Consumables

Abstract

A consumable (100) for use in a non-combustion aerosol delivery device, the consumable (100) comprising a hollow section formed from a laminate material, the laminate material (130) comprising a first layer (131) and a second layer (132), and a laminate sheet formed in the section such that edges of the first layer abut to form a first butt seam (133).

Description

[Technical Field]

[0001] The present disclosure relates to components for articles for use in or as aerosol delivery systems, articles for use in or as aerosol delivery systems, and methods for forming components for articles for use in or as aerosol delivery systems. [Background technology]

[0002] Certain tobacco industry products, during use, generate an aerosol that is inhaled by the user. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, to form an aerosol by heating rather than burning the substrate. Such tobacco industry products generally include consumables containing aerosol-generating materials for use in the heating device. Summary of the Invention

[0003] In a first aspect of the present invention, there is provided a consumable for use in a non-combustion aerosol delivery device, the consumable comprising a hollow section formed from a laminate material, the laminate material comprising a first layer and a second layer, the laminate sheet being formed in the section such that edges of the first layer abut to form a first butt seam.

[0004] In a second aspect of the present invention, there is provided a method of forming a consumable for use with a non-combustion aerosol delivery device, comprising the steps of: adhering a second layer of sheet material to the first layer to form a laminate, wherein longitudinal edges of the first layer are offset from respective longitudinal edges of the second layer, such that a portion of the first layer does not overlap the second layer and a portion of the second layer does not overlap the first layer; forming the laminate into a hollow section such that a portion of the first layer and a portion of the second layer are in opposing relationship with one another and longitudinal edges of each of the first layer and second layer abut and are bonded to form a butt seam.

[0005] In a third aspect of the present invention, there is provided a non-combustion aerosol delivery system comprising a consumable of the first aspect and a non-combustion aerosol delivery device, the non-combustion aerosol delivery device comprising an aerosol generator configured to heat the consumable to generate an aerosol when the consumable and device are combined during use.

[0006] Embodiments of the present invention will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0007] [Figure 1] 1 illustrates a schematic of a system including a consumable and a non-combustion aerosol delivery device. [Figure 2] 1 shows a cross section of the consumable projected onto a plane parallel to the longitudinal axis of the consumable. [Figure 3] 3 illustrates a cross-section of the example consumable of FIG. 2 projected onto a plane perpendicular to the longitudinal axis of the consumable. [Figure 4] 3 illustrates a cross-section of the example consumable of FIG. 2 projected onto a plane perpendicular to the longitudinal axis of the consumable. [Figure 5] 1 shows a cross section of the consumable projected onto a plane parallel to the longitudinal axis of the consumable. [Figure 6] 6 illustrates a cross-section of the example consumable of FIG. 5 projected onto a plane perpendicular to the longitudinal axis of the consumable. [Figure 7] 1 illustrates a schematic of a system including a consumable and a non-combustion aerosol delivery device. [Figure 8] 1 shows a schematic representation of consumables. [Figure 9] Here's how. [Figure 10]1 illustrates a laminate for forming a hollow section of a consumable according to an example herein. DETAILED DESCRIPTION OF THE INVENTION

[0008] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user, including non-combustion aerosol delivery systems that release compounds from an aerosol-forming material without burning the aerosol-forming material, such as electronic cigarettes, tobacco heating products, and hybrid systems that generate an aerosol using a combination of aerosol-forming materials.

[0009] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials (or components of those materials) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0010] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0011] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system.

[0012] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0013] The non-combustion aerosol delivery systems described herein include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0014] The present disclosure relates to consumables, sometimes referred to as articles throughout this disclosure, that include aerosol-forming materials and are configured for use with non-combustion aerosol delivery devices.

[0015] In some embodiments, a non-combustion aerosol delivery system, such as a non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, an electrical power source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol-generating material or a heat-transfer material proximate the heat-generating power source.

[0016] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0017] In some embodiments, a consumable for use with a non-combustion aerosol delivery device may include an aerosol-generating material, an aerosol-generating material storage region, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating region, a housing, a packaging material, a filter, a mouthpiece, and / or an aerosol modifier. The consumable may also include an aerosol generator, such as a heater, that generates heat upon use to cause the aerosol-generating material to generate an aerosol. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0018] In some embodiments, the substance to be delivered may be an aerosol-generating material or a material not intended to be aerosolized. Optionally, either material may include one or more active ingredients, one or more flavors, one or more aerosol-former materials, and / or one or more other functional materials.

