Consumables

Abstract

A consumable (100) for use with an aerosol delivery system, the consumable (100) comprising a section (1) formed from a roll of corrugated sheet material (2), wherein one or more surfaces of the corrugations (3) of the roll of corrugated sheet material abut corresponding surfaces of adjacent corrugations.

Description

[Technical Field]

[0001] SUMMARY The present disclosure relates to consumables for use with aerosol delivery systems, aerosol delivery systems including the consumables, and methods for forming the consumables. [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 system, the consumable comprising a section formed from a roll of corrugated sheet material, wherein a surface of each corrugation of the roll of corrugated sheet material abuts a corresponding surface of an adjacent corrugation.

[0004] In a second aspect of the present invention, there is provided a method of forming the consumable product of the first aspect, comprising the steps of: Providing a sheet of corrugated material; and winding the sheet of corrugated material into a section such that each corrugation of the roll of corrugated sheet material abuts an adjacent corrugation.

[0005] In a third 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.

[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] FIG. 1 illustrates an exemplary section for consumables. [Figure 2] FIG. 2 shows a corrugated sheet material for forming the section of FIG. 1. [Figure 3a] FIG. 2 is an end view of the section of FIG. 1. [Figure 3b] FIG. 3 is an end view of the corrugated sheet material of FIG. 2. [Figure 4a] FIG. 10 is an end view of another example of a consumable section. [Figure 4b] FIG. 4b is an end view of a corrugated sheet material for forming the section of FIG. 4a. [Figure 5a] FIG. 10 is an end view of another example of a consumable section. [Figure 5b] FIG. 5b is an end view of a corrugated sheet material for forming the section of FIG. 5a. [Figure 6a] FIG. 10 is an end view of another example of a consumable section. [Figure 6b] FIG. 6b is an end view of a corrugated sheet material for forming the section of FIG. 6a. [Figure 7a] FIG. 10 is an end view of another example of a consumable section. [Figure 7b] FIG. 7b is an end view of a corrugated sheet material for forming the section of FIG. 7a. [Figure 8a] FIG. 10 is an end view of another example of a consumable section. [Figure 8b] 8b is an end view of a corrugated sheet material for forming the section of FIG. 8a. FIG. [Figure 9] FIG. 1 illustrates a consumable including sections according to any of the examples described herein. [Figure 10] FIG. 1 is a schematic diagram of a system including a consumable and a non-combustion aerosol delivery device. [Figure 11] FIG. 1 is a schematic diagram illustrating a combination of a consumable and an aerosol generator. 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 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.

[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.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.

[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 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.

[0033] 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.

[0034] 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.

[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 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 shows section 1 of a consumable product 100 formed from a roll of corrugated sheet material 2. Figure 2 shows the corrugated sheet material in a stretched state prior to being rolled into section 1 of the consumable product 100 shown in Figure 1. The corrugated sheet material 2 includes a series of corrugations 3 extending longitudinally of the corrugated sheet material 2. When the corrugated sheet material 2 is rolled into said section 1, each corrugation 3 abuts a corresponding surface of an adjacent corrugation 3, as described further below.

[0052] FIG. 3b is a cross-sectional view of the corrugated sheet of FIG. 1. The corrugated sheet material comprises a flat base sheet 4 and a folded sheet 5 positioned across the base sheet 4. The folded sheet 5 comprises convex folds 6 and concave folds 7. In this example, the folds are formed as scored fold lines. Between the fold lines, the sheet material is generally flat, forming the surface of the corrugation 3. The concave folds 7 are defined by an angle between adjacent top surfaces that is less than 180 degrees. The convex folds 6 are defined by an angle between adjacent top surfaces that is greater than 180 degrees. By "top surface" is meant the surface of the folded sheet 5 that faces outward from the base sheet 4. Each corrugation 3 is defined as the shape enclosed by the folded sheet 5 and the base sheet 4 between adjacent concave folds 7. In this example, this shape is polygonal in cross section, having four sides, and each corrugation of the corrugated sheet material comprises two primary walls 8 and a single secondary wall 9 connecting the primary walls 8 at the convex folds 6. The folded sheet 5 contacts the base sheet 4 where adjacent primary walls 8 meet and may be adhered thereto by a suitable adhesive. The secondary walls 9 of the folded sheet 5 are parallel to the base sheet 4.

