WO2024084228A1

WO2024084228A1 - A consumable

Info

Publication number: WO2024084228A1
Application number: PCT/GB2023/052730
Authority: WO
Inventors: Richard Hepworth
Original assignee: Nicoventures Trading Limited
Priority date: 2022-10-21
Filing date: 2023-10-20
Publication date: 2024-04-25
Also published as: GB202215601D0

Abstract

A consumable (100) for use in a non-combustible aerosol provision device, the consumable comprising a hollow section formed from a laminate material, wherein the laminate material (130) comprises a first layer (131) and a second layer (132), the laminate sheet being formed into said section so that edges of the first layer abut to form a first butted seam (133).

Description

A Consumable

Technical Field

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

Background

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

In a first aspect of the present invention, there is provided a consumable for use in a non-combustible aerosol provision device, the consumable comprising a hollow section formed from a laminate material, wherein the laminate material comprises a first layer and a second layer, the laminate sheet being formed into said section so that edges of the first layer abut to form a first butted seam.

In a second aspect of the present invention, there is provided a method of forming a consumable for use with a non-combustible aerosol provision device, the method comprising: adhering a second layer of sheet material to the first layer to form a laminate, wherein longitudinal edges of the first layer are offset from respective longitudinal edges of the second layer, so that a portion of the first layer does not overlap the second layer and a portion of the second layer does not overlap the first layer; and forming the laminate into a hollow section so that said portions of the first and second layers are brought into facing relation and adhered to each other with longitudinal edges of each of the first and second layers abutting to form butted seams.

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, the non-combustible aerosol provision device comprising an aerosol generator configured to heat the consumable to generate an aerosol when, in use, the consumable and the device are combined.

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 schematically illustrates a system comprising a consumable and a noncombustible aerosol provision device;

Fig. 2 illustrates a cross section of a consumable projected onto a plane parallel to the longitudinal axis of the consumable;

Fig. 3 illustrates a cross section of an example of the consumable of Fig. 2, projected onto a plane perpendicular to the longitudinal axis of the consumable;

Fig. 4 illustrates a cross section an example of the consumable of Fig. 2, projected onto a plane perpendicular to the longitudinal axis of the consumable; Fig- 5 illustrates a cross section of a consumable projected onto a plane parallel to the longitudinal axis of the consumable;

Fig. 6 illustrates a cross section of an example of the consumable of Fig. 5, projected onto a plane perpendicular to the longitudinal axis of the consumable;

Fig. 7 schematically illustrates a system comprising a consumable and a non- combustible aerosol provision device;

Fig. 8 schematically illustrates a consumable;

Fig. 9 illustrates a method; and

Fig. 10 illustrates a laminate for forming a hollow section of a consumable according to the examples herein.

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 cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens

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

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

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

In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent 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 continuous sheet of material may be a laminate comprising a support and an aerosol generating film provided continuously across the support. The sheet may be in the form of a wrapper, it may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of 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 aerosol - generating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.

The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the 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 heating 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 illustrates a non-combustible aerosol provision system comprising a consumable too and a non-combustible aerosol provision device 200. The device comprises an area 201 for receiving the consumable too and an aerosol generator 202. Fig. 2 illustrates the consumable too in cross section. The cross section is projected onto a plane that bisects the consumable too in a longitudinal direction. The consumable too comprises a hollow section 101. The hollow section 101 comprises a wall 102 surrounding an air gap 103. The consumable too is configured to generate an aerosol in the air gap 103 when heated by the non-combustible aerosol provision device 200 for inhalation by a user. Fig. 3 illustrates the consumable too in a section projected onto a plane that bisects the consumable too perpendicular to the longitudinal direction. Fig. 3 shows further details of the wall 102 of the consumable. In the present example, the wall is formed from a laminate material 130 that is rolled into the hollow section 101. The laminate material 130 comprises first and second layers 131, 132. When the laminate material 130 is rolled into the section 101, edges of the first layer 131 abut to form a first butted seam 133 and edges of the second layer 132 abut to form a second butted seam 134. The first butted seam 133 is offset about the perimeter of the hollow section 101 from the second butted seam 134. The hollow sections 101 illustrated herein are tubular, but in other examples may be a hollow prism having a wall 102 with a polygonal cross section.

