Susceptor for consumable for use with non-combustible aerosol provision device

Abstract

To provide a susceptor to be at least partially embedded in an object during manufacture of a consumable for use with a non-combustible aerosol provision device.SOLUTION: An object 2 comprises aerosol-generating material 3. At least a portion of a susceptor 1 has a non-linear cross-sectional shape 4 perpendicular to the length of the susceptor. Also provided herein are a method of manufacturing the susceptor, a consumable for use with a non-combustible aerosol provision device, a method of manufacturing the consumable, and a non-combustible aerosol provision system.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a susceptor for at least partially embedding in an object during the manufacture of a consumable for use in a non-combustion aerosol supply device, a method for manufacturing the susceptor for at least partially embedding in an object during the manufacture of a consumable, a method for manufacturing a consumable for use in a non-combustion aerosol supply device, and a non-combustion aerosol supply system.

Background Art

[0002] Smoking articles such as cigarettes and cigars burn tobacco during use to generate smoke. Attempts have been made to produce products that release compounds without combustion as an alternative to these articles. Examples of such products include so-called "non-combustion heating" products or tobacco heating devices or products that release compounds by heating without burning the material. The material may be, for example, tobacco or other tobacco products, which may or may not contain nicotine.

Summary of the Invention

[0003] In a first aspect of the present invention, there is provided a susceptor for at least partially embedding in an object during the manufacture of a consumable for use in a non-combustion aerosol supply device, the object including an aerosol generating material, the susceptor being heatable by the intrusion of a variable magnetic field, and at least a part of the susceptor having a non-linear cross-sectional shape perpendicular to the length of the susceptor.

[0004] Optionally, the susceptor includes a surface having at least one recess, and the surface and the at least one recess form a non-linear cross-sectional shape.

[0005] Optionally, the susceptor includes at least one waveform extending parallel to the length of the susceptor, and the at least one waveform forms a non-linear cross-sectional shape.

[0006] Optionally, the non-linear cross-sectional shape is crescent-shaped or includes a crescent shape.

[0007] Optionally, at least one longitudinal end of the susceptor is tapered to facilitate insertion of the susceptor into the object.

[0008] In a second aspect of the present invention, there is provided a method for manufacturing a susceptor for use in a non-combustion aerosol supply device and for at least partially embedding in an object during manufacture of a consumable, the object including an aerosol generating material, the method including providing a non-linear cross-sectional shape perpendicular to the length of the strip at at least a part of the strip, the strip including a susceptor material heatable by penetration of a varying magnetic field.

[0009] Optionally, the method of the present invention includes dividing the strip from a supply source.

[0010] Dividing optionally includes using a cutter for cutting the strip from a supply source.

[0011] Subjecting occurs optionally after dividing.

[0012] Dividing occurs optionally after subjecting.

[0013] In a third aspect of the present invention, there is provided a consumable for use in a non-combustion aerosol supply device The consumable includes an object including an aerosol generating material and a susceptor according to the first aspect of the present invention at least partially embedded in the object.

[0014] Optionally, the susceptor is substantially coaxial with the central axis of the consumable.

[0015] In a fourth aspect of the present invention, there is provided a method of manufacturing a consumable for use in a non-combustion aerosol supply device, the method comprising providing an object containing an aerosol generating material, providing a susceptor according to the first aspect of the present invention, and moving the susceptor and the object relative to each other such that the susceptor is at least partially embedded within the object.

[0016] In a fifth embodiment of the present invention, there is provided a method of manufacturing a consumable for use in a non-combustion aerosol supply device, the method comprising providing an object containing an aerosol generating material, providing a susceptor, and retracting the susceptor to at least partially embed the susceptor within the object.

[0017] Retracting optionally includes engaging a tool with the susceptor and then using the tool to retract the susceptor at least partially into the object.

[0018] Engaging optionally includes gripping the susceptor with the tool.

[0019] Optionally, the method of the present invention includes removing the tool from the susceptor once the susceptor is at least partially embedded within the object.

[0020] Optionally, the susceptor comprises one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper, and bronze.

[0021] Optionally, the susceptor contains nickel.

[0022] Optionally, the susceptor comprises nickel-coated steel.

[0023] Optionally, the susceptor is hollow or perforated, or includes dimples, mesh, or expanded metal.

[0024] Optionally, the susceptor includes pins, a mesh, or blades.

[0025] Optionally, the susceptor includes a plurality of pins, a mesh, or blades.

