Aerosol generating segment

Abstract

The disclosure relates to an aerosol generating segment for a heat-not-burn consumable, a heat-not-burn consumable comprising the aerosol generating segment, a method of preparing an aerosol generating segment and use of the aerosol generating segment or heat-not-burn consumable. The aerosol generating segment comprises one or more sheets of an aerosol forming material, wherein the aerosol forming material comprises a carrier material and an aerosol forming liquid; wherein a first portion of the aerosol forming material has a first concentration of the aerosol forming liquidand a second portion of the aerosol forming material has a second concentration of the aerosol forming liquid, wherein the first concentration is greater than the second concentration.

Description

FIELD

[0001] The present disclosure relates to aerosol generating segment for a heat-not-burn consumable, a heat-not-burn consumable, a method of preparing an aerosol generating segment and use of the aerosol generating segment or heat-not-burn consumable.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 forming material, 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. Traditional aerosol generating apparatus typically comprise a single aerosol forming material comprising a homogeneous mixture of aerosol former and flavourant.

[0003] A drawback with these traditional aerosol forming materials is that a high temperature is needed to generate aerosol vapour from liquid aerosol former components, such as propylene glycol and glycerol. Therefore, at the start of a session, a high rate of heating is needed to achieve these high temperatures quickly and provide the vapour desired by the user. However, both the high temperature and high rate of heating may burn or char the aerosol forming material, resulting in a bitter taste. Moreover, the high temperature and high rate of heating may cause the flavourant to be released from the aerosol forming material prematurely, resulting in a high level of flavour at the start of the session but a low level of flavour later in the session.

[0004] Aerosol forming materials including a high level of aerosol forming liquid are typically difficult to handle during manufacturing processes, and are difficult to store in the assembled consumable. The high level of aerosol forming liquid makes the aerosol forming material sticky and liable to take on water during storage.

[0005] In spite of the effort already invested in the development of aerosol generating precursors, further improvements are desirable.

[0006] It is against this background that the present invention has been developed.SUMMARY

[0007] In a general, the present disclosure provides an aerosol generating segment comprising one or more sheets of an aerosol forming material, wherein a first portion of the aerosol forming material has a first concentration of an aerosol forming liquidand a second portion of the aerosol forming material has a second concentration of an aerosol forming liquid.

[0008] In a first aspect the present disclosure provides an aerosol generating segment for a heat-not-burn consumable, wherein the aerosol generating segment comprises one or more sheets of an aerosol forming material, wherein the aerosol forming material comprises a aerosol forming liquid; wherein a first portion of the aerosol forming material has a first concentration of the aerosol forming liquidand a second portion of the aerosol forming material has a second concentration of the aerosol forming liquid. In some examples, the first concentration is greater than the second concentration. In this way, the aerosol forming material includes an area which has a high concentration of aerosol forming liquid and an area with a low concentration of aerosol forming material. Without wishing to be bound by theory, it is thought that a non-uniform distribution of the aerosol forming material is able to increase generation of aerosol during heating, while maintaining the flavour release profile.

[0009] In particular , the sections of high aerosol forming material concentration allow for preferential vaporisation of the aerosol forming material, to generate vapour from the aerosol forming material. Thus, even when the average concentration of aerosol forming material is low, the high local concentration of aerosol forming material provides a high rate of aerosol generation, especially, at the start of a session. In addition, the portions of low aerosol forming material concentration allow for a gradual flavour release. The portions of low aerosol forming material concentration have a lower rate of vaporisation and heating, and so the flavour release is more gradual.

[0010] In general, it is desirable to heat the aerosol forming liquid to a higher temperature and / or at a higher rate than other components of the aerosol forming material, such as tobacco and / or flavourants. Thus, by providing a portion of the aerosol forming material which has a higher concentration of aerosol forming liquid, these portions can be preferentially heated to a higher temperature and / or at a higher rate, in order to increase vaporisation of the aerosol forming liquid. Thus, more vapour can be produced, especially at the start of a session, without overheating the tobacco and / or flavourants. It is desirable to heat the tobacco and / or flavourants to a lower temperature, so they are gradually released over the course of the session and to prevent charring / burning, which may compromise the taste.

[0011] In this way, the aerosol generating segment provides a good level of vapour at the start of the session combined with a good level of flavour at the end of the session.

[0012] The aerosol generating segment may also allow for differential heating. In some examples, the heat applied to the first portion is greater than the heat applied to the second portion. By 'heat applied' we may refer to the extent of heating, the rate of heating and / or the temperature of heating. This means that a single aerosol generating segment can provide differential heating, where the first portion (having a higher concentration of aerosol forming liquid) can be heated more intensely than a second portion (having a lower concentration of aerosol forming liquid). Typically, differential heating is only possible using a two-segment consumable, with different heating being applied to different segments. However, the aerosol generating segment described herein facilitates differential heating with a single segment, reducing the complexity and cost of the heat-not-burn consumable and the aerosol generating unit, while providing an improved user experience.

[0013] The differential heating allows the properties of the consumable to be customised, for example, to increase or decrease the ratio of vapour to flavour. The greater flexibility allows for a larger variety of products variants to be developed around the same segment architecture, with more tailored flavour profile, vapour generation, and user experience.

[0014] In some examples, the one or more sheets of aerosol precursor are multiple strips of aerosol precursor.

[0015] In some examples, the strips extend in an axial direction from an upstream end of the aerosol generating segment to a downstream end of the aerosol generating segment. In some examples, the strips extend continuously from an upstream end of the aerosol generating segment to a downstream end of the aerosol generating segment.

[0016] In some examples, the strips have a length of from 6 to 20 mm, such as from 8 to 16 mm, such as from 10 to 14 mm. The strips may have a length of about 12 mm. The strips may have a length which is the same as the axial length of the aerosol generating segment. The length may refer to the dimension of the sheet aligned with the axial direction of the aerosol generating segment, such as along the flow path of the aerosol generating segment.

[0017] In some examples, the strips have a width of 0.01 to 3 mm, such as 0.1 to 1 mm, such a 0.2 to 0.3 mm. The width of the strips may be measured as the longest distance perpendicular to the length direction of the strips. The width may refer to the dimension of the sheet perpendicular to the axial direction of the aerosol generating segment, such as perpendicular to the flow path of the aerosol generating segment.

[0018] In some examples, the strips have a thickness of about 0.01 to 0.6 mm, such as 0.2to 0.5 mm, such as 0.3 to 0.45 mm.

[0019] The strips may be crimped and / or embossed. The strips may be divided. The strips may be substantially cuboidal.

[0020] In some examples, the first portion of the aerosol forming material is one or more first strips of aerosol forming material and the second portion of the aerosol precursor is one or more second strips of aerosol forming material. The first strips of the aerosol forming material have a first concentration of the aerosol forming liquidand a second strips of the aerosol precursor have a second concentration of the aerosol forming liquid, wherein the first concentration is greater than the second concentration.

[0021] In some examples, the first portion of the aerosol forming material is 10 or more first strips of aerosol forming material and the second portion of the aerosol precursor is 10 or more second strips of aerosol forming material In some examples, the first portion of the aerosol forming material is 20 or more first strips of aerosol forming material and the second portion of the aerosol precursor is 20 or more second strips of aerosol forming material In some examples, the first portion of the aerosol forming material is from 20 to 60 first strips of aerosol forming material and the second portion of the aerosol precursor is from 20 to 60 second strips of aerosol forming material.

[0022] The first and second strips are different, at least in terms of the concentration of the aerosol forming liquid. In some examples, the first strips and the second strips comprise the same aerosol forming material carrier material. In some examples, the first strips and the second strips comprise a different liquid aerosol precursor. In other examples, the first strips and the second strips comprise the same aerosol forming liquid.

[0023] In some examples, the first strips and the second strips are homogeneously dispersed within the aerosol generating segment. In some examples, the first strips and the second strips are homogeneously dispersed in an axial direction of the aerosol generating segment. In some examples, the first strips and the second strips are homogeneously dispersed in a radial direction of the aerosol generating segment.

[0024] In some examples, the first strips and the second strips are inhomogeneously dispersed within the aerosol generating segment. In some examples, a higher concentration of the first strips are located towards the outside (e.g., circumference) of the segment and a higher concentration of the second strips are located towards the inside (e.g., core) of the aerosol generating segment. In some examples, a higher concentration of the second strips are located towards the outside (e.g., circumference) of the segment and a higher concentration of the first strips are located towards the inside (e.g., core) of the aerosol generating segment. In some examples, a higher concentration of the first strips are located towards a first radial side of the segment and a higher concentration of the second strips are located towards a second radial side of the aerosol generating segment.

[0025] In some examples, the first portion of the aerosol forming material is one or more first areas of the strips of aerosol forming material and the second portion of the aerosol precursor is one or more second areas of the strips of aerosol forming material. The first and second areas are different. In some examples, the first portion of the aerosol forming material is a first area of each strip and the second portion of the aerosol forming material carrier material is a second area of each strip.

[0026] In some examples, the first areas of the strips may be a first end of the strips, and the second areas of the strips may be a second end of the strips. In some examples, the first end of the strips is an upstream end of the strips and the second end of the strips is a downstream end of the strips. In some examples, the first end of the strips is a downstream end of the strips and the second end of the strips is a upstream end of the strips.

[0027] In some examples, the first areas of the strips may be an end of the strips, and the second areas of the strips may be a middle area of the strips. In some examples, the first areas of the strips may be a middle area of the strips, and the second areas of the strips may be an end of the strips (e.g., the upstream and downstream ends).

[0028] In some examples, a first area of the strips has a first concentration of the aerosol forming liquidand a second area of strips has a second concentration of the aerosol forming liquid, wherein the first concentration is greater than the second concentration.

[0029] In some examples, the first area of the strips is 20% or more of the surface area of the strips, based on the total surface area of the strips, such as 30% or more, 40% or more, 50% or more, 60% or more, 70% or more, or 80% or more.

[0030] In some examples, the second area of the strips is 20% or less of the surface area of the strips, based on the total surface area of the strips, such as 30% or less, 40% or less, 50% or less, 60% or less, 70% or less, or 80% or less.

[0031] In some examples, the one or more sheets of an aerosol precursor is a sheet of aerosol precursor.

[0032] In some examples, the sheets extend in an axial direction from an upstream end of the aerosol generating segment to a downstream end of the aerosol generating segment. In some examples, the sheets extend continuously from an upstream end of the aerosol generating segment to a downstream end of the aerosol generating segment.

[0033] In some examples, the aerosol generating segment comprises 2 or more sheets, such as 4 or more sheets, such as 6 or more sheets. In some examples, the aerosol generating segment comprises 1 or less sheets, such as 8 or less sheets. Typically, the aerosol generating segment comprises from 2 to 10 sheets.

[0034] In some examples, the aerosol generating segment comprises a single sheet of aerosol precursor. The sheet may be a single continous sheet of aerosol forming material. The sheet may be crimped, embossed, folded, slit and / or gathered.

[0035] In some examples, the sheets have a length of from 6 to 20 mm, such as from 8 to 16 mm, such as from 10 to 14 mm. The sheets may have a length of about 12 mm. The sheets may have a length which is the same as the axial length of the aerosol generating segment. The length may refer to the dimension of the sheet aligned with the axial direction of the aerosol generating segment, such as along the flow path of the aerosol generating segment.

[0036] In some examples, the sheets have a width of from 5 to 30 mm, such as from 10 to 25 mm, such as from 15 to 20 mm. The sheets may have a width which is the same as the diameter of the aerosol generating segment. The width may refer to the dimension of the sheet perpendicular to the axial direction of the aerosol generating segment, such as perpendicular to the flow path of the aerosol generating segment.

[0037] In some examples, the sheets have a thickness of about 0.1 to 0.6 mm, such as 0.2 to 0.5 mm, such as 0.3 to 0.45 mm.

[0038] In some examples, the first portion of the aerosol forming material is one or more first areas of the sheet and the second portion of the aerosol forming material is one or more second areas of the sheet. The first and second areas are different. In some examples, the first portion of the aerosol forming material is one first area of the sheet and the second portion of the aerosol forming material is one second area of the sheet.

[0039] In some examples, the first areas of the sheets may be a first end of the one or more sheets, and the second areas may be a second end of the one or more sheets. In some examples, the first end of the sheets is an upstream end of the one or more sheets and the second end of the sheets is a downstream end of the one or more sheets. In some examples, the first end of the sheets is a downstream end of the one or more sheets and the second end of the sheet is a upstream end of the one or more sheets.

[0040] In some examples, the first areas of the sheets may be an end of the one or more sheets, and the second areas of the sheets may be a middle area of the one or more sheets. In some examples, the first areas of the sheets may be a middle area of the one or more sheets, and the second areas of the sheet may be an end of the one or more sheets (e.g., the upstream and downstream ends).

[0041] In some examples, a first area of the sheets has a first concentration of the aerosol forming liquid and a second area of sheets has a second concentration of the aerosol forming liquid, wherein the first concentration is greater than the second concentration.

[0042] In some examples, the first area of the sheet is 20% or more of the surface area of the sheet, based on the total surface area of the sheet, such as 30% or more, 40% or more, 50% or more, 60% or more, 70% or more, or 80% or more.

[0043] In some examples, the second area of the sheet is 20% or less of the surface area of the sheet, based on the total surface area of the sheet, such as 30% or less, 40% or less, 50% or less, 60% or less, 70% or less, or 80% or less.

[0044] The aerosol forming material comprises a carrier material and a aerosol forming liquid. The aerosol forming liquid is carried by the carrier material. The aerosol forming liquid may form an aerosol upon heating.

[0045] In some examples, the aerosol forming liquid is selected from the list consisting of propylene glycol, glycerine, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, 1,2-butanediol, 1,3-butadediol, glycerol mono-, di- or triacetate, dimethyl dodecanedioate and dimethyl tetradecanedioate, or a combination thereof.

[0046] In some examples, the aerosol forming liquid comprise propylene glycol (PG), vegetable glycerine (VG), or a combination thereof. In some examples, the aerosol forming liquid comprise PG. In some examples, the aerosol forming liquid comprises VG.

[0047] In some examples, the aerosol forming liquid comprises PG and VG. In some examples, the mass ratio of PG:VG is 10:90 or more, 20:80 or more, 30:70 or more, 40:60 or more. In some examples, the mass ratio of PG:VG is 90:10 or less, 80:20 or less, 70:30 or less, 60:40 or less. In some examples, the mass ratio of PG:VG is from 90:10 to 10:90, from 70:30 to 70:30, from 60:40 to 40:60. In some examples, the PG:VG ratio is about 50:50.

