Consumables

Abstract

A consumable (100) for use with an aerosol delivery device having an area (201) for receiving the consumable (100), the consumable (100) having a mouth end (101) and a distal end (102) opposite the mouth end (101), the distal end (102) being shaped for insertion into the area (201) and the mouth end (101) being shaped to prevent insertion into the area (201), and / or a portion (102) of the consumable (100) being shaped for insertion into the area (201) in at least one predetermined orientation about the longitudinal axis of the consumable (100).

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 generate aerosols that are inhaled by a user during use. 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 devices. Summary of the Invention

[0003] In a first aspect of the present invention, there is provided a consumable for use with an aerosol delivery device comprising a region for receiving the consumable, the consumable including a mouth end and a distal end opposite the mouth end, the distal end being shaped for insertion into the region and the mouth end being shaped to prevent insertion into the region and / or a portion of the consumable being shaped for insertion into the region in at least one predetermined orientation about a longitudinal axis of the consumable.

[0004] In a second aspect of the present invention, there is provided a non-combustion aerosol delivery system comprising: a consumable product according to the first aspect; A non-combustion aerosol delivery system is provided, comprising: a non-combustion aerosol delivery device for heating a consumable aerosol-generating material to generate an aerosol, the non-combustion aerosol delivery device comprising an area for receiving the consumable; and an aerosol generator for causing the heating of the aerosol-generating material when the consumable is within the area.

[0005] 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]

[0006] [Figure 1] 1 illustrates exemplary consumables. [Figure 2] 2 shows an end view of the consumable of FIG. 1. [Figure 3] 2 is a cross section through the consumable of FIG. 1. [Figure 4] 1 illustrates another exemplary consumable item. [Figure 5] 5 is a cross section through the consumable of FIG. 4. [Figure 6] 1 illustrates another exemplary consumable item. [Figure 7] 1 illustrates another exemplary consumable item. [Figure 8] 1 illustrates another exemplary consumable item. [Figure 9] FIG. 7 is an end view of an exemplary device configured for use with the exemplary consumable of FIG. 6. [Figure 10] 7 is a cross section through the exemplary consumable of FIG. 6. [Figure 11] FIG. 8 is an end view of an exemplary device configured for use with the exemplary consumable of FIG. 7. [Figure 12] 8 is a cross section through the exemplary consumable of FIG. 7. [Figure 13] 9 is an end view of an exemplary device configured for use with the exemplary consumable of FIG. 8. [Figure 14] 9 is a cross section through the exemplary consumable of FIG. 8. [Figure 15]1 is a schematic diagram of an exemplary system including a consumable and a device. [Figure 16] 9 is a schematic diagram of an exemplary system including the consumable of FIG. 8 and a device configured for use with the consumable of FIG. 8. [Figure 17] FIG. 17 is a detailed diagram of the system of FIG. 16. [Figure 18] 7 is a schematic diagram of an exemplary system including the consumable of FIG. 6 and a device configured for use with the consumable of FIG. 6. [Figure 19] 8 is a schematic diagram of an exemplary system including the consumable of FIG. 7 and a device configured for use with the consumable of FIG. 7. DETAILED DESCRIPTION OF THE INVENTION

[0007] 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.

[0008] 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.

[0009] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0010] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system.

[0011] 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.

[0012] 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.

[0013] 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.

[0014] 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.

[0015] 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.

[0016] 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.

[0017] 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.

[0018] In some embodiments, the substance to be delivered comprises an active agent.

[0019] 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.

[0020] In one embodiment, the active substance is a legally permitted recreational drug.

[0021] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0022] 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.

[0023] The active substance may be CBD or a derivative thereof.

[0024] 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 a synthetically derived active compound naturally present in the botanical substance. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, or sheets. Examples of plants 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, and saffron. , lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiento, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following mint varieties: Mentha americana, Mentha cv, Egyptian mint, peppermint, eau de cologne mint, candy mint, curly mint, Kentucky kernel mint, horse mint, pineapple mint, pennyroyal mint, green mentha, and apple mint.

