WO2024084225A1

WO2024084225A1 - A consumable

Info

Publication number: WO2024084225A1
Application number: PCT/GB2023/052726
Authority: WO
Inventors: Gary Fallon; John Richardson; Richard LEBBON; Scott Park
Original assignee: Nicoventures Trading Limited
Priority date: 2022-10-21
Filing date: 2023-10-20
Publication date: 2024-04-25
Also published as: GB202215599D0

Abstract

A consumable (100) for use with an aerosol provision system, the consumable comprising a section (1) formed from a rolled corrugated sheet material (2), wherein a surface of one or more of the corrugations (3) of the rolled corrugated sheet material abuts a corresponding surface of an adjacent corrugation.

Description

A Consumable

Technical Field

The present disclosure relates to a consumable for use with an aerosol provision system, an aerosol provision system comprising the consumable and a method for forming the consumable.

Background

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

In a first aspect of the present invention, there is provided a consumable for use with an aerosol provision system, the consumable comprising a section formed from a rolled corrugated sheet material, wherein a surface of each corrugation of the rolled corrugated sheet material abuts a corresponding surface of an adjacent corrugation.

In a second aspect of the present invention, there is provided a method of forming the consumable of the first aspect, the method comprising: providing a sheet of corrugated material; rolling the sheet of corrugated material into a section so that each corrugation of the rolled corrugated sheet material abuts an adjacent corrugation.

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

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

Fig. i shows an example section for a consumable;

Fig. 2 shows a corrugated sheet material for forming the section of Fig. 1; Fig. 3a is an end on view of the section of Fig. 1;

Fig. 3b is an end on view of the corrugated sheet material of Fig. 2;

Fig. 4a is an end on view of another example of a section for a consumable;

Fig. 4b is an end on view of a corrugated sheet material for forming the section of Fig. 4a; Fig. 5a is an end on view of another example of a section for a consumable;

Fig. 5b is an end on view of a corrugated sheet material for forming the section of Fig.

5a;

Fig. 6a is an end on view of another example of a section for a consumable;

Fig. 6b is an end on view of a corrugated sheet material for forming the section of Fig. 6a;

Fig. 7a is an end on view of another example of a section for a consumable;

Fig. 7b is an end on view of a corrugated sheet material for forming the section of Fig. 7a;

Fig. 8a is an end on view of another example of a section for a consumable; Fig. 8b is an end on view of a corrugated sheet material for forming the section of Fig. 8a;

Fig. 9 shows a consumable comprising a section in accordance with any of the examples described herein;

Fig. io schematically shows a system comprising a consumable and a non combustible aerosol provision device; and

Fig. n schematically illustrates a consumable and aerosol generator in combination.

Detailed Description

As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes: non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials. According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

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

In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system.

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol -generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a nontobacco product.

The non-combustible aerosol provision systems described herein comprise a non- combustible aerosol provision device and a consumable for use with the non- combustible aerosol provision device. The disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source. In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol -modifying agent.

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

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

In some embodiments, the substance to be delivered comprises an active substance.

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

In one embodiment the active substance is a legally permissible recreational drug In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

The active substance may be CBD or a derivative thereof

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

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

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

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

In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3. Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol - generating material may, for example, be in the form of a solid, liquid or semi -solid (such as a gel) which may or may not contain an active substance and/or flavourants.

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

The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. The aerosol-generating film may be up to 0.5mm thick, preferably 0.05mm to

0.5mm microns thick. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, it maybe gathered to form a gathered sheet or it maybe shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosol-generating material. The aerosol-generating film may be discontinuous. For example, the aerosolgenerating film may comprise one or more discrete portions or regions of aerosolgenerating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.

The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film. The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.

The aerosol-generating material may comprise or be an “amorphous solid”. In some embodiments, the aerosol-generating material comprises an aerosol- generating film that is an amorphous solid. The amorphous solid may be a “monolithic solid”. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 6owt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid.

