Consumable and method for aerosol generating apparatus

Abstract

A consumable for an aerosol generating apparatus comprising: a mouthpiece (71) for a user to draw on to generate a flow through the consumable, and a solid aerosol precursor (6) which is upstream of the mouthpiece, the solid aerosol precursor having an upstream portion (72) and a downstream portion (73), and an upstream end (74) and a downstream end (75), wherein the upstream portion has one or more upstream flow passages (76) and the downstream portion has one or more downstream flow passages (77), wherein the upstream flow passages are in flow communication with the downstream flow passages and the downstream flow passages are in flow communication with the mouthpiece, wherein the one or more upstream flow passages are arranged to provide a first draw resistance and the one or more downstream flow passages are arranged to provide a second draw resistance, wherein the second draw resistance is greater than the first draw resistance. This may improve the consistency of the pressure drop across the precursor during use across different consumables.

Description

FIELD

[0001] The present disclosure relates to a consumable for an aerosol generating apparatus and a method of preparing 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 there may be a low pressure drop across the precursor if there is an undesired void which allows air to pass through the precursor. This may also result in poor aerosol formation if most of the precursor is bypassed by airflow. On the other hand, the precursor may have a very high pressure drop if a solid plug forms, e.g. as a result of injection, since then air cannot easily pass through the precursor. It is known to use pressure regulators or flow restrictors (for example, filter segments with a small pore size) to improve control of the pressure drop across a 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 for an aerosol generating apparatus. The consumable comprises a solid aerosol precursor. The solid aerosol precursor has an upstream portion and a downstream portion which include one or more upstream flow passages and one or more downstream flow passages, respectively. The upstream flow passages are arranged to provide a first draw resistance and the one or more downstream flow passages are arranged to provide a second draw resistance which is greater than the first draw resistance. The draw resistance may be defined in accordance with ISO / DIS 6565.

[0006] In this way, the downstream portion of the solid aerosol precursor may act as a pressure regulator and may provide a more consistent pressure drop across the solid aerosol precursor across different consumables. By providing a pressure regulator, the pressure drop of a consumable is largely dependent on the pressure regulator rather than the nature of the consumable, and so this allows for greater control of the pressure drop and thus more consistent pressure drop across different consumables. Advantageously, when the pressure regulator is provided by the downstream portion of the solid aerosol precursor itself rather than, or in addition to, an external pressure regulator, the amount of aerosol and flavourant loss from the precursor may be reduced. This is because there is no or less concentration gradient of aerosol and flavourant across the upstream and downstream portions of the solid aerosol precursor since the upstream and downstream portion may have a similar or the same precursor composition. When an external pressure regulator is used, the concentration gradient across the solid aerosol precursor and the external pressure regulator (due to their differing materials) results in a loss of aerosol and / or flavourant to the external pressure regulator when an airflow is created through the consumable. This loss of aerosol and / or flavourant is circumvented by reducing or eliminating the concentration gradient by having the downstream portion of the solid aerosol precursor itself acting as a pressure regulator.

[0007] Additionally, the provision of one or more flow upstream flow passages and the one or more downstream flow passages may enhance the flow path through the solid aerosol precursor. The greater the surface area of the solid aerosol precursor exposed to the airflow, or the greater the total cross-sectional area of the flow passages, the smaller the draw resistance may be.

[0008] The consumable may comprise a mouthpiece. In use, a user may engage the mouthpiece to create an airflow through the consumable. The airflow may exit from the consumable at the mouthpiece, which may provide a downstream end of the consumable. The consumable may further have an upstream end, which may be arranged with at least one air inlet. Generally, the terminology upstream and downstream may be used in accordance with the airflow when the consumable is in use.

[0009] The solid aerosol precursor may be upstream of the mouthpiece. For example, the solid aerosol precursor may be at or towards the upstream end of the consumable.

[0010] The solid aerosol precursor may have an upstream end and a downstream end. The upstream end of the solid aerosol precursor may be arranged at or towards the upstream end of the consumable. The downstream end of the solid aerosol precursor may be arranged towards the downstream end of the consumable, and / or may be arranged towards the mouthpiece.

[0011] The upstream portion of the solid aerosol precursor may define the upstream end of the solid aerosol precursor. The downstream portion of the solid aerosol precursor may define the downstream end of the solid aerosol precursor.

[0012] The upstream portion may be located towards or at the upstream end of the consumable. The downstream portion may be located towards or at the mouthpiece.

[0013] In some examples, the solid aerosol precursor has an axial length extending from the upstream end to the downstream end of the solid aerosol precursor. That is, the upstream end and the downstream end may delimit an axial length of the solid aerosol precursor.

[0014] The upstream flow passages may be in flow communication with the downstream flow passages and the downstream flow passages may be in flow communication with the mouthpiece. In use, airflow drawn through the consumable may, in flow sequence, flow through the upstream flow passages and then flow through the downstream passages, and subsequently be communicated to the mouthpiece.