[0053] To form section 1 of consumable product 100, the stretched corrugated sheet material 2 is rolled about the longitudinal axis until the outermost corrugations 3' abut. Thus, the roll of corrugated sheet material 2 forms a closed shape, in this case a tube. In the illustrated example, shown by Figures 2, 3b, 4b, 5b, and 6b, the recess angle 7 between adjacent primary walls 8 is 60 degrees. Because the corrugated sheet 2 includes six corrugations 3, the act of rolling the example corrugated sheet material 2 into section 1 causes each primary wall 8 to abut against the primary wall 8 of an adjacent corrugation 3.

[0054] Pairs of abutting primary walls 8 form radially extending walls 10 of section 1. Secondary walls 9 interconnect radially extending walls 10 and form inner walls 11 of section 1. Radially extending walls 10 and inner walls 11 increase the secondary moment of area of ​​section 1, thereby increasing its bending stiffness. Thus, forming section 1 of consumable 100 in this manner increases its structural integrity and makes it more resilient when handled by a user.

[0055] The base sheet 4 forms an outer wall 12 of the section. A radially extending wall 10 separates an outer channel 13 bounded by an inner wall 11 and an outer wall 12 of the section 1. The inner wall 11 defines a central channel 14 of the section 1.

[0056] At least a portion of the central channel 14 and at least a portion of each of the outer channels 13 comprise an air gap. In other words, said at least a portion of the central channel 14 and said at least a portion of each outer channel 13 is empty, i.e., free of material or obstructions.

[0057] This section further includes an aerosol-generating material 15 configured to generate an aerosol when heated by an aerosol generator of a non-combustion aerosol-delivery device, as further described below. The aerosol-generating material 15 may be positioned to generate an aerosol in any of the air gaps defined above.

[0058] In the example of Figures 1 and 3a, the aerosol-generating material 15 is provided as a film on the inside of the central section 14. This is achieved by providing a film of aerosol-generating material 15 on the upper surface of the secondary wall 9 of the stretched corrugated sheet material 2, as shown in Figures 2 and 3b. Thus, when the stretched corrugated sheet material 2 is rolled to form the section of Figures 1 and 3a, the inner wall 11 is provided with a film of aerosol-generating material 15 lining its inner surface. When the section 1 is heated, the aerosol-generating material 15 forms an aerosol in the air gap of the central section 14.

[0059] In the example of FIG. 4a, the aerosol-generating material 15 is provided as a film on the inside of selected outer channels 13. This is achieved by providing a film of aerosol-generating material 15 on the inner surfaces of selected corrugated primary and secondary walls 8 and 9, as shown in FIG. 4b. Thus, when the stretched corrugated sheet material 2 of FIG. 4b is rolled to form the section shown in FIG. 4a, a portion of the outer surface of the central section 14 and the adjacent radially extending walls 10 are provided with a film of aerosol-generating material 15. By "selected outer channel" is meant "at least one outer channel." In the illustrated example, all other outer channels 14 are provided with aerosol-generating material 15. However, it will be understood that any or all of the outer channels 14 may be provided with aerosol-generating material 15. When the section shown in FIG. 4a is heated, the aerosol-generating material 15 forms an aerosol in the air gaps of the outer channels 14 in which the aerosol-generating material 15 is provided.

[0060] In the example of Figure 5a, aerosol-generating material 15 is provided as a film on the inside of outer channel 13. This is achieved by providing a film of aerosol-generating material 15 on the top surface of base sheet 4, as shown in Figure 5b. Thus, when stretched corrugated sheet material 2 of Figure 5b is rolled to form section 1 as shown in Figure 5a, a film of aerosol-generating material 15 is provided on the inside surface of outer wall 12. When the section shown in Figure 5a is heated, aerosol-generating material 15 forms an aerosol in the air gap of outer channel 13.