[0048] A first portion of the aerosol forming material has a first concentration of the aerosol forming liquidand a second portion of the aerosol forming material has a second concentration of the aerosol forming liquid.

[0049] In some examples, the first concentration is 10% or more greater than the second concentration, such as 20% or more, 30% or more, 40% or more, 50% or more, 60% or more, 70% or more, 80% or more, 90% or more greater than the second concentration.

[0050] In some examples, the first concentration is 10 to 1000% greater than the second concentration, such as 20 to 500%, 30 to 200%, 40 to 100%, 50 to 90%, 70 to 80% greater than the second concentration.

[0051] In some examples, the ratio of the first concentration to the second concentration is 60:40 or more, 70:30 or more, 80:20 or more, 90:10 or more, or 95:5 or more.

[0052] In some examples, the ratio of the first concentration to the second concentration is 51:49 to 100:0, such as 60:40 to 95:5, such as 70:30 to 90:10, such as 80:20 to 85:15.

[0053] The first portion may comprise 15 wt.% or more of aerosol forming liquid, based on the mass of the aerosol forming liquid and carrier material. The first portion may comprise 20 wt.% or more of aerosol forming liquid, such as 25 wt.% or more, 30 wt.% or more, 35 wt.% or more, 40 wt.% or more, based on the mass of the aerosol forming liquid and carrier material.

[0054] The first portion may comprise from 15 to 50 wt.% of aerosol forming liquid, based on the mass of the aerosol forming liquid and carrier material. The first portion may comprise from 20 to 45 wt.% of aerosol forming liquid, such as from 25 to 40 wt.%, from 30 to 35 wt.%, based on the mass of the aerosol forming liquid and carrier material.

[0055] The second portion may comprise 30 wt.% or less of aerosol forming liquid, based on the mass of the aerosol forming liquid and carrier material. The second portion may comprise 25 wt.% or less of aerosol forming liquid, such as 20 wt.% or less, 15 wt.% or less, 10 wt.% or less, 5 wt.% or less, based on the mass of the aerosol forming liquid and carrier material.

[0056] The second portion may comprise from 0 to 30 wt.% of aerosol forming liquid, based on the mass of the aerosol forming liquid and carrier material. The second portion may comprise from 1 to 25 wt.% of aerosol forming liquid, such as from 2 to 20 wt.%, from 3 to 15 wt.%, from 4 to 10 wt.%, or about 5 wt.%, based on the mass of the aerosol forming liquid and carrier material.

[0057] The first concentration of aerosol forming liquid may be 50 mg / cm 3< or more, based on the mass of aerosol forming liquid and carrier material in the first portion. The first concentration of aerosol forming liquid may be 100 mg / cm 3< or more, 150 mg / cm 3< or more, 200 mg / cm 3< or more, 250 mg / cm 3< or more, 300 mg / cm 3< or more, based on the mass of aerosol forming liquid and carrier material.

[0058] The first concentration of aerosol forming liquid may be from 50 to 400 mg / cm 3< , based on the mass of aerosol forming liquid and carrier material in the first portion. The first concentration of aerosol forming liquid may be from 100 to 300 mg / cm 3< , from 150 to 250 mg / cm 3< , from 180 to 220 mg / cm 3< based on the mass of aerosol forming liquid and carrier material.

[0059] The second concentration of aerosol forming liquid may be 200 mg / cm 3< or less, based on the mass of aerosol forming liquid and carrier material in the second portion. The second concentration of aerosol forming liquid may be 150 mg / cm 3< or less, 100 mg / cm 3< or less, 50 mg / cm 3< or less, 20 mg / cm 3< or less, based on the mass of aerosol forming liquid and carrier material.

[0060] The second concentration of aerosol forming liquid may be from 0 to 200 mg / cm 3< , based on the mass of aerosol forming liquid and carrier material in the second portion. The second concentration of aerosol forming liquid may be from 10 to 150 mg / cm 3< , from 20 to 100 mg / cm 3< , from 30 to 50 mg / cm 3< based on the mass of aerosol forming liquid and carrier material.

[0061] The first areal concentration of aerosol forming liquid may be 20 g / m 2< or more, based on the mass of aerosol forming liquid and the area of the carrier material in the first portion. The first areal concentration of aerosol forming liquid may be 30 g / m 2< or more, 40 g / m 2< or more, 50 g / m 2< or more, 60 g / m 2< or more, 70 g / m 2< or more, based on the mass of aerosol forming liquid and the area of the carrier material.

[0062] The first areal concentration of aerosol forming liquid may be from 20 to 100 g / m 2< , based on the mass of aerosol forming liquid and the area of the carrier material in the first portion. The first areal concentration of aerosol forming liquid may be from 30 to 90 g / m 2< , from 40 to 80 g / m 2< , from 50 to 70 g / m 2< based on the mass of aerosol forming liquid and the area of the carrier material.

[0063] The second areal concentration of aerosol forming liquid may be 50 g / m 2< or less, based on the mass of aerosol forming liquid and the area of the carrier material in the second portion. The second areal concentration of aerosol forming liquid may be 40 g / m 2< or less, 30 g / m 2< or less, 20 g / m 2< or less, 10 g / m 2< or less, based on the mass of aerosol forming liquid and the area of the carrier material.

[0064] The second areal concentration of aerosol forming liquid may be from 0 to 50 g / m 2< , based on the mass of aerosol forming liquid and the area of the carrier material in the second portion. The second areal concentration of aerosol forming liquid may be from 1 to 30 g / m 2< , from 2 to 20 g / m 2< , from 3 to 10 g / m 2< based on the mass of aerosol forming liquid and the area of the carrier material.

[0065] The concentration of the aerosol forming liquid may be measured using any suitable means.

[0066] The concentration may be a local concentration. The concentration may be a point concentration. That is, the concentration is the concentration at a specific location or point of the sheet of aerosol forming material. The concentration may be determined at a specific area of the sheet of aerosol forming material.

[0067] In some examples, the concentration is calculated on a mass basis. In some examples, the concentration is calculated as the mass of aerosol forming liquid per unit mass of the aerosol forming material carrier material.

[0068] In some examples, the concentration is calculated on a volume basis. In some examples, the concentration is calculated as the volume of aerosol forming liquid per unit volume of the aerosol forming material carrier material.

[0069] In some examples, the areal concentration is calculated on an area basis. In some examples, the concentration is calculated as the mass of aerosol forming liquid per unit area of the aerosol forming material carrier material. The area is determined based on the area of the sheet of aerosol forming material.

[0070] In some examples, a mass of the aerosol forming material absorbed into the first portion of the aerosol forming material is greater than the mass of the aerosol forming material absorbed into the second portion of the aerosol forming material.

[0071] In some examples, the mass of the aerosol forming material absorbed into the first portion of the aerosol forming material is 10% or more greater than the mass of the aerosol forming material absorbed into the second portion of the aerosol forming material, such as 20% or more, 30% or more, 40% or more, 50% or more, 60% or more, 70% or more, 80% or more, 90% or more.

[0072] In some examples, the mass of the aerosol forming material absorbed into the first portion of the aerosol forming material is 10 to 1000% greater than the mass of the aerosol forming material absorbed into the second portion of the aerosol forming material, such as 20 to 500%, 30 to 200%, 40 to 100%, 50 to 90%, 70 to 80%.

[0073] In some examples, the ratio of the mass of the aerosol forming material absorbed into the first portion of the aerosol forming material to the mass of the aerosol forming material absorbed into the second portion of the aerosol forming material is 60:40 or more, 70:30 or more, 80:20 or more, 90:10 or more, or 95:5 or more.

[0074] In some examples, the ratio of the mass of the aerosol forming material absorbed into the first portion of the aerosol forming material to the mass of the aerosol forming material absorbed into the second portion of the aerosol forming material is 51:49 to 100:0, such as 60:40 to 95:5, such as 70:30 to 90:10, such as 80:20 to 85:15.

[0075] The mass of the aerosol forming liquid may be measured using any suitable means.

[0076] The second portion of the aerosol forming material may not include any liquid aerosol precursor. That is, the second portion of the aerosol forming material may be free of liquid aerosol precursor.

[0077] The second portion of the aerosol forming material may be free from additional aerosol forming liquid. That is, the second portion of the aerosol forming material may include aerosol precursor which is present inherently in the carrier material, but not include any aerosol forming liquidadded to the carrier material. For example, the second portion of the aerosol forming material may be free from PG and VG.

[0078] In some examples, the first portion of the aerosol forming material comprise 10 wt.% or more of aerosol forming liquid and the second portion of the aerosol forming material comprise less than 10 wt.% of aerosol forming liquid. In some examples, the first portion of the aerosol forming material comprise 15 wt.% or more of aerosol forming liquid and the second portion of the aerosol forming material comprise less than 15 wt.% of aerosol forming liquid. In some examples, the first portion of the aerosol forming material comprise 20 wt.% or more of aerosol forming liquid and the second portion of the aerosol forming material comprises less than 20 wt.% of aerosol forming liquid. In some examples, the first portion of the aerosol forming material comprise 30 wt.% or more of aerosol forming liquid and the second portion of the aerosol forming material comprise less than 30 wt.% of aerosol forming liquid.

[0079] The aerosol forming material comprises a carrier material and a aerosol forming liquid. The carrier material is able to carry the aerosol forming liquid. The carrier material may be a solid material. The carrier material may be an absorbent material. The carrier material may be a porous material.

[0080] In some examples, the composition of the first portion of the sheets of aerosol precursor and the second portion of the sheets of the aerosol precursor differ only in the concentration of the liquid aerosol former. That is, the aerosol forming material carrier material is the same for the first portion and the second portion.

[0081] The carrier material may be any suitable carrier material, which is able to carry a aerosol forming liquid. The aerosol forming liquid can be released from the carrier material upon heating, to form an aerosol.

[0082] The aerosol-forming material may comprise plant material.

[0083] The plant material may comprise or be formed of tobacco. Any type of tobacco may be used, including, but is not limited to, flue-cured tobacco, burley tobacco, Virginia tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco, rustica tobacco. This also includes blends of the above mentioned tobaccos. Any suitable parts of the tobacco plant may be used, including leaves, stems, roots, bark, seeds and flowers. The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and / or reconstituted tobacco (e.g. slurry recon or paper recon). For example, the aerosol-forming material may comprise a gathered sheet of homogenised (e.g. paper / slurry recon) tobacco or gathered shreds / strips formed from such a sheet.

[0084] The tobacco may be processed tobacco, steam treated stems or shredded dried stems. The tobacco material may be fermented, cured, uncured, toasted, or otherwise pre-treated. The tobacco may be unprocessed and / or untreated.

[0085] The aerosol-forming material may be absent of tobacco and / or nicotine.

[0086] The plant material may comprise at least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Oestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia califomica (California Poppy), Fittonia albivenis, Hippobroma longi flora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombi folia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and / or synthetic alternatives of the foregoing.

[0087] The aerosol-forming material may comprise one or more additives selected from vapour generators, carrier agents, humectants, flavourants, fillers, aqueous / non-aqueous solvents and binders.

[0088] The aerosol-forming material may comprise propylene glycol (PG) and / or vegetable glycerin (VG). Propylene glycol (PG) and vegetable glycerin (VG) are typically used as base materials that act as aerosol generators (alternatively referred to as aerosol-formers), carrier agents, and / or humectants. The aerosol-forming material may comprise, alternatively or in addition, other substances that function as one or more of aerosol generators, carrier agents, and humectants.

[0089] In some examples, the aerosol forming material carrier material comprises a cellulose based material such as cotton, paper, maize fibres, oat fibres, tomato fibres, barley fibres, rye fibres, sugar beet fibres, buck wheat fibres, wheat fibres, pea fibres, potato fibres, apple fibres, cocoa fibres, bamboo fibres, citrus fibres, microcrystalline cellulose or any combination thereof.

[0090] Flavourants may be provided in solid form, liquid form, gel form, or a combination thereof. Flavourants may include one or more of menthol (e.g. peppermint (mentha piperita), spearmint (mentha spicata), wild mint (Mentha Arventis), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), applemint (Mentha suaveolens), pennyroyal (Mentha pulegium)), liquorice, chocolate / cocoa, fruit flavour (including e.g. apple, citrus, cherry, banana (Isoamyl acetate)), rose, vanilla (Ethylvanillin), spice (e.g. ginger, clove, cinnamon, star anise), tobacco extract / flavour, marijuana, hemp, cannabinoid compounds, citronella, orange, lemon, geraniol, thyme, fennel, green tea, black tea, coffee, salvia dorrii, salvia, passiflora incarnata, arctostaphylos uva-ursi, lobelia inflata, matcha, Yerba mate, lemon grass, flax, cedar wood, coumarin, helio, eucalyptus, ginkgo biloba, hazel, hibiscus, laurel, chamomile, rosemary, lavender, rooibos, or combinations thereof. The flavourant may be evenly dispersed throughout the aerosol-forming material or may be provided in isolated locations and / or varying concentrations throughout the aerosol-forming material.

[0091] The cannabinoid compounds may be selected from the non-exhaustive list comprising: tetrahydrocannabinol (THC), cannabidiol (CBD), cannabinol (CBN).

[0092] Fillers can strengthen the aerosol-forming material. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g. wood fibres), jute fibres and combinations thereof.

[0093] Binders can act to bind together the components forming the aerosol-forming material. Binders may comprise starches and / or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxy propyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and / or locust bean gum, organic acids and their salts such as alginic acid / sodium alginate, agar and pectins.

[0094] In some examples, the aerosol forming material carrier material comprises reconstituted tobacco. The reconstituted tobacco may comprise tobacco and a binder. The reconstituted tobacco may comprise tobacco, binder and cellulose. The reconstituted tobacco may comprise tobacco, binder, cellulose and an aerosol forming material. The reconstituted tobacco may comprise tobacco, binder, cellulose, an aerosol forming material and flavour.

[0095] In some examples, the aerosol forming material carrier material is free of aerosol forming material. In some examples, the aerosol forming material carrier material is free of aerosol forming liquid.

[0096] The cellulose may be a wood pulp.

[0097] The binder may be a gum binder. The binder may be a cellulose binder. The binder may be a konjac manan, guar gum, carregennan, gelatine, alginate or pectin.

