WO2021144547A1 - Consumable for use with a non-combustible aerosol provision device - Google Patents

Consumable for use with a non-combustible aerosol provision device Download PDF

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Publication number
WO2021144547A1
WO2021144547A1 PCT/GB2020/052757 GB2020052757W WO2021144547A1 WO 2021144547 A1 WO2021144547 A1 WO 2021144547A1 GB 2020052757 W GB2020052757 W GB 2020052757W WO 2021144547 A1 WO2021144547 A1 WO 2021144547A1
Authority
WO
WIPO (PCT)
Prior art keywords
susceptor
consumable
arrangement
aerosol
susceptor arrangement
Prior art date
Application number
PCT/GB2020/052757
Other languages
French (fr)
Inventor
Patrick MOLONEY
Anton KORUS
Original Assignee
Nicoventures Trading Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nicoventures Trading Limited filed Critical Nicoventures Trading Limited
Priority to PCT/GB2021/050107 priority Critical patent/WO2021144591A1/en
Priority to EP21700996.8A priority patent/EP4090180A1/en
Priority to KR1020227024182A priority patent/KR20220114059A/en
Priority to US17/792,729 priority patent/US20230050426A1/en
Priority to JP2022543195A priority patent/JP7474855B2/en
Publication of WO2021144547A1 publication Critical patent/WO2021144547A1/en

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Classifications

    • 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
    • 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
    • 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