[0061] In the example of Figure 6a, the aerosol-generating material 15 is provided as a film on the inside of the outer channel 13. This is achieved by providing a film of aerosol-generating material 15 on the inner surface of the secondary wall 9 of each corrugation 3, as shown in Figure 6b. Thus, when the stretched corrugated sheet material 2 of Figure 6b is rolled to form section 1 as shown in Figure 6a, a film of aerosol-generating material 15 is provided on the outer surface of the inner wall 11. When section 1 shown in Figure 6a is heated, the aerosol-generating material 15 forms an aerosol in the air gap of the outer channel 13.

[0062] It will be appreciated that the selection of the location of the aerosol-generating material 15 will depend, among other things, on the design of the non-combustion aerosol delivery device for which the corresponding consumable is configured for use, as further described below. Apart from the location of the aerosol-generating material 15, the example sections of Figures 1-6b are the same.

[0063] Another exemplary section 1', shown in Figure 7a, is formed by rolling a corrugated sheet material 2' about its longitudinal axis. In this example, the secondary walls 9 of the folded sheet 5 are omitted; instead, the sheet 5' comprises primary walls 8' attached directly to each other at convex folds 6'. Thus, each corrugation 3" is triangular in cross section. The cross section 1' formed when such a corrugated sheet 2' is rolled is shown in Figure 7b.

[0064] As in the previous example, the stretched corrugated sheet material 2' is rolled about its longitudinal axis until the outermost corrugations 3"' abut. Again, the corrugated sheet material 2' includes six corrugations 3', with each concave fold 7 having an angle between adjacent primary walls 8' of 60 degrees. Thus, the act of rolling the corrugated sheet material 2' of the example of Figure 7b onto the section of Figure 7a causes each primary wall 8' to abut against the primary wall 8' of an adjacent corrugation 3".

[0065] The pair of abutting primary walls 8' form radially extending walls 10' of section 1'. The radially extending walls 10' increase the second moment of gravity of the area of ​​section 1', thereby increasing its bending stiffness. Thus, as noted above, forming section 1' of consumable 100 in this manner increases its structural integrity and makes it more resilient when handled by a user.

[0066] Again, as in the previous example, base sheet 4' forms outer wall 12' of section 1'. However, in this example, central section 14 is not geometrically possible without secondary wall 9 and radially extending wall 10' meeting at the center of section 1'. Thus, radially extending wall 10' separates segment-shaped channels 13' bounded by outer wall 12'. At least a portion of at least one of segment-shaped channels 13' comprises an air gap through which aerosol can be generated when consumable 100 is heated by a heater of an aerosol generator.

[0067] In the configuration of Figure 7a, while a central section is not geometrically possible, section 1' can have a smaller overall diameter while still providing a similar level of performance compared to exemplary section 1 above, particularly when heated externally. Thus, the aerosol-generating material may be provided as a film on the top or bottom surface of folded section 5' or on the top surface of base sheet 4'. Thus, when section 1' is heated, the aerosol-generating material forms an aerosol within the air gap of channel 13'.

[0068] While the corrugated sheet material 2, 2' in the above example includes corrugations 3, 3' having polygonal cross-sections, it should be understood that section 1 may be formed from a roll of corrugated sheet material, with the corrugations having curved cross-sections. For example, section 1" shown in Figure 8a is formed from corrugated sheet material 2" having sinusoidal corrugations 83, as shown in Figure 8b.

[0069] As in the examples above, the corrugated sheet material 2" in Figure 8b comprises a flat base sheet 4" and a folded sheet 5" positioned across the base sheet 4". The folded sheet 5" comprises convex folds 86 and concave folds 87 that form part of a continuous sinusoidal curve. The concave folds 87 are defined where the folded sheet 5" contacts the base sheet 4". The convex folds 86 are defined where the folded sheet 5" is furthest from the base sheet 4". Each corrugation 83 is defined as the shape enclosed by the folded sheet 5" and base sheet 4" between adjacent concave folds 87.