[0098] In some examples, the aerosol forming material carrier material comprises a cellulose-based material. In some examples, the aerosol forming material carrier material comprises a cellulose based material selected from the list consisting of: cotton, paper, maize fibers, oat fibers, tomato fibers, barley fibers, rye fibers, sugar beet fibers, buck wheat fibers, wheat fibers, pea fibers, potato fibers, apple fibers, cocoa fibers, bamboo fibers, citrus fibers, tea, tobacco, microcrystalline cellulose or any combination thereof. In some examples, the cellulose based material is selected from the list consisting of: cotton, paper, maize fibers, oat fibers, tomato fibers, barley fibers, rye fibers, sugar beet fibers, buck wheat fibers, wheat fibers, pea fibers, potato fibers, apple fibers, cocoa fibers, bamboo fibers, citrus fibers, tea, microcrystalline cellulose or any combination thereof. In some examples the second carrier material is cotton, paper or microcrystalline cellulose.

[0099] In some examples, aerosol forming material carrier material is substantially free from tobacco material. In some examples, the second aerosol carrier material comprises 1 wt.% or less of tobacco material, such as 0.1 wt.% or less, such as 0.01 wt.% or less.

[0100] The aerosol forming material may be a aerosol forming liquid, as described herein.

[0101] In some examples, the first portion of the aerosol forming material comprises 20 wt.% or more of carrier material, based on the total mass of the aerosol forming material, such as 30% or more, 40% or more, 50% or more, 60% or more, 70% or more, or 80% or more.

[0102] In some examples, the second portion of the aerosol forming material comprises 90% or less of carrier material, based on the total mass of the aerosol forming material carrier material, such as 80% or less, 70% or less, 60% or less, 50% or less, 30% or less, or 20% or less.

[0103] The aerosol generating segment comprises one or more sheets of an aerosol forming material.

[0104] The aerosol generating segment may further comprise a wrapping paper. The wrapping paper may overwrap the one or more sheets of aerosol forming material to form the segment.

[0105] Any suitable wrapping paper may be used. The wrapping paper may comprise a laminate wrapping paper. The laminate wrapping paper may be a foil-paper laminate. The foil may be an aluminium foil.

[0106] The wrapping paper may be fixed in place with an adhesive. Any suitable adhesive may be used.

[0107] The present disclosure may provide a heat-not-burn consumable comprising the aerosol generating segment according to the first aspect.

[0108] The heat-not-burn consumable may further comprise a filter segment, a cooling segment, a combining paper, and / or a tipping paper. The heat-not-burn consumable may comprise an aerosol generating segment, a cooling segment downstream of the aerosol generating segment, and a mouthpiece filter downstream of the cooling segment. The heat-not-burn consumable may comprise an aerosol generating segment, a cooling segment adjacent to and downstream of the aerosol generating segment, and a mouthpiece filter adjacent to and downstream of the cooling segment.

[0109] The heat-not-burn consumable may comprise an aerosol generating segment, a filter segment downstream of the aerosol generating segment, a cooling segment downstream of the filter segment, and a mouthpiece filter downstream of the cooling segment. The heat-not-burn consumable may comprise an aerosol generating segment, a filter segment adjacent to and downstream of the aerosol generating segment, a cooling segment adjacent to and downstream of the filter segment, and a mouthpiece filter adjacent to and downstream of the cooling segment.

[0110] The aerosol generating segment may be at the upstream end of the heat-not-burn consumable.

[0111] In some examples, the heat-not-burn consumable may further comprise a further segment upstream of the aerosol generating segment and a covering over the upstream end of the aerosol generating segment.

[0112] The presence of a further segment and / or a covering over the upstream end of the aerosol generating segment is beneficial for the prevention of migration of propylene glycol and / or glycerine from the aerosol generating segment e.g., into the packaging of the consumable, particularly when there is a high loading of aerosol forming liquid in the carrier material of the first and / or second precursor. Migration of propylene glycol and / or glycerine may lead to discoloration of the product or otherwise visually affect the consumable, and it may structurally weaken the consumable due to saturation or partial saturation of the various segments and / or wrapper (when present) which can lead to breakage. Provision of the further segment and / or covering can therefore lead to improved shelf life and strength of the product and improved user experience.

[0113] The present disclosure may provide an aerosol-generating system comprising an unit and the heat-not-burn consumable according to the second aspect.

[0114] The aerosol generating apparatus is as described herein.

[0115] The aerosol generating apparatus may comprise a penetrative heater. This heater is configured to heat the inside of an aerosol generating segment. This may be known as an 'inside-out' heater. Where the aerosol generating apparatus comprises an inside-out heater, the aerosol generating segment may be adapted for inside-out heating. In some examples, a higher concentration of the second strips are located towards the outside (e.g., circumference) of the segment and a higher concentration of the first strips are located towards the inside (e.g., core) of the aerosol generating segment.

[0116] The aerosol generating apparatus may comprise an external or circumferential heater. This heater is configured to heat the outside of an aerosol generating segment. This may be known as an 'outside-in' heater. Where the aerosol generating apparatus comprises an outside-in heater, the aerosol generating segment may be adapted for outside-in heating. In some examples, a higher concentration of the first strips are located towards the outside (e.g., circumference) of the segment and a higher concentration of the second strips are located towards the inside (e.g., core) of the aerosol generating segment.

[0117] In this way, the first portion (with a higher concentration of liquid aerosol former) is located closer to the heater. As a result, the liquid aerosol former may be preferentially heated to produce aerosol.

[0118] The present disclosure may provide a method of preparing an aerosol generating segment for a heat-not-burn consumable, which may implement any one or more features disclosed herein. The method may comprise: providing a sheet of aerosol forming material carrier material; applying a aerosol forming liquid to a first portion of the aerosol forming material carrier material to form a sheet of an aerosol forming material, wherein the first portion of the aerosol forming material has a first concentration of the aerosol forming liquid and a second portion of the aerosol precursor has a second concentration of the aerosol forming liquid; forming an aerosol generating segment from one or more sheets of aerosol forming material.

[0119] In a further aspect, there is provided an aerosol generating segment obtained or obtainable by the method of the fourth aspect.

[0120] In some examples, the method further comprises a step of dividing the sheet of an aerosol forming material to form one or more sheets of aerosol forming material. In some examples, the method further comprises a step of dividing the sheet of an aerosol forming material to form multiple strips of aerosol forming material. This dividing step may take place between the step of applying a aerosol forming liquid and the step of forming an aerosol generating segment.

[0121] The dividing step may take place using any suitable means. In some examples, the dividing step may comprise cutting the sheet of aerosol precursor.

[0122] In some examples, the method further comprises a step of crimping the sheet of an aerosol forming material to form one or more crimped sheets of aerosol forming material.

[0123] In some examples, the method further comprises a step of embossing the sheet of an aerosol forming material to form one or more embossed sheets of aerosol forming material.

[0124] In some examples, the method comprises arranging the first portion of the aerosol forming material towards an upstream end of the aerosol generating segment and arranging the second portion of the aerosol forming material towards a downstream end of the aerosol generating segment.

[0125] The method comprises a step of providing a sheet of aerosol forming material carrier material.

[0126] The aerosol forming material carrier material is as described above.

[0127] In some examples, the step comprises providing a bobbin, the bobbin comprising a sheet of aerosol forming material carrier material. The bobbin may be unwound to provide a sheet of aerosol forming material.

[0128] The method comprises a step of applying a aerosol forming liquid to a first portion of the aerosol forming material carrier material. This provides a first portion of the aerosol forming material with a first concentration of the aerosol forming liquid, and a second portion of aerosol forming material with a second concentration of the aerosol forming liquid.

[0129] The aerosol forming liquid is as described above.

[0130] The application may be achieved by any suitable means. In some examples, the aerosol forming liquid is applied by spraying onto a first potion of the aerosol forming material carrier material. In some examples, the aerosol forming liquid is applied by rolling onto a first potion of the aerosol forming material carrier material. In some examples, the aerosol forming liquid is applied by brushing onto a first portion of the aerosol forming material carrier material.

[0131] In some examples, aerosol forming liquid is only applied to the first portion of the carrier material.

[0132] In some examples, aerosol forming liquid is not applied to the second portion of the carrier material.

[0133] In some examples, the method comprises a step of applying aerosol forming liquid to a second portion of the precursor carrier material. This provides a second portion of the aerosol forming material with a second concentration of the aerosol forming liquid. The first concentration is greater than the second concentration. The application may be achieved as described above for the application to the first portion. However, the application is at a lower concentration.

[0134] In some examples, the first concentration is greater than the second concentration In this way, an aerosol forming material carrier material with a relatively low amount of aerosol forming liquid can be used, as the aerosol forming liquid is added to the carrier material during formation of the segment. This has advantages in terms of the handling and storage of the carrier material, as the aerosol forming liquid makes the aerosol forming material carrier material difficult to handle. Thus, adding the aerosol forming liquid during formation of the segment addresses these issues.

[0135] The aerosol forming liquid can also be added to a first portion of the aerosol forming material. This selective addition of the aerosol forming liquid has the advantage that a high, localised concentration of aerosol forming liquid can be achieved. Such a high concentration may not be possible without applying the aerosol forming liquid during formation of the segment.

[0136] The high concentration of aerosol forming liquid in a first portion has the advantages described above, in connection with the aerosol generating segment.

[0137] The method comprises a step of forming an aerosol generating segment from one or more sheets of aerosol forming material.

[0138] The step of forming an aerosol generating segment may use any suitable means. In some examples, the aerosol generating segment is formed by forming a rod comprising the one or more sheets of aerosol forming material. The rod may be formed by gathering the one or more sheets (e.g., strips) of aerosol forming material and wrapping the one or more sheets of aerosol forming material in a combining paper. The combining paper may be fixed in place with an adhesive.

[0139] The one or more sheets (e.g., strips) may be gathered such that they are aligned parallel to the axial direction of the rod.

[0140] The one or more sheets may be wrapper using any suitable combining paper. The combining paper may be a foil-paper laminate. The adhesive may be applied to the combining paper along a seam line. In this way, the combining paper may be closed around the one or more sheets of aerosol forming material.

[0141] The aerosol-forming material may be circumscribed by a wrapping layer e.g. a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper / foil laminate (with the foil innermost).

[0142] Any elements (e.g. filter elements, cooling element, spacer elements) downstream of the aerosol-forming material may be at least partially (e.g. entirely) circumscribed by the wrapping layer. Accordingly, the wrapping layer may alternatively be referred to as a 'combining layer'. The wrapping layer may at least partially (e.g. entirely) circumscribe elements upstream of the terminal filter element.

[0143] The terminal filter element (at the downstream end of the article / consumable) may be joined to the upstream elements forming the article / consumable by a circumscribing tipping layer e.g. a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

[0144] Any elements (e.g. filter elements, cooling element, spacer elements) may be further circumscribed by a respective plug wrap e.g. a paper plug wrap.

[0145] The rod may be divided to form multiple aerosol generating segments.

[0146] The aerosol generating segment may be assembled into a heat-not-burn consumable.

[0147] In some examples, the step of forming an aerosol generating segment further comprise arranging the first portion of the aerosol forming material towards an upstream end of the aerosol generating segment and arranging the second portion of the aerosol forming material towards a downstream end of the aerosol generating segment.

[0148] The present disclosure may provide a use of an aerosol generating segment for generating an aerosol.

[0149] The present disclosure may provide a use of an aerosol generating segment to increase a volume of aerosol generated, wherein the volume is increased compared to aerosol generating segment having a uniform distribution of aerosol forming liquid.

[0150] The aerosol generating segment according or the heat-not-burn consumable may be used with an aerosol generating apparatus.

[0151] In some examples, the aerosol is formed from the aerosol forming liquid.

[0152] In some examples, the volume of visible aerosol produced is increased.

[0153] In some examples, the volume of aerosol produced is increased compared to an aerosol generating segment wherein the aerosol forming material comprises a uniform distribution of aerosol forming liquid.

[0154] In some examples, the volume of aerosol produced is the initial aerosol volume. That is, the aerosol generated from the first puff of the consumable. In some examples, the volume of aerosol produced is increased at the start of a session. In some examples, the volume of aerosol produced is increased for the first five puffs of the session.

[0155] In some examples, the concentration of aerosol produced is increased compared to an aerosol generating segment wherein the aerosol forming material comprises a uniform distribution of aerosol forming liquid.

[0156] In some examples, the concentration of aerosol produced is the initial aerosol concentration. That is, the aerosol generated from the first puff of the consumable. In some examples, the concentration of aerosol produced is increased at the start of a session. In some examples, the concentration of aerosol produced is increased for the first five puffs of the session.

[0157] In some examples, the mass of aerosol produced is increased compared to an aerosol generating segment wherein the aerosol forming material comprises a uniform distribution of aerosol forming liquid. In some examples, the mass of aerosol produced is the initial aerosol mass. That is, the aerosol generated from the first puff of the consumable. In some examples, the mass of aerosol produced is increased at the start of a session. In some examples, the mass of aerosol produced is increased for the first five puffs of the session.

[0158] The present disclosure may provide a use of a heat-not-burn consumable according to the first aspect with an aerosol-generating apparatus, to improve the flavour profile of an aerosol generated in use, wherein the flavour profile is improved compared to aerosol generating segment having a uniform distribution of aerosol forming liquid.

[0159] In some examples, an improved flavour profile may comprise a more gradual release of flavourant. In some examples, the flavour profile may be compared for five puffs at the start of the session to five puffs at the end of a session (e.g., puffs 21-25). A smaller difference between the flavourant concentration at the start and end of a session may be indicative of an improved flavour profile.

[0160] In some examples, the improved flavour profile may comprise a lower concentration of burnt or charred compounds. In some examples, burnt or charred compounds may include acrylamide, carbon monoxide or carbon. A lower concentration of burnt or charred compounds is indicative of an improved flavour profile, as such compounds can contribute to a bitter taste.

[0161] The present disclosure may provide a method of generating an aerosol, which may implement any one or more features disclosed herein.

[0162] 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

[0163] 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. 3. Fig. 4a and Fig. 4b are cross-sectional diagrams showing an example implementation of the aerosol generating segment, including a sheet of aerosol forming material. Fig. 5a and Fig. 5b are cross-sectional diagrams showing an example implementation of the aerosol generating segment, including a strips of aerosol forming material. Fig. 6 is a cross-sectional diagram of an example implementation of a heat-not-burn consumable, including the aerosol generating segment of Fig. 4a. Fig. 7a is a cross-sectional diagram of an example implementation of a heat-not-burn consumable. including the aerosol generating segment of Fig. 5b, when the consumable is engaged with the heater elements of an aerosol generating apparatus. Fig. 7b is a cross-sectional diagram of an example implementation of a heat-not-burn consumable. including the aerosol generating segment of Fig. 4b, when the consumable is engaged with the heater elements of an aerosol generating apparatus. Fig. 8 and Fig. 9 are schematic diagrams showing an example implementation of a bobbin of aerosol forming material and how the bobbin may be used in a method of manufacturing the aerosol generating segment. DETAILED DESCRIPTION OF EMBODIMENTS

[0164] 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.