[0026] Optionally, the susceptor includes a plurality of openings or recesses, and when the susceptor is at least partially embedded in the object, these openings and / or recesses are filled with the aerosol generating material.

[0027] Optionally, at least a part of the susceptor is annular.

[0028] Optionally, the susceptor includes a plurality of annular portions, and preferably these annular portions are arranged substantially concentrically.

[0029] Optionally, the aerosol generating material is non-liquid.

[0030] Optionally, the aerosol generating material includes tobacco.

[0031] Optionally, after the susceptor is at least partially embedded in the object, the susceptor extends over most of the length of the object, and preferably, after the susceptor is at least partially embedded in the object, the susceptor extends substantially over the entire length of the object.

[0032] Optionally, the susceptor includes a first region made of a first material and a second region made of a second material, and the first and second materials are different.

[0033] Optionally, the first and second materials have different conductivity and / or magnetoconductivity.

[0034] Optionally, the first material includes a material that can be heated by the penetration of a varying magnetic field, and the second material includes a material that cannot be heated or is substantially not heated by the penetration of a varying magnetic field.

[0035] Optionally, one of the first and second materials is coated with the other of the first and second materials.

[0036] Optionally, the first material is coated with the second material.

[0037] Optionally, the first and second materials are configured such that when an alternating magnetic field penetrates the first and second materials during use, the penetration of the alternating magnetic field into the first and second materials causes a temperature difference between the first and second materials.

[0038] Optionally, the first and second materials have different heat masses.

[0039] Optionally, the susceptor includes a base and an embeddable portion, the embeddable portion being configured to be at least partially embedded in an object.

[0040] Optionally, the base is substantially flat.

[0041] Optionally, the base is substantially circular.

[0042] Optionally, the base includes a material that can be heated by the penetration of an alternating magnetic field.

[0043] Optionally, the embeddable portion includes a thermally conductive material.

[0044] Optionally, the embeddable portion includes a material that can be heated by the penetration of an alternating magnetic field.

[0045] Optionally, the embeddable portion includes a material that cannot be heated or is substantially not heated by the penetration of an alternating magnetic field.

[0046] Optionally, the embeddable portion includes the first and second materials.

[0047] Optionally, the embeddable portion includes one of the first and second materials, and the base includes the other of the first and second materials.

[0048] The above-described features, including those of the susceptor and / or the aerosol generating material, are applicable to any of the aspects of the invention described herein.

[0049] In a sixth aspect of the invention, a consumable for use in a non-combustion aerosol supply device is provided, the consumable being manufactured by a method including the method according to the fourth aspect of the invention.

[0050] Optionally, the susceptor is substantially coaxial with the central axis of the consumable.

[0051] In a seventh aspect of the invention, a non-combustion aerosol supply system is provided, the system including a consumable according to the third or sixth aspect of the invention and a non-combustion aerosol supply device for causing heating of the aerosol generating material of the consumable to volatilize at least one component of the aerosol generating material, the device including a heating region for accommodating the consumable and a magnetic field generator for generating a fluctuating magnetic field that penetrates the susceptor of the consumable when the consumable is at least partially in the heating region, thereby causing heating of the aerosol generating material.

[0052] Optionally, the device is for causing heating of the aerosol generating material of the consumable without burning the aerosol generating material to volatilize at least one component of the aerosol generating material.

[0053] Optionally, the magnetic field generator includes at least one coil.

[0054] Optionally, the coil is helical.

[0055] Optionally, the coil is a flat coil and may be a two-dimensional helix.

[0056] Optionally, the system of the invention includes a second coil, the second coil being helical.

[0057] Optionally, the magnetic field generator is configured to generate a variable magnetic field that penetrates into the base of the susceptor when the consumable is at least partially in the heating region.

[0058] Optionally, the coil is configured to generate a variable magnetic field that penetrates into the base of the susceptor when the consumable is at least partially in the heating region, and the second coil is configured to generate a variable magnetic field that penetrates into the embeddable portion of the susceptor when the consumable is at least partially in the heating region.

[0059] Optionally, the second coil extends along at least a part of the circumference of the embeddable portion of the susceptor.

[0060] Optionally, the susceptor may include one or more materials selected from the group consisting of a conductive material, a magnetic material, and a magnetoconductive material.

[0061] Optionally, the susceptor includes a metal or a metal alloy.

[0062] Optionally, the susceptor includes one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper, and bronze.

[0063] Optionally, the aerosol generating material is a non-liquid material.

[0064] Optionally, the aerosol generating material includes tobacco.