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

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

The aerosol generating material may be present on or in a support, the support forming a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material. A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically- conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

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

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

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

Fig. 1 shows a section 1 of a consumable too formed from a rolled corrugated sheet material 2. Fig. 2 shows the corrugated sheet material in an extended state, prior to being rolled into the section 1 of the consumable too shown in Fig. 1. The corrugated sheet material 2 comprises a series of corrugations 3 that extend in a longitudinal direction of the corrugated sheet material 2. When the corrugated sheet material 2 is rolled into said section 1, each corrugation 3 abuts a corresponding surface of an adjacent corrugation 3, as will be explained further below.

Fig. 3b shows a cross section taken through the corrugated sheet of Fig. 1. The corrugated sheet material comprises a flat, base sheet 4 and a folded sheet 5 that is laid across the base sheet 4. The folded sheet 5 comprises a convex folds 6 and concave folds . In the present example, the folds are formed as creased fold lines. Between the fold lines, the sheet material is substantially planar and forms surfaces of the corrugations 3. The concave folds 7 are defined by an angle between adjacent upper surfaces being less than 180 degrees. The convex folds 6 are defined by the angle between adjacent upper surfaces being greater than 180 degrees. By ‘upper surface’, it is meant a surface of the folded sheet 5 that faces away from the base sheet 4. Each corrugation 3 is defined as the shape enclosed by the folded sheet 5 and base sheet 4 between adjacent concave folds 7. In the present example, this shape is polygonal in section and has four sides, each corrugation of the corrugated sheet material comprising two primary walls 8 and a single secondary wall 9 that connects the primary walls 8 at convex folds 6. The folded sheet 5 touches the base sheet 4 where adjacent primary walls 8 meet and may be adhered thereto by a suitable adhesive. The secondary walls 9 of the folded sheet 5 are parallel to the base sheet 4.

To form the section 1 of the consumable too, the extended corrugated sheet material 2 is rolled about a longitudinal axis until outermost corrugations 3’ abut. The rolled corrugated sheet material 2 therefore forms a closed shape, in this case a tube. In the examples illustrated by Figs. 2, 3b, 4b, 5b and 6b, the concave angle 7 between adjacent primary walls 8 is 60 degrees. As the corrugated sheet 2 comprises six corrugations 3, the act of rolling the corrugated sheet material 2 of said examples into said section 1 causes each primary wall 8 to abut a primary wall 8 of an adjacent corrugation 3.

The abutting pairs of primary walls 8 form radially extending walls 10 of the section 1. The secondary walls 9 interconnect the radially extending walls 10 and form an inner wall 11 of the section 1. The radially extending walls 10 and inner wall 11 add to the second moment of area of the section 1, thereby increasing its stiffness in bending. Therefore, forming a section 1 of a consumable too in this way increases its structural integrity and makes it more resilient when being handled by a user.

The base sheet 4 forms an outer wall 12 of the section. The radially extending walls 10 separate outer channels 13 bounded by the inner and outer walls 11, 12 of the section 1. The inner wall 11 defines a central channel 14 of the section 1.

At least a portion of the central channel 14 and at least a portion of each of the outer channels 13 comprises an air gap. In other words, said at least a portion of the central section 14 and said at least a portion of each outer channel 13 is empty, that is to say, free of material or obstruction. The section further comprises aerosol generating material 15 configured to generate an aerosol when heated by an aerosol generator of a non-combustible aerosol provision device, as will be explained further below. The aerosol generating material 15 may be disposed so as to generate an aerosol in any of the air gaps defined above.