[0165] 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.

[0166] Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.

[0167] 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.

[0168] 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.

[0169] 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).

[0170] 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.

[0171] 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.

[0172] 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).

[0173] As used herein, an "aerosol generating component" may refer to a component that includes an aerosol forming material. The component may include an aerosol generating unit e.g. it may be arranged as a cartomizer. The component may include a mouthpiece. The component may include an information carrying medium. The component may include a storage portion, e.g. a reservoir or tank, for storage of the aerosol forming material.

[0174] With solid material implementations of the precursor, e.g. tobacco or reconstituted tobacco formulation, the component 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.

[0175] The aerosol generating component e.g. the capsule, pod, stick, package or consumable may be for releasable coupling to a device body to form the aerosol generating apparatus.

[0176] The device body may comprise a power supply for powering the aerosol generating unit.

[0177] 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.

[0178] 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).

[0179] 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.

[0180] As used herein, an "aerosol generating system" may be a system that includes an aerosol generating apparatus and optionally other circuitry / components associated with the function of the apparatus, e.g. one or more external devices and / or one or more external components (here "external" is intended to mean external to the aerosol generating apparatus). As used herein, an "external device" and "external component" may include one or more of a: a charging device, a mobile device (which may be connected to the aerosol generating apparatus, e.g. via a wireless or wired connection); a networked-based computer (e.g. a remote server); a cloud-based computer; any other server system.

[0181] An example aerosol generating system may be a system for managing an aerosol generating apparatus. Such a system may include, for example, a mobile device, a network server, as well as the aerosol generating apparatus.

[0182] 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. As used herein, a "precursor" may include one or more of a: liquid; 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.

[0183] As used herein, a "storage portion" may be a portion of the apparatus adapted to store the precursor. It may be implemented as fluid-holding reservoir or carrier for solid material depending on the implementation of the precursor as defined above.

[0184] 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.

[0185] 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. The delivery system may be at least partly within the aerosol generating component.

[0186] 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. 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.

[0187] 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 forming materials) may be present in an aerosol generating apparatus.

[0188] 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. The heating system may be provided within the aerosol generating component or within the device body.

[0189] As used herein, an "information carrying medium" may include one or more arrangements for storage of information on any suitable medium. Examples include: a computer readable medium; a Radio Frequency Identification (RFID) transponder; codes encoding information, such as optical (e.g. a bar code or QR code) or mechanically read codes (e.g. a configuration of the absence or presents of cutouts to encode a bit, through which pins or a reader may be inserted).

[0190] 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).

[0191] 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 1 includes a delivery system 8 for delivery of the aerosol to a user.

[0192] Electrical circuitry (not shown in figure 1) may be implemented to control the interoperability of the power supply 2 and aerosol generating unit 4.

[0193] 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.

[0194] 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.

[0195] In this example, the apparatus 1 includes a device body 50 and a consumable 70.

[0196] In this example, the body 50 includes the power supply 2 and a heating system 52. The heating system 52 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.

[0197] 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.

[0198] The wireless interface 60 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.

[0199] 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).

[0200] 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 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 precursor 6 of the consumable (without combusting it) by conductive heat transfer, to generate an aerosol which is inhaled by the user.

[0201] Fig. 3 shows an example implementation of the aerosol generating device 1 of Fig. 2.

[0202] 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 precursor 6.

[0203] The consumable 70 includes the solid 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 precursor 6 may be a reconstituted tobacco formulation.

[0204] 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).

[0205] 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.

[0206] 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.

[0207] 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 2. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user. 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.

[0208] 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.

[0209] 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.

[0210] Referring to Fig. 4a and Fig. 4b, an aerosol generating segment 40, which may be implemented in any of the preceding examples, such as in the consumable 70, includes a sheet of an aerosol forming material 43. The aerosol forming material 43 includes a solid aerosol precursor carrier material. A first portion 44 of the aerosol forming material has a first concentration of a aerosol forming liquidand a second portion 46 of the aerosol forming material has a second concentration of the aerosol forming liquid. The first concentration (in the first portion 44) is greater than the second concentration (in the second portion 46).

[0211] The aerosol generating segment 40 is wrapped in a combining paper 42. The combining paper 42 may be a foil-paper laminate.

[0212] In Fig. 4a, the first portion 44 of the aerosol precursor is positioned downstream of the second portion 46 of the aerosol forming material. In alternative examples, the first portion 44 of the aerosol precursor is positioned upstream of the second portion 46 of the aerosol forming material. In this way, the first portion 44 and second portion 46 are separated along the axial length of the aerosol generating segment.

[0213] In Fig. 4b, the first portion 44 of the aerosol precursor is transversely displaced from the second portion 46 of the aerosol forming material. In this way, the first portion 44 and second portion 46 are separated along the radial width of the aerosol generating segment. The first portion 44 and second portion 46 extend along about the same axial length of the aerosol generating segment.

[0214] Referring to Fig. 5a and Fig. 5b, an aerosol generating segment 40, which may be implemented in any of the preceding examples, such as in the consumable 70, includes multiple strips of an aerosol forming material 43. In some examples, the aerosol generating segment comprises 20 or more strips, such as 40 or more strips, such as 60 or more strips. In some examples, the aerosol generating segment comprises 100 or less trips, such as 80 or less trips. Typically, the aerosol generating segment comprises from 20 to 100 strips, such as from 40 to 80 strips.

[0215] The aerosol forming material 43 includes a solid aerosol precursor carrier material. A first portion 44 of the aerosol forming material has a first concentration of a aerosol forming liquidand a second portion 46 of the aerosol forming material has a second concentration of the aerosol forming liquid. The first concentration (in the first portion 44) is greater than the second concentration (in the second portion 46).

[0216] The aerosol generating segment 40 is wrapped in a combining paper 42. The combining paper 42 may be a foil-paper laminate.

[0217] In Fig. 5a, the first portion 44 of the aerosol precursor is displaced from the second portion 46 of the aerosol forming material. The first portion 44 and the second portion 46 may be located at different axial and radial positions. Some strips may only include a first portion 44. Some stips may only include a second portion 46. In some strips, the first portion 44 is located at the downstream end and the second portion 46 is located at the upstream end. In some strips, the first portion 44 is located at the upstream end and the second portion 46 is located at the downstream end. In some strips, the first portion 44 is located in the middle of the strip, and the second portion 46 is located at the upstream and downstream ends. In some strips, the second portion 46 is located in the middle of the strip, and the first portion 44 is located at the upstream and downstream ends. That is, the position of the first portion and second portion is random.

[0218] In Fig. 5b, the first portion 44 of the aerosol precursor is positioned downstream of the second portion 46 of the aerosol forming material. In alternative examples, the first portion 44 of the aerosol precursor is positioned upstream of the second portion 46 of the aerosol forming material. In this way, the first portion 44 and second portion 46 are separated along the axial length of the aerosol generating segment.

[0219] Referring to Fig. 6, an aerosol generating segment 40 is shown in an example heat-not-burn consumable 70. The aerosol generating segment 40 is located at the upstream end of the consumable 70. Downstream of the aerosol generating segment 40 is a tubular segment 72. The tubular segment 72 may be known as a cooling segment. Downstream of the tubular segment 72 is a mouthpiece filter 74. The mouthpiece filter 74 is at the downstream end of the consumable 70. The aerosol generating segment 40, the tubular segment 72 and the mouthpiece filter 74 are wrapped together using a combining paper 76. The combining paper 76 is wrapped around the segments and glued into place using an adhesive.

[0220] Any of the aerosol generating segment 40, as shown in Fig. 4a, Fig. 4b, Fig. 5a, and Fig. 5b may be used in the consumable 70 shown in Fig. 6.

[0221] Referring to Fig. 7a, the aerosol generating segment 40, as illustrated in Fig. 5b, is provided in an example consumable 70. The consumable 70 is shown relative to the heater elements 54 of the aerosol generating apparatus. As explained for Fig. 3, the consumable 70 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 be located adjacent to the aerosol forming material segment 40. In this example, the heating elements 54 are annular heating elements that are positioned about the circumference of the aerosol generating segment 40.

[0222] In Fig. 7a, a first annular heating element 54a is located adjacent to the first portion 44 of the aerosol forming material, and a second annular heating element 54b is located adjacent to the second portion 46 of the aerosol forming material. The annular heating elements each heat their respective section of the aerosol generating segment.

[0223] Referring to Fig. 7b, the aerosol generating segment 40, as illustrated in Fig. 4b, is provided in an example consumable 70. The consumable 70 is shown relative to the heater elements 54 of the aerosol generating apparatus. As explained for Fig. 3, the consumable 70 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 be located adjacent to the aerosol forming material segment 40. In this example, the heating elements 54 are semi-annular heating elements that are positioned about the circumference of the aerosol generating segment 40. A first semi annular heating element 54a is located adjacent to the first portion 44 of the aerosol forming material, and a second semi annular heating element 54b is located adjacent to the second portion 46 of the aerosol forming material. The semi-annular heating elements each heat one side of the aerosol generating segment, which include the first and second portions of aerosol forming material respectively.

[0224] As shown in Fig. 7a and Fig. 7b, the use of a separate first heating element 54a and second heating element 54b allows for the first portion 44 and second portion 46 to be heated differently. In some examples, the first heating element 54a may heat to a higher maximum temperature than the second heating element 54b. In some examples, the first heating element 54a may heat at a higher rate than the second heating element 54b.

[0225] In this way, the higher concentration of aerosol forming liquid present in the first portion may be aerosolised quickly, for example, at the start of a session. The lower concentration of aerosol forming liquid present in the second portion is aerosolised more slowly, to allow for the gradual release of nicotine and / or flavour components, without burning or charring the aerosol forming material. Referring to Fig. 8, this shows an example bobbin 80 of aerosol forming material. The bobbin 80 includes one sheets of carrier material. During manufacturing of the aerosol generating segment, the bobbin 80 is unwound to provide the sheet of carrier material 83. A aerosol forming liquid is then applied to the carrier material 83 using an applicator 81 (e.g., a sprayer). The applicator 81 applies aerosol forming liquid to one side (e.g., the right side) of the carrier material, and does not apply aerosol forming liquid to the other side (e.g., the left side) of the carrier material. The portion of the carrier material which is not sprayed with aerosol forming liquid corresponds to the second portion. The portion of the carrier material which is sprayed with a aerosol forming liquid corresponds to the first portion 84. The sheet of aerosol forming material (including the sprayed and non-sprayed portions) are then divided to form strip, which include a first portion 44 with a higher concentration of aerosol forming liquid and a second portion 46 with a lower concentration of aerosol forming substrate. The strips are then gathered together. The gathered strips are then arranged into a rod shape and formed into an aerosol generating segment, by wrapping with a combining paper. The strips formed by the examples of Fig. 8 may be used in the aerosol generating segment illustrated in Fig. 5b.

[0226] In an alternative example of Fig. 8 , the sheet of carrier material is divided into sheets, the sheets both including an area (first portion) with a high concentration of aerosol forming liquid and an area (second portion) with a low concentration of aerosol forming liquid. The sheets formed by this method may be used in the aerosol generating segment illustrated in Fig. 4a.

[0227] Referring to Fig. 9, this shows an example bobbin 80 of aerosol forming material. The bobbin 80 includes one sheets of carrier material. During manufacturing of the aerosol generating segment, the bobbin 80 is unwound to provide the sheet of carrier material 83. A aerosol forming liquid is then applied to the carrier material 83 using an applicator 81 (e.g., a sprayer). The applicator 81 intermittently applies aerosol forming liquid across the full width of the aerosol forming material, to give alternating portions which are and are not sprayed with aerosol forming liquid. The portion of the carrier material which is not sprayed with aerosol forming liquid corresponds to the second portion. The portion of the carrier material which is sprayed with a aerosol forming liquid corresponds to the first portion 84. The sheet of aerosol forming material (including the sprayed and non-sprayed portions) are then divided to form strips. Some strips correspond to a first portion 44 and have a higher concentration of aerosol forming liquid and some strips corresponds to a second portion 46 with a lower concentration of aerosol forming liquid. The strips may then be further divided to reduce their length. The strips are then gathered together. The gathered strips are then arranged into a rod shape and formed into an aerosol generating segment, by wrapping with a combining paper.

[0228] In an alternative example of Fig. 9 , the sheet of carrier material is divided into sheets, the sheets both including an area (first portion) with a high concentration of aerosol forming liquid and an area (second portion) with a low concentration of aerosol forming liquid. The sheets formed by this method may be used in the aerosol generating segment illustrated in Fig. 4b.

Examples

Embodiment Construction

[0164]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.

[0165]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.

[0166]Any paten...

FIELD

[0001] The present disclosure relates to aerosol generating segment for a heat-not-burn consumable, a heat-not-burn consumable, a method of preparing an aerosol generating segment and use of the aerosol generating segment or heat-not-burn consumable.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 forming material, 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. Traditional aerosol generating apparatus typically comprise a single aerosol forming material comprising a homogeneous mixture of aerosol former and flavourant.

[0003] A drawback with these traditional aerosol forming materials is that a high temperature is needed to generate aerosol vapour from liquid aerosol former components, such as propylene glycol and glycerol. Therefore, at the start of a session, a high rate of heating is needed to achieve these high temperatures quickly and provide the vapour desired by the user. However, both the high temperature and high rate of heating may burn or char the aerosol forming material, resulting in a bitter taste. Moreover, the high temperature and high rate of heating may cause the flavourant to be released from the aerosol forming material prematurely, resulting in a high level of flavour at the start of the session but a low level of flavour later in the session.

[0004] Aerosol forming materials including a high level of aerosol forming liquid are typically difficult to handle during manufacturing processes, and are difficult to store in the assembled consumable. The high level of aerosol forming liquid makes the aerosol forming material sticky and liable to take on water during storage.

[0005] In spite of the effort already invested in the development of aerosol generating precursors, further improvements are desirable.

[0006] It is against this background that the present invention has been developed.SUMMARY

[0007] In a general, the present disclosure provides an aerosol generating segment comprising one or more sheets of an aerosol forming material, wherein a first portion of the aerosol forming material has a first concentration of an aerosol forming liquidand a second portion of the aerosol forming material has a second concentration of an aerosol forming liquid.