[0025] 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.

[0026] 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.

[0027] 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.

[0028] In some embodiments, the substance to be delivered comprises a flavor.

[0029] 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.They 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, 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, eggplant, 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, 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 or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damiento, maize The present invention may also include other additives such as joram, olive, lemon balm, lemon basil, chives, Calvi, 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, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be of imitation, synthetic, or natural origin, 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.

[0030] 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.

[0031] In some embodiments, the flavor may include a sensation eliciting agent 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, and 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.

[0032] An aerosol-forming material is a material that can generate an aerosol when, for example, heated, irradiated, or energized in any other manner. The aerosol-forming material may be, for example, in solid, liquid, or semi-solid (such as a gel) form, which may or may not contain an active agent and / or flavoring.

[0033] The aerosol-generating materials may include one or more active agents and / or flavorings, one or more aerosol former materials, and optionally one or more other functional materials.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] The aerosol-generating films described herein may include an aerosol-forming agent, a binder, optionally a filler, and optionally an active agent and / or a flavoring agent.

[0038] The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. 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 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[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 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] The susceptor is a material that can be heated by penetration by a varying magnetic field, such as an alternating magnetic field. The susceptor may 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 may 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 may be both conductive and magnetic, such that the susceptor is heatable 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] Figure 1 illustrates a consumable 100 for use with a non-combustion aerosol delivery device, such as non-combustion aerosol delivery device 200 shown schematically in Figure 15. Non-combustion aerosol delivery device 200 comprises an area 201 for receiving consumable 100 and an aerosol generator 202. Aerosol generator 202 is configured to heat an aerosol-generating material of consumable 100 when consumable 100 is received within area 201 to generate an aerosol for inhalation by a user, as described further below.

[0052] Consumable 100 is elongated and includes a mouth end 101 and a distal end 102 opposite mouth end 101. Distal end 102 is defined as the portion 102 of consumable 100 configured to be inserted into region 201 of aerosol delivery device 200.

[0053] In some examples described herein, the distal end 102 is shaped for insertion into the region 201 in at least one predetermined orientation about the longitudinal axis XX of the consumable 100. By "predetermined orientation" is meant at least one rotational position about the longitudinal axis XX of the consumable 100 relative to the device 200. Additionally or alternatively, in other examples described herein, the mouth end 101 is shaped to prevent insertion into the region 201 for receiving the consumable. In other words, the cross-sectional profile of the mouth end 101 differs in size, shape, or both from the cross-sectional profile of the distal end 102. An example of this is shown in FIGS. 1 and 2. FIG. 2 shows an end view of the consumable of FIG. 1. It can be seen that in this example, the mouth end 101 includes an elliptical cross-sectional profile and the distal end 102 includes a circular cross-sectional profile. The width W of the elliptical cross-sectional profile of the mouth end 101 is greater than the diameter D of the circular cross-sectional profile of the distal end 102. Thus, the consumable 100 is configured for use with a device 200 having an area 201 for receiving the consumable 100, the cross-sectional profile of which is substantially the same size and shape as the cross-sectional profile of the distal end 102 of the consumable 100. This means that the distal end 102 of the consumable 100 can be inserted into said area 201, but the mouthpiece end 101 cannot. The advantage of this is that a user cannot unintentionally insert the mouthpiece end 101 into said area 201.