Definitions

  • the present invention relates to a method of manufacturing a consumable for use in a non-combustible aerosol provision device, a susceptor arrangement for use in a method of manufacturing a consumable for use with a non-combustible aerosol provision device, an assembly for use in a method of manufacturing a consumable for use with a non-combustible aerosol provision device, consumable for use with a non- combustible aerosol provision device, and a non-combustible aerosol provision system.
  • 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 method of manufacturing a consumable for use in a non-combustible aerosol provision device comprising: providing a susceptor arrangement comprising first and second susceptor portions and a connector joining the first and second susceptor portions to each other, wherein the first and second susceptor portions are spaced apart from each other by the connector; forming an assembly comprising the susceptor arrangement and aerosol-generating material; and dividing the assembly, wherein the dividing comprises dividing the connector and the aerosol-generating material.
  • the dividing comprises using a cutter to cut the connector.
  • the forming comprises at least partially embedding the susceptor arrangement in the aerosol-generating material.
  • the forming comprises: combining the susceptor arrangement with the aerosol-generating material on a wrapper; and wrapping the wrapper around the susceptor arrangement and the aerosol-generating material.
  • the susceptor arrangement is placed on the wrapper before the aerosol-generating material.
  • the aerosol-generating material is placed on the wrapper before the susceptor arrangement.
  • the connector comprises a weakened region of the susceptor arrangement.
  • the susceptors are integrally formed with the weakened region.
  • the connector comprises a carrier to which the susceptors are affixed.
  • the carrier comprises heating material that is heatable by penetration with a varying magnetic field.
  • the carrier is free from heating material that is heatable by penetration with a varying magnetic field.
  • the carrier comprises one or more of: paper, metal foil, metal alloy foil, and aerosol-generating material.
  • a susceptor arrangement for use in a method of manufacturing a consumable for use with a non-combustible aerosol provision device, the susceptor arrangement comprising first and second susceptor portions and a connector joining the first and second susceptor portions to each other, wherein the first and second susceptor portions are spaced apart from each other by the connector.
  • the connector comprises a weakened region of the susceptor arrangement.
  • the susceptor portions are integrally formed with the weakened region.
  • the susceptor arrangement comprises at least one further susceptor portion and at least one further connector, wherein the susceptor arrangement is arranged such that a repeating sequence of susceptor portion followed by connector followed by susceptor portion is present.
  • the connector comprises a carrier to which the susceptor portions are affixed.
  • the susceptor arrangement comprises at least one further susceptor portion and wherein the first susceptor portion, the second susceptor portion and at least one further susceptor portion are affixed to the carrier.
  • the susceptor portions are spaced apart from one another on the carrier, and wherein the carrier comprises a weakened region between the susceptor portions.
  • the carrier comprises heating material that is heatable by penetration with a varying magnetic field.
  • the carrier is free from heating material that is heatable by penetration with a varying magnetic field.
  • the carrier comprises one or more of: paper, metal foil, metal alloy foil, and aerosol-generating material.
  • the assembly comprises a wrapper that is wrapped around the susceptor arrangement and the aerosol-generating material.
  • a consumable for use with a non-combustible aerosol provision device the consumable being manufactured according to a method comprising the method according to the first aspect of the present invention.
  • a consumable for use with a non-combustible aerosol provision device comprising: at least one susceptor portion and a connector portion affixed to or integrally formed with the or each susceptor portion, and aerosol-generating material in thermal contact with the or each susceptor portion; wherein the connector portion extends to at least one end of the aerosol-generating material.
  • the consumable comprises a susceptor arrangement that comprises the at least one susceptor portion, wherein the connector portion comprises a weakened region of the susceptor arrangement.
  • the weakened region is integrally formed with the at least one susceptor portion.
  • the connector portion comprises a carrier to which the at least one susceptor portion is affixed.
  • the or each susceptor portion is at least partially embedded in the aerosol-generating material.
  • the or each susceptor portion is substantially coaxial with a central axis of the consumable.
  • the carrier comprises heating material that is heatable by penetration with a varying magnetic field.
  • the carrier is free from heating material that is heatable by penetration with a varying magnetic field.
  • the carrier comprises one or more of: paper, metal foil, metal alloy foil, and aerosol-generating material.
  • the or each susceptor portion 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 or each susceptor portion comprises nickel.
  • the or each susceptor portion comprises steel with a nickel coating.
  • the susceptor arrangement comprises perforations.
  • the susceptor arrangement comprises a weakened region.
  • the susceptor arrangement comprises first and second materials that are different.
  • the or each susceptor portion comprises a first region comprising the first material and a second region comprising the second material.
  • the first and second materials have a different electrical conductivity and/or magnetic electrical conductivity.
  • the first material comprises a material that is heatable by penetration with a varying magnetic field and the second material comprises a material that is not, or substantially is not, heatable by penetration with a varying magnetic field.
  • one of first and second materials is coated with the other one of the first and second materials.
  • the first material is coated with the second material.
  • the first and second materials are configured such that, in use, when the first and second materials are penetrated by a varying magnetic field, the penetration of the first and second materials by the varying magnetic field causes a temperature difference between the first and second materials.
  • the first and second materials have different thermal masses.
  • the or each susceptor portion comprises a base portion and an embeddable portion for at least partially embedding in aerosol-generating material.
  • the base portion is generally flat.
  • the base portion is generally circular.
  • the base portion is comprises a material that is heatable by penetration with a varying magnetic field.
  • the embeddable portion comprises a thermally conductive material.
  • the embeddable portion comprises a material that is heatable by penetration with a varying magnetic field.
  • the embeddable portion comprises a material that is not, or substantially is not, heatable by penetration with a varying magnetic field.
  • the embeddable portion comprises the first and second materials.
  • the embeddable portion comprises one of the first and second materials and the base portion comprises the other one of the first and second materials.
  • the or each susceptor portion is hollow or perforated, or comprises indentations, a mesh or an expanded metal.
  • the or each susceptor portion comprises a pin, mesh or blade.
  • the or each susceptor portion comprises a plurality of pins, meshes or blades.
  • the or each susceptor portion comprises a plurality of apertures or recesses, wherein the apertures and/or recesses are filled with the aerosol-generating material.
  • At least part of the or each susceptor portion is annular.
  • the or each susceptor portion comprises a plurality of annular portions and, preferably, wherein the annular portions of each respective susceptor portion are arranged generally concentrically.
  • the aerosol-generating material is non-liquid.
  • the aerosol-generating material comprises tobacco.
  • the susceptor extends the majority of the length of the consumable and, preferably, the susceptor extends substantially the entire length of the consumable.
  • a non combustible aerosol provision system comprising: the consumable according to the fourth aspect of the present invention or the fifth aspect of the present invention, and a non-combustible aerosol provision device for causing heating of the aerosol-generating material of the consumable to volatilise at least one component of the aerosol generating material; wherein the device comprises a heating zone for receiving the consumable, and a magnetic field generator for generating a varying magnetic field for penetrating the susceptor portion of the consumable when the consumable is in the heating zone, thereby to cause heating of the aerosol-generating material.
  • the device is for causing heating of the aerosol-generating material of the consumable to volatilise at least one component of the aerosol-generating material without burning the aerosol-generating material.
  • the magnetic field generator comprises at least one coil.
  • the coil is helical.
  • the coil is a flat coil and may be a two-dimensional spiral.
  • the system further comprises a second coil and, preferably, the second coil is helical.
  • the magnetic field generator is configured to generate a varying magnetic field for penetrating the base portion of the susceptor portion when the consumable is at least partially in the heating zone.
  • the coil is configured to generate a varying magnetic field for penetrating the base portion of the susceptor portion when the consumable is at least partially in the heating zone and wherein the second coil is configured to generate a varying magnetic field for penetrating the embeddable portion of the susceptor portion when the consumable is at least partially in the heating zone.
  • the second coil extends about the circumference of at least a portion of the embeddable portion of the susceptor portion.
  • the susceptor portion and/or 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 susceptor portion and/or heating material comprises a metal or a metal alloy.
  • the susceptor portion and/or 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 aerosol-generating material is a non-liquid material.
  • the aerosol-generating material comprises tobacco.
  • the aerosol-generating material is reconstituted aerosolisable material, such as reconstituted tobacco.
  • Figure 1 shows a schematic view of a susceptor arrangement according to one embodiment of the present invention.
  • Figure 2 shows a schematic view of a susceptor arrangement according to one embodiment of the present invention.
  • Figure 3 shows a schematic view of a susceptor arrangement according to one embodiment of the present invention.
  • Figure 4 shows a flow chart of a method according to one embodiment of the present invention.
  • Figure 5 shows a schematic view of an assembly according to one embodiment of the present invention.
  • Figure 6 shows a schematic view of a consumable according to one embodiment of the present invention.
  • Figure 7 shows a non-combustible aerosol provision system according to one embodiment of the present invention.
  • aerosol-generating material is material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way.
  • Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants.
  • the aerosol-generating material may comprise an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous).
  • the amorphous solid may be a dried gel.
  • the amorphous solid is a solid material that may retain some fluid, such as liquid, within it.
  • the aerosol-generating material may for example comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.
  • the aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional materials.
  • the aerosol-generating material may comprise tobacco material, wherein tobacco material is any material comprising tobacco or derivatives thereof.
  • 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 aerosol-generating material may comprise a tobacco substitute.
  • a “consumable” is an item comprising or consisting of aerosol generating material, part or all of which is intended to be consumed during use by a user.
  • a consumable may comprise one or more other components, such as an aerosol generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol modifying agent.
  • a consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use.
  • a “susceptor” is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field.
  • the susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material.
  • the heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material.
  • the susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms.
  • a susceptor When a susceptor is incorporated into a consumable, as heat is generated inside the susceptor itself, rather than by an external heat source by heat conductions, a rapid temperature rise in the consumable and more uniform heat distribution can be achieved, particularly through the selection of suitable materials and geometry, and suitable varying magnetic field magnitude and orientation relative to the susceptor. Moreover, as induction heating and magnetic hysteresis heating do not require physical connection to be provided between the source of the varying magnetic field and the susceptor, material deposits on the susceptor, such as residue or condensate, may be less of an issue, design freedom and control over the heating profile may be greater, and cost may be lower.
  • aerosol-generating material such as tobacco is placed in contact with a paper.
  • the paper is then wrapped around the aerosol generating material to encase the aerosol-generating material and create a rod.
  • the rod is cut to a desired length, and a filter may subsequently be attached (typically at one end of the cut rod), to form the consumable.
  • a susceptor may be provided within such a consumable in order to enable heating of the consumable in any of the ways discussed above.