[0008] In a first aspect the present disclosure provides an aerosol generating segment for a heat-not-burn consumable, wherein the aerosol generating segment comprises one or more sheets of an aerosol forming material, wherein the aerosol forming material comprises a aerosol forming liquid; wherein a first portion of the aerosol forming material has a first concentration of the aerosol forming liquidand a second portion of the aerosol forming material has a second concentration of the aerosol forming liquid. In some examples, the first concentration is greater than the second concentration. In this way, the aerosol forming material includes an area which has a high concentration of aerosol forming liquid and an area with a low concentration of aerosol forming material. Without wishing to be bound by theory, it is thought that a non-uniform distribution of the aerosol forming material is able to increase generation of aerosol during heating, while maintaining the flavour release profile.

[0009] In particular , the sections of high aerosol forming material concentration allow for preferential vaporisation of the aerosol forming material, to generate vapour from the aerosol forming material. Thus, even when the average concentration of aerosol forming material is low, the high local concentration of aerosol forming material provides a high rate of aerosol generation, especially, at the start of a session. In addition, the portions of low aerosol forming material concentration allow for a gradual flavour release. The portions of low aerosol forming material concentration have a lower rate of vaporisation and heating, and so the flavour release is more gradual.

[0010] In general, it is desirable to heat the aerosol forming liquid to a higher temperature and / or at a higher rate than other components of the aerosol forming material, such as tobacco and / or flavourants. Thus, by providing a portion of the aerosol forming material which has a higher concentration of aerosol forming liquid, these portions can be preferentially heated to a higher temperature and / or at a higher rate, in order to increase vaporisation of the aerosol forming liquid. Thus, more vapour can be produced, especially at the start of a session, without overheating the tobacco and / or flavourants. It is desirable to heat the tobacco and / or flavourants to a lower temperature, so they are gradually released over the course of the session and to prevent charring / burning, which may compromise the taste.

[0011] In this way, the aerosol generating segment provides a good level of vapour at the start of the session combined with a good level of flavour at the end of the session.

[0012] The aerosol generating segment may also allow for differential heating. In some examples, the heat applied to the first portion is greater than the heat applied to the second portion. By 'heat applied' we may refer to the extent of heating, the rate of heating and / or the temperature of heating. This means that a single aerosol generating segment can provide differential heating, where the first portion (having a higher concentration of aerosol forming liquid) can be heated more intensely than a second portion (having a lower concentration of aerosol forming liquid). Typically, differential heating is only possible using a two-segment consumable, with different heating being applied to different segments. However, the aerosol generating segment described herein facilitates differential heating with a single segment, reducing the complexity and cost of the heat-not-burn consumable and the aerosol generating unit, while providing an improved user experience.

[0013] The differential heating allows the properties of the consumable to be customised, for example, to increase or decrease the ratio of vapour to flavour. The greater flexibility allows for a larger variety of products variants to be developed around the same segment architecture, with more tailored flavour profile, vapour generation, and user experience.

[0014] In some examples, the one or more sheets of aerosol precursor are multiple strips of aerosol precursor.

[0015] In some examples, the strips extend in an axial direction from an upstream end of the aerosol generating segment to a downstream end of the aerosol generating segment. In some examples, the strips extend continuously from an upstream end of the aerosol generating segment to a downstream end of the aerosol generating segment.

[0016] In some examples, the strips have a length of from 6 to 20 mm, such as from 8 to 16 mm, such as from 10 to 14 mm. The strips may have a length of about 12 mm. The strips may have a length which is the same as the axial length of the aerosol generating segment. The length may refer to the dimension of the sheet aligned with the axial direction of the aerosol generating segment, such as along the flow path of the aerosol generating segment.

[0017] In some examples, the strips have a width of 0.01 to 3 mm, such as 0.1 to 1 mm, such a 0.2 to 0.3 mm. The width of the strips may be measured as the longest distance perpendicular to the length direction of the strips. The width may refer to the dimension of the sheet perpendicular to the axial direction of the aerosol generating segment, such as perpendicular to the flow path of the aerosol generating segment.

[0018] In some examples, the strips have a thickness of about 0.01 to 0.6 mm, such as 0.2to 0.5 mm, such as 0.3 to 0.45 mm.

[0019] The strips may be crimped and / or embossed. The strips may be divided. The strips may be substantially cuboidal.

[0020] In some examples, the first portion of the aerosol forming material is one or more first strips of aerosol forming material and the second portion of the aerosol precursor is one or more second strips of aerosol forming material. The first strips of the aerosol forming material have a first concentration of the aerosol forming liquidand a second strips of the aerosol precursor have a second concentration of the aerosol forming liquid, wherein the first concentration is greater than the second concentration.

[0021] In some examples, the first portion of the aerosol forming material is 10 or more first strips of aerosol forming material and the second portion of the aerosol precursor is 10 or more second strips of aerosol forming material In some examples, the first portion of the aerosol forming material is 20 or more first strips of aerosol forming material and the second portion of the aerosol precursor is 20 or more second strips of aerosol forming material In some examples, the first portion of the aerosol forming material is from 20 to 60 first strips of aerosol forming material and the second portion of the aerosol precursor is from 20 to 60 second strips of aerosol forming material.

[0022] The first and second strips are different, at least in terms of the concentration of the aerosol forming liquid. In some examples, the first strips and the second strips comprise the same aerosol forming material carrier material. In some examples, the first strips and the second strips comprise a different liquid aerosol precursor. In other examples, the first strips and the second strips comprise the same aerosol forming liquid.

[0023] In some examples, the first strips and the second strips are homogeneously dispersed within the aerosol generating segment. In some examples, the first strips and the second strips are homogeneously dispersed in an axial direction of the aerosol generating segment. In some examples, the first strips and the second strips are homogeneously dispersed in a radial direction of the aerosol generating segment.

[0024] In some examples, the first strips and the second strips are inhomogeneously dispersed within the aerosol generating segment. In some examples, a higher concentration of the first strips are located towards the outside (e.g., circumference) of the segment and a higher concentration of the second strips are located towards the inside (e.g., core) of the aerosol generating segment. In some examples, a higher concentration of the second strips are located towards the outside (e.g., circumference) of the segment and a higher concentration of the first strips are located towards the inside (e.g., core) of the aerosol generating segment. In some examples, a higher concentration of the first strips are located towards a first radial side of the segment and a higher concentration of the second strips are located towards a second radial side of the aerosol generating segment.

[0025] In some examples, the first portion of the aerosol forming material is one or more first areas of the strips of aerosol forming material and the second portion of the aerosol precursor is one or more second areas of the strips of aerosol forming material. The first and second areas are different. In some examples, the first portion of the aerosol forming material is a first area of each strip and the second portion of the aerosol forming material carrier material is a second area of each strip.

[0026] In some examples, the first areas of the strips may be a first end of the strips, and the second areas of the strips may be a second end of the strips. In some examples, the first end of the strips is an upstream end of the strips and the second end of the strips is a downstream end of the strips. In some examples, the first end of the strips is a downstream end of the strips and the second end of the strips is a upstream end of the strips.

[0027] In some examples, the first areas of the strips may be an end of the strips, and the second areas of the strips may be a middle area of the strips. In some examples, the first areas of the strips may be a middle area of the strips, and the second areas of the strips may be an end of the strips (e.g., the upstream and downstream ends).

[0028] In some examples, a first area of the strips has a first concentration of the aerosol forming liquidand a second area of strips has a second concentration of the aerosol forming liquid, wherein the first concentration is greater than the second concentration.

[0029] In some examples, the first area of the strips is 20% or more of the surface area of the strips, based on the total surface area of the strips, such as 30% or more, 40% or more, 50% or more, 60% or more, 70% or more, or 80% or more.

[0030] In some examples, the second area of the strips is 20% or less of the surface area of the strips, based on the total surface area of the strips, such as 30% or less, 40% or less, 50% or less, 60% or less, 70% or less, or 80% or less.

[0031] In some examples, the one or more sheets of an aerosol precursor is a sheet of aerosol precursor.

[0032] In some examples, the sheets extend in an axial direction from an upstream end of the aerosol generating segment to a downstream end of the aerosol generating segment. In some examples, the sheets extend continuously from an upstream end of the aerosol generating segment to a downstream end of the aerosol generating segment.

[0033] In some examples, the aerosol generating segment comprises 2 or more sheets, such as 4 or more sheets, such as 6 or more sheets. In some examples, the aerosol generating segment comprises 1 or less sheets, such as 8 or less sheets. Typically, the aerosol generating segment comprises from 2 to 10 sheets.

[0034] In some examples, the aerosol generating segment comprises a single sheet of aerosol precursor. The sheet may be a single continous sheet of aerosol forming material. The sheet may be crimped, embossed, folded, slit and / or gathered.

[0035] In some examples, the sheets have a length of from 6 to 20 mm, such as from 8 to 16 mm, such as from 10 to 14 mm. The sheets may have a length of about 12 mm. The sheets may have a length which is the same as the axial length of the aerosol generating segment. The length may refer to the dimension of the sheet aligned with the axial direction of the aerosol generating segment, such as along the flow path of the aerosol generating segment.

[0036] In some examples, the sheets have a width of from 5 to 30 mm, such as from 10 to 25 mm, such as from 15 to 20 mm. The sheets may have a width which is the same as the diameter of the aerosol generating segment. The width may refer to the dimension of the sheet perpendicular to the axial direction of the aerosol generating segment, such as perpendicular to the flow path of the aerosol generating segment.

[0037] In some examples, the sheets have a thickness of about 0.1 to 0.6 mm, such as 0.2 to 0.5 mm, such as 0.3 to 0.45 mm.

[0038] In some examples, the first portion of the aerosol forming material is one or more first areas of the sheet and the second portion of the aerosol forming material is one or more second areas of the sheet. The first and second areas are different. In some examples, the first portion of the aerosol forming material is one first area of the sheet and the second portion of the aerosol forming material is one second area of the sheet.

[0039] In some examples, the first areas of the sheets may be a first end of the one or more sheets, and the second areas may be a second end of the one or more sheets. In some examples, the first end of the sheets is an upstream end of the one or more sheets and the second end of the sheets is a downstream end of the one or more sheets. In some examples, the first end of the sheets is a downstream end of the one or more sheets and the second end of the sheet is a upstream end of the one or more sheets.

[0040] In some examples, the first areas of the sheets may be an end of the one or more sheets, and the second areas of the sheets may be a middle area of the one or more sheets. In some examples, the first areas of the sheets may be a middle area of the one or more sheets, and the second areas of the sheet may be an end of the one or more sheets (e.g., the upstream and downstream ends).

[0041] In some examples, a first area of the sheets has a first concentration of the aerosol forming liquid and a second area of sheets has a second concentration of the aerosol forming liquid, wherein the first concentration is greater than the second concentration.

[0042] In some examples, the first area of the sheet is 20% or more of the surface area of the sheet, based on the total surface area of the sheet, such as 30% or more, 40% or more, 50% or more, 60% or more, 70% or more, or 80% or more.

[0043] In some examples, the second area of the sheet is 20% or less of the surface area of the sheet, based on the total surface area of the sheet, such as 30% or less, 40% or less, 50% or less, 60% or less, 70% or less, or 80% or less.

[0044] The aerosol forming material comprises a carrier material and a aerosol forming liquid. The aerosol forming liquid is carried by the carrier material. The aerosol forming liquid may form an aerosol upon heating.

[0045] In some examples, the aerosol forming liquid is selected from the list consisting of propylene glycol, glycerine, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, 1,2-butanediol, 1,3-butadediol, glycerol mono-, di- or triacetate, dimethyl dodecanedioate and dimethyl tetradecanedioate, or a combination thereof.

[0046] In some examples, the aerosol forming liquid comprise propylene glycol (PG), vegetable glycerine (VG), or a combination thereof. In some examples, the aerosol forming liquid comprise PG. In some examples, the aerosol forming liquid comprises VG.

[0047] In some examples, the aerosol forming liquid comprises PG and VG. In some examples, the mass ratio of PG:VG is 10:90 or more, 20:80 or more, 30:70 or more, 40:60 or more. In some examples, the mass ratio of PG:VG is 90:10 or less, 80:20 or less, 70:30 or less, 60:40 or less. In some examples, the mass ratio of PG:VG is from 90:10 to 10:90, from 70:30 to 70:30, from 60:40 to 40:60. In some examples, the PG:VG ratio is about 50:50.

[0048] A first portion of the aerosol forming material has a first concentration of the aerosol forming liquidand a second portion of the aerosol forming material has a second concentration of the aerosol forming liquid.

[0049] In some examples, the first concentration is 10% or more greater than the second concentration, such as 20% or more, 30% or more, 40% or more, 50% or more, 60% or more, 70% or more, 80% or more, 90% or more greater than the second concentration.

[0050] In some examples, the first concentration is 10 to 1000% greater than the second concentration, such as 20 to 500%, 30 to 200%, 40 to 100%, 50 to 90%, 70 to 80% greater than the second concentration.

[0051] In some examples, the ratio of the first concentration to the second concentration is 60:40 or more, 70:30 or more, 80:20 or more, 90:10 or more, or 95:5 or more.

[0052] In some examples, the ratio of the first concentration to the second concentration is 51:49 to 100:0, such as 60:40 to 95:5, such as 70:30 to 90:10, such as 80:20 to 85:15.

[0053] The first portion may comprise 15 wt.% or more of aerosol forming liquid, based on the mass of the aerosol forming liquid and carrier material. The first portion may comprise 20 wt.% or more of aerosol forming liquid, such as 25 wt.% or more, 30 wt.% or more, 35 wt.% or more, 40 wt.% or more, based on the mass of the aerosol forming liquid and carrier material.

[0054] The first portion may comprise from 15 to 50 wt.% of aerosol forming liquid, based on the mass of the aerosol forming liquid and carrier material. The first portion may comprise from 20 to 45 wt.% of aerosol forming liquid, such as from 25 to 40 wt.%, from 30 to 35 wt.%, based on the mass of the aerosol forming liquid and carrier material.

[0055] The second portion may comprise 30 wt.% or less of aerosol forming liquid, based on the mass of the aerosol forming liquid and carrier material. The second portion may comprise 25 wt.% or less of aerosol forming liquid, such as 20 wt.% or less, 15 wt.% or less, 10 wt.% or less, 5 wt.% or less, based on the mass of the aerosol forming liquid and carrier material.