Example polygonal cross sections can include, but are not limited to, octagons, hexagons, heptagons or squares. Rather than being rolled, as such, non-tubular hollow sections 101 maybe folded. Irrespective of the cross sectional shape of the hollow section 101, the first and second butted seams 133, 134 are offset about the section’s 101 perimeter to provide a region of overlap 135 in which the first layer 131 of the laminate

130 overlaps the second layer 132 of the laminate 130. In illustrated examples, the wall 102 of the hollow section 101 is a tubular wall and said first and second button seams 133? 134 are offset about the circumference of the tubular wall 102 The first layer of the laminate is adhered to the second layer of the laminate by an adhesive provided between the first and second layers. The adhesive extends into the region of overlap 135 to prevent unravelling of the hollow section 101. In one example, the adhesive extends unbroken between the first and second layers. In other words, there is no region between the first and second layers free of adhesive. Alternatively, in order to limit the use of adhesive, the adhesive may be provided only in discreet regions or may be patterned. In one example, a spiral pattern of adhesive may used comprising overlapping loops of adhesive. Spiral patterning of adhesive has been found to provide good adhesive efficiency - creating a strong bond for the amount of adhesive used relative to other patterns.

The first and second butted seams 133, 134 ensure that both inner and outer surfaces 135? 136 of the wall 102 of the hollow section 101 are smooth. That is to say, both inner and outer surfaces 135, 136 of the wall 102 are free of a step. Such a step is usually caused when a non-laminated material is rolled or folded to form a hollow section, with the edges overlapped and adhered to each other to prevent the section unravelling. By contrast, in the present examples, edges of the first and second layers 131, 132 are abutted to present a flush inner surface 136 and outer surface 137, respectively.

In the examples described herein, the second layer 132 is disposed outward of the first layer 131. In other words, the second layer 132 forms the outer surface 137 of the wall 102 and the first layer 131 forms the inner surface 136. In the present example, the outer surface 137 is an outermost surface, although in other examples further layers of material may be added. In one example, illustrated by Fig. 8 and described below, the consumable too further comprises a wrapping material 110.

In the example of Fig. 3, the first layer 131 comprises a support 104 and aerosol generating material 105 provided on the support 104. The aerosol generating material 105 forms the inner surface 136 of the wall 102. The support 104 is therefore disposed between the aerosol generating material 105 and the second layer of the laminate 132. The support 104 may be made from any suitable material such as paper or paperboard.

Fig. 4 illustrates another example consumable too, wherein like features retain the same reference numbers. Like Fig. 3, Fig. 4 is a section projected onto a plane that bisects the consumable too perpendicular to the longitudinal direction. In the example of Fig. 4, the support 104 further comprises a first layer 106 and a second layer 107, the first layer 106 being located between the aerosol generating material 105 and the second layer 107. The first layer 106 is a susceptor 106 and is heatable by penetration with a varying magnetic field. The second layer 107 is not heatable by penetration with a varying magnetic field and may be any suitable material falling within this criteria, such as paper or paperboard. The aerosol generating material 105 is provided directly on the susceptor 106. However, in other examples, further materials maybe provided between the aerosol generating material 105 and the susceptor 106. An advantage of the present example is that the susceptor 106 never overlaps itself. In other example consumables outside the scope of the present disclosure, susceptors are known to be formed by rolling the susceptor material into a tube with remote edges overlapping.

These overlapping edges tend to be form hotspots when heated, which is not a problem associated with the present example.

Another example consumable too is shown in Fig. 5 in which like features retain the same reference numbers. Fig. 5 illustrates the consumable too in cross section. The cross section is projected onto a plane that bisects the consumable too in a longitudinal direction. The consumable of Fig. 5 further comprises an inner member 150 inside the hollow section 101 and spacers 150, 150’. The spacers 150 space the inner member 150 relative to the hollow section 101 so that the air gap 103 is provided between the inner member and the hollow section 101. In the present example, the hollow section 101 and inner member 150 are tubular. In other words, the inner member 150 is an inner tube

150. The spacers are located between the inner member 150 and the hollow section 101. In the present example, the spacers 151, 151’ are annular. In other words, the spacers 151, 151’ extend all the way around the inner member 150. However, it will be appreciated that the spacers 151, 151’ may instead not be annular, but instead discreet radially extending spacers 151, 151’. The spacers 151, 151’ may be made of any suitable material, including, but not limited to, paper, cellulose acetate or another fibrous material.