  • Conventional consumables may not include a susceptor and hence the cutting equipment used to cut the rods to the desired length are typically configured to cut through the aerosol generating material (e.g., tobacco) and the paper layer(s).
  • the susceptor is provided as a continuous uniform item (e.g., a strip of metal having uniform dimensions and uniform material properties) through the rod before the rod is cut to length, then damage may be caused to the existing cutting instruments used to cut the rod to the desired length on-line.
  • the time required to perform the cutting of the rods may be comparably longer when the continuous susceptor is present, thus impacting the production rate (and quantity) of consumables that can be manufactured.
  • FIG. 1 shows a schematic view of a susceptor arrangement 1 for use in a method of manufacturing a consumable for use with a non-combustible aerosol provision device, according to one embodiment of the present invention.
  • the susceptor arrangement 1 comprises susceptor portions 2 and a connector 3 joining the susceptor portions 2 to each other. This arrangement therefore represents a series of susceptor portions 2 physically connected to one another.
  • the physical connection may be a direct connection (e.g., where the susceptor portions 2 are integrally formed with the connector 3) or an indirect connection (e.g., where the susceptor portions 2 are not physically connected to each other).
  • the susceptors 2 are spaced apart from each other by the connector 3.
  • the connector 3 performs several functions, including: maintaining the susceptor portions 2 at a predetermined separation distance from one another, enabling a single item which is more easily handled during manufacture, and maintaining the susceptor portions 2 in a uniform arrangement.
  • the connector 3 may reduce twisting of the susceptor portions 2 relative to one another such that the susceptor portions 2 are each placed at roughly the same location and at the same orientation during manufacture of the consumable.
  • susceptor portions herein should be understood to refer to the portions of the susceptor assembly which predominantly or exclusively act as the susceptor (or heater) when a consumable including a susceptor portion is exposed to a varying magnetic field.
  • susceptors or “discrete susceptors” are used instead of susceptor portions to indicate that these are the portions of the susceptor arrangement 1 which predominantly act as a heater.
  • the connector 3 in some embodiments may comprise or consist of material which heats up upon exposure to a varying magnetic field; however, generally speaking, the primary function of the connector 3 is not to act as the main source of heat in some implementations .
  • susceptors 2 are shown in Figure 1. However, any suitable number of susceptors 2 may be comprised in the susceptor arrangement 1, for example, two, three, four, five or six susceptors 2.
  • the susceptor arrangement 1 may comprise a sequence of alternating susceptors 2 and connectors 3.
  • the susceptor arrangement 1 may be wound onto a reel or the like for convenient storage of the susceptor arrangement 1.
  • the susceptor arrangement 1 comprises the susceptors 2 and a weakened region 4 of the susceptor arrangement 1 between the susceptors 2.
  • the connector 3 comprises or consists of the weakened region 4.
  • the weakened region 4 allows for the susceptors 2 to be more easily separated from each other, if desired. This reduces the risk of damaging any cutting instruments used to cut the susceptor arrangement 1 during consumable manufacture, as will be described below.
  • the weakened region 4 may be a region that is relatively weaker than each of the susceptors 2.
  • the weakened region 4 may be a region that is easier to cut than each of the susceptors 2.
  • the, or each, weakened region is a region of the susceptor arrangement 1 having certain properties that enable the weakened region to be more easily cut that other regions of the susceptor arrangement (and in particular those regions containing the susceptors).
  • the weakened region 4 is formed by providing perforations in the susceptor arrangement 1. That is, in these embodiments, in the weakened region the amount of material to be cut is reduced relative to the other regions of the susceptor arrangement.
  • the weakened region 4 may have a different geometric property (e.g. width and/or length) to the susceptors 2, for example as shown in Figure 3. That is, in these embodiments, in the weakened region the amount of material to be cut is reduced relative to the other regions of the susceptor arrangement.
  • the weakened region 4 may alternatively or additionally comprise a different material from the susceptors 2.
  • the susceptors 2 are integrally formed with the weakened region 4.
  • the susceptors 2 and the connector 3 may be formed as discrete elements and subsequently connected together.
  • FIG 2 shows a schematic view of a susceptor arrangement 1 according to one embodiment of the present invention.
  • the susceptor arrangement 1 comprises discrete susceptors 2 and a connector 3.
  • the connector 3 comprises a carrier 5 to which the susceptors 2 are affixed.
  • the susceptors 2 may be affixed to the carrier 5 by any suitable means including, but not limited to, gluing, welding, etc..
  • the type of affixing mechanism may be chosen based on the material of the carrier 5 and the material of the susceptor 2.
  • the susceptors 2 may be crimped onto the carrier 5 using any suitable method, so as to effectively staple the susceptors 2 to the carrier 5.
  • the susceptors 2 may be encapsulated by or embedded within the carrier 5.
  • the carrier 5 may comprise two laminae (such as two sheets of paper) that are adhered to each other to capture the susceptors 2 therebetween.
  • the carrier 5 may help to prevent the susceptors 2 from twisting or warping and keep the susceptors 2 planar. In some embodiments, the susceptors 2 may not be planar.
  • the carrier 5 may help the susceptors 2 to maintain their shape.
  • the susceptor arrangement 1 is provided with markings on at least one surface thereof.
  • the marking may be provided on at least one surface of the carrier 5.
  • the markings may aid in monitoring movement of the carrier 5 and/or the susceptor arrangement 1 during a manufacturing process.
  • the markings may be used to determine how much of the carrier 5 is disposed in a consumable and/or to adjust timing of the movement of the carrier 5.
  • the carrier 5 is provided on, or wound onto, a bobbin.
  • the carrier 5 comprises heating material that is heatable by penetration with a varying magnetic field.
  • the carrier 5 is free from heating material that is heatable by penetration with a varying magnetic field.
  • the carrier 5 may comprise one or more of paper, metal foil, metal alloy foil and aerosol generating material, for example.
  • a single carrier 5 is shown. In other embodiments, more than one carrier 5 may be utilised.
  • two carriers 5 may be affixed to opposite sides of the susceptors 2, so that the susceptors 2 are sandwiched between the carriers 5.
  • the susceptors 2 and/or 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 susceptors and/or heating material comprises a metal or a metal alloy.
  • the susceptors and/or 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.
  • FIG 3 shows a schematic view of a susceptor arrangement 1 according to one embodiment.
  • the susceptor arrangement 1 comprises susceptors 2 and a connector 3.
  • the connector 3 comprises a carrier 5.
  • the carrier may comprise a weakened region along line X, which is formed by a change in geometric property of the carrier 5.
  • FIG. 4 shows a flowchart of a method 10 of manufacturing a consumable for use with a non-combustible aerosol provision device, according to one embodiment of the present invention.
  • the method 10 comprises providing 11 a susceptor arrangement 1 comprising discrete susceptors 2 and a connector 3 joining the susceptors 2 to each other.
  • the susceptors 2 are spaced apart from each other by the connector 3.
  • the method 10 also comprises forming 12 an assembly comprising the susceptor arrangement 1 and aerosol-generating material and dividing 13 the assembly.
  • the dividing 13 comprises dividing the connector 3 and the aerosol-generating material.
  • the dividing 13 comprises using a cutter to cut the connector 3.
  • the cutter may be an on-line component of a consumable-manufacturing system, or may be separate to a consumable-manufacturing system.
  • the cutter may be the same cutter used to cut the consumable to a desired length.
  • the forming 12 comprises at least partially embedding the susceptor arrangement 1 in the aerosol-generating material.
  • the forming 12 may comprise fully embedding the susceptor arrangement 1 in the aerosol-generating material.
  • the forming 12 comprises combining the susceptor arrangement 1 with the aerosol-generating material on a wrapper and wrapping the wrapper around the susceptor arrangement 1 and the aerosol-generating material.
  • the susceptor arrangement 1 may be placed on the wrapper before the aerosol-generating material.
  • the aerosol-generating material may be placed on the wrapper before the susceptor arrangement 1.
  • the connector 3 comprises a weakened region of the susceptor arrangement 1.
  • the susceptors 2 may be integrally formed with the weakened region.
  • the connector 3 comprises a carrier to which the susceptors 2 are affixed.
  • the carrier may be made from any of the materials discussed above for the carrier.
  • FIG. 5 shows a schematic view of an assembly 20 for use with a method of manufacturing a consumable for use with a non-combustible aerosol provision device, according to one embodiment of the present invention.
  • the assembly 20 comprises a susceptor arrangement 1 and aerosol-generating material 21 in thermal contact with the susceptor arrangement 1.
  • the susceptor arrangement 1 may be any susceptor arrangement described herein, such as one of the susceptor arrangements 1 described in relation to Figures 1 to 3.
  • the assembly 20 is dividable by a process comprising dividing the connector 3 and the aerosol-generating material 21.
  • the dividing forms individual objects.
  • Each of the individual objects may be a consumable or may be used in the manufacture of a consumable.
  • the assembly 20 may be dividable along line Y.
  • the assembly 20 comprises a wrapper that is wrapped around the susceptor arrangement 1 and the aerosol-generating material 21.
  • FIG. 6 shows a schematic view of a consumable 30 for use with a non combustible aerosol provision device, according to one embodiment.
  • the consumable 30 comprises at least one discrete susceptor 31 and a connector portion 32 affixed to or integrally formed with the or each susceptor 31.
  • the consumable comprises aerosol generating material 33 in thermal contact with the or each susceptor 31.
  • the connector portion 32 extends to at least one end 34 of the aerosol-generating material 33. As shown in Figure 6, in one embodiment respective connector portions 32 may extend to two opposite ends of the aerosol-generating material 33.
  • the connector portion 32 is a part of a connector described herein.
  • the consumable 30 is manufactured according to a method described herein.
  • the consumable 30 may be manufactured according to the method described with relation to Figure 4.
  • the consumable 30 comprises a susceptor arrangement that comprises the at least one susceptor 31 , wherein the connector portion 32 comprises a weakened region of the susceptor arrangement.
  • the weakened region may be integrally formed with the at least one susceptor 31.
  • the weakened region may be formed separately to and subsequently attached to the at least one susceptor 31, such as in the form of a carrier.
  • the connector portion 32 comprises a carrier to which the at least one susceptor 31 is affixed.
  • the carrier may comprise heating material that is heatable with a varying magnetic field.
  • the carrier may be free from heating material that is heatable by penetration with a varying magnetic field.
  • the carrier comprises one or more of paper, metal foil, metal alloy foil and aerosol-generating material.
  • the or each susceptor 31 is at least partially embedded in the aerosol-generating material 33.
  • the or each susceptor 31 may be embedded such that at least a portion of the susceptor 31 protrudes from the aerosol generating material 33.
  • the or each susceptor 31 may be fully embedded in the aerosol-generating material 33 such that no part of the susceptor 31 protrudes from the aerosol-generating material 33. This can help to avoid a user contacting the susceptor 31, which may be hot, during use of the consumable 30.
  • the or each susceptor 31 may be substantially coaxial with a central axis of the consumable 30.
  • the or each susceptor 31 may be disposed in any other way that allows the or each susceptor 31 to heat the aerosol generating material 33 of the consumable 30.
  • FIG 7 shows a schematic view of a non-combustible aerosol provision system 40 according to an embodiment of the invention.
  • the non-combustible aerosol provision system 40 comprises a consumable 30.
  • the consumable 30 may be any consumable 30 described herein, such as the consumable described with reference to Figure 6 or any variant thereof discussed herein.
  • the system also comprises a non combustible aerosol provision device 42 for causing heating of the aerosol-generating material of the consumable 30 to volatilise at least one component of the aerosol generating material.
  • the device 42 comprises a heating zone 43 for receiving the consumable 30 and a magnetic field generator 44 for generating a varying magnetic field for penetrating the susceptor of the consumable 30 when the consumable 30 is in the heating zone 43, thereby causing heating of the aerosol generating material.
  • the device 42 is for causing heating of the aerosol generating material of the consumable 30 to volatilise at least one component of the aerosol-generating material without burning the aerosol-generating material.
  • the aerosol-generating material is a non-liquid material.
  • the aerosol-generating material comprises tobacco. In some embodiments, the aerosol-generating material is reconstituted aerosolisable material, such as reconstituted tobacco.
  • the above embodiments are to be understood as illustrative examples of the invention. Further embodiments of the invention are envisaged. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims.

