Consumable for aerosol generating apparatus

Abstract

A consumable for use with an aerosol generating apparatus comprising: a solid aerosol precursor arrangement (6) and a mouthpiece (71) downstream of the solid aerosol precursor arrangement, the solid aerosol precursor arrangement having an axial length extending from an upstream end (72) to a downstream end (73) of the solid aerosol precursor arrangement, wherein the solid aerosol precursor arrangement includes a plurality of separate precursor bodies, including a first precursor body (74) and a second precursor body (75); wherein a gap (76) is formed between the first precursor body and the second precursor body and the gap extends along the entire axial length of the solid precursor arrangement.

Description

FIELD

[0001] The present disclosure relates to a consumable for an aerosol generating apparatus.BACKGROUND

[0002] A typical aerosol generating apparatus may comprise a power supply, an aerosol generating unit that is driven by the power supply, an aerosol precursor, which in use is aerosolised by the aerosol generating unit to generate an aerosol, and a delivery system for delivery of the aerosol to a user. Aerosol precursors may be formed by injection of the aerosol forming material into a card tube.

[0003] A drawback with at least some known aerosol precursors is that the injection process can result in aerosol precursors with variable shapes. As a result, the pressure drop across the consumable may be different between consumables, thereby providing an inconsistent and possibly inferior experience. For example, for some consumables there may be a comparatively low pressure drop across the precursor if there is a void which allows air to pass through the precursor. This also results in poor aerosol formation as most of the precursor is bypassed by airflow. On the other hand, for some consumables the precursor may have a comparatively high pressure drop if a solid plug forms as a result of injection, since air cannot easily pass through the precursor.

[0004] The present invention has been devised in light of the above considerations.SUMMARY

[0005] In a first aspect the present disclosure provides a consumable that may comprise a solid aerosol precursor arrangement and a mouthpiece.

[0006] The mouthpiece may be downstream of the solid aerosol precursor arrangement. In use, a user may engage the mouthpiece to create an airflow through the consumable. In particular, the airflow may flow from the solid aerosol precursor arrangement to the mouthpiece, and may exit from the consumable at the mouthpiece. Generally, the terminology upstream and downstream may be used in accordance with the airflow when the consumable is in use. As such, the mouthpiece may be at the downstream end of the consumable and airflow through the consumable, e.g. through the precursor arrangement, may be towards the mouthpiece in a downstream direction.

[0007] In some examples, the solid aerosol precursor arrangement has an upstream end and a downstream end. In use, the airflow may flow from the upstream end to the downstream end. The upstream end and the downstream end may delimit an axial length of the solid aerosol precursor arrangement.

[0008] In some examples, the solid aerosol precursor arrangement includes a plurality of separate precursor bodies, which may include a first precursor body and a second precursor body.

[0009] In some examples, a gap is formed between the first precursor body and the second precursor body, the gap extending along the entire axial length of the solid aerosol precursor arrangement.

[0010] The provision of the separate precursor bodies and arranging these to form the gap may enhance airflow through the solid aerosol precursor arrangement. In particular, the separate precursor bodies can be arranged so as to provide the gap along the entire axial length of the solid aerosol precursor arrangement to thereby enhance airflow through the solid aerosol precursor arrangement. This may improve the consistency of the pressure drop across different consumables, e.g. since arrangement of the precursor bodies and formation of the gap may be more easily controllable than an injection processes. Additionally, the gap may improve flavour delivery, because the solid aerosol precursor bodies may have a higher density compared with a single-segment solid aerosol precursor arrangement. This is because the gap will occupy some volume of the consumable, such that the mass of the precursor material will occupy a reduced volume and hence have a higher density. A higher density of precursor material may result in more intense and longer-lasting flavour delivered by the solid aerosol precursor arrangement to the user.

[0011] In some examples, the first precursor body and the second precursor body each have the shape of a cylinder segment. For example, the first precursor body and the second precursor body may each have the shape of a semi-cylinder. For example, the first precursor body and the second precursor body may each have the shape of a quarter-cylinder.

[0012] In some examples, the precursor bodies are arranged in the consumable such that the solid aerosol precursor arrangement has a generally cylindrical overall shape.

[0013] In some examples, the solid aerosol precursor arrangement further includes a third precursor body. In these examples, a second gap is formed between the second precursor body and the third precursor body, and a third gap is formed between the third precursor body and the first precursor body. In other words, when the solid aerosol precursor arrangement includes three precursor bodies, three gaps may be formed. The second and third gap may each extend along the entire axial length of the solid aerosol precursor arrangement.

[0014] In some examples, the solid aerosol precursor arrangement further includes a third and a fourth precursor body. In these examples, a second gap is formed between the second precursor body and the third precursor body, a third gap is formed between the third precursor body and the fourth precursor body, and a fourth gap is formed between the fourth precursor body and the first precursor body. In other words, when the solid aerosol precursor arrangement includes four precursor bodies, four gaps may be formed. The second, third and fourth gap may each extend along the entire axial length of the solid aerosol precursor arrangement.

[0015] In some examples, the solid aerosol precursor arrangement includes up to and including ten precursor bodies, such as up to and including eight precursor bodies, such as up to and including six precursor bodies. That is, in some examples, the solid aerosol precursor arrangement includes two to ten precursor bodies, such as two to eight precursor bodies, such as two to six precursor bodies. In other examples, the solid aerosol precursor arrangement includes three to ten precursor bodies, such as four to ten precursor bodies, such as six to ten precursor bodies. In these examples, the number of gaps that form between the precursor bodies may be equal to the number of precursor bodies. Each of the gaps may extend along the entire axial length of the solid aerosol precursor arrangement.

[0016] In some examples, all the precursor bodies have the shape of a cylinder segment. In these examples, the precursor bodies may be arranged in the consumable such that the solid aerosol precursor arrangement has a generally cylindrical overall shape. For example, in examples where the solid aerosol precursor arrangement further comprises a third and fourth precursor body, the first and second precursor bodies and the third and the fourth precursor bodies each may have the shape of a cylinder segment, such as the shape of a quarter-cylinder.

[0017] The plurality of separate precursor bodies of the solid aerosol precursor arrangement may enhance airflow through the solid aerosol precursor arrangement since the bodies can be arranged so as to provide gaps which may extend along the entire axial length of the solid aerosol precursor arrangement. The airflow through the solid aerosol precursor arrangement may be more reliable and consistent and / or may result in improved consistency of the pressure drop across different consumables. Consequently, this may improve the amount and consistency of aerosol and flavour delivered to the user from the precursor arrangement between different consumables.

[0018] Additionally, the shaping of the solid aerosol precursor arrangement (e.g. by way of the provision of a plurality of separate precursor bodies) may allow for greater customisability and flexibility of design. In other words, the solid aerosol precursor arrangement may be shaped depending on, for example, the composition of the precursor, the types and amounts or quality of flavourant present in the solid aerosol precursor arrangement or the desired pressure drop. These factors maybe varied by changing the number of precursor bodies present in the precursor arrangement.

[0019] In some examples, the solid aerosol precursor arrangement may be disposed in an envelope. The solid aerosol precursor arrangement and the mouthpiece may be disposed in the envelope. For example, the aerosol precursor arrangement and the mouthpiece may both be held by the envelope.

[0020] As used herein, the term "envelope" may define a covering or containing structure or layer. The envelope may be arranged around the solid aerosol precursor arrangement and may extend along the axial length of the solid aerosol precursor arrangement, and / or may be arranged around and extend along the entire mouthpiece. In some examples, the envelope extends along the entire axial length of the solid aerosol precursor arrangement. In some examples, the envelope surrounds the whole of the solid aerosol precursor arrangement, and / or may surround the whole of the mouthpiece. In this way, the envelope may encase the solid aerosol precursor arrangement and improve handleability of the solid aerosol precursor arrangement before it is assembled into a consumable for an aerosol generating apparatus.

[0021] The envelope may be made from any suitable material and may have any suitable shape. In some examples, the envelope may comprise a rigid material such as card. In some examples, the envelope may be a tube, such as a card tube. In other examples, the envelope may comprise a less rigid material such as paper, foil or foil-paper laminate. In some examples, the envelope may be a wrapper, such as a foil-paper laminate wrapper.

[0022] The envelope may have an outside surface and may have an inside surface. The inside surface is the surface of the envelope facing the solid aerosol precursor arrangement when the arrangement is disposed in an envelope. The outside surface is the surface of the envelope facing away from the solid aerosol precursor arrangement when the arrangement is disposed in an envelope. In some examples, the precursor bodies of the solid aerosol precursor arrangement are adhered to the inside surface of the envelope. In some examples, the precursor bodies have a peripheral surface. The peripheral surface may be a surface of the precursor bodies which is adjacent the envelope, e.g. the inside surface, when the solid aerosol precursor arrangement is disposed in the envelope. In some examples, the peripheral surface of each of the precursor bodies is adhered to the envelope.

[0023] Adhesion of the precursor bodies to the inside surface of the envelope maintains the arrangement of the precursor bodies in the consumable. In other words, adhesion of the precursor bodies to the inside surface of the envelope maintains the gap formed between each precursor body in the consumable, leading to enhanced airflow, and therefore improved consistency of aerosol and flavour delivered to the user across different consumables.