Fig. 6 illustrates the consumable too in a section projected onto a plane that bisects the consumable too perpendicular to the longitudinal direction. Fig. 6 shows further details of the inner member 150 of the consumable. In this example, the wall 102 of the hollow section 101 is free of aerosol generating material 105, instead the aerosol generating material 105 is provided on the inner member 150. Specifically, the aerosol generating material 105 is provided on a support 154. The support 154 comprises a first layer 156 and a second layer 157, the first layer 156 being disposed between the aerosol generating material 105 and the second layer 157. The support 154 may be made from any suitable material, such as paper or paperboard, and may include a susceptor. In the present example, the first layer 156 is a susceptor 156 and is heatable by penetration with a varying magnetic field. The second layer 157 is not heatable by penetration with a varying magnetic field and may be any suitable material falling within this criteria, such as paper or paperboard.is a susceptor. The aerosol generating material 105 is provided directly on the susceptor 156. However, in other examples, further materials maybe provided between the aerosol generating material 105 and the susceptor 156. The inner member 150 defines a passageway 152 that is open at axial ends of the consumable too. Therefore, in some examples, the passageway maybe configured to receive a component of an aerosol generator as will be explained further below.

It will be appreciated that the second butted seam 134 may be omitted in some examples and replaced with a lap seam 138, as shown in Fig. 11. Fig. 11 is a section projected onto a plane that bisects the consumable too perpendicular to the longitudinal direction. The first layer 131 is shown schematically and may comprise any or all the support 104, aerosol generating material 105 and susceptor 106 of the examples described above. Importantly, the first layer 131 retains the first butted seam 133 and, therefore, the advantages afforded by preventing overlapping of materials associated with the first layer 131. By providing the second layer 132 with a lap seam 138 rather than butted seam, the consumable too maybe manufactured using convention rod making machinery that are known to the person skilled in the manufacture of rods of the tobacco industry. Referring again to Fig. 1, the aerosol generator 202 of the device 200 is configured to heat the aerosol generating material 105 of the consumable too when the consumable too is received in the area 201 for receiving the consumable. The device also comprises a power source 203, a controller 204 and a puff sensor 205. In use, a user inserts the consumable too into the area 201 for receiving the consumable and activates the aerosol generator 202 to generate an aerosol for inhalation. The user may then draw on a mouth end of the consumable too or, alternatively, on a mouthpiece (not shown) of the device 200 to inhale the aerosol. In the illustrated example, the consumable too and device 200 are configured so that the mouth end is a part of the consumable too that protrudes from the area 201 when the consumable too is fully inserted into the device 200. Therefore, the mouth end is available for a user to draw on the mouth-end while the user holds the device 200.

The puff sensor 205 is configured to detect when a user is drawing on the mouth end of the consumable within the device 200 and to send a signal to the controller 204 to activate the aerosol generator 202. Therefore, aerosol is generated concurrently with the user inhaling on the consumable. Alternatively, the device 200 may be provided with a user interface - such as a button (not shown) - that the user may press to cause activation of the aerosol generator 202. The area 201 for receiving the consumable too is provided with an inlet (not shown) to allow air into area 201 before passing through the consumable too when a user draws on the mouth end 101 of the consumable too. Therefore, a flow of air is directed through the consumable too when a user draws on the consumable too. Specifically, air is directed through the air gap 103 of the hollow section 101. The flow of air entrains the aerosol generated by the aerosol generating material 105 of the consumable for inhalation by the user. The aerosol generator 202 comprises any suitable means for heating the aerosol generating material 105 of a consumable too received in said area 201 of the device 200. Power for the aerosol generator 202 is provided by the power source 203, which in the illustrated example is an electrical power source 203, such as a battery 203.

In one example, the aerosol generator 202 comprises a magnetic field generator configured to generate a varying magnetic field that penetrates the area 201 for receiving the consumable too. Therefore, the device 200 is configured for use with the consumables too comprising a susceptor, such as the consumable exemplified by Figs.

4 and 6. The varying magnetic field heats the susceptor 106, 156 by magnetic hysteresis.

