Non-combustion aerosol delivery system

Abstract

1. A non-combustion aerosol delivery system comprising a consumable (100) and a non-combustion aerosol delivery device (200), the non-combustion aerosol delivery device comprising an aerosol generator (202) configured to heat the consumable and generate an aerosol when the consumable and the device are combined during use, the consumable comprising a hollow section (101), the hollow section comprising a substrate (104) and a film (105) of an aerosol-generating material coated on the substrate, the hollow section defining an air gap (203) in the consumable through which aerosol is generated during use, and the device comprising a protrusion (206) configured to be inserted into the air gap in the consumable when the device and the consumable are combined.

Description

[Technical Field]

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

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

[0003] In a first aspect of the present invention, there is provided a non-combustion aerosol delivery system comprising a consumable and a non-combustion aerosol delivery device, the non-combustion aerosol delivery device comprising an aerosol generator configured to heat the consumable and generate an aerosol when the consumable and device are combined in use, the consumable comprising a hollow section, the hollow section comprising a support and a film of aerosol-generating material coated on the support, the hollow section defining an air gap in the consumable in which aerosol is generated in use, and the device comprising a protrusion configured to be inserted into the air gap in the consumable when the device and consumable are combined.

[0004] 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]

[0005] [Figure 1] 1 illustrates a schematic of a system including a consumable and a non-combustion aerosol delivery device. [Figure 2] 1 shows a cross section of the consumable projected onto a plane parallel to the longitudinal axis of the consumable. [Figure 3] 3 shows a cross-section of the first example consumable of FIG. 2 projected onto a plane perpendicular to the longitudinal axis of the consumable. [Figure 4] 3 shows a cross section of the second example consumable of FIG. 2 projected onto a plane perpendicular to the longitudinal axis of the consumable. [Figure 5] 1 shows a cross section of the consumable projected onto a plane parallel to the longitudinal axis of the consumable. [Figure 6] 1 shows a cross section of a consumable and a protrusion of a non-combustion aerosol delivery device projected onto a plane perpendicular to the longitudinal axis of the consumable. [Figure 7] 1 shows a cross section of a consumable and a protrusion of a non-combustion aerosol delivery device projected onto a plane perpendicular to the longitudinal axis of the consumable. [Figure 8] FIG. 10 is a flow chart showing an example of a method for manufacturing a consumable item. [Figure 9] 1 illustrates a schematic of a system including a consumable and a non-combustion aerosol delivery device. [Figure 10] 1 shows a cross section of a consumable in combination with a tapered protrusion. DETAILED DESCRIPTION OF THE INVENTION

[0006] 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.

[0007] 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.

[0008] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0009] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system.

[0010] 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.

[0011] 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.

[0012] 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.

[0013] 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.

[0014] 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.

[0015] 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.

[0016] 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.

[0017] In some embodiments, the substance to be delivered comprises an active agent.

[0018] 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.

[0019] In one embodiment, the active substance is a legally permitted recreational drug.

[0020] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0021] 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.

[0022] The active substance may be CBD or a derivative thereof.

[0023] As described herein, an active substance may comprise or be derived from one or more botanical substances or their components, derivatives, or extracts. As used herein, the term "botanical substance" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, or shells. Alternatively, the material may comprise an active compound naturally occurring in the botanical substance or a synthetically obtained active compound. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, or sheets. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , 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, chive, carvi, 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, cologne mint, peppermint, curly mint, Kentucky kernel mint, horse mint, pineapple mint, pennyroyal mint, spearmint, and apple mint.

[0024] 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.

[0025] 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.

[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 substances are selected from rooibos and fennel.

[0027] In some embodiments, the substance to be delivered comprises a flavor.

[0028] 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 flavor materials, botanical substances, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, etc.). Ji, mango, clementine, lemon, lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla La, 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, hazel, hibiscus, bay leaf, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oat Regano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damiento, marjoram, olive, lemon balm, lemon basil, chives, carvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame,The compositions may contain other additives such as saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol, as well as other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. They may be imitation, synthetic, or natural, or blends thereof. They may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

[0029] 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.

[0030] In some embodiments, the flavor may include a sensate intended to achieve somatic sensations typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to, or instead of, the aroma or taste nerves, and may include agents that produce heating, cooling, tingling, or numbing effects. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol, WS-3.

