Consumable for use with apparatus for heating aerosolizable material

Abstract

To provide a consumable for use with an apparatus for heating aerosolizable material to volatilize at least one component of the aerosolizable material.SOLUTION: A consumable 1 comprises an outer tube 10, an inner member 11 inside the outer tube, and at least one support 12 that supports the inner member relative to the outer tube so that at least one air gap 13 exists between the inner member and the outer tube. At least one of the inner member, the outer tube and the support comprises aerosolizable material that is heatable to generate aerosol in the air gap. The consumable has at least one outlet for permitting the aerosol to pass out of the consumable from the air gap.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to consumables for use with devices that heat aerosolizable material, and to systems that include such consumables and devices that heat the aerosolizable material of the consumables to volatilize at least one component of the aerosolizable material. [Background technology]

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these articles by creating products that release compounds without combustion. Examples of such products include so-called "heat-and-burn" products, or tobacco heating devices or products, which release compounds by heating rather than burning a material. The material may be, for example, tobacco or other non-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 consumable for use with a device that heats an aerosolizable material to volatilize at least one component of the aerosolizable material, the consumable comprising: an outer pipe; an inner member inside the outer pipe; and at least one support supporting the inner member relative to the outer pipe such that there is at least one gap between the inner member and the outer pipe; at least one of the inner member, the outer tube, and the support includes an aerosolizable material that is heatable to generate an aerosol in the cavity; The consumable has at least one outlet that allows the aerosol to exit the consumable from the void.

[0004] In one exemplary embodiment, the at least one support includes a plurality of supports circumferentially spaced apart from one another.

[0005] In one exemplary embodiment, the at least one support is disposed between the inner member and the outer tube.

[0006] In one exemplary embodiment, the at least one support includes an annular non-circular support between the inner member and the outer tube.

[0007] In one exemplary embodiment, the at least one support comprises a folded or corrugated element between the inner member and the outer tube.

[0008] In one exemplary embodiment, the or each support is located at an axial end of the consumable.

[0009] In one exemplary embodiment, at least one of the inner member and the outer tube comprises an aerosolizable material.

[0010] In one exemplary embodiment, at least one of the inner member and the outer tube includes a carrier to which the aerosolizable material is applied, hi one exemplary embodiment, the aerosolizable material is coated onto the carrier by spraying, electrospraying, casting, band casting, or the like.

[0011] In a second aspect of the present invention, there is provided a consumable for use with a device that heats an aerosolizable material to volatilize at least one component of the aerosolizable material, the consumable comprising: An outer tube; an inner member inside the outer tube, at least a portion of the inner member being spaced from the outer tube by at least one gap, the inner member including an aerosolizable material that is heatable to generate an aerosol within the gap; The consumable has at least one outlet that allows the aerosol to exit the consumable from the void.

[0012] In one exemplary embodiment, the inner member includes a carrier to which the aerosolizable material is applied, hi one exemplary embodiment, the aerosolizable material is coated onto the carrier by spraying, electrospraying, casting, band casting, or the like.

[0013] In one exemplary embodiment of the consumable of the first or second aspect, the aerosolizable material comprises an amorphous solid.

[0014] In a third aspect of the present invention, there is provided a consumable for use with a device that heats an aerosolizable material to volatilize at least one component of the aerosolizable material, the consumable comprising: An outer tube; an inner member inside the outer tube, at least a portion of the inner member being spaced from the outer tube by at least one gap; and an aerosolizable material comprising an amorphous solid that can be heated to generate an aerosol within the void; The consumable has at least one outlet that allows the aerosol to exit the consumable from the void.

[0015] In one exemplary embodiment of the consumable of the third aspect, at least one of the inner member and the outer tube comprises an aerosolizable material.

[0016] In an exemplary embodiment of the consumable of any one of the first through third aspects, at least one of the inner member and the outer tube is circular.

[0017] In an exemplary embodiment of the consumable of any one of the first through third aspects, at least one of the inner member and the outer tube is non-circular.

[0018] In an exemplary embodiment of the consumable of any one of the first to third aspects, at least one of the inner member and the outer tube is corrugated.

[0019] In an exemplary embodiment of the consumable of any one of the first to third aspects, the inner member and the outer tube are coaxial.

[0020] In an exemplary embodiment of the consumable of any one of the first to third aspects, the inner member includes an inner tube.

[0021] In one exemplary embodiment, the inner tube is disposed about a passageway that opens to an axial end of the consumable such that a heating element for heating the aerosolizable material can be inserted into the passageway during use. In one exemplary embodiment, the passageway extends only partially along the length or axial dimension of the consumable. In one exemplary embodiment, the passageway extends over at least a majority of the length or axial dimension of the consumable. In one exemplary embodiment, the passageway extends completely through the consumable from a first axial end of the consumable to an opposite second axial end of the consumable.

[0022] In an exemplary embodiment of the consumable of any one of the first to third aspects, the at least one outlet is at an axial end of the consumable.

[0023] In an exemplary embodiment of the consumable of any one of the first to third aspects, the inner tube is disposed about a passageway that is open to a first axial end of the consumable, and the at least one outlet is at a second axial end of the consumable that is opposite the first axial end of the consumable.

[0024] In an exemplary embodiment of the consumable of any one of the first to third aspects, the at least one outlet is at an axial end of the consumable, and the inner tube is disposed around a passageway that opens at the same axial end of the consumable.

[0025] In one exemplary embodiment of the consumable of any one of the first to third aspects, the void extends only partially along the length or axial dimension of the consumable.

[0026] In one exemplary embodiment of the consumable of any one of the first to third aspects, the void extends across at least a majority of the length or axial dimension of the consumable.

[0027] In an exemplary embodiment of the consumable of any one of the first to third aspects, the void extends completely through the consumable from a first axial end of the consumable to an opposite second axial end of the consumable.

[0028] In an exemplary embodiment of the consumable of any one of the first through third aspects, the consumable is non-flammable.

[0029] In one exemplary embodiment of the consumable of any one of the first through third aspects, the consumable includes a heating material that is heatable by a changing magnetic field penetrating and heating the aerosolizable material.

[0030] In one exemplary embodiment, the heating material includes one or more materials selected from the group consisting of an electrically conductive material, a magnetic material, and a magnetically conductive material.

[0031] In one exemplary embodiment, the heating material comprises a metal or metal alloy.

[0032] In one exemplary embodiment, the heating material 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.

[0033] In one exemplary embodiment, at least one of the inner member and the outer tube comprises a heating material.

[0034] In one exemplary embodiment of the consumable of the first aspect, the at least one support comprises a heating material.

[0035] In a fourth aspect of the present invention, there is provided a system for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the system comprising: A consumable product according to any one of the first to third aspects; and an apparatus for heating the consumable aerosolizable material to volatilize at least one component of the aerosolizable material, the apparatus including a heating area for receiving the consumable, the system further comprising a device for causing heating of the aerosolizable material when the consumable is in the heating area.

[0036] In one exemplary embodiment, the device comprises a magnetic field generator for generating a varying magnetic field that penetrates the heating region when the consumable is in the heating region.

[0037] In one exemplary embodiment, the device of the apparatus includes a heatable heating element in the heating region, and the inner member of the consumable includes an inner tube disposed about a passageway, the passageway being open at an axial end of the consumable such that the heating element can be inserted into the passageway.

[0038] In one exemplary embodiment, the heatable heating element has an outer cross-sectional shape, and the consumable inner member includes an inner tube having an inner cross-sectional shape that matches the outer cross-sectional shape of the heating element.

[0039] In one exemplary embodiment, a device that causes heating of the aerosolizable material when the consumable is in the heating region is configured to heat separate portions of the heating region independently of each other.

[0040] Another aspect of the invention may enable the use of a consumable of the first or second or third aspect of the invention to generate an inhalable aerosol.

[0041] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0042] [Figure 1]1 is a schematic cross-sectional end view of an example of a consumable for use with a device that heats an aerosolizable material to volatilize at least one component of the aerosolizable material. [Figure 2] 2 is a schematic cross-sectional side view of the consumable of FIG. 1 taken along line II-II of FIG. 1. [Figure 3] 1 is a schematic cross-sectional end view of another exemplary consumable item for use with a device that heats an aerosolizable material to volatilize at least one component of the aerosolizable material. [Figure 4] 4 is a schematic cross-sectional side view of the consumable of FIG. 3 taken along line IV-IV of FIG. 3. [Figure 5] 1 is a schematic cross-sectional side view of another exemplary consumable item for use with a device that heats an aerosolizable material to volatilize at least one component of the aerosolizable material. [Figure 6] 1 is a schematic cross-sectional side view of an example system including a consumable and a device for heating a consumable aerosolizable material to volatilize at least one component of the aerosolizable material. DETAILED DESCRIPTION OF THE INVENTION

[0043] As used herein, the term "aerosolizable material" includes materials that can be heated to produce volatile components, typically in the form of a vapor or aerosol. "Aerosolizable material" may be a non-tobacco-containing material or a tobacco-containing material. "Aerosolizable material" may include, for example, one or more of tobacco itself, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco extract, homogenized tobacco, or tobacco substitutes. Aerosolizable material may be in the form of ground tobacco, cut rag tobacco, extruded tobacco, reconstituted tobacco, reconstituted aerosolizable material, liquid, gel, gelled sheet, powder, chunk, or the like. "Aerosolizable material" may also include other non-tobacco products, which may or may not contain nicotine, depending on the product. "Aerosolizable material" may include one or more humectants, such as glycerol or propylene glycol.

[0044] In some embodiments, the aerosolizable material comprises an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous) or a "dry gel." An amorphous solid is a solid material that can hold some fluid, such as a liquid, within it. In some cases, the aerosolizable material comprises from about 50%, 60%, or 70% by weight of an amorphous solid, up to about 90%, 95%, or 100% by weight of an amorphous solid. In some cases, the aerosolizable material is composed of an amorphous solid.

[0045] "Aerosolizable materials" may also include other non-tobacco products, which may or may not contain nicotine, depending on the product. "Aerosolizable materials" may also include one or more humectants, such as glycerol or propylene glycol.

[0046] The amorphous solid can be formed as a sheet. The amorphous solid may be incorporated into the consumable in sheet form. In some cases, the aerosolizable material may be included in a flat sheet, a bundled or gathered sheet, a pressed sheet, or a rolled sheet (i.e., in the form of a tube). In some cases, the amorphous solid in these embodiments may be included in the consumable or system as a sheet, such as a sheet surrounding a rod of aerosolizable material (e.g., tobacco). In some cases, the aerosolizable material may be formed as a sheet and then shredded and incorporated into the consumable. In some cases, the shredded sheet may be mixed with cut rag tobacco and incorporated into the consumable.