When the consumable too is placed within the device 200 and the aerosol generator 202 is activated, a vaiying magnetic field penetrates the susceptor 106, 156 of the consumable too and causes heating of aerosol generating material 105 in thermal contact with the susceptor 106, 156, generating an aerosol for inhalation by a user.

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

Another example non-combustible aerosol provision device 200 is illustrated by Fig. 7 in which like features retain the same reference numbers. In the example of Fig. 7 the aerosol generator 202 further comprises a projection 206 that extends into the area for receiving the consumable 201. The projection 206 is a column that upstands from a base of the area 201. The projection is spaced from a wall 207 of the area 201 for receiving the consumable too. Therefore, when the consumable too is inserted into the area 201 for receiving the consumable, the wall 102 of the consumable too is disposed between the projection 206 and the wall 207 of said area 201. The projection 206 is configured so that, when a consumable in accordance with the examples of Fig. 2 is inserted into the area 201 for receiving the consumable, the projection 206 is received in the air gap 103 and is spaced from the inner surface 136 of the wall 102. Alternatively or additionally, the projection 206 is configured so that, when a consumable in accordance with the examples of Fig. 5 is inserted into the area 201 for receiving the consumable, the projection 206 is received in the passageway 152.

In one example, the projection 206 is a susceptor 206 and the aerosol generator 202 comprises a magnetic field generator configured to generate a varying magnetic field that penetrates the projection 206. The vaiying magnetic field heats the projection 206 by magnetic hysteresis. The projection 206 in turn heats the consumable too when the device 200 and the consumable too are combined. In particular, when a consumable too is placed within the device 200 and the aerosol generator 202 is activated, a varying magnetic field penetrates the projection 206 and causes heating of aerosol generating material 105 by its proximity to the projection. Heat is thereby transferred to the aerosol generating material 105 of the consumable too, generating an aerosol for inhalation by the user. In one example, the aerosol generator 202 comprises the projection 206 and the projection 206 comprises a magnetic field generator 206. In such examples the magnetic field generator 206 is configured to generate a varying magnetic field that penetrates the area 201 for receiving the consumable too. In one related example, the projection 206 is configured so that, when a consumable in accordance with the examples of Fig. 5 is inserted into the area 201 for receiving the consumable, the projection 206 is received in the passageway 152. Therefore, the device 200 of said example is configured for use with the consumables too in which the inner member 150 comprises the susceptor 156, such as the consumable exemplified by Fig. 6. The varying magnetic field heats the susceptor 156 by magnetic hysteresis. When the consumable too is placed within the device 200 and the aerosol generator 202 is activated, a varying magnetic field penetrates the susceptor 156 of the consumable too and causes heating of aerosol generating material 105 in thermal contact with the susceptor 156, generating an aerosol for inhalation by a user.

The consumable too may be provided with any number of additional components for attachment to the hollow sections 101 described above. An example consumable too with an additional component 90 is shown schematically in Fig. 8, in which example the consumable comprises a porous body 108 in addition to the hollow section 101. It will be appreciated that the schematically illustrated hollow section 101 of Fig. 8 is representative any hollow section 101 described herein, including examples with and without the inner member 150.

The additional component 90 comprises an outside diameter substantially the same hollow section 101 and is connected thereto in axial alignment by a wrapping material

110. Additional components 90 may include, but are not limited to, cooling sections or other sections containing aerosol generating material, as is known in the field. The porous body 108 of the example of Fig. 8 may be a paper filter component or a cellulose filter component.

Including a porous body 108 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 porous material in the porous body 108, or by increasing or decreasing the axial length of the porous body 108.

The consumable too comprises a mouth end 111 and a distal end 112, axially opposite the mouth end 111. In use a user may place the mouth end 111 between their lips and draw on the consumable too to inhale a component of the aerosol generating material 105. Where a porous body 108 is provided, it maybe attached to either the mouth end

111, as illustrated in Fig. 8, or to the distal end 112 Referring to Fig. 9, there is shown a flow diagram showing an example of a method 80 of manufacturing a consumable 100 for use with the system of examples described herein. The method of Fig. 9 is usable to manufacture any of the consumables too described herein.

The method 80 comprises providing the hollow section 101 and, optionally, attaching 84 any desired additional components 90 to the hollow section 101.

