Aerosol-generating segment

Abstract

Disclosed is an aerosol-generating segment for a heat-not-burn consumable, the aerosol-generating segment being wrapped by a layered wrapper comprising a paper layer and a foil layer, wherein the paper layer has a basis weight of 70 gsm or more and the foil layer has a basis weight of about 10 to about 20 gsm; an aerosol-generating system comprising the aerosol-generating segment or the heat-not-burn consumable and an aerosol-generating unit; and use of the layered wrapper.

Description

FIELD

[0001] The present disclosure relates to an aerosol-generating segment for a heat-not-burn consumable. The aerosol-generating segment comprises a layered wrapper to improve the hardness characteristics of the segment. The present disclosure also relates to a method of making said aerosol-generating segment; a heat-not-burn consumable comprising said aerosol-generating segment; an aerosol-generating apparatus comprising said aerosol-generating segment or said heat-not-burn consumable; and the use of a layered wrapper to increase the hardness of an aerosol-generating segment.BACKGROUND

[0002] A heat-not-burn (HNB) device, also known as a heated tobacco device, is a type of aerosol-generating system in which an aerosol precursor (e.g., a solid precursor such as tobacco, where "solid precursor" may also be referred to herein as an "aerosol-forming material") is heated by a heating system to produce an aerosol that can be inhaled by the user.

[0003] A typical aerosol-generating consumable (aerosol-generating article) comprises an aerosol-generating segment. The aerosol-generating consumable is typically used in an aerosol-generating system. A typical aerosol-generating apparatus may comprise a power supply, an aerosol-generating unit that is driven by the power supply, an aerosol precursor, which in use is aerosolised by the aerosol-generating unit to generate an aerosol, and a delivery system for delivery of the aerosol to a user. The aerosol precursor may be contained within the aerosol-generating consumable.

[0004] A drawback with known aerosol-generating segments, especially those comprising aerosol-forming materials that are soft (for example, cotton or gel-based pre-cursors), is that they can have low and / or inconsistent hardness. The low and / or inconsistent hardness can result in deformation during manufacture or in use.

[0005] In spite of the effort already invested in the development of aerosol-generating consumables for use in aerosol-generating apparatuses / systems, further improvements are desirable.

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

[0007] In a general aspect the present disclosure provides an aerosol-generating segment for heat-not-burn consumable, the aerosol-generating segment being wrapped by a layered wrapper. In some examples, the paper layer has a greater basis weight than the foil layer. In some examples, the paper layer has a basis weight of 70 gsm or more. In some examples, the foil layer has a basis weight of about 10 to about 20 gsm. In some examples, the paper layer has a basis weight of 70 gsm or more and the foil layer has a basis weight of about 10 to about 20 gsm.

[0008] In a first aspect the present disclosure provides an aerosol-generating segment for heat-not-burn consumable, the aerosol-generating segment being wrapped by a layered wrapper comprising a paper layer and a foil layer. In some examples, the paper layer has a basis weight of 70 gsm or more. In some examples, the foil layer has a basis weight of about 10 to about 20 gsm. In some examples, the paper layer has a basis weight of 70 gsm or more and the foil layer has a basis weight of about 10 to about 20 gsm.

[0009] In some examples of the aerosol-generating segment wrapped by a layered wrapper, the wrapping is complete. In some examples, the wrapping extends completely around the aerosol-generating segment. In some examples, the aerosol-generating segment has a generally cylindrical form, and the wrapping extends completely circumferentially around the aerosol-generating segment. In some examples, the aerosol-generating segment has a shape other than generally cylindrical, and the wrapping extends completely around a perimeter length of the aerosol-generating segment. In some examples the wrapping is incomplete or partial. In such examples, the wrapping may not extend completely around the aerosol-generating segment. The incomplete or partial wrapping may be up to 90% complete, or up to 80% complete, or up to 70% complete, or up to 60% complete, or up to 50% complete. The incomplete or partial wrapping may be at least 20 % complete, or at least 30% complete, or at least 40% complete. The foregoing values may be combined in any way to create a range. The incomplete or partial wrapping may be continuous or may be discontinuous.

[0010] The layered wrapper may comprise a paper layer and a foil layer. In some examples, the layers of the layered wrapper are abutting. In some examples, the foil layer and the paper layer are abutting, e.g. in direct contact with one another. In some examples, the layers of the layered wrapper are not adhered together. In some examples, the layers of the layered wrapper are adhered together. In some examples, the layered wrapper comprises a foil layer and a paper layer that are laminated together. As such, in some examples, the layered wrapper is or comprises a foil-paper laminate. In some examples, the layered wrapper is a foil-paper laminate. The layered wrapper may have at least one layer of foil immediately adjacent to a layer of paper. The foil layer and the paper layer may be joined using, for example, adhesive. Any adhesive used to adhere the two layers is not considered a separate layer. In some examples, the paper layer and the foil layer are laminated in a facially adjacent arrangement, such as having facial contact. In some examples the foil layer is an inner layer, and closer to centre of the aerosol-generating segment, and the paper layer is an outer layer.

[0011] In some examples the paper layer is an inner layer, and closer to the centre of the aerosol-generating segment, and the foil layer is an outer layer. In some examples the layered wrapper comprises one or more further layers of foil and / or paper. In some examples, the layered wrapper comprises one or more further layers of a material other than foil or paper.

[0012] In some examples, the paper layer has a basis weight of 70 gsm or more and the foil layer has a basis weight of about 10 to about 20 gsm. It is understood that the basis weight, having units of gsm, or grams per square metre, may be a function of both the bulk density of that layer (ρ = m / v; where ρ is bulk density, m is mass and v is volume) and the thickness of that layer. As such, the density and thickness of the layered wrapper, or the foil layer and paper layer thereof, can be adjusted to achieve the required basis weight. The basis weight, bulk density and thickness may be related by the equation: ρ = basis weight thickness

[0013] In some examples the basis weight of the paper layer is 70 gsm or more. In some examples the basis weight of the paper layer is 80 gsm or more. In some examples the basis weight of the paper layer is 90 gsm or more. In some examples the basis weight of the paper layer is 100 gsm or more. In some examples the basis weight of the paper layer is 200 gsm or less. In some examples the basis weight of the paper layer is 180 gsm or less. In some examples the basis weight of the paper layer is 150 gsm or less. In some examples the basis weight of the paper layer is 120 gsm or less. In some examples the basis weight of the paper layer is about 100 gsm. Any of the lower and upper bounds discussed in the foregoing may be combined to create a range of possible basis weights for the paper layer. For example the basis weight of the paper layer may be between 70 gsm and 200 gsm; between 80 gsm and 180 gsm; between 80 gsm and 150 gsm; between 80 gsm and 120 gsm; between 80 gsm and 100 gsm; between 90 gsm and 150 gsm; between 90 gsm and 200 gsm; between 100 gsm and 200 gsm; between 90 gsm and 150 gsm; or between 100 gsm and 120 gsm.

[0014] In some examples the basis weight of the foil layer is about A ≤ foil basis weight ≤ B, wherein A is a lower bound and B is an upper bound of basis weight. In some examples A is about 10, about 11, about 12, about 13, or about 14. In some examples B is about 20, about 19, about 18, about 17, about 16 or about 15. Any of the lower and upper bounds discussed in the foregoing may be combined to create a range of possible basis weights for the foil layer. For example the basis weight of the foil layer may be between 10 gsm and 20 gsm; between 10 gsm and 19 gsm; between 11 gsm and 18 gsm; between 11 gsm and 20 gsm; between 12 gsm and 20 gsm; between 12 gsm and 18 gsm; between 13 gsm and 20 gsm; between 13 gsm and 19 gsm; between 14 gsm and 20 gsm; between 14 gsm and 18 gsm; between 15 gsm and 20 gsm; between 15 gsm and 19 gsm; or between 13 gsm and 20 gsm.

[0015] It may be that the basis weight of the layered wrapper is given by the equation: ρ p ∗ thickness p + ρ f ∗ thickness f = basisweight layered wrapper

[0016] In the above equation, subscript p refers to the paper layer, and subscript f refers to the foil layer. That is, the basis weight of the layered wrapper may in some examples be the sum of the basis weights of the paper and the foil layers. In some examples the basis weight of the layered wrapper is at least 80 gsm, and may be up to 220 gsm. In some examples the basis weight of the layered wrapper is given by about A ≤ foil basis weight ≤ B. In some examples A is about 80 gsm, about 90 gsm, about 100 gsm, about 110 gsm or about 120 gsm. In some examples B is about 220 gsm, about 210 gsm, about 200 gsm, about 180 gsm, about 150 gsm or about 140 gsm. The lower and upper bounds discussed in the foregoing may be combined to create a range of possible basis weights for the layered wrapper. For example, the basis weight of the layered wrapper may be any of about 80 gsm to about 220 gsm; or about 80 gsm to about 210 gsm; or about 80 gsm to about 200 gsm; or about 80 gsm to about 150 gsm; or about 80 gsm to about 140 gsm; or about 100 gsm to about 150 gsm; or about 90 gsm to about 150 gsm; or about 90 gsm to about 180 gsm; or about 100 gsm to about 180 gsm; or about 100 gsm to about 140 gsm.

[0017] The basis weight of the paper and foil layers can be easily measured using techniques known to the person skilled in the art. For example, it may be derived by measuring the thickness, acquiring bulk density of the layer, and using the relationship described above.

[0018] In some examples, the basis weight of a sample (foil, paper, or layered wrapper) (in gsm) is measured using a Frank Universal Thickness Tester, for example Type 16502 or IDF 130. In some examples, the measurement uses a calculation for gsm from measurement of the weight of a sample related to its surface dimension.