[0015] In some examples, the ratio of the second draw resistance over the first draw resistance is 2 or more. In some examples, the ratio of the second draw resistance over the first draw resistance is 3 or more. In some examples, the ratio of the second draw resistance over the first draw resistance is 4 or more.

[0016] In some examples, the second draw resistance is from 70 to 100 mmHzO, such as 80 to 100 mmHzO such as 90 to 100 mmH 2 O. In some examples, the second draw resistance is up to and including 100 mmH 2 O. The resistance to draw is measured in accordance with ISO / DIS 6565, where 1 mmWG is equivalent to 1 mmHzO.

[0017] In some examples, the upstream portion has a first axial length and the downstream portion has a second axial length. In some examples, the second axial length is equal to or shorter than the first axial length. In other words, the axial length of the downstream portion may be equal to or shorter than the axial length of the upstream portion. When the axial length of the upstream portion is longer than the downstream portion, this may result in increased aerosol formation. This is because, when the consumable is in use, the upstream portion is heated. When the upstream portion is equal to or longer than the downstream portion of the solid aerosol precursor, the amount of aerosol generated may be maximised since a greater amount of solid aerosol precursor is heated. In some examples, the axial length of the upstream portion may be 11.5 to 12.5 mm, such as 11.5 to 12.0 mm, such as 12.0 mm. In some examples, the axial length of the downstream portion may be 7.5 to 8.5 mm, such as 7.5 to 8.0 mm, such as 8.0 mm.

[0018] The upstream portion of the solid aerosol precursor may have an upstream end and a downstream end. The upstream end of the upstream portion may be located at or towards the upstream end of the solid aerosol precursor. In some examples, the one or more upstream passages extend from the upstream end of the upstream portion of the solid aerosol precursor to the downstream end of the upstream portion of the solid aerosol precursor.

[0019] The downstream portion of the solid aerosol precursor may have an upstream end and a downstream end. The downstream end of the downstream portion may be located at or towards the downstream end of the solid aerosol precursor. In some examples, the one or more downstream flow passages extend from the upstream end of the downstream portion to the downstream end of the downstream portion.

[0020] In some examples, the downstream end of the upstream portion is adjacent the upstream end of the downstream portion. In some examples, the downstream end of the upstream portion is in direct contact with the upstream end of the downstream portion.

[0021] In some examples, the number of upstream flow passages in the upstream portion of the solid aerosol precursor is greater than the number of downstream flow passages in the downstream portion of the solid aerosol precursor.

[0022] In some examples, each of the one or more upstream flow passages defines a cross-sectional area and all of the one of more upstream flow passages define a total upstream cross-sectional area. In some examples, each of the one or more downstream flow passages defines a cross-sectional area and all of the one or more downstream flow passages define a total downstream cross-sectional area. In some examples, the total upstream cross-sectional area is more than the total downstream cross-sectional area.

[0023] In this way, the downstream portion of the solid aerosol precursor may act as a pressure regulator.

[0024] In some examples, all upstream flow passages have the same cross-sectional area. In other words, the cross-sectional area of each upstream flow passage is the same. In some examples, all downstream flow passages have the same cross-sectional area. In other words, the cross-sectional area of each downstream flow passage is the same. In some examples, when the total upstream cross-sectional area is more than the total downstream cross-sectional area, the number of upstream flow passages in the upstream portion of the solid aerosol precursor is more than the number of downstream flow passages in the downstream portion of the solid aerosol precursor.

[0025] In some examples, the one or more upstream flow passages are circular in cross-section. In some examples, the one or more downstream flow passages are circular in cross-section. In some examples, both the one or more upstream flow passages and the one or more downstream flow passages are circular in cross-section.

[0026] In some examples, the one or more upstream flow passages have a diameter of up to about 1.5 mm, such as up to about 1.25 mm, such as up to about 1 mm. In some examples, the one or more upstream flow passages have a diameter of about 0.5 mm or more, such as 0.75 mm or more, such as about 1 mm or more. In some examples, the one or more upstream flow passages have a diameter selected from a range with the upper and lower amounts selected from the values given above. In some examples, the one or more upstream flow passages have a diameter of from 0.5 to 1.5 mm, such as 0.75 to 1.5 mm, such as 1 to 1.5 mm, such as 1.25 to 1.5 mm. In some examples, the diameter of the one or more upstream flow passages is up to and including 1.5 mm.

[0027] In some examples, the diameter of the one or more downstream flow passages is dependent on the arrangement of the downstream flow passages and the extent to which the one or more downstream flow passages are contiguous with the one or more upstream flow passages.