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Abstract

A manufacturing method providing a susceptor arrangement (1) comprising first and second susceptor portions (2) and a connector (3) joining the first and second susceptor portions to each other, wherein the first and second susceptor portions are spaced apart from each other by the connector. The method further comprises forming an assembly comprising the susceptor arrangement and aerosol- generating material and dividing the assembly, wherein the dividing comprises dividing the connector and the aerosol-generating material. According to the present disclosure, there is also provided a susceptor arrangement for use in a method of manufacturing a consumable for use with a non-combustible aerosol provision device, an assembly for use in a method of manufacturing a consumable, a consumable for use with a non-combustible aerosol provision device, and non- combustible aerosol provision system.

Description

CONSUMABLE FOR USE WITH A NON-COMBUSTIBLE AEROSOL
PROVISION DEVICE
Technical Field The present invention relates to a method of manufacturing a consumable for use in a non-combustible aerosol provision device, a susceptor arrangement for use in a method of manufacturing a consumable for use with a non-combustible aerosol provision device, an assembly for use in a method of manufacturing a consumable for use with a non-combustible aerosol provision device, consumable for use with a non- combustible aerosol provision device, and a non-combustible aerosol provision system.
Background
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.
Summary
According to a first aspect of the present invention, there is provided a method of manufacturing a consumable for use in a non-combustible aerosol provision device, the method comprising: providing a susceptor arrangement comprising first and second susceptor portions and a connector joining the first and second susceptor portions to each other, wherein the first and second susceptor portions are spaced apart from each other by the connector; forming an assembly comprising the susceptor arrangement and aerosol-generating material; and dividing the assembly, wherein the dividing comprises dividing the connector and the aerosol-generating material.
Optionally, the dividing comprises using a cutter to cut the connector. Optionally, the forming comprises at least partially embedding the susceptor arrangement in the aerosol-generating material.
Optionally, the forming comprises: combining the susceptor arrangement with the aerosol-generating material on a wrapper; and wrapping the wrapper around the susceptor arrangement and the aerosol-generating material.
Optionally, the susceptor arrangement is placed on the wrapper before the aerosol-generating material.
Optionally, the aerosol-generating material is placed on the wrapper before the susceptor arrangement.
Optionally, the connector comprises a weakened region of the susceptor arrangement.
Optionally, the susceptors are integrally formed with the weakened region.
Optionally, the connector comprises a carrier to which the susceptors are affixed.
Optionally, the carrier comprises heating material that is heatable by penetration with a varying magnetic field. Optionally, the carrier is free from heating material that is heatable by penetration with a varying magnetic field.
Optionally, the carrier comprises one or more of: paper, metal foil, metal alloy foil, and aerosol-generating material.
According to a second aspect of the present invention, there is provided a susceptor arrangement for use in a method of manufacturing a consumable for use with a non-combustible aerosol provision device, the susceptor arrangement comprising first and second susceptor portions and a connector joining the first and second susceptor portions to each other, wherein the first and second susceptor portions are spaced apart from each other by the connector.
Optionally, the connector comprises a weakened region of the susceptor arrangement.
Optionally, the susceptor portions are integrally formed with the weakened region.
Optionally, the susceptor arrangement comprises at least one further susceptor portion and at least one further connector, wherein the susceptor arrangement is arranged such that a repeating sequence of susceptor portion followed by connector followed by susceptor portion is present.
Optionally, the connector comprises a carrier to which the susceptor portions are affixed.
Optionally, the susceptor arrangement comprises at least one further susceptor portion and wherein the first susceptor portion, the second susceptor portion and at least one further susceptor portion are affixed to the carrier.
Optionally, the susceptor portions are spaced apart from one another on the carrier, and wherein the carrier comprises a weakened region between the susceptor portions.
Optionally, the carrier comprises heating material that is heatable by penetration with a varying magnetic field.
Optionally, the carrier is free from heating material that is heatable by penetration with a varying magnetic field. Optionally, the carrier comprises one or more of: paper, metal foil, metal alloy foil, and aerosol-generating material. According to a third aspect of the present invention, there is provided an assembly for use in a method of manufacturing a consumable for use with a non combustible aerosol provision device, the assembly comprising: the susceptor arrangement according to the second aspect of the present invention; and aerosol generating material in thermal contact with the susceptor arrangement; wherein the assembly is dividable by a process comprising dividing the connector and the aerosol generating material.
Optionally, the assembly comprises a wrapper that is wrapped around the susceptor arrangement and the aerosol-generating material.
According to a fourth embodiment of the present invention, there is provided a consumable for use with a non-combustible aerosol provision device, the consumable being manufactured according to a method comprising the method according to the first aspect of the present invention.
According to a fifth aspect of the present invention, there is provided a consumable for use with a non-combustible aerosol provision device, the consumable comprising: at least one susceptor portion and a connector portion affixed to or integrally formed with the or each susceptor portion, and aerosol-generating material in thermal contact with the or each susceptor portion; wherein the connector portion extends to at least one end of the aerosol-generating material.
Optionally, the consumable comprises a susceptor arrangement that comprises the at least one susceptor portion, wherein the connector portion comprises a weakened region of the susceptor arrangement. Optionally, the weakened region is integrally formed with the at least one susceptor portion.
Optionally, the connector portion comprises a carrier to which the at least one susceptor portion is affixed.
Optionally, the or each susceptor portion is at least partially embedded in the aerosol-generating material.
Optionally, the or each susceptor portion is substantially coaxial with a central axis of the consumable.
Optionally, the carrier comprises heating material that is heatable by penetration with a varying magnetic field.
Optionally, the carrier is free from heating material that is heatable by penetration with a varying magnetic field.
Optionally, the carrier comprises one or more of: paper, metal foil, metal alloy foil, and aerosol-generating material.
Optionally, the or each susceptor portion 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.
Optionally, the or each susceptor portion comprises nickel.
Optionally, the or each susceptor portion comprises steel with a nickel coating.
Optionally, the susceptor arrangement comprises perforations. Optionally, the susceptor arrangement comprises a weakened region.
Optionally, the susceptor arrangement comprises first and second materials that are different.
Optionally, the or each susceptor portion comprises a first region comprising the first material and a second region comprising the second material.
Optionally, the first and second materials have a different electrical conductivity and/or magnetic electrical conductivity.
Optionally, the first material comprises a material that is heatable by penetration with a varying magnetic field and the second material comprises a material that is not, or substantially is not, heatable by penetration with a varying magnetic field.
Optionally, one of first and second materials is coated with the other one of the first and second materials.
Optionally, the first material is coated with the second material.
Optionally, the first and second materials are configured such that, in use, when the first and second materials are penetrated by a varying magnetic field, the penetration of the first and second materials by the varying magnetic field causes a temperature difference between the first and second materials.
Optionally, the first and second materials have different thermal masses.
Optionally, the or each susceptor portion comprises a base portion and an embeddable portion for at least partially embedding in aerosol-generating material.
Optionally, the base portion is generally flat. Optionally, the base portion is generally circular.
Optionally, the base portion is comprises a material that is heatable by penetration with a varying magnetic field.
Optionally, the embeddable portion comprises a thermally conductive material.
Optionally, the embeddable portion comprises a material that is heatable by penetration with a varying magnetic field.
Optionally, the embeddable portion comprises a material that is not, or substantially is not, heatable by penetration with a varying magnetic field.
Optionally, the embeddable portion comprises the first and second materials.
Optionally, the embeddable portion comprises one of the first and second materials and the base portion comprises the other one of the first and second materials.
Optionally, the or each susceptor portion is hollow or perforated, or comprises indentations, a mesh or an expanded metal.
Optionally, the or each susceptor portion comprises a pin, mesh or blade.
Optionally, the or each susceptor portion comprises a plurality of pins, meshes or blades.
Optionally, the or each susceptor portion comprises a plurality of apertures or recesses, wherein the apertures and/or recesses are filled with the aerosol-generating material.
Optionally, at least part of the or each susceptor portion is annular. Optionally, the or each susceptor portion comprises a plurality of annular portions and, preferably, wherein the annular portions of each respective susceptor portion are arranged generally concentrically.
Optionally, the aerosol-generating material is non-liquid.
Optionally, the aerosol-generating material comprises tobacco.