In the examples of Figs. 1 and 3a, aerosol generating material 15 is provided as a film inside the central section 14. This is achieved by providing a film of aerosol generating material 15 on upper surfaces of the secondary walls 9 of the extended corrugated sheet material 2, as illustrated by Figs. 2 and 3b. Therefore, when the extended corrugated sheet material 2 is rolled to form the section of Figs. 1 and 3a, the inner wall 11 is provided with a film of aerosol generating material 15 lining its inside surface. When said section 1 is heated, the aerosol generating material 15 forms an aerosol in the air gap of the central section 14. In the example of Fig. 4a, aerosol generating material 15 is provided as a film inside select outer channels 13. This is achieved by providing a film of aerosol generating material 15 on inner surfaces of the primary and secondary walls 8, 9 of select corrugations, as shown in Fig. 4b. Therefore, when the extended corrugated sheet material 2 of Fig. 4b is rolled to form the section as shown in Fig. 4a, portions of the outer surface of the central section 14 and radially extending walls 10 adjacent to said portions are provided with a film of aerosol generating material 15. By ‘select outer channels’, it is meant ‘at least one outer channel’. In the illustrated example, every other outer channel 14 is provided with aerosol generating material 15. However, it will be appreciated any or all of the outer channels 14 may be provided with aerosol generating material 15. When the section shown in Fig. 4a is heated, the aerosol generating material 15 forms an aerosol in the air gap of outer channels 14 provided with the aerosol generating material 15.

In the example of Fig. 5a, aerosol generating material 15 is provided as a film inside the outer channels 13. This is achieved by providing a film of aerosol generating material 15 on an upper surface of the base sheet 4, as shown in Fig. 5b. Therefore, when the extended corrugated sheet material 2 of Fig. 5b is rolled to form the section 1 as shown in Fig. 5a, the inner surface of the outer wall 12 is provided with a film of aerosol generating material 15. When the section shown in Fig. 5a is heated, the aerosol generating material forms 15 an aerosol in the air gap of outer channels 13. In the example of Fig. 6a, aerosol generating material 15 is provided as a film inside the outer channels 13. This is achieved by providing a film of aerosol generating material 15 on the inner surface of the secondaiy walls 9 of each corrugation 3, as shown in Fig. 6b. Therefore, when the extended corrugated sheet material 2 of Fig. 6b is rolled to form the section 1 as shown in Fig. 6a, the outer surface of the inner wall 11 is provided with a film of aerosol generating material 15. When the section 1 shown in Fig. 6a is heated, the aerosol generating material 15 forms an aerosol in the air gap of outer channels 13.

It will be appreciated that the choice of location for the aerosol generating material 15 will depend, among other things, on the design of a non-combustible aerosol provision device for which the corresponding consumable is configured for use, as explained further below. Apart from the location of the aerosol generating material 15, the sections of the examples of Figs. 1 through 6b are the same. In another example section 1’, illustrated by Fig. 7a, is formed by rolling corrugated sheet material 2’ about a longitudinal axis. In the present example, the secondary wall 9 of the folded sheet 5 is omitted and, instead, the sheet 5’ comprises primary walls 8’ directly attached to each other at convex folds 6’. Therefore, each corrugation 3” is triangular in section. The section 1’ formed when such a corrugated sheet 2’ is rolled is shown in Fig. 7b.

Just as in the above examples, the extended corrugated sheet material 2’ is rolled about its longitudinal axis until outermost corrugations 3”’ abut. Again, the corrugated sheet material 2’ comprises six corrugations 3’, while each concave fold 7 comprises an angle between adjacent primary walls 8’ of 60 degrees. Therefore, the act of rolling the corrugated sheet material 2’ of the example of Fig. 7b into the section of Fig. 7a causes each primary wall 8’ to abut a primary wall 8’ of an adjacent corrugation 3”.

The abutting pairs of primary walls 8’ form radially extending walls 10’ of the section 1’. The radially extending walls 10’ add to the second moment of area of the section 1’, thereby increasing its stiffness in bending. Therefore, as above, forming a section 1’ of a consumable too in this way increases its structural integrity and makes it more resilient when being handled by a user. Again, just as in the examples above, the base sheet 4’ forms an outer wall 12’ of the section 1’. However, in the present example, a central section 14 is not geometrically possible without the secondary walls 9 and the radially extending walls 10’ meet in the centre of the section 1’. Therefore, the radially extending walls 10’ separate segment shaped channels 13’ bounded by the outer wall 12’. At least a portion of at least one of the segment shaped channels 13’ comprises an air gap in which an aerosol maybe generated when the consumable too is heated by a heater of aerosol generator.