[0028] In some examples, the diameter of each of the one or more downstream flow passages and / or each of the one or more upstream flow passages is constant along the axial length of the respective downstream or upstream portion of the solid aerosol precursor. In some examples, the diameter of the one or more downstream flow passages and / or the one or more downstream flow passages may not be constant along the axial length of the respective downstream or upstream portion of the solid aerosol precursor. For example, the diameter of each of the one or more downstream flow passages and / or each of the one or more upstream flow passages may decrease towards a downstream end of the respective downstream or upstream portion of the solid aerosol precursor. In other words, each of the one or more downstream flow passages and / or each of the one or more upstream flow passages may taper towards a downstream end of the respective downstream or upstream portion of the solid aerosol precursor. In other examples, the diameter of each of the one or more downstream flow passages and / or each of the one or more upstream flow passages may widen from an upstream end to a downstream end of the respective downstream or upstream portion of the solid aerosol precursor.

[0029] In some examples, the one or more upstream flow passages and the one or more downstream flow passages are arranged in pairs of flow passages. Each pair may consist of an upstream flow passage and a downstream flow passage and may be arranged to form a continuous flow passage from the upstream end to the downstream end of the solid aerosol precursor. That is to say, the downstream end of the upstream flow passages and the upstream end of the downstream flow passages correspond such that a continuous flow passage extending from the upstream end to the downstream end of the solid aerosol precursor is formed.

[0030] In some examples, the solid aerosol precursor has one upstream flow passage and one downstream flow passage. The upstream and downstream flow passage may be arranged such that a single continuous flow passage extending from the upstream end to the downstream end of the solid aerosol precursor is formed. In these examples, the diameter of the single continuous flow passage may decrease towards the downstream end of the solid aerosol precursor. In other words, the single continuous flow passage tapers towards a downstream end of the solid aerosol precursor. In other examples, the diameter of the one upstream flow passage making up the single continuous flow passage may taper from an upstream end to a downstream end of the upstream portion, but the diameter of the one downstream flow passage making up the single continuous flow passage may be constant along the downstream portion.

[0031] In some examples, the solid aerosol precursor has a plurality of upstream flow passages and one downstream flow passage. The plurality of upstream flow passages and the downstream flow passage are arranged such that the upstream flow passages correspond with the downstream flow passage. In this way, continuous flow passages extending from the upstream end to the downstream end of the solid aerosol precursor are formed.

[0032] In some examples, the solid aerosol precursor comprises a precursor composition, where the precursor composition is an agglomeration of particles.

[0033] In some examples, the upstream portion and the downstream portion of the solid aerosol precursor have the same precursor composition.

[0034] 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 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. In some examples, dry mass tobacco does not encompass tobacco extract or tobacco essence.

[0035] 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. 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.

[0036] 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 some 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.

[0037] For example, when the precursor composition comprises cellulose particles and tea particles, the precursor may be 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.

[0038] In some examples, the amounts of cellulose particles and tea particles in the precursor composition is equal. In other examples, the amounts of cellulose particles and tea particles in the precursor composition is not equal.

[0039] In some examples, the precursor composition comprises a flavourant, such as tobacco extract or other plant extracts. The flavourant may provide flavour and odour to the solid aerosol 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.

[0040] In some examples, the precursor composition comprises a humectant. In some examples, the humectant comprises propylene glycol (PG) and / or glycerol (VG). In some examples, the amount of humectant present in the precursor composition may be 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.

[0041] In some examples, the precursor composition comprises a binding agent, which may act as a thickening agent, or 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 orxanthan 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 binding and / or thickening agent may be a binding and / or 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.

[0042] 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 5 wt% 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 is 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 around 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 around 25 to 50 wt%, such as 30 to 50 wt% relative to the total weight of the precursor composition.

[0043] 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 wt% or more, such as 10 or more wt%, 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 is 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 around 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 around 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.

[0044] 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 flavourants10-15Solvent20-50

[0045] In some examples, the upstream portion and / or the downstream portion of the solid aerosol precursor are formed or formable by extrusion. Advantageously, extrusion may allow for a low or more consistent water content of the solid aerosol precursor, particularly at the point of manufacture. Extrusion may also result in better process control and allows for continuous production. Continuous production may be beneficial as it may have the advantages of high speed and large-scale manufacturing. Material waste, costs and lead times may also be reduced. Further beneficially, extrusion may result in a solid aerosol precursor which can be portioned, cut, wrapped and assembled with minimal handling and increased automation.

[0046] In some examples, the solid aerosol precursor is disposed in an envelope. As used herein, the term "envelope" defines a covering or containing structure or layer. The envelope may be arranged around the solid aerosol precursor and may extend along the axial length of the solid aerosol precursor. In some examples, the envelope extends along the entire axial length of the solid aerosol precursor. In some examples, the envelope surrounds the whole of the solid aerosol precursor. In this way, the envelope may encase the solid aerosol precursor and improve handleability of the solid aerosol precursor before it is assembled into a consumable for an aerosol generating apparatus.