Optionally, the susceptor extends the majority of the length of the consumable and, preferably, the susceptor extends substantially the entire length of the consumable.
The features described hereinbefore, including the features of the susceptor and/or aerosol-generating material, are applicable to any of the aspects of the invention described herein.
According to a sixth aspect of the present invention, there is provided a non combustible aerosol provision system, comprising: the consumable according to the fourth aspect of the present invention or the fifth aspect of the present invention, and a non-combustible aerosol provision device for causing heating of the aerosol-generating material of the consumable to volatilise at least one component of the aerosol generating material; wherein the device comprises a heating zone for receiving the consumable, and a magnetic field generator for generating a varying magnetic field for penetrating the susceptor portion of the consumable when the consumable is in the heating zone, thereby to cause heating of the aerosol-generating material.
Optionally, the device is for causing heating of the aerosol-generating material of the consumable to volatilise at least one component of the aerosol-generating material without burning the aerosol-generating material.
Optionally, the magnetic field generator comprises at least one coil.
Optionally, the coil is helical. Optionally, the coil is a flat coil and may be a two-dimensional spiral.
Optionally, the system further comprises a second coil and, preferably, the second coil is helical.
Optionally, the magnetic field generator is configured to generate a varying magnetic field for penetrating the base portion of the susceptor portion when the consumable is at least partially in the heating zone.
Optionally, the coil is configured to generate a varying magnetic field for penetrating the base portion of the susceptor portion when the consumable is at least partially in the heating zone and wherein the second coil is configured to generate a varying magnetic field for penetrating the embeddable portion of the susceptor portion when the consumable is at least partially in the heating zone.
Optionally, the second coil extends about the circumference of at least a portion of the embeddable portion of the susceptor portion. Optionally, the susceptor portion and/or 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.
Optionally, the susceptor portion and/or heating material comprises a metal or a metal alloy.
Optionally, the susceptor portion and/or 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.
Optionally, the aerosol-generating material is a non-liquid material. Optionally, the aerosol-generating material comprises tobacco.
Optionally, the aerosol-generating material is reconstituted aerosolisable material, such as reconstituted tobacco.
Further features and advantages of the invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only, which is made with reference to the accompanying drawings.
Brief Description of the Drawings
Embodiments of the invention will now be described, by way of example only, with reference to accompanying drawings, in which:
Figure 1 shows a schematic view of a susceptor arrangement according to one embodiment of the present invention.
Figure 2 shows a schematic view of a susceptor arrangement according to one embodiment of the present invention.
Figure 3 shows a schematic view of a susceptor arrangement according to one embodiment of the present invention. Figure 4 shows a flow chart of a method according to one embodiment of the present invention.
Figure 5 shows a schematic view of an assembly according to one embodiment of the present invention.
Figure 6 shows a schematic view of a consumable according to one embodiment of the present invention.
Figure 7 shows a non-combustible aerosol provision system according to one embodiment of the present invention.
Detailed Description As used herein, “aerosol-generating material” is material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants. In some embodiments, the aerosol-generating material may comprise an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating material may for example comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.
The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional materials.
In some embodiments, the aerosol-generating material may comprise tobacco material, wherein tobacco material is any material comprising tobacco or derivatives thereof. 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. In some embodiments, the aerosol-generating material may comprise a tobacco substitute.
As used herein, a “consumable” is an item comprising or consisting of aerosol generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use.
As used herein, a “susceptor” is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms.
When a susceptor is incorporated into a consumable, as heat is generated inside the susceptor itself, rather than by an external heat source by heat conductions, a rapid temperature rise in the consumable and more uniform heat distribution can be achieved, particularly through the selection of suitable materials and geometry, and suitable varying magnetic field magnitude and orientation relative to the susceptor. Moreover, as induction heating and magnetic hysteresis heating do not require physical connection to be provided between the source of the varying magnetic field and the susceptor, material deposits on the susceptor, such as residue or condensate, may be less of an issue, design freedom and control over the heating profile may be greater, and cost may be lower.
During manufacture of a consumable, for example a consumable for use with a non-combustible aerosol provision device, aerosol-generating material such as tobacco is placed in contact with a paper. The paper is then wrapped around the aerosol generating material to encase the aerosol-generating material and create a rod. The rod is cut to a desired length, and a filter may subsequently be attached (typically at one end of the cut rod), to form the consumable.
A susceptor may be provided within such a consumable in order to enable heating of the consumable in any of the ways discussed above. Conventional consumables may not include a susceptor and hence the cutting equipment used to cut the rods to the desired length are typically configured to cut through the aerosol generating material (e.g., tobacco) and the paper layer(s). However, if the susceptor is provided as a continuous uniform item (e.g., a strip of metal having uniform dimensions and uniform material properties) through the rod before the rod is cut to length, then damage may be caused to the existing cutting instruments used to cut the rod to the desired length on-line. Additionally, not only may the equipment not be suitable for cutting through the susceptor from a strength/robustness point of view, the time required to perform the cutting of the rods may be comparably longer when the continuous susceptor is present, thus impacting the production rate (and quantity) of consumables that can be manufactured.
Figure 1 shows a schematic view of a susceptor arrangement 1 for use in a method of manufacturing a consumable for use with a non-combustible aerosol provision device, according to one embodiment of the present invention. The susceptor arrangement 1 comprises susceptor portions 2 and a connector 3 joining the susceptor portions 2 to each other. This arrangement therefore represents a series of susceptor portions 2 physically connected to one another. The physical connection may be a direct connection (e.g., where the susceptor portions 2 are integrally formed with the connector 3) or an indirect connection (e.g., where the susceptor portions 2 are not physically connected to each other). The susceptors 2 are spaced apart from each other by the connector 3. The connector 3 performs several functions, including: maintaining the susceptor portions 2 at a predetermined separation distance from one another, enabling a single item which is more easily handled during manufacture, and maintaining the susceptor portions 2 in a uniform arrangement. For example, the connector 3 may reduce twisting of the susceptor portions 2 relative to one another such that the susceptor portions 2 are each placed at roughly the same location and at the same orientation during manufacture of the consumable.
The term “susceptor portions” herein should be understood to refer to the portions of the susceptor assembly which predominantly or exclusively act as the susceptor (or heater) when a consumable including a susceptor portion is exposed to a varying magnetic field. In some instances, the terms “susceptors” or “discrete susceptors” are used instead of susceptor portions to indicate that these are the portions of the susceptor arrangement 1 which predominantly act as a heater. As discussed below, the connector 3 in some embodiments may comprise or consist of material which heats up upon exposure to a varying magnetic field; however, generally speaking, the primary function of the connector 3 is not to act as the main source of heat in some implementations .
Two susceptors 2 are shown in Figure 1. However, any suitable number of susceptors 2 may be comprised in the susceptor arrangement 1, for example, two, three, four, five or six susceptors 2. The susceptor arrangement 1 may comprise a sequence of alternating susceptors 2 and connectors 3. The susceptor arrangement 1 may be wound onto a reel or the like for convenient storage of the susceptor arrangement 1.
As shown in Figure 1, the susceptor arrangement 1 comprises the susceptors 2 and a weakened region 4 of the susceptor arrangement 1 between the susceptors 2. The connector 3 comprises or consists of the weakened region 4. The weakened region 4 allows for the susceptors 2 to be more easily separated from each other, if desired. This reduces the risk of damaging any cutting instruments used to cut the susceptor arrangement 1 during consumable manufacture, as will be described below.
The weakened region 4 may be a region that is relatively weaker than each of the susceptors 2. For example, the weakened region 4 may be a region that is easier to cut than each of the susceptors 2.
In general, the, or each, weakened region is a region of the susceptor arrangement 1 having certain properties that enable the weakened region to be more easily cut that other regions of the susceptor arrangement (and in particular those regions containing the susceptors). In some embodiments, the weakened region 4 is formed by providing perforations in the susceptor arrangement 1. That is, in these embodiments, in the weakened region the amount of material to be cut is reduced relative to the other regions of the susceptor arrangement. Alternatively or additionally, the weakened region 4 may have a different geometric property (e.g. width and/or length) to the susceptors 2, for example as shown in Figure 3. That is, in these embodiments, in the weakened region the amount of material to be cut is reduced relative to the other regions of the susceptor arrangement. In other embodiments, the weakened region 4 may alternatively or additionally comprise a different material from the susceptors 2.