[0047] In some cases, the amorphous solid may contain 1-60% by weight of gelling agent, these weights being calculated on a dry weight basis.

[0048] Suitably, the amorphous solid may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 60%, 50%, 45%, 40%, 35%, 30%, or 27% by weight of gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1-50%, 5-40%, 10-30%, or 15-27% by weight of gelling agent.

[0049] In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginic acid, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginic acid, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the gelling agent comprises alginic acid and / or pectin and may be mixed with a setting agent (such as a calcium source) during the formation of the amorphous solid. In some embodiments, the amorphous solid may comprise calcium-crosslinked alginic acid and / or calcium-crosslinked pectin.

[0050] In some embodiments, the gelling agent comprises alginic acid, which is present in the amorphous solid in an amount of 10-30% by weight (calculated on a dry weight basis) of the amorphous solid. In some embodiments, alginic acid is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginic acid and at least one other gelling agent, such as pectin.

[0051] In some embodiments, the amorphous solid may include a gelling agent, including carrageenan.

[0052] Suitably, the amorphous solid can comprise from about 5%, 10%, 15%, or 20% to about 80%, 70%, 60%, 55%, 50%, 45%, 40%, or 35% by weight of an aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent can act as a plasticizer. For example, the amorphous solid can comprise 10-60%, 15-50%, or 20-40% by weight of an aerosol generating agent. In some cases, the aerosol generating agent comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol generating agent comprises, consists essentially of, or consists of glycerol. The inventors have determined that if the plasticizer content is too high, the amorphous solid will absorb water, resulting in a material that does not provide a satisfactory consumer experience upon use. The inventors have determined that if the plasticizer content is too low, the amorphous solid will become brittle and may easily crumble. The plasticizer content specified herein provides the amorphous solid flexibility that allows the amorphous solid sheet to be wound onto a bobbin, useful for producing aerosol products.

[0053] In some cases, the amorphous solid may include a flavoring agent. Conveniently, the amorphous solid may include up to about 60%, 50%, 40%, 30%, 20%, 10%, or 5% by weight of flavoring agent. In some cases, the amorphous solid may include at least about 0.1%, 0.5%, 1%, 2%, 5%, 10%, 20%, or 30% by weight of flavoring agent (all calculated on a dry weight basis). For example, the amorphous solid may include 0.1-60%, 1-60%, 5-60%, 10-60%, 20-50%, or 30-40% by weight of flavoring agent. In some cases, the flavoring agent (if present) includes, consists essentially of, or consists of menthol. In some cases, the amorphous solid does not include a flavoring agent.

[0054] In some cases, the amorphous solid further comprises an active substance. For example, in some cases, the amorphous solid comprises tobacco material and / or nicotine. For example, the amorphous solid may comprise powdered tobacco and / or nicotine and / or tobacco extract. In some cases, the amorphous solid may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% by weight to about 70%, 50%, 45%, or 40% by weight of the active substance (calculated on a dry weight basis). In some cases, the amorphous solid may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% by weight to about 70%, 60%, 50%, 45%, or 40% by weight of the tobacco material and / or nicotine (calculated on a dry weight basis).

[0055] In some cases, the amorphous solid includes an active substance such as tobacco extract. In some cases, the amorphous solid may include 5-60% by weight of tobacco extract (calculated on a dry weight basis). In some cases, the amorphous solid may include about 5%, 10%, 15%, 20%, or 25% by weight to about 55%, 50%, 45%, or 40% by weight of tobacco extract (calculated on a dry weight basis). For example, the amorphous solid may include 5-60%, 10-55%, or 25-55% by weight of tobacco extract. The tobacco extract may include a concentration of nicotine such that the amorphous solid includes 1%, 1.5%, 2%, or 2.5% by weight to about 6%, 5%, 4.5%, or 4% by weight of nicotine (calculated on a dry weight basis). In some cases, the amorphous solid may be free of nicotine other than that originating from the tobacco extract.

[0056] In some embodiments, the amorphous solid does not contain tobacco material but does contain nicotine. In some such cases, the amorphous solid may contain from about 1%, 2%, 3%, or 4% to about 20%, 15%, 10%, or 5% nicotine by weight (calculated on a dry weight basis). For example, the amorphous solid may contain 1-20% or 2-5% nicotine by weight.

[0057] In some cases, the total active and / or fragrance content can be at least about 0.1%, 1%, 5%, 10%, 20%, 25%, or 30% by weight. In some cases, the total active and / or fragrance content can be less than about 80%, 70%, 60%, 50%, or 40% by weight (all calculated on a dry weight basis).

[0058] In some cases, the total content of tobacco material, nicotine, and flavorings can be at least about 1%, 5%, 10%, 20%, 25%, or 30% by weight. In some cases, the total content of tobacco material, nicotine, and flavorings can be less than about 70%, 60%, 50%, or 40% by weight (all calculated on a dry weight basis).

[0059] In some cases, the amorphous solid contains about 1 to about 15% water, or about 5 to 15% water, calculated on a wet weight basis. Suitably, the water content of the amorphous solid can be from about 5%, 7%, or 9% to about 15%, 13%, or 11% (WWB), most preferably about 10%.

[0060] In some embodiments, the amorphous solid is a hydrogel and contains less than about 20% water by weight, calculated on a wet weight basis. In some cases, the hydrogel may contain about 15%, 12%, or 10% water by weight, calculated on a wet weight basis (WWB). In some cases, the hydrogel may contain at least 2% or at least 5% water by weight (WWB).

[0061] The amorphous solid can be made from a gel, which may further contain a solvent present in an amount of 0.1 to 50% by weight. However, the present inventors have confirmed that the inclusion of a solvent in which the fragrance is soluble can reduce gel stability and cause the fragrance to crystallize from the gel. Therefore, in some cases, the gel does not contain a solvent in which the fragrance is soluble.

[0062] In some embodiments, the amorphous solid comprises less than 60% by weight of filler, such as 1-60% by weight, or 5-50% by weight, or 5-30% by weight, or 10-20% by weight.

[0063] In other embodiments, the amorphous solid contains less than 20% by weight of filler, preferably less than 10% by weight, or less than 5% by weight. In some cases, the amorphous solid contains less than 1% by weight of filler, and in some cases, no filler.

[0064] When present, the filler may comprise one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may comprise one or more inorganic filler materials such as wood pulp, cellulose, and cellulose derivatives. In particular cases, the amorphous solid does not comprise calcium carbonate, such as chalk.

[0065] In certain embodiments that include a filler, the filler is fibrous. For example, the filler can be an organic fibrous filler material, such as wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that including a fibrous filler in the amorphous solid can increase the tensile strength of the material. This increased tensile strength can be particularly advantageous in instances where the amorphous solid is provided as a sheet, such as when the amorphous solid sheet surrounds a rod of aerosolizable material.

[0066] In some embodiments, the amorphous solid does not include tobacco fiber. In certain embodiments, the amorphous solid does not include fibrous material.

[0067] In some embodiments, the aerosol-forming material does not include tobacco fiber. In certain embodiments, the aerosol-forming material does not include fibrous material.

[0068] In some embodiments, the aerosol-forming substrate does not contain tobacco fibers. In certain embodiments, the aerosol-forming substrate does not contain fibrous material.

[0069] In some embodiments, the consumable product does not contain tobacco fiber, hi certain embodiments, the consumable product does not contain fibrous material.

[0070] In some cases, the amorphous solid may consist essentially of or consist of a gelling agent, an aerosol-forming agent, a tobacco material and / or a nicotine source, water, and optionally a flavoring agent.

[0071] A method of making an aerosolizable material may include the steps of: (a) forming a slurry containing an amorphous solid or precursor component; (b) forming a layer of the slurry; (c) hardening the slurry to form a gel; and (d) drying to form the amorphous solid.

[0072] Step (b) of forming a layer of the slurry can include, for example, spraying, casting, or extruding the slurry. In some cases, the layer is formed by electrospraying the slurry. In some cases, the layer is formed by casting the slurry.

[0073] Optionally, the slurry is applied to a carrier.

[0074] In some cases, steps (b) and / or (c) and / or (d) may occur at least partially simultaneously (e.g., during electrospraying). In some cases, these steps may occur sequentially.

[0075] The step (c) of hardening the gel may include adding a hardening agent to the slurry. For example, the slurry may include sodium, potassium, or ammonium alginate as a gel precursor, and a hardening agent including a calcium source (such as calcium chloride) may be added to the slurry to form a calcium alginate gel.

[0076] The total amount of hardening agent, such as a calcium source, can be 0.5 to 5 wt. % (calculated on a dry weight basis). The inventors have found that adding too little hardening agent results in an amorphous solid that does not stabilize the amorphous solid components, causing these components to shed from the amorphous solid. The inventors have found that adding too much hardening agent results in an amorphous solid that is very sticky and therefore difficult to handle.

[0077] Alginates are derivatives of alginic acid and are generally high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer consisting of units (blocks) of β-D-mannuronic acid (M) and α-L-guluronic acid (G) linked by (1,4)-glycosidic bonds to form polysaccharides. Upon addition of calcium cations, alginic acid crosslinks to form gels. The inventors have determined that alginates with a high G monomer content more readily form gels upon addition of a calcium source. Thus, in some cases, the gel precursor may comprise an alginate in which at least about 40%, 45%, 50%, 55%, 60%, or 70% of the monomer units of the alginic acid copolymer are α-L-guluronic acid (G) units.

[0078] The drying step may reduce the cast thickness by at least 80%, preferably 85% or 87%. For example, the slurry may be cast at a thickness of 2 mm, and the resulting dried amorphous solid material may be 0.2 mm thick.

[0079] In some cases, the amorphous solid may have a thickness of about 0.015 to 1.0 mm. Conveniently, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm. The inventors have found that materials having a thickness of 0.2 mm are particularly suitable. The amorphous solid may comprise two or more layers, and the thicknesses described herein refer to the combined thickness of these layers.

[0080] In some cases, the slurry solvent can consist essentially of or consist of water. In some cases, the slurry can include about 50%, 60%, 70%, 80%, or 90% by weight of the solvent (WWB).

[0081] When the solvent is comprised of water, the dry weight content of the slurry can correspond to the dry weight content of the amorphous solids. Thus, any discussion herein of solid constituents is expressly disclosed in conjunction with the slurry aspect of the invention.

[0082] In some examples, the slurry has a viscosity at 46.5°C of about 10 to about 20 Pas, such as about 14 to about 16 Pas at 46.5°C.