[0047] In some examples, the envelope comprises a rigid material such as card. In some examples, the envelope is a tube, such as a card tube. In other examples, the envelope comprises a less rigid material such as paper, foil or foil-paper laminate. In some examples, the envelope is a wrapper, such as a foil-paper laminate wrapper. In some examples, the envelope comprises a single piece of wrapping (such as foil-paper laminate or paper) which may be folded around the solid aerosol precursor. In some examples, the envelope comprises two or more pieces of wrapping which may be used to spiral wrap the solid aerosol precursor. Advantageously, spiral wrapping the solid aerosol precursor may reduce the amount of overlap of the envelope (compared with the single piece of wrapping) and so thickness control of the envelope may be improved. Excessive overlap of the envelope may lead to a flow path which may negatively affect the pressure drop across the solid aerosol precursor.

[0048] In some examples, the consumable comprises a hollow element, where the hollow element is downstream of the solid aerosol precursor and upstream of the mouthpiece. That is, the hollow element may be a portion of the consumable comprising no segment. In some examples, the hollow element is bound 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 during use. In this way, overheating of the mouthpiece may be prevented.

[0049] 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 is 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.

[0050] In some examples, the consumable may comprise an external pressure regulator. In some examples, the external pressure regulator comprises a filter. In some examples, the filter comprises one or more bores. The use of an external pressure regulator in addition to downstream portion acting as a pressure regulator may increase the tolerance of the solid aerosol precursor for variation in e.g., formulation, size, shape and porosity. This is because these factors may have less of an impact on the pressure drop across the precursor.

[0051] In some examples, the external pressure regulator is downstream of the solid aerosol precursor. In some examples, the external pressure regulator is located in the hollow element.

[0052] In some examples, the mouthpiece 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 precursor 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 undesirable particulates and preventing their inhalation by the user.

[0053] In a second aspect the present disclosure provides a method of preparing the consumable of the first aspect.

[0054] In some examples, the method comprises forming the solid aerosol precursor having an upstream portion and a downstream portion, and arranging the solid aerosol precursor into an envelope to form a consumable for an aerosol generating apparatus.

[0055] In some examples, forming the solid aerosol precursor having an upstream portion and a downstream portion includes forming one or more upstream flow passages in the upstream portion and forming one or more downstream flow passages in the downstream portion. In some examples, the upstream flow passages are in flow communication with the downstream flow passages and the downstream flow passages are in flow communication with the mouthpiece. In some examples, the one or more upstream flow passages are arranged to provide a first draw resistance and the one or more downstream flow passages are arranged to provide a second draw resistance, where the second draw resistance is greater than the first draw resistance. The draw resistance may be defined in accordance with ISO / DIS 6565.

[0056] In this way, the downstream portion of the solid aerosol precursor may act as a pressure regulator and may provide a more consistent pressure drop across the solid aerosol precursor across different consumables.

[0057] In some examples, the upstream and / or downstream portions of the solid aerosol precursor is formed by extruding a slurry of precursor composition.

[0058] In some examples, the slurry of precursor composition 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, thickening agents and / or solvent.

[0059] 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 precursor composition the first aspect.

[0060] 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 precursor composition of the first aspect.

[0061] In some examples, the amount of solvent present in the precursor slurry is as described herein in relation to the precursor composition of the first aspect. In some examples, the solvent may be aqueous. In some examples, the solvent is water. 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 is advantageous for the extrusion process.

[0062] In some examples, the extrusion process uses a single screw extruder. In other examples, the extrusion process uses a twin-screw extruder.

[0063] 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 are 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, mixing of the ingredients may be staggered as it takes 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 wet ingredients are added to the extruder further upstream than the dry ingredients. Separate addition may allow for the wet ingredients to be thoroughly mixed before mixing with the dry ingredients, and similarly may allow for the dry ingredients to be thoroughly mixed before mixing with the wet ingredients. This ensures complete mixing of the wet ingredients, and the dry ingredients, before the wet and dry ingredients are mixed. In this way, blockages in the extruder may be prevented, reduced or minimised. In some examples, the ingredients may be introduced into the extruder in the following order, starting from the most upstream to the most downstream: solvent, humectant, fibrous or particulate filler, thickening agent, and finally flavourants.

[0064] 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).

[0065] In some examples, assembling the solid aerosol precursor into a consumable for an aerosol generating apparatus comprises inserting the upstream portion and downstream portions into an envelope, and drying the upstream and downstream portions. In some examples, during drying, the upstream portion and / or the downstream portion adhere to the envelope. In some examples, an adhesive is used to adhere the upstream portion and / or the downstream portion to the envelope. In some examples, the envelope may have any of the features as described above in relation to the first aspect. In some examples, the envelope comprises a tube, such as a card tube. Therefore, in some examples, assembling the solid aerosol precursor into a consumable for an aerosol generating apparatus comprises inserting the upstream and downstream portions into a tube, and drying the upstream and downstream portions.