While a central section is not geometrically possible in the configuration of Fig. 7a, the section 1’ may have a smaller overall diameter while delivering similar levels of performance compared to the example sections 1 above, particularly when heated externally. Accordingly, aerosol generating material may be provided as a film on the upper surface or lower surface of the folded section 5’, or the upper surface of the base sheet 4’. Therefore, when the section 1’ is heated, the aerosol generating material forms an aerosol in the air gap of the channels 13’. While the corrugated sheet materials 2, 2’ of the above examples comprise corrugations 3, 3’ having a polygonal cross section, it shall be appreciated that a section 1 may be formed from a rolled corrugated sheet material, wherein the corrugations have a curved cross section. For example, a section 1” illustrated by Fig. 8a is formed from a corrugated sheet material 2” having sinusoidal corrugations 83, as illustrated by Fig. 8b.

As in the above examples, the corrugated sheet material 2” of Fig.8b comprises a flat, base sheet 4” and a folded sheet 5” that is laid across the base sheet 4”. The folded sheet 5” comprises convex folds 86 and concave folds 87 that form part of a continuous, sinusoidal curve. The concave folds 87 are defined where the folded sheet 5” touches the base sheet 4”. The convex folds 86 are defined where the folded sheet 5” is furthest from the base sheet 4”. Each corrugation 83 is defined as the shape enclosed by the folded sheet 5” and base sheet 4” between adjacent concave folds 87. To form the section 1” of the consumable too shown in Fig. 8a, the extended corrugated sheet material 2” of Fig. 8b is rolled about its longitudinal axis until outermost corrugations 83’ abut. The rolled corrugated sheet material 2” therefore forms a closed shape, in this case a tube. A portion of a surface of each corrugation 83 abuts a corresponding portion of a surface of an adjacent corrugation 83 to form the shape shown in Fig. 8a. Abutting pairs of corrugations 83 form loops 85 where the upper surface of the folded sheet 5” abuts itself. Arced sections 88 are formed where the folded sheet 2” extends between abutting pairs of adjacent corrugations 83 and define an inner wall 11” of the section 1”.

The base sheet 4” forms an outer wall 12” of the section. The loops 85 separate outer channels 13” bounded by the inner and outer walls 11”, 12” of the section 1”. The inner wall 11” defines a central channel 14” of the section 1”.

At least a portion of the central channel 14” and at least a portion of each of the outer channels 13” comprises an air gap. In other words, said at least a portion of the central section 14” and said at least a portion of each outer channel 13” is empty, that is to say, free of material or obstruction.

The section 1” further comprises aerosol generating material configured to generate an aerosol when heated by a heater of an aerosol generator, as will be explained further below. The aerosol generating material may be disposed so as to generate an aerosol in any of the air gaps.

In the present example, aerosol generating material 15” is provided as a film inside the outer channels 13”. This is achieved by providing a film of aerosol generating material 15” on an upper surface of the base sheet4”, as shown in Fig. 8b. Therefore, when the extended corrugated sheet material 2” of Fig. 8b is rolled to form the section 1” as shown in Fig. 8a, the inner surface of the outer wall 12” is provided with a film of aerosol generating material 15”. When the section shown in Fig. 8a is heated, the aerosol generating material 15” forms an aerosol in the air gap of outer channels 13”.