[0019] In some examples, a sample is provided as a bobbin and / or a sheet such as an A4 sheet.

[0020] In some examples, a specified length of a sample provided as a bobbin is taken and cut or slit into individual samples. In some examples, a cutter is used, for example a circular cutter. In some examples, the specified length is 1 to 10 m. In some examples, the size of the individual samples depends on the bobbin width or the sheet width. In some examples, individual samples of a sample provided as a sheet are prepared, for example using a cutter such as a circular cutter. In some examples, the circular cutter has a diameter of 100 mm, or 50 mm, or 16 mm.

[0021] In some examples, the thickness is measured using a suitable measurement device, such as the Frank Universal Thickness Tester device mentioned above.

[0022] In some examples, the sample is prepared by separating layers of a sample. Separation can be carried out by any suitable process.

[0023] In some examples, the sample thickness is at least 1 µm.

[0024] In some examples the thickness of the layered wrapper is about 20-200 µm, or about 20-150 µm, or about 20-100 µm, or about 40-200 µm, or about 40-150 µm, or about 40-80 µm, or about 150 µm. In some examples, the thickness of the layered wrapper is about 120 µm. In some examples, the thickness of the layered wrapper is about 100 µm. In some examples, the thickness of the layered wrapper is about 80 µm. In some examples the thickness of the layered wrapper is about 60µm. In some examples, the thickness of the paper layer is about 10-180 µm, or about 10-150 µm, or about 10-100 µm, or about 10-70 µm, or about 30-180 µm, or about 30-150 µm, or about 30-100 µm, or about 30-50 µm. In some examples the thickness of the paper layer is about 150 µm. In some examples the thickness of the paper layer is about 100 µm. In some examples the thickness of the paper layer is about 40 µm. In some examples the thickness of the foil layer is about 2-20 µm, or about 2-10 µm, or about 4-15 µm, or about 4-8 µm. In some examples the thickness of the foil layer is about 12 µm. In some examples the thickness of the foil layer is about 6 µm.

[0025] In some examples the wrapping covers the entire length of the aerosol-generating segment. In some examples, the wrapping covers the entire length, and full circumference of the aerosol-generating segment. In some examples the layered wrapper extends beyond the length of aerosol-generating segment. In some examples where the layered wrapper extends beyond the length of the aerosol-generating segment, the layered wrapper at least partially wraps an adjacent segment.

[0026] In some examples the aerosol-generating segment has a length of 1 to 50 mm. In some examples the length of the aerosol-generating segment is 5 to 30 mm. In some examples the aerosol-generating segment has a thickness (e.g. diameter, or other chosen thickness dimension) of 1 to 15 mm. In some examples the thickness of the aerosol-generating segment is 4 to 12 mm.

[0027] In some examples the paper layer and foil layer in the layered wrapper are held together by an adhesive.

[0028] In some examples a wrapping comprising a layered wrapper as claimed improves strength, rigidity and / or hardness to the aerosol-generating segment. This may improve ease of handling of the aerosol-generating segment. In some examples, handling is easier during manufacturing (for example, during assembly, or during a cutting step or during a combining step) and / or when using the aerosol-generating segment (for example, during insertion or removal from an aerosol-generating unit). In some examples the layered wrapper improves the consistency of the hardness by providing a greater contribution to the hardness of the wrapped aerosol-producing segment than the precursor (equivalently, "aerosol-forming material") of the aerosol-generating segment. Advantageously, the use of the layered wrapper achieves increased hardness without changing the air flow properties of the aerosol-generating segment, for example a consistent pressure drop can be provided across the aerosol-generating segment. In some examples, the use of both paper and foil in the layered wrapper may result in synergistic improvements in hardness, whilst not compromising other parameters like the weight, air flow and general performance of the aerosol-generating segment.

[0029] It may be that softness / hardness is characterised by a Borgwaldt hardness (DD60A). The Borgwaldt hardness may be measured using a Borgwaldt DD60A method. In some examples, the Borgwaldt hardness value is an average of 50 samples. In some examples, the Borgwaldt hardness value is measured by a method in which the average (mean) diameter of the samples (in mm) and the mass of the samples (in g) is taken before and after application of a load. In some examples, the load is around or is 3 kg. In some examples, the load is applied for a specified number of seconds, such as around 10 s or 10 s. In some examples, a 3 kg load is applied for 10 s.

[0030] In some examples, the method involves measuring an average diameter of the samples (in mm) before application of the load, using any suitable method such as SEM, and measuring the weight (in g) of those samples using any suitable method, such as a weighing scale, and determining the average (mean) weight per sample. In some examples, the method includes measuring an average (mean) diameter of a sample (mm) after application of the load.

[0031] In some examples, a Borgwaldt hardness (%) may be calculated as follows: average diameter after applying load mm / average diameter before applying load mm × 100

[0032] In some examples the wrapped aerosol-generating segment has a Borgwaldt hardness (DD60A) value >90%. In such examples, the hardness of the aerosol-generating segment may advantageously enhance the structural integrity of the segment, and therefore a heat-not-burn consumable that the aerosol-generating segment might be part of. In some examples, the hardness, or specifically the Borgwaldt hardness (DD60A), may refer to the average hardness over the length of the aerosol-generating segment. In some examples, the hardness, or specifically the Borgwaldt hardness (DD60A) may refer to a point hardness of a representative region or point of the aerosol-generating segment.

[0033] In some examples the Borgwaldt hardness (DD60A) value is > 91%. In some examples the Borgwaldt hardness (DD60A) value is > 92%. In some examples the Borgwaldt hardness (DD60A) value is > 93%. In some examples the Borgwaldt hardness (DD60A) value is > 94%. In some examples the Borgwaldt hardness (DD60A) value is > 95%.

[0034] In some examples the layered wrapper is secured to the precursor by an adhesive.

[0035] In some examples the aerosol-generating segment comprises an aerosol-forming material that is softer than the layered wrapper. As used herein, "softer" or "soft", and likewise "harder" or "hard", relates to how easily the material can be locally plastically deformed (such as dented, deformed or scratched). In some examples the aerosol-forming material comprises one or more of cellulose, cotton and a gel.

[0036] The aerosol-forming material may be contained in the aerosol-generating segment. The aerosol-forming material provides a contribution to the hardness of the segment. This may be determined based on the hardness (e.g., Borgwaldt hardness) of the aerosol-forming material. The layered wrapper may also provide a contribution to the hardness (e.g., Borgwaldt hardness) of the segment. Thus, in some examples, the aerosol-generating segment comprises an aerosol-forming material that provides a smaller contribution to the hardness of the aerosol-generating segment than the layered wrapper.

[0037] In such examples, the aerosol-forming material may be described as "soft". Such precursors may be desirable for a number of reasons. For example, such soft precursor may provide desirable aerosol generation characteristics, or a desirable active ingredient perception. In known aerosol-generating segments a soft precursor might lead to poor physical characteristics that can lead to damage in manufacture and in use. The aerosol-generating segment of the present invention, comprising the wrapping described herein, allows for the use of aerosol-forming materials comprising cellulose, cotton and / or gel whilst ensuring the aerosol-generating segment remains intact throughout manufacture and use. For example, improving the hardness of the aerosol-generating segment may more generally allow for the use of soft aerosol-forming materials. In some examples the layered wrapper is responsible for the majority of the hardness of the aerosol-generating segment.

[0038] As used herein, "cotton" describes processed or unprocessed cotton or a cotton derived product. As used herein, "cellulose" describes processed or unprocessed cellulose, or a cellulose derived product. Cellulose and cotton used herein may be naturally derived, for example from renewable, sustainable sources. As used herein, "a gel" describes a material comprising a colloidal network that is expanded through its whole volume by a fluid. In some examples the gel is a hydrogel.

[0039] In some examples the aerosol precursor further comprises one or more of a carrier, an active ingredient, and a flavouring.

[0040] In some examples the foil of the foil layer comprises a metal or is a metal. In some examples, the metal comprises aluminium, or is aluminium foil. In such a case, the foil may be described as an aluminium foil.

[0041] Including aluminium in the foil layer may be desirable due to the strength to weight ratio of aluminium.

[0042] In addition to wrapping the aerosol-generating segment, the layered wrapper may also wrap 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.

[0043] 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.

[0044] 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.

[0045] In some examples the aerosol-generating segment is elongate or prolate. In some examples, the aerosol-generating segment is cylindrical. In some examples, the aerosol-generating segment is rod-shaped. In some examples, the aerosol-generating consumable has a corresponding shape to, or the same shape, as the aerosol-generating segment.

[0046] In some examples the aerosol-generating segment has a length which is greater than a width and height. In some examples, the length is aligned with a flowpath of the segment. In some examples, the difference in Borgwaldt hardness (DD60A) along the length of the wrapped aerosol-generating segment is (substantially) consistent or uniform. In some examples the wrapped aerosol-generating segment has a low rate of change of hardness across the stick length. In some examples, the wrapped aerosol-generating segment has a difference in Borgwaldt hardness (DD60A) of within 2% along its length. In some examples the difference in Borgwaldt hardness (DD60A) is within 1.5% along its length. In some examples the difference in Borgwaldt hardness (DD60A) is within 1% along its length.

[0047] As used herein, "within 2%" (or any other value) is understood to mean that the hardness values of all points along the length of the aerosol-generating segment will be within a range of hardness values that is 2% wide.