[0066] In other examples, assembling the solid aerosol precursor into a consumable for an aerosol generating apparatus comprises drying the upstream and downstream portion and wrapping the solid aerosol precursor in an envelope. In this way, leaching of water into the wrapping may be avoided, reduced or minimised. In some examples, the envelope has any of the features as described above in relation to the first aspect. In some examples, the envelope is a foil-paper laminate. In some examples, the envelope is paper. In some examples, the envelope comprises a single piece of wrapping (such as foil-paper laminate or paper) which may be folded around the solid aerosol precursor. In some examples, the envelope comprises two or more pieces of wrapping which may be used to spiral wrap the solid aerosol precursor. Advantageously, spiral wrapping the solid aerosol precursor may reduce the amount of overlap of the envelope (compared with the single piece of wrapping) and so thickness control of the envelope may be improved. Excessive overlap of the envelope may lead to a flow path which may negatively affect the pressure drop across the solid aerosol precursor.

[0067] In some examples, drying the upstream and downstream portions comprises heating the portions 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 upstream and downstream portions comprises heating the portions at a temperature of at least 30 °C, such as at least 35 °C or at least 40 °C. In some examples, drying the upstream and downstream portions comprises heating the portions at a temperature of 40 to 70 °C, such as 40 to 60 °C. In this way, the water content of the solid aerosol precursor may be reduced, whilst retaining the other components of the precursor composition. In some examples, solvent / water content of the upstream and / or downstream portions of the solid aerosol precursor after drying is around 5 to 10 wt% relative to the total weight of the respective portion of the solid aerosol precursor.

[0068] In some examples, drying the upstream and downstream portions comprises drying the sectors in line. In examples where the upstream and / or downstream portion of the solid aerosol precursor is formed by extruding a slurry of precursor composition, extruding the precursor slurry and drying the upstream and downstream portions may be a continuous process. That is, the upstream and downstream portions may be dried continuously straight after extrusion, for example the upstream and downstream portions may be dried continuously in line.

[0069] In some examples, the solvent content of the upstream and / or downstream portion of the solid aerosol precursor after drying is up to about 10 weight% (wt%), such as up to about 9 wt%, such as up to about 8 wt% relative to the total weight of the upstream and / or downstream portion of the solid aerosol precursor after drying, respectively. In some examples, the solvent content of the upstream and / or downstream portion of the solid aerosol precursor after drying is about 5 wt% or more, such as about 7 wt% or more relative to the total weight of the upstream and / or downstream portion of the solid aerosol precursor after drying, respectively. In some examples, the solvent content of the upstream and / or downstream portion of the solid aerosol precursor after drying is selected from a range with the upper and lower amounts selected from the values given above. In some examples, the solvent content of the upstream and / or downstream portion of the solid aerosol precursor after drying is 5 to 10 wt%, such as 7 to 10 wt%, such as 9 to 10 wt % relative to the total weight of the upstream and / or downstream portion of the solid aerosol precursor after drying, respectively.

[0070] In some examples, the upstream and / or downstream portions of the solid aerosol precursor is formed by injecting a slurry of precursor composition into an envelope. In some examples, the envelope is a tube, such as a card tube. In these examples, drying of the upstream and downstream portions of the solid aerosol precursor occurs after injection of the slurry into the envelope.

[0071] In a third aspect the present disclosure provides a consumable for an aerosol generating apparatus obtained or obtainable by the method of the second aspect.

[0072] In a fourth aspect the present disclosure provides an aerosol generating system comprising the consumable of the first aspect and an aerosol generating unit comprising a heating element.

[0073] In some examples, the heating element may extend in the upstream portion of the solid aerosol precursor and may not extend in the downstream portion of the solid aerosol precursor. The heater may heat the solid aerosol precursor by conductive heat transfer.

[0074] By only extending into the upstream portion of the solid aerosol precursor, and thus by heating only the upstream portion, the upstream portion of the solid aerosol precursor may act as a precursor, whilst the non-heated downstream portion of the solid aerosol precursor may act as a pressure regulator. This may allow for a reduction in the loss of aerosol and flavourants from the precursor, and may improve the consistency of the pressure drop across different consumables.

[0075] In some examples, the heating element may be in direct contact with the upstream portion of the solid aerosol precursor. In some examples, the heating element may be separated from the upstream portion of the solid precursor and the upstream portion may be heated by the radiant heat of the heating element.

[0076] In a fifth aspect the present disclosure provides a use of the aerosol generating system of the fourth aspect, to reduce loss of aerosol and / or flavourant from the solid aerosol precursor.

[0077] In a sixth aspect the present disclosure provides a use of the aerosol generating system of the fourth aspect, to provide a more consistent pressure drop across the solid aerosol precursor.

[0078] The uses of the fifth or sixth aspects may be provided when a user inhales through the mouthpiece.