[0056] The second portion may comprise from 0 to 30 wt.% of aerosol forming liquid, based on the mass of the aerosol forming liquid and carrier material. The second portion may comprise from 1 to 25 wt.% of aerosol forming liquid, such as from 2 to 20 wt.%, from 3 to 15 wt.%, from 4 to 10 wt.%, or about 5 wt.%, based on the mass of the aerosol forming liquid and carrier material.

[0057] The first concentration of aerosol forming liquid may be 50 mg / cm 3< or more, based on the mass of aerosol forming liquid and carrier material in the first portion. The first concentration of aerosol forming liquid may be 100 mg / cm 3< or more, 150 mg / cm 3< or more, 200 mg / cm 3< or more, 250 mg / cm 3< or more, 300 mg / cm 3< or more, based on the mass of aerosol forming liquid and carrier material.

[0058] The first concentration of aerosol forming liquid may be from 50 to 400 mg / cm 3< , based on the mass of aerosol forming liquid and carrier material in the first portion. The first concentration of aerosol forming liquid may be from 100 to 300 mg / cm 3< , from 150 to 250 mg / cm 3< , from 180 to 220 mg / cm 3< based on the mass of aerosol forming liquid and carrier material.

[0059] The second concentration of aerosol forming liquid may be 200 mg / cm 3< or less, based on the mass of aerosol forming liquid and carrier material in the second portion. The second concentration of aerosol forming liquid may be 150 mg / cm 3< or less, 100 mg / cm 3< or less, 50 mg / cm 3< or less, 20 mg / cm 3< or less, based on the mass of aerosol forming liquid and carrier material.

[0060] The second concentration of aerosol forming liquid may be from 0 to 200 mg / cm 3< , based on the mass of aerosol forming liquid and carrier material in the second portion. The second concentration of aerosol forming liquid may be from 10 to 150 mg / cm 3< , from 20 to 100 mg / cm 3< , from 30 to 50 mg / cm 3< based on the mass of aerosol forming liquid and carrier material.

[0061] The first areal concentration of aerosol forming liquid may be 20 g / m 2< or more, based on the mass of aerosol forming liquid and the area of the carrier material in the first portion. The first areal concentration of aerosol forming liquid may be 30 g / m 2< or more, 40 g / m 2< or more, 50 g / m 2< or more, 60 g / m 2< or more, 70 g / m 2< or more, based on the mass of aerosol forming liquid and the area of the carrier material.

[0062] The first areal concentration of aerosol forming liquid may be from 20 to 100 g / m 2< , based on the mass of aerosol forming liquid and the area of the carrier material in the first portion. The first areal concentration of aerosol forming liquid may be from 30 to 90 g / m 2< , from 40 to 80 g / m 2< , from 50 to 70 g / m 2< based on the mass of aerosol forming liquid and the area of the carrier material.

[0063] The second areal concentration of aerosol forming liquid may be 50 g / m 2< or less, based on the mass of aerosol forming liquid and the area of the carrier material in the second portion. The second areal concentration of aerosol forming liquid may be 40 g / m 2< or less, 30 g / m 2< or less, 20 g / m 2< or less, 10 g / m 2< or less, based on the mass of aerosol forming liquid and the area of the carrier material.

[0064] The second areal concentration of aerosol forming liquid may be from 0 to 50 g / m 2< , based on the mass of aerosol forming liquid and the area of the carrier material in the second portion. The second areal concentration of aerosol forming liquid may be from 1 to 30 g / m 2< , from 2 to 20 g / m 2< , from 3 to 10 g / m 2< based on the mass of aerosol forming liquid and the area of the carrier material.

[0065] The concentration of the aerosol forming liquid may be measured using any suitable means.

[0066] The concentration may be a local concentration. The concentration may be a point concentration. That is, the concentration is the concentration at a specific location or point of the sheet of aerosol forming material. The concentration may be determined at a specific area of the sheet of aerosol forming material.

[0067] In some examples, the concentration is calculated on a mass basis. In some examples, the concentration is calculated as the mass of aerosol forming liquid per unit mass of the aerosol forming material carrier material.

[0068] In some examples, the concentration is calculated on a volume basis. In some examples, the concentration is calculated as the volume of aerosol forming liquid per unit volume of the aerosol forming material carrier material.

[0069] In some examples, the areal concentration is calculated on an area basis. In some examples, the concentration is calculated as the mass of aerosol forming liquid per unit area of the aerosol forming material carrier material. The area is determined based on the area of the sheet of aerosol forming material.

[0070] In some examples, a mass of the aerosol forming material absorbed into the first portion of the aerosol forming material is greater than the mass of the aerosol forming material absorbed into the second portion of the aerosol forming material.

[0071] In some examples, the mass of the aerosol forming material absorbed into the first portion of the aerosol forming material is 10% or more greater than the mass of the aerosol forming material absorbed into the second portion of the aerosol forming material, such as 20% or more, 30% or more, 40% or more, 50% or more, 60% or more, 70% or more, 80% or more, 90% or more.

[0072] In some examples, the mass of the aerosol forming material absorbed into the first portion of the aerosol forming material is 10 to 1000% greater than the mass of the aerosol forming material absorbed into the second portion of the aerosol forming material, such as 20 to 500%, 30 to 200%, 40 to 100%, 50 to 90%, 70 to 80%.

[0073] In some examples, the ratio of the mass of the aerosol forming material absorbed into the first portion of the aerosol forming material to the mass of the aerosol forming material absorbed into the second portion of the aerosol forming material is 60:40 or more, 70:30 or more, 80:20 or more, 90:10 or more, or 95:5 or more.

[0074] In some examples, the ratio of the mass of the aerosol forming material absorbed into the first portion of the aerosol forming material to the mass of the aerosol forming material absorbed into the second portion of the aerosol forming material is 51:49 to 100:0, such as 60:40 to 95:5, such as 70:30 to 90:10, such as 80:20 to 85:15.

[0075] The mass of the aerosol forming liquid may be measured using any suitable means.

[0076] The second portion of the aerosol forming material may not include any liquid aerosol precursor. That is, the second portion of the aerosol forming material may be free of liquid aerosol precursor.

[0077] The second portion of the aerosol forming material may be free from additional aerosol forming liquid. That is, the second portion of the aerosol forming material may include aerosol precursor which is present inherently in the carrier material, but not include any aerosol forming liquidadded to the carrier material. For example, the second portion of the aerosol forming material may be free from PG and VG.

[0078] In some examples, the first portion of the aerosol forming material comprise 10 wt.% or more of aerosol forming liquid and the second portion of the aerosol forming material comprise less than 10 wt.% of aerosol forming liquid. In some examples, the first portion of the aerosol forming material comprise 15 wt.% or more of aerosol forming liquid and the second portion of the aerosol forming material comprise less than 15 wt.% of aerosol forming liquid. In some examples, the first portion of the aerosol forming material comprise 20 wt.% or more of aerosol forming liquid and the second portion of the aerosol forming material comprises less than 20 wt.% of aerosol forming liquid. In some examples, the first portion of the aerosol forming material comprise 30 wt.% or more of aerosol forming liquid and the second portion of the aerosol forming material comprise less than 30 wt.% of aerosol forming liquid.

[0079] The aerosol forming material comprises a carrier material and a aerosol forming liquid. The carrier material is able to carry the aerosol forming liquid. The carrier material may be a solid material. The carrier material may be an absorbent material. The carrier material may be a porous material.

[0080] In some examples, the composition of the first portion of the sheets of aerosol precursor and the second portion of the sheets of the aerosol precursor differ only in the concentration of the liquid aerosol former. That is, the aerosol forming material carrier material is the same for the first portion and the second portion.

[0081] The carrier material may be any suitable carrier material, which is able to carry a aerosol forming liquid. The aerosol forming liquid can be released from the carrier material upon heating, to form an aerosol.

[0082] The aerosol-forming material may comprise plant material.

[0083] The plant material may comprise or be formed of tobacco. Any type of tobacco may be used, including, but is not limited to, flue-cured tobacco, burley tobacco, Virginia tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco, rustica tobacco. This also includes blends of the above mentioned tobaccos. Any suitable parts of the tobacco plant may be used, including leaves, stems, roots, bark, seeds and flowers. The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and / or reconstituted tobacco (e.g. slurry recon or paper recon). For example, the aerosol-forming material may comprise a gathered sheet of homogenised (e.g. paper / slurry recon) tobacco or gathered shreds / strips formed from such a sheet.

[0084] The tobacco may be processed tobacco, steam treated stems or shredded dried stems. The tobacco material may be fermented, cured, uncured, toasted, or otherwise pre-treated. The tobacco may be unprocessed and / or untreated.

[0085] The aerosol-forming material may be absent of tobacco and / or nicotine.

[0086] The plant material may comprise at least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Oestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia califomica (California Poppy), Fittonia albivenis, Hippobroma longi flora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombi folia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and / or synthetic alternatives of the foregoing.

[0087] The aerosol-forming material may comprise one or more additives selected from vapour generators, carrier agents, humectants, flavourants, fillers, aqueous / non-aqueous solvents and binders.

[0088] The aerosol-forming material may comprise propylene glycol (PG) and / or vegetable glycerin (VG). Propylene glycol (PG) and vegetable glycerin (VG) are typically used as base materials that act as aerosol generators (alternatively referred to as aerosol-formers), carrier agents, and / or humectants. The aerosol-forming material may comprise, alternatively or in addition, other substances that function as one or more of aerosol generators, carrier agents, and humectants.

[0089] In some examples, the aerosol forming material carrier material comprises a cellulose based material such as cotton, paper, maize fibres, oat fibres, tomato fibres, barley fibres, rye fibres, sugar beet fibres, buck wheat fibres, wheat fibres, pea fibres, potato fibres, apple fibres, cocoa fibres, bamboo fibres, citrus fibres, microcrystalline cellulose or any combination thereof.

[0090] Flavourants may be provided in solid form, liquid form, gel form, or a combination thereof. Flavourants may include one or more of menthol (e.g. peppermint (mentha piperita), spearmint (mentha spicata), wild mint (Mentha Arventis), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), applemint (Mentha suaveolens), pennyroyal (Mentha pulegium)), liquorice, chocolate / cocoa, fruit flavour (including e.g. apple, citrus, cherry, banana (Isoamyl acetate)), rose, vanilla (Ethylvanillin), spice (e.g. ginger, clove, cinnamon, star anise), tobacco extract / flavour, marijuana, hemp, cannabinoid compounds, citronella, orange, lemon, geraniol, thyme, fennel, green tea, black tea, coffee, salvia dorrii, salvia, passiflora incarnata, arctostaphylos uva-ursi, lobelia inflata, matcha, Yerba mate, lemon grass, flax, cedar wood, coumarin, helio, eucalyptus, ginkgo biloba, hazel, hibiscus, laurel, chamomile, rosemary, lavender, rooibos, or combinations thereof. The flavourant may be evenly dispersed throughout the aerosol-forming material or may be provided in isolated locations and / or varying concentrations throughout the aerosol-forming material.

[0091] The cannabinoid compounds may be selected from the non-exhaustive list comprising: tetrahydrocannabinol (THC), cannabidiol (CBD), cannabinol (CBN).

[0092] Fillers can strengthen the aerosol-forming material. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g. wood fibres), jute fibres and combinations thereof.

[0093] Binders can act to bind together the components forming the aerosol-forming material. Binders may comprise starches and / or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxy propyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and / or locust bean gum, organic acids and their salts such as alginic acid / sodium alginate, agar and pectins.

[0094] In some examples, the aerosol forming material carrier material comprises reconstituted tobacco. The reconstituted tobacco may comprise tobacco and a binder. The reconstituted tobacco may comprise tobacco, binder and cellulose. The reconstituted tobacco may comprise tobacco, binder, cellulose and an aerosol forming material. The reconstituted tobacco may comprise tobacco, binder, cellulose, an aerosol forming material and flavour.

[0095] In some examples, the aerosol forming material carrier material is free of aerosol forming material. In some examples, the aerosol forming material carrier material is free of aerosol forming liquid.

[0096] The cellulose may be a wood pulp.

[0097] The binder may be a gum binder. The binder may be a cellulose binder. The binder may be a konjac manan, guar gum, carregennan, gelatine, alginate or pectin.

[0098] In some examples, the aerosol forming material carrier material comprises a cellulose-based material. In some examples, the aerosol forming material carrier material comprises a cellulose based material selected from the list consisting of: cotton, paper, maize fibers, oat fibers, tomato fibers, barley fibers, rye fibers, sugar beet fibers, buck wheat fibers, wheat fibers, pea fibers, potato fibers, apple fibers, cocoa fibers, bamboo fibers, citrus fibers, tea, tobacco, microcrystalline cellulose or any combination thereof. In some examples, the cellulose based material is selected from the list consisting of: cotton, paper, maize fibers, oat fibers, tomato fibers, barley fibers, rye fibers, sugar beet fibers, buck wheat fibers, wheat fibers, pea fibers, potato fibers, apple fibers, cocoa fibers, bamboo fibers, citrus fibers, tea, microcrystalline cellulose or any combination thereof. In some examples the second carrier material is cotton, paper or microcrystalline cellulose.

[0099] In some examples, aerosol forming material carrier material is substantially free from tobacco material. In some examples, the second aerosol carrier material comprises 1 wt.% or less of tobacco material, such as 0.1 wt.% or less, such as 0.01 wt.% or less.

[0100] The aerosol forming material may be a aerosol forming liquid, as described herein.

[0101] In some examples, the first portion of the aerosol forming material comprises 20 wt.% or more of carrier material, based on the total mass of the aerosol forming material, such as 30% or more, 40% or more, 50% or more, 60% or more, 70% or more, or 80% or more.

[0102] In some examples, the second portion of the aerosol forming material comprises 90% or less of carrier material, based on the total mass of the aerosol forming material carrier material, such as 80% or less, 70% or less, 60% or less, 50% or less, 30% or less, or 20% or less.

[0103] The aerosol generating segment comprises one or more sheets of an aerosol forming material.

[0104] The aerosol generating segment may further comprise a wrapping paper. The wrapping paper may overwrap the one or more sheets of aerosol forming material to form the segment.

[0105] Any suitable wrapping paper may be used. The wrapping paper may comprise a laminate wrapping paper. The laminate wrapping paper may be a foil-paper laminate. The foil may be an aluminium foil.

[0106] The wrapping paper may be fixed in place with an adhesive. Any suitable adhesive may be used.

[0107] The present disclosure may provide a heat-not-burn consumable comprising the aerosol generating segment according to the first aspect.