[0019] In some embodiments, the substance to be delivered comprises an active agent.

[0020] As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. The active substance may be naturally derived or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another plant material.

[0021] In one embodiment, the active substance is a legally permitted recreational drug.

[0022] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0023] As described herein, the active substance may include one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0024] The active substance may be CBD or a derivative thereof.

[0025] As described herein, an active substance may comprise or be derived from one or more botanical substances or their components, derivatives, or extracts. As used herein, the term "botanical substance" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, or shells. Alternatively, the material may comprise an active compound naturally occurring in the botanical substance or a synthetically obtained active compound. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, or sheets. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange skin, 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, and lavender. The mint may be selected from the following mint varieties: Mentha acuta (spicy mint), Mentha cv (spicy mint), Egyptian mint, Mentha piperita (peppermint), Eau de Cologne (cologne mint), Peppermint, Curly mint, Kentucky kernel mint, Horse mint, Pineapple mint, Pennyroyal mint, Spearmint, and Apple mint.

[0026] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substance is tobacco.

[0027] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, wherein the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0028] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0029] In some embodiments, the substance to be delivered comprises a flavor.

[0030] As used herein, the terms "flavor" and "flavoring agent" refer to materials that may be used, where local regulations permit, to create a desired taste, aroma, or other somatic sensation in products intended for adult consumers, including naturally occurring flavor materials, botanical substances, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange). , mango, clementine, lemon, lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, 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, peppermint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, bay leaf, yerba mate, 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, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damiento, marjoram, olive, lemon balm, lemon basil, chives, carvi, 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., sucralose, acesulfame potassium, aspartame,The compositions may contain other additives such as saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol, as well as other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. They may be imitation, synthetic, or natural, or blends 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.

[0031] In some embodiments, the flavor comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavor comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.

[0032] In some embodiments, the flavor may include a sensate intended to achieve somatic sensations typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to, or instead of, the aroma or taste nerves, and may include agents that produce heating, cooling, tingling, or numbing effects. A suitable heating 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.

[0033] An aerosol-forming material is a material that can generate an aerosol when, for example, heated, irradiated, or energized in any other way. The aerosol-forming material may be, for example, in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain an active agent and / or flavoring.

[0034] The aerosol-generating materials may include one or more active agents and / or flavors, one or more aerosol former materials, and optionally one or more other functional materials.

[0035] The aerosol-generating material may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a substance to be delivered and / or a filler material may also be present. Optionally, a solvent, such as water, may also be present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0036] The aerosol-generating material may include or be in the form of an aerosol-generating film. The aerosol-generating film may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a substance to be delivered and / or a filler material may also be present. The aerosol-generating film may be substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0037] The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. The aerosol-generating film may be up to 0.5 mm thick, preferably 0.05 mm to 0.5 mm microns. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

[0038] The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The continuous sheet of material may be a laminate comprising a substrate and aerosol-generating film disposed continuously across the substrate. The sheet may be in the form of a wrapper, gathered to form a gathered sheet, or chopped to form a chopped sheet. The chopped sheet may comprise one or more strands or strips of aerosol-generating material.

[0039] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may include one or more discrete portions or regions of aerosol-generating material, such as dots, stripes, or lines, that may be supported on a substrate. In such embodiments, the substrate may be planar or non-planar.

[0040] The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-forming agent, and one or more other ingredients, such as one or more substances to be delivered, to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent and form the aerosol-generating film.

[0041] The slurry may be heated to remove at least about 60%, 70%, 80%, 85%, or 90% by weight of the solvent.

[0042] An aerosol-generating material may include or be an "amorphous solid." In some embodiments, the aerosol-generating material includes an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid." The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material that may retain some fluid, such as a liquid, within the amorphous solid. In some embodiments, the amorphous solid may comprise, for example, about 50%, 60%, or 70% amorphous solid by weight, to about 90%, 95%, or 100% amorphous solid by weight.

[0043] The amorphous solid may be substantially free of plant material.The amorphous solid may be substantially free of tobacco.