[0079] 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

[0080] 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 aerosol precursor. Fig. 3 is a schematic diagram showing an example implementation of the apparatus of Fig. 2. Figs. 4-6 are schematic diagrams showing example consumables of the apparatus of Fig. 2. DETAILED DESCRIPTION OF EMBODIMENTS

[0081] 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.

[0082] 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.

[0083] Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.

[0084] 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.

[0085] 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.

[0086] 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).

[0087] 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.

[0088] 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.

[0089] 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.

[0090] 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).

[0091] 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.

[0092] 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.

[0093] As used herein, a "precursor" may include one or more of a: solid; gel; 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.

[0094] As used herein, a "storage portion " may be a portion of the apparatus adapted to store the precursor.

[0095] 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.

[0096] 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.

[0097] 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.

[0098] 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.

[0099] 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.

[0100] 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.

[0101] 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. With solid precursors, 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.

[0102] 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).

[0103] 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".

[0104] 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.

[0105] 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.

[0106] 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 precursor 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.

[0107] Electrical circuitry (not shown in figure 1) may be implemented to control the interoperability of the power supply 4 and aerosol generating unit 6.

[0108] 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.

[0109] 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.

[0110] In this example, the apparatus 1 includes a device body 50 and a consumable 70.

[0111] 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.

[0112] 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.

[0113] The wireless interface 60 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.

[0114] 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).

[0115] 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 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 6 of the consumable (without combusting it) by conductive heat transfer, to generate an aerosol which is inhaled by the user.

[0116] Fig. 3 shows an example implementation of the aerosol generating device 1 of Fig. 2.

[0117] 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 6.

[0118] The consumable 70 includes the solid aerosol precursor 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 6 may be a reconstituted tobacco formulation.

[0119] In this example, the at least one heating element 54 is a rod-shaped element with a circular transverse profile. 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).

[0120] 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.

[0121] 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.

[0122] 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.

[0123] 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.

[0124] 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.

[0125] 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.

[0126] Fig. 4 shows an example of the consumable that may be used in the apparatus of Fig. 2.

[0127] Referring to Fig. 4, a consumable 70, which may be implemented in any of the preceding examples, comprises a mouthpiece 71 and a solid aerosol precursor 6 which is upstream of the mouthpiece 71. In use, the user may draw on the mouthpiece 71 to generate an airflow through the consumable. Generally, the terminology upstream and downstream may be used in accordance with the airflow when the consumable is in use.

[0128] The solid aerosol precursor 6 has an upstream portion 72 and a downstream portion 73. In this example, the axial length of the upstream portion 72 and the axial length of the downstream portion 73 are approximately equal. The upstream and downstream portions of the solid aerosol precursor 6 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.

[0129] The upstream portion 72 of the solid aerosol precursor 6 has one or more upstream flow passages 76 extending from an upstream end of the upstream portion to a downstream end of the upstream portion. In this example, the upstream portion 72 has three upstream flow passages 76. The downstream portion 73 of the solid aerosol precursor 6 has one or more downstream flow passages 77 extending from an upstream end of the downstream portion to a downstream end of the downstream portion. In this example, the downstream portion 73 has two downstream flow passages 77. Therefore, in this example, the number of upstream flow passages is greater than the number of downstream flow passages.

[0130] The upstream flow passages 76 are in flow communication with the downstream flow passages 77, and the downstream flow passages 77 are in flow communication with the mouthpiece 71. In use airflow drawn through the consumable 70 may, in flow sequence, flow through the upstream flow passages 76 and then flow through the downstream passages 77, and subsequently be communicated to the mouthpiece 71. The upstream flow passages 76 are arranged to provide a first draw resistance and the downstream flow passages 77 are arranged to provide a second draw resistance, where the second draw resistance is greater than the first draw resistance. For example, the ratio of the second resistance to draw over the first resistance to draw may be 2 or more, or 3 or more, or 4 or more. Preferably, the second resistance to draw is from 70 to 100 mmHzO. In this way, the downstream portion may act as a pressure regulator and may provide a more consistent pressure drop across the solid aerosol precursor. Additionally, the use of the downstream portion as the pressure regulator reduces the amount of aerosol and / or flavourant lost when the consumable is in use compared with when an external pressure regulator is used.

[0131] In Fig. 4, the diameter of the upstream flow passages 76 is constant in the upstream portion 72, and each upstream flow passage 76 has the same diameter. The diameter of the upstream flow passages 76 in the upstream portion 72 may have any value from 0.5 to 1.5 mm. In this example, the cross-sectional area of each upstream flow passage 76 is the same.

[0132] In the example of the consumable 70 shown in Fig. 4, the diameter of the downstream flow passages 76 is constant in the downstream portion 72, and each downstream flow passage 77 has the same diameter. In this example, the cross-sectional area of each downstream flow passage 77 is the same.

[0133] In this example, the upstream flow passages 76 are not contiguous with the downstream flow passages 77.