In examples described herein, providing the hollow section comprises forming a laminate material 130 in which the first layer 131 of the laminate is adhered 82 to the second layer 132 of the laminate. To form a consumable too in accordance with examples comprising the second butted seam 134, the first and second layers 131, 132 are arranged so that longitudinal edges 131’ of the first layer 131 are offset from respective longitudinal edges 132’ of the second layer 132, as shown in Fig. 10. In other words, a portion 135’ of the first layer 131 does not overlap the second layer 132 and a portion 135” of the second layer 132 does not overlap the first layer 131. The laminate 130 is then formed 83 into the hollow section 101 so that said portions of the first and second layers 131, 132 are brought into facing relation to form the region of overlap 135.

To form a consumable in accordance with examples comprising the lap seam 138, the first and second layers 131, 132 are arranged so that, along one edge 130’ of the laminate 130, the longitudinal edges 131’, 132’ of the first and second layers 131, 132 are offset from one another forming an offset portion 138 of the laminate 130; and, along the other longitudinal edge 130” of the laminate 130, the longitudinal edges 131’, 132’ of the first and second layers 131, 132 are colinear, as shown in Fig. 12. The laminate is formed 83 into the hollow section 101 so that the longitudinal edges 131’ of the first layer 131 abut to form the first butted seam 133 and the offset portion 139 of the second layer 132 overlaps itself to form the lap seam 138.

Forming 83 may comprise rolling or wrapping the laminate into a - typically tubular - hollow section 101. However, it will be appreciated that the laminate 130 may instead be folded into a section 101 having a non-circular cross section. Such rolling, wrapping or folding may be around a mandrel, for example.

In some examples, in which the first layer 131 of the laminate 130 comprises the support 104, the providing 81 the hollow section 101 further comprises affixing the aerosol generating material 105 to the support 104 of the laminate 130 and then forming 83 the hollow section 101. Accordingly, in some examples, the laminate 130 maybe flat or substantially flat at the time the aerosol generating material 105 is affixed to it. Thereafter, in some examples, the laminate 130 and aerosol generating material 105 maybe formed 83 together during formation of the hollow section 101. Such forming 83 may comprise rolling or wrapping the combination of the laminate 104 and aerosol generating material 105 into a - typically tubular - section 101. However, it will be appreciated that the combination of the laminate 130 and aerosol generating material 105 may instead be folded into a section 101 having a non-circular cross section. Such rolling, wrapping or folding may be around a mandrel, for example. In some examples, affixing the aerosol generating material 105 to the support 104 comprises affixing the aerosol generating material 105 to the first layer 131 prior to adhering the first layer 131 to the second layer 132 to form the laminate 130 in the way described. In some examples, affixing the aerosol generating material 105 to the support comprises stencil application or pulsed spray coating to create discreet regions of aerosol generating material 105 on the support 104.

In some examples, the affixing comprises coating the aerosol generating material 105 onto the support 104 to form a film of aerosol generating material 105. Such coating may comprise spraying, electro-spraying, casting or band casting casting, for example. Such casting may involve providing material in liquid or other fluid form on a surface of the support 104 (or material that ultimately will form the support 104), and then allowing the material to at least partially solidify or cure on the surface of the support 104 to form the aerosol generating material 105 comprising the film. The material in liquid or other fluid form may be aerosol generating in that form, or may only become aerosol generating once it has solidified or cured.

In some examples, the affixing may comprise a technique other than coating. For example, the affixing comprises adhering the aerosol generating material 105 to the support 104 using an adhesive. Adhering aerosol generating material 105 may comprising adhering a sheet of aerosol generating material to the support 104, such as strips of reconstituted tobacco material.

In some examples, the method of manufacturing the consumable too further comprises forming the inner member 150 and inserting the inner member 150 into the hollow section 101. Forming the inner member 150 comprises manipulating a sheet material comprising the first layer 156 and second layer 157 into the inner member. Such manipulation may comprise rolling or wrapping the combination of the first and second layers 156, 157 into a - typically tubular - member 150. Such rolling, wrapping or folding may be around a mandrel, for example. In some examples, in which the first layer 156 of the inner member 150 comprises the support 154, the forming the inner member further comprises affixing the aerosol generating material 105 to the support 154 of the sheet material and then forming the inner member 150. Accordingly, in some examples, the support 154 may be flat or substantially flat at the time the aerosol generating material 105 is affixed to it. Thereafter, in some examples, the support 154 and aerosol generating material 105 may be manipulated together during formation of the inner member 150. Such manipulation may comprise rolling or wrapping the combination of the support 154 and aerosol generating material 105 into a - typically tubular -member 150. Should additional components be required - such as the components of the example of Fig. 8 - then said components maybe attached 84 to the hollow section 101 by first arranging each of the components in axial alignment to form an assembly of components and then wrapping the components in a wrapping material 110. The aerosol generating material 105 of any of the examples described herein may comprise an aerosol former, a binder, optionally a filler and optionally an active and/or a flavourant. The aerosol generating material may comprise a substrate of reconstituted tobacco on which may be provided the aerosol former, binder, filler and optional active and/or flavourant.