[0065] Optionally, the aerosol generating material is a regenerated aerosol generating material such as regenerated tobacco.

[0066] Further features and advantages of the present invention will become apparent from the following description of the preferred embodiments of the present invention, which are merely given by way of example with reference to the accompanying drawings.

[0067] Embodiments of the present invention will be described by way of example only with reference to the accompanying drawings.

Brief Description of the Drawings

[0068]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Modes for Carrying Out the Invention

[0069] In the present specification, an "aerosol generating material" is a material that can generate an aerosol when excited by, for example, heating, irradiation, or any other method. The aerosol generating material may be in the form of a solid, liquid, or gel that may or may not contain, for example, an active substance and / or a flavoring agent. In some embodiments, the aerosol generating material may include an "amorphous solid", which is also sometimes referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that holds a fluid such as a liquid inside it. In some embodiments, the aerosol generating material includes from about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0070] The aerosol generating material may include one or more active substances and / or flavorants, one or more aerosol forming materials, and, if necessary, one or more other functional materials.

[0071] In some embodiments, the aerosol generating material may include a tobacco material, which may be any material including tobacco or its derivatives. The tobacco material may include one or more of ground tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco stalks, reconstituted tobacco, and / or tobacco extracts. In some embodiments, the aerosol generating material may include a tobacco substitute.

[0072] As used herein, a "consumable" is an article that includes or consists of an aerosol generating material, and some or all of which is intended to be consumed by the user during use. The consumable may include one or more other components such as an aerosol generating material storage area, aerosol generating material transfer components, an aerosol generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. The consumable may also include an aerosol generator such as a heater that radiates heat so that the aerosol generating material generates an aerosol during use.

[0073] As used herein, a "susceptor" is a material that can be heated by the intrusion of a fluctuating magnetic field such as an alternating magnetic field. The susceptor may be a conductive material and may cause induction heating of the heating material by the intrusion of the fluctuating magnetic field. The heating material may be a conductive material and may cause magnetic hysteresis heating of the heating material by the intrusion of the fluctuating magnetic field. The susceptor may be due to both conductivity and magnetic force, whereby the heating material can be heated by both heating mechanisms.

[0074] When the susceptor is incorporated into the consumable, heat is generated not by heat conduction from an external heat source but inside the consumable itself, so that a rapid temperature rise within the consumable and a more uniform heat distribution can be achieved. This can be achieved in particular by appropriately selecting the material and geometry and by appropriately selecting the magnitude and direction of the alternating magnetic field for the susceptor. Furthermore, in induction heating and magnetic hysteresis heating, there is no need to provide a physical connection between the source of the alternating magnetic field and the susceptor, so that material deposits on the susceptor such as residues or condensates do not pose a problem, enhancing the design freedom and the controllability of the heating pattern and reducing costs.

[0075] When manufacturing a consumable, for example, a consumable for use in a non-combustion aerosol supply device, an aerosol-generating material such as tobacco is placed on paper. The paper is then wound around the aerosol-generating material to surround the aerosol-generating material and form a rod. The rod is cut to the desired length and then a filter is attached to form the consumable.

[0076] A susceptor may be provided within the consumable so that the consumable can be heated by any of the methods described above. However, if the susceptor is provided as a continuous object through the rod before the rod is cut to the desired length, it may cause damage to the cutting equipment when cutting the rod to the desired length online.

[0077] Figure 1 schematically shows an object 2 in which a susceptor 1 according to one embodiment is at least partially embedded. Figure 1 shows a cross-section perpendicular to the length of the susceptor 1 (i.e., Figure 1 shows the width and height of the susceptor 1, which extends within the page). The susceptor 1 is for at least partially embedding in the object 2 during the manufacture of a consumable for use in a non-combustion aerosol supply device. In some embodiments, the susceptor 1 is completely embedded within the object 2 such that no portion of the susceptor 1 extends beyond the face of the object 2. The object 2 includes an aerosol generating material 3. At least a portion of the susceptor 1 has a non-linear cross-sectional shape 4 perpendicular to the length of the susceptor. In one embodiment as shown in Figure 1, the non-linear cross-sectional shape is crescent-shaped or includes a crescent shape. In some embodiments, the non-linear cross-sectional shape is polygonal, curved, and / or curvilinear or includes a polygon, a curve, and / or a curve.