[0031] An aerosol-forming material is a material that can generate an aerosol when, for example, heated, irradiated, or energized in any other way. The aerosol-forming material may be, for example, in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain an active agent and / or flavoring.

[0032] The aerosol-generating materials may include one or more active agents and / or flavors, one or more aerosol former materials, and optionally one or more other functional materials.

[0033] 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.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] The slurry may be heated to remove at least about 60%, 70%, 80%, 85%, or 90% by weight of the solvent.

[0040] An aerosol-generating material may include or be an "amorphous solid." In some embodiments, the aerosol-generating material includes an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid." The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material that may retain some fluid, such as a liquid, within the amorphous solid. In some embodiments, the amorphous solid may comprise, for example, about 50%, 60%, or 70% amorphous solid by weight, to about 90%, 95%, or 100% amorphous solid by weight.

[0041] The amorphous solid may be substantially free of plant material.The amorphous solid may be substantially free of tobacco.

[0042] 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.

[0043] 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.

[0044] The aerosol-generating material may be present on or in a support forming a substrate. The support may be or comprise, for example, paper, card, paperboard, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support includes a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0045] A 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 1 shows a non-combustion aerosol delivery system comprising a consumable product 100 and a non-combustion aerosol delivery device 200. The device comprises an area 201 for receiving the consumable product 100 and an aerosol generator 202.

[0050] 2 shows a cross-section of consumable 100. The cross-section is projected onto a plane that bisects the consumable longitudinally. Consumable 100 comprises a hollow section 101. Hollow section 101 comprises a wall 102 that encloses an air gap 103. Consumable 100 is configured to generate an aerosol within air gap 103 when heated by a non-combustion aerosol delivery device for inhalation by a user.

[0051] FIG. 3 shows the consumable 100 as cut onto a plane that bisects the consumable 100 perpendicular to the longitudinal direction. FIG. 3 shows further details of the wall 102 of the consumable. In this example, the wall 102 further comprises a support 104 and a film of aerosol-generating material 105 disposed on the support 104. The film of aerosol-generating material 105 forms the inner surface of the wall 102. The support forms the outer surface of the wall 102. In this example, the outer surface is the outermost surface, but in other examples, additional layers of material may be added. In one example shown in FIG. 5 and described below, the consumable 100 further includes a wrapping material. The support may be made of any suitable material, such as paper or paperboard.

[0052] FIG. 4 illustrates another exemplary consumable 100, in which similar features retain the same reference numerals. Similar to FIG. 3, FIG. 4 is a cross-section projected onto a plane that bisects the consumable 100 perpendicular to the longitudinal direction. In the example of FIG. 4, the support 104 further includes a first layer 106 and a second layer 107, with the first layer 106 positioned between the aerosol-generating material 105 and the second layer 107. The first layer 106 is a susceptor 106 and is heatable by penetration with a fluctuating magnetic field. The second layer 107 is not heatable by penetration with a fluctuating magnetic field and may be any suitable material within this standard, such as paper or paperboard. The aerosol-generating material 105 is disposed directly on the susceptor 106. However, in other examples, additional materials may be provided between the aerosol-generating material and the susceptor.

[0053] In the illustrated example, the hollow section is tubular, i.e., comprises a circular cross-section. However, it should be understood that other cross-sectional shapes may be used. For example, the wall may be a prism having a polygonal cross-section. Exemplary polygonal cross-sections may include, but are not limited to, an octagon, a hexagon, a heptagon, or a square.

[0054] The aerosol generator 202 is configured to heat the aerosol-generating material 105 of the consumable 100 when the consumable 100 is received in the area 201 for receiving the consumable. The device further comprises a power source 203, a controller 204, and a puff sensor 205. During use, a user inserts the consumable 100 into the area 201 for receiving the consumable and activates the aerosol generator 202 to generate an aerosol for inhalation. The user can then inhale the aerosol by drawing on the mouth end of the consumable 100, or alternatively, on the mouthpiece (not shown) of the device 200. In the illustrated example, the consumable 100 and device 200 are configured such that when the consumable 100 is fully inserted into the device 200, the mouth end is the portion of the consumable 100 that protrudes from the area 201. Thus, the mouth end is available for the user to draw on while the user is holding the device 200.