[0044] The aerosol former material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol former material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0045] The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0046] The aerosol-generating material may be present on or in a support forming a substrate. The support may be or comprise, for example, paper, card, paperboard, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support includes a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0047] A susceptor is a heating material that can be heated by penetration by a varying magnetic field, such as an alternating magnetic field. The susceptor can be a conductive material, such that penetration of the conductive material by the varying magnetic field causes induction heating of the heating material. The heating material can be a magnetic material, such that penetration of the magnetic material by the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor can be both conductive and magnetic, such that the susceptor can be heated by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0048] An aerosol modifier is a substance, typically located downstream of the aerosol-generation area, configured to modify the generated aerosol, for example, by changing the taste, flavor, acidity, or another property of the aerosol. The aerosol modifier may be provided within an aerosol modifier-releasing component operable to selectively release the aerosol modifier.

[0049] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a string, or granules. The aerosol modifier may not include a filtering material.

[0050] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy to release one or more volatile substances from the aerosol-generating material to form an aerosol.

[0051] 1 shows a non-combustion aerosol delivery system comprising a consumable product 100 and a non-combustion aerosol delivery device 200. The device comprises an area 201 for receiving the consumable product 100 and an aerosol generator 202.

[0052] 2 shows a cross-section of consumable 100. The cross-section is projected onto a plane that bisects consumable 100 longitudinally. Consumable 100 comprises hollow section 101. Hollow section 101 comprises wall 102 that encloses air gap 103. Consumable 100 is configured to generate an aerosol within air gap 103 when heated by non-combustion aerosol delivery device 200 for inhalation by a user.

[0053] FIG. 3 shows the consumable 100 in a cut plane projected onto a plane that bisects the consumable 100 perpendicular to its longitudinal direction. FIG. 3 shows further detail of the wall 102 of the consumable. In this example, the wall is formed from a laminate material 130 that is rolled into the hollow section 101. The laminate material 130 includes a first layer 131 and a second layer 132. As the laminate material 130 is rolled into the section 101, the edges of the first layer 131 abut to form a first butt seam 133, and the edges of the second layer 132 abut to form a second butt seam 134. The first butt seam 133 is offset from the second butt seam 134 around the hollow section 101. While the hollow section 101 shown here is tubular, in other examples it may be a hollow prism with a wall 102 having a polygonal cross-section. Exemplary polygonal cross-sections can include, but are not limited to, an octagon, a hexagon, a heptagon, or a square. Rather than being rolled in this manner, the non-tubular hollow section 101 may be folded. Regardless of the cross-sectional shape of the hollow section 101, the first and second butt seams 133, 134 are offset around the section 101 to provide an overlap region 135 where the first layer 131 of the laminate 130 overlaps the second layer 132 of the laminate 130. In the illustrated example, the wall 102 of the hollow section 101 is a tubular wall, and the first and second button seams 133, 134 are offset around the tubular wall 102.

[0054] The first layer of the laminate is bonded to the second layer of the laminate by an adhesive disposed between the first and second layers. The adhesive extends into the overlap region 135 to prevent the hollow section 101 from coming apart. In one example, the adhesive extends continuously between the first and second layers. In other words, there are no adhesive-free areas between the first and second layers. Alternatively, to limit the use of adhesive, the adhesive may be provided only in discrete areas or may be patterned. In one example, a spiral pattern of adhesive including overlapping loops of adhesive may be used. The spiral pattern of adhesive has been found to provide good bonding efficiency, producing a stronger bond for the amount of adhesive used compared to other patterns.

[0055] The first and second butt seams 133, 134 ensure that both the inner surface 135 and the outer surface 136 of the wall 102 of the hollow section 101 are smooth. That is, both the inner surface 135 and the outer surface 136 of the wall 102 are free of steps. Such steps typically occur when non-laminated material is rolled or folded to form the hollow section, overlapping the edges and bonding them together to prevent disassembly of the section. In contrast, in this example, the edges of the first and second layers 131, 132 are abutted to present coplanar inner and outer surfaces 136, 137, respectively.

[0056] In the example described herein, the second layer 132 is disposed on the outside of the first layer 131. In other words, the second layer 132 forms the outer surface 137 of the wall 102, and the first layer 131 forms the inner surface 136. In this example, the outer surface 137 is the outermost surface, but in other examples, additional layers of material may be added. In one example shown in FIG. 8 and described below, the consumable 100 further includes a wrapping material 110.