[0078] It should be understood that the term "linear cross-sectional shape" as used herein means a cross-sectional shape perpendicular to the length of the susceptor 1 that is a single straight line or substantially a single straight line. For example, if the susceptor 1 has a rectangular cross-sectional shape perpendicular to the length of the susceptor 1, such a susceptor is considered to be substantially a single straight line (having the thickness of the height of the susceptor 1). Another way to view this is that the major faces of the susceptor 1 (i.e., the front and back surfaces of the rectangular cross-sectional shape) are each entirely in a single flat plane, and each plane is parallel to the other.

[0079] It should be understood that the term "non-linear cross-sectional shape" as used herein includes any cross-sectional shape that is not a single straight line or substantially a single straight line. Of course, the "non-linear cross-sectional shape" may include a cross-sectional shape that is a plurality of non-parallel linear lines or substantially a plurality of non-parallel linear lines. For example, as shown in Figure 2, two non-parallel lines are arranged to form a pointed structure such that the two straight lines abut to form a point. As shown in Figure 2, the surfaces 1a and 1b are parallel and are positioned along a first direction, and the surfaces 1c and 1d are parallel and are positioned along a second direction (non-parallel to the first direction).

[0080] Figure 2 schematically shows an object 2 in which the susceptor 1 according to one embodiment is at least partially embedded. The object 2 includes an aerosol generating material 3. In the embodiment shown in Figure 2, at least one surface 9 of the susceptor 1 includes a recess 8. In the embodiment of Figure 2, the recess 8 is elongate and extends parallel to the length of the susceptor 1 along the length of the susceptor. In some embodiments, the recess 8 is provided at a point of the susceptor 1. In some embodiments, the non-linear cross-sectional shape as shown in Figure 2 forms, or is formed by, a ridge or recess 8 provided along at least a part of the length of the susceptor 1. In some embodiments, one or more recesses 8 form one or more corrugations 5. In some embodiments, the surface 9 is omitted and the susceptor 1 includes one or more corrugations 5. In some embodiments, one or more recesses 8 do not form one or more corrugations 5, for example, one or more recesses 8 form one or more islands such as circular islands recessed in the surface 9.

[0081] In the embodiments shown in Figures 1 and 2, the susceptor 1 is at least partially disposed within the aerosol generating material 3. Alternatively, the susceptor 1 may be disposed on the object 2 adjacent to one edge of the aerosol generating material 3 or away from the aerosol generating material 3.

[0082] Figure 3 schematically shows the susceptor 1 of Figure 2 as viewed from above. The susceptor 1 includes at least one corrugation 5 parallel to the length of the susceptor 1. The corrugation 5 is formed by the elongate recess 8 (shown in Figure 2) of the surface 9. In some embodiments, the at least one corrugation 5 forms a non-linear cross-sectional shape of the susceptor 1. For example, in the embodiment shown in Figure 3, the corrugation 5 forms the non-linear cross-sectional shape shown in Figure 2. In some embodiments, the non-linear cross-sectional shape formed by the corrugation 5 may have a different shape or profile from the cross-sectional shape shown in Figure 2.

[0083] The non-linear cross-sectional shape of susceptor 1 helps to improve the strength and / or rigidity of susceptor 1 along its length, and is advantageous because it can substantially withstand buckling when a significant force is applied along its length as compared to an equivalent susceptor having a linear cross-sectional shape. For example, susceptor 1 may be pushed into object 2 from the longitudinal end of object 2 (in some embodiments, specifically the aerosol generating material 3 of object 2). The non-linear cross-sectional shape of susceptor 1 makes it easy to push in because susceptor 1 is difficult to bend and deform.

[0084] As shown in FIG. 3, in some embodiments, at least one longitudinal end of susceptor 1 is tapered 6. The taper 6 further facilitates the insertion of susceptor 1 into object 2. In some embodiments, susceptor 1 may be tapered at the point of at least one longitudinal end of susceptor 1. In some embodiments, both longitudinal ends of susceptor 1 may be tapered so that susceptor 1 can be more easily inserted into object 2 from both directions. In other embodiments, only one longitudinal end is tapered. Of course, the taper 6 may be present in any non-linear cross-sectional shape of susceptor 1.

[0085] FIG. 4 is a flow diagram of a method 10 for manufacturing a susceptor 1 for at least partially embedding in an object 2 during the manufacture of a consumable for use in a non-combustion aerosol supply device according to one embodiment, where object 2 includes an aerosol generating material 3. Method 10 includes providing at least a portion of a strip having a non-linear cross-sectional shape perpendicular to the length of the strip, the strip including a susceptor material that can be heated by the penetration of a varying magnetic field. As shown in FIG. 4, in some embodiments, the method of the present invention includes dividing 11 the strip from a source. In some embodiments, dividing 11 may include using a cutter to cut the strip from the source.