[0054] A cross section through FIG. 1 is shown in FIG. 3. The cross section is projected onto a plane that bisects the consumable 100 perpendicular to its longitudinal axis XX. The cross section passes through the distal end 102 of the consumable 100. The distal end 102 can be seen to comprise a rod 103 formed of a cylindrical support 104 that surrounds an air gap 106. The aerosol-generating material 105 is provided as a film on the inner surface of the support 104, such that the aerosol-generating material 105 forms the inner surface of the rod 103. The aerosol-generating material 105 may be an amorphous solid comprising a binder, a gelling agent, and an aerosol-forming agent, as described above. In use, when the consumable 100 and the device 200 are combined and the aerosol-generating material 105 is heated by the aerosol generator 202, the aerosol-generating material 105 forms an aerosol within the air gap 106 for inhalation by the user. In the example shown in FIG. 3 , the support 104 is a laminate including first and second layers 107, 108. The second layer 108 is disposed between the first layer 107 and the aerosol-generating material 105 and includes a material heatable by penetration by a varying magnetic field. The material heatable by penetration by a varying magnetic field is referred to herein as a susceptor 108. Such a consumable 100 is configured for use with a device 200 including an aerosol generator 202 configured to generate a varying magnetic field that penetrates a region 201 for receiving the consumable 100, as described further below. However, it will be understood that the susceptor 108 is optional, and in some examples, the support 104 includes only a single layer, with the aerosol-generating material 105 disposed directly on the single layer. In addition to the optional susceptor 108, the support 104 can include a card or paper-based material spirally wound, for example, around a mandrel into a hollow tube 103, in a conventional manner during manufacture of the consumable 100. The aerosol-forming material 105 may be added to the support before or after it is wrapped around the rod 103 .

[0055] The mouth end 101 in the example of FIG. 1 may be a molded fiber material. In some such examples, the mouth end 101 may be cellulose acetate. Such a mouth end 101 is breathable to allow a user to place their lips around the mouth end 101 and draw air through the distal end 102 during use. Alternatively or additionally, the mouth end 101 may include an opening (not shown) configured to allow air to pass through the mouth end 101 during use. The mouth end 101 may be attached to the distal end 102 by a wrapping material that overlaps both the mouth end 101 and the distal end 102 to hold the two together. The mouth end 101 may include an end with a circular outline opposite an end with an oval outline. This allows the wrapping material to extend over at least a portion of the mouth end 101 and be flush with the distal end 102. In one example, the mouth end 101 is formed from a cylindrical plug of fibrous material having the same outer diameter as the distal end 102, with a wrapping material overlapping at least a portion of the mouth end 101 and the distal end 102 to allow the two 101, 102 to be attached together. The oval shape can then be provided by compressing the mouth end 101 opposite where it is attached to the distal end 102. A plasticizer or another stiffening solution may then be applied to the compressed portion of the mouth end 101 to retain the oval shape.

[0056] Another example of a consumable 100 is shown in Figure 4. The consumable 100 of Figure 4 may be the same as the consumable 100 of Figure 1, except that the consumable of Figure 4 includes a mouth end 101 that has a different shape relative to the mouth end 101 of the example of Figure 1. In the example of Figure 4, the mouth end 101 has the same shape as the distal end 102, but a larger diameter. Thus, the consumable 100 is configured for use with a device 200 that has a region 201 for receiving the consumable 100, the cross-sectional profile of said region 201 being substantially the same in diameter as the cross-sectional profile of the distal end 102 of the consumable 100. As in the example of Figure 1, this means that the distal end 102 of the consumable 100 of Figure 4 can be inserted into said region 201, but the mouth end 101 cannot.

[0057] A cross-section of the mouth end 101 of the example of Figure 4 is shown in Figure 5. The cross-section is projected onto a plane that bisects the consumable 100 perpendicular to its longitudinal axis XX. The mouth end 101 comprises an outer sheath 109. The outer sheath 109 is a cylindrical component that can be push-fit onto the distal end 102 of the consumable to form the mouth end 101. The outer sheath 109 may be formed from a fibrous material such as card, paper, cellulose acetate, or the like.

[0058] 1 and 4 include a distal end 102 with an air gap 106, while in other examples, the distal end 102 may be filled with aerosol-generating material. For example, the distal end 102 may include cut or crimped reconstituted tobacco paper filling the rod 103. In particular, such a distal end 102 may be formed by collecting the cut or crimped aerosol-generating material 105 on a garniture and then wrapping the aerosol-generating material 105 with a substrate 104 in a conventional manner. The substrate 104 may be cigarette paper or the like.