[0057] 3, first layer 131 includes a support 104 and an aerosol-generating material 105 disposed on support 104. Aerosol-generating material 105 forms inner surface 136 of wall 102. Thus, support 104 is disposed between aerosol-generating material 105 and the second layer of laminate 132. Support 104 may be made of any suitable material, such as paper or paperboard.

[0058] FIG. 4 illustrates another exemplary consumable 100, in which similar features retain the same reference numerals. Similar to FIG. 3, FIG. 4 is a cross-section projected onto a plane that bisects the consumable 100 perpendicular to its longitudinal axis. In the example of FIG. 4, the support 104 further includes a first layer 106 and a second layer 107, with the first layer 106 positioned between the aerosol-generating material 105 and the second layer 107. The first layer 106 is a susceptor 106 and is heatable by penetration with a fluctuating magnetic field. The second layer 107 is not heatable by penetration with a fluctuating magnetic field and may be any suitable material within this criterion, such as paper or paperboard. The aerosol-generating material 105 is disposed directly on the susceptor 106. However, in other examples, additional materials may be provided between the aerosol-generating material 105 and the susceptor 106. An advantage of this example is that the susceptor 106 never overlaps itself. In other exemplary consumables outside the scope of this disclosure, susceptors are known to be formed by rolling susceptor material into a tube with overlapping edges at the separated portions, which tend to form hot spots when heated, although this is not an issue with this embodiment.

[0059] Another exemplary consumable 100, in which like features retain the same reference numerals, is shown in FIG. 5. A cross-section of the consumable 100 is shown in FIG. 5. The cross-section is projected onto a plane that bisects the consumable 100 longitudinally. The consumable of FIG. 5 further comprises an inner member 150 inside the hollow section 101 and spacers 150, 150′. The spacer 150 spaces the inner member 150 relative to the hollow section 101 so that an air gap 103 is provided between the inner member and the hollow section 101. In this example, the hollow section 101 and the inner member 150 are tubular. In other words, the inner member 150 is an inner tube 150. The spacer is located between the inner member 150 and the hollow section 101. In this example, the spacers 151, 151′ are annular. In other words, the spacers 151, 151′ extend completely around the inner member 150. However, it will be appreciated that the spacers 151, 151' may instead not be annular, but instead be radially extending individual spacers 151, 151'. The spacers 151, 151' may be made of any suitable material, including, but not limited to, paper, cellulose acetate, or another fibrous material.

[0060] FIG. 6 illustrates the consumable 100 in cross section, projected onto a plane that bisects the consumable 100 perpendicular to the longitudinal direction. FIG. 6 also illustrates further details of the inner member 150 of the consumable. In this example, the wall 102 of the hollow section 101 is free of the aerosol-generating material 105; instead, the aerosol-generating material 105 is provided on the inner member 150. Specifically, the aerosol-generating material 105 is provided on a support 154. The support 154 includes a first layer 156 and a second layer 157, with the first layer 156 disposed between the aerosol-generating material 105 and the second layer 157. The support 154 may be made of any suitable material, such as paper or paperboard, and may include a susceptor. In this example, the first layer 156 is the susceptor 156, which is heatable by penetration with a fluctuating magnetic field. The second layer 157 is not heatable by penetration with a fluctuating magnetic field and may be any suitable material that falls within this criterion, such as paper or paperboard. The aerosol-generating material 105 is provided directly on the susceptor 156. However, in other examples, an additional material may be provided between the aerosol-generating material 105 and the susceptor 156.

[0061] The inner member 150 defines a passageway 152 that opens at an axial end of the consumable 100. Accordingly, in some examples, the passageway may be configured to receive components of an aerosol generator, as described further below.

[0062] It will be appreciated that, as shown in FIG. 11 , the second butt seam 134 may be omitted and replaced with a lap seam 138 in some examples. FIG. 11 is a cross-section projected onto a plane that bisects the consumable 100 perpendicular to the longitudinal direction. The first layer 131 is shown schematically and may include any or all of the support 104, aerosol-generating material 105, and susceptor 106 of the above examples. Importantly, the first layer 131 retains the first butt seam 133, thus preserving the advantages provided by preventing overlap of material associated with the first layer 131. By providing the second layer 132 with a lap seam 138 rather than a butt seam, the consumable 100 can be manufactured using conventional rod-making machinery known to those skilled in the art of tobacco industry rod manufacturing.