[0086] In some embodiments, providing 12 occurs after dividing 11. Alternatively, dividing 11 occurs after providing 12.

[0087] FIG. 5 is a flowchart of a manufacturing method 20 of a consumable for use in a non-combustion aerosol supply device according to an embodiment. The method 20 includes providing a target object 2 including an aerosol generating material 3 and a susceptor 1. The susceptor 1 may be any of the susceptors 1 exemplified and described herein, or may be a displacement type of the susceptor described herein. For example, it may be the susceptor 1 manufactured according to the method exemplified in FIG. 4. The method 20 includes moving the susceptor 1 and the target object 2 relative to each other so that the susceptor 1 is at least partially embedded in the target object 2. The susceptor 1 may be completely embedded in the target object 2.

[0088] In some embodiments, the susceptor 1 may be moved towards the target object 2 while the target object 2 is held in a predetermined position. Alternatively, the target object 2 may be moved towards the susceptor 1 while the susceptor 1 is held in a predetermined position. Naturally, in some embodiments, both the susceptor 1 and the target object 2 may be moved towards each other.

[0089] FIG. 6 is a flowchart of a manufacturing method 30 of a consumable for use in a non-combustion aerosol supply device according to an embodiment. This method includes providing a target object 2 including an aerosol generating material 3 and drawing in the susceptor 1 to at least partially embed the susceptor 1 in the target object 2. The susceptor 1 may be completely embedded in the target object 2.

[0090] ​In some embodiments, pulling 33 includes engaging a tool with susceptor 1 and then using the tool to at least partially pull susceptor 1 into object 2. For example, the tool may engage the leading end of susceptor 1 such that the leading end is pulled by suitable operation of the tool. Alternatively, susceptor 1 may be pushed into object 2. For example, the tool may engage the trailing end of susceptor 1 such that the trailing end of susceptor 1 is pushed by suitable operation of the tool. In either case, the direction of the applied force is in the direction that directs susceptor 1 towards object 2. In some embodiments, engaging includes gripping susceptor 1 with the tool. In some embodiments, pulling 33 includes at least partially pulling susceptor 1 into object 2 magnetically, with or without a magnetic source that engages susceptor 1.

[0091] In some embodiments, method 30 also includes removing 34 the tool from susceptor 1 when susceptor 1 is at least partially embedded in object 2. The same tool may then be engaged with the next susceptor 1 and embedded in another object 2, and this method may be repeated.

[0092] FIG. 7 shows a consumable 7 for use in a non-combustion aerosol supply device according to one embodiment. The consumable 7 includes an object 2 containing an aerosol generating material 3 and a susceptor 1 at least partially embedded in object 2. Susceptor 1 may be any of the susceptors 1 illustrated and described herein, or may be a displacement type of susceptor described herein. For example, susceptor 1 may be fabricated according to the method illustrated in FIG. 4.

[0093] The consumable 7 is, in this example, a cylinder made of an aerosol generating material 3 (e.g., tobacco or reconstituted tobacco), and a cylindrical rod having a paper (or other suitable material) selectively wound around the circumference of the cylinder of the aerosol generating material. In some embodiments, the consumable 7 is manufactured according to any suitable method described herein. In particular, the consumable 7 may be manufactured according to the method described with respect to FIGS. 5 or 6. The consumable 7 may be formed completely or partially when the susceptor 1 is inserted into the object 2. That is, some additional manufacturing steps may be performed before or after the susceptor 1 is inserted into the object 2. For example, a filter (such as a cellulose acetate plug) may be attached to one end of the object 2 (usually the end of the object 2 opposite to the end where the susceptor 1 is inserted) before or after the susceptor 1 is inserted. may also.

[0094] In some embodiments, the susceptor 1 is substantially coaxial with the central axis of the consumable 7, that is, substantially coaxial with the central axis of the aerosol generating material 3. This is advantageous because it leads to substantially uniformly heating the consumable 7 or the aerosol generating material 3 in the radial direction around the susceptor 1. Alternatively, the susceptor 1 may be at least partially embedded in any other suitable position of the consumable 7 such that the heat generated by the susceptor 1 transfers to the aerosol generating material.