[0083] Aerosolizable materials, including amorphous solids, can have any suitable areal density, such as 30-120 g / m. In some embodiments, the aerosolizable material may have an areal density of about 30-70 g / m, or about 40-60 g / m. In some embodiments, the amorphous solid may have an areal density of about 80-120 g / m, or about 70-110 g / m, or particularly about 90-110 g / m. Such areal densities may be particularly suitable when the aerosol-generating material is included in a consumable product or system in sheet form or as shredded sheets (discussed further below).

[0084] In some examples, the amorphous solid in sheet form may have a tensile strength of about 200-900 N / m. In some examples, such as when the amorphous solid does not contain a filler, the amorphous solid may have a tensile strength of 200-400 N / m, or 200-300 N / m, or about 250 N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosolizable material is formed as a sheet and then shredded and incorporated into a consumable product. In some examples, such as when the amorphous solid contains a filler, the amorphous solid may have a tensile strength of 600-900 N / m, or 700-900 N / m, or about 800 N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosolizable material is included in a consumable product or system as a wound sheet, preferably in a tubular shape.

[0085] In one particular case, the carrier may be a paper-backed foil, with the paper layer abutting the amorphous solid layer, providing the properties discussed in the previous section. The foil backing is substantially impermeable, allowing for control of the aerosol flow path. The metal foil backing may also serve to conduct heat to the amorphous solid.

[0086] In other cases, the foil layer of the paper-backed foil abuts the amorphous solid, and because the foil is substantially impermeable, it prevents the water provided in the amorphous solid from being absorbed into the paper, which could weaken the structural integrity of the paper.

[0087] In some cases, the carrier is formed from or includes a metal foil, such as aluminum foil. The metal carrier can allow for good conduction of thermal energy to the amorphous solid. Additionally or alternatively, the metal foil can function as a susceptor in an induction heating system. In particular embodiments, the carrier comprises a metal foil layer and a support layer, such as cardboard. In these embodiments, the metal foil layer can have a thickness of less than 20 μm, such as about 1-10 μm, preferably about 5 μm.

[0088] As used herein, an active substance can refer to a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance can be, for example, a dietary supplement, a nootropic, or a psychoactive drug. The active substance can be naturally occurring or synthetically derived. The active substance can include, for example, nicotine, caffeine, taurine, theine, vitamins B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance can include one or more components, derivatives, or extracts of tobacco, cannabis, or other plants.

[0089] In some embodiments, the active agent comprises nicotine.

[0090] In some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0091] As provided herein, the active substance may include one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0092] Cannabinoids are a class of natural or synthetic compounds that act on cannabinoid receptors (i.e., CB1 and CB2) in cells in the brain, inhibiting neurotransmitter release. Cannabinoids can be naturally occurring (phytocannabinoids) from plants, such as cannabis, or animals (endocannabinoids), or can be artificially produced (synthetic cannabinoids). Cannabis species express at least 85 different phytocannabinoids, divided into subclasses including cannabigerol, cannabichromene, cannabidiol, tetrahydrocannabinol, cannabinol, and cannabinodiol, as well as other cannabinoids. Cannabinoids found in cannabis include, but are not limited to, cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabidiol (CBO), tetrahydrocannabimolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).

[0093] As used herein, an active agent may include or be derived from one or more botanical substances or components, derivatives, or extracts thereof. As used herein, the term "botanical substance" includes any material obtained from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruit, pollen, husks, shells, etc. Alternatively, the material may include active compounds naturally occurring in the plant or synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, dust, crushed grains, granules, pellets, chips, strips, sheets, etc. Exemplary botanicals include eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, laurel wreath, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, and lemon peel. , mint, juniper, elderflower, vanilla, wintergreen, sedge, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or combinations thereof.The mint may be selected from the following mint varieties: cool mint, Mentha cv, Egyptian mint (Mentha niliaca), common mint (Mentha piperita), lime mint (Mentha piperita citrata cv), black peppermint (Mentha piperita cv), Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, pineapple mint (Mentha suaveolens variegata), Borrelia mint (Mentha pulegium), Moroccan mint (Mentha spicata cv), and apple mint (Mentha suaveolens).

[0094] In some embodiments, the plant is selected from eucalyptus, star anise, cocoa, and hemp.

[0095] In some embodiments, the plant is selected from rooibos and fennel.

[0096] As used herein, the terms "flavor" and "flavoring" refer to materials that may be used in products for adult consumers to create a desired flavor or aroma or other bodily sensation, where permitted by local regulations.

[0097] These include naturally occurring flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, mint, aniseed, cinnamon, turmeric, Indian varieties, Asian varieties, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, ruba, etc.). Ruby, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, Barbados aloe, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, Ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay leaf, mate tea tree, orange peel, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, Pedunculaceae, curcuma, cilantro, myrtle, black currant, valerian, pimento , mace, damien, marjoram, olive, lemon balm, lemon basil, chive, kalbi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucrose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be imitation, synthetic or natural ingredients, or mixtures thereof. They may be in any suitable form, for example a liquid such as an oil, a solid such as a powder, or a gas.

[0098] The flavoring may optionally include one or more mint flavorings, preferably mint oil from any species of the genus Mentha. The flavoring may optionally include, consist essentially of, or consist of menthol.

[0099] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint.

[0100] In some embodiments, the flavoring comprises cucumber, blueberry, citrus, and / or red berry flavor ingredients.

[0101] In some embodiments, the fragrance comprises eugenol.

[0102] In some embodiments, the flavoring comprises flavoring ingredients extracted from tobacco.

[0103] In some embodiments, the flavoring comprises flavoring ingredients extracted from cannabis.

[0104] In some embodiments, the fragrance may include a sensation eliciting agent intended to produce a bodily sensation, usually chemically induced and perceived, by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and may include agents that produce a warming, cooling, tingling, or numbing effect. A suitable warming agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol WS-3.

[0105] As used herein, the term "aerosol-generating agent" refers to an agent that facilitates the generation of an aerosol. An aerosol-generating agent can facilitate the generation of an aerosol by promoting the initial vaporization and / or condensation of a gas into an inhalable solid and / or liquid aerosol.

[0106] Suitable aerosol generating agents include, but are not limited to, polyols such as erythritol, sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol; non-polyols such as monohydric alcohols; high-boiling hydrocarbons; acids such as lactic acid; glycerol derivatives; esters such as diacetin; triacetin; triethylene glycol diacetate; myristates, including triethyl citrate or ethyl myristate and isopropyl myristate; and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate. The aerosol generating agent may optionally have a component that does not dissolve menthol. The aerosol generating agent may optionally include, consist essentially of, or consist of glycerol.

[0107] As used herein, the term "tobacco material" refers to any material containing tobacco or a derivative thereof. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extract.

[0108] The tobacco used to produce the tobacco material can be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia, and / or Burley, and / or Oriental. The tobacco material can also be tobacco particle "fines" or dust, expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut roll stems. The tobacco material can be ground tobacco or reconstituted tobacco material. Reconstituted tobacco material may contain tobacco fiber and can be formed by casting, Fourdrinier-based papermaking-type techniques including back-addition of tobacco extract, or extrusion.

[0109] In some embodiments, the amorphous solid comprises menthol.

[0110] Certain embodiments comprising menthol-containing amorphous solids may be particularly suitable for inclusion in consumables or systems as shredded sheets. In these embodiments, the amorphous solids may have the following components (DWB): a gelling agent (preferably comprising alginic acid, more preferably a combination of alginic acid and pectin) in an amount of about 20 to about 40% by weight, or about 25 to 35% by weight; menthol in an amount of about 35 to about 60% by weight, or about 40 to 55% by weight; and an aerosol-forming agent (preferably comprising glycerol) in an amount of about 10 to about 30% by weight, or about 15 to about 25% by weight (DWB).

[0111] In one embodiment, the amorphous solid comprises about 32-33% by weight of an alginate / pectin gelling agent mixture, about 47-48% by weight of a menthol flavoring, and about 19-20% by weight of a glycerol aerosol forming agent (DWB).

[0112] As noted above, the amorphous solids of these embodiments may be included in the consumable or system as a shredded sheet. The shredded sheet may be mixed with the cut tobacco and added to the consumable or system. Alternatively, the amorphous solids may be added as an unshredded sheet. Suitably, the shredded or unshredded sheet has a thickness of from about 0.015 mm to about 1 mm, preferably from about 0.02 mm to about 0.07 mm.

[0113] Certain embodiments of the menthol-containing amorphous solid may be particularly suitable for inclusion in a consumable product or system as a sheet, such as a sheet surrounding a rod of aerosolizable material (e.g., tobacco). In these embodiments, the amorphous solid may have the following components (DWB): a gelling agent (preferably comprising alginic acid, more preferably a combination of alginic acid and pectin) in an amount of about 5 to about 40% by weight, or about 10 to about 30% by weight; menthol in an amount of about 10 to about 50% by weight, or about 15 to about 40% by weight; an aerosol-forming agent (preferably comprising glycerol) in an amount of about 5 to about 40% by weight, or about 10 to about 35% by weight; and, optionally, a filler in an amount up to 60% by weight, e.g., 5 to 20% by weight, or about 40 to 60% by weight (DWB).

[0114] In one of these embodiments, the amorphous solid comprises about 11% by weight of an alginate / pectin gelling agent mixture, about 56% by weight of wood pulp filler, about 18% by weight of menthol flavoring, and about 15% by weight of glycerol (DWB).

[0115] In other of these embodiments, the amorphous solid comprises about 22% by weight of an alginate / pectin gelling agent mixture, about 12% by weight of a wood pulp filler, about 36% by weight of a menthol flavoring, and about 30% by weight of glycerol (DWB).

[0116] As noted above, the amorphous solid of these embodiments may be included as a sheet. In one embodiment, the sheet is disposed on a carrier comprising paper. In one embodiment, the sheet is disposed on a carrier comprising metal foil, preferably aluminum foil. In this embodiment, the amorphous solid may abut against the metal foil.

[0117] In one embodiment, the sheet forms part of a laminate material, with one layer (preferably comprising paper) attached to the top and bottom surfaces of the sheet. Suitably, the sheet of amorphous solid has a thickness of from about 0.015 to about 1 mm.

[0118] In some embodiments, the amorphous solid comprises a menthol-free flavoring. In these embodiments, the amorphous solid may comprise the following components (DWB): a gelling agent (preferably comprising alginic acid) in an amount of about 5 to about 40% by weight, or about 10 to about 35% by weight, or about 20 to about 35% by weight; a flavoring agent in an amount of about 0.1 to about 40% by weight, or about 1 to about 30% by weight, or about 1 to about 20% by weight, or about 5 to about 20% by weight; an aerosol-forming agent (preferably comprising glycerol) in an amount of 15 to 75% by weight, or about 30 to about 70% by weight, or about 50 to about 65% by weight; and, optionally, a filler (suitably wood pulp) in an amount of less than about 60% by weight, or about 20% by weight, or about 10% by weight, or about 5% by weight (preferably, the amorphous solid does not comprise a filler).