[0134] Other numbers and configurations of upstream and downstream flow passages to that shown in the specific arrangement of Fig. 4 are possible. The provision of one or more upstream flow passages and one or more downstream flow passages may enhance the flow path through the solid aerosol precursor.

[0135] In this example, the solid aerosol precursor 6 is disposed in an envelope 78. The envelope 78 may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 78 is arranged around the solid aerosol precursor 6 and extends along the axial length of the precursor 6 such that the envelope 78 surrounds the whole of the precursor. The solid aerosol precursor 6 may be adhered to the envelope 78, e.g., using a suitable adhesive.

[0136] In this example, the mouthpiece 71 of the consumable 70 comprises a filter element 79. When the mouthpiece 71 comprises a filter element 79, in use airflow may pass through the filter element 79 before exiting from the consumable 70 at the mouthpiece 71, thereby removing undesirable particulates and preventing their inhalation by the user. In this example, the consumable 70 further comprises a hollow element 710 downstream of the solid precursor 6 and upstream of the mouthpiece 71. The hollow element 710 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.

[0137] Referring to Fig. 5, a variant of the consumable 70 described in relation to Fig. 4 is illustrated. The consumable shown in Fig. 5 shares features with the consumable described with reference to Fig. 4, and detailed description thereof is omitted.

[0138] In this example, the upstream portion 72 of the solid aerosol precursor 6 has one upstream flow passage 76 extending from an upstream end of the upstream portion to a downstream end of the upstream portion. The downstream portion 73 of the solid aerosol precursor 6 has one downstream flow passage 76 extending from an upstream end of the downstream portion to a downstream end of the downstream portion. In this example, the upstream flow passage 76 and the downstream flow passage 77 are arranged such that a single continuous flow passage extending from the upstream end 74 to the downstream end 75 of the solid aerosol precursor 6 is formed. In use airflow drawn through the consumable 70 may, in flow sequence, flow through the upstream flow passage 76 and then flow through the downstream passage 77, and subsequently be communicated to the mouthpiece 71. The upstream flow passage 76 is arranged to provide a first draw resistance and the downstream flow passage 77 is arranged to provide a second draw resistance, where the second draw resistance is greater than the first draw resistance.

[0139] In this example, the diameter of the upstream flow passage 76 tapers from the upstream end of the upstream portion 72 to the downstream end of the upstream portion 72, such that the diameter at the downstream end of the upstream portion is the same as the diameter of the downstream flow passage 77. The diameter of the upstream portion 72 at its widest point in the upstream portion 72 may be up to and including 1.5 mm. The diameter of the downstream flow passage 77 is constant along the downstream portion 73. Since the diameter of the upstream flow passage at its widest point is larger than the diameter of the downstream passage, and the axial length of the upstream portion and the downstream portion are approximately equal, the total cross-sectional area of the upstream flow passage 76 is greater than the total cross-sectional area of the downstream flow passage 77. The ratio of the second resistance to draw to the first resistance to draw may be 2 or more, or 3 or more, or 4 or more. Preferably, the second resistance to draw is from 70 to 100 mmHzO. In this way, the downstream portion may act as a pressure regulator and may provide a more consistent pressure drop across the solid aerosol precursor.

[0140] Referring to Fig. 6, a variant of the consumable 70 described in relation to Fig. 4 is illustrated. The consumable shown in Fig. 6 shares features with the consumable described with reference to Fig. 4, and detailed description thereof is omitted.

[0141] In this example, the hollow element 710 contains a frangible capsule 711 which is held in position adjacent the mouthpiece 71 by a support structure 712, downstream of the solid aerosol precursor 6. The frangible capsule 711 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 712 is a paper roll.

[0142] In use, each of the examples shown in Figs. 4-6 may be heated by a heating element. Such heating may be "outside-in" (i.e., a heating element external to the consumable) or "inside-out" (i.e., a penetrative heating element). When the heating element is a penetrative heating element, the heating element may be configured to extend in the upstream portion 72 of the solid aerosol precursor 6, and may terminate in the upstream portion 72 such that the heating element does not extend into the downstream portion 73 of the solid aerosol precursor 6. In use, the upstream portion may act as a precursor, whilst the downstream portion 73 may act as a pressure regulator. This may allow for a reduction in the loss of aerosol and flavourants from the precursor, and may improve the consistency of the pressure drop across different consumables.

[0143] The upstream and / or downstream portion of the solid aerosol precursor 6 of each of the examples shown in Figs. 4-6 may be formed by extruding a slurry of precursor composition. Advantageously, extrusion may allow for a low or more consistent water content of the solid aerosol precursor, particularly at the point of manufacture. Extrusion may also result in better process control and allows for continuous production. Continuous production may be beneficial as it may have the advantages of 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 can be portioned, cut, wrapped and assembled with minimal handling and increased automation. In each of the examples, assembling the solid aerosol precursor into a consumable for an aerosol generating apparatus comprises inserting the portions 72, 73 into an envelope such as a card tube, and drying the portions to form a solid aerosol precursor. Alternatively, the portions may be formed by injecting a slurry of precursor composition into an envelope.