[0024] In some examples, the gap extends across the entire aerosol precursor arrangement, when viewed in cross-section (e.g. perpendicular to the downstream direction). For example, the gap may extend from the inside surface of the envelope on one side to the inside surface on the other side. In other examples, multiple gaps may be provided; these gaps may meet centrally and the gaps may extend in different transverse directions to the inside surface of the envelope.

[0025] In some examples, the gap formed between the first precursor body and the second precursor body extends across the solid aerosol precursor arrangement from a first region on the inside surface of the envelope to a second region on the inside surface of the envelope. The first region and the second region may be on opposite sides of the solid aerosol precursor arrangement. That is, in some examples, the gap formed between the first precursor body and the second precursor body extends across the solid aerosol precursor arrangement in a direction from a first region on the inside surface of the envelope to a second region on the inside surface of the envelope.

[0026] In some examples, the solid aerosol precursor arrangement has a central axis. The central axis of the solid aerosol precursor arrangement extends along the axial length of the solid aerosol precursor arrangement. The upstream end and the downstream end may delimit the solid aerosol precursor arrangement along the central axis. Where the solid aerosol precursor arrangement is generally cylindrical, the central axis may be a cylinder axis. The solid aerosol precursor arrangement may be rotationally symmetric with respect to the central axis. In some examples, the central axis may be a central axis for the whole consumable.

[0027] In some examples, the gap formed between the first precursor body and the second precursor body extends in a first transverse direction from the central axis to the inside surface of the envelope. In some examples, a second gap extends in a second transverse direction from the central axis to the inside surface of the envelope. In these examples, the first transverse direction is different from the second transverse direction; the first transverse direction and the second transverse direction may be perpendicular to the downstream direction and / or the central axis.

[0028] In some examples, further gaps extend in transverse directions from the central axis to the inside surface of the envelope. In these examples, the transverse direction of each gap is different to the transverse direction of other gaps. For example, a third gap may extend in a third transverse direction from the central axis to the inside surface of the envelope, where the third transverse direction is different from the first and second transverse directions, and a fourth gap may extend in a fourth transverse direction from the central axis to the inside surface of the envelope, where the fourth transverse direction is different from the first, second and third directions. In some examples, the precursor bodies may be arranged such that the gaps form the shape of a cross or of an asterisk.

[0029] In examples where the solid aerosol precursor arrangement further includes a third precursor body such that a second gap is formed between the second precursor body and the third precursor body, and a third gap is formed between the third precursor body and the first precursor body, the gap formed between the first precursor body and the second precursor body extends in a first transverse direction from the central axis to the inside surface of the envelope, the second gap formed between the second precursor body and the third precursor body extends in a second transverse direction from the central axis to the inside surface of the envelope and the third gap formed between the third precursor body and the first precursor body extends in a third transverse direction from the central axis to the inside surface of the envelope, where the first, second and third transverse directions are all different.

[0030] In examples where the solid aerosol precursor arrangement includes more than three precursor bodies, such as up to and including ten precursor bodies, the gaps that form between each of the precursor bodies may each extend in a transverse direction from the central axis to the inside surface of the envelope, where the transverse direction of each gap is different from the transverse directions of the other gaps. In some examples, the precursor bodies may be arranged such that the gaps form the shape of a cross or of an asterisk.

[0031] When the precursor bodies each have the shape of a cylinder segment, the gaps formed between the precursor bodies may extend radially in transverse directions from the central axis of the solid aerosol precursor arrangement to the inside surface of the envelope, where the transverse direction of each gap is different.

[0032] In this way, the airflow through the solid aerosol precursor arrangement may be enhanced since the gap(s) extends both along the axial length of the solid precursor arrangement and in a transverse direction from the central axis to the inside surface of the envelope such that there is no contact between any of the precursor bodies.

[0033] In some examples, the gap or gaps have approximately constant width in the transverse direction from the central axis all the way to the inside surface of the envelope. In other examples, the width of the gap or gaps varies in the transverse direction from the central axis to the inside surface of the envelope. In some examples, the width of the gap or gaps decreases along the transverse direction from the central axis to the inside surface of the envelope. In other words, the width of the gap or gaps is narrower nearer the peripheral surface of the precursor bodies (i.e., at the inside surface of the envelope), expanding to the widest at the central axis of the solid aerosol precursor arrangement. In other examples, the width of the gap or gaps increases along the transverse direction from the central axis to the inside surface of the envelope. In other words, the width of the gap or gaps is wider nearer a peripheral surface of precursor bodies (i.e., at the inside surface of the envelope).

[0034] In some examples, the gap or gaps are provided as one or more of a channel, a groove, a cut, a hollow bore, or a perforation. These may take any form, for example the channel may be a spiral shaped channel. In some examples, each gap is delineated by the surfaces of the precursor bodies bounding the gap, so as to produce for example a conical, cylindrical, cuboid such as rectangular cuboid, or pyramidal shape of gap.

[0035] In some examples, the gap or gaps is arranged to receive a penetrative heater, such as a blade heater or a pin heater. For example, solid precursor arrangement may be configured to receive the penetrative heater exclusively into the gap or gaps and without penetrating any of the precursor bodies.

[0036] In some examples, when the gap or gaps extends in a transverse direction from the central axis of the solid aerosol precursor arrangement to the inside surface of the envelope, the penetrative heater may be located at the centre of the consumable. In some examples, the penetrative heater is located along the central axis of the solid aerosol precursor arrangement, and extends along the central axis. The penetrative heater may heat the solid aerosol precursor arrangement by conductive heat transfer, and generate an aerosol which is inhaled by the user. Particularly, the use of a penetrative heater may be beneficial for, for example, influencing the airflow through the solid precursor, which may be beneficial for improving the pressure drop across different consumables during use. The effect of the penetrative heater on the airflow may be dependent on, for example, the proximity of the heater to the solid aerosol precursor arrangement and the density of the precursor bodies. Additionally, where the heater is received within the gap or gaps of the solid aerosol precursor arrangement the need for cleaning of the apparatus may be reduced.

[0037] In some examples, the precursor bodies of the solid precursor arrangement comprises a precursor composition, where the precursor composition is or comprises an agglomeration of particles, such as is an agglomeration of particles.

[0038] In some examples, the first precursor body and the second precursor body have the same precursor composition. In some examples, the first precursor body and the second precursor body have a precursor composition comprising an agglomeration of particles. In examples where the solid precursor arrangement comprises more than two precursor bodies, each of the precursor bodies have the same precursor composition. In these examples, each of the precursor bodies has a precursor composition comprising an agglomeration of particles.

[0039] In some examples, the precursor composition comprises non-tobacco particles, such as cellulose particles and / or tea particles. In some examples, the tea particles comprise oolong tea. In other examples, the tea particles comprise green tea. In some examples, the tea particles comprise a mixture of oolong and green tea. In some examples, the precursor composition is free or substantially free of tobacco particles. By substantially free, it is meant that the precursor composition comprises no dry mass tobacco in accordance with regulatory standards. As used herein, dry mass tobacco does not encompass tobacco extract or tobacco essence.

[0040] In some examples, the precursor composition comprises up to about 60 weight% (wt%) non-tobacco particles relative to the total weight of the precursor composition (the total weight of the precursor composition being 100 wt%). In some examples, the precursor composition comprises up to about 55 wt% non-tobacco particles, or up to about 50 wt% non-tobacco particles relative to the total weight of the precursor composition. In some examples, the precursor composition comprises about 40 wt% or more non-tobacco particles, such as about 45 wt% or more non-tobacco particles, such as about 50 wt% or more non-tobacco particles relative to the total weight of the precursor composition.

[0041] In some examples, the precursor composition comprises an amount of non-tobacco particles selected from a range with the upper and lower amounts selected from the values given above. In some examples, the precursor composition comprises 40 to 60 wt% non-tobacco particles, such as 50 to 60 wt% non-tobacco particles, such as 55 to 60 wt% non-tobacco particles relative to the total weight of the precursor composition. In other examples, the precursor composition comprises 40 to 50 wt% non-tobacco particles relative to the total weight of the precursor composition. In some examples, the precursor composition comprises up to and including 60 wt% non-tobacco particles relative to the total weight of the precursor composition.

[0042] For example, when the precursor composition comprises cellulose particles and tea particles, the precursor composition is 20 to 25 wt% cellulose particles and 20 to 25 wt% tea particles relative to the total weight of the precursor composition. In some examples, the precursor composition comprises up to about 25 wt% cellulose particles, such as up to about 24 wt% cellulose particles, such as up to about 23 wt% cellulose particles relative to the total weight of the precursor composition. In some examples, the precursor composition comprises about 20 wt% or more cellulose particles, such as about 21 wt% or more, such as about 22 wt% or more relative to the total weight of the precursor composition. In some examples, the precursor composition comprises cellulose particles in a range with the upper and lower amounts selected from the values given above. In some examples, the precursor composition comprises up to about 25 wt% tea particles, such as up to about 24 wt% tea particles, such as up to about 23 wt% tea particles relative to the total weight of the precursor composition. In some examples, the precursor composition comprises about 20 wt% or more tea particles, such as about 21 wt% or more, such as about 22 wt% or more relative to the total weight of the precursor composition. In some examples, the precursor composition comprises an amount of tea particles selected from a range with the upper and lower amounts selected from the values given above.