[0059] FIG. 6 illustrates an exemplary consumable 100 including a distal end 102 shaped for insertion into a device 200 in at least one predetermined orientation about a longitudinal axis XX of the consumable 100. The distal end 102 of the consumable 100 includes an outer wrapper 110 that is wrapped around the distal end 102 such that an edge 114 of the outer wrapper forms a fin seal 111. By "fin seal 111," it is meant that an edge-adjacent portion 112 of the outer wrapper 110 abuts an outer surface 113 of the outer wrapper 110 in an upright, radially spaced relationship. Although not shown, the exemplary consumable of FIG. 6 may further include an oval-shaped mouth end 101 attached to the distal end 102 by the outer wrapper 110 in the manner described above. Thus, the outer wrapper 110 that forms the fin seal 111 also serves as a wrapping material for attaching the mouth end 101.

[0060] 9 shows an end view of an exemplary device 200 configured to receive the consumable of FIG. 6 in said predetermined orientation. In particular, the region 201 for receiving the consumable is defined by a wall 207 having a cross-sectional profile that is substantially the same size and shape as the cross-sectional profile of the distal end 102 of the consumable 100 of FIG. 6. Due to the fin seal 111, the cross-sectional profile of the distal end 102 of the consumable 100 has first-order rotational symmetry. This means that there is only one predetermined orientation of the consumable 100 relative to the device 200 in which the distal end 102 of the consumable is insertable into said region 201.

[0061] A cross section through FIG. 6 is shown in FIG. 10. The cross section is projected onto a plane that bisects the distal end 102 of the consumable 100 perpendicular to its longitudinal axis XX. In this example, it can be seen that the aerosol-generating material 105 comprises a crimped and gathered tobacco paper 105 filling an outer wrapper 110. However, it will be understood that an outer wrapper 110 with a fin seal 111 may be provided in other examples, such as around the rod 103 in the example of FIG. 3. In the example of FIG. 6, the distal end 102 further comprises a material that can be heated by penetration by a varying magnetic field. Said material is referred to herein as a susceptor 115. The susceptor 115 is a flat strip that extends along the longitudinal axis XX of the consumable. Such a consumable 100 is configured for use with a device 200 that comprises an aerosol generator 202 configured to generate a varying magnetic field that penetrates a region 201 for receiving the consumable 100.

[0062] The exemplary consumable 100 of FIG. 6 enables the design of more efficient devices 200 and consumable 100 systems. Because the consumable 100 can be inserted into the device 200 in only one predetermined orientation, it is possible to design the consumable 100 so that the orientation of the susceptor 115 relative to the aerosol generator 202 is known. In particular, by orienting the susceptor 115 within the consumable 100 in a predetermined orientation relative to the fin seal 111, it is possible to determine the orientation of the susceptor 115 relative to the device 200, and therefore relative to the aerosol generator 202. This means that an aerosol generator 202 can be used that generates only the magnetic field necessary to penetrate the susceptor 115 in a single predetermined orientation. The aerosol generator 202 can then generate a smaller magnetic field than would otherwise be required, and therefore the aerosol generator 202 can consume less power for a given heating level. As a result, such a device 200 consumes less electrical energy during heating of the consumable 100. It will be appreciated that this effect can be extended to other exemplary consumables. What is important is that the distal end 102 of the consumable 100 has one or two degrees of rotational symmetry, and the susceptor 115 comprises a flat strip in a predetermined orientation relative to the distal end 102. Exemplary consumables included in this description are shown in Figures 7 and 8.

[0063] FIG. 7 illustrates another exemplary consumable 100 including a distal end 102 shaped for insertion into the device 200 in a single, predetermined orientation relative to the device 200. The distal end 102 of the consumable 100 includes an outer wrapper 110 that is wrapped around the distal end 102 such that an edge 114 of the outer wrapper 110 forms a lap seam 116. By "lap seam 116," it is meant that the edge 114 of the outer wrapper 110 overlaps. This creates a lip 117 on the outer surface 113 of the distal end 102 that is equal to the thickness of the outer wrapper 110. Although not shown, the exemplary consumable of FIG. 7 can further include an oval-shaped mouth end 101 attached to the distal end 102 by the outer wrapper 110 in the manner described above. Thus, the outer wrapper 110 that forms the lap seam also serves as a wrapping material for attaching the mouth end 101.