[0063] Referring again to FIG. 1 , the aerosol generator 202 of the device 200 is configured to heat the aerosol-generating material 105 of the consumable 100 when the consumable 100 is received in the area 201 for receiving the consumable. The device also includes a power source 203, a controller 204, and a puff sensor 205. In use, a user inserts the consumable 100 into the area 201 for receiving the consumable and activates the aerosol generator 202 to generate an aerosol for inhalation. The user can then inhale the aerosol by drawing on the mouth end of the consumable 100, or alternatively, on the mouthpiece (not shown) of the device 200. In the illustrated example, the consumable 100 and device 200 are configured such that when the consumable 100 is fully inserted into the device 200, the mouth end is the portion of the consumable 100 that protrudes from the area 201. Thus, the mouth end is available for the user to draw on while holding the device 200.

[0064] Puff sensor 205 is configured to detect when a user inhales on the mouth end of a consumable within device 200 and send a signal to controller 204 to activate aerosol generator 202. Thus, aerosol is generated simultaneously as the user inhales the consumable. Alternatively, device 200 may be provided with a user interface, such as a button (not shown), that a user can press to cause activation of aerosol generator 202.

[0065] The area 201 for receiving the consumable 100 is provided with an inlet (not shown) that allows air to enter the area 201 before passing through the consumable 100 when a user inhales at the mouth end 101 of the consumable 100. Thus, when a user inhales on the consumable 100, a flow of air is directed through the consumable 100. Specifically, the air is directed through the air gap 103 in the hollow section 101. The air flow entrains the aerosol generated by the aerosol-generating material 105 of the consumable for inhalation by the user.

[0066] The aerosol generator 202 includes any suitable means for heating the aerosol-forming material 105 of the consumable 100 received in the region 201 of the device 200. Power for the aerosol generator 202 is provided by a power source 203, which in the illustrated example is a power source 203 such as a battery 203.

[0067] In one example, the aerosol generator 202 comprises a magnetic field generator configured to generate a varying magnetic field that penetrates the region 201 for receiving the consumable 100. Thus, the device 200 is configured for use with a consumable 100 that includes a susceptor, such as the consumables illustrated by Figures 4 and 6. The varying magnetic field heats the susceptor 106, 156 by magnetic hysteresis. When the consumable 100 is placed in the device 200 and the aerosol generator 202 is activated, the varying magnetic field penetrates the susceptor 106, 156 of the consumable 100, heating the aerosol-generating material 105 in thermal contact with the susceptor 106, 156 and generating an aerosol for inhalation by the user.

[0068] In another example, the aerosol generator 202 includes a susceptor in thermal contact with the region 201 for receiving the consumable 100 and a magnetic field generator for generating a varying magnetic field that penetrates the susceptor. The varying magnetic field heats the susceptor by magnetic hysteresis. The susceptor then heats the region 201 for receiving the consumable. Thus, when the consumable 100 is placed in the device 200 and the aerosol generator 202 is activated, the varying magnetic field penetrates the susceptor and heats the region 201 for receiving the consumable 100. The heat is transferred to the aerosol-generating material 105 of the consumable 100, generating an aerosol for inhalation by the user. In such an example, the wall 207 of the region 201 for receiving the consumable 100 can include a susceptor. The consumable 100 can be configured to be in direct contact with the wall 207 for efficient heat transfer.

[0069] In another example, the aerosol generator 202 includes a material that can be heated by electrical conduction, and the material is provided in thermal contact with the area 201 for receiving the consumable 100. Thus, when the consumable 100 is placed in the device 200 and the aerosol generator 202 is activated, an electric current passes through the material, heating the area 201 for receiving the consumable 100. The heat is transferred to the aerosol-generating material 105 of the consumable 100, generating an aerosol for inhalation by the user. In such an embodiment, the wall 207 of the area 201 for receiving the consumable 100 may include said material, and the consumable 100 may be configured to be in direct contact with the wall 207 for efficient heat transfer.