[0043] In some examples, the amounts of cellulose particles and tea particles in the precursor composition are equal. In other examples, the amounts of cellulose particles and tea particles in the precursor composition are not equal.

[0044] In some examples, the precursor composition comprises a flavourant, such as tobacco extract or other plant extracts. In some examples, the flavourant may provide flavour and odour to the solid precursor. In some examples, the precursor composition comprises a tobacco extract. In some examples, the precursor composition comprises other plant extracts such as fig, maple, or acer saccharum extract. In some examples, the precursor composition comprises up to about 40 weight (wt%) flavourant, such as up to about 35 wt% flavourant, such as up to about 30 wt% flavourant relative to the total weight of the precursor composition. In some examples, the precursor composition comprises about 20 wt% or more flavourant, such as about 25 wt% or more flavourant, such as about 30 wt% or more flavourant relative to the total weight of the precursor composition. In some examples, the precursor composition comprises an amount of flavourant selected from a range with the upper and lower amounts selected from the values given above. In some examples, the precursor composition comprises 20 to 40 wt% flavourant, such as 25 to 40 wt%, such as 30 to 40 wt%, such as 35 to 40 wt% relative to the total weight of the precursor composition. In some examples, the precursor composition comprises up to and including 40 wt% flavourant relative to the total weight of the precursor composition.

[0045] In some examples, the precursor composition comprises a humectant. In some examples, the humecant may comprise propylene glycol (PG) and / or glycerol (VG). In some examples, the amount of humectant present in the precursor composition is up to about 30 weight% (wt%), such as up to about 25 wt%, such as up to about 20 wt% relative to the total weight of the precursor composition. In some examples, the amount of humectant present in the precursor composition is about 20 wt% or more, such as about 25 wt% or more, such as about 30 wt% or more relative to the total weight of the precursor composition. In some examples, the precursor composition comprises an amount of humectant selected from a range with the upper and lower amounts selected from the values given above. In some examples, the amount of humectant present in the precursor composition is about 20 to 30 wt%, such as 25 to 30 wt%, such as up to and including 30 wt% relative to the total weight of the precursor composition.

[0046] In some examples, the precursor composition comprises a binding agent, which in some examples may act as a thickening agent, or may comprise a thickening agent. In some examples, the binding and / or thickening agent is selected from one or more of microcrystalline cellulose (MCC), Konjac Mannan, carrageenan, starches such as corn starch, gelatine, pectin, gums such as guar or xanthan gum, or alginates. In some examples, the binding and / or thickening agent is Konjac Mannan. In some examples, the binding and / or thickening agent is a water-independent thickening agent. A water-independent thickening agent may be a thickening agent which does not require water for activation. In some examples, the precursor composition comprises up to about 5 weight% (wt%) binding and / or thickening agent, such as up to about 4 wt% binding and / or thickening agent, such as up to about 3 wt% binding and / or thickening agent relative to the total weight of the precursor composition. In some examples, the precursor composition comprises about 1 wt% or more binding and / or thickening agent, such as about 2 wt% or more binding and / or thickening agent, such as about 3 wt% or more binding and / or thickening agent relative to the total weight of the precursor composition. In some examples, the precursor composition comprises an amount of binding and / or thickening agent selected from a range with the upper and lower amounts selected from the values given above. In some examples, the precursor composition comprises 1 to 5 wt% binding and / or thickening agent, such as 2 to 5%, such as 3 to 5% relative to the total weight of the precursor composition. In some examples, the precursor composition comprises up to and including 5 wt% binding and / or thickening agent relative to the total weight of the precursor composition.

[0047] In some examples, the precursor composition comprises a solvent. In some examples the solvent is aqueous. In some examples, the amount of solvent present in the precursor composition is up to about 75 weight% (wt%), such as up to about 60 wt%, such as up to about 50 wt% relative to the total weight of the precursor composition. In some examples, the amount of solvent present in the precursor composition is up to about 45 wt%, such as up to about 40 wt% relative to the total weight of the precursor composition. In some examples, the amount of solvent present in the precursor composition is about 5wt% or more, such as 10 wt% or more, such as 20 wt% or more, such as 30 wt% or more relative to the total weight of the precursor composition. In some examples, the amount of solvent present in the precursor composition may be selected from a range with the upper and lower amounts selected from the values given above. In some examples, the amount of solvent present in the precursor composition is about 20 to 50 wt%, such as 20 to 45 wt%, such as 20 to 40 wt% relative to the total weight of the precursor composition. In some examples, the amount of solvent present in the precursor composition is about 25 to 50 wt%, such as 30 to 50 wt% relative to the total weight of the precursor composition.

[0048] In some examples, the amount of water (as the solvent) present in the precursor composition is up to about 75 weight% (wt%), such as up to about 60 wt%, such as up to about 50 wt% relative to the total weight of the precursor composition. In some examples, the amount of water present in the precursor composition is up to about 45 wt%, such as up to about 40 wt% relative to the total weight of the precursor composition. In some examples, the amount of water present in the precursor composition is about 5 or more weight% (wt%), such as 10 wt% or more, such as 15 wt% or more, such as 20 wt% or more, such as 30 wt% or more relative to the total weight of the precursor composition. In some examples, the amount of water present in the precursor composition may be selected from a range with the upper and lower amounts selected from the values given above. In some examples, the amount of water present in the precursor composition is about 20 to 50 wt%, such as 20 to 45 wt%, such as 20 to 40 wt% relative to the total weight of the precursor composition. In some examples, the amount of water present in the precursor composition is about 25 to 50 wt%, such as 30 to 50 wt% relative to the total weight of the precursor composition. In some examples, the amount of water present in the precursor composition is up to and including 20 wt% relative to the total weight of the precursor composition. In other examples, the amount of water present in the precursor composition is less than 10 wt% relative to the total weight of the precursor composition.

[0049] When the solvent content (for example, water content) is less than 10 wt% relative to the total weight of the precursor composition, this may require a higher amount of other wet ingredients in the precursor composition, such as an increased amount of humectant. A low solvent content may increase the viscosity of the precursor bulk material which is advantageous for the extrusion process (see below).

[0050] In some examples, the precursor composition has a composition according to Table 1. Table 1Component Weight% (wt%) relative to the total weight of the precursor composition Additional cellulose20-25Konjac Mannan1-5Tea (oolong and green)20-25Glycerol18-30Propylene glycol0-5Tobacco extract10-25Other flavourant(s)10-15Solvent20-50

[0051] In some examples, the precursor bodies of the solid aerosol precursor arrangement are formed or formable by extrusion. Advantageously, extrusion may allow for a low or more consistent water content of the solid precursor between different samples, particularly at the point of manufacture. Extrusion may also result in better process control and may allow for continuous production. Continuous production may be beneficial for high speed and large-scale manufacturing. Material waste, costs and lead times may also be reduced. Further beneficially, extrusion may result in an extrudate which may be portioned, cut, wrapped and assembled with minimal handling and increased automation.

[0052] In some examples, the mouthpiece of the consumable comprises a filter element. In use, a user may engage the mouthpiece to create an airflow through the consumable. In particular, the airflow may flow from the solid aerosol arrangement to the mouthpiece, and may exit from the consumable at the mouthpiece. Therefore, when the mouthpiece comprises a filter element, the airflow may pass through the filter element before exiting from the consumable at the mouthpiece, thereby removing any particulates and preventing their inhalation by the user.

[0053] In some examples, the consumable comprises a hollow element, where the hollow element is downstream of the solid aerosol precursor arrangement and upstream of the mouthpiece. The hollow element may be a portion of the consumable comprising no segment. In some examples, the hollow element is bounded by or comprises a paper tube. Advantageously, the hollow element may function as a mixing container, allowing for cooling and mixing of the generated vapour from the solid aerosol precursor arrangement during use. In this way, overheating of the mouthpiece may be prevented or reduced.

[0054] In some examples, the hollow element contains a frangible capsule. In some examples, the frangible capsule is heat activated. In some examples, the heat-activated frangible capsule comprises a capsule shell which may be melted to release the contents of the capsule. In some examples, the frangible capsule is mechanically activated. In some examples, the mechanically activated frangible capsule may be crushed during use to release the contents of the capsule. In this way, flavour delivered to the user may be enhanced since the frangible capsule may contain one or more additional flavourants which may be released during use. The frangible capsule may be held in position adjacent the mouthpiece of the consumable by a support structure. In some examples, the support structure is a paper roll.

[0055] In a second aspect the present disclosure provides a method of preparing the consumable of the first aspect.

[0056] In some examples, the method comprises extruding a precursor slurry to form an extrudate, dividing the extrudate to form at least two extruded bodies, drying the at least two extruded bodies to form a solid aerosol precursor arrangement comprising at least two precursor bodies, and assembling the solid aerosol precursor arrangement into a consumable for an aerosol generating apparatus.