[0119] In one of these embodiments, the amorphous solid comprises about 27% by weight alginate gelling agent, about 14% by weight flavoring, and about 57% by weight glycerol aerosol forming agent (DWB).

[0120] In other of these embodiments, the amorphous solid comprises about 29% by weight alginate gelling agent, about 9% by weight flavoring, and about 60% by weight glycerol (DWB).

[0121] The amorphous solids of these embodiments may be included in the consumable or system as shredded sheets, optionally with cut tobacco. Alternatively, the amorphous solids of these embodiments may be included in the consumable or system as sheets, such as a sheet surrounding a rod of aerosolizable material (e.g., tobacco). Alternatively, the amorphous solids of these embodiments may be included in the consumable or system as a layer portion disposed on a carrier.

[0122] In some embodiments, the amorphous solid comprises tobacco extract. In these embodiments, the amorphous solid may comprise the following components (DWB): a gelling agent (preferably comprising alginic acid) in an amount of about 5 to about 40% by weight, or about 10 to about 30% by weight, or about 15 to about 25% by weight, a tobacco extract in an amount of about 30 to about 60% by weight, or about 40 to about 55% by weight, or about 45 to about 50% by weight, and an aerosol-forming agent (preferably comprising glycerol) in an amount of about 10 to about 50% by weight, or about 20 to about 40% by weight, or about 25 to about 35% by weight (DWB).

[0123] In one embodiment, the amorphous solid comprises about 20% by weight alginate gelling agent, about 48% by weight Virginia tobacco extract, and about 32% by weight glycerol (DWB).

[0124] The amorphous solid of these embodiments can have any suitable water content, for example, the amorphous solid can have a water content of about 5 to about 15% by weight, or about 7 to about 13% by weight, or about 10% by weight.

[0125] The amorphous solid of these embodiments may be included in the consumable or system as a shredded sheet, optionally mixed with cut tobacco. Alternatively, the amorphous solid of these embodiments may be included in the consumable or system as a sheet, such as a sheet surrounding a rod of aerosolizable material (e.g., tobacco). Alternatively, the amorphous solid of these embodiments may be included in the consumable or system as a layer disposed on a carrier. Suitably, in any of these embodiments, the amorphous solid has a thickness of 50 to 200 μm, or about 50 to about 100 μm, or about 60 to about 90 μm, preferably about 77 μm.

[0126] The slurry for forming this amorphous solid may also form part of the present invention. In some cases, the slurry may have an elastic modulus (also called storage modulus) of about 5 to 1200 Pa. In some cases, the slurry may have a viscous modulus (also called loss modulus) of about 5 to 600 Pa.

[0127] All weight percentages (expressed as wt. %) given herein are calculated on a dry weight basis unless otherwise specified. All weight ratios are also calculated on a dry weight basis. Weights quoted on a dry weight basis relate to all of the extract or slurry or material other than water, and may include components that are themselves liquid at room temperature and pressure, such as glycerol. Conversely, weight percentages quoted on a wet weight basis relate to all components, including water.

[0128] As used herein, the term "sheet" refers to an element whose width and length are significantly greater than its thickness. A sheet can be, for example, a strip.

[0129] As used herein, the term "heating material" or "heater material" refers to a material that can be heated by the penetration of a changing magnetic field.

[0130] Dielectric heating is a process by which a conductive object is heated by the penetration of a changing magnetic field into the object. This process is described by Faraday's law of induction and Ohm's law. An induction heater may include an electromagnet and a device for passing a changing current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are appropriately positioned relative to each other so that the resulting changing magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are generated within the object. The object has a resistance to the flow of current. Therefore, when such eddy currents are generated in the object, the object heats due to the eddy currents flowing against the object's electrical resistance. This process is called Joule heating, ohmic heating, or resistive heating. An object that can be inductively heated is known as a susceptor.

[0131] It has been found that when the susceptor is in the form of a closed electrical circuit, the electromagnetic coupling between the susceptor and the electromagnet is enhanced in use, resulting in greater or improved Joule heating.

[0132] Magnetic hysteresis heating is the process by which an object made of a magnetic material is heated by the penetration of a changing magnetic field into the object. Magnetic materials can be thought of as containing many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipoles align with the field. Thus, when a changing magnetic field, such as an alternating magnetic field generated by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes with the changing applied field. This reorientation of the magnetic dipoles generates heat in the magnetic material.

[0133] If an object is both conductive and magnetic, both Joule heating and magnetic hysteresis heating can occur in the object when a changing magnetic field penetrates it. Furthermore, magnetic materials can be used to strengthen the magnetic field, thereby enhancing Joule heating and magnetic hysteresis heating.

[0134] In each of the above processes, because heat is generated within the object itself rather than from an external heat source by thermal conduction, rapid temperature rise and more uniform heat distribution within the object can be achieved, particularly by selecting the appropriate object material and geometry and the appropriate magnitude and orientation of the changing magnetic field relative to the object. Furthermore, because induction heating and magnetic hysteresis heating do not require a physical connection to be formed between the source of the changing magnetic field and the object, there may be greater design freedom and control over the heating profile, and costs may be lower.

[0135] 1 and 2, there are shown schematic cross-sectional end and side views of an exemplary consumable according to one embodiment of the present invention. The consumable 1 is for use with a device that heats an aerosolizable material to volatilize at least one component of the aerosolizable material, such as device 100 shown in FIG. 6 and described below. The device can be a tobacco heating product (also known in the art as a tobacco heating device or a non-combustion heating device).

[0136] Consumable 1 includes an outer tube 10, an inner member 11 inside outer tube 10, and a plurality of supports 12. Supports 12 support inner member 11 relative to outer tube 10 such that a plurality of voids 13 exist between inner member 11 and outer tube 10. Supports 12 connect inner member 11 to outer tube 10. In this embodiment, inner member 11 includes a hollow inner tube 11 defining a passageway 14 therein, although in other embodiments, inner member 11 may be non-tubular, such as a solid rod.

[0137] The consumable 1 in this embodiment has circular inner and outer cross-sectional shapes. Furthermore, the inner member 11 and the outer tube 10 are both circular. In other embodiments, one or each of the inner member 11 and the outer tube 10 is non-circular, such as oval, polygonal, rectangular, square, triangular, or star-shaped. In some embodiments, the inner member 11 and / or the outer tube 10 are corrugated.

[0138] In this embodiment, the consumable 1 extends along an axis AA. The axis AA is a central axis extending along the passageway 14, although in other embodiments, the shape of the consumable may be such that the axis AA is offset from the passageway 14. In this embodiment, the consumable 1 is elongated in the direction of the axis AA, although in other embodiments, the width or diameter of the consumable 1 may be equal to or greater than the dimension of the consumable 1 in the direction of the axis AA, thereby making the consumable 1 non-elongated. In this embodiment, the inner member 11 and the outer tube 10 are substantially coaxial, each having a center that lies on the axis AA. In other embodiments, the inner member 11 may be non-coaxial with the outer tube 10, and the center of one or each of the inner member 11 and the outer tube 10 may be spaced apart from the axis AA.

[0139] In this embodiment, the consumable 1 comprises three supports 12 that support the inner member 11 relative to the outer tube 10. In some embodiments, the consumable can comprise more or less than three supports 12, such as four, five, or six supports 12, only two supports 12, or only one support 12.

[0140] In this embodiment, the supports 12 are disposed between the inner member 11 and the outer tube 10 and are circumferentially spaced apart from one another by a gap 13, although in other embodiments this may not be the case. For example, in some embodiments, a support 12 may be disposed in contact with the axial end faces of the inner member 11 and the outer tube 10, or two supports 12 may be disposed at the axial ends of the inner member 11 and the outer tube 10, respectively. Such support(s) 12 may be end pieces. These supports may be made of any suitable material, such as a plastic material. The end pieces may have features for receiving the inner member 11 and the outer tube 10, respectively, and may be configured to hold the inner member 11 relative to the outer tube 10.

[0141] In some embodiments, the support(s) 12 may be omitted. For example, the inner member 11 and / or the outer tube 10 may be shaped such that the inner member 11 and the outer tube 10 contact each other at least one location. For example, the inner member 11 and / or the outer tube 10 may be corrugated. Thus, the inner member 11 and the outer tube 10 themselves are configured to support the inner member 11 relative to the outer tube 10 without any separate support 12 being provided. In such embodiments, at least a portion of the inner member 11 is spaced from the outer tube 10 by a gap 13. In some such embodiments, multiple portions of the inner member 11 are spaced from the outer tube 10 by respective gaps 13.

[0142] In this embodiment, each void 13 is circumferentially spaced apart and separated by supports 12. In this embodiment, there are three voids 13. In other embodiments, the consumable 1 may include more or fewer than three voids 13, such as four, five, or six voids 13, only two voids 13, or only one void 13. In some embodiments, the number of void(s) 13 is equal to the number of support(s) 12 disposed between the inner member 11 and the outer tube 10.

[0143] The supports 12 radiate from the inner member 11 to the outer tube 10 such that each of the supports 12 extends in a generally radial direction perpendicular to the axis AA of the consumable 1. Each of the supports 12 may take the form of a spoke or fin. In this embodiment, each of the supports 12 is substantially flat. In other embodiments, the supports 12 may extend from the inner member 11 to the outer tube 10 in a direction other than radial and / or may be non-flat, such as curved or wavy.

[0144] In some embodiments, such as those shown in FIGS. 3 and 4, the or each support 12 includes an annular, non-circular support 12C between the inner member 11 and the outer tube 10. FIGS. 3 and 4 show schematic cross-sectional end and side views of another exemplary consumable according to an embodiment of the present invention. The consumable 2 of FIGS. 3 and 4 is intended for use with a device, such as device 100 shown in FIG. 6 and described below, that heats an aerosolizable material to volatilize at least one component of the aerosolizable material. In the consumable 2 of FIGS. 3 and 4, the inner member 11 is similar to that described above with reference to FIGS. 1 and 2, and therefore a discussion of the inner member will be omitted for the sake of brevity. While the outer tube 10 of this embodiment is devoid of aerosolizable material, in other embodiments, the outer tube 10 may include aerosolizable material.