In some embodiments, as shown in Figure 1, the susceptors 2 are integrally formed with the weakened region 4. Alternatively, the susceptors 2 and the connector 3 may be formed as discrete elements and subsequently connected together.
Figure 2 shows a schematic view of a susceptor arrangement 1 according to one embodiment of the present invention. As in Figure 1, the susceptor arrangement 1 comprises discrete susceptors 2 and a connector 3. In the embodiment of Figure 2, the connector 3 comprises a carrier 5 to which the susceptors 2 are affixed. The susceptors 2 may be affixed to the carrier 5 by any suitable means including, but not limited to, gluing, welding, etc.. The type of affixing mechanism may be chosen based on the material of the carrier 5 and the material of the susceptor 2. In some embodiments, the susceptors 2 may be crimped onto the carrier 5 using any suitable method, so as to effectively staple the susceptors 2 to the carrier 5. In some embodiments, the susceptors 2 may be encapsulated by or embedded within the carrier 5. For example, the carrier 5 may comprise two laminae (such as two sheets of paper) that are adhered to each other to capture the susceptors 2 therebetween. The carrier 5 may help to prevent the susceptors 2 from twisting or warping and keep the susceptors 2 planar. In some embodiments, the susceptors 2 may not be planar. The carrier 5 may help the susceptors 2 to maintain their shape.
In some embodiments, the susceptor arrangement 1 is provided with markings on at least one surface thereof. For example, the marking may be provided on at least one surface of the carrier 5. The markings may aid in monitoring movement of the carrier 5 and/or the susceptor arrangement 1 during a manufacturing process. For example, the markings may be used to determine how much of the carrier 5 is disposed in a consumable and/or to adjust timing of the movement of the carrier 5. In some embodiments, the carrier 5 is provided on, or wound onto, a bobbin. In some embodiments, the carrier 5 comprises heating material that is heatable by penetration with a varying magnetic field. Alternatively, the carrier 5 is free from heating material that is heatable by penetration with a varying magnetic field. The carrier 5 may comprise one or more of paper, metal foil, metal alloy foil and aerosol generating material, for example. In the embodiment of Figure 2, a single carrier 5 is shown. In other embodiments, more than one carrier 5 may be utilised. For example, two carriers 5 may be affixed to opposite sides of the susceptors 2, so that the susceptors 2 are sandwiched between the carriers 5.
The susceptors 2 and/or 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. In some embodiments, the susceptors and/or heating material comprises a metal or a metal alloy. In some embodiments, the susceptors and/or 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.
Figure 3 shows a schematic view of a susceptor arrangement 1 according to one embodiment. The susceptor arrangement 1 comprises susceptors 2 and a connector 3. The connector 3 comprises a carrier 5. As shown in Figure 3, the carrier may comprise a weakened region along line X, which is formed by a change in geometric property of the carrier 5.
Figure 4 shows a flowchart of a method 10 of manufacturing a consumable for use with a non-combustible aerosol provision device, according to one embodiment of the present invention. The method 10 comprises providing 11 a susceptor arrangement 1 comprising discrete susceptors 2 and a connector 3 joining the susceptors 2 to each other. The susceptors 2 are spaced apart from each other by the connector 3. The method 10 also comprises forming 12 an assembly comprising the susceptor arrangement 1 and aerosol-generating material and dividing 13 the assembly. The dividing 13 comprises dividing the connector 3 and the aerosol-generating material. In some embodiments, the dividing 13 comprises using a cutter to cut the connector 3. The cutter may be an on-line component of a consumable-manufacturing system, or may be separate to a consumable-manufacturing system. The cutter may be the same cutter used to cut the consumable to a desired length.
In some embodiments, the forming 12 comprises at least partially embedding the susceptor arrangement 1 in the aerosol-generating material. The forming 12 may comprise fully embedding the susceptor arrangement 1 in the aerosol-generating material.
In some embodiments, the forming 12 comprises combining the susceptor arrangement 1 with the aerosol-generating material on a wrapper and wrapping the wrapper around the susceptor arrangement 1 and the aerosol-generating material. The susceptor arrangement 1 may be placed on the wrapper before the aerosol-generating material. Alternatively, the aerosol-generating material may be placed on the wrapper before the susceptor arrangement 1.
As discussed above, in some embodiments, the connector 3 comprises a weakened region of the susceptor arrangement 1. The susceptors 2 may be integrally formed with the weakened region.
In some embodiments, the connector 3 comprises a carrier to which the susceptors 2 are affixed. The carrier may be made from any of the materials discussed above for the carrier.
Figure 5 shows a schematic view of an assembly 20 for use with a method of manufacturing a consumable for use with a non-combustible aerosol provision device, according to one embodiment of the present invention. The assembly 20 comprises a susceptor arrangement 1 and aerosol-generating material 21 in thermal contact with the susceptor arrangement 1. The susceptor arrangement 1 may be any susceptor arrangement described herein, such as one of the susceptor arrangements 1 described in relation to Figures 1 to 3. The assembly 20 is dividable by a process comprising dividing the connector 3 and the aerosol-generating material 21. In one embodiment, the dividing forms individual objects. Each of the individual objects may be a consumable or may be used in the manufacture of a consumable. For example, the assembly 20 may be dividable along line Y. In some embodiments, the assembly 20 comprises a wrapper that is wrapped around the susceptor arrangement 1 and the aerosol-generating material 21.
Figure 6 shows a schematic view of a consumable 30 for use with a non combustible aerosol provision device, according to one embodiment. The consumable 30 comprises at least one discrete susceptor 31 and a connector portion 32 affixed to or integrally formed with the or each susceptor 31. The consumable comprises aerosol generating material 33 in thermal contact with the or each susceptor 31. The connector portion 32 extends to at least one end 34 of the aerosol-generating material 33. As shown in Figure 6, in one embodiment respective connector portions 32 may extend to two opposite ends of the aerosol-generating material 33. In one embodiment, the connector portion 32 is a part of a connector described herein.
In some embodiments, the consumable 30 is manufactured according to a method described herein. In particular, the consumable 30 may be manufactured according to the method described with relation to Figure 4.
In some embodiments, the consumable 30 comprises a susceptor arrangement that comprises the at least one susceptor 31 , wherein the connector portion 32 comprises a weakened region of the susceptor arrangement.
As shown in Figure 6, the weakened region may be integrally formed with the at least one susceptor 31. Alternatively, the weakened region may be formed separately to and subsequently attached to the at least one susceptor 31, such as in the form of a carrier. In some embodiments, the connector portion 32 comprises a carrier to which the at least one susceptor 31 is affixed. The carrier may comprise heating material that is heatable with a varying magnetic field. Alternatively, the carrier may be free from heating material that is heatable by penetration with a varying magnetic field. In some embodiments, the carrier comprises one or more of paper, metal foil, metal alloy foil and aerosol-generating material.
In some embodiments, the or each susceptor 31 is at least partially embedded in the aerosol-generating material 33. For example, the or each susceptor 31 may be embedded such that at least a portion of the susceptor 31 protrudes from the aerosol generating material 33. Alternatively, the or each susceptor 31 may be fully embedded in the aerosol-generating material 33 such that no part of the susceptor 31 protrudes from the aerosol-generating material 33. This can help to avoid a user contacting the susceptor 31, which may be hot, during use of the consumable 30.
As shown in Figure 6, the or each susceptor 31 may be substantially coaxial with a central axis of the consumable 30. Alternatively, the or each susceptor 31 may be disposed in any other way that allows the or each susceptor 31 to heat the aerosol generating material 33 of the consumable 30.
Figure 7 shows a schematic view of a non-combustible aerosol provision system 40 according to an embodiment of the invention. The non-combustible aerosol provision system 40 comprises a consumable 30. The consumable 30 may be any consumable 30 described herein, such as the consumable described with reference to Figure 6 or any variant thereof discussed herein. The system also comprises a non combustible aerosol provision device 42 for causing heating of the aerosol-generating material of the consumable 30 to volatilise at least one component of the aerosol generating material. The device 42 comprises a heating zone 43 for receiving the consumable 30 and a magnetic field generator 44 for generating a varying magnetic field for penetrating the susceptor of the consumable 30 when the consumable 30 is in the heating zone 43, thereby causing heating of the aerosol generating material. In some embodiments, the device 42 is for causing heating of the aerosol generating material of the consumable 30 to volatilise at least one component of the aerosol-generating material without burning the aerosol-generating material. In some embodiments, the aerosol-generating material is a non-liquid material.
In some embodiments, the aerosol-generating material comprises tobacco. In some embodiments, the aerosol-generating material is reconstituted aerosolisable material, such as reconstituted tobacco. The above embodiments are to be understood as illustrative examples of the invention. Further embodiments of the invention are envisaged. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims.