[0057] In this way the uniformity of the solid aerosol precursor arrangement may be improved, and may result in more consistent porosity within the solid precursor arrangement and more consistent shape of the solid precursor arrangement. This may result in a more consistent pressure drop across the precursor arrangement during use across different consumables. Extrusion may also allow for lower and more consistent water content of the precursor bodies, particularly at point of manufacture, as well as potentially resulting in better process control. Further, extrusion may allow for continuous production of the consumable. This may have advantages of high speed and large-scale manufacturing, and reduction in material waste, costs and lead times. Further, extrusion may allow for reduced handing and increased automation of the stick manufacturing process.

[0058] In some examples, the extrudate is divided to form at least two extruded bodies at a mouth of the extruder. A "mouth of the extruder" may be an aperture of the extruder from which the extrudate is expelled. In some examples, the extrudate is divided by a mesh located over the mouth of the extruder, where the pattern of the mesh defines the portions into which the extrudate is separated or divided. During the extrusion process, the precursor slurry is introduced into the extruder and is forced out of the mouth of the extruder, past the mesh. As the slurry passes the mesh, the resulting extrudate is divided into at least two extruded bodies, the extruded bodies corresponding to the pattern of the mesh.

[0059] In some examples, a die of the extruder is adapted to divide the extrudate as it is expelled.

[0060] In some examples, extrusion and division of the extrudate to form at least two extruded bodies occur simultaneously. In other examples, the extrudate is divided to form at least two extruded bodies in a downstream process separate from the extrusion process.

[0061] In some examples, the precursor slurry comprises dry ingredients and wet ingredients. In some examples, the dry ingredients and the wet ingredients are mixed using an extruder to form the precursor slurry. The dry ingredients of the precursor slurry may comprise a fibrous or particulate filler, such as cellulose and / or tea particles. The wet ingredients of the precursor slurry may comprise humectant, flavourants, binding and / or thickening agents and solvent.

[0062] In some examples, the amount of fibrous or particulate filler in the precursor slurry is about 50 wt%. In some examples, the precursor slurry comprises non-tobacco particles in an amount as described herein in relation to the precursor composition of the first aspect.

[0063] In some examples, the humectant includes glycerol (VG) and / or propylene glycol (PG). In some examples, the amount of humectant present in the precursor slurry is as described herein in relation to the precursor composition of the first aspect.

[0064] In some examples, the amount of solvent present in the precursor slurry is as described herein in relation to the precursor of the first aspect. In some examples, the solvent is aqueous. In some examples, the solvent is water.

[0065] When the solvent content (for example, water content) is less than 10 wt% relative to the total weight of the precursor slurry, this may require a higher amount of other wet ingredients in the precursor slurry, such as an increased amount of humectant. A low solvent content may increase the viscosity of the slurry which may be advantageous for the extrusion process.

[0066] The extrusion process may be any extrusion process known to the skilled person. In some examples, the extrusion process may use a single screw extruder. In other examples, the extrusion process may use a twin-screw extruder.

[0067] In some examples, the wet and dry ingredients of the precursor slurry are added to the extruder at different points in the extrusion process. For example, the ingredients may be introduced into the extruder at different points along a barrel of the extruder. In this way, although the ingredients may be introduced into the extruder simultaneously in time, mixing of the ingredients may be staggered as it may take time for the most upstream ingredients to be transported along the barrel such that they can be mixed with the downstream ingredients. Upstream and downstream may be set in accordance with the direction of travel of the precursor slurry in the extruder. In some examples, the raw materials of the precursor slurry may be separated into dry ingredients and wet ingredients as the first and second portions of raw material. In some examples, the first portion comprises the dry ingredients and the second portion comprises the wet ingredients. In some examples, the second portion of raw material is added into the extrusion machine downstream of the first portion of raw material. In some examples, the first portion of raw material is added to the extrusion machine downstream of the second portion of raw material. This staggered approach may ensure complete mixing of the wet and dry ingredients separately. In some examples, such an approach may prevent or reduce or minimise blockages in the extruder.

[0068] In some examples, the first portion comprises dry ingredients and is added upstream of the second portion comprising wet ingredients. In such examples, the dry ingredients have time to mix independently of wet ingredients in the extrusion machine, before becoming mixed with the wet ingredients.

[0069] In some examples, the first portion comprises dry ingredients and is added downstream of the second portion comprising wet ingredients.

[0070] In some examples, the ingredients are introduced into the extruder in the following order, starting from the most upstream to the most downstream: filler, thickening and / or binding agent, solvent, humectant, and finally flavourant. In some examples, the solvent and humectant are added in the same portion.

[0071] In some examples, the precursor slurry is extruded without any applied heat. That is, in some examples, the precursor slurry is extruded at room temperature, which may be between 20-30°C such as 22-26°C. In some examples, the precursor slurry is extruded at an elevated temperature. In this way, the flowability of the precursor slurry may be improved. In some examples, the precursor slurry is extruded at a reduced temperature (under cooling).

[0072] In some examples, the at least two extruded bodies are inserted into an envelope before drying the at least two extruded bodies to form a solid aerosol precursor arrangement comprising at least two precursor bodies. As used herein, the term "envelope" defines a covering or containing structure or layer. In some examples, during drying, the peripheral surface of the at least two extruded bodies adhere to the envelope. In some examples, an adhesive is used to adhere the peripheral surface of the at least two extruded bodies to the envelope. Adhesion of the precursor bodies to the inside surface of the envelope maintains the arrangement of the precursor bodies in the consumable. In some examples, the envelope comprises a rigid material such as card. In some examples, the envelope is a rigid tube, such as a card tube. In some examples, during drying, the at least two extruded bodies of the extrudate shrink to form a gap between the precursor bodies, where the gap extends along the entire axial length of the solid aerosol precursor arrangement. In this way the air flow route through the precursor arrangement may be enhanced, resulting in improved consistency of the pressure drop across the solid aerosol precursor arrangement during use across different consumables.

[0073] In other examples, the at least two extruded bodies are dried to form a solid aerosol precursor arrangement comprising at least two precursor bodies before the solid aerosol precursor arrangement is encased in an envelope. In some examples, the envelope is a wrapper. In these examples, the envelope comprises a less rigid material such as paper, foil or foil-paper laminate. In this way, leaching of water into the envelope may be reduced or avoided. Encasing the solid aerosol precursor arrangement may be carried out by any method known to the skilled person. In some examples, the envelope may be a foil-paper laminate. In some examples, the envelope is paper. In some examples, the envelope comprises a single piece of wrapping which may be folded around the solid aerosol precursor arrangement. In some examples, the envelope comprises two or more pieces of wrapping which may be used to spiral wrap the solid aerosol precursor arrangement. Advantageously, spiral wrapping the precursor arrangement may reduce the amount of overlap of the wrapping (compared with the single piece of wrapping) and so thickness control of the wrapping may be improved. Excessive overlap of the wrapping may lead to an air flow path which may negatively affect the pressure drop across the solid aerosol precursor arrangement.

[0074] In some examples, drying the at least two extruded bodies comprises heating the extruded bodies at a temperature of up to 70 °C, such as up to 60 °C, such as up to 50 °C. In some examples, drying the at least two extruded bodies comprises heating the extruded bodies at a temperature of at least 30°C, such as at least 35 °C or at least 40 °C. Any of these may be combined to form a suitable range. In some examples, drying the at least two extruded bodies comprises heating the extruded bodies to within a range of 40 to 70 °C, such as 40 to 60 °C, such as 40 to 50 °C. In this way, the solvent / water content of the extruded bodies may be reduced, whilst retaining the other components of the precursor composition. In some examples, drying the at least two extruded bodies comprises drying the extruded bodies in line. In some examples, solvent / water content of the extrudate after drying is about 5 to 10 wt% relative to the total weight of the extrudate.

[0075] In some examples, extruding the precursor slurry, dividing the extrudate to form at least two extruded bodies, and drying the at least two extruded bodies to form a solid aerosol precursor arrangement comprising at least two precursor bodies is a continuous process. That is, the extruded bodies may be dried continuously straight after extrusion and division of the extrudate, for example the extruded bodies may be dried continuously in line.

[0076] In some examples, the extrudate is cylindrical. In some examples, the cylindrical extrudate has a diameter of about 6 mm at the point of extrusion. In some examples, the solid aerosol precursor arrangement obtained from a cylindrical extrudate has a total diameter of 6.95-7.00 mm. The increase in diameter of the solid aerosol precursor arrangement compared with the cylindrical extrudate may be due to the compressible nature of the precursor slurry. In the extruder, the precursor slurry may be compressed and the resultant cylindrical extrudate therefore may have the same diameter as the aperture of the mouth of the extruder (for example, 6 mm). Once the extrudate has been expelled from the extruder, the extrudate may expand. Since the extrudate is divided into at least two extruded bodies, as it expands, a gap between the extruded bodies may form. The gap may further increase in size during the drying process forming the solid aerosol precursor arrangement, in which 'shrinking back' of the extruded bodies may be observed. This therefore results in a solid aerosol precursor arrangement with a larger diameter than the cylindrical extrudate from which it is derived from.