It will be appreciated that, although unillustrated, aerosol generating material may be provided on any of the other surfaces of the corrugated sheet material 2”. For example, a film of aerosol generating material may be provided on the upper surface of the folded sheet 5” so that, when rolled to form the section 1”, aerosol generating material is provided within the central section I4”and within the loops 85. Alternatively, or additionally, aerosol generating material may be provided on the lower surface of the folded sheet 5” so that, when rolled to form the section 1”, aerosol generating material is provided within the outer channels 13”. The consumable too may comprise any number of additional components 90 for attachment to any of the sections 1 described above. Alternatively, the consumable too may consist of only the sections i described above. Where the consumable too comprises an additional component 90, the additional component maybe, for example, a filter component 91, as shown in the example consumable too of Fig. 9. Other components 90 may comprise cooling sections or other sections containing aerosol generating material, as is known in the field. The filter component 91 may be a paper filter component or a cellulose filter component. Preferably, any additional component 90 comprises an outside diameter substantially the same as the section 1 to which it is to be attached. Therefore, the additional component 90 may be attached by an overlapping layer of wrapping material 92, such as tipping paper.

Including a filter component 91 advantageously allows for finer control of the closed pressure drop - or draw resistance - of the consumable too. For example, the closed pressure drop may be controlled by setting the density of filter material in the filter component, or by increasing or decreasing the axial length of the filter component.

In one example, the closed pressure drop of the consumable too is in the range of about 30 to 90 mmWg. In another example, the closed pressure drop of the consumable too is in the range of about 40 to 60 mmWg. It will be appreciated that each component of the consumable makes a cumulative contribution to the overall closed pressure drop of the consumable too. In one example, the section 1 makes a contribution to the overall closed pressure drop of the consumable too of between about 10 and 40 mmWg. In other words, the closed pressure drop across the section 1 is between about 10 and 40 mmWg. In one example, the filter component 91 (where present) makes a contribution to the overall closed pressure drop of the consumable too of between about 15 and 20 mmWg. In other words, the closed pressure drop across the filter component 91 is between about 15 and 20 mmWg. It will be appreciated that the overall closed pressure drop of the any of the above described sections 1, 1’, 1” maybe affected by the number of corrugations provided on the sheet material used to form the section 1, 1’, 1”. By increasing the number of corrugations used, the overall closed pressure drop of the section can be increased. This may be advantageous as it reduces the dependence on a filter component to deliver a satisfactory closed pressure drop across the consumable, allowing more volatile flavour components to pass into the mouth of a consumer. The consumable 100 comprises a mouth end 101 and a distal end 102, axially opposite the mouth end 101. In use a user may place the mouth end 101 between their lips and draw on the consumable too to inhale a component of the aerosol generating material 15, as will be explained further below. Where a filter component 91 is provided, it may be attached to either the mouth end 101, as illustrated in Fig. 9, or to the distal end 102.

The sections 1 described herein maybe made of any suitable material. For example, the corrugated sheet material 2 of the above examples may comprise paper or paperboard; and, optionally, a metallic material, such as a metal foil. The base sheet 4 and the folded sheet 5 maybe made from the same material or from a different material. For example, the base sheet 4 maybe a different thickness of paperboard to the folded sheet 5; or only one or other of the base sheet and folded sheet 4, 5 may comprise a metallic material. The base sheet and/or the folded sheet may serve as a substrate or support for the aerosol generating material 15. In examples where the base sheet or the folded sheet 4, 5 are provided with aerosol generating material 15, they may be made of a metallic material or may be additionally be provided with a metallic material. The metallic material serves as a susceptor. Where a metallic material is provided in addition, it may be provided as a laminate with the paper or paperboard material. The aerosol generating material 15 may be provided directly on the paper or paperboard layer of the laminate, or it may be provided directly on the metallic layer of the laminate. The layers of the laminate may be ordered accordingly. For example, where the aerosol generating material 15 is provided on the upper surface of the base sheet 4 (such as the example of Fig. 5b), the upper layer of the laminate may be the paper material or the metallic material in dependence on whether it is desirable to have the aerosol generating material 15 directly contacting the paper material or the metallic material.