[0048] In some examples, a uniform hardness across the length of the wrapped aerosol-generating segment advantageously promotes the structural integrity of the wrapped segment during manufacture and during use, no matter at what point on the wrapped segment it is stressed.

[0049] As described herein, the aerosol-forming material may comprise plant material.

[0050] 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.

[0051] 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.

[0052] The aerosol-forming material may be absent of tobacco and / or nicotine.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] The humectant content of the aerosol-forming material may have a lower limit of at least 5 wt %, such as at least 10 wt %. The humectant content of the combustible material of the smoking body may have an upper limit of at most 50 % by weight of the plant material, such as at most 40 wt %.

[0057] 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.

[0058] The cannabinoid compounds may be selected from the non-exhaustive list comprising: tetrahydrocannabinol (THC), cannabidiol (CBD), cannabinol (CBN).

[0059] 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.

[0060] 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.

[0061] In a second aspect the present disclosure provides an aerosol-generating segment for a heat-not-burn consumable, the aerosol-generating segment being wrapped by a layered wrapper comprising a paper layer and a foil layer, wherein the aerosol-generating segment comprises an aerosol-forming material comprising one or more of cellulose, cotton, and a gel, and wherein the wrapped aerosol-generating segment has a Borgwaldt hardness (DD60) value of >90%.

[0062] In some examples the Borgwaldt hardness (DD60A) value is > 91%. In some examples the Borgwaldt hardness (DD60A) value is > 92%. In some examples the Borgwaldt hardness (DD60A) value is > 93%. In some examples the Borgwaldt hardness (DD60A) value is > 94%. In some examples the Borgwaldt hardness (DD60A) value is > 95%.

[0063] In some examples the aerosol-generating segment of the second aspect is an aerosol-generating segment of the first aspect.

[0064] In a third aspect the present disclosure provides an aerosol-generating segment for a heat-not-burn consumable, the aerosol-generating segment being wrapped by a layered wrapper comprising a paper layer and a foil layer, wherein the aerosol-generating segment comprises an aerosol-forming material comprising one or more of cellulose, cotton, and a gel, and wherein the wrapped aerosol-generating segment has a difference in Borgwaldt hardness (DD60A) of within 2% along its length.

[0065] In some examples the difference in Borgwaldt hardness (DD60A) is within 1.5% along its length. In some examples the difference in Borgwaldt hardness (DD60A) is within 1% along its length. In some examples, the Borgwaldt hardness across the length of the segment is calculated by measuring the hardness as described above at pre-determined points along the length of the segment. It may be that two measurements are taken, or it may be that more than two measurements are taken along the length of the segment. It may be that 3, 4 or 5 measurements are taken along the length of the segment.

[0066] In some examples, the wrapped aerosol-generating segment is part of an aerosol-generating consumable. In some examples the aerosol-generating consumable is a heat-not-burn (HNB) consumable. In some examples the aerosol-generating apparatus comprises a power supply, an aerosol-generating unit that is driven by the power supply, an aerosol precursor (e.g. the aerosol-generating consumable which comprises the wrapped aerosol-generating segment), 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.

[0067] In a fourth aspect the present disclosure provides a method of making the aerosol-generating segment of the first, second or third aspects.

[0068] In some examples, the method of making the aerosol-generating segment comprises a bending step (e.g. "pre-bending") carried out on the layered wrapper in which the layered wrapper is bent independent of (e.g. before contact with) an aerosol-forming material and then it is subsequently used to wrap the aerosol-forming material. That is, the bending step is in some examples carried out in the absence of the aerosol-forming material; the bent (or pre-bent) layered wrapper is then subsequently used to wrap the aerosol-forming material to form the aerosol-generating segment. In some examples, the subsequent wrapping may involve further bending or shaping. In some examples, such pre-bending may allow for less pressure to be applied in the presence of the aerosol-forming material, thereby reducing, minimising or avoiding mis-shaping of the aerosol-forming material. In some examples, the pre-bending may do so particularly when the aerosol-forming material is soft.

[0069] In some examples, "bending" refers to the creation of a curve or arc in the layered wrapper. In some examples the bend is smooth and of constant curvature or concavity.

[0070] In some examples, the use of high basis weights in the paper and foil layers of the layered wrapper may beneficially employ a bending step. For example, a bending step might be used when the basis weight of the layered wrapper exceeds 100 gsm.

[0071] In some examples the method of making the aerosol-generating segment comprises wrapping a precursor in the layered wrapper. In some examples the method of making the aerosol-generating segment comprises securing the layered wrapper to the aerosol-forming material and / or to itself, to completely wrap the aerosol-forming material. In some examples the method of making the aerosol-generating segment comprises inserting or applying aerosol-forming material into a pre-bent layered wrapper. The methods for implementing the aerosol-generating segment as described herein in a heat-not-burn consumable are well known in the art and are readily available to the skilled person.

[0072] In a fifth aspect the present invention provides a heat-not-burn consumable, comprising the aerosol-generating segment of the first, second or third aspects.

[0073] In some examples, the heat-not-burn consumable is described as such because the aerosol-forming material in the aerosol-generating segment exhibits heat-not-burn characteristics.

[0074] In some examples the heat-not-burn consumable further comprises a hard segment adjacent to the aerosol-generating segment.

[0075] The hard segment may be so named because it may be harder than the aerosol-forming material of the aerosol-generating segment. In some examples the hard segment is inherently hard, that is it is not made hard by a wrapping. In some examples, the wrapped aerosol-generating segment is harder than the hard segment. In some examples, the wrapped aerosol-generating segment is softer than the hard segment. In some examples the wrapped aerosol-generating segment and the hard segment are of a comparable, or approximately equal hardness. In some examples the hard segment is upstream of the wrapped aerosol-generating segment. In some examples the hard segment is downstream of the wrapped aerosol-generating segment. Upstream and downstream are set in accordance with the direction of the flow of aerosol when the consumable is in use (i.e. the flowpath).

[0076] In some examples the hard segment is an additional aerosol-generating segment or a cooling segment.

[0077] In such examples the cooling segment is so-called as it cools the aerosol generated when the consumable is in use. In some examples the cooling segment comprises a paper tube. In some examples the cooling segment comprises a spiral paper tube, that is a continuous paper tube, wound in a spiral.

[0078] In some examples the hard segment is a second aerosol-generating segment. For example, the alternative aerosol-generating segment may comprise a reconstituted aerosol-forming material that is harder than the aerosol-forming material used in the wrapped aerosol-generating segment.

[0079] Where a soft segment (i.e. an unwrapped aerosol-generating segment comprising a soft aerosol-forming material) is adjacent to a hard segment, the soft segment is particularly prone to deformation during manufacture or in use. The wrapping of the present invention makes the hardness of the wrapped aerosol-generating segment comparable to hard segments and reduces the chance of deformation or damage during manufacture and use.

[0080] In some examples the heat-not-burn consumable comprises further segments in series with the wrapped aerosol-generating segment. In some examples the heat-not-burn consumable comprises one or more filter segments in series, for example downstream, of the wrapped aerosol-generating segment. In some examples, all segments of the heat-not-burn consumable are held together by a combination of combining paper and tipping paper. In some examples the heat-not-burn consumable comprises a mouthpiece filter, at the end of the consumable configured to be engaged by a user when in use.

[0081] In a sixth aspect the present disclosure provides an aerosol-generating system comprising the aerosol-generating segment of the first, second or third aspects or the heat-not-burn consumable of the fifth aspect.

[0082] In some examples the aerosol-generating apparatus is referred to as a heat-not-burn apparatus.

[0083] In some examples the aerosol-generating apparatus comprises a power supply, an aerosol-generating unit that is driven by the power supply, an aerosol precursor (i.e. the aerosol-generating consumable which comprises the wrapped aerosol-generating segment), 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.

[0084] In an seventh aspect the present disclosure provides the use of a layered wrapper to increase the hardness of an aerosol-generating segment, wherein a paper layer of the layered wrapper has a basis weight of >50 gsm and a foil layer has a basis weight of about 10 to about 20 gsm; and / or the aerosol-generating segment comprises an aerosol-forming material comprising one or more of cellulose, cotton, and a gel, and wherein the wrapped aerosol-generating segment has a Borgwaldt hardness (DD60) value of >90%; and / or the aerosol-generating segment comprises an aerosol-forming material comprising one or more of cellulose, cotton, and a gel, and wherein the wrapped aerosol-generating segment has a difference in Borgwaldt hardness (DD60A) of within 2% along its length. In some examples, the layered wrapped is substantially as described herein for the other aspects.

[0085] The present disclosure may provide a method of generating an aerosol which may implement any one or more features disclosed herein. The method may comprise heating the aerosol-generating segment of the first, second or third aspects to generate an aerosol.

[0086] 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

[0087] Aspects, features and advantages of the present disclosure will become apparent from the following description of examples in reference to the appended drawings in which like numerals denote like elements. Fig. 1 is a block system diagram showing an example aerosol-generating apparatus. Fig. 2 is a block system diagram showing an example implementation of the apparatus of Fig. 1, where the aerosol-generating apparatus is configured to generate aerosol from a solid precursor. Fig. 3 is a schematic diagram showing an example implementation of the apparatus of Fig. 2. Fig. 4 is a perspective view of an example aerosol-generating segment. Fig. 5 is a cross-sectional view of an example aerosol-generating segment in an example heat-not-burn consumable. DETAILED DESCRIPTION OF EMBODIMENTS

[0088] Before describing 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.

[0089] 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.

[0090] Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.

[0091] 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.

[0092] 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.

[0093] 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).

[0094] 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.

[0095] 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.