[0077] In a third aspect the present disclosure provides a consumable obtained or obtainable by the method of the second aspect.

[0078] In a fourth aspect the present disclosure provides an aerosol generating system comprising a consumable of the first aspect and an aerosol generating unit comprising a heating element, wherein the heating element is configured to heat at least a part of the solid precursor.

[0079] In some examples, the heating element is a penetrative heater configured to penetrate the gap extending between the precursor bodies of the solid aerosol precursor arrangement. Particularly, in examples where the solid aerosol precursor arrangement comprises a plurality of precursor bodies and therefore a plurality of gaps and where the gaps extend in a transverse direction from the central axis of the solid aerosol precursor arrangement to the inside surface of the envelope, the penetrative heater may be located at the centre of the consumable. In some examples, the penetrative heater may be located along the central axis of the solid aerosol precursor arrangement, and extend along the central axis. The penetrative heater may heat the solid aerosol precursor arrangement by conductive heat transfer, and generate an aerosol which is inhaled by the user. Particularly, the use of a penetrative heater may be beneficial for, for example, influencing the airflow through the solid precursor, which may be beneficial for improving the pressure drop across different consumables during use. The effect of the penetrative heater on the airflow may be dependent on, for example, the proximity of the heater to the solid aerosol precursor arrangement and the density of the precursor bodies. Additionally, the use of a penetrative heater may reduce the need for cleaning of the consumable since the heater is enclosed within the solid aerosol precursor arrangement.

[0080] The present disclosure may provide a method of generating an aerosol, which may implement any one or more features disclosed herein. The method may comprise heating the heat-not-burn consumable of the first aspect.

[0081] The present disclosure may provide a use of solid precursor for improving the pressure drop of an aerosol generating segment during use. In some examples, the solid precursor is as described for the first aspect.

[0082] The preceding summary is provided for purposes of summarizing some examples to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the above-described features should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and / or proceeding examples may be combined in any suitable combination to provide further examples, except where such a combination is clearly impermissible or expressly avoided. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following text and the accompanying drawings.BRIEF DESCRIPTION OF THE FIGURES

[0083] Aspects, features and advantages of the present disclosure will become apparent from the following description of examples in reference to the appended drawings in which like numerals denote like elements. Fig. 1 is a block system diagram showing an example aerosol generating apparatus. Fig. 2 is a block system diagram showing an example implementation of the apparatus of Fig. 1, where the aerosol generating apparatus is configured to generate aerosol from a solid precursor. Fig. 3 is a schematic diagram showing an example implementation of the apparatus of Fig. 2. Figs. 4A and 4B are schematic diagrams showing examples of the consumable of the apparatus of Fig. 2. Fig. 5 shows a schematic diagram of the cross section of an example solid aerosol precursor arrangement of the consumable of the apparatus of Fig. 2, where the solid aerosol precursor arrangement comprises two precursor bodies. Fig. 6 shows a schematic diagram of the cross section of an example solid aerosol precursor arrangement of the consumable of the apparatus of Fig. 2, where the solid aerosol precursor arrangement comprises three precursor bodies. Fig. 7 shows a schematic diagram of the cross section of an example solid aerosol precursor arrangement of the consumable of the apparatus of Fig. 2, where the solid aerosol precursor arrangement comprises four precursor bodies. Fig. 8 shows a schematic diagram of the cross section of an example solid aerosol precursor arrangement of the consumable of the apparatus of Fig. 2, where the solid aerosol precursor arrangement comprises eight precursor bodies. Fig. 9 shows a schematic diagram of the cross section of an example solid aerosol precursor arrangement of the consumable of the apparatus of Fig. 2, where the solid aerosol precursor arrangement comprises four precursor bodies and where the gaps separating the precursor bodies vary in width. Fig. 10A shows a schematic diagram of an extrusion process, a step in the method of preparing a consumable, where the extrudate is not divided during the extrusion process. Fig. 10B shows a schematic diagram of an extrusion process, a step in the method of preparing the consumable of the apparatus of Fig. 2, where the extrudate is divided during the extrusion process to form at least two extruded bodies. DETAILED DESCRIPTION OF EMBODIMENTS

[0084] Before describing several examples implementing the present disclosure, it is to be understood that the present disclosure is not limited by specific construction details or process steps set forth in the following description and accompanying drawings. Rather, it will be apparent to those skilled in the art having the benefit of the present disclosure that the systems, apparatuses and / or methods described herein could be embodied differently and / or be practiced or carried out in various alternative ways.

[0085] Unless otherwise defined herein, scientific and technical terms used in connection with the presently disclosed inventive concept(s) shall have the meanings that are commonly understood by those of ordinary skill in the art, and known techniques and procedures may be performed according to conventional methods well known in the art and as described in various general and more specific references that may be cited and discussed in the present specification.

[0086] Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.

[0087] All examples implementing the present disclosure can be made and executed without undue experimentation in light of the present disclosure. While particular examples have been described, it will be apparent to those of skill in the art that variations may be applied to the systems, apparatus, and / or methods and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit, and scope of the inventive concept(s). All such similar substitutions and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the inventive concept(s) as defined by the appended claims.

[0088] The use of the term "a" or "an" in the claims and / or the specification may mean "one," as well as "one or more," "at least one," and "one or more than one." As such, the terms "a," "an," and "the," as well as all singular terms, include plural referents unless the context clearly indicates otherwise. Likewise, plural terms shall include the singular unless otherwise required by context.

[0089] The use of the term "or" in the present disclosure (including the claims) is used to mean an inclusive "and / or" unless explicitly indicated to refer to alternatives only or unless the alternatives are mutually exclusive. For example, a condition "A or B" is satisfied by any of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0090] As used in this specification and claim(s), the words "comprising, "having," "including," or "containing" (and any forms thereof, such as "comprise" and "comprises," "have" and "has," "includes" and "include," or "contains" and "contain," respectively) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[0091] Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, examples, or claims prevent such a combination, the features of examples disclosed herein, and of the claims, may be integrated together in any suitable arrangement, especially ones where there is a beneficial effect in doing so. This is not limited to only any specified benefit, and instead may arise from an "ex post facto" benefit. This is to say that the combination of features is not limited by the described forms, particularly the form (e.g. numbering) of example(s), embodiment(s), or dependency of claim(s). Moreover, this also applies to the phrase "in one embodiment," "according to an embodiment," and the like, which are merely a stylistic form of wording and are not to be construed as limiting the following features to a separate embodiment to all other instances of the same or similar wording. This is to say, a reference to 'an,' 'one,' or 'some' embodiment(s) may be a reference to any one or more, and / or all embodiments, or combination(s) thereof, disclosed. Also, similarly, the reference to "the" embodiment may not be limited to the immediately preceding embodiment. Further, all references to one or more embodiments or examples are to be construed as non-limiting to the claims.

[0092] The present disclosure may be better understood in view of the following explanations, wherein the terms used that are separated by "or" may be used interchangeably: As used herein, an "aerosol generating apparatus" (or "electronic(e)-cigarette" ) may be an apparatus configured to deliver an aerosol to a user for inhalation by the user. The apparatus may additionally / alternatively be referred to as a "smoking substitute apparatus", if it is intended to be used instead of a conventional combustible smoking article. As used herein a combustible "smoking article" may refer to a cigarette, cigar, pipe or other article, that produces smoke (an aerosol comprising solid particulates and gas) via heating above the thermal decomposition temperature (typically by combustion and / or pyrolysis). An aerosol generated by the apparatus may comprise an aerosol with particle sizes of 0.2 - 7 microns, or less than 10 microns, or less than 7 microns. This particle size may be achieved by control of one or more of: heater temperature; cooling rate as the vapour condenses to an aerosol; flow properties including turbulence and velocity. The generation of aerosol by the aerosol generating apparatus may be controlled by an input device. The input device may be configured to be user-activated, and may for example include or take the form of an actuator (e.g. actuation button) and / or an airflow sensor.

[0093] Each occurrence of the aerosol generating apparatus being caused to generate aerosol for a period of time (which may be variable) may be referred to as an "activation" of the aerosol generating apparatus. The aerosol generating apparatus may be arranged to allow an amount of aerosol delivered to a user to be varied per activation (as opposed to delivering a fixed dose of aerosol), e.g. by activating an aerosol generating unit of the apparatus for a variable amount of time, e.g. based on the strength / duration of a draw of a user through a flow path of the apparatus (to replicate an effect of smoking a conventional combustible smoking article).

[0094] The aerosol generating apparatus may be portable. As used herein, the term "portable" may refer to the apparatus being for use when held by a user.

[0095] As used herein, an "aerosol" may include a suspension of precursor, including as one or more of: solid particles; liquid droplets; gas. Said suspension may be in a gas including air. An aerosol herein may generally refer to / include a vapour. An aerosol may include one or more components of the precursor.