[0145] In contrast to the support 12 of the consumable 1 of FIGS. 1 and 2, the consumable 2 of FIGS. 3 and 4 includes a support 12C between the inner member 11 and the outer tube 10 in the form of a folded or corrugated element 12C. The folded or corrugated element 12C can be made from any suitable material, such as paper, paperboard, patterned paper, cardboard, or a plastic material. In some embodiments, the support 12C of the consumable 2 includes or is made from a heating material, such as one of the heating materials discussed elsewhere herein. The support 12C is annular and therefore extends completely around the inner member 11, while in other embodiments, the support 12C is non-annular and therefore may only partially extend around the inner member 11.

[0146] In some embodiments, such as those shown in Figures 1 and 2, the or each support 12 extends along the entire length or axial dimension of the outer tube 10 and, optionally, along the entire length or axial dimension of the consumables 1, 2, 3. In other embodiments, such as those shown in Figures 3 and 4, the or each support 12C can extend along only a portion of the outer tube 10 or consumable 4. In use, in the embodiment of Figures 3 and 4, the support 12C is located only at the upstream end of the outer tube 10. In some embodiments, a plurality of spaced supports 12 may be provided axially along the entire length or axial dimension of the outer tube 10 or consumables 1, 2, 3, at respective intervals.

[0147] The consumable 2 of Figures 3 and 4 includes a porous filter 18 located at one end of the cavity 13. The filter 18 preferably comprises a filtering material such as cellulose acetate. In use, this filter 18 may be at the downstream end of the consumable 2 and may be used to filter aerosols generated in the cavity 13 during use. Such a filter 18 may be provided in other embodiment variations described herein as well.

[0148] 1-4, the inner tube 11 is disposed about a passageway 14 that opens to an axial end 15 of the consumables 1, 2 so that a heating element of the device can be inserted into the passageway 14 during use, as discussed in more detail below. In each of the embodiments of FIGS. 1-4, the passageway 14 extends completely through the inner tube 11 from one axial end of the inner tube 11 to the opposite axial end of the inner tube 11. Furthermore, in each of these embodiments, the passageway 14 extends completely through the consumables 1, 2 from a first axial end 15 of the consumables 1, 2 to an opposite second axial end 16 of the consumables 1, 2. However, in some embodiments, such as that shown in FIG. 5, the passageway 14 extends only partially along the length or axial dimension of the consumable, such as along a majority of the length or axial dimension of the consumable, or along only a portion of the length or axial dimension of the consumable.

[0149] FIG. 5 shows a schematic cross-sectional side view of another exemplary consumable according to an embodiment of the present invention. The consumable 3 of FIG. 5 is for use with an apparatus, such as apparatus 100 shown in FIG. 6 and described below, that heats an aerosolizable material to volatilize at least one component of the aerosolizable material. The consumable 3 of FIG. 5 is identical to the consumable of FIGS. 1 and 2 , except that a body of material 19 is radially disposed inside the inner tube 11 at the second axial end 16 of the consumable 3 so as to fill the inner hollow region of the inner tube 11 at the second axial end 16. Thus, the passageway 14 is a blind hole that extends the distance from the first axial end 15 of the consumable 3 to the body of material 19. In this embodiment, this distance is greater than half the length or axial dimension of the consumable 3, such that the passageway 14 extends the majority of the length or axial dimension of the consumable 3. In other embodiments, the body of material 19 and the consumable 3 as a whole may be configured such that the passageway 14 extends only half, or less than half, of the length or axial dimension of the consumable 3. The body of material 19 may be porous or non-porous.

[0150] Each of consumables 1, 2, 3 includes an aerosolizable material that can be heated to generate an aerosol in void(s) 13. In each embodiment, the aerosolizable material can include, for example, an amorphous solid, or can be in any of the other forms discussed herein.

[0151] In some embodiments, the inner member 11 includes an aerosolizable material. In some such embodiments, a heating element for heating the aerosolizable material is insertable into the passageway 14 during use, and upon heating the heating element, thermal energy passes radially outward from the heating element to the aerosolizable material of the adjacent inner member 11. This thermal energy heats the aerosolizable material, volatilizing at least one component of the aerosolizable material. The at least one component of the aerosolizable material then passes radially outward from the inner member 11 to the void(s) 13. The aerosol may be formed within the inner member 11 or subsequently within the void(s) 13; in either case, heating the inner member 11 generates or provides an aerosol within the void(s) 13. Heating the consumables 1, 2, 3 from the inside out in this manner may be more efficient than heating the consumables from the outside inward, because heat from the device's internal heater can only radiate outward.

[0152] In some embodiments, the outer tube 10 includes an aerosolizable material that can be heated to generate an aerosol within the void(s) 13. In some such embodiments, a heating element for heating the aerosolizable material can be positioned radially outward around the outer tube 10, such that heating the heating element causes thermal energy to pass radially inward from the heating element to the aerosolizable material of an adjacent outer tube 10. This thermal energy heats the aerosolizable material, volatilizing at least one component of the aerosolizable material. This at least one component of the aerosolizable material then passes radially inward from the outer tube 10 to the void(s) 13. Again, the aerosol can be formed within the outer tube 10 or subsequently within the void(s) 13, but in either case, heating the outer tube 10 generates or provides an aerosol within the void(s) 13.

[0153] In some embodiments, the inner member 11 and the outer tube 10 each include an aerosolizable material that is heatable to generate an aerosol within the void(s) 13. In some such embodiments, in use, a first heating element for heating the aerosolizable material of the inner member 11 is insertable into the passageway 14 as discussed above, and a second heating element for heating the aerosolizable material of the outer tube 10 is positionable radially outwardly around the outer tube 10 as discussed above. The first and second heating elements may be independently controllable.

[0154] In some embodiments, the or each substrate 12 (if present) comprises an aerosolizable material that is heatable to generate an aerosol within the void(s) 13. In some such embodiments, in use, a heating element for heating the aerosolizable material of the substrate(s) 12 can be inserted into the passage 14 as discussed above, and thermal energy from the heating element passes by thermal conduction through the inner member 11 to the substrate(s) 12. In some embodiments, in use, a heating element for heating the aerosolizable material of the substrate(s) 12 can be disposed radially outwardly around the outer tube 10 as discussed above, and thermal energy from the heating element passes by thermal conduction through the outer tube 10 to the substrate 12. In some such embodiments, the passage 14 may be omitted. The conducted thermal energy heats the aerosolizable material of the substrate(s) 12, causing at least one component of the aerosolizable material to volatilize. At least one component of the aerosolizable material then travels, e.g., circumferentially, from substrate(s) 12 to void(s) 13. The aerosol may be formed within substrate(s) 12 or subsequently within void(s) 13, but in either case, heating substrate(s) 12 generates or provides the aerosol within void(s) 13.

[0155] In some embodiments, the support(s) 12, and one or each of the inner member 11 and outer tube 10, also comprise an aerosolizable material that can be heated to generate an aerosol within the void(s) 13.

[0156] In some embodiments, the substrate(s) 12 (if present), outer tube 10, or inner member 11 are composed of or consist essentially of an aerosolizable material. For example, the substrate(s) 12 (if present), outer tube 10, or inner member 11 may be composed of a reconstituted aerosolizable material, such as reconstituted tobacco. In some embodiments, the substrate(s) 12 (if present), outer tube 10, or inner member 11 comprises a carrier and an aerosolizable material.

[0157] When the inner member 11 includes the aerosolizable material 11b, the aerosolizable material 11b of the inner member 11 may be radially outward of the carrier 11a of the inner member 11 (see FIGS. 1-4). The aerosolizable material 11b of the inner member 11 may at least partially define the gap(s) 13. When the outer tube 10 includes the aerosolizable material 10b, the aerosolizable material 10b of the outer tube 10 may be radially inward of the carrier 10a of the outer tube 10 (see FIGS. 1 and 2). The aerosolizable material 10b of the outer tube 10 may at least partially define the gap(s) 13. Such a configuration may help prevent contact between the consumable aerosolizable material and the device or the user's fingers. If the or each substrate 12 includes aerosolizable material 12b, the aerosolizable material 12b of each substrate 12 can be circumferentially adjacent to the carrier 12a of the respective substrate 12 (see FIGS. 1 and 2). The aerosolizable material(s) 12b of the substrate(s) 12 can at least partially define gap(s) 13.

[0158] In some embodiments where the inner member is corrugated, the corrugated inner member defines a plurality of wave troughs, and the aerosolizable material (such as an amorphous solid described herein) is disposed in at least one of the wave troughs, such as the plurality of wave troughs.

[0159] In some embodiments where the outer tube is corrugated, the corrugated outer tube defines a plurality of wave troughs, and the aerosolizable material (such as an amorphous solid described herein) is disposed in at least one of the wave troughs, such as the plurality of wave troughs.

[0160] In some embodiments in which the support includes a folded or corrugated element, the folded or corrugated element defines a plurality of wave troughs, and the aerosolizable material (such as an amorphous solid described herein) is disposed in at least one of the wave troughs, such as the plurality of wave troughs.

[0161] In some embodiments, the carrier 11a of the inner member 11 (see FIGS. 1-4) and / or the carrier 10a of the outer tube 10 (see FIGS. 1 and 2) and / or the carrier 12a of each support 12 (if provided) (see FIGS. 1 and 2) are made of or include one or more materials selected from the group consisting of paper, fabric paper, paperboard, cardboard, reconstituted tobacco, and plastic materials. In some embodiments, the carrier 10a of the inner member 11 and / or the carrier 11a of the outer tube 10 and / or the carrier 12a of the support 12 are made of or include a heating material, such as one of the heating materials discussed elsewhere herein. The aerosolizable material 10b, 11b, 12b can be applied to the carrier 10a, 11a, 12a. This application can be by any suitable technique, such as gluing, coating, or coextrusion. Coating can include, for example, spraying, electrospraying, casting, or band casting. The carriers 10a, 11a, 12a may be laminates.

[0162] In some cases, the surface of the carrier 10a, 11a, 12a that abuts the aerosolizable material 10b, 11b, 12b can be porous. For example, in some cases, the carrier 10a, 11a, 12a comprises paper. In some embodiments, the carrier 10a, 11a, 12a comprises or is composed of a tobacco material, such as a sheet of reconstituted tobacco, which can be porous. The inventors have found that porous carriers, such as paper, are particularly suitable for some embodiments of the present invention, where the porous layer abuts and forms a strong bond with the aerosolizable material 10b, 11b, 12b. The amorphous solid of the aerosolizable material 10b, 11b, 12b in some embodiments is formed by drying a gel. Without wishing to be limited by theory, it is believed that the gel-forming slurry partially impregnates the porous carrier (e.g., paper), thereby partially bonding the carrier to the gel as the gel hardens and forms crosslinks. This provides a strong bond between the gel and the carrier (and between the dried gel and the carrier). A porous layer (e.g., paper) can also be used to hold the perfume. In some cases, the porous layer may comprise paper having a porosity of preferably 0 to 300 Coresta units (CU), preferably 5 to 100 CU or 25 to 75 CU.