[0108] The heat-not-burn consumable may further comprise a filter segment, a cooling segment, a combining paper, and / or a tipping paper. The heat-not-burn consumable may comprise an aerosol generating segment, a cooling segment downstream of the aerosol generating segment, and a mouthpiece filter downstream of the cooling segment. The heat-not-burn consumable may comprise an aerosol generating segment, a cooling segment adjacent to and downstream of the aerosol generating segment, and a mouthpiece filter adjacent to and downstream of the cooling segment.

[0109] The heat-not-burn consumable may comprise an aerosol generating segment, a filter segment downstream of the aerosol generating segment, a cooling segment downstream of the filter segment, and a mouthpiece filter downstream of the cooling segment. The heat-not-burn consumable may comprise an aerosol generating segment, a filter segment adjacent to and downstream of the aerosol generating segment, a cooling segment adjacent to and downstream of the filter segment, and a mouthpiece filter adjacent to and downstream of the cooling segment.

[0110] The aerosol generating segment may be at the upstream end of the heat-not-burn consumable.

[0111] In some examples, the heat-not-burn consumable may further comprise a further segment upstream of the aerosol generating segment and a covering over the upstream end of the aerosol generating segment.

[0112] The presence of a further segment and / or a covering over the upstream end of the aerosol generating segment is beneficial for the prevention of migration of propylene glycol and / or glycerine from the aerosol generating segment e.g., into the packaging of the consumable, particularly when there is a high loading of aerosol forming liquid in the carrier material of the first and / or second precursor. Migration of propylene glycol and / or glycerine may lead to discoloration of the product or otherwise visually affect the consumable, and it may structurally weaken the consumable due to saturation or partial saturation of the various segments and / or wrapper (when present) which can lead to breakage. Provision of the further segment and / or covering can therefore lead to improved shelf life and strength of the product and improved user experience.

[0113] The present disclosure may provide an aerosol-generating system comprising an unit and the heat-not-burn consumable according to the second aspect.

[0114] The aerosol generating apparatus is as described herein.

[0115] The aerosol generating apparatus may comprise a penetrative heater. This heater is configured to heat the inside of an aerosol generating segment. This may be known as an 'inside-out' heater. Where the aerosol generating apparatus comprises an inside-out heater, the aerosol generating segment may be adapted for inside-out heating. In some examples, a higher concentration of the second strips are located towards the outside (e.g., circumference) of the segment and a higher concentration of the first strips are located towards the inside (e.g., core) of the aerosol generating segment.

[0116] The aerosol generating apparatus may comprise an external or circumferential heater. This heater is configured to heat the outside of an aerosol generating segment. This may be known as an 'outside-in' heater. Where the aerosol generating apparatus comprises an outside-in heater, the aerosol generating segment may be adapted for outside-in heating. In some examples, a higher concentration of the first strips are located towards the outside (e.g., circumference) of the segment and a higher concentration of the second strips are located towards the inside (e.g., core) of the aerosol generating segment.

[0117] In this way, the first portion (with a higher concentration of liquid aerosol former) is located closer to the heater. As a result, the liquid aerosol former may be preferentially heated to produce aerosol.

[0118] The present disclosure may provide a method of preparing an aerosol generating segment for a heat-not-burn consumable, which may implement any one or more features disclosed herein. The method may comprise: providing a sheet of aerosol forming material carrier material; applying a aerosol forming liquid to a first portion of the aerosol forming material carrier material to form a sheet of an aerosol forming material, wherein the first portion of the aerosol forming material has a first concentration of the aerosol forming liquid and a second portion of the aerosol precursor has a second concentration of the aerosol forming liquid; forming an aerosol generating segment from one or more sheets of aerosol forming material.

[0119] In a further aspect, there is provided an aerosol generating segment obtained or obtainable by the method of the fourth aspect.

[0120] In some examples, the method further comprises a step of dividing the sheet of an aerosol forming material to form one or more sheets of aerosol forming material. In some examples, the method further comprises a step of dividing the sheet of an aerosol forming material to form multiple strips of aerosol forming material. This dividing step may take place between the step of applying a aerosol forming liquid and the step of forming an aerosol generating segment.

[0121] The dividing step may take place using any suitable means. In some examples, the dividing step may comprise cutting the sheet of aerosol precursor.

[0122] In some examples, the method further comprises a step of crimping the sheet of an aerosol forming material to form one or more crimped sheets of aerosol forming material.

[0123] In some examples, the method further comprises a step of embossing the sheet of an aerosol forming material to form one or more embossed sheets of aerosol forming material.

[0124] In some examples, the method comprises arranging the first portion of the aerosol forming material towards an upstream end of the aerosol generating segment and arranging the second portion of the aerosol forming material towards a downstream end of the aerosol generating segment.

[0125] The method comprises a step of providing a sheet of aerosol forming material carrier material.

[0126] The aerosol forming material carrier material is as described above.

[0127] In some examples, the step comprises providing a bobbin, the bobbin comprising a sheet of aerosol forming material carrier material. The bobbin may be unwound to provide a sheet of aerosol forming material.

[0128] The method comprises a step of applying a aerosol forming liquid to a first portion of the aerosol forming material carrier material. This provides a first portion of the aerosol forming material with a first concentration of the aerosol forming liquid, and a second portion of aerosol forming material with a second concentration of the aerosol forming liquid.

[0129] The aerosol forming liquid is as described above.

[0130] The application may be achieved by any suitable means. In some examples, the aerosol forming liquid is applied by spraying onto a first potion of the aerosol forming material carrier material. In some examples, the aerosol forming liquid is applied by rolling onto a first potion of the aerosol forming material carrier material. In some examples, the aerosol forming liquid is applied by brushing onto a first portion of the aerosol forming material carrier material.

[0131] In some examples, aerosol forming liquid is only applied to the first portion of the carrier material.

[0132] In some examples, aerosol forming liquid is not applied to the second portion of the carrier material.

[0133] In some examples, the method comprises a step of applying aerosol forming liquid to a second portion of the precursor carrier material. This provides a second portion of the aerosol forming material with a second concentration of the aerosol forming liquid. The first concentration is greater than the second concentration. The application may be achieved as described above for the application to the first portion. However, the application is at a lower concentration.

[0134] In some examples, the first concentration is greater than the second concentration In this way, an aerosol forming material carrier material with a relatively low amount of aerosol forming liquid can be used, as the aerosol forming liquid is added to the carrier material during formation of the segment. This has advantages in terms of the handling and storage of the carrier material, as the aerosol forming liquid makes the aerosol forming material carrier material difficult to handle. Thus, adding the aerosol forming liquid during formation of the segment addresses these issues.

[0135] The aerosol forming liquid can also be added to a first portion of the aerosol forming material. This selective addition of the aerosol forming liquid has the advantage that a high, localised concentration of aerosol forming liquid can be achieved. Such a high concentration may not be possible without applying the aerosol forming liquid during formation of the segment.

[0136] The high concentration of aerosol forming liquid in a first portion has the advantages described above, in connection with the aerosol generating segment.

[0137] The method comprises a step of forming an aerosol generating segment from one or more sheets of aerosol forming material.

[0138] The step of forming an aerosol generating segment may use any suitable means. In some examples, the aerosol generating segment is formed by forming a rod comprising the one or more sheets of aerosol forming material. The rod may be formed by gathering the one or more sheets (e.g., strips) of aerosol forming material and wrapping the one or more sheets of aerosol forming material in a combining paper. The combining paper may be fixed in place with an adhesive.

[0139] The one or more sheets (e.g., strips) may be gathered such that they are aligned parallel to the axial direction of the rod.

[0140] The one or more sheets may be wrapper using any suitable combining paper. The combining paper may be a foil-paper laminate. The adhesive may be applied to the combining paper along a seam line. In this way, the combining paper may be closed around the one or more sheets of aerosol forming material.

[0141] The aerosol-forming material may be circumscribed by a wrapping layer e.g. a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper / foil laminate (with the foil innermost).

[0142] Any elements (e.g. filter elements, cooling element, spacer elements) downstream of the aerosol-forming material may be at least partially (e.g. entirely) circumscribed by the wrapping layer. Accordingly, the wrapping layer may alternatively be referred to as a 'combining layer'. The wrapping layer may at least partially (e.g. entirely) circumscribe elements upstream of the terminal filter element.

[0143] The terminal filter element (at the downstream end of the article / consumable) may be joined to the upstream elements forming the article / consumable by a circumscribing tipping layer e.g. a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

[0144] Any elements (e.g. filter elements, cooling element, spacer elements) may be further circumscribed by a respective plug wrap e.g. a paper plug wrap.

[0145] The rod may be divided to form multiple aerosol generating segments.

[0146] The aerosol generating segment may be assembled into a heat-not-burn consumable.

[0147] In some examples, the step of forming an aerosol generating segment further comprise arranging the first portion of the aerosol forming material towards an upstream end of the aerosol generating segment and arranging the second portion of the aerosol forming material towards a downstream end of the aerosol generating segment.

[0148] The present disclosure may provide a use of an aerosol generating segment for generating an aerosol.

[0149] The present disclosure may provide a use of an aerosol generating segment to increase a volume of aerosol generated, wherein the volume is increased compared to aerosol generating segment having a uniform distribution of aerosol forming liquid.

[0150] The aerosol generating segment according or the heat-not-burn consumable may be used with an aerosol generating apparatus.

[0151] In some examples, the aerosol is formed from the aerosol forming liquid.

[0152] In some examples, the volume of visible aerosol produced is increased.

[0153] In some examples, the volume of aerosol produced is increased compared to an aerosol generating segment wherein the aerosol forming material comprises a uniform distribution of aerosol forming liquid.

[0154] In some examples, the volume of aerosol produced is the initial aerosol volume. That is, the aerosol generated from the first puff of the consumable. In some examples, the volume of aerosol produced is increased at the start of a session. In some examples, the volume of aerosol produced is increased for the first five puffs of the session.

[0155] In some examples, the concentration of aerosol produced is increased compared to an aerosol generating segment wherein the aerosol forming material comprises a uniform distribution of aerosol forming liquid.

[0156] In some examples, the concentration of aerosol produced is the initial aerosol concentration. That is, the aerosol generated from the first puff of the consumable. In some examples, the concentration of aerosol produced is increased at the start of a session. In some examples, the concentration of aerosol produced is increased for the first five puffs of the session.

[0157] In some examples, the mass of aerosol produced is increased compared to an aerosol generating segment wherein the aerosol forming material comprises a uniform distribution of aerosol forming liquid. In some examples, the mass of aerosol produced is the initial aerosol mass. That is, the aerosol generated from the first puff of the consumable. In some examples, the mass of aerosol produced is increased at the start of a session. In some examples, the mass of aerosol produced is increased for the first five puffs of the session.

[0158] The present disclosure may provide a use of a heat-not-burn consumable according to the first aspect with an aerosol-generating apparatus, to improve the flavour profile of an aerosol generated in use, wherein the flavour profile is improved compared to aerosol generating segment having a uniform distribution of aerosol forming liquid.

[0159] In some examples, an improved flavour profile may comprise a more gradual release of flavourant. In some examples, the flavour profile may be compared for five puffs at the start of the session to five puffs at the end of a session (e.g., puffs 21-25). A smaller difference between the flavourant concentration at the start and end of a session may be indicative of an improved flavour profile.

[0160] In some examples, the improved flavour profile may comprise a lower concentration of burnt or charred compounds. In some examples, burnt or charred compounds may include acrylamide, carbon monoxide or carbon. A lower concentration of burnt or charred compounds is indicative of an improved flavour profile, as such compounds can contribute to a bitter taste.

[0161] The present disclosure may provide a method of generating an aerosol, which may implement any one or more features disclosed herein.

[0162] 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

[0163] 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. 3. Fig. 4a and Fig. 4b are cross-sectional diagrams showing an example implementation of the aerosol generating segment, including a sheet of aerosol forming material. Fig. 5a and Fig. 5b are cross-sectional diagrams showing an example implementation of the aerosol generating segment, including a strips of aerosol forming material. Fig. 6 is a cross-sectional diagram of an example implementation of a heat-not-burn consumable, including the aerosol generating segment of Fig. 4a. Fig. 7a is a cross-sectional diagram of an example implementation of a heat-not-burn consumable. including the aerosol generating segment of Fig. 5b, when the consumable is engaged with the heater elements of an aerosol generating apparatus. Fig. 7b is a cross-sectional diagram of an example implementation of a heat-not-burn consumable. including the aerosol generating segment of Fig. 4b, when the consumable is engaged with the heater elements of an aerosol generating apparatus. Fig. 8 and Fig. 9 are schematic diagrams showing an example implementation of a bobbin of aerosol forming material and how the bobbin may be used in a method of manufacturing the aerosol generating segment. DETAILED DESCRIPTION OF EMBODIMENTS

[0164] 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.

[0165] 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.

[0166] Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.

[0167] 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.

[0168] 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.

[0169] 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).

[0170] 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.

[0171] 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.

[0172] 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).

[0173] As used herein, an "aerosol generating component" may refer to a component that includes an aerosol forming material. The component may include an aerosol generating unit e.g. it may be arranged as a cartomizer. The component may include a mouthpiece. The component may include an information carrying medium. The component may include a storage portion, e.g. a reservoir or tank, for storage of the aerosol forming material.

[0174] With solid material implementations of the precursor, e.g. tobacco or reconstituted tobacco formulation, the component 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.

[0175] The aerosol generating component e.g. the capsule, pod, stick, package or consumable may be for releasable coupling to a device body to form the aerosol generating apparatus.

[0176] The device body may comprise a power supply for powering the aerosol generating unit.

[0177] 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.

[0178] 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).

[0179] 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.

[0180] As used herein, an "aerosol generating system" may be a system that includes an aerosol generating apparatus and optionally other circuitry / components associated with the function of the apparatus, e.g. one or more external devices and / or one or more external components (here "external" is intended to mean external to the aerosol generating apparatus). As used herein, an "external device" and "external component" may include one or more of a: a charging device, a mobile device (which may be connected to the aerosol generating apparatus, e.g. via a wireless or wired connection); a networked-based computer (e.g. a remote server); a cloud-based computer; any other server system.

[0181] An example aerosol generating system may be a system for managing an aerosol generating apparatus. Such a system may include, for example, a mobile device, a network server, as well as the aerosol generating apparatus.

[0182] 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. As used herein, a "precursor" may include one or more of a: liquid; 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.

[0183] As used herein, a "storage portion" may be a portion of the apparatus adapted to store the precursor. It may be implemented as fluid-holding reservoir or carrier for solid material depending on the implementation of the precursor as defined above.

[0184] 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.