[0096] The present disclosure may be better understood in view of the following explanations, wherein the terms used that are separated by "or" may be used interchangeably: As used herein, an "aerosol-generating apparatus" (or "electronic(e)-cigarette") may be an apparatus configured to deliver an aerosol to a user for inhalation by the user. The apparatus may additionally / alternatively be referred to as a "smoking substitute apparatus", if it is intended to be used instead of a conventional combustible smoking article. As used herein a combustible "smoking article" may refer to a cigarette, cigar, pipe or other article, that produces smoke (an aerosol comprising solid particulates and gas) via heating above the thermal decomposition temperature (typically by combustion and / or pyrolysis). An aerosol generated by the apparatus may comprise an aerosol with particle sizes of 0.2 - 7 microns, or less than 10 microns, or less than 7 microns. This particle size may be achieved by control of one or more of: heater temperature; cooling rate as the vapour condenses to an aerosol; flow properties including turbulence and velocity. The generation of aerosol by the aerosol-generating apparatus may be controlled by an input device. The input device may be configured to be user-activated, and may for example include or take the form of an actuator (e.g. actuation button) and / or an airflow sensor.

[0097] 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).

[0098] 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.

[0099] 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.

[0100] 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.

[0101] 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.

[0102] 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.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] 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.

[0107] As used herein, an "aerosol-generating unit" may refer to a device configured to generate an aerosol from a precursor. The aerosol-generating unit may include a unit to generate a vapour directly from the precursor (e.g. a heating system or other system) or an aerosol directly from the precursor (e.g. an atomiser including an ultrasonic system, a flow expansion system operative to carry droplets of the precursor in the flow without using electrical energy or other system). A plurality of aerosol-generating units to generate a plurality of aerosols (for example, from a plurality of different aerosol precursors) may be present in an aerosol-generating apparatus.

[0108] 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.

[0109] As used herein, a "consumable" may refer to a unit that includes a precursor. The consumable may include an aerosol-generating unit, e.g. it may be arranged as a cartomizer. The consumable may include a mouthpiece. The consumable may include an information carrying medium. With liquid or gel implementations of the precursor the consumable may be referred to as a "capsule" or a "pod". The capsule / pod may include a storage portion, e.g. a reservoir or tank, for storage of the precursor. With solid material implementations of the precursor, e.g. tobacco or reconstituted tobacco formulation, the consumable may be referred to as a "stick" or "package" or "heat-not-burn consumable". In a heat-not-burn consumable, the mouthpiece may be implemented as a filter and the consumable may be arranged to carry the precursor. The consumable may be implemented as a dosage or pre-portioned amount of material, including a loose-leaf product.

[0110] 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 cut-outs to encode a bit, through which pins or a reader may be inserted).

[0111] 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).

[0112] As used herein, a "laminate" may refer to an arrangement of two or more separate layers of material that are facially adjacent. A laminate is considered to comprise at least two layers joined together directly. In some examples, the laminate might be described as a stacked or layered structure. The two or more layers may be fused or adhered, reversibly or irreversibly, or may be in contact. For example, a foil-paper laminate may comprise at least one layer of paper and one layer of foil that are facially adjacent, and that may be fused or adhered together, to create a composite layered structure.

[0113] As used herein, a "foil" may describe a generally thin (i.e. substantially planar) sheet of material, such as a metallic material. The foil, by virtue of its dimensions, is, at least to an extent, pliable and deformable.

[0114] As used herein, "paper" may be given its normal and commonly understood meaning in the art and may refer to a material manufactured, for example in sheets, from the pulp of wood or other fibrous substances.

[0115] As used herein, "basis weight" may refer to the weight of a material per unit area of that material. It may be measured in grams per square metre, (gsm).

[0116] "Inner" and "outer" as used herein may refer to the inner and outer layers of the layered material structure when wrapped around the aerosol-generating segment, or when bent and ready to be wrapped around the aerosol-generating segment; the "inner" layer is that on the inside of the curve in the layered wrapper, the "outer" layer that on the outside of the curve in the wrapper.

[0117] As used herein, "length" describes an axial length of an elongate aerosol-generating segment. The segment is elongate when it has a length dimension that is greater than a width or a height dimension.

[0118] As used herein, "hard" and "soft", and any comparative term derived therefrom, may refer to the ease with which a material can be locally plastically deformed (such as dented, deformed, scratched, etc). A hard material may be more difficult to deform, and a soft material may be easier to deform. In some examples, the hardness may be measured using the Borgwaldt hardness scale as detailed herein.

[0119] Referring to Fig. 1, an example aerosol-generating apparatus 1 includes a power supply 2, for supply of electrical energy. The apparatus 1 includes an aerosol-generating unit 4 that is driven by the power supply 2. The power supply 2 may include an electric power supply in the form of a battery and / or an electrical connection to an external power source. The apparatus 1 includes a precursor 6, which in use is aerosolised by the aerosol-generating unit 4 to generate an aerosol. The apparatus 2 includes a delivery system 8 for delivery of the aerosol to a user. In the present invention at least a portion of the precursor is provided in a wrapped aerosol-generating segment, which is wrapped by a layered wrapper.

[0120] Electrical circuitry (not shown in figure 1) may be implemented to control the interoperability of the power supply 4 and aerosol-generating unit 6.

[0121] 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.

[0122] 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.

[0123] In this example, the apparatus 1 includes a device body 50 and a consumable 70.

[0124] 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.

[0125] 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.

[0126] The wireless interface 60 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.

[0127] 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).

[0128] 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.

[0129] Fig. 3 shows an example implementation of the aerosol-generating device 1 of Fig. 2.

[0130] 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.

[0131] 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 comprise a reconstituted tobacco formulation. The solid precursor is wrapped in a layered wrapper. As such, the precursor may be soft compared to the wrapping (for example, based on cotton, cellulose or a gel), whilst the wrapped segment, and therefore the consumable as a whole, maintains structural integrity.

[0132] 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).

[0133] 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. 5, 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.

[0134] 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.

[0135] The body 50 also includes a user interface device configured to convey information to a user. Here, the user interface device is implemented as a plurality of lights 57, which may e.g. be configured to illuminate when the apparatus 1 is activated and / or to indicate a charging state of the power supply 4. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.

[0136] 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.

[0137] 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.

[0138] 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.

[0139] Fig. 4 illustrates an aerosol-generating segment 100 according to one example of the present disclosure. The aerosol-generating segment 100 comprises an aerosol forming material 120, and a layered wrapper 140. The aerosol forming material may comprise an aerosol generating substrate and an aerosol former. The wrapper 140 includes two layers, a paper layer 122 and a foil layer 124. The foil layer 124 is sandwiched between the paper layer 122 and the aerosol-forming material 120. The paper layer 122 and the foil layer 124 are, in this example, laminated. In this example, the foil layer 124 has a basis weight of about 10 to 20 gsm and the paper layer 122 has a basis weight of 70 gsm or more. 130 is the longitudinal axis of the aerosol-generating segment 100, which is the lengthwise dimension in the direction of the flowpath.

[0140] Fig. 5 shows an aerosol generating segment 100 in an example heat-not-burn consumable 70. The aerosol generating segment 100, corresponding to the segment 100 of Fig. 4, is located at the upstream end of the consumable 70. Downstream of the aerosol generating segment 100 is a tubular segment 172. The tubular segment 172 may be known as a cooling segment. Downstream of the tubular segment 172 is a mouthpiece filter 174. The mouthpiece filter 174 is at the downstream end of the consumable 70. The aerosol generating segment 100, the tubular segment 172 and the mouthpiece filter 174 are wrapped together using a combining paper 141. Combining paper 141 is wrapped around the segments and glued into place using an adhesive.

[0141] Any aerosol generating segment described herein, may be used in the consumable 70 shown in Fig. 5.

Examples

Embodiment Construction

[0088]Before describing 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.

[0089]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.

[0090]Any patents, publ...

FIELD

[0001] The present disclosure relates to an aerosol-generating segment for a heat-not-burn consumable. The aerosol-generating segment comprises a layered wrapper to improve the hardness characteristics of the segment. The present disclosure also relates to a method of making said aerosol-generating segment; a heat-not-burn consumable comprising said aerosol-generating segment; an aerosol-generating apparatus comprising said aerosol-generating segment or said heat-not-burn consumable; and the use of a layered wrapper to increase the hardness of an aerosol-generating segment.BACKGROUND

[0002] A heat-not-burn (HNB) device, also known as a heated tobacco device, is a type of aerosol-generating system in which an aerosol precursor (e.g., a solid precursor such as tobacco, where "solid precursor" may also be referred to herein as an "aerosol-forming material") is heated by a heating system to produce an aerosol that can be inhaled by the user.

[0003] A typical aerosol-generating consumable (aerosol-generating article) comprises an aerosol-generating segment. The aerosol-generating consumable is typically used in an aerosol-generating system. A typical aerosol-generating apparatus may comprise a power supply, an aerosol-generating unit that is driven by the power supply, an aerosol precursor, which in use is aerosolised by the aerosol-generating unit to generate an aerosol, and a delivery system for delivery of the aerosol to a user. The aerosol precursor may be contained within the aerosol-generating consumable.

[0004] A drawback with known aerosol-generating segments, especially those comprising aerosol-forming materials that are soft (for example, cotton or gel-based pre-cursors), is that they can have low and / or inconsistent hardness. The low and / or inconsistent hardness can result in deformation during manufacture or in use.

[0005] In spite of the effort already invested in the development of aerosol-generating consumables for use in aerosol-generating apparatuses / systems, further improvements are desirable.