[0070] To form section 1" of consumable 100 shown in Figure 8a, the stretched corrugated sheet material 2" of Figure 8b is rolled about its longitudinal axis until the outermost corrugations 83' abut. The roll of corrugated sheet material 2" thus forms a closed shape, in this case a tube. A portion of the surface of each corrugation 83 abuts a corresponding portion of the surface of an adjacent corrugation 83, forming the shape shown in Figure 8a. The abutting pair of corrugations 83 forms a loop 85 against which the upper surface of the folded sheet 5" abuts. The folded sheet 2" extends between the abutting pair of adjacent corrugations 83 to form an arcuate section 88 that defines the inner wall 11" of section 1".

[0071] Base sheet 4" forms the outer wall 12" of section 1". Loop 85 separates outer channels 13" bounded by inner wall 11" and outer wall 12" of section 1". Inner wall 11" defines a central channel 14" of section 1".

[0072] At least a portion of the central channel 14" and at least a portion of each of the outer channels 13" comprise an air gap. In other words, said at least a portion of the central channel 14" and said at least a portion of each outer channel 13" is empty, i.e., free of material or obstructions.

[0073] Section 1″ further includes an aerosol-generating material configured to generate an aerosol when heated by a heater of the aerosol generator, as further described below. The aerosol-generating material may be positioned to generate an aerosol in either of the air gaps.

[0074] In this example, the aerosol-generating material 15" is provided as a film on the inside of the outer channel 13". This is achieved by providing a film of aerosol-generating material 15" on the top surface of the base sheet 4", as shown in Figure 8b. Thus, when the stretched corrugated sheet material 2" of Figure 8b is rolled to form section 1" as shown in Figure 8a, a film of aerosol-generating material 15" is provided on the inside surface of the outer wall 12". When the section shown in Figure 8a is heated, the aerosol-generating material 15" forms an aerosol in the air gap of the outer channel 13".

[0075] Although not shown, it will be understood that aerosol-generating material may be provided on any of the other surfaces of the corrugated sheet material 2". For example, a film of aerosol-generating material may be provided on the upper surface of the folded sheet 5", such that when rolled to form section 1", the aerosol-generating material is provided in central section 14" and in loops 85. Alternatively or additionally, aerosol-generating material may be provided on the lower surface of the folded sheet 5", such that when rolled to form section 1", the aerosol-generating material is provided in outer channels 13".

[0076] The consumable 100 can include any number of additional components 90 for attachment to any of the above-described sections 1. Alternatively, the consumable 100 may consist solely of the above-described section 1. If the consumable 100 includes additional components 90, the additional components may be, for example, a filter component 91, as shown in the exemplary consumable 100 of FIG. 9. Other components 90 may include a cooling section or other sections containing aerosol-generating material, as known in the art. The filter component 91 may be a paper filter component or a cellulose filter component. Preferably, any additional component 90 has substantially the same outer diameter as the section 1 to which it is attached. Thus, the additional component 90 may be attached by an overlapping layer of wrapping material 92, such as tipping paper.

[0077] The inclusion of filter component 91 advantageously allows for more precise control of the occlusion pressure drop or resistance to draw of consumable 100. For example, occlusion pressure drop can be controlled by setting the density of the filter material within the filter component or by increasing or decreasing the axial length of the filter component.

[0078] In one example, the occlusion pressure drop of the consumable 100 is in the range of approximately 30-90 mmWg. In another example, the occlusion pressure drop of the consumable 100 is in the range of approximately 40-60 mmWg.

[0079] It will be appreciated that each component of the consumable cumulatively contributes to the overall occlusion pressure drop of the consumable 100. In one example, section 1 contributes approximately 10-40 mmWg to the overall occlusion pressure drop of the consumable 100. In other words, the occlusion pressure drop across section 1 is approximately 10-40 mmWg. In one example, filter component 91 (if present) contributes approximately 15-20 mmWg to the overall occlusion pressure drop of the consumable 100. In other words, the occlusion pressure drop across filter component 91 is approximately 15-20 mmWg.