[0095] In some embodiments, the object may be a consumable. For example, in some embodiments, additional manufacturing steps may be performed on the object to form a consumable (such as providing a filter), and in other embodiments, no additional manufacturing steps are required to form a consumable from the object once the susceptor is inserted.

[0096] FIG. 8 schematically shows a non-combustion aerosol supply system 40 according to an embodiment of the present invention. The non-combustion aerosol supply system 40 includes the consumable 7 of FIG. 7, but of course any suitable displacement type of consumables described herein may be used separately therefrom. The system also includes a non-combustion aerosol supply device 42 for causing heating of the aerosol generating material 3 of the consumable 7 and volatilizing at least one component of the aerosol generating material. The device 42 includes a heating region 43 for accommodating the consumable 7 and a variable magnetic field generator 44 that generates a variable magnetic field that penetrates the susceptor 1 when the consumable 7 is within the heating region 43, thereby causing heating of the aerosol generating material 3.

[0097] In some embodiments, the device 42 is for causing heating of the aerosol generating material 3 of the consumable 7 without burning the aerosol generating material 3 and volatilizing at least one component of the aerosol generating material 3. In some embodiments, the device may be a tobacco heating device, also known as a tobacco heating product.

[0098] In some embodiments, the susceptor 1 may be embedded in the object 2 after cutting the object 2 to a desired length. Thus, the susceptor 1 does not need to be cut online by the same cutting tool that cuts the material supplied to a predetermined length to form the object 2. Thus, there is no need or minimal need to modify the cutting mechanism in the existing manufacturing apparatus, and the possibility of damage such as the cutting mechanism is significantly reduced or avoided compared to cutting the object from the supply source to a predetermined length after the susceptor 1 is embedded.

[0099] In some embodiments, susceptor 1 may include one or more materials selected from the group consisting of conductive materials, magnetic materials, and magnetoconductive materials. In some embodiments, susceptor 1 includes a metal or a metal alloy. In some embodiments, susceptor 1 includes one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper, and bronze.

[0100] In some embodiments, the aerosol generating material is a non-liquid material. Separately or in addition thereto, the aerosol generating material includes tobacco. In some embodiments, the aerosol generating material includes a regenerated aerosol generating material such as regenerated tobacco.

[0101] The above embodiments should be understood as illustrative examples for explaining the present invention. Further embodiments of the present invention are also contemplated. Of course, any feature described for any one embodiment may be used alone or in combination with other described features, or in combination with any one or more features of any other embodiment or any combination of any other embodiments. It is also possible to employ equivalents and modifications not described above without departing from the scope of the present invention as defined in the appended claims.

Claims

1. A susceptor for at least partially embedding within an object during manufacture of a consumable for use in a non-combustion based aerosol delivery device, the object including an aerosol generating material, at least a portion of the susceptor having a non-linear cross-sectional shape perpendicular to a length of the susceptor.

2. 10. The susceptor of claim 1, comprising a surface having at least one indentation, the surface and the at least one indentation forming a non-linear cross-sectional shape.

3. 3. A susceptor as in claim 1 or 2, including at least one corrugation extending parallel to a length of the susceptor, the at least one corrugation forming a non-linear cross-sectional shape.

4. 4. The susceptor of claim 3, wherein the non-linear cross-sectional shape is or includes a crescent shape.

5. 5. A susceptor according to claim 1, wherein at least one longitudinal end of the susceptor is tapered to facilitate insertion of the susceptor into an object.

6. A method for manufacturing a susceptor for at least partially embedding in an object during the manufacture of a consumable for use in a non-combustion based aerosol delivery device, the object comprising an aerosol generating material, the method including providing at least a portion of a strip with a non-linear cross-sectional shape perpendicular to a length of the strip, the strip comprising susceptor material that can be heated by the penetration of a fluctuating magnetic field.

7. 7. The method of claim 6, further comprising splitting the strip from the source.

8. 8. The method of claim 7, wherein said dividing step includes using a cutter to sever the strips from the source.

9. 9. The method of claim 7 or 8, wherein said subjecting occurs after partitioning.

10. 9. The method of claim 7 or 8, wherein the dividing occurs after subjecting.

11. 6. A consumable for use in a non-combustion based aerosol delivery device comprising: an object containing an aerosol-generating material; and a susceptor according to any one of claims 1 to 5 at least partially embedded in the object.

12. The consumable of claim 11 , wherein the susceptor is substantially coaxial with a central axis of the consumable.

13. Providing an object including an aerosol-generating material and a susceptor according to any one of claims 1 to 5; and moving a susceptor and a target relative to one another such that the susceptor becomes at least partially embedded within the target.