Claims

1. A method of manufacturing a consumable for use in a non-combustible aerosol provision device, the method comprising: providing a susceptor arrangement comprising first and second susceptor portions and a connector joining the first and second susceptor portions to each other, wherein the first and second susceptor portions are spaced apart from each other by the connector; forming an assembly comprising the susceptor arrangement and aerosol- generating material; and dividing the assembly, wherein the dividing comprises dividing the connector and the aerosol-generating material.
2. The method of claim 1, wherein the dividing comprises using a cutter to cut the connector.
3. The method of claim 1 or claim 2, wherein the forming comprises at least partially embedding the susceptor arrangement in the aerosol-generating material.
4. The method of any one of claims 1 to 3, wherein the forming comprises: combining the susceptor arrangement with the aerosol-generating material on a wrapper; and wrapping the wrapper around the susceptor arrangement and the aerosol generating material.
5. The method of claim 4, wherein the susceptor arrangement is placed on the wrapper before the aerosol-generating material.
6. The method of claim 4, wherein the aerosol-generating material is placed on the wrapper before the susceptor arrangement.
7. A susceptor arrangement for use in a method of manufacturing a consumable for use with a non-combustible aerosol provision device, the susceptor arrangement comprising first and second susceptor portions and a connector joining the first and second susceptor portions to each other, wherein the first and second susceptor portions are spaced apart from each other by the connector.
8. The susceptor arrangement of claim 7, wherein the connector comprises a weakened region of the susceptor arrangement.
9. The susceptor arrangement of claim 8, wherein the susceptor portions are integrally formed with the weakened region.
10. The susceptor arrangement of claim 9, wherein the susceptor arrangement comprises at least one further susceptor portion and at least one further connector, wherein the susceptor arrangement is arranged such that a repeating sequence of susceptor portion followed by connector followed by susceptor portion is present.
11. The susceptor arrangement of claim 7, wherein the connector comprises a carrier to which the susceptor portions are affixed.
12. The susceptor arrangement of claim 11, wherein the susceptor arrangement comprises at least one further susceptor portion and wherein the first susceptor portion, the second susceptor portion and at least one further susceptor portion are affixed to the carrier.
13. The susceptor arrangement of claim 11 or 12, wherein the susceptor portions are spaced apart from one another on the carrier, and wherein the carrier comprises a weakened region between the susceptor portions.
14. The susceptor arrangement of any one of claims 11 to 13, wherein the carrier comprises heating material that is heatable by penetration with a varying magnetic field.
15. The susceptor arrangement of any one of claims 11 to 13, wherein the carrier is free from heating material that is heatable by penetration with a varying magnetic field.
16. The susceptor arrangement of any one of claims 11 to 15, wherein the carrier comprises one or more of: paper, metal foil, metal alloy foil, and aerosol-generating material.
17. An assembly for use in a method of manufacturing a consumable for use with a non-combustible aerosol provision device, the assembly comprising: the susceptor arrangement of any one of claims 7 to 16; and aerosol-generating material in thermal contact with the susceptor arrangement; wherein the assembly is dividable by a process comprising dividing the connector and the aerosol-generating material.
18. A consumable for use with a non-combustible aerosol provision device, the consumable being manufactured according to a method comprising the method of any one of claims 1 to 6.
19. A consumable for use with a non-combustible aerosol provision device, the consumable comprising: at least one susceptor portion and a connector portion affixed to or integrally formed with the or each susceptor portion, and aerosol-generating material in thermal contact with the or each susceptor portion; wherein the connector portion extends to at least one end of the aerosol generating material.
20. The consumable of claim 19, comprising a susceptor arrangement that comprises the at least one susceptor portion, wherein the connector portion comprises a weakened region of the susceptor arrangement.
21. The consumable of claim 20, wherein the weakened region is integrally formed with the at least one susceptor portion.
22. The consumable of claim 19, wherein the connector portion comprises a carrier to which the at least one susceptor portion is affixed.
23. The consumable of any one of claims 18 to 22, wherein the or each susceptor portion is at least partially embedded in the aerosol-generating material.
24. The consumable of any one of claims 18 to 23, wherein the or each susceptor portion is substantially coaxial with a central axis of the consumable.
25. The method of any one of claims 1 to 6, the susceptor arrangement of any one of claims 7 to 16, the assembly according to claim 17, or the consumable according to any one of claims 18 to 24, wherein the or each susceptor portion 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.
26. The method of any one of claims 1 to 6 or 25, the susceptor arrangement of any one of claims 7 to 16 or 25, the assembly according to claim 17 or claim 25, or the consumable according to any one of claims 18 to 25, wherein the or each susceptor portoin comprises nickel.
27. The method of any one of claims 1 to 6, 25 or 26, the susceptor arrangement of any one of claims 7 to 16, 25 or 26, the assembly according to claim 17, 25 or 26, or the consumable according to any one of claims 18 to 26, wherein the or each susceptor portion comprises steel with a nickel coating.
28. The method of any one of claims 1 to 6 or 25 to 27, the susceptor arrangement of any one of claims 7 to 16 or 25 to 27, the assembly according to claim 17 or 25 to 27, or the consumable according to any one of claims 18 to 27, wherein the susceptor arrangement comprises perforations.
29. The method of any one of claims 1 to 6 or 25 to 28, the susceptor arrangement of any one of claims 7 to 16 or 25 to 28, the assembly according to claim 17 or 25 to
28, or the consumable according to any one of claims 18 to 28, wherein the susceptor arrangement comprises a weakened region.
30. The method of any one of claims 1 to 6 or 25 to 29, the susceptor arrangement of any one of claims 7 to 16 or 25 to 29, the assembly according to claim 17 or 25 to
29, or the consumable according to any one of claims 18 to 29, wherein the susceptor arrangement comprises first and second materials that are different.
31. The method, susceptor arrangement, assembly or consumable of claim 30, wherein the or each susceptor portion comprises a first region comprising the first material and a second region comprising the second material.
32. The method, susceptor arrangement, assembly or consumable of claim 30 or claim 31, wherein the first and second materials have a different electrical conductivity and/or magnetic electrical conductivity.
33. The method, susceptor arrangement, assembly or consumable of any one of claims 30 to 32, wherein the first material comprises a material that is heatable by penetration with a varying magnetic field and the second material comprises a material that is not, or substantially is not, heatable by penetration with a varying magnetic field.
34. The method, susceptor arrangement, assembly or consumable of any one of claims 30 to 33, wherein one of first and second materials is coated with the other one of the first and second materials.
35. The method, susceptor arrangement, assembly or consumable of claim 34, wherein the first material is coated with the second material.
36. The method, susceptor arrangement, assembly or consumable of any one of claims 30 to 35, wherein the first and second materials are configured such that, in use, when the first and second materials are penetrated by a varying magnetic field, the penetration of the first and second materials by the varying magnetic field causes a temperature difference between the first and second materials.
37. The method, susceptor arrangement, assembly or consumable of any one of claims 30 to 36, wherein the first and second materials have different thermal masses.
38. The method of any one of claims 1 to 6 or 25 to 37, the susceptor arrangement of any one of claims 7 to 16 or 25 to 37, the assembly according to claim 17 or 25 to 37, or the consumable according to any one of claims 18 to 37, wherein the or each susceptor portion comprises a base portion and an embeddable portion for at least partially embedding in aerosol-generating material.
39. The method, susceptor arrangement, assembly or consumable of claim 38, wherein the base portion is generally flat.
40. The method, susceptor arrangement, assembly or consumable of claim 38 or 39, wherein the base portion is generally circular.
41. The method, susceptor arrangement, assembly or consumable of any one of claims 38 to 40, wherein the base portion is comprises a material that is heatable by penetration with a varying magnetic field.
42. The method, susceptor arrangement, assembly or consumable of any one of claims 38 to 41, wherein the embeddable portion comprises a thermally conductive material.
43. The method, susceptor arrangement, assembly or consumable of any one of claims 38 to 42, wherein the embeddable portion comprises a material that is heatable by penetration with a varying magnetic field.
44. The method, susceptor arrangement, assembly or consumable of any one of claims 38 to 43, wherein the embeddable portion comprises a material that is not, or substantially is not, heatable by penetration with a varying magnetic field.
45. The method, susceptor arrangement, assembly or consumable of any one of claims 38 to 44, when dependent on any one of claims 30 to 37, wherein the embeddable portion comprises the first and second materials.
46. The method, susceptor arrangement, assembly or consumable of any one of claims 38 to 45, when dependent on any one of claims 30 to 37, wherein the embeddable portion comprises one of the first and second materials and the base portion comprises the other one of the first and second materials.
47. The method of any one of claims 1 to 6 or 25 to 46, the susceptor arrangement of any one of claims 7 to 16 or 25 to 46, the assembly according to claim 17 or 25 to
46, or the consumable according to any one of claims 18 to 46, wherein the or each susceptor portion is hollow or perforated, or comprises indentations, a mesh or an expanded metal.
48. The method of any one of claims 1 to 6 or 25 to 47, the susceptor arrangement of any one of claims 7 to 16 or 25 to 47, the assembly according to claim 17 or 25 to
47, or the consumable according to any one of claims 18 to 47, wherein the or each susceptor portion comprises a pin, mesh or blade.
49. The method, susceptor arrangement, assembly or consumable of claim 48, wherein the or each susceptor portion comprises a plurality of pins, meshes or blades.
50. The method of any one of claims 1 to 6 or 25 to 49, the susceptor arrangement of any one of claims 7 to 16 or 25 to 49, the assembly according to claim 17 or 25 to
49, or the consumable according to any one of claims 18 to 49, wherein the or each susceptor portion comprises a plurality of apertures or recesses, wherein the apertures and/or recesses are filled with the aerosol-generating material.
51. The method of any one of claims 1 to 6 or 25 to 50, the susceptor arrangement of any one of claims 7 to 16 or 25 to 50, the assembly according to claim 17 or 25 to 50, or the consumable according to any one of claims 18 to 50, wherein at least part of the or each susceptor portion is annular.
52. The method, susceptor arrangement, assembly or consumable of claim 51, wherein the or each susceptor portion comprises a plurality of annular portions and, preferably, wherein the annular portions of each respective susceptor portion are arranged generally concentrically.
53. The method of any one of claims 1 to 6 or 25 to 52, the susceptor arrangement of any one of claims 7 to 16 or 25 to 52, the assembly according to claim 17 or 25 to
52, or the consumable according to any one of claims 18 to 52, wherein the aerosol generating material is non-liquid.
54. The method of any one of claims 1 to 6 or 25 to 53, the susceptor arrangement of any one of claims 7 to 16 or 25 to 53, the assembly according to claim 17 or 25 to
53, or the consumable according to any one of claims 18 to 53, wherein the aerosol generating material comprises tobacco.
55. The method of any one of claims 1 to 6 or 25 to 54, the susceptor arrangement of any one of claims 7 to 16 or 25 to 54, the assembly according to claim 17 or 25 to
54, or the consumable according to any one of claims 18 to 54, wherein the susceptor extends the majority of the length of the consumable and, preferably, the susceptor extends substantially the entire length of the consumable.
56. A non-combustible aerosol provision system, comprising: the consumable of any one of claims 18 to 55, and a non-combustible aerosol provision device for causing heating of the aerosol generating material of the consumable to volatilise at least one component of the aerosol-generating material; wherein the device comprises a heating zone for receiving the consumable, and a magnetic field generator for generating a varying magnetic field for penetrating the susceptor portion of the consumable when the consumable is in the heating zone, thereby to cause heating of the aerosol-generating material.
57. The system of claim 56, wherein the device is for causing heating of the aerosol generating material of the consumable to volatilise at least one component of the aerosol-generating material without burning the aerosol-generating material.
58. The system of claim 56 or 57, wherein the magnetic field generator comprises at least one coil.
59. The system of claim 58, wherein the coil is helical.
60. The system of claim 58, wherein the coil is a flat coil, and may be a two- dimensional spiral.
61. The system of claim 60, comprises a second coil and, preferably, the second coil is helical.
62. The system of any one of claims 56 to 61, when dependent on any one of claims 38 to 46, wherein the magnetic field generator is configured to generate a varying magnetic field for penetrating the base portion of the susceptor portion when the consumable is at least partially in the heating zone.
63. The system of claim 62, when dependent on claim 61, wherein the coil is configured to generate a varying magnetic field for penetrating the base portion of the susceptor portion when the consumable is at least partially in the heating zone and wherein the second coil is configured to generate a varying magnetic field for penetrating the embeddable portion of the susceptor portion when the consumable is at least partially in the heating zone.
64. The system of claim 63, wherein the second coil extends about the circumference of at least a portion of the embeddable portion of the susceptor portion.
PCT/GB2020/052757 2020-01-16 2020-10-30 Consumable for use with a non-combustible aerosol provision device WO2021144547A1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
PCT/GB2021/050107 WO2021144591A1 (en) 2020-01-16 2021-01-18 Consumable for use with a non-combustible aerosol provision device
EP21700996.8A EP4090180A1 (en) 2020-01-16 2021-01-18 Consumable for use with a non-combustible aerosol provision device
KR1020227024182A KR20220114059A (en) 2020-01-16 2021-01-18 Consumables for use with non-flammable aerosol delivery devices
US17/792,729 US20230050426A1 (en) 2020-01-16 2021-01-18 Consumable for use with a noncombustible aerosol provision device
JP2022543195A JP7474855B2 (en) 2020-01-16 2021-01-18 Consumables for use in non-combustion aerosol delivery devices