[0163] Additionally, surface roughness can contribute to the strength of the bond between the aerosolizable material 10b, 11b, 12b and the carrier 10a, 11a, 12a. The inventors have found that the paper roughness (of the surface that abuts the aerosolizable material) can preferably be in the range of 50 to 1000 Bekk seconds, preferably 50 to 150 Bekk seconds, and preferably 100 Bekk seconds (measured over an air pressure range of 50.66 to 48.00 kPa). (The Bekk smoothness tester is an instrument used to determine the smoothness of a paper surface; air at a specified pressure is leaked between a smooth glass surface and a paper sample, and the time (in seconds) for a predetermined amount of air to leak between the surfaces is the "Bekk smoothness.")

[0164] In some embodiments, the aerosolizable material of the substrate(s) 12 has a different shape or chemical composition than the aerosolizable material of the inner member 11 or outer tube 10. In some embodiments, the aerosolizable material of the outer tube 10 has a different shape or chemical composition than the aerosolizable material of the inner member 11.

[0165] For example, in some embodiments, the difference in shape can include a difference in the average particle size of the aerosolizable material. Typically, particles of aerosolizable material having a smaller average particle size can be heated by a given heating source more quickly, e.g., to volatilize at least one component of the aerosolizable material, than particles of aerosolizable material having a larger average particle size.

[0166] In some embodiments, the difference in shape may include an aerosolizable material in one of the substrate(s) 12 (if provided), outer tube 10, and inner member 11 comprising a regenerated aerosolizable material (such as regenerated tobacco), and an aerosolizable material in another of the substrate(s) 12 (if provided), outer tube 10, and inner member 11 comprising an amorphous solid.

[0167] In some embodiments, the difference in chemical composition can include a difference in one or more compositions of the aerosolizable material, such as a difference in the chemical composition of the respective amorphous solids. In some embodiments, the difference in chemical composition can include a difference in the type or concentration of an aerosol-forming agent, such as glycerol, in the aerosolizable material. In some embodiments, the difference in chemical composition can include a difference in the amount by weight of a smoke modifying agent, such as a flavoring, as a percentage of the total weight of the aerosolizable material.

[0168] In some embodiments, the support(s) 12 (if present) and / or the outer tube 10 and / or the inner member 11 may include multiple, spaced-apart, discrete regions of aerosolizable material. In use, such discrete regions of aerosolizable material may be individually heatable by respective heaters of a device in which the consumables 1, 2, 3 are usable.

[0169] In some embodiments, each of the voids 13 extends along the entire outer tube 10, from one axial end of the outer tube 10 to the opposite axial end of the outer tube 10. Further, each of the voids 13 extends along the entire consumables 1, 2, 3, from a first axial end 15 of the consumables 1, 2, 3 to an opposite second axial end 16 of the consumables 1, 2, 3. In other embodiments, the or each or some of the voids 13 extend only partially along the length or axial dimension of the consumables 1, 2, 3, such as across a majority of the length or axial dimension of the consumables 1, 2, 3 or across a portion of the length or axial dimension of the consumables 1, 2, 3.

[0170] Each of the illustrated consumables 1, 2, 3 has at least one outlet 17 that allows aerosol to exit the consumables 1, 2, 3 through the void 13. In the embodiment of Figures 1 and 2, there are multiple outlets 17, one for each of the voids 13. The outlet 17 of consumable 1 is defined by the inner member 11 and the outer tube 10. In contrast, in the embodiment of Figures 3 and 4, the outlet 17 of consumable 2 is defined by the porous filter 18, and more specifically, by the pores of the porous filter 18. In other embodiments, such as those in which there is only one void 13 between the inner member 11 and the outer tube 10, there may be only one outlet 17. The aerosol can exit the consumables 1, 2, 3 from the void(s) 13 via the outlet(s) 17, such as when a user inhales on the consumables 1, 2, 3 or when negative pressure is otherwise applied to the consumables 1, 2, 3, causing movement of the aerosol out of the consumables 1, 2, 3.

[0171] In each of the illustrated embodiments, each of the outlets 17 is at an axial end 16 of the consumables 1, 2, 3. In the consumable 3 of Figure 5, the passages 14 open at a first axial end 15 of the consumable 3, and each of the outlets 17 is at a second axial end 16 of the consumable 3 opposite the first axial end 15 of the consumable 3. In some other embodiments, the outlet(s) 17 are at an axial end of the consumable, and the passages 14 open at the same axial end of the consumable.

[0172] In some embodiments, the outer tube 10 forms at least a portion of one surface, such as the outermost surface, of the consumable 1, 2, 3. In some embodiments, the outer tube 10 forms at least a majority of the surface, such as the entirety of the surface. In some embodiments, the inner tube 11 forms at least a portion of one surface, such as the innermost surface, of the consumable 1, 2, 3. In some embodiments, the inner tube 11 forms at least a majority of the surface, such as the entirety of the surface.

[0173] Each of the inner member 11 and the outer tube 10 can be made of any suitable material. Each of the inner member 11 and the outer tube 10 should be sufficiently heat-resistant to withstand temperatures to which the consumables 1, 2, and 3 are exposed during normal use, such as those discussed later herein. The inner member 11 and / or the outer tube 10 can help provide rigidity to the consumables 1, 2, and 3. In some embodiments, the outer tube 10 is thicker than the inner tube 11, and in some other embodiments, the outer tube 10 is thinner than the inner tube 11. In some embodiments, the inner member 11 and / or the outer tube 10 comprises one or more materials selected from the group consisting of paper, fabric paper, paperboard, cardboard, reconstituted tobacco, and plastic materials. In some embodiments, the inner member 11 and / or the outer tube 10 comprises or is made of a heating material, such as one of the heating materials discussed elsewhere herein. In some embodiments, the inner member 11 and / or the outer tube 10 can comprise, for example, a rolling sheet or strip of paper, fabric paper, or reconstituted tobacco. In other embodiments, the inner member 11 and / or the outer tube 10 may comprise an extrusion of a material, for example, a plastic material, or a material including one or more metals or metal alloys. In some embodiments, the inner member 11 and / or the outer tube 10 may be extruded, such as co-extruded, and may be co-extruded with the support(s) 12 (if present).

[0174] In some embodiments, the inner member 11 and / or outer tube 10 are non-porous to the aerosol generated from the aerosolizable material during use. This can help prevent or impede the generated aerosol from contacting or depositing within the device in which the consumables 1, 2, 3 are usable. This can also help direct the flow of aerosol through the gap(s) 13 towards the outlet(s) 17.

[0175] The support(s) 12 (if present) can be made of any suitable material. The or each support 12 should be sufficiently heat resistant to withstand temperatures to which the consumables 1, 2, 3 are exposed during normal use, such as those discussed later herein. The or each support 12 may help provide rigidity to the consumables 1, 2, 3. In some embodiments, the or each support 12 comprises one or more materials selected from the group consisting of paper, cardboard, paperboard, cardboard, reconstituted tobacco, and plastic materials. In some embodiments, the or each support 12 comprises or is made from a heating material, such as one of the heating materials discussed elsewhere herein.

[0176] In some embodiments, the outer tube 10 extends across the entire length or axial dimension of the consumable 1, 2, 3. In other embodiments, the consumable 1, 2, 3 may include one or more elements (not shown) at one or each axial end of the outer tube 10, such that the outer tube 10 extends across only a portion of the length or axial dimension of the consumable 1, 2, 3.

[0177] In some embodiments, the consumable 1, 2, 3 comprises a porous body (not shown). The porous body can be for filtering aerosol or vapor emitted from the aerosolizable material during use. Alternatively or additionally, the porous body can be for controlling the pressure drop across the length or axial dimension of the consumable 1, 2, 3. The porous body can be of any type used in the tobacco industry. For example, the porous body can be made of cellulose acetate. In some embodiments, the porous body is substantially cylindrical, having a substantially circular cross-section and longitudinal axis. In other embodiments, the filter can have another cross-section or can be non-elongated.

[0178] In some embodiments, the porous body abuts the axial ends 15, 16 of the outer tube 10 and is axially aligned with the outer tube 10. In other embodiments, the porous body may be spaced apart from the outer tube 10, such as by a gap and / or one or more other components of the consumables 1, 2, 3. An exemplary other component(s) is an additive or flavor source (such as an additive or flavor-containing capsule or thread), which may be held, for example, by a body of filtration material or between two bodies of filtration material.

[0179] The consumables 1, 2, and 3 may also include a wrap that is wrapped around the outer tube 10 and the porous body to hold the porous body to the outer tube 10. The wrap may surround the outer tube 10 and the porous body. The wrap may be wrapped around the outer tube 10 and the porous body such that the free ends of the wrap overlap each other. The wrap may form part or all of the peripheral outer surface of the consumables 1, 2, and 3. The wrap may be made of any suitable material, such as paper, patterned paper, or recycled aerosolizable material (e.g., reconstituted tobacco). The wrap may also include an adhesive that bonds the overlapping free ends of the wrap together. This adhesive helps prevent the overlapping free ends of the wrap from separating. In other embodiments, the adhesive may be omitted or may take a different form than that described. In other embodiments, the porous body may be held to the outer tube 10 by a connection other than the wrap, such as an adhesive.

[0180] In some embodiments, the consumables 1, 2, 3 have a length or axial dimension between 30 and 150 millimeters, such as between 70 and 120 millimeters.

[0181] In some embodiments, the consumables 1, 2, 3 have an internal dimension (eg, inner diameter) perpendicular to the axial direction of between 2 and 10 millimeters, such as between 4 and 8 millimeters.

[0182] In some embodiments, the consumables 1, 2, 3 have an outer dimension (eg, outer diameter) perpendicular to the axial direction of between 4 and 10 millimeters, such as between 4.5 and 8 millimeters.

[0183] In some embodiments, the aerosolizable material, wherever located on the consumable 1, 2, 3, has a thickness between 0.05 and 2 millimeters, such as between 0.05 and 1 millimeter, or between 0.1 and 1 millimeter, or between 0.15 and 0.5 millimeters. The thickness can be 1 millimeter or less, such as 0.5 millimeters or less, or 0.25 millimeters or less, or 0.2 millimeters or less, or 0.1 millimeters or less, or 0.05 millimeters or less.