[0080] It will be appreciated that the overall occlusion pressure drop of any of the above sections 1, 1', 1" may be affected by the number of corrugations provided in the sheet material used to form section 1, 1', 1". Increasing the number of corrugations used can increase the overall occlusion pressure drop of the section. This can be advantageous as it reduces reliance on filter components to provide a sufficient occlusion pressure drop throughout the consumable, allowing more volatile flavor components to enter the consumer's mouth.

[0081] Consumable 100 includes mouth end 101 and a distal end 102 axially opposite mouth end 101. In use, as described further below, a user can place mouth end 101 between their lips and draw on consumable 100 to inhale components of aerosol-forming material 15. Filter component 91 may be attached to either mouth end 101 or distal end 102, as shown in FIG. 9 .

[0082] Section 1 described herein can be made of any suitable material. For example, the corrugated sheet material 2 in the above example can include paper or paperboard and, optionally, a metal material such as metal foil. The base sheet 4 and the folded sheet 5 can be made of the same material or different materials. For example, the base sheet 4 can be paperboard of a different thickness than the folded sheet 5, or only one or both of the base sheet 4 and the folded sheet 5 can include a metal material. The base sheet and / or the folded sheet can function as a substrate or support for the aerosol-generating material 15. In examples in which the aerosol-generating material 15 is provided on the base sheet 4 or the folded sheet 5, they can be made of a metal material or can be further provided with a metal material. The metal material functions as a susceptor. If a metal material is further provided, it can be provided as a laminate with the paper or paperboard material. The aerosol-generating material 15 can be provided directly on the paper or paperboard layer of the laminate, or directly on the metal layer of the laminate. The layers of the laminate may be ordered accordingly. For example, if the aerosol-generating material 15 is provided on the top surface of the base sheet 4 (e.g., the example of FIG. 5b), the top layer of the laminate may be a paper or metal material, depending on whether it is desired to have the aerosol-generating material 15 in direct contact with the paper or metal material. Alternatively, the base sheet 4 or the folded sheet 5 may be made solely of a metal material, with the aerosol-generating material 15 disposed directly on the metal material. The base sheet 4 and the folded sheet 5 may also be made of different materials. For example, if the aerosol-generating material 15 is provided on the base sheet 4, as in the examples of FIGS. 5a and 5b, the base sheet 4 may be made of a metal material, and the folded sheet 5 may be made of any other suitable material. Alternatively, if the aerosol-generating material 15 is provided on the folded sheet 5, as in the examples of FIGS. 1-4b, the folded sheet 5 may be made of a metal material, and the base sheet 4 may be made of any other suitable material. Other suitable materials include card or paper, as described herein.

[0083] 10 shows a system including a consumable product 100 and a non-combustion aerosol delivery device 200. The device includes an area 201 for receiving the consumable product 100 and an aerosol generator 202. The aerosol generator is configured to heat the aerosol-generating material 15 of the consumable product 100 when the consumable product 100 is received within the area 201 to generate an aerosol for inhalation by a user. The device further includes a power source 203, a controller 204, and a puff sensor 205. In use, a user first inserts the distal end 102 of the consumable product 100 into the area for receiving the consumable product 201 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 101 of the consumable product, 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 the mouth end 101 protrudes from the area 201 for receiving the consumable 100 when fully inserted into the device 200. The mouth end 101 is therefore available to be placed between the user's lips while the user is holding the device.

[0084] The puff sensor 205 is configured to detect when a user inhales on the mouth end 101 of the consumable in the device 200 and send a signal to the controller 204 to activate the aerosol generator 202. Thus, aerosol is generated simultaneously as the user inhales the consumable. Alternatively, the device 200 may be provided with a user interface, such as a button (not shown), that the user can press to cause activation of the aerosol generator 202.

[0085] The area 201 for receiving the consumable 100 is provided with an inlet (not shown) that allows air to enter the area to pass through the consumable 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 15 of the consumable when heated by the aerosol generator 202.

[0086] The aerosol generator 202 comprises any suitable means for heating the consumable aerosol-generating material 15 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.