[0096] As used herein, a "precursor" may include one or more of a: solid; loose leaf material; other substance. The precursor may be processed by an aerosol generating unit of an aerosol generating apparatus to generate an aerosol. The precursor may include one or more of: an active component; a carrier; a flavouring. The active component may include one or more of nicotine; caffeine; a cannabidiol oil; a non-pharmaceutical formulation, e.g. a formulation which is not for treatment of a disease or physiological malfunction of the human body. The active component may be carried by the carrier, which may be a liquid, including propylene glycol and / or glycerine. The term "flavouring" may refer to a component that provides a taste and / or a smell to the user. The flavouring may include one or more of: Ethylvanillin (vanilla); menthol, Isoamyl acetate (banana oil); or other. The precursor may include a substrate, e.g. reconstituted tobacco to carry one or more of the active component; a carrier; a flavouring.

[0097] As used herein, a "storage portion" may be a portion of the apparatus adapted to store the precursor.

[0098] As used herein, a "flow path" may refer to a path or enclosed passageway through an aerosol generating apparatus, e.g. for delivery of an aerosol to a user. The flow path may be arranged to receive aerosol from an aerosol generating unit. When referring to the flow path, upstream and downstream may be defined in respect of a direction of flow in the flow path, e.g. with an outlet being downstream of an inlet.

[0099] As used herein, a "delivery system" may be a system operative to deliver an aerosol to a user. The delivery system may include a mouthpiece and a flow path.

[0100] As used herein, a "flow" may refer to a flow in a flow path. A flow may include aerosol generated from the precursor. The flow may include air, which may be induced into the flow path via a puff by a user.

[0101] As used herein, a "puff" (or "inhale" or "draw" ) by a user may refer to expansion of lungs and / or oral cavity of a user to create a pressure reduction that induces flow through the flow path.

[0102] As used herein, an "aerosol generating unit" may refer to a device configured to generate an aerosol from a precursor. The aerosol generating unit may include a unit to generate a vapour directly from the precursor (e.g. a heating system or other system) or an aerosol directly from the precursor (e.g. an atomiser including an ultrasonic system, a flow expansion system operative to carry droplets of the precursor in the flow without using electrical energy or other system). A plurality of aerosol generating units to generate a plurality of aerosols (for example, from a plurality of different aerosol precursors) may be present in an aerosol generating apparatus.

[0103] As used herein, a "heating system" may refer to an arrangement of at least one heating element, which is operable to aerosolise a precursor once heated. The at least one heating element may be electrically resistive to produce heat from the flow of electrical current therethrough. The at least one heating element may be arranged as a susceptor to produce heat when penetrated by an alternating magnetic field. The heating system may be configured to heat a precursor to below 300 or 350 degrees C, including without combustion.

[0104] As used herein, a "consumable" may refer to a unit that includes a precursor. The consumable may include an aerosol generating unit, e.g. it may be arranged as a cartomizer. The consumable may include a mouthpiece. The consumable may include an information carrying medium. The capsule / pod may include a storage portion, e.g. a reservoir or tank, for storage of the precursor. With solid material implementations of the precursor, e.g. tobacco or reconstituted tobacco formulation, the consumable may be referred to as a "stick" or "package" or "heat-not-burn consumable". In a heat-not-burn consumable, the mouthpiece may be implemented as a filter and the consumable may be arranged to carry the precursor. The consumable may be implemented as a dosage or pre-portioned amount of material, including a loose-leaf product.

[0105] As used herein "heat-not-burn" (or "HNB" or "heated precursor" ) may refer to the heating of a precursor, typically tobacco, without combustion, or without substantial combustion (i.e. localised combustion may be experienced of limited portions of the precursor, including of less than 5% of the total volume).

[0106] As used herein "solid" refers to a state of matter. It may distinguish from liquid forms such as slurries or solutions, and gaseous forms. Semi-solid forms, such as gels or pastes, may be encompassed by "solid".

[0107] As used herein "slurry" refers to a suspension of solid particles in liquid. It may distinguish from a solution, which has dissolved solute rather than suspended particles.

[0108] As used herein "water-independent binding and / or thickening agent" may refer to a binding and / or thickening agent which does not require water for activation. That is, the presence of water may not be required for the binding and / or thickening agent to increase the viscosity of precursor composition.

[0109] As used herein "about" in relation to a value should be interpreted to include a disclosure of the value mentioned e.g. "about 20%" includes a disclosure of exactly 20%. The value may include up to ±5% of the mentioned value, such as up to ±2% or up to ±1% of the mentioned value.

[0110] Referring to Fig. 1, an example aerosol generating apparatus 1 includes a power supply 2, for supply of electrical energy. The apparatus 1 includes an aerosol generating unit 4 that is driven by the power supply 2. The power supply 2 may include an electric power supply in the form of a battery and / or an electrical connection to an external power source. The apparatus 1 includes a solid aerosol precursor arrangement 6, which in use is aerosolised by the aerosol generating unit 4 to generate an aerosol. The apparatus 2 includes a delivery system 8 for delivery of the aerosol to a user.

[0111] Electrical circuitry (not shown in figure 1) may be implemented to control the interoperability of the power supply 4 and aerosol generating unit 6.

[0112] In variant examples, which are not illustrated, the power supply 2 may be omitted since, e.g. an aerosol generating unit implemented as an atomiser with flow expansion may not require a power supply.

[0113] Fig. 2 shows an implementation of the apparatus 1 of Fig. 1, where the aerosol generating apparatus 1 is configured to generate aerosol by a-heat not-burn process.

[0114] In this example, the apparatus 1 includes a device body 50 and a consumable 70.

[0115] In this example, the body 50 includes the power supply 4 and a heating system 52. The heating system 54 includes at least one heating element 54. The body may additionally include any one or more of electrical circuitry 56, a memory 58, a wireless interface 60, one or more other components 62.

[0116] The electrical circuitry 56 may include a processing resource for controlling one or more operations of the body 50, e.g. based on instructions stored in the memory 58.

[0117] The wireless interface 60 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.

[0118] The other component(s) 62 may include an actuator, one or more user interface devices configured to convey information to a user and / or a charging port, for example (see e.g. Fig. 3).

[0119] The body 50 is configured to engage with the consumable 70 such that the at least one heating element 54 of the heating system 52 penetrates into the solid aerosol precursor arrangement 6 of the consumable. In use, a user may activate the aerosol generating apparatus 1 to cause the heating system 52 of the body 50 to cause the at least one heating element 54 to heat the solid aerosol precursor arrangement 6 of the consumable (without combusting it) by conductive heat transfer, to generate an aerosol which is inhaled by the user.

[0120] Fig. 3 shows an example implementation of the aerosol generating device 1 of Fig. 2.

[0121] As depicted in Fig. 3, the consumable 70 is implemented as a stick, which is engaged with the body 50 by inserting the stick into an aperture at a top end 53 of the body 50, which causes the at least one heating element 54 of the heating system 52 to penetrate into the solid aerosol precursor arrangement 6.

[0122] The consumable 70 includes the solid aerosol precursor arrangement 6 proximal to the body 50, and a filter distal to the body 50. The filter serves as the mouthpiece of the consumable 70 and thus the apparatus 1 as a whole. The solid aerosol precursor arrangement 6 may be a reconstituted tobacco formulation.

[0123] In this example, the at least one heating element 54 is a penetrative heating element. Other heating element shapes are possible, e.g. the at least one heating element may be blade-shaped (with a rectangular transverse profile) or tube-shaped (e.g. with a hollow transverse profile).

[0124] In this example, the body 50 includes a cap 51. In use the cap 51 is engaged at a top end 53 of the body 50. Although not apparent from Fig. 3, the cap 51 is moveable relative to the body 50. In particular, the cap 51 is slidable and can slide along a longitudinal axis of the body 50.

[0125] The body 50 also includes an actuator 55 on an outer surface of the body 50. In this example, the actuator 55 has the form of a button.

[0126] The body 50 also includes a user interface device configured to convey information to a user. Here, the user interface device is implemented as a plurality of lights 57, which may e.g. be configured to illuminate when the apparatus 1 is activated and / or to indicate a charging state of the power supply 4. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.

[0127] The body may also include an airflow sensor which detects airflow in the aerosol generating apparatus 1 (e.g. caused by a user inhaling through the consumable 70). This may be used to count puffs, for example.

[0128] In this example, the consumable 70 includes a flow path which transmits aerosol generated by the at least one heating element 54 to the mouthpiece of the consumable.

[0129] In this example, the aerosol generating unit 4 is provided by the above-described heating system 52 and the delivery system 8 is provided by the above-described flow path and mouthpiece of the consumable 70.

[0130] Fig. 4 shows examples of the consumable of the apparatus of Fig. 2.

[0131] Referring to Fig. 4A, a consumable 70, which may be implemented in any of the preceding examples, comprises a solid aerosol precursor arrangement 6 and a mouthpiece 71 downstream of the precursor arrangement 6. The solid aerosol precursor arrangement 6 has an upstream end 72 and a downstream end 73, defining the axial length of the precursor arrangement 6. The solid aerosol precursor arrangement 6 includes a first precursor body 74 and a second precursor body 75. A gap 76 extends along the entire axial length of the solid aerosol precursor arrangement 6 between the first 74 and second 75 precursor bodies. In use, a user may engage the mouthpiece 71 to create an airflow through the consumable 70. In particular, the airflow may flow from the solid aerosol arrangement 6 to the mouthpiece 71 along a flow path, and may exit from the consumable 70 at the mouthpiece 71. Aerosol may be entrained into the airflow as the airflow flows through a portion of the flow path which is formed by the solid aerosol precursor arrangement 6.