Claims

1. A consumable for use in a non-combustible aerosol provision device, the consumable comprising a hollow section formed from a laminate material, wherein the laminate material comprises a first layer and a second layer, the laminate sheet being formed into said section so that edges of the first layer abut to form a first butted seam.

2. A consumable according to claim i, wherein edges of the second layer abut to form a second butted seam.

3. A consumable according to claim 2, wherein the first butted seam is offset about the perimeter of the section from the second butted seam.

4. A consumable according to claim 3, wherein the second layer is disposed outward of the first layer.

5. A consumable according to claim 4, wherein the first layer comprises a support and aerosol generating material coated on the support.

6. A consumable according to claim 5, wherein the hollow section defines an air gap of the consumable in which aerosol is generated in use.

7. A consumable according to claim 6, wherein the support is part of a wall of the hollow section that surrounds the air gap and wherein the aerosol generating material forms an inner surface of the wall.

8. A consumable according to claim 7, wherein the aerosol generating material forms an internal surface of the hollow section.

9. A consumable according to any of claims 5 to 8, wherein the aerosol-generating material comprises:

- an aerosol former

- a binder;

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

10. A consumable according to claim 9, wherein the aerosol generating material comprises an aerosol generating film and wherein the aerosol generating film is up to about 1 mm thick and, optionally, up to 500 microns thick and, optionally, 50 to 500 microns thick.

11. A consumable according to any preceding claim, wherein the hollow section comprises a susceptor heatable by penetration with a vaiying magnetic field.

12. A consumable according to claim 11 when dependent on claim 5, wherein the support comprises a first layer and a second layer, wherein the first layer comprises the susceptor, wherein the second layer is not heatable by penetration with a varying magnetic field, and wherein the first layer is located between the aerosol generating material and the second layer.

13. A consumable according to any preceding claim wherein the hollow section is a hollow tube.

14. A consumable according to any preceding claim wherein the consumable further comprises an inner member inside the hollow section and at least one spacer that spaces the inner member relative to the hollow section so that at least one air gap exists between the inner member and the hollow section..

15. A consumable according to claim 14, wherein the at least one spacer is located between the inner member and the hollow section.

16. A consumable according to any of claim 14 or claim 15, wherein the inner member comprises an inner tube.

17. A consumable according to claim 16, wherein the inner tube is located around a passageway that opens at an axial end of the consumable.

18. A consumable according to claim any of claims 14 to 17, wherein the inner member comprises a support and aerosol generating material coated on the support.

19. A consumable according to claim 18, wherein the inner member comprises a susceptor

20. A consumable according to claim 19, wherein the support of the inner member comprises a first layer and a second layer, wherein the first layer comprises the susceptor, wherein the second layer is not heatable by penetration with a varying magnetic field, and wherein the first layer is located between the aerosol generating material and the second layer.

21. A method of forming a consumable for use with a non-combustible aerosol provision device, the method comprising: adhering a second layer of sheet material to the first layer to form a laminate, wherein longitudinal edges of the first layer are offset from respective longitudinal edges of the second layer, so that a portion of the first layer does not overlap the second layer and a portion of the second layer does not overlap the first layer; and forming the laminate into a hollow section so that said portions of the first and second layers are brought into facing relation and adhered to each other with longitudinal edges of each of the first and second layers abutting to form butted seams.

22. A non-combustible aerosol provision system comprising the consumable of any of claims 1 to 20 and a non-combustible aerosol provision device, the non-combustible aerosol provision device comprising an aerosol generator configured to heat the consumable to generate an aerosol when, in use, the consumable and the device are combined.