[0070] Another exemplary non-combustion aerosol delivery device 200 is shown in FIG. 7 , where similar features retain the same reference numerals. In the example of FIG. 7 , the aerosol generator 202 further includes a protrusion 206 extending into the region for receiving a consumable 201. The protrusion 206 is a post that stands upright from the base of the region 201. The protrusion is spaced apart from a wall 207 of the region 201 for receiving a consumable 100. Thus, when the consumable 100 is inserted into the region 201 for receiving a consumable, the wall 102 of the consumable 100 is disposed between the protrusion 206 and the wall 207 of the region 201. The protrusion 206 is configured such that when a consumable according to the example of FIG. 2 is inserted into the region 201 for receiving a consumable, the protrusion 206 is received within the air gap 103 and is spaced apart from the inner surface 136 of the wall 102. Alternatively or additionally, the protrusion 206 is configured such that when a consumable according to the example of FIG. 5 is inserted into the region 201 for receiving a consumable, the protrusion 206 is received in the passage 152 .

[0071] In one example, the protrusions 206 are susceptors 206, and the aerosol generator 202 includes a magnetic field generator configured to generate a varying magnetic field that penetrates the protrusions 206. The varying magnetic field heats the protrusions 206 due to magnetic hysteresis. The protrusions 206 then heat the consumable 100 when the device 200 and the consumable 100 are combined. In particular, when the consumable 100 is placed within the device 200 and the aerosol generator 202 is activated, the varying magnetic field penetrates the protrusions 206 and heats the aerosol-generating material 105 due to its proximity to the protrusions. Heat is thereby transferred to the aerosol-generating material 105 of the consumable 100, generating an aerosol for inhalation by the user.

[0072] In one example, the aerosol generator 202 comprises a protrusion 206, which in turn comprises a magnetic field generator 206. In such an example, the magnetic field generator 206 is configured to generate a varying magnetic field that penetrates the region 201 for receiving the consumable 100. In a related example, the protrusion 206 is configured such that when a consumable according to the example of FIG. 5 is inserted into the region 201 for receiving the consumable, the protrusion 206 is received in the passage 152. Thus, the device 200 of the example is configured for use with a consumable 100 whose inner member 150 comprises a susceptor 156, such as the consumable illustrated by FIG. 6. The varying magnetic field heats the susceptor 156 by magnetic hysteresis. When the consumable 100 is placed in the device 200 and the aerosol generator 202 is activated, a fluctuating magnetic field penetrates the susceptor 156 of the consumable 100, heating the aerosol-generating material 105 in thermal contact with the susceptor 156 and generating an aerosol for inhalation by the user.

[0073] The consumable 100 may be provided with any number of additional components for attachment to the hollow section 101 described above. An exemplary consumable 100 with additional components 90 is shown schematically in Figure 8, where the consumable includes a porous body 108 in addition to the hollow section 101. It will be understood that the schematically shown hollow section 101 in Figure 8 is representative of any hollow section 101 described herein, including examples with and without an inner member 150.

[0074] The additional component 90 includes substantially the same outer diameter of the hollow section 101 and is axially aligned and connected thereto by wrapping material 110. The additional component 90 may include, but is not limited to, a cooling section or other section containing aerosol-generating material, as known in the art. The porous body 108 in the example of Figure 8 may be a paper filter component or a cellulose filter component.

[0075] The inclusion of the porous body 108 advantageously allows for more precise control of the closed pressure drop or resistance to draw of the consumable 100. For example, the closed pressure drop can be controlled by setting the density of the porous material within the porous body 108 or by increasing or decreasing the axial length of the porous body 108.

[0076] Consumable 100 comprises a mouth end 111 and a distal end 112 axially opposite mouth end 111. In use, a user can place mouth end 111 between their lips and draw on consumable 100 to inhale components of aerosol-generating material 105. If porous body 108 is provided, it may be attached to either mouth end 111 or distal end 112, as shown in FIG.

[0077] 9, a flow diagram illustrating an example method 80 for manufacturing a consumable product 100 for use with the example systems described herein is shown. The method of FIG. 9 can be used to manufacture any of the consumable products 100 described herein.

[0078] The method 80 includes providing a hollow section 101 and, optionally, attaching 84 any desired additional components 90 to the hollow section 101 .