[0132] The solid aerosol precursor arrangement 6 is disposed in an envelope 79. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 79 is arranged around the solid aerosol precursor arrangement 6 and extends along the axial length of the arrangement 6 such that the envelop 79 surrounds the whole of the arrangement.

[0133] The first 74 and second 75 precursor bodies and the mouthpiece 71 are adhered to the envelope 79.

[0134] The gap 76 between the first 74 and second 75 precursor bodies extends across the solid aerosol precursor arrangement 6, when viewed in cross-section, from a first region on the inside surface of the envelope 79 to a second region on the inside surface of the envelope 79. The first region and second region are on opposite sides of the solid aerosol precursor arrangement 6.

[0135] The first 75 and second 75 precursor bodies may have the same precursor composition. The precursor composition is as described herein and may comprise an agglomeration of particles. The precursor composition may comprise non-tobacco particles. The precursor composition may also or alternatively be substantially free of tobacco particles.

[0136] In this example, the mouthpiece 71 of the consumable 70 comprises a filter element 77. The airflow in use passes through the filter element 77 before exiting from the consumable 70 at the mouthpiece 71, thereby removing particulates and preventing their inhalation by the user.

[0137] In this example, the consumable 70 comprises a hollow element 78 downstream of the solid precursor 6 and upstream of the mouthpiece 71. The hollow element 78 may function as a mixing container, allowing for cooling and mixing of the generated vapour from the precursor arrangement 6 and preventing overheating of the mouthpiece 71.

[0138] Referring to Fig. 4B, a consumable 70, which may be implemented in any of the preceding examples, comprises a solid aerosol precursor arrangement 6 and a mouthpiece 71 downstream of the precursor arrangement 6. The solid aerosol precursor arrangement 6 has an upstream end 72 and a downstream end 73, defining the axial length of the precursor arrangement 6.

[0139] The solid aerosol precursor arrangement 6 includes a first precursor body 74, a second precursor body 75 and a third precursor body 710. A gap 76 extends along the entire axial length of the solid aerosol precursor arrangement 6 between the first 74 and second 75 precursor bodies. A second gap 711 extends along the entire axial length of the solid aerosol precursor 6 between the second 75 and third 710 precursor bodies. Although not shown, a third gap extends along the entire axial length of the solid aerosol precursor 6 between the third 710 and first 74 precursor bodies.

[0140] In this example, the solid aerosol precursor arrangement 6 is disposed in an envelope 79. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 79 is arranged around the solid aerosol precursor arrangement 6 and extends along the axial length of the arrangement 6 such that the envelop 79 surrounds the whole of the arrangement.

[0141] The first 74 and second 75 precursor bodies may be adhered to the envelope 79.

[0142] The gap 76 between the first 74 and second 75 precursor bodies and the second gap between the second 75 and third 710 precursor bodies (and the third gap between the third 710 and first 74 precursor bodies that is not shown) also extend across the solid aerosol precursor arrangement 6 from a first region on the inside surface of the envelope 79 to a second region on the inside surface of the envelope 79. The first region and second region are on opposite sides of the solid aerosol precursor arrangement 6.

[0143] The first 75 and second 75 precursor bodies may have the same precursor composition. The precursor composition is as described herein and may comprise an agglomeration of particles. The precursor composition may comprise non-tobacco particles. The precursor composition may also be substantially free of tobacco particles.

[0144] In this example, the mouthpiece 71 of the consumable 70 comprises a filter element 77. In use, a user may engage the mouthpiece 71 to create an airflow through the consumable 70. In particular, the airflow may flow from the solid aerosol precursor arrangement 6 to the mouthpiece 71, and may exit from the consumable 70 at the mouthpiece 71. Therefore, when the mouthpiece 71 comprises a filter element 77, the airflow may pass through the filter element 77 before exiting from the consumable 70 at the mouthpiece 71, thereby removing particulates and preventing their inhalation by the user.

[0145] In this example, the consumable 70 further comprises a hollow element 78 downstream of the solid precursor 6 and upstream of the mouthpiece 71. In this example, the hollow element 78 contains a frangible capsule 712 which is held in position adjacent the mouthpiece 71 by a support structure 713. The frangible capsule 712 may be heat activated or mechanically activated in order to release the contents of the capsule to deliver flavour to the user during use. In this example, the support structure 713 is a paper roll.

[0146] Figs. 5 to 9 show cross sections of example solid aerosol precursor arrangements. In each of these examples, the precursor bodies of each solid aerosol precursor arrangement may have the same precursor composition. The precursor composition is as described herein and may comprise an agglomeration of particles. The precursor composition may comprise non-tobacco particles. The precursor composition may also or alternatively be substantially free of tobacco particles.

[0147] Referring to Fig. 5, the solid aerosol precursor arrangement 6 comprises a first precursor body 74 and a second precursor body 75 and a gap 76 between the first 74 and second 75 precursor body. The first 74 and second 75 precursor body each have the shape of a semi-cylinder. Therefore, in this example, the solid aerosol precursor arrangement 6 has an overall shape of a cylinder.

[0148] In this example, the solid aerosol precursor arrangement 6 is disposed in an envelope 79. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 79 is arranged around the solid aerosol precursor arrangement 6 and extends along the axial length of the arrangement 6 such that the envelop 79 surrounds the whole of the arrangement.

[0149] The first 74 and second 75 precursor bodies are adhered to the envelope 79 and are held by the envelope 70 so that the solid aerosol precursor arrangement 6 has an overall shape of a cylinder.

[0150] Additionally, adhering the first 74 and second 75 precursor bodies to the envelop 79 maintains the gap 76 between the first 74 and second 75 precursor bodies is maintained.

[0151] The gap 76 between the first 74 and second 75 precursor bodies also extends across the solid aerosol precursor arrangement 6 from a first region 715 on the inside surface of the envelope 79 to a second region 716 on the inside surface of the envelope 79.

[0152] Referring to Fig. 6, the solid aerosol precursor arrangement 6 comprises a first precursor body 74, a second precursor body 75 and a third precursor body 710. The solid aerosol precursor arrangement 6 also comprises a gap 76 between the first 74 and second 75 precursor bodies, a second gap 711 between the second 75 and third 710 precursor bodies, and a third gap 717 between the third 710 and first 74 precursor bodies. In this example, the solid aerosol precursor arrangement 6 has an overall shape of a cylinder. In this example, the solid aerosol precursor arrangement 6 is disposed in an envelope 79. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 79 is arranged around the solid aerosol precursor arrangement 6 and extends along the axial length of the arrangement 6 such that the envelop 79 surrounds the whole of the arrangement. The precursor bodies 74, 75, 710 may be adhered to the envelope 79. In this way, the first 76, second 711 and third 717 gaps between the precursor bodies may be maintained. The first 76, second 711 and third 717 gaps extend in different transverse directions from the central axis 714 of the solid aerosol precursor arrangement 6 to the envelope 79. In this example, the width of each gap along the transverse direction from the central axis to the envelope 79 is constant.

[0153] Referring to Fig. 7, the solid aerosol precursor arrangement 6 comprises a first precursor body 74, a second precursor body 75, a third precursor body 710 and a fourth precursor body 718. The solid aerosol precursor arrangement 6 also comprises a gap 76 between the first 74 and second 75 precursor bodies, a second gap 711 between the second 75 and third 710 precursor bodies, a third gap 717 between the third 710 and fourth 718 precursor bodies and a fourth gap 719 between the fourth 718 and first 74 precursor bodies. The first 74, second 75, third 710 and fourth 718 precursor bodies each have the shape of a quarter-cylinder. Therefore, in this example, the solid aerosol precursor arrangement 6 has an overall shape of a cylinder. In this example, the solid aerosol precursor arrangement 6 is disposed in an envelope 79. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 79 is arranged around the solid aerosol precursor arrangement 6 and extends along the axial length of the arrangement 6 such that the envelop 79 surrounds the whole of the arrangement. The precursor bodies 74, 75, 710, 718 may be adhered to the envelope 79. In this way, the first 76, second 711, third 717 and fourth 719 gaps may be maintained. The first 76, second 711, third 717 and fourth 719 gaps extend in different transverse directions from the central axis of the solid aerosol precursor arrangement 6 to the envelope 79 to result in a "cross" shape. In this example, the width of each gap along the transverse direction from the central axis to the envelope 79 is constant.

[0154] Referring to Fig. 8, the solid aerosol precursor arrangement 6 comprises eight precursor bodies and eight gaps, where the gaps extend between the precursor bodies. In this example, the solid aerosol precursor arrangement 6 has an overall shape of a cylinder. In this example, the solid aerosol precursor arrangement 6 is disposed in an envelope 79. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 79 is arranged around the solid aerosol precursor arrangement 6 and extends along the axial length of the arrangement 6 such that the envelop 79 surrounds the whole of the arrangement. The precursor bodies may be adhered to the envelope 79. In this way, the gaps between the precursor bodies may be maintained. The gaps extend in different transverse directions from the central axis of the solid aerosol precursor arrangement 6 to the envelope 79 to results in an "asterisk" shape. In this example, the width of each gap along the transverse direction from the central axis to the envelope 79 is constant.