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

[0007] In a general aspect the present disclosure provides an aerosol-generating segment for heat-not-burn consumable, the aerosol-generating segment being wrapped by a layered wrapper. In some examples, the paper layer has a greater basis weight than the foil layer. In some examples, the paper layer has a basis weight of 70 gsm or more. In some examples, the foil layer has a basis weight of about 10 to about 20 gsm. In some examples, the paper layer has a basis weight of 70 gsm or more and the foil layer has a basis weight of about 10 to about 20 gsm.

[0008] In a first aspect the present disclosure provides an aerosol-generating segment for heat-not-burn consumable, the aerosol-generating segment being wrapped by a layered wrapper comprising a paper layer and a foil layer. In some examples, the paper layer has a basis weight of 70 gsm or more. In some examples, the foil layer has a basis weight of about 10 to about 20 gsm. In some examples, the paper layer has a basis weight of 70 gsm or more and the foil layer has a basis weight of about 10 to about 20 gsm.

[0009] In some examples of the aerosol-generating segment wrapped by a layered wrapper, the wrapping is complete. In some examples, the wrapping extends completely around the aerosol-generating segment. In some examples, the aerosol-generating segment has a generally cylindrical form, and the wrapping extends completely circumferentially around the aerosol-generating segment. In some examples, the aerosol-generating segment has a shape other than generally cylindrical, and the wrapping extends completely around a perimeter length of the aerosol-generating segment. In some examples the wrapping is incomplete or partial. In such examples, the wrapping may not extend completely around the aerosol-generating segment. The incomplete or partial wrapping may be up to 90% complete, or up to 80% complete, or up to 70% complete, or up to 60% complete, or up to 50% complete. The incomplete or partial wrapping may be at least 20 % complete, or at least 30% complete, or at least 40% complete. The foregoing values may be combined in any way to create a range. The incomplete or partial wrapping may be continuous or may be discontinuous.

[0010] The layered wrapper may comprise a paper layer and a foil layer. In some examples, the layers of the layered wrapper are abutting. In some examples, the foil layer and the paper layer are abutting, e.g. in direct contact with one another. In some examples, the layers of the layered wrapper are not adhered together. In some examples, the layers of the layered wrapper are adhered together. In some examples, the layered wrapper comprises a foil layer and a paper layer that are laminated together. As such, in some examples, the layered wrapper is or comprises a foil-paper laminate. In some examples, the layered wrapper is a foil-paper laminate. The layered wrapper may have at least one layer of foil immediately adjacent to a layer of paper. The foil layer and the paper layer may be joined using, for example, adhesive. Any adhesive used to adhere the two layers is not considered a separate layer. In some examples, the paper layer and the foil layer are laminated in a facially adjacent arrangement, such as having facial contact. In some examples the foil layer is an inner layer, and closer to centre of the aerosol-generating segment, and the paper layer is an outer layer.

[0011] In some examples the paper layer is an inner layer, and closer to the centre of the aerosol-generating segment, and the foil layer is an outer layer. In some examples the layered wrapper comprises one or more further layers of foil and / or paper. In some examples, the layered wrapper comprises one or more further layers of a material other than foil or paper.

[0012] In some examples, the paper layer has a basis weight of 70 gsm or more and the foil layer has a basis weight of about 10 to about 20 gsm. It is understood that the basis weight, having units of gsm, or grams per square metre, may be a function of both the bulk density of that layer (ρ = m / v; where ρ is bulk density, m is mass and v is volume) and the thickness of that layer. As such, the density and thickness of the layered wrapper, or the foil layer and paper layer thereof, can be adjusted to achieve the required basis weight. The basis weight, bulk density and thickness may be related by the equation: ρ = basis weight thickness

[0013] In some examples the basis weight of the paper layer is 70 gsm or more. In some examples the basis weight of the paper layer is 80 gsm or more. In some examples the basis weight of the paper layer is 90 gsm or more. In some examples the basis weight of the paper layer is 100 gsm or more. In some examples the basis weight of the paper layer is 200 gsm or less. In some examples the basis weight of the paper layer is 180 gsm or less. In some examples the basis weight of the paper layer is 150 gsm or less. In some examples the basis weight of the paper layer is 120 gsm or less. In some examples the basis weight of the paper layer is about 100 gsm. Any of the lower and upper bounds discussed in the foregoing may be combined to create a range of possible basis weights for the paper layer. For example the basis weight of the paper layer may be between 70 gsm and 200 gsm; between 80 gsm and 180 gsm; between 80 gsm and 150 gsm; between 80 gsm and 120 gsm; between 80 gsm and 100 gsm; between 90 gsm and 150 gsm; between 90 gsm and 200 gsm; between 100 gsm and 200 gsm; between 90 gsm and 150 gsm; or between 100 gsm and 120 gsm.

[0014] In some examples the basis weight of the foil layer is about A ≤ foil basis weight ≤ B, wherein A is a lower bound and B is an upper bound of basis weight. In some examples A is about 10, about 11, about 12, about 13, or about 14. In some examples B is about 20, about 19, about 18, about 17, about 16 or about 15. Any of the lower and upper bounds discussed in the foregoing may be combined to create a range of possible basis weights for the foil layer. For example the basis weight of the foil layer may be between 10 gsm and 20 gsm; between 10 gsm and 19 gsm; between 11 gsm and 18 gsm; between 11 gsm and 20 gsm; between 12 gsm and 20 gsm; between 12 gsm and 18 gsm; between 13 gsm and 20 gsm; between 13 gsm and 19 gsm; between 14 gsm and 20 gsm; between 14 gsm and 18 gsm; between 15 gsm and 20 gsm; between 15 gsm and 19 gsm; or between 13 gsm and 20 gsm.

[0015] It may be that the basis weight of the layered wrapper is given by the equation: ρ p ∗ thickness p + ρ f ∗ thickness f = basisweight layered wrapper

[0016] In the above equation, subscript p refers to the paper layer, and subscript f refers to the foil layer. That is, the basis weight of the layered wrapper may in some examples be the sum of the basis weights of the paper and the foil layers. In some examples the basis weight of the layered wrapper is at least 80 gsm, and may be up to 220 gsm. In some examples the basis weight of the layered wrapper is given by about A ≤ foil basis weight ≤ B. In some examples A is about 80 gsm, about 90 gsm, about 100 gsm, about 110 gsm or about 120 gsm. In some examples B is about 220 gsm, about 210 gsm, about 200 gsm, about 180 gsm, about 150 gsm or about 140 gsm. The lower and upper bounds discussed in the foregoing may be combined to create a range of possible basis weights for the layered wrapper. For example, the basis weight of the layered wrapper may be any of about 80 gsm to about 220 gsm; or about 80 gsm to about 210 gsm; or about 80 gsm to about 200 gsm; or about 80 gsm to about 150 gsm; or about 80 gsm to about 140 gsm; or about 100 gsm to about 150 gsm; or about 90 gsm to about 150 gsm; or about 90 gsm to about 180 gsm; or about 100 gsm to about 180 gsm; or about 100 gsm to about 140 gsm.

[0017] The basis weight of the paper and foil layers can be easily measured using techniques known to the person skilled in the art. For example, it may be derived by measuring the thickness, acquiring bulk density of the layer, and using the relationship described above.

[0018] In some examples, the basis weight of a sample (foil, paper, or layered wrapper) (in gsm) is measured using a Frank Universal Thickness Tester, for example Type 16502 or IDF 130. In some examples, the measurement uses a calculation for gsm from measurement of the weight of a sample related to its surface dimension.

[0019] In some examples, a sample is provided as a bobbin and / or a sheet such as an A4 sheet.

[0020] In some examples, a specified length of a sample provided as a bobbin is taken and cut or slit into individual samples. In some examples, a cutter is used, for example a circular cutter. In some examples, the specified length is 1 to 10 m. In some examples, the size of the individual samples depends on the bobbin width or the sheet width. In some examples, individual samples of a sample provided as a sheet are prepared, for example using a cutter such as a circular cutter. In some examples, the circular cutter has a diameter of 100 mm, or 50 mm, or 16 mm.

[0021] In some examples, the thickness is measured using a suitable measurement device, such as the Frank Universal Thickness Tester device mentioned above.

[0022] In some examples, the sample is prepared by separating layers of a sample. Separation can be carried out by any suitable process.

[0023] In some examples, the sample thickness is at least 1 µm.

[0024] In some examples the thickness of the layered wrapper is about 20-200 µm, or about 20-150 µm, or about 20-100 µm, or about 40-200 µm, or about 40-150 µm, or about 40-80 µm, or about 150 µm. In some examples, the thickness of the layered wrapper is about 120 µm. In some examples, the thickness of the layered wrapper is about 100 µm. In some examples, the thickness of the layered wrapper is about 80 µm. In some examples the thickness of the layered wrapper is about 60µm. In some examples, the thickness of the paper layer is about 10-180 µm, or about 10-150 µm, or about 10-100 µm, or about 10-70 µm, or about 30-180 µm, or about 30-150 µm, or about 30-100 µm, or about 30-50 µm. In some examples the thickness of the paper layer is about 150 µm. In some examples the thickness of the paper layer is about 100 µm. In some examples the thickness of the paper layer is about 40 µm. In some examples the thickness of the foil layer is about 2-20 µm, or about 2-10 µm, or about 4-15 µm, or about 4-8 µm. In some examples the thickness of the foil layer is about 12 µm. In some examples the thickness of the foil layer is about 6 µm.