[0064] The outer wrapper 110 in the example of FIG. 7 should have a sufficient thickness to allow the lip 117 to function as a guide for the orientation of the consumable. It will be understood that the thickness of the outer wrapper 110 is equal to the height of the lip 117. In one example, the outer wrapper 110 includes a thickness greater than 0.7 mm. In another example, the thickness of the outer wrapper is greater than 0.9 mm. In another example, the thickness of the outer wrapper is between 0.7 mm and 1.2 mm.

[0065] Figure 11 shows an end view of an exemplary device 200 configured to accept the consumable of Figure 7 in the predetermined orientation. In particular, the region 201 for accepting the consumable is defined by a wall 207 having a cross-sectional profile that is substantially the same size and shape as the cross-sectional profile of the distal end 102 of the consumable 100 of Figure 7. Due to the lip 117, the cross-sectional profile of the distal end 102 of the consumable 100 has first-order rotational symmetry. This means that there is only one predetermined orientation of the consumable 100 relative to the device 200 in which the distal end 102 of the consumable is insertable into the region 201.

[0066] A cross section through FIG. 7 is shown in FIG. 12. The cross section is projected onto a plane that bisects the distal end 102 of the consumable 100 perpendicular to its longitudinal axis XX. In this example, as in the example of FIG. 6, it can be seen that the aerosol-generating material 105 includes a crimped and gathered tobacco paper 105 that fills an outer wrapper 110. However, it will be understood that in other examples, such as around the rod 103 in the example of FIG. 3, the outer wrapper 110 may be provided with a lap seam. The distal end 102 further includes a susceptor 115 in a predetermined orientation relative to the lip 117, such that the consumable 100 of FIG. 7 provides the same advantages in system design as discussed above. In particular, the system can use an aerosol generator 202 that generates a smaller magnetic field than would be required if the susceptor were not in the predetermined orientation; therefore, the aerosol generator 202 can consume less power for a given heating level.

[0067] 8 shows another exemplary consumable 100 that includes a distal end 102 that is shaped for insertion into the device 200 in a single predetermined orientation relative to the device 200. The distal end of the consumable 100 includes an elliptical cross-section. Thus, the cross-section of the distal end 102 includes second-order rotational symmetry.

[0068] Figure 13 shows an end view of an exemplary device 200 configured to receive the consumable of Figure 8 in said predetermined orientations. In particular, the region 201 for receiving the consumable is defined by a wall 207 having a cross-sectional profile that is substantially the same size and shape as the cross-sectional profile of the distal end 102 of the consumable 100 of Figure 8. Because the cross-sectional profile of the distal end 102 of the consumable 100 has second-order rotational symmetry, there are two predetermined orientations of the consumable 100 relative to the device 200 in which the distal end 102 of the consumable is insertable into said region 201.

[0069] A cross section through FIG. 8 is shown in FIG. 13. The cross section is projected onto a plane that bisects the distal end 102 of the consumable 100 perpendicular to its longitudinal axis XX. In this example, as in the examples of FIGS. 6 and 7, it can be seen that the aerosol-generating material 105 comprises crimped and gathered cigarette paper 105. However, it will be understood that the consumable 100 may alternatively comprise a hollow oval portion that includes a film of aerosol-generating material coated on its inner surface. In such an example, the consumable 100 instead comprises an air gap through which aerosol is generated when the aerosol-generating material is heated during use. In the illustrated example, the distal end 102 further comprises a susceptor 115 in a predetermined orientation relative to the oval cross section. Importantly, the susceptor 115 lies in a plane P that coincides with the major axis of the oval cross section. Therefore, regardless of whether the consumable 100 is in one of two predetermined orientations when inserted into the device 200, the orientation of the susceptor 115 relative to the device will be the same. This means that the consumable 100 of Figure 7 provides the same advantages as the system design described above. In particular, the system can use an aerosol generator 202 that generates a smaller magnetic field than would be required if the susceptor were not in the known orientation, and therefore the aerosol generator 202 can consume less power for a given heating level.