14. Providing an object including an aerosol-generating material; Providing a susceptor; and drawing a susceptor into the object so as to at least partially embed the susceptor.

15. retracting engages the tool with the susceptor; The method of claim 14 further comprising: next using a tool to pull the susceptor at least partially into the object.

16. The method of claim 15, wherein said engaging comprises gripping the susceptor with a tool.

17. 17. The method of claim 15 or 16, further comprising removing the tool from the susceptor when the susceptor is at least partially embedded in the object.

18. The susceptor of any one of claims 1 to 5, the method of any one of claims 6 to 10, the consumable of claim 11 or 12 or the method of any one of claims 13 to 17, wherein the susceptor comprises one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper and bronze.

19. The susceptor of any one of claims 1 to 5 or 18, the method of any one of claims 6 to 10 or 18, the consumable of claim 11, 12 or 18 or the method of any one of claims 13 to 18, wherein the susceptor comprises nickel.

20. 20. The susceptor of any one of claims 1 to 5, 18 or 19, the method of any one of claims 6 to 10, 18 or 19, the consumable of claim 11, 12, 18 or 19 or the method of any one of claims 13 to 19, wherein the susceptor comprises nickel coated steel.

21. A susceptor according to any one of claims 1 to 5 or 18 to 20, wherein the susceptor is hollow or perforated or comprises a recess, mesh or expanded metal, a method according to any one of claims 6 to 10 or 18 to 20, a consumable according to any one of claims 11, 12, 18 to 20 or a method according to any one of claims 13 to 20.

22. A susceptor according to any one of claims 1 to 5 or 18 to 21, the method according to any one of claims 6 to 10 or 18 to 21, the consumable according to any one of claims 11, 12, 18 to 21 or the method according to any one of claims 13 to 21, wherein the susceptor comprises a pin, a mesh or a blade.

23. 23. The susceptor, method or consumable of claim 22, wherein the susceptor comprises a plurality of pins, meshes or blades.

24. A susceptor as claimed in any one of claims 1 to 5 or 18 to 23, characterized in that the susceptor includes a plurality of openings or recesses which are filled with an aerosol-generating material when the susceptor is at least partially embedded in the target object, a method as claimed in any one of claims 6 to 10 or 18 to 23, a consumable as claimed in any one of claims 11, 12, 18 to 23 or a method as claimed in any one of claims 13 to 23.

25. The susceptor according to any one of claims 1 to 5, 18 to 24, or any one of claims 6 to 10, 18 to 24, wherein at least a portion of the susceptor is annular. A method according to any one of claims 11, 12, 18 to 24, a consumable according to any one of claims 13 to 24 or a method according to any one of claims 13 to 24.

26. 26. The susceptor, method or consumable of claim 25, wherein the susceptor includes a plurality of annular portions, preferably the annular portions being substantially concentrically disposed.

27. A susceptor as claimed in any one of claims 1 to 5 or 18 to 26, a method as claimed in any one of claims 6 to 10 or 18 to 26, a consumable as claimed in any one of claims 11, 12, 18 to 26 or a method as claimed in any one of claims 13 to 26, wherein the aerosol-generating material is non-liquid.

28. A susceptor as claimed in any one of claims 1 to 5 or 18 to 27, a method as claimed in any one of claims 6 to 10 or 18 to 27, a consumable as claimed in any one of claims 11, 12, 18 to 27 or a method as claimed in any one of claims 13 to 27, wherein the aerosol-generating material comprises tobacco.

29. A susceptor as claimed in any one of claims 1 to 5 or 18 to 28, a method as claimed in any one of claims 6 to 10 or 18 to 28, a consumable as claimed in any one of claims 11, 12, 18 to 28 or a method as claimed in any one of claims 13 to 28, characterized in that the susceptor extends along most of the length of the object after the susceptor is at least partially embedded in the object, preferably the susceptor extends along substantially the entire length of the object after the susceptor is at least partially embedded in the object.

30. A susceptor as claimed in any one of claims 1 to 5 or 18 to 29, wherein the susceptor comprises a first region made of a first material and a second region made of a second material, the first and second materials being different, a method as claimed in any one of claims 6 to 10 or 18 to 29, a consumable as claimed in any one of claims 11, 12, 18 to 29 or a method as claimed in any one of claims 13 to 29.

31. 31. The susceptor, method or consumable of claim 30, wherein the first and second materials have different electrical and / or magnetic conductivity.