[0079] In the examples described herein, providing the hollow section includes forming 82 a laminate material 130 in which a first layer 131 of the laminate is bonded to a second layer 132 of the laminate. To form the example consumable 100 including the second butt seam 134, the first and second layers 131, 132 are positioned such that a longitudinal edge 131' of the first layer 131 is offset from a respective longitudinal edge 132' of the second layer 132, as shown in FIG. 10 . In other words, a portion 135' of the first layer 131 does not overlap with the second layer 132, and a portion 135" of the second layer 132 does not overlap with the first layer 131. The laminate 130 is then formed 83 into the hollow section 101 such that the portions of the first and second layers 131, 132 are in opposing relationship to form the overlap region 135.

[0080] To form the example consumable with the lap seam 138, the first and second layers 131, 132 are arranged such that along one edge 130' of the laminate 130, the longitudinal edges 131', 132' of the first and second layers 131, 132 are offset from one another to form the offset portion 138 of the laminate 130, and along the other longitudinal edge 130" of the laminate 130, the longitudinal edges 131', 132' of the first and second layers 131, 132 are collinear, as shown in FIG. 12 . The laminate is formed in the hollow section 101 83 such that the longitudinal edge 131' of the first layer 131 abuts to form the first butt seam 133, and the offset portion 139 of the second layer 132 overlaps itself to form the lap seam 138.

[0081] Forming 83 may include winding or wrapping the laminate into a typically tubular hollow section 101. However, it will be understood that the laminate 130 may alternatively be folded into a section 101 having a non-circular cross section. Such winding, wrapping, or folding may be, for example, around a mandrel.

[0082] In some examples where the first layer 131 of the laminate 130 comprises a support 104, providing 81 the hollow section 101 further includes applying 83 the aerosol-generating material 105 to the support 104 of the laminate 130 and then forming 83 the hollow section 101. Thus, in some examples, the laminate 130 may be flat or substantially flat at the time the aerosol-generating material 105 is applied. Then, in some examples, the laminate 130 and the aerosol-generating material 105 may be formed 83 together during the formation of the hollow section 101. Such forming 83 may include rolling or wrapping the combination of the laminate 104 and the aerosol-generating material 105 into a typically tubular section 101. However, it will be understood that the combination of the laminate 130 and the aerosol-generating material 105 may instead be folded into a section 101 having a non-circular cross-section. Such wrapping, wrapping, or folding may be, for example, around a mandrel.

[0083] In some examples, applying the aerosol-generating material 105 to the substrate 104 includes applying the aerosol-generating material 105 to the first layer 131 before adhering the first layer 131 to the second layer 132 to form the laminate 130 as described above. In some examples, applying the aerosol-generating material 105 to the substrate includes stencil application or pulse spray coating to create discrete areas of the aerosol-generating material 105 on the substrate 104.

[0084] In some examples, applying includes coating the aerosol-generating material 105 onto the substrate 104 to form a film of the aerosol-generating material 105. Such coating may include, for example, spraying, electrospraying, casting, or band casting. Such casting may include providing the material (or the material that will ultimately form the substrate 104) in liquid or other fluid form on the surface of the substrate 104 and then at least partially solidifying or curing the material on the surface of the substrate 104 to form the aerosol-generating material 105 comprising a film. The material in liquid or other fluid form may be an aerosol-generating form in that form, or may become an aerosol-generating form only after solidifying or curing.

[0085] In some examples, the attaching may include techniques other than coating. For example, the attaching may include adhering the aerosol-forming material 105 to the substrate 104 using an adhesive. Adhering the aerosol-forming material 105 may include adhering a sheet of aerosol-forming material, such as a strip of reconstituted tobacco material, to the substrate 104.

[0086] In some examples, the method of manufacturing the consumable product 100 further includes forming the inner member 150 and inserting the inner member 150 into the hollow section 101. Forming the inner member 150 includes processing a sheet material including the first layer 156 and the second layer 157 into the inner member. Such processing may include rolling or wrapping the combination of the first and second layers 156, 157 into the typically tubular member 150. Such wrapping, wrapping, or folding may be, for example, around a mandrel.

[0087] In some examples where the first layer 156 of the inner member 150 includes a substrate 154, forming the inner member further includes applying the aerosol-generating material 105 to the substrate 154 of sheet material and then forming the inner member 150. Thus, in some examples, the substrate 154 may be flat or substantially flat at the time the aerosol-generating material 105 is applied. Then, in some examples, the substrate 154 and the aerosol-generating material 105 may be processed together during formation of the inner member 150. Such processing may include rolling or wrapping the combination of the substrate 154 and the aerosol-generating material 105 into the typically tubular-shaped member 150.