Claims

1. A consumable (70) for an aerosol generating apparatus comprising: a mouthpiece (71) for a user to draw on to generate a flow through the consumable, and a solid aerosol precursor (6) which is upstream of the mouthpiece, wherein the solid aerosol precursor has an upstream end (74) and a downstream end (75); the solid aerosol precursor having an upstream portion (72) and a downstream portion (73); wherein the upstream portion has one or more upstream flow passages (76) and the downstream portion has one or more downstream flow passages (77); wherein the upstream flow passages are in flow communication with the downstream flow passages and the downstream flow passages are in flow communication with the mouthpiece; wherein the one or more upstream flow passages are arranged to provide a first draw resistance and the one or more downstream flow passages are arranged to provide a second draw resistance; wherein the second draw resistance is greater than the first draw resistance.

2. The consumable of claim 1, wherein a ratio of the second draw resistance over the first draw resistance is 2 or more, and / or wherein the second draw resistance is from 70 to 100 mmH2O.

3. The consumable of claim 1 or 2, wherein the upstream portion (72) has a first axial length and the downstream portion (73) has a second axial length, wherein the second axial length is equal to or shorter than the first axial length.

4. The consumable of any one of claims 1 to 3, wherein the one or more upstream flow passages (76) extend from an upstream end of the upstream portion to a downstream end of the upstream portion and / or the one or more downstream flow passages (77) extend from an upstream end of the downstream portion to a downstream end of the downstream portion.

5. The consumable of any one of claims 1 to 4, wherein each of the one or more upstream flow passages (76) defines a cross-sectional area and all of the one or more upstream flow passages define a total upstream cross-sectional area; wherein each of the one or more downstream flow passages (77) defines a cross-sectional area and all of the one or more downstream flow passages define a total downstream cross-sectional area; wherein the total upstream cross-sectional area is more than the total downstream cross-sectional area.

6. The consumable of any one of claims 1 to 5, all upstream flow passages (76) have the same cross-sectional area and / or wherein all downstream flow passages (77) have the same cross-sectional area.

7. The consumable of any one of claims 1 to 6, wherein the one or more upstream flow passages (76) and / or the one or more downstream flow passages (77) are circular in cross-section, optionally wherein the diameter of the one or more upstream flow passages is from 0.5 to 1.5 mm.

8. The consumable of any one of claims 1 to 7, wherein the one or more upstream flow passages (76) and the one or more downstream flow passages (77) are arranged in pairs of flow passages, each pair consisting of an upstream flow passage and a downstream flow passage arranged to form a continuous flow passage from the upstream end (74) to the downstream end (75) of the solid aerosol precursor; optionally wherein the solid aerosol precursor has one upstream flow passage and has one downstream flow passage, wherein the upstream flow passage and downstream flow passage are arranged such that a single continuous flow passage extending from the upstream end to the downstream end of the solid aerosol precursor is formed.

9. The consumable of any one of claims 1 to 8, wherein the solid aerosol precursor (6) comprises a precursor composition, wherein the precursor composition is an agglomeration of particles, optionally wherein the upstream portion (72) and downstream portion (73) of the solid aerosol precursor comprise the same precursor composition.

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

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

12. The consumable of any of claims 1 to 11, wherein the solid aerosol precursor (6) is disposed in an envelope (78).

13. A method of preparing the consumable (70) of any one of claims 1 to 12, the method comprising: forming the solid aerosol precursor (6) having an upstream portion (72) and a downstream portion (73), including: forming one or more upstream flow passages (76) in the upstream portion and forming one or more downstream flow passages (77) in the downstream portion; wherein the upstream flow passages are in flow communication with the downstream flow passages and the downstream flow passages are in flow communication with the mouthpiece; wherein the one or more upstream flow passages are arranged to provide a first draw resistance and the one or more downstream flow passages are arranged to provide a second draw resistance; wherein the second draw resistance is greater than the first draw resistance; arranging the solid aerosol precursor into an envelope to form a consumable for an aerosol generating apparatus, optionally wherein upstream and / or downstream portion of the solid aerosol precursor is formed by extruding a slurry of precursor composition.

14. An aerosol generating system comprising the consumable (70) of any one of claims 1 to 12 and an aerosol generating unit comprising a heating element (54), wherein the heating element extends in the upstream portion (72) of the solid aerosol precursor and does not extend in the downstream portion (73) of the solid aerosol precursor.

15. A use of the aerosol generating system of claim 14, to reduce loss of aerosol and / or flavourant from the solid aerosol precursor (6), and / or to provide a more consistent pressure drop across the solid aerosol precursor, optionally when a user inhales through the mouthpiece (71).

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