Alternatively, the base sheet or the folded sheet 4, 5 may be made solely of a metallic material and the aerosol generating 15 disposed directly on the metallic material. The base sheet and the folded sheet 4, 5 may also be made of different materials. For example, where aerosol generating material 15 is provided on the base sheet 4- such as in the example of Fig. 5 - the base sheet 4 may be made of a metallic material and the folded sheet 5 made of any other suitable material. Alternatively, where the aerosol generating material 15 is provided on the folded sheet 5 - such as the examples of Figs.

1 to 4 - the folded sheet 5 may be made of a metallic material and the base sheet 4 made of any other suitable material. Other suitable materials include card or paper, as described herein. Fig. 10 illustrates a system comprising the consumable 100 and a non-combustible aerosol provision device 200. The device comprises an area 201 for receiving the consumable 100 and an aerosol generator 202. The aerosol generator is configured to heat the aerosol generating material 15 of the consumable 100 when it is received in the area 201 to generate an aerosol for inhalation by a user. The device further comprises a power source 203, a controller 204 and a puff sensor 205. In use, a user inserts a consumable 100 distal end 102 first into the area for receiving the consumable 201 and activates the aerosol generator 202 to generate an aerosol for inhalation. The user may then draw on the mouth end 101 of the consumable or, alternatively, on a mouthpiece (not shown) of the device 200 to inhale the aerosol. In the illustrated example, the consumable too and device 200 are configured so that the mouth end 101 protrudes from the area 201 for receiving the consumable too when fully inserted into the device 200. Therefore, the mouth end 101 is available for placing between the lips of the user while the user holds the device.

The puff sensor 205 is configured to detect when a user is drawing on the mouth end 101 of the consumable within the device 200 and to send a signal to the controller 204 to activate the aerosol generator 202. Therefore, aerosol is generated concurrently with the user inhaling on the consumable. Alternatively, the device 200 may be provided with a user interface - such as a button (not shown) - that the user may press to cause activation of the aerosol generator 202.

The area 201 for receiving the consumable too is provided with an inlet (not shown) to allow air into the area for passing through the consumable when a user inhales on the mouth end 101 of the consumable too. Therefore, a flow of air is directed through the consumable too when a user draws on the consumable too. The flow of air entrains the aerosol generated by the aerosol generating material 15 of the consumable when heated by the aerosol generator 202.

The aerosol generator 202 comprises any suitable means for heating the aerosol generating material 15 of a consumable received in said area 201 of the device 200. Power for the aerosol generator 202 is provided by the power source 203, which in the illustrated example is an electrical power source 203, such as a battery 203. In one example, the aerosol generator 202 comprises a magnetic field generator configured to generate a varying magnetic field that penetrates the area 201 for receiving the consumable too. The varying magnetic field heats a susceptor that is placed within the area for the receiving the consumable by magnetic hysteresis. This example is used where the consumable too comprises a susceptor in thermal contact with the aerosol generating material 15, such as the metallic material of the base sheet 4 of folded sheet 5 described above. Therefore, when such a consumable too is placed within the device 200 and the aerosol generator 202 is activated, a varying magnetic field penetrates the susceptor of the consumable too and causes heating of aerosol generating material 15 in thermal contact with the susceptor, generating an aerosol for inhalation by a user.

In another example, the aerosol generator 202 comprises a susceptor in thermal contact with the area 201 for receiving the consumable; and a magnetic field generator for generating a varying magnetic field that penetrates the susceptor. The varying magnetic field heats the susceptor by magnetic hysteresis. The susceptor in turn heats the area 201 for receiving the consumable. Therefore, when a consumable too is placed within the device 200 and the aerosol generator 202 is activated, a varying magnetic field penetrates the susceptor and causes heating of area 201 in which the consumable too is received. The heat is transferred to the aerosol generating material 15 of the consumable too, generating an aerosol for inhalation by the user. In such embodiments, the susceptor may be a wall of the area 201 for receiving the consumable too and the consumable too may be configured for direct contact with the wall for efficient heat transfer. In such an example, the susceptor is optimised for use with consumables comprising a section 1 as illustrated in the example of Fig. 5a.