[0184] In some embodiments, the outer tube 10 has a thickness between 0.1 and 3 millimeters, such as between 0.15 and 2 millimeters.

[0185] In some embodiments, the inner tube 11 has a thickness between 0.1 and 3 millimeters, such as between 0.15 and 2 millimeters.

[0186] In some embodiments, the consumables 1, 2, 3 are suitable for insertion into a heating region of an apparatus, such as the heating region 110 of the apparatus 100 shown in Figure 6, which apparatus has a device that causes heating of the aerosolizable material of the consumables 1, 2, 3 when the consumables 1, 2, 3 are in the heating region. Once in the heating region 110, the device of the apparatus causes heating of the aerosolizable material to volatilize at least one component of the aerosolizable material.

[0187] In some embodiments, the device is configured to apply thermal energy to the consumables 1, 2, 3, and in particular to the aerosolizable material, via the outer tube 10 and / or the inner member 11. In some such embodiments, the device comprises a resistive heater that is heated by electrically connecting the resistive heater to a source of electricity, and thermal energy passes from the resistive heater to the consumables 1, 2, 3.

[0188] In some other embodiments, the device may comprise a magnetic field generator 112 for generating a changing magnetic field that penetrates the heating region 110 when the consumables 1, 2, 3 are in the heating region, and the consumables 1, 2, 3 comprise a heating material that is heatable by the changing magnetic field penetrating and heating the aerosolizable material. Thus, in such embodiments, the device is configured such that electromagnetic energy is applied to the heating material of the consumables 1, 2, 3 to generate heat in the heating material, and then thermal energy is applied from the heating material to the aerosolizable material. In some embodiments, the consumables 1, 2, 3 may comprise a heating material that is partially or wholly embedded in the aerosolizable material.

[0189] In yet another embodiment, the device 100 has a heatable element comprising a heating material, the heatable element being in thermal contact with the heating region, and the magnetic field generator is for generating a varying magnetic field that penetrates the heatable element of the device to cause heating of the heatable element and therefore heating of the heating region.

[0190] In either case, the volatile component(s) of the aerosolizable material can travel from the aerosolizable material and enter the void(s) 13 when the user draws on the consumable 1, 2, 3 or the device's mouthpiece (if provided), and from there exit the consumable 1, 2, 3 via the outlet(s) 17.

[0191] It should therefore be understood that in some embodiments, the consumables 1, 2, 3 include a heating material that is heatable by the penetration of a changing magnetic field. The heating material can be, for example, any one or more of those discussed herein.

[0192] The outer tube 10 may include, consist of, or consist essentially of a heating material, or the outer tube 10 may be free of a heating material. The inner member 11 may include, consist of, or consist essentially of a heating material, or the inner member 11 may be free of a heating material. One or each of the support(s) 12 (if present) may include, consist of, or consist essentially of a heating material, or may be free of a heating material. Although not required, it is preferred that the consumables 1, 2, 3 include a closed path of a heating material. The heating material may be, for example, any one or more of those discussed herein. In some embodiments, the consumables 1, 2, 3 may be free of a heating material.

[0193] Referring to Figure 6, a schematic cross-sectional side view of an example system including a consumable and an apparatus for heating a consumable aerosolizable material to volatilize at least one component of the aerosolizable material is shown, in accordance with one embodiment of the present invention.

[0194] 1 and 2 and an apparatus 100 that heats the aerosolizable material of the consumable 1 to volatilize at least one component of the aerosolizable material. In other embodiments, the consumable 1 may be replaced with any of the other consumables described herein, such as one of the consumables 2 and 3 shown in Figures 3-5. In this embodiment, the apparatus 100 is a tobacco heating product (also known in the art as a tobacco heating device or a non-combustion heating device).

[0195] The apparatus comprises a heating area 110 for receiving the consumables 1, 2, 3, and a device 112 for causing heating of the aerosolizable material when the consumables 1, 2, 3 are in the heating area 110.

[0196] Device 100 may define at least one air inlet (not shown) fluidly connecting heating region 110 with the exterior of device 100. A user may be able to aspirate the volatile component(s) of the aerosolizable material by breathing on the volatile component(s) from heating region 110. As the volatile component(s) are removed from heating region 110 and consumables 1, 2, 3, air may be drawn into heating region 110 via air inlet(s) of device 100.

[0197] In this embodiment, the heating area 110 includes a recess for receiving at least a portion of the consumable 1, 2, 3. In other embodiments, the heating area 110 may be other than a recess, such as a ledge, surface, or protrusion, and may need to mechanically mate with the consumable 1, 2, 3 in order to cooperate with or receive the consumable 1, 2, 3. In this embodiment, the heating area 110 is elongated and sized and shaped to accommodate the entire consumable 1, 2, 3. In other embodiments, the heating area 110 may be sized to receive only a portion of the consumable 1, 2, 3.

[0198] In some embodiments, the device 112 comprises a power source, a resistive heater that is heated by passing electricity through the resistive heater, and a controller for controlling the passage of electricity through the resistive heater. The resistive heater is configured to apply thermal energy to the heated region 110, and thus to the consumables 1, 2, and 3, when the consumable is in the heated region 110. The resistive heater can apply thermal energy to the aerosolizable material in or through the outer tube 10 or the inner member 11. In some embodiments, the resistive heater can protrude into the heated region 110 so as to be located within the passageway 14 of the consumable when the consumable is in the heated region 110. For example, such a configuration can be used when the consumable is one of those shown in FIGS. 1-4. In some other embodiments, the resistive heater can be located radially outward of the consumable when the consumable is in the heated region 110. For example, the resistive heater can at least partially define the heated region 110. Such a configuration can be used when the inner member 11 of the consumable does not define a passageway 14 therein. In some embodiments, the device may include a first resistive heater located in the consumable passageway 14 when the consumable is in the heating zone 110 and a second resistive heater located radially outside the consumable when the consumable is in the heating zone 110.

[0199] In some embodiments, such as that shown in FIG. 6, the device 12 comprises a magnetic field generator for generating a changing magnetic field that penetrates the heating area 110 when the consumables 1, 2, 3 are in the heating area 110.

[0200] In use, in some cases, substantially all of the amorphous solid is less than about 4 mm, 3 mm, 2 mm, or 1 mm from the heater (i.e., the heatable element or resistance heater). In some cases, the solid is positioned between about 0.010 and 2.0 mm, preferably between about 0.02 and 1.0 mm, and preferably between about 0.1 and 0.5 mm from the heater. These minimum distances may in some cases reflect the thickness of the carrier supporting the amorphous solid. In some cases, the surface of the amorphous solid may directly abut the heater.

[0201] As discussed above, in some embodiments, the consumables include a heating material for use in heating the aerosolizable material. In such embodiments, the magnetic field generator of the device can be configured to generate a varying magnetic field that penetrates the heating material of the consumables 1, 2, 3 when the consumables 1, 2, 3 are in the heating zone 110.

[0202] In other embodiments, such as that shown in FIG. 6 , the device 112 of the apparatus 100 includes a heatable heating element 111 in the heating region 110, and the magnetic field generator of the apparatus is configured to generate a changing magnetic field that penetrates the heating element 111. In some embodiments, the heating element is located radially outward of the consumables 1, 2, 3 when the consumables 1, 2, 3 are in the heating region 110. For example, the heating element can at least partially define the heating region 110. In other embodiments, such as that shown in FIG. 6 , the heating element 111 protrudes into the heating region 110. Such a configuration is preferred when the inner member 11 of the consumables 1, 2, 3 includes an inner tube disposed around the passage 14, which opens at an axial end of the consumables 1, 2, 3 so that the heating element 111 can be inserted into the passage 14 of the consumables 1, 2, 3 during use. 6, the heating element 111 enters the passage 14 while the consumables 1, 2, 3 are inserted into the heating zone 110. In other embodiments, the device may be configured such that the heating element 111 is movable relative to the heating zone 110 to protrude into the passage 14 when the consumables 1, 2, 3 are already positioned in the heating zone 110.

[0203] In some embodiments, the heating element 111 of the device has an outer cross-sectional shape, and the inner tube 11 of the consumables 1, 2, 3 has an inner cross-sectional shape that matches the outer cross-sectional shape of the heating element 111. For example, the inner and outer cross-sectional shapes can be circular or non-circular, such as oval, polygonal, rectangular, square, triangular, wave-shaped, or star-shaped. In some embodiments, the heating element 111 of the device and the inner tube 11 of the consumables 1, 2, 3 are relatively sized so that the inner tube 11 abuts the heating element 111 in use to increase the efficiency and effectiveness of the delivery of thermal energy from the heating element 111 to the inner tube 11. The inner tube 11 can be an interference fit or a snug fit with the heating element 111.

[0204] In this embodiment, the magnetic field generator 112 comprises a power supply 113, a coil 114, a device 116 for passing a varying current, such as an alternating current, through the coil 114, a controller 117, and a user interface 118 for user operation of the controller 117.

[0205] In this embodiment, power source 113 is a rechargeable battery. In other embodiments, power source 113 may be other than a rechargeable battery, such as a non-rechargeable battery, a capacitor, a battery-capacitor hybrid, or a connection to a mains power source.

[0206] The coil 114 can take any suitable form. In some embodiments, the coil 114 is a helical coil made of a conductive material such as copper. In some embodiments, the coil is a flat coil. That is, the coil can be a two-dimensional helix made of a conductive material such as copper. In some embodiments, the coil 114 surrounds the heating region 110. In some embodiments, the coil 114 extends along a longitudinal axis that is substantially aligned with the longitudinal axis of the heating region 110. These aligned axes can be coincident. Alternatively, the aligned axes can be parallel or oblique to one another.

[0207] In this embodiment, device 116 for passing a varying current through coil 114 is electrically connected between power source 113 and coil 114. In this embodiment, controller 117 is also electrically connected to power source 113 and communicatively connected to device 116 for controlling device 116. More particularly, in this embodiment, controller 117 is for controlling device 116 to control the supply of power from power source 113 to coil 114. In this embodiment, controller 117 comprises an integrated circuit (IC), such as an IC on a printed circuit board (PCB). In other embodiments, controller 117 may take a different form. In some embodiments, apparatus 100 may have a single electrical or electronic component including device 116 and controller 117. Controller 117, in this embodiment, is operated by user manipulation of user interface 118. User interface 118 may include push buttons, toggle switches, dials, a touch screen, etc. In other embodiments, the user interface 118 is remote and connects wirelessly to the rest of the device 100, such as via Bluetooth.