[0185] 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. The delivery system may be at least partly within the aerosol generating component.

[0186] 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. 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.

[0187] 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 forming materials) may be present in an aerosol generating apparatus.

[0188] 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. The heating system may be provided within the aerosol generating component or within the device body.

[0189] As used herein, an "information carrying medium" may include one or more arrangements for storage of information on any suitable medium. Examples include: a computer readable medium; a Radio Frequency Identification (RFID) transponder; codes encoding information, such as optical (e.g. a bar code or QR code) or mechanically read codes (e.g. a configuration of the absence or presents of cutouts to encode a bit, through which pins or a reader may be inserted).

[0190] 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).

[0191] 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 1 includes a delivery system 8 for delivery of the aerosol to a user.

[0192] Electrical circuitry (not shown in figure 1) may be implemented to control the interoperability of the power supply 2 and aerosol generating unit 4.

[0193] 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.

[0194] 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.

[0195] In this example, the apparatus 1 includes a device body 50 and a consumable 70.

[0196] In this example, the body 50 includes the power supply 2 and a heating system 52. The heating system 52 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.

[0197] 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.

[0198] The wireless interface 60 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.

[0199] 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).

[0200] 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 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 precursor 6 of the consumable (without combusting it) by conductive heat transfer, to generate an aerosol which is inhaled by the user.

[0201] Fig. 3 shows an example implementation of the aerosol generating device 1 of Fig. 2.

[0202] 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 precursor 6.

[0203] The consumable 70 includes the solid 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 precursor 6 may be a reconstituted tobacco formulation.

[0204] 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).

[0205] 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.

[0206] 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.

[0207] 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 2. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user. 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.

[0208] 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.

[0209] 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.

[0210] Referring to Fig. 4a and Fig. 4b, an aerosol generating segment 40, which may be implemented in any of the preceding examples, such as in the consumable 70, includes a sheet of an aerosol forming material 43. The aerosol forming material 43 includes a solid aerosol precursor carrier material. A first portion 44 of the aerosol forming material has a first concentration of a aerosol forming liquidand a second portion 46 of the aerosol forming material has a second concentration of the aerosol forming liquid. The first concentration (in the first portion 44) is greater than the second concentration (in the second portion 46).

[0211] The aerosol generating segment 40 is wrapped in a combining paper 42. The combining paper 42 may be a foil-paper laminate.

[0212] In Fig. 4a, the first portion 44 of the aerosol precursor is positioned downstream of the second portion 46 of the aerosol forming material. In alternative examples, the first portion 44 of the aerosol precursor is positioned upstream of the second portion 46 of the aerosol forming material. In this way, the first portion 44 and second portion 46 are separated along the axial length of the aerosol generating segment.

[0213] In Fig. 4b, the first portion 44 of the aerosol precursor is transversely displaced from the second portion 46 of the aerosol forming material. In this way, the first portion 44 and second portion 46 are separated along the radial width of the aerosol generating segment. The first portion 44 and second portion 46 extend along about the same axial length of the aerosol generating segment.

[0214] Referring to Fig. 5a and Fig. 5b, an aerosol generating segment 40, which may be implemented in any of the preceding examples, such as in the consumable 70, includes multiple strips of an aerosol forming material 43. In some examples, the aerosol generating segment comprises 20 or more strips, such as 40 or more strips, such as 60 or more strips. In some examples, the aerosol generating segment comprises 100 or less trips, such as 80 or less trips. Typically, the aerosol generating segment comprises from 20 to 100 strips, such as from 40 to 80 strips.

[0215] The aerosol forming material 43 includes a solid aerosol precursor carrier material. A first portion 44 of the aerosol forming material has a first concentration of a aerosol forming liquidand a second portion 46 of the aerosol forming material has a second concentration of the aerosol forming liquid. The first concentration (in the first portion 44) is greater than the second concentration (in the second portion 46).

[0216] The aerosol generating segment 40 is wrapped in a combining paper 42. The combining paper 42 may be a foil-paper laminate.

[0217] In Fig. 5a, the first portion 44 of the aerosol precursor is displaced from the second portion 46 of the aerosol forming material. The first portion 44 and the second portion 46 may be located at different axial and radial positions. Some strips may only include a first portion 44. Some stips may only include a second portion 46. In some strips, the first portion 44 is located at the downstream end and the second portion 46 is located at the upstream end. In some strips, the first portion 44 is located at the upstream end and the second portion 46 is located at the downstream end. In some strips, the first portion 44 is located in the middle of the strip, and the second portion 46 is located at the upstream and downstream ends. In some strips, the second portion 46 is located in the middle of the strip, and the first portion 44 is located at the upstream and downstream ends. That is, the position of the first portion and second portion is random.

[0218] In Fig. 5b, the first portion 44 of the aerosol precursor is positioned downstream of the second portion 46 of the aerosol forming material. In alternative examples, the first portion 44 of the aerosol precursor is positioned upstream of the second portion 46 of the aerosol forming material. In this way, the first portion 44 and second portion 46 are separated along the axial length of the aerosol generating segment.

[0219] Referring to Fig. 6, an aerosol generating segment 40 is shown in an example heat-not-burn consumable 70. The aerosol generating segment 40 is located at the upstream end of the consumable 70. Downstream of the aerosol generating segment 40 is a tubular segment 72. The tubular segment 72 may be known as a cooling segment. Downstream of the tubular segment 72 is a mouthpiece filter 74. The mouthpiece filter 74 is at the downstream end of the consumable 70. The aerosol generating segment 40, the tubular segment 72 and the mouthpiece filter 74 are wrapped together using a combining paper 76. The combining paper 76 is wrapped around the segments and glued into place using an adhesive.

[0220] Any of the aerosol generating segment 40, as shown in Fig. 4a, Fig. 4b, Fig. 5a, and Fig. 5b may be used in the consumable 70 shown in Fig. 6.

[0221] Referring to Fig. 7a, the aerosol generating segment 40, as illustrated in Fig. 5b, is provided in an example consumable 70. The consumable 70 is shown relative to the heater elements 54 of the aerosol generating apparatus. As explained for Fig. 3, the consumable 70 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 be located adjacent to the aerosol forming material segment 40. In this example, the heating elements 54 are annular heating elements that are positioned about the circumference of the aerosol generating segment 40.

[0222] In Fig. 7a, a first annular heating element 54a is located adjacent to the first portion 44 of the aerosol forming material, and a second annular heating element 54b is located adjacent to the second portion 46 of the aerosol forming material. The annular heating elements each heat their respective section of the aerosol generating segment.

[0223] Referring to Fig. 7b, the aerosol generating segment 40, as illustrated in Fig. 4b, is provided in an example consumable 70. The consumable 70 is shown relative to the heater elements 54 of the aerosol generating apparatus. As explained for Fig. 3, the consumable 70 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 be located adjacent to the aerosol forming material segment 40. In this example, the heating elements 54 are semi-annular heating elements that are positioned about the circumference of the aerosol generating segment 40. A first semi annular heating element 54a is located adjacent to the first portion 44 of the aerosol forming material, and a second semi annular heating element 54b is located adjacent to the second portion 46 of the aerosol forming material. The semi-annular heating elements each heat one side of the aerosol generating segment, which include the first and second portions of aerosol forming material respectively.

[0224] As shown in Fig. 7a and Fig. 7b, the use of a separate first heating element 54a and second heating element 54b allows for the first portion 44 and second portion 46 to be heated differently. In some examples, the first heating element 54a may heat to a higher maximum temperature than the second heating element 54b. In some examples, the first heating element 54a may heat at a higher rate than the second heating element 54b.

[0225] In this way, the higher concentration of aerosol forming liquid present in the first portion may be aerosolised quickly, for example, at the start of a session. The lower concentration of aerosol forming liquid present in the second portion is aerosolised more slowly, to allow for the gradual release of nicotine and / or flavour components, without burning or charring the aerosol forming material. Referring to Fig. 8, this shows an example bobbin 80 of aerosol forming material. The bobbin 80 includes one sheets of carrier material. During manufacturing of the aerosol generating segment, the bobbin 80 is unwound to provide the sheet of carrier material 83. A aerosol forming liquid is then applied to the carrier material 83 using an applicator 81 (e.g., a sprayer). The applicator 81 applies aerosol forming liquid to one side (e.g., the right side) of the carrier material, and does not apply aerosol forming liquid to the other side (e.g., the left side) of the carrier material. The portion of the carrier material which is not sprayed with aerosol forming liquid corresponds to the second portion. The portion of the carrier material which is sprayed with a aerosol forming liquid corresponds to the first portion 84. The sheet of aerosol forming material (including the sprayed and non-sprayed portions) are then divided to form strip, which include a first portion 44 with a higher concentration of aerosol forming liquid and a second portion 46 with a lower concentration of aerosol forming substrate. The strips are then gathered together. The gathered strips are then arranged into a rod shape and formed into an aerosol generating segment, by wrapping with a combining paper. The strips formed by the examples of Fig. 8 may be used in the aerosol generating segment illustrated in Fig. 5b.

[0226] In an alternative example of Fig. 8 , the sheet of carrier material is divided into sheets, the sheets both including an area (first portion) with a high concentration of aerosol forming liquid and an area (second portion) with a low concentration of aerosol forming liquid. The sheets formed by this method may be used in the aerosol generating segment illustrated in Fig. 4a.

[0227] Referring to Fig. 9, this shows an example bobbin 80 of aerosol forming material. The bobbin 80 includes one sheets of carrier material. During manufacturing of the aerosol generating segment, the bobbin 80 is unwound to provide the sheet of carrier material 83. A aerosol forming liquid is then applied to the carrier material 83 using an applicator 81 (e.g., a sprayer). The applicator 81 intermittently applies aerosol forming liquid across the full width of the aerosol forming material, to give alternating portions which are and are not sprayed with aerosol forming liquid. The portion of the carrier material which is not sprayed with aerosol forming liquid corresponds to the second portion. The portion of the carrier material which is sprayed with a aerosol forming liquid corresponds to the first portion 84. The sheet of aerosol forming material (including the sprayed and non-sprayed portions) are then divided to form strips. Some strips correspond to a first portion 44 and have a higher concentration of aerosol forming liquid and some strips corresponds to a second portion 46 with a lower concentration of aerosol forming liquid. The strips may then be further divided to reduce their length. The strips are then gathered together. The gathered strips are then arranged into a rod shape and formed into an aerosol generating segment, by wrapping with a combining paper.

[0228] In an alternative example of Fig. 9 , the sheet of carrier material is divided into sheets, the sheets both including an area (first portion) with a high concentration of aerosol forming liquid and an area (second portion) with a low concentration of aerosol forming liquid. The sheets formed by this method may be used in the aerosol generating segment illustrated in Fig. 4b.

Examples

Embodiment Construction

[0164]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.

[0165]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.

[0166]Any paten...

Claims

1. An aerosol generating segment for a heat-not-burn consumable, the aerosol generating segment comprising: one or more sheets of an aerosol forming material, wherein the aerosol forming material comprises a carrier material and a aerosol forming liquid; wherein a first portion of the aerosol forming material has a first concentration of the aerosol forming liquid and a second portion of the aerosol forming material has a second concentration of the aerosol forming liquid, wherein the first concentration is greater than the second concentration.

2. The aerosol generating segment according to claim 1, wherein the ratio of the first concentration to the second concentration is 60:40 or more, optionally 70:30 or more, 80:20 or more, 90:10 or more, or 95:5 or more.

3. The aerosol generating segment according to claim 1 or claim 2, wherein the first portion comprise from 15 to 50 wt.% aerosol forming liquid, based on the mass of the aerosol forming liquid and carrier material; and / or the second portion comprises from 0 to 30 wt.% aerosol forming liquid, based on the mass of the aerosol forming liquid and carrier material.

4. The aerosol generating segment according to any preceding claim, wherein the first concentration of aerosol forming liquid is from 50 to 400 mg / cm3, based on the mass of aerosol forming liquid and carrier material in the first portion; and / or the second concentration of aerosol forming liquid is from 0 to 200 mg / cm3, based on the mass of aerosol forming liquid and carrier material in the second portion.

5. The aerosol generating segment according to any preceding claim, wherein the first portion of the aerosol forming material is one or more first areas of the one or more sheets of aerosol forming material and the second portion of the aerosol precursor is one or more second areas of the one or more sheets of aerosol forming material.

6. The aerosol generating segment according to claim 5, wherein the first areas are located towards an upstream end of the aerosol generating segment and the second areas are located towards a downstream end of the aerosol generating segment.

7. The aerosol generating segment according to any preceding claim, wherein a first portion of the aerosol forming material is one or more first strips of aerosol forming material and the second portion of the aerosol precursor is one or more second strips of aerosol forming material.

8. The aerosol generating segment according to claim 7, wherein the first strips and the second strips are inhomogeneously dispersed within the aerosol generating segment.

9. The aerosol generating segment according to claim 8, wherein the first strips are located towards the circumference of the aerosol generating segment and the second strips are located towards a centre of the aerosol generating segment.

10. The aerosol generating segment according to any preceding claim, wherein the first portion and the second portion comprise the same type of aerosol forming material carrier material and / or the same type of aerosol forming liquid.

11. A heat-not-burn consumable comprising an aerosol generating segment according to any one of claims 1 to 10.

12. An aerosol-generating system comprising an aerosol generating unit and the heat-not-burn consumable according to claim 11.

13. A method of preparing an aerosol generating segment for a heat-not-burn consumable, the method comprising: providing a sheet of aerosol forming material carrier material; applying an aerosol forming liquid to a first portion of the carrier material to form a sheet of an aerosol forming material, wherein the first portion of the aerosol forming material has a first concentration of the aerosol forming liquid and a second portion of the aerosol precursor has a second concentration of the aerosol forming liquid, wherein the first concentration is greater than the second concentration ; and forming an aerosol generating segment from one or more sheets of aerosol forming material.

14. The method of claim 13, wherein the method further comprises a step of: arranging the first portion of the aerosol forming material towards an upstream end of the aerosol generating segment and arranging the second portion of the aerosol forming material towards a downstream end of the aerosol generating segment.

15. A use of an aerosol generating segment according to any one of claims 1 to 10 or the heat-not-burn consumable of claim 11 with an aerosol generating unit, to increase a volume of aerosol generated in use, wherein the volume is increased compared to aerosol generating segment having a uniform distribution of aerosol forming liquid, and / or to improve the flavour profile to improve the flavour profile of an aerosol generated in use, wherein the flavour profile is improved compared to an aerosol generating segment having a uniform distribution of aerosol forming liquid.

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