Alternatively, the susceptor may comprise one or more projections (not shown) that upstand within the area 201 for receiving the consumable too. Therefore, the susceptor maybe directly locatable within one or more of the outer channels 13, or within the central channel 14, depending on the configuration of the susceptor. In one example the susceptor comprises projections configured for location within the outer channels 13.

In such an example, the susceptor is optimised for use with consumables too comprising a section 1 as illustrated in the example of Fig. 1, or Fig. 3a. In another example, the susceptor comprises projections configured for location only in select outer channels 13. In such an example, the susceptor is optimised for use with consumables too comprising a section 1 as illustrated in the example of Fig. 4a. In particular, the projections may be configured for location only in outer channels 14 adjacent outer channels 14 comprising aerosol generating material 15. In another example, the susceptor comprises a projection configured for location within the central channel 14. In such an example, the susceptor is optimised for use with consumables too comprising a section 1 as illustrated in the examples of Figs. 4a, 5a or 6a. In each of the above example susceptor configurations, it will be appreciated that the susceptor is configured for location in close proximity to the aerosol generating material 15, but prevented from coming into direct contact with the aerosol generating material 15. In another example, the aerosol generator 202 comprises a material heatable by electrical conduction (herein ‘the material’). The material is provided in thermal contact with the area 201 for receiving the consumable too. Therefore, when a consumable too is placed within the device 200 and the aerosol generator 202 is activated, a current is passed through the material to heat area 201 in which the consumable too is received. The heat is transferred to the aerosol generating material 15 of the consumable too, generating an aerosol for inhalation by the user. In such embodiments, the material may be a wall of the area 201 for receiving the consumable too and the consumable too may be configured for direct contact with the wall for efficient heat transfer. In such an example, the material is optimised for use with consumables comprising a section 1 as illustrated in the example of Fig. 5a.

Alternatively, the material may comprise one or more projections (not shown) that upstand within the area 201 for receiving the consumable too. Therefore, the material maybe directly locatable within one or more of the outer channels 13, or within the central channel 14, depending on the configuration of the projection. In one example the material comprises projections configured for location within the outer channels 13. In such an example, the material is optimised for use with consumables too comprising a section 1 as illustrated in the example of Fig. 1, or Fig. 3a. In another example, the material comprises projections configured for location only in select outer channels 13.

In such an example, the material is optimised for use with consumables too comprising a section 1 as illustrated in the example of Fig. 4a. In particular, the projections may be configured for location only in outer channels 14 adjacent outer channels 14 comprising aerosol generating material 15. In another example, the material comprises a projection configured for location within the central channel 14. In such an example, the material is optimised for use with consumables too comprising a section 1 as illustrated in the examples of Figs. 4a, 5a or 6a. In each of the above example projection configurations, it will be appreciated that the material is configured for location in close proximity to the aerosol generating material 15, but prevented from coming into direct contact with the aerosol generating material 15.

An example consumable too in combination with a projection 206 of an aerosol generator 202 is shown in section in Fig. 11, other features of the device 200 are omitted for clarity. In the present example, the projection 206 is configured for insertion into the central channel 14 of the consumable too. The projection 206 maybe a material heatable by electrical conduction or the projection 206 maybe a susceptor, in either case, the projection 206 is heated. The illustrated consumable too comprises the section of Figs, la and 3b, though it will be appreciated that any of the sections 1 described herein may be used. It can be seen that the projection 206 is closely spaced to the aerosol generating material 15, but does not come into contact with it. Therefore, a gap 16 is provided between the projection 206 and the aerosol generating material 15 into which an aerosol maybe generated during use of the device 200.