32. 32. The susceptor, method or consumable of claim 30 or 31, wherein the first material comprises a material that is heatable by the penetration of a fluctuating magnetic field and the second material comprises a material that is not heatable by the penetration of a fluctuating magnetic field or that is not substantially heatable by the penetration of a fluctuating magnetic field.

33. 33. The susceptor, method or consumable of any one of claims 30 to 32, wherein one of the first and second materials is coated with the other of the first and second materials.

34. 34. The susceptor, method or consumable of claim 33, wherein the first material is coated with the second material.

35. 35. The susceptor, method or consumable of any one of claims 30 to 34, wherein the first and second materials are configured such that, in use, when a changing magnetic field penetrates the first and second materials, a temperature differential is created between the first and second materials due to the penetration of the changing magnetic field into the first and second materials.

36. 36. The susceptor, method or consumable of any one of claims 30 to 35, wherein the first and second materials have different thermal masses.

37. A susceptor as claimed in any one of claims 1 to 5 or 18 to 36, wherein the susceptor comprises a base and an embeddable portion, the embeddable portion being configured to be at least partially embedded in the object, a method as claimed in any one of claims 6 to 10 or 18 to 36, a consumable as claimed in any one of claims 11, 12, 18 to 36 or a method as claimed in any one of claims 13 to 36.

38. 38. The susceptor, method or consumable of claim 37, wherein the base is substantially flat.

39. 39. The susceptor, method or consumable of claim 37 or 38, wherein the base is generally circular.

40. 40. The susceptor, method or consumable of any one of claims 37 to 39, wherein the base comprises a material that is heatable by penetration of a varying magnetic field.

41. 41. The susceptor, method or consumable of any one of claims 37 to 40, wherein the embeddable portion comprises a thermally conductive material.

42. 42. The susceptor, method or consumable of any one of claims 37 to 41, wherein the implantable portion comprises a material that is heatable by penetration of a changing magnetic field.

43. 43. The susceptor, method or consumable of any one of claims 37 to 42, wherein the implantable portion comprises a material that is not heatable by the penetration of a fluctuating magnetic field or that is not substantially heatable by the penetration of a fluctuating magnetic field.

44. 44. A susceptor, method or consumable according to any one of claims 37 to 43 when dependent on any one of claims 30 to 36, wherein the implantable portion comprises a first and a second material.

45. 45. The susceptor, method or consumable of any one of claims 37 to 44 when dependent on any one of claims 30 to 36, wherein the implantable portion comprises one of the first and second materials and the base comprises the other of the first and second materials.

46. 46. ​​A consumable for use in a non-combustion based aerosol delivery device manufactured according to a method including the method of any one of claims 14-45.

47. 47. The consumable of claim 46, wherein the susceptor is substantially coaxial with a central axis of the consumable.

48. A consumable product according to any one of claims 11, 12 or 18 to 47; a non-combustion aerosol delivery device for causing heating of the consumable aerosol-generating material to volatilize at least one component of the aerosol-generating material; The device is a non-combustion aerosol delivery system that includes a heating area for containing a consumable and a magnetic field generator that generates a varying magnetic field that penetrates a susceptor of the consumable when the consumable is at least partially in the heating area, thereby causing heating of the aerosol generating material.

49. 49. The system of claim 48, wherein the device is adapted to cause heating of the consumable aerosol-generating material without burning the aerosol-generating material to volatilize at least one component of the aerosol-generating material.

50. 50. The system of claim 48 or 49, wherein the magnetic field generator comprises at least one coil.

51. 51. The system of claim 50, wherein the coil is helical.

52. 51. The system of claim 50, wherein the coil is a flat coil, preferably a two-dimensional spiral.

53. 53. The system of claim 52, further comprising a second coil, preferably the second coil being helical.

54. The system of any one of claims 48 to 53 when dependent on any one of claims 37 to 45, wherein the magnetic field generator is configured to generate a varying magnetic field for penetrating the base of the susceptor when the consumable is at least partially in the heating zone.

55. 55. The system of claim 54 when dependent on claim 53, wherein the coil is configured to generate a varying magnetic field for penetrating a base of the susceptor when the consumable is at least partially in the heating region, and the second coil is configured to generate a varying magnetic field for penetrating an implantable portion of the susceptor when the consumable is at least partially in the heating region.

56. 56. The system of claim 55, wherein the second coil extends around at least a portion of the circumference of the implantable portion of the susceptor.

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