[0087] 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 a susceptor disposed within the region for receiving the consumable 100 by magnetic hysteresis. This example is used when the consumable 100 comprises a susceptor in thermal contact with an aerosol-generating material 15, such as the metallic material of the base sheet 4 of the folded sheet 5 described above. Thus, when the consumable 100 is placed within the device 200 and the aerosol generator 202 is activated, the varying magnetic field penetrates the susceptor of the consumable 100, heating the aerosol-generating material 15 in thermal contact with the susceptor and generating an aerosol for inhalation by the user.

[0088] 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 15 of the consumable 100, generating an aerosol for inhalation by the user. In such an embodiment, the susceptor may be a wall of the region 201 for receiving the consumable 100, and the consumable 100 may be configured to be in direct contact with the wall for efficient heat transfer. In such an example, the susceptor is optimized for use with a consumable having section 1, as shown in the example of FIG. 5a. Alternatively, the susceptor may include one or more protrusions (not shown) extending upright within the region 201 for receiving the consumable 100. Thus, the susceptor may be positionable within one or more of the outer channels 13 or directly within the central channel 14, depending on the configuration of the susceptor. In one example, the susceptor includes protrusions configured for positioning within the outer channels 13. In such an example, the susceptor is optimized for use with a consumable 100 including section 1, as shown in the example of FIG. 1 or FIG. 3a. In another example, the susceptor includes protrusions configured for positioning only within selected outer channels 13. In such an example, the susceptor is optimized for use with a consumable 100 including section 1, as shown in the example of FIG. 4a. In particular, the protrusions may be configured for positioning only within the outer channel 14 adjacent to the outer channel 14 containing the aerosol-generating material 15. In another example, the susceptor includes protrusions configured for positioning within the central channel 14. In such an example, the susceptor is optimized for use with a consumable 100 that includes section 1, as shown in the examples of Figures 4a, 5a or 6a.It will be appreciated that in each of the above exemplary susceptor configurations, the susceptor is configured to be positioned in proximity to the aerosol-forming material 15 but prevented from direct contact with the aerosol-forming material 15 .

[0089] In another example, the aerosol generator 202 includes a material (herein "material") that can be heated by electrical conduction. 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 15 of the consumable 100, generating an aerosol for inhalation by the user. In such an embodiment, the material may be a wall of the area 201 for receiving the consumable 100, and the consumable 100 may be configured to be in direct contact with the wall for efficient heat transfer. In such an example, the material is optimized for use with a consumable comprising section 1, as shown in the example of FIG. 5a. Alternatively, the material may comprise one or more protrusions (not shown) that stand upright within the area 201 for receiving the consumable 100. Thus, the material may be disposable within one or more of the outer channels 13 or directly within the central channel 14, depending on the configuration of the protrusions. In one example, the material includes protrusions configured for placement within the outer channels 13. In such an example, the material is optimized for use with a consumable 100 having section 1, as shown in the example of FIG. 1 or FIG. 3a. In another example, the material includes protrusions configured for placement only within selected outer channels 13. In such an example, the material is optimized for use with a consumable 100 having section 1, as shown in the example of FIG. 4a. In particular, the protrusions may be configured for placement only within outer channels 14 adjacent to the outer channel 14 containing the aerosol-generating material 15. In another example, the material includes protrusions configured for placement within the central channel 14. In such an example, the material is optimized for use with a consumable 100 having section 1, as shown in the example of FIG. 4a, FIG. 5a, or FIG. 6a. It will be appreciated that in each of the above exemplary protrusion configurations, the material is configured to be positioned proximate to, but prevented from direct contact with, the aerosol-generating material 15.

[0090] An exemplary consumable 100 in combination with a protrusion 206 of an aerosol generator 202 is shown in cross-section in FIG. 11 , with other features of the device 200 omitted for clarity. In this example, the protrusion 206 is configured for insertion into the central channel 14 of the consumable 100. The protrusion 206 may be a material that can be heated by electrical conduction, or the protrusion 206 may be a susceptor; in either case, the protrusion 206 is heated. The consumable 100 shown comprises the sections of FIGS. 1 and 3b, but it will be understood that any of the sections 1 described herein may be used. It can be seen that the protrusion 206 is in close proximity to, but does not contact, the aerosol-generating material 15. Thus, a gap 16 is provided between the protrusion 206 and the aerosol-generating material 15 from which aerosol can be generated during use of the device 200.