[0070] FIG. 15 shows a system including a consumable 100 and a non-combustion aerosol delivery device 200. The device includes a power source 203, a controller 204, and a puff sensor 205. In use, a user inserts the consumable 100 into area 201 for receiving the consumable and activates aerosol generator 202 to generate an aerosol for inhalation. The user can then inhale the aerosol by drawing on the consumable 100, or alternatively, on a mouthpiece (not shown) of device 200. In the illustrated example, consumable 100 and device 200 are configured such that mouthpiece end 101 of consumable 100 protrudes from area 201 for receiving consumable 100 when fully inserted into device 200. Thus, consumable 100 is available to be placed between a user's lips while the user is holding device 200.

[0071] The puff sensor 205 is configured to detect when a user is inhaling the consumable 100 in the device 200 and send a signal to the controller 204 to activate the aerosol generator 202. Thus, aerosol is generated simultaneously when the user inhales the consumable 100. Alternatively, the device 200 may be provided with a user interface, such as a button (not shown), that the user can interact with to cause activation of the aerosol generator 202.

[0072] The area 201 for receiving the consumable 100 is provided with an inlet (not shown) that allows air to enter the area 201 for 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. The air flow entrains an aerosol generated by the aerosol-generating material 105 of the consumable 100 when heated by the aerosol generator 202.

[0073] Aerosol generator 202 includes any suitable means for heating consumable aerosol-generating material 105 received in said region 201 of device 200. Power for aerosol generator 202 is provided by power source 203, which in the illustrated example is a power source 203 such as a battery 203.

[0074] 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. The varying magnetic field heats the susceptors 107, 115 disposed within the region 201 for receiving the consumable 100 by magnetic hysteresis. Thus, this example can be used with a consumable 100 that includes a material that can be heated by a varying magnetic field, as described above. Thus, when such a consumable 100 is placed within the device 200 and the aerosol generator 202 is activated, the varying magnetic field penetrates the material of the consumable 100, heating the aerosol-generating material 105 in thermal contact with the material and generating an aerosol for inhalation by a user.

[0075] In another example, the aerosol generator 202 includes a susceptor in thermal contact with the region 201 for receiving the consumable 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 embodiment, the susceptor may be a wall 207 of the region 201 for receiving the consumable 100, and the consumable 100 may be configured to be in direct contact with the wall 207 for efficient heat transfer.

[0076] 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 material may be a wall 207 of the area 201 for receiving the consumable 100, and the consumable 100 may be configured to be in direct contact with the wall 207 for efficient heat transfer.

[0077] FIG. 16 schematically illustrates an exemplary device 200 in which an aerosol generator 202 includes a magnetic field generator configured to generate a varying magnetic field that penetrates a region 201 for receiving a consumable item 100. The aerosol generator 202 of FIG. 16 is configured to generate only the magnetic field necessary to penetrate a susceptor 115 in a predetermined orientation. It will be understood that if the susceptor can be received within the device in any orientation, the aerosol generator need not surround the region for receiving a consumable item. Instead, the aerosol generator 202 may extend around only a portion of the region 201 for receiving a consumable item because the susceptor 115 is received within the device 200 in a predetermined orientation. In this example, the aerosol generator 202 includes two induction heaters 208 positioned on either side of the region 201 for receiving a consumable item 100. FIG. 17 illustrates elements 209 of the induction heaters 208 and their positions relative to the susceptor 115 in the predetermined orientation. Other details of the device are omitted from FIG. 17 for clarity. Each element 209 comprises a flat, spiral-shaped coil that lies in a plane parallel to the plane in which the susceptor 115 lies in its predetermined orientation. During activation of the device 200, a current is induced in each element, causing a magnetic field to penetrate the susceptor 115 and heat it by magnetic hysteresis. Each element comprises a connection point 210 for electrical connection to the battery 203. The receiving area 201 in the example of FIG. 6 may be replaced by the receiving area in the examples of FIGS. 9 and 11.