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB2000687.0A GB202000687D0 (en) 2020-01-16 2020-01-16 Consumable for use with a non-combustible aerosol provision device
GB2000687.0 2020-01-16

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WO2021144547A1 true WO2021144547A1 (en) 2021-07-22

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Citations (6)

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EP3552500A1 (en) * 2018-04-09 2019-10-16 Hauni Maschinenbau GmbH Device and method for producing rod-shaped tobacco segments each having a heating strip
WO2019224073A1 (en) * 2018-05-21 2019-11-28 Jt International Sa An aerosol generating article, a method for manufacturing an aerosol generating article and an aerosol generating system
US20190364973A1 (en) * 2017-01-25 2019-12-05 British American Tobacco (Investments) Limited Apparatus for heating smokable material
WO2020021430A1 (en) * 2018-07-24 2020-01-30 International Tobacco Machinery Poland Sp. Z O.O. Continuous tape material for inductive heating of tobacco materials comprising reduced strength areas, feeding apparatus and feeding method thereof
WO2020025562A1 (en) * 2018-07-31 2020-02-06 Philip Morris Products S.A. Inductively heatable aerosol-generating article comprising an aerosol-forming rod segment and method for manufacturing such aerosol-forming rod segments

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WO2018122320A1 (en) * 2016-12-29 2018-07-05 Philip Morris Products S.A. Method and apparatus for the production of a component of an aerosol generating article
US20190364973A1 (en) * 2017-01-25 2019-12-05 British American Tobacco (Investments) Limited Apparatus for heating smokable material
EP3552500A1 (en) * 2018-04-09 2019-10-16 Hauni Maschinenbau GmbH Device and method for producing rod-shaped tobacco segments each having a heating strip
WO2019224073A1 (en) * 2018-05-21 2019-11-28 Jt International Sa An aerosol generating article, a method for manufacturing an aerosol generating article and an aerosol generating system
WO2020021430A1 (en) * 2018-07-24 2020-01-30 International Tobacco Machinery Poland Sp. Z O.O. Continuous tape material for inductive heating of tobacco materials comprising reduced strength areas, feeding apparatus and feeding method thereof
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