Claims

1. 1. A consumable for use with an aerosol delivery system, the consumable comprising a section formed from a roll of corrugated sheet material, wherein one or more surfaces of the corrugations of the roll of corrugated sheet material abut corresponding surfaces of adjacent corrugations.

2. The consumable article, wherein each corrugation of the corrugated sheet material is defined between adjacent concave folds of the stretched corrugated sheet material.

3. The consumable of claim 2 , wherein each corrugation of the corrugated sheet material comprises a polygonal cross-section.

4. The consumable of claim 2 , wherein each corrugation of the corrugated sheet material comprises a curved cross-section.

5. 4. The consumable of claim 3, wherein each corrugation of the corrugated sheet material comprises two flat primary walls, the primary walls arranged such that each primary wall abuts a primary wall of an adjacent corrugation of the roll of corrugated sheet material, the pair of abutting primary walls forming a radially extending wall of the consumable.

6. 6. The consumable of claim 5, wherein each corrugation of the corrugated sheet material further comprises a secondary wall connecting the primary walls of each corrugation, such that the secondary walls interconnect the radially extending walls and form interior walls of the section.

7. The consumable of claim 6 , wherein the interior wall defines a central channel of the section.

8. The consumable product of any one of claims 1 to 7, wherein the roll of corrugated sheet material further comprises a base sheet forming an outer wall of the section.

9. 9. The consumable of claim 8 when dependent on claim 6, wherein the radially extending walls separate airflow channels bounded by the inner and outer walls of the section.

10. 5. The consumable product of claim 1, wherein an inner wall of the section is formed from a first rolled sheet of material and an outer wall of the section is formed from a second rolled sheet of material, the rolled sheet of corrugated material being disposed radially between the first rolled sheet and the second rolled sheet, whereby the rolled sheet of corrugated material extends between the inner wall and the outer wall of the section and forms a radially extending inner wall of the section that is bounded by the inner wall and the outer wall of the section.

11. The consumable of claim 10 , wherein the inner wall separates airflow channels bounded by the inner and outer walls of the section.

12. The consumable product of any one of claims 1 to 11, wherein the consumable product comprises an aerosol-forming material.

13. The consumable product of claim 12 , wherein the aerosol-forming material comprises an aerosol-forming film.

14. 14. A consumable product according to claim 13 when dependent on claim 8 or claim 10, wherein the aerosol-generating film is provided within at least one of the airflow channels.

15. 15. The consumable product of claim 14, wherein the aerosol-generating film is provided on the radially outermost surface of the inner wall of the section and / or on the radially innermost surface of the outer wall of the section.

16. A consumable product according to claim 13 when dependent on any one of claims 5 to 9, wherein the aerosol-generating film is provided on at least one of the radially extending walls.

17. 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 14. The consumable product of claim 12 or claim 13, comprising:

18. 18. The consumable product of claim 17, wherein the aerosol-generating film is up to about 1 mm thick, optionally up to 500 microns thick, and optionally from 50 to 500 microns thick.

19. A method of forming the consumable product of any one of claims 1 to 18, comprising the steps of: providing a sheet of corrugated material; winding the roll of corrugated sheet material into sections such that each corrugation of the corrugated sheet material abuts an adjacent corrugation; A method comprising:

20. A consumable product according to any one of claims 1 to 18; 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; A non-combustion aerosol delivery system comprising:

21. 21. The non-combustion aerosol delivery system of claim 20, wherein the aerosol generator comprises a magnetic field generator for generating a varying magnetic field that penetrates the area for receiving the consumable product.

22. 21. The non-combustion aerosol delivery system of claim 20, wherein the aerosol generator comprises a susceptor in thermal contact with the area for receiving the consumable, and a magnetic field generator for generating a varying magnetic field penetrating the susceptor.

23. 21. The non-combustion aerosol delivery system of claim 20, wherein the aerosol generator includes a material heatable by electrical conduction, the material being in thermal contact with the area for receiving the consumable.

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