Claims

1. A consumable for use with an aerosol provision system, the consumable comprising a section formed from a rolled corrugated sheet material, wherein a surface of one or more of the corrugations of the rolled corrugated sheet material abuts a corresponding surface of an adjacent corrugation.

2. A consumable wherein each corrugation of the corrugated sheet material is defined between adjacent concave folds of the extended corrugated sheet material.

3. A consumable according to claim 2, wherein each corrugation of the corrugated sheet material comprises a polygonal cross section.

4. A consumable according to claim 2, wherein each corrugation of the corrugated sheet material comprises a curved cross section.

5. A consumable according to claim 3, wherein each corrugation of the corrugated sheet material comprises two planar primary walls, the primary walls being arranged so that each primary wall abuts a primary wall of an adjacent corrugation of the rolled corrugated sheet material, so that the abutting pairs of primary walls form radially extending walls of the consumable.

6. A consumable according to claim 5, wherein each corrugation of the corrugated sheet material further comprises secondary walls that connect the primary walls of each corrugation so that the secondary walls interconnect the radially extending walls and form an inner wall of the section.

7. A consumable according to claim 6, wherein the inner wall defines a central channel of the section.

8. A consumable according to any of preceding claim, wherein the rolled corrugated sheet material further comprises a base sheet that forms an outer wall of the section.

9. A consumable according to claim 8 when dependent on claim 6, wherein the radially extending walls separate airflow channels bounded by the inner and outer walls of the section. io. A consumable according to any of claims 1 to 4, wherein an inner wall of the section is formed from a first rolled sheet of material and an outer wall of the section is formed from a second rolled sheet of material, and wherein the rolled sheet of corrugated material is provided radially between the rolled first sheet and the rolled second sheet such that, the rolled sheet of corrugated material forms radially extending internal walls of the section that extend between, and are enclosed by, the inner and outer walls of the section..

11. A consumable according to claim 10, wherein the internal walls separate airflow channels bounded by the inner and outer walls of the section.

12. A consumable according to any preceding claim, wherein the consumable comprises an aerosol generating material.

13. A consumable according to claim 12, wherein the aerosol generating material comprises an aerosol generating film.

14. A consumable according to claim 13 when dependent on claim 8 or claim 10, wherein the aerosol generating film is provided within at least one of the airflow channels.

15. A consumable according to claim 14, wherein the aerosol generating film is provided on a radially outermost surface of the inner wall of the section and/ or a radially innermost surface of the outer wall of the section. 16. A consumable according to claim 13 when dependent on any of claims 5 to 9, wherein the aerosol generating film is provided on at least one of the radially extending walls.

17. A consumable according to any of claims 12 or claim 13, wherein the aerosol- generating material comprises: an aerosol former a binder; optionally a filler; and optionally an active and/ or a flavourant. 18. A consumable according to claim 17, wherein the aerosol generating film is up to about 1 mm thick and, optionally, up to 500 microns thick and, optionally, 50 to 500 microns thick.

19. A method of forming the consumable of any of claims 1 to 18, the method comprising: providing a sheet of corrugated material; rolling the sheet of corrugated material into a section so that each corrugation of the rolled corrugated sheet material abuts an adjacent corrugation. 20. A non-combustible aerosol provision system comprising: the consumable of any one of claims 1 to 18; and a non-combustible aerosol provision device for heating the aerosol generating material of the consumable to generate an aerosol, the device comprising an area for receiving the consumable, and an aerosol generator for causing said heating of the aerosol generating material when the consumable is in said area.

21. The system of claim 20, wherein the aerosol generator comprises a magnetic field generator for generating a varying magnetic field that penetrates the area for receiving the consumable.

22. The system of claim 20, wherein the aerosol generator comprises a susceptor in thermal contact with the area for receiving the consumable; and a magnetic field generator for generating a varying magnetic field that penetrates the susceptor. 23. The system of claim 20, wherein the aerosol generator comprises a material heatable by electrical conduction, wherein said material is in thermal contact with the area for receiving the consumable.