[0025] In some examples the wrapping covers the entire length of the aerosol-generating segment. In some examples, the wrapping covers the entire length, and full circumference of the aerosol-generating segment. In some examples the layered wrapper extends beyond the length of aerosol-generating segment. In some examples where the layered wrapper extends beyond the length of the aerosol-generating segment, the layered wrapper at least partially wraps an adjacent segment.

[0026] In some examples the aerosol-generating segment has a length of 1 to 50 mm. In some examples the length of the aerosol-generating segment is 5 to 30 mm. In some examples the aerosol-generating segment has a thickness (e.g. diameter, or other chosen thickness dimension) of 1 to 15 mm. In some examples the thickness of the aerosol-generating segment is 4 to 12 mm.

[0027] In some examples the paper layer and foil layer in the layered wrapper are held together by an adhesive.

[0028] In some examples a wrapping comprising a layered wrapper as claimed improves strength, rigidity and / or hardness to the aerosol-generating segment. This may improve ease of handling of the aerosol-generating segment. In some examples, handling is easier during manufacturing (for example, during assembly, or during a cutting step or during a combining step) and / or when using the aerosol-generating segment (for example, during insertion or removal from an aerosol-generating unit). In some examples the layered wrapper improves the consistency of the hardness by providing a greater contribution to the hardness of the wrapped aerosol-producing segment than the precursor (equivalently, "aerosol-forming material") of the aerosol-generating segment. Advantageously, the use of the layered wrapper achieves increased hardness without changing the air flow properties of the aerosol-generating segment, for example a consistent pressure drop can be provided across the aerosol-generating segment. In some examples, the use of both paper and foil in the layered wrapper may result in synergistic improvements in hardness, whilst not compromising other parameters like the weight, air flow and general performance of the aerosol-generating segment.

[0029] It may be that softness / hardness is characterised by a Borgwaldt hardness (DD60A). The Borgwaldt hardness may be measured using a Borgwaldt DD60A method. In some examples, the Borgwaldt hardness value is an average of 50 samples. In some examples, the Borgwaldt hardness value is measured by a method in which the average (mean) diameter of the samples (in mm) and the mass of the samples (in g) is taken before and after application of a load. In some examples, the load is around or is 3 kg. In some examples, the load is applied for a specified number of seconds, such as around 10 s or 10 s. In some examples, a 3 kg load is applied for 10 s.

[0030] In some examples, the method involves measuring an average diameter of the samples (in mm) before application of the load, using any suitable method such as SEM, and measuring the weight (in g) of those samples using any suitable method, such as a weighing scale, and determining the average (mean) weight per sample. In some examples, the method includes measuring an average (mean) diameter of a sample (mm) after application of the load.

[0031] In some examples, a Borgwaldt hardness (%) may be calculated as follows: average diameter after applying load mm / average diameter before applying load mm × 100

[0032] In some examples the wrapped aerosol-generating segment has a Borgwaldt hardness (DD60A) value >90%. In such examples, the hardness of the aerosol-generating segment may advantageously enhance the structural integrity of the segment, and therefore a heat-not-burn consumable that the aerosol-generating segment might be part of. In some examples, the hardness, or specifically the Borgwaldt hardness (DD60A), may refer to the average hardness over the length of the aerosol-generating segment. In some examples, the hardness, or specifically the Borgwaldt hardness (DD60A) may refer to a point hardness of a representative region or point of the aerosol-generating segment.

[0033] In some examples the Borgwaldt hardness (DD60A) value is > 91%. In some examples the Borgwaldt hardness (DD60A) value is > 92%. In some examples the Borgwaldt hardness (DD60A) value is > 93%. In some examples the Borgwaldt hardness (DD60A) value is > 94%. In some examples the Borgwaldt hardness (DD60A) value is > 95%.

[0034] In some examples the layered wrapper is secured to the precursor by an adhesive.

[0035] In some examples the aerosol-generating segment comprises an aerosol-forming material that is softer than the layered wrapper. As used herein, "softer" or "soft", and likewise "harder" or "hard", relates to how easily the material can be locally plastically deformed (such as dented, deformed or scratched). In some examples the aerosol-forming material comprises one or more of cellulose, cotton and a gel.

[0036] The aerosol-forming material may be contained in the aerosol-generating segment. The aerosol-forming material provides a contribution to the hardness of the segment. This may be determined based on the hardness (e.g., Borgwaldt hardness) of the aerosol-forming material. The layered wrapper may also provide a contribution to the hardness (e.g., Borgwaldt hardness) of the segment. Thus, in some examples, the aerosol-generating segment comprises an aerosol-forming material that provides a smaller contribution to the hardness of the aerosol-generating segment than the layered wrapper.

[0037] In such examples, the aerosol-forming material may be described as "soft". Such precursors may be desirable for a number of reasons. For example, such soft precursor may provide desirable aerosol generation characteristics, or a desirable active ingredient perception. In known aerosol-generating segments a soft precursor might lead to poor physical characteristics that can lead to damage in manufacture and in use. The aerosol-generating segment of the present invention, comprising the wrapping described herein, allows for the use of aerosol-forming materials comprising cellulose, cotton and / or gel whilst ensuring the aerosol-generating segment remains intact throughout manufacture and use. For example, improving the hardness of the aerosol-generating segment may more generally allow for the use of soft aerosol-forming materials. In some examples the layered wrapper is responsible for the majority of the hardness of the aerosol-generating segment.

[0038] As used herein, "cotton" describes processed or unprocessed cotton or a cotton derived product. As used herein, "cellulose" describes processed or unprocessed cellulose, or a cellulose derived product. Cellulose and cotton used herein may be naturally derived, for example from renewable, sustainable sources. As used herein, "a gel" describes a material comprising a colloidal network that is expanded through its whole volume by a fluid. In some examples the gel is a hydrogel.

[0039] In some examples the aerosol precursor further comprises one or more of a carrier, an active ingredient, and a flavouring.

[0040] In some examples the foil of the foil layer comprises a metal or is a metal. In some examples, the metal comprises aluminium, or is aluminium foil. In such a case, the foil may be described as an aluminium foil.

[0041] Including aluminium in the foil layer may be desirable due to the strength to weight ratio of aluminium.

[0042] In addition to wrapping the aerosol-generating segment, the layered wrapper may also wrap 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.

[0043] 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.

[0044] 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.

[0045] In some examples the aerosol-generating segment is elongate or prolate. In some examples, the aerosol-generating segment is cylindrical. In some examples, the aerosol-generating segment is rod-shaped. In some examples, the aerosol-generating consumable has a corresponding shape to, or the same shape, as the aerosol-generating segment.

[0046] In some examples the aerosol-generating segment has a length which is greater than a width and height. In some examples, the length is aligned with a flowpath of the segment. In some examples, the difference in Borgwaldt hardness (DD60A) along the length of the wrapped aerosol-generating segment is (substantially) consistent or uniform. In some examples the wrapped aerosol-generating segment has a low rate of change of hardness across the stick length. In some examples, the wrapped aerosol-generating segment has a difference in Borgwaldt hardness (DD60A) of within 2% along its length. In some examples the difference in Borgwaldt hardness (DD60A) is within 1.5% along its length. In some examples the difference in Borgwaldt hardness (DD60A) is within 1% along its length.

[0047] As used herein, "within 2%" (or any other value) is understood to mean that the hardness values of all points along the length of the aerosol-generating segment will be within a range of hardness values that is 2% wide.

[0048] In some examples, a uniform hardness across the length of the wrapped aerosol-generating segment advantageously promotes the structural integrity of the wrapped segment during manufacture and during use, no matter at what point on the wrapped segment it is stressed.

[0049] As described herein, the aerosol-forming material may comprise plant material.

[0050] 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.

[0051] 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.

[0052] The aerosol-forming material may be absent of tobacco and / or nicotine.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] The humectant content of the aerosol-forming material may have a lower limit of at least 5 wt %, such as at least 10 wt %. The humectant content of the combustible material of the smoking body may have an upper limit of at most 50 % by weight of the plant material, such as at most 40 wt %.

[0057] 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.

[0058] The cannabinoid compounds may be selected from the non-exhaustive list comprising: tetrahydrocannabinol (THC), cannabidiol (CBD), cannabinol (CBN).

[0059] 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.

[0060] 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.

[0061] In a second aspect the present disclosure provides an aerosol-generating segment for a heat-not-burn consumable, the aerosol-generating segment being wrapped by a layered wrapper comprising a paper layer and a foil layer, wherein the aerosol-generating segment comprises an aerosol-forming material comprising one or more of cellulose, cotton, and a gel, and wherein the wrapped aerosol-generating segment has a Borgwaldt hardness (DD60) value of >90%.

[0062] In some examples the Borgwaldt hardness (DD60A) value is > 91%. In some examples the Borgwaldt hardness (DD60A) value is > 92%. In some examples the Borgwaldt hardness (DD60A) value is > 93%. In some examples the Borgwaldt hardness (DD60A) value is > 94%. In some examples the Borgwaldt hardness (DD60A) value is > 95%.

[0063] In some examples the aerosol-generating segment of the second aspect is an aerosol-generating segment of the first aspect.

[0064] In a third aspect the present disclosure provides an aerosol-generating segment for a heat-not-burn consumable, the aerosol-generating segment being wrapped by a layered wrapper comprising a paper layer and a foil layer, wherein the aerosol-generating segment comprises an aerosol-forming material comprising one or more of cellulose, cotton, and a gel, and wherein the wrapped aerosol-generating segment has a difference in Borgwaldt hardness (DD60A) of within 2% along its length.

