070735 patent/WO2020025737A1/en unknown

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