[0208] In this embodiment, when a user operates the user interface 118, the controller 117 causes the device 116 to pass an alternating current through the coil 114, which in turn generates an alternating magnetic field. The coil 114 and heating region 110 of the apparatus 100 are appropriately positioned relative to one another so that when the consumables 1, 2, and 3 are placed in the heating region 110, the changing magnetic field generated by the coil 114 penetrates the heating element 111 of the apparatus 100. If the heating material of the heating element 111 is conductive, this penetration generates one or more eddy currents in the heating material. As the eddy currents flow in the heating material against the heating material's electrical resistance, the heating material heats due to Joule heating. If the heating material of the heating element 111 is magnetic, the changing applied magnetic field changes the orientation of magnetic dipoles in the heating material, generating heat in the heating material.

[0209] In some embodiments, the consumables 1, 2, and 3 comprise a heating material, and the coil 114 and heating region 110 of the device 100 are suitably positioned relative to one another such that when the consumables 1, 2, and 3 are disposed in the heating region 110, a changing magnetic field generated by the coil 114 penetrates the heating material of the consumables 1, 2, and 3. In some embodiments, the device 100 comprises a heating element 111, the heating element 111 comprises a heating material, and the consumables 1, 2, and 3 also comprise a heating material. In some such embodiments, the coil 114 and heating region 110 of the device 100 are suitably positioned relative to one another such that when the consumables 1, 2, and 3 are disposed in the heating region 110, a changing magnetic field generated by the coil 114 penetrates the heating material of the consumables 1, 2, and 3 and the heating material of the heating element 111.

[0210] In this embodiment, the apparatus 100 includes a temperature sensor 119 for sensing the temperature of the heated region 110. The temperature sensor 119 is communicatively connected to the controller 117 so that the controller 117 can monitor the temperature of the heated region 110. Based on one or more signals received from the temperature sensor 119, the controller 117 can cause the device 112 to adjust the characteristics of the varying or alternating current passed through the coil 114 as needed to ensure that the temperature of the heated region 110 remains within a predetermined temperature range. This characteristic can be, for example, amplitude, frequency, or duty cycle. Within the predetermined temperature range, during use, the aerosolizable material in the consumable placed in the heated region 110 is heated sufficiently to volatilize at least one component of the aerosolizable material 14 without burning the aerosolizable material 14. Thus, the controller, and the apparatus 100 as a whole, are configured to heat the aerosolizable material to volatilize at least one component of the aerosolizable material without burning the aerosolizable material. In some embodiments, the temperature range is between about 50 and about 350°C, such as between about 100 and about 300°C, or between about 120 and about 350°C, or between about 140 and about 250°C, or between about 200 and about 270°C. In other embodiments, the temperature range may be other than one of these ranges. In some embodiments, the upper limit of the temperature range may be greater than 350°C. In some embodiments, the consumable may be non-flammable, for example, in these temperature ranges. In some embodiments, the temperature sensor 119 may be omitted.

[0211] In some embodiments, the device 112 that causes heating of the aerosolizable material when the consumable is in the heating region 110 is configured to heat separate portions of the heating region 110 independently of each other, such as by having separately controllable heatable elements 111.

[0212] In some embodiments, the heating material of consumables 1, 2, 3 or of heatable heating element 111 of device 100 is aluminum. However, in other embodiments, the heating material may include one or more materials selected from the group consisting of an electrically conductive material, a magnetic material, and a magnetically conductive material. In some embodiments, the heating material may include a metal or metal alloy. In some embodiments, the heating material may include 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. Other heating material(s) may be used in other embodiments.

[0213] In some embodiments, such as those in which the heating material comprises iron, such as steel (e.g., mild steel or stainless steel), or aluminum, the heating material may be coated to help prevent corrosion or oxidation of the heating material during use. Such coatings may include, for example, nickel plating, gold plating, or ceramic or inert polymer coatings.

[0214] In some embodiments, consumables 1, 2, 3 may include a heating material that is partially or entirely embedded in the aerosolizable material of consumables 1, 2, 3. In some embodiments, the aerosolizable material may include a heating material. In some embodiments, the aerosolizable material may be free of a heating material.

[0215] In some embodiments, the aerosolizable material includes tobacco. However, in other embodiments, the aerosolizable material may consist of tobacco, consist essentially entirely of tobacco, include tobacco and aerosolizable materials other than tobacco, include aerosolizable materials other than tobacco, or be tobacco-free. In some embodiments, the aerosolizable material may include a vapor or aerosol-forming agent or humectant, such as glycerol, propylene glycol, triacetin, or diethylene glycol.

[0216] In some embodiments, the consumable is non-flammable. In some embodiments, the consumable is configured so that it does not become flammable when in use.

[0217] In some embodiments, once all or substantially all of the volatilizable component(s) of the aerosolizable material in consumables 1, 2, 3 have been depleted, the user can remove consumables 1, 2, 3 from the heating zone of device 100 and discard consumables 1, 2, 3. The user can then reuse device 100 with another of consumables 1, 2, 3. However, in each other embodiment, device 100 and consumables 1, 2, 3 may be discarded together once the volatilizable component(s) of the aerosolizable material have been depleted.

[0218] In some embodiments, the consumables 1, 2, 3 are sold, supplied, or otherwise provided separately from the device 100 with which the consumables 1, 2, 3 are usable. However, in some embodiments, the device 100 and one or more consumables 1, 2, 3 may be provided together as a system, such as a kit or assembly, possibly with additional components such as cleaning tools.

[0219] For the avoidance of doubt, where the term "comprising" is used herein to define the invention, or a feature of the invention, embodiments are also disclosed in which the invention or feature may be defined using the terms "consisting essentially of" or "consisting of" in place of "comprising." Reference to a material "comprising" certain features means that these features are included, contained, or retained in the material.

[0220] To address various problems and advance the art, this entire disclosure illustrates, by way of illustration and example, various embodiments that may practice the claimed invention and provide an improved consumable for use with an apparatus that heats an aerosolizable material to volatilize at least one component of the aerosolizable material, as well as a system including such a consumable and such an apparatus. The advantages and features of the present disclosure are merely representative of embodiments and are not intended to be exhaustive and / or exclusive. These advantages and features are presented solely to aid in and teach understanding of the claimed or otherwise disclosed features. It is to be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects of the present disclosure should not be construed as limiting the present disclosure, as defined by the claims, or the equivalents of other claims, and that other embodiments may be utilized and modifications may be made without departing from the scope and / or spirit of the present disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of various combinations of the disclosed elements, components, features, members, steps, means, etc. This disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. 1. A consumable for use with a device that heats an aerosolizable material to volatilize at least one component of said aerosolizable material, comprising: an outer pipe; an inner member inside the outer pipe; and at least one support supporting the inner member relative to the outer pipe such that at least one gap exists between the inner member and the outer pipe; at least one of the inner member, the outer tube, and the support includes an aerosolizable material that is heatable to generate an aerosol in the gap; The consumable has at least one outlet that allows the aerosol to exit the consumable from the void.

2. The consumable of claim 1 , wherein the at least one support comprises a plurality of supports circumferentially spaced from one another.

3. The consumable of claim 1 or claim 2, wherein the at least one support is disposed between the inner member and the outer tube.

4. The consumable of claim 3 , wherein the at least one support comprises an annular non-circular support between the inner member and the outer tube.

5. 5. The consumable product of claim 3 or 4, wherein the at least one support comprises a folded or corrugated element between the inner member and the outer tube.

6. The consumable product of any one of claims 1 to 5, wherein at least one of the inner member and the outer tube comprises the aerosolizable material.

7. The consumable product of claim 6 , wherein at least one of the inner member and the outer tube includes a carrier, and the aerosolizable material is affixed to the carrier.

8. 1. A consumable for use with a device that heats an aerosolizable material to volatilize at least one component of said aerosolizable material, comprising: An outer tube; an inner member inside the outer tube, at least a portion of the inner member being spaced from the outer tube by at least one gap, the inner member including an aerosolizable material that is heatable to generate an aerosol within the gap; The consumable has at least one outlet that allows the aerosol to exit the consumable from the void.

9. The consumable product of claim 8 , wherein the inner member includes a carrier, and the aerosolizable material is affixed to the carrier.

10. The consumable product of any one of claims 1 to 9, wherein the aerosolizable material comprises an amorphous solid.

11. 1. A consumable for use with a device that heats an aerosolizable material to volatilize at least one component of said aerosolizable material, comprising: An outer tube; an inner member inside the outer pipe, at least a portion of the inner member being spaced from the outer pipe by at least one gap; and an aerosolizable material comprising an amorphous solid that can be heated to generate an aerosol within the void; The consumable has at least one outlet that allows the aerosol to exit the consumable from the void.

12. The consumable product of any one of claims 1 to 11, wherein at least one of the inner member and the outer tube is circular.

13. The consumable according to any one of claims 1 to 12, wherein the inner member and the outer tube are coaxial.

14. The consumable product of any one of claims 1 to 13, wherein the inner member comprises an inner tube.

15. 15. The consumable of claim 14, wherein the inner tube is disposed about a passageway that is open at an axial end of the consumable such that a heating element for heating the aerosolizable material can be inserted into the passageway during use.

16. The consumable of any one of claims 1 to 15, wherein the at least one outlet is at an axial end of the consumable.

17. The consumable product of any one of claims 1 to 16, comprising a heating material that is heatable by the penetration of a changing magnetic field to heat the aerosolizable material.

18. 20. The consumable of claim 17, wherein the heating material comprises one or more materials selected from the group consisting of an electrically conductive material, a magnetic material, and a magnetically conductive material.

19. 19. The consumable of claim 17 or claim 18, wherein the heating material comprises a metal or metal alloy.

20. 20. The consumable of any one of claims 17 to 19, wherein the heating material 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.

21. The consumable product of any one of claims 17 to 20, wherein at least one of the inner member and the outer tube comprises the heating material.

22. 22. The consumable of any one of claims 17 to 21 when directly or indirectly dependent on claim 1, wherein the at least one support comprises the heating material.

23. 1. A system for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, comprising: The consumable product according to any one of claims 1 to 22; and an apparatus for heating the aerosolizable material of the consumable to volatilize at least one component of the aerosolizable material, the apparatus including a heating area for receiving the consumable, and further including a device for causing heating of the aerosolizable material when the consumable is in the heating area.

24. 24. The system of claim 23, wherein the device comprises a magnetic field generator for generating a changing magnetic field that penetrates the heating region when the consumable is in the heating region.

25. 25. The system of claim 23 or claim 24, wherein the device of the apparatus includes a heatable heating element in the heating region, and the inner member of the consumable includes an inner tube arranged around a passageway, the passageway being open at an axial end of the consumable so that the heating element can be inserted into the passageway.

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