[0065] In some examples the difference in Borgwaldt hardness (DD60A) is within 1.5% along its length. In some examples the difference in Borgwaldt hardness (DD60A) is within 1% along its length. In some examples, the Borgwaldt hardness across the length of the segment is calculated by measuring the hardness as described above at pre-determined points along the length of the segment. It may be that two measurements are taken, or it may be that more than two measurements are taken along the length of the segment. It may be that 3, 4 or 5 measurements are taken along the length of the segment.

[0066] In some examples, the wrapped aerosol-generating segment is part of an aerosol-generating consumable. In some examples the aerosol-generating consumable is a heat-not-burn (HNB) consumable. In some examples the aerosol-generating apparatus comprises a power supply, an aerosol-generating unit that is driven by the power supply, an aerosol precursor (e.g. the aerosol-generating consumable which comprises the wrapped aerosol-generating segment), 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.

[0067] In a fourth aspect the present disclosure provides a method of making the aerosol-generating segment of the first, second or third aspects.

[0068] In some examples, the method of making the aerosol-generating segment comprises a bending step (e.g. "pre-bending") carried out on the layered wrapper in which the layered wrapper is bent independent of (e.g. before contact with) an aerosol-forming material and then it is subsequently used to wrap the aerosol-forming material. That is, the bending step is in some examples carried out in the absence of the aerosol-forming material; the bent (or pre-bent) layered wrapper is then subsequently used to wrap the aerosol-forming material to form the aerosol-generating segment. In some examples, the subsequent wrapping may involve further bending or shaping. In some examples, such pre-bending may allow for less pressure to be applied in the presence of the aerosol-forming material, thereby reducing, minimising or avoiding mis-shaping of the aerosol-forming material. In some examples, the pre-bending may do so particularly when the aerosol-forming material is soft.

[0069] In some examples, "bending" refers to the creation of a curve or arc in the layered wrapper. In some examples the bend is smooth and of constant curvature or concavity.

[0070] In some examples, the use of high basis weights in the paper and foil layers of the layered wrapper may beneficially employ a bending step. For example, a bending step might be used when the basis weight of the layered wrapper exceeds 100 gsm.

[0071] In some examples the method of making the aerosol-generating segment comprises wrapping a precursor in the layered wrapper. In some examples the method of making the aerosol-generating segment comprises securing the layered wrapper to the aerosol-forming material and / or to itself, to completely wrap the aerosol-forming material. In some examples the method of making the aerosol-generating segment comprises inserting or applying aerosol-forming material into a pre-bent layered wrapper. The methods for implementing the aerosol-generating segment as described herein in a heat-not-burn consumable are well known in the art and are readily available to the skilled person.

[0072] In a fifth aspect the present invention provides a heat-not-burn consumable, comprising the aerosol-generating segment of the first, second or third aspects.

[0073] In some examples, the heat-not-burn consumable is described as such because the aerosol-forming material in the aerosol-generating segment exhibits heat-not-burn characteristics.

[0074] In some examples the heat-not-burn consumable further comprises a hard segment adjacent to the aerosol-generating segment.

[0075] The hard segment may be so named because it may be harder than the aerosol-forming material of the aerosol-generating segment. In some examples the hard segment is inherently hard, that is it is not made hard by a wrapping. In some examples, the wrapped aerosol-generating segment is harder than the hard segment. In some examples, the wrapped aerosol-generating segment is softer than the hard segment. In some examples the wrapped aerosol-generating segment and the hard segment are of a comparable, or approximately equal hardness. In some examples the hard segment is upstream of the wrapped aerosol-generating segment. In some examples the hard segment is downstream of the wrapped aerosol-generating segment. Upstream and downstream are set in accordance with the direction of the flow of aerosol when the consumable is in use (i.e. the flowpath).

[0076] In some examples the hard segment is an additional aerosol-generating segment or a cooling segment.

[0077] In such examples the cooling segment is so-called as it cools the aerosol generated when the consumable is in use. In some examples the cooling segment comprises a paper tube. In some examples the cooling segment comprises a spiral paper tube, that is a continuous paper tube, wound in a spiral.

[0078] In some examples the hard segment is a second aerosol-generating segment. For example, the alternative aerosol-generating segment may comprise a reconstituted aerosol-forming material that is harder than the aerosol-forming material used in the wrapped aerosol-generating segment.

[0079] Where a soft segment (i.e. an unwrapped aerosol-generating segment comprising a soft aerosol-forming material) is adjacent to a hard segment, the soft segment is particularly prone to deformation during manufacture or in use. The wrapping of the present invention makes the hardness of the wrapped aerosol-generating segment comparable to hard segments and reduces the chance of deformation or damage during manufacture and use.

[0080] In some examples the heat-not-burn consumable comprises further segments in series with the wrapped aerosol-generating segment. In some examples the heat-not-burn consumable comprises one or more filter segments in series, for example downstream, of the wrapped aerosol-generating segment. In some examples, all segments of the heat-not-burn consumable are held together by a combination of combining paper and tipping paper. In some examples the heat-not-burn consumable comprises a mouthpiece filter, at the end of the consumable configured to be engaged by a user when in use.

[0081] In a sixth aspect the present disclosure provides an aerosol-generating system comprising the aerosol-generating segment of the first, second or third aspects or the heat-not-burn consumable of the fifth aspect.

[0082] In some examples the aerosol-generating apparatus is referred to as a heat-not-burn apparatus.

[0083] In some examples the aerosol-generating apparatus comprises a power supply, an aerosol-generating unit that is driven by the power supply, an aerosol precursor (i.e. the aerosol-generating consumable which comprises the wrapped aerosol-generating segment), 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.

[0084] In an seventh aspect the present disclosure provides the use of a layered wrapper to increase the hardness of an aerosol-generating segment, wherein a paper layer of the layered wrapper has a basis weight of >50 gsm and a foil layer has a basis weight of about 10 to about 20 gsm; and / or the aerosol-generating segment comprises an aerosol-forming material comprising one or more of cellulose, cotton, and a gel, and wherein the wrapped aerosol-generating segment has a Borgwaldt hardness (DD60) value of >90%; and / or the aerosol-generating segment comprises an aerosol-forming material comprising one or more of cellulose, cotton, and a gel, and wherein the wrapped aerosol-generating segment has a difference in Borgwaldt hardness (DD60A) of within 2% along its length. In some examples, the layered wrapped is substantially as described herein for the other aspects.

[0085] The present disclosure may provide a method of generating an aerosol which may implement any one or more features disclosed herein. The method may comprise heating the aerosol-generating segment of the first, second or third aspects to generate an aerosol.

[0086] 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

[0087] Aspects, features and advantages of the present disclosure will become apparent from the following description of examples in reference to the appended drawings in which like numerals denote like elements. Fig. 1 is a block system diagram showing an example aerosol-generating apparatus. Fig. 2 is a block system diagram showing an example implementation of the apparatus of Fig. 1, where the aerosol-generating apparatus is configured to generate aerosol from a solid precursor. Fig. 3 is a schematic diagram showing an example implementation of the apparatus of Fig. 2. Fig. 4 is a perspective view of an example aerosol-generating segment. Fig. 5 is a cross-sectional view of an example aerosol-generating segment in an example heat-not-burn consumable. DETAILED DESCRIPTION OF EMBODIMENTS

[0088] Before describing 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.

[0089] 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.

[0090] Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.

[0091] 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.

[0092] 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.

[0093] 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).

[0094] 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.

[0095] 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.

[0096] The present disclosure may be better understood in view of the following explanations, wherein the terms used that are separated by "or" may be used interchangeably: As used herein, an "aerosol-generating apparatus" (or "electronic(e)-cigarette") may be an apparatus configured to deliver an aerosol to a user for inhalation by the user. The apparatus may additionally / alternatively be referred to as a "smoking substitute apparatus", if it is intended to be used instead of a conventional combustible smoking article. As used herein a combustible "smoking article" may refer to a cigarette, cigar, pipe or other article, that produces smoke (an aerosol comprising solid particulates and gas) via heating above the thermal decomposition temperature (typically by combustion and / or pyrolysis). An aerosol generated by the apparatus may comprise an aerosol with particle sizes of 0.2 - 7 microns, or less than 10 microns, or less than 7 microns. This particle size may be achieved by control of one or more of: heater temperature; cooling rate as the vapour condenses to an aerosol; flow properties including turbulence and velocity. The generation of aerosol by the aerosol-generating apparatus may be controlled by an input device. The input device may be configured to be user-activated, and may for example include or take the form of an actuator (e.g. actuation button) and / or an airflow sensor.

[0097] 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).

[0098] 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.

[0099] 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.

[0100] 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.

[0101] 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.

[0102] 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.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] 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.

[0107] As used herein, an "aerosol-generating unit" may refer to a device configured to generate an aerosol from a precursor. The aerosol-generating unit may include a unit to generate a vapour directly from the precursor (e.g. a heating system or other system) or an aerosol directly from the precursor (e.g. an atomiser including an ultrasonic system, a flow expansion system operative to carry droplets of the precursor in the flow without using electrical energy or other system). A plurality of aerosol-generating units to generate a plurality of aerosols (for example, from a plurality of different aerosol precursors) may be present in an aerosol-generating apparatus.

[0108] 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.

[0109] As used herein, a "consumable" may refer to a unit that includes a precursor. The consumable may include an aerosol-generating unit, e.g. it may be arranged as a cartomizer. The consumable may include a mouthpiece. The consumable may include an information carrying medium. With liquid or gel implementations of the precursor the consumable may be referred to as a "capsule" or a "pod". The capsule / pod may include a storage portion, e.g. a reservoir or tank, for storage of the precursor. With solid material implementations of the precursor, e.g. tobacco or reconstituted tobacco formulation, the consumable may be referred to as a "stick" or "package" or "heat-not-burn consumable". In a heat-not-burn consumable, the mouthpiece may be implemented as a filter and the consumable may be arranged to carry the precursor. The consumable may be implemented as a dosage or pre-portioned amount of material, including a loose-leaf product.