[0078] While the particular example of Figure 16 shows a device 200 with a receiving area 201 for use with the consumable of Figure 14 (i.e., a device 200 with a receiving area shaped as shown in Figure 13), it will be understood that the teachings of the example of Figure 16 can be extended to a device 200 having a receiving area 201 shaped as shown in Figure 9 or Figure 11 for receiving the consumable 100 of Figures 10 and 12, respectively. As long as each of the two elements 209 is located in a plane parallel to the plane in which the susceptor 115 is oriented in a predetermined direction, the susceptor 115 will be effectively heated. This is illustrated by Figures 18 and 19, which show the relative positions of the elements 209 and the susceptor 115 for systems configured for use with the consumables of Figures 6 and 7, respectively.

Claims

1. A consumable for use with an aerosol delivery device having a region for receiving the consumable, the consumable including a mouth end and a distal end opposite the mouth end, the distal end shaped for insertion into the region and the mouth end shaped to prevent insertion into the region, and / or a portion of the consumable shaped for insertion into the region in at least one predetermined orientation around a longitudinal axis of the consumable.

2. The consumable of claim 1 , wherein when the portion is inserted into the region in the predetermined orientation, the consumable is fixed in the predetermined orientation to prevent rotation of the consumable about the longitudinal axis.

3. The consumable of claim 1 or 2, wherein the portion of the consumable is shaped for insertion into the region in only one orientation about the longitudinal axis of the consumable.

4. The consumable product of claim 1 or 2, wherein the cross-sectional shape of the portion includes first or second order rotational symmetry.

5. 5. The consumable product of claim 1, wherein the portion is enclosed in an outer wrapper configured such that edges of the outer wrapper overlap to form a lap seam, the lap seam extending along the longitudinal axis of the consumable product.

6. 6. The consumable product of claim 5, wherein the outer wrapper has a thickness of between 0.7 mm and 1.2 mm.

7. 5. The consumable product of claim 1, wherein the portion is wrapped in an outer wrapper such that an edge of the outer wrapper forms a fin seal, and the fin seal includes an edge-adjacent portion of the outer wrapper that abuts an outer surface of the portion of the consumable product so as to be radially upright.

8. The consumable product according to any one of claims 1 to 7, wherein the cross-sectional shape of the mouth end is elliptical.

9. The consumable product according to any one of claims 1 to 8, wherein the cross-sectional shape of the portion is elliptical.

10. The consumable product of any one of claims 1 to 9, wherein the consumable product comprises an aerosol-forming material.

11. The consumable product of claim 10 , wherein the aerosol-forming material is disposed within the portion.

12. 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 12. The consumable product of claim 10 or claim 11, comprising:

13. 13. The consumable product of claim 12, 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.

14. 14. The consumable of claim 1, wherein the consumable comprises a susceptor embedded in the aerosol-generating material, the susceptor being a material that can be heated by penetration with a fluctuating magnetic field, and the susceptor comprising a flat plate extending along the longitudinal axis of the consumable.

15. 15. The consumable of claim 14, wherein the susceptor is embedded in the aerosol-generating material in a predetermined orientation about the longitudinal axis of the consumable, such that when the consumable is inserted into the device in the predetermined orientation, the susceptor assumes a predetermined orientation relative to the device.

16. A consumable product according to any preceding claim, wherein the mouth end is configured to allow a user to draw directly on the mouth end during use to draw air through the consumable product.

17. A consumable product according to any one of claims 1 to 16; a non-combustion aerosol delivery system comprising: a non-combustion aerosol delivery device for heating the aerosol-generating material of the consumable to generate an aerosol, the device comprising an area for receiving the consumable and an aerosol generator for causing the heating of the aerosol-generating material when the consumable is within the area.

18. The system of claim 17 , wherein the region includes a cross-sectional shape configured to allow insertion of the portion of the consumable into the region in the at least one predetermined orientation.

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