[0155] Referring to Fig. 9, the solid aerosol precursor arrangement 6 comprises a first precursor body 74, a second precursor body 75, a third precursor body 710 and a fourth precursor body 718. The solid aerosol precursor arrangement 6 also comprises a gap 76 between the first 74 and second 75 precursor bodies, a second gap 711 between the second 75 and third 710 precursor bodies, a third gap 717 between the third 710 and fourth 718 precursor bodies and a fourth gap 719 between the fourth 718 and first 74 precursor bodies. In this example, the solid aerosol precursor arrangement 6 has an overall shape of a cylinder. In this example, the solid aerosol precursor arrangement 6 is disposed in an envelope 79. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 79 is arranged around the solid aerosol precursor arrangement 6 and extends along the axial length of the arrangement 6 such that the envelop 79 surrounds the whole of the arrangement. The precursor bodies 74, 75, 710, 718 may be adhered to the envelope 79. In this way, the first 76, second 711, third 717 and fourth 719 gaps may be maintained. The first 76, second 711, third 717 and fourth 719 gaps extend in different transverse directions from the central axis of the solid aerosol precursor arrangement 6 to the envelope 79. In this example, the width of each gap along the transverse direction decreases from the central axis towards the envelope 79. In other words, each gap is wider at the central axis of the solid aerosol precursor arrangement 6 and narrower at the envelope 79. The width of the gaps at the envelope 79 may be such that the precursor bodies are in contact at the envelope.

[0156] Fig. 10 shows schematic diagrams of the extrusion process, a step in the method of preparing the consumable of Fig. 4.

[0157] Referring to Fig. 10A an extruder 80 is used to extrude the precursor slurry to form an extrudate 81. In this example, the extrudate 81 is cylindrical and unitary. The cylindrical shape of the extrudate 81 may be imparted by the shape of the mouth 82 of the extruder, or by a die. Other shapes of extrudate 81 are possible and known to the skilled person. That is, the cylindrical extrudate 81 is not divided into at least two extruded bodies. In this case, separation of the extrudate 81 to form at least two extruded bodies may be achieved in a downstream process separate from the extrusion process. The extruded bodies are then dried to form a solid aerosol precursor arrangement 6 comprising at least two precursor bodies 74, 75, before being assembled into a consumable 70 for an aerosol generating apparatus. Assembly of the at least two precursor bodies 74,75 into a consumable may involve adhering the precursor bodies to an envelope 79, such that a gap or gaps between the at least two precursor bodies 74, 75 and the overall cylindrical shape of the solid aerosol precursor arrangement is maintained.

[0158] Referring to Fig. 10B an extruder 80 is used to extrude the precursor slurry to form an extrudate 81. In this example, the extrudate 81 is cylindrical. The cylindrical shape of the extrudate 81 may be imparted by the shape of the mouth 82 of the extruder 80, or by a die. Other shapes of extrudate 81 are possible and known to the skilled person. In this example, a mesh 83 is located over the mouth 82 of the extruder 80. This results in a cylindrical extrudate 81 which is divided to form at least two extruded bodies 84. In this example, the division occurs at the point the extrudate 81 is expelled from the mouth 82 of the extruder 80. During the extrusion process, the precursor slurry is introduced into the extruder 80 and is forced out of the mouth 82 of the extruder 80, past the mesh 83. As the slurry passes the mesh 83, the resulting cylindrical extrudate 81 is divided into at least two extruded bodies 84, the extruded bodies corresponding to the pattern of the mesh. In this example, the extrudate 81 is divided into four extruded bodies 84. Each extruded body 84 has the shape of a quarter cylinder. In this example, the extruded bodies 84 are then dried to form a solid aerosol precursor arrangement 6 comprising at least two precursor bodies 74, 75, before being assembled into a consumable 70 for an aerosol generating apparatus. Assembly of the at least two precursor bodies 74,75 into a consumable may involve adhering the precursor bodies to an envelope 79, such that a gap or gaps between the at least two precursor bodies 74, 75 and the overall cylindrical shape of the solid aerosol precursor arrangement is maintained.

[0159] The provision of at least two precursor bodies in the solid aerosol precursor arrangement 6 may provide an air flow route through the precursor arrangement 6 since the precursor bodies may be arranged so as to provide gaps between the bodies as described herein.

Claims

1. A consumable (70) for use with an aerosol generating apparatus comprising: a solid aerosol precursor arrangement (6) and a mouthpiece (71) downstream of the solid aerosol precursor arrangement, the solid aerosol precursor arrangement having an axial length extending from an upstream end (72) to a downstream end (73) of the solid aerosol precursor arrangement, wherein the solid aerosol precursor arrangement includes a plurality of separate precursor bodies including a first precursor body (74) and a second precursor body (75); wherein a gap (76) is formed between the first precursor body and the second precursor body and the gap extends along the entire axial length of the solid precursor arrangement.

2. The consumable of claim 1 or 2, wherein the first precursor body (74) and the second precursor body (75) each have the shape of a cylinder segment.

3. The consumable of claim 2, wherein the first precursor body (74) and the second precursor body (75) each have the shape of a semi-cylinder or a quarter-cylinder.

4. The consumable of any one of claims 1 to 3, wherein the solid aerosol precursor arrangement further includes a third precursor body (710), wherein a second gap (711) is formed between the second precursor body (75) and the third precursor body and a third gap (717) is formed between the third precursor body and the first precursor body (74), wherein the second gap (711) and the third gap extend along the entire axial length of the solid aerosol precursor arrangement, or wherein the solid aerosol precursor arrangement further includes a third precursor body (710) and a fourth precursor body (718), wherein a second gap (711) is formed between the second precursor body (75) and the third precursor body, a third gap (717) is formed between the third precursor body and the fourth precursor body, and a fourth gap (719) is formed between the fourth precursor body and the first precursor body (74), wherein the second gap, the third gap and the fourth gap extend along the entire axial length of the solid precursor arrangement, optionally wherein the third precursor body and the fourth precursor body each have the shape of a quarter-cylinder.

5. The consumable of any one of claims 1 to 4, wherein the solid aerosol precursor arrangement is disposed in an envelope (79), wherein the envelope is arranged around the solid aerosol precursor arrangement and extends along the axial length of the solid aerosol precursor arrangement, optionally wherein precursor bodies are adhered to the inside surface of the envelope.

6. The consumable of claim 5, wherein the gap (76) extends across the solid aerosol precursor arrangement from a first region (715) on the inside surface of the envelope to a second region (716) on the inside surface of the envelope, wherein the first region and the second region are on opposite sides of the solid aerosol precursor arrangement (6).

7. The consumable of claim 5, wherein the solid aerosol precursor arrangement (6) has a central axis (714) extending along the axial length of the solid aerosol precursor arrangement, wherein the gap extends in a first transverse direction from the central axis to the inside surface of the envelope, wherein a second gap extends in a second transverse direction from the central axis to the inside surface of the envelope, and wherein the first transverse direction is different from the second transverse direction.

8. The consumable of any one of claims 1 to 7, wherein the precursor bodies of the solid precursor arrangement (6) comprise a precursor composition, wherein the precursor composition comprises an agglomeration of particles, optionally wherein the first precursor body and the second precursor body have the same precursor composition.

9. The consumable of claim 8, wherein the precursor composition comprises non-tobacco particles, and / or wherein the precursor composition is substantially free of tobacco particles.

10. The consumable of claim 8 or 9, wherein the precursor composition comprises at least one of a tobacco extract, a humectant, a binding agent, or a thickening agent.

11. The consumable of any one of claims 1 to 10, wherein the precursor bodies (74, 75) of the solid precursor arrangement (6) are formed or formable by extrusion.

12. A method of preparing the consumable of any one of claims 1 to 11, the method comprising: extruding a precursor slurry to form an extrudate (81), dividing the extrudate to form at least two extruded bodies (84), drying the at least two extruded bodies to form a solid aerosol precursor arrangement (6) comprising at least two precursor bodies (74, 75), and assembling the solid aerosol precursor arrangement into a consumable for an aerosol generating apparatus, optionally wherein the extrudate is divided to form at least two extruded bodies at a mouth of the extruder (82).

13. The method of claim 12 wherein the at least two extruded bodies (84) are inserted into an envelope (79) before drying the at least two extruded bodies to form a solid precursor arrangement (6) comprising at least two precursor bodies (74, 75), or wherein the at least two extruded bodies are dried to form a solid aerosol precursor arrangement comprising at least two precursor bodies before the solid aerosol precursor arrangement is encased in an envelope.

14. A consumable obtained or obtainable by the method of any one of claims 12 or 13.

15. An aerosol generating system comprising the consumable of any one of claims 1 to 11 and an aerosol generating unit comprising a heating element (54), wherein the heating element is configured to heat at least a part of the solid precursor arrangement, optionally wherein the heating element is a penetrative heating element, configured to penetrate the gap (76) extending through the solid aerosol precursor arrangement.

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