[0088] If additional components are required, such as the example components of FIG. 8, they can be attached 84 to hollow section 101 by first axially aligning and positioning each of the components to form an assembly of components, and then encasing the components in wrapping material 110.

[0089] The aerosol-forming material 105 of any of the examples described herein may include an aerosol-forming agent, a binder, optionally a filler, and optionally an active agent and / or a flavoring. The aerosol-forming material may include a base of reconstituted tobacco in which the aerosol-forming agent, binder, filler, and optional active agent and / or flavoring may be provided.

Claims

1. 1. A consumable for use in a non-combustion aerosol delivery device, the consumable comprising a hollow section formed from a laminate material, the laminate material comprising a first layer and a second layer, and a laminate sheet formed in the section such that edges of the first layer abut to form a first butt seam.

2. The consumable of claim 1 , wherein edges of the second layer abut to form a second butt seam.

3. The consumable of claim 2 , wherein the first butt seam is offset from the second butt seam around the section.

4. The consumable product of claim 3 , wherein the second layer is disposed outside the first layer.

5. The consumable product of claim 4 , wherein the first layer comprises a substrate and an aerosol-forming material coated on the substrate.

6. The consumable of claim 5 , wherein the hollow section defines an air gap in the consumable in which aerosol is generated during use.

7. The consumable of claim 6 , wherein the support is a portion of a wall of the hollow section surrounding the air gap, and the aerosol-forming material forms an interior surface of the wall.

8. The consumable of claim 7 , wherein the aerosol-generating material forms an interior surface of the hollow section.

9. the aerosol-forming material is an aerosol forming agent; a binder; and optionally a filler; Optionally, an active agent and / or a flavoring agent; and The consumable product according to any one of claims 5 to 8, comprising:

10. 10. The consumable product of claim 9, wherein the aerosol-generating material comprises an aerosol-generating film, the aerosol-generating film having a thickness of up to about 1 mm, and optionally a thickness of up to 500 microns, and optionally a thickness of 50 to 500 microns.

11. The consumable of any one of claims 1 to 10, wherein the hollow section comprises a susceptor that is heatable by penetration with a fluctuating magnetic field.

12. The consumable of claim 11 when dependent on claim 5, wherein the support comprises a first layer and a second layer, the first layer comprises the susceptor, the second layer is not heatable by penetration by a fluctuating magnetic field, and the first layer is positioned between the aerosol-generating material and the second layer.

13. The consumable product according to any one of claims 1 to 12, wherein the hollow section is a hollow tube.

14. 14. The consumable of any one of claims 1 to 13, further comprising an inner member inside the hollow section, and at least one spacer spacing the inner member relative to the hollow section such that there is at least one air gap between the inner member and the hollow section.

15. The consumable of claim 14 , wherein the at least one spacer is located between the inner member and the hollow section.

16. 16. The consumable of claim 14 or 15, wherein the inner member comprises an inner tube.

17. 17. The consumable of claim 16, wherein the inner tube is positioned about a passageway that opens at an axial end of the consumable.

18. The consumable product of any one of claims 14 to 17, wherein the inner member includes a support and an aerosol-forming material coated on the support.

19. The consumable of claim 18 , wherein the inner member comprises a susceptor.

20. 20. The consumable of claim 19, wherein the support of the inner member comprises a first layer and a second layer, the first layer comprising the susceptor, the second layer not being heatable by penetration by a fluctuating magnetic field, and the first layer being positioned between the aerosol-generating material and the second layer.

21. 1. A method of forming a consumable for use with a non-combustion aerosol delivery device, comprising: adhering a second layer of sheet material to the first layer to form a laminate, wherein longitudinal edges of the first layer are offset from respective longitudinal edges of the second layer such that a portion of the first layer does not overlap the second layer and a portion of the second layer does not overlap the first layer; forming the laminate into a hollow section such that the portion of the first layer and the portion of the second layer are in opposing relationship to one another and longitudinal edges of each of the first layer and second layer abut and are bonded to form a butt seam.

22. 21. A non-combustion aerosol delivery system comprising the consumable of any one of claims 1 to 20 and a combustion aerosol delivery device, the non-combustion aerosol delivery device comprising an aerosol generator configured to heat the consumable to generate an aerosol when the consumable and the device are combined in use.

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