[0110] 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 cut-outs to encode a bit, through which pins or a reader may be inserted).

[0111] 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).

[0112] As used herein, a "laminate" may refer to an arrangement of two or more separate layers of material that are facially adjacent. A laminate is considered to comprise at least two layers joined together directly. In some examples, the laminate might be described as a stacked or layered structure. The two or more layers may be fused or adhered, reversibly or irreversibly, or may be in contact. For example, a foil-paper laminate may comprise at least one layer of paper and one layer of foil that are facially adjacent, and that may be fused or adhered together, to create a composite layered structure.

[0113] As used herein, a "foil" may describe a generally thin (i.e. substantially planar) sheet of material, such as a metallic material. The foil, by virtue of its dimensions, is, at least to an extent, pliable and deformable.

[0114] As used herein, "paper" may be given its normal and commonly understood meaning in the art and may refer to a material manufactured, for example in sheets, from the pulp of wood or other fibrous substances.

[0115] As used herein, "basis weight" may refer to the weight of a material per unit area of that material. It may be measured in grams per square metre, (gsm).

[0116] "Inner" and "outer" as used herein may refer to the inner and outer layers of the layered material structure when wrapped around the aerosol-generating segment, or when bent and ready to be wrapped around the aerosol-generating segment; the "inner" layer is that on the inside of the curve in the layered wrapper, the "outer" layer that on the outside of the curve in the wrapper.

[0117] As used herein, "length" describes an axial length of an elongate aerosol-generating segment. The segment is elongate when it has a length dimension that is greater than a width or a height dimension.

[0118] As used herein, "hard" and "soft", and any comparative term derived therefrom, may refer to the ease with which a material can be locally plastically deformed (such as dented, deformed, scratched, etc). A hard material may be more difficult to deform, and a soft material may be easier to deform. In some examples, the hardness may be measured using the Borgwaldt hardness scale as detailed herein.

[0119] Referring to Fig. 1, an example aerosol-generating apparatus 1 includes a power supply 2, for supply of electrical energy. The apparatus 1 includes an aerosol-generating unit 4 that is driven by the power supply 2. The power supply 2 may include an electric power supply in the form of a battery and / or an electrical connection to an external power source. The apparatus 1 includes a precursor 6, which in use is aerosolised by the aerosol-generating unit 4 to generate an aerosol. The apparatus 2 includes a delivery system 8 for delivery of the aerosol to a user. In the present invention at least a portion of the precursor is provided in a wrapped aerosol-generating segment, which is wrapped by a layered wrapper.

[0120] Electrical circuitry (not shown in figure 1) may be implemented to control the interoperability of the power supply 4 and aerosol-generating unit 6.

[0121] 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.

[0122] 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.

[0123] In this example, the apparatus 1 includes a device body 50 and a consumable 70.

[0124] 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.

[0125] 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.

[0126] The wireless interface 60 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.

[0127] 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).

[0128] 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.

[0129] Fig. 3 shows an example implementation of the aerosol-generating device 1 of Fig. 2.

[0130] 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.

[0131] 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 comprise a reconstituted tobacco formulation. The solid precursor is wrapped in a layered wrapper. As such, the precursor may be soft compared to the wrapping (for example, based on cotton, cellulose or a gel), whilst the wrapped segment, and therefore the consumable as a whole, maintains structural integrity.

[0132] 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).

[0133] 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. 5, 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.

[0134] 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.

[0135] The body 50 also includes a user interface device configured to convey information to a user. Here, the user interface device is implemented as a plurality of lights 57, which may e.g. be configured to illuminate when the apparatus 1 is activated and / or to indicate a charging state of the power supply 4. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.

[0136] 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.

[0137] 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.

[0138] 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.

[0139] Fig. 4 illustrates an aerosol-generating segment 100 according to one example of the present disclosure. The aerosol-generating segment 100 comprises an aerosol forming material 120, and a layered wrapper 140. The aerosol forming material may comprise an aerosol generating substrate and an aerosol former. The wrapper 140 includes two layers, a paper layer 122 and a foil layer 124. The foil layer 124 is sandwiched between the paper layer 122 and the aerosol-forming material 120. The paper layer 122 and the foil layer 124 are, in this example, laminated. In this example, the foil layer 124 has a basis weight of about 10 to 20 gsm and the paper layer 122 has a basis weight of 70 gsm or more. 130 is the longitudinal axis of the aerosol-generating segment 100, which is the lengthwise dimension in the direction of the flowpath.

[0140] Fig. 5 shows an aerosol generating segment 100 in an example heat-not-burn consumable 70. The aerosol generating segment 100, corresponding to the segment 100 of Fig. 4, is located at the upstream end of the consumable 70. Downstream of the aerosol generating segment 100 is a tubular segment 172. The tubular segment 172 may be known as a cooling segment. Downstream of the tubular segment 172 is a mouthpiece filter 174. The mouthpiece filter 174 is at the downstream end of the consumable 70. The aerosol generating segment 100, the tubular segment 172 and the mouthpiece filter 174 are wrapped together using a combining paper 141. Combining paper 141 is wrapped around the segments and glued into place using an adhesive.

[0141] Any aerosol generating segment described herein, may be used in the consumable 70 shown in Fig. 5.

Examples

Embodiment Construction

[0088]Before describing 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.

[0089]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.

[0090]Any patents, publ...

Claims

1. An aerosol-generating segment for a heat-not-burn consumable, the aerosol-generating segment being wrapped by a layered wrapper comprising a paper layer and a foil layer, wherein the paper layer has a basis weight of 70 gsm or more and the foil layer has a basis weight of about 10 to about 20 gsm.

2. The aerosol-generating segment of claim 1, wherein the foil layer has a basis weight of 12 gsm or more and 18 gsm or less, and optionally wherein the foil layer comprises aluminium.

3. The aerosol-generating segment of any one of the preceding claims, wherein the aerosol-generating segment comprises an aerosol-forming material that comprises one or more of cellulose, cotton and a gel.

4. The aerosol-generating segment of any one of the preceding claims, wherein the aerosol-generating segment comprises an aerosol-forming material, and the aerosol-forming material provides a smaller contribution to the hardness of the aerosol-generating segment than the layered wrapper.

5. The aerosol-generating segment of any one of the preceding claims, wherein the wrapped aerosol-generating segment has a Borgwaldt hardness (DD60A) value of 90% or more.

6. The aerosol-generating segment of any one of the preceding claims, wherein the aerosol-generating segment has a length aligned with a flowpath of the segment, and the wrapped aerosol-generating segment has a difference in Borgwaldt hardness (DD60A) of within 2% along its length.

7. An aerosol-generating segment for a heat-not-burn consumable, the aerosol-generating segment being wrapped by a layered wrapper comprising a paper layer and a foil layer, wherein the aerosol-generating segment comprises an aerosol-forming material comprising one or more of cellulose, cotton, and a gel, and wherein the wrapped aerosol-generating segment has a Borgwaldt hardness (DD60) value of 90% or more.

8. An aerosol-generating segment for a heat-not-burn consumable, the aerosol-generating segment being wrapped by a layered wrapper comprising a paper layer and a foil layer, wherein the aerosol-generating segment comprises an aerosol-forming material comprising one or more of cellulose, cotton, and a gel, and wherein the aerosol-generating segment has a length aligned with a flowpath of the segment, and the wrapped aerosol-generating segment has a difference in Borgwaldt hardness (DD60A) of within 2% along its length.

9. A method of making the aerosol-generating segment of any one of the preceding claims, comprising a bending step in which the layered wrapper is bent independent of an aerosol-forming material and then subsequently used to wrap the aerosol-forming material.

10. A heat-not-burn consumable, comprising the aerosol-generating segment of any one of claims 1 to 8.

11. The heat-not-burn consumable of claim 10, further comprising a hard segment adjacent to the aerosol-generating segment, and optionally wherein the hard segment is an additional aerosol-generating segment or a cooling segment.

12. The heat-not-burn consumable of claim 10, wherein the hard segment has a Borgwaldt hardness (DD60) of 90% or more, and optionally a Borgwaldt hardness (DD60) greater than the aerosol-generating segment.

13. The heat-not-burn consumable of any of claims 10 to 12, wherein the hard segment is downstream of the aerosol-generating segment.

14. An aerosol-generating system comprising the aerosol-generating segment of any one of claims 1 to 8, or the heat-not-burn consumable of any one of claims 10 to 13, and an aerosol-generating unit.

15. Use of a layered wrapper to increase the hardness of an aerosol-generating segment, wherein: a paper layer of the layered wrapper has a basis weight of 70 gsm or more and a foil layer has a basis weight of about 10 to about 20 gsm; and / or the aerosol-generating segment comprises an aerosol-forming material comprising one or more of cellulose, cotton, and a gel, and wherein the wrapped aerosol-generating segment has a Borgwaldt hardness (DD60) value of 90% or more; and / or the aerosol-generating segment comprises an aerosol-forming material comprising one or more of cellulose, cotton, and a gel, and wherein the aerosol-generating segment has a length aligned with a flowpath of the segment, and the wrapped aerosol-generating segment has a difference in Borgwaldt hardness (DD60A) of within 2% along its length.

Images