[0055] Puff sensor 205 is configured to detect when a user inhales on the mouth end of a consumable within device 200 and send a signal to controller 204 to activate aerosol generator 202. Thus, aerosol is generated simultaneously as the user inhales the consumable. Alternatively, device 200 may be provided with a user interface, such as a button (not shown), that a user can press to cause activation of aerosol generator 202.

[0056] The area 201 for receiving the consumable 100 is provided with an inlet (not shown) that allows air to enter the area 201 and pass through the consumable 100 when a user inhales at the mouth end 101 of the consumable 100. Thus, when a user inhales on the consumable 100, a flow of air is directed through the consumable 100. Specifically, the air is directed through the air gap 103 in the hollow section 101. The air flow entrains the aerosol generated by the aerosol-generating material 105 of the consumable for inhalation by the user.

[0057] In the example system described herein, the device 200 includes a protrusion 206. The protrusion 206 is configured to insert into the air gap 103 when the consumable is inserted into the area 201 for receiving the consumable 100. The protrusion 206 is a post that stands upright from the base of the area 201. In one example, the protrusion 206 has a cross-sectional shape that is substantially the same as the cross-sectional shape of the air gap 103. For example, the protrusion 206 can have a circular cross-sectional shape for use with the circular air gap 103 of the example consumable 100 described above. The protrusion is spaced from a wall 207 of the area 201 for receiving the consumable 100. Thus, when the consumable 100 is inserted into the area 201 for receiving the consumable, the wall 102 of the consumable 100 is positioned between the protrusion 206 and the wall 207.

[0058] FIG. 6 illustrates, in cross section, an example of a protrusion 206 disposed within the air gap 103 of a consumable. The cross section is a projection onto a plane that bisects the consumable 100 and the protrusion 206 perpendicular to the longitudinal direction of the consumable 100 and the protrusion 206. Other than the protrusion 206, details of the device 200 are omitted for clarity. In the example of FIG. 6, the air gap 103 and the protrusion 206 have a circular cross section. Thus, along at least a portion of the air gap 103, the wall 102 is spaced from the outer surface of the protrusion 206 around the entire circumference of the protrusion 206. In such an example, the consumable may be disposed within the region 201 for receiving the consumable 100 by abutment of the outermost surface of the consumable 100 with the wall 207 of the region 201. In other words, the overall diameter of the consumable 100 may be substantially equal to the diameter of the region 201 due to the interference-fit interaction of the consumable 100 within the region 201.

[0059] FIG. 7 illustrates, in cross section, another exemplary protrusion 206 disposed within the air gap 103. Similar to the example of FIG. 6, the cross section of the example of FIG. 7 is projected onto a plane that bisects the consumable 100 and the protrusion 206 perpendicular to the longitudinal direction of the consumable 100 and the protrusion 206. Again, for clarity, details of the device 200 other than the protrusion 206 are omitted. In the example of FIG. 7, the air gap 103 has a circular cross section, and the protrusion has a hexagonal cross section that is inscribed in the circular wall 102 of the consumable 100. "Inscribed in the circular wall 102 of the consumable 100" means that each of the six vertices of the hexagon abuts the inner surface of the wall 102 of the consumable. In this manner, the air gap 103 is divided into six compartments. Also, when the protrusion 206 abuts the inner surface of the wall 102 of the consumable, the consumable is positioned within the area 201 for receiving the consumable without the outermost surface of the consumable necessarily abutting the wall 207 of said area 201.

[0060] While the example in FIG. 7 shows a hexagonal shape, it will be understood that protrusions of other cross-sectional shapes may be used. For example, protrusion 206 may have a pentagonal, square, or triangular cross-sectional shape. Protrusion 206 may, in fact, take the form of any suitable prism having a polygonal cross-section. In each example, the protrusion may be positioned such that the vertices of the polygonal cross-section abut the wall 102 of the consumable 102. That is, such a polygonal prism may be inscribed in the circular wall 102 of the consumable. Alternatively, protrusion 206 may be positioned such that the wall 102 of the consumable is spaced from protrusion 206 all around the protrusion 206.

[0061] In the examples described herein, the system may be configured such that, when the consumable 100 is fully inserted into the receiving area 201, the protrusions 206 occupy 20% to 80% of the cross-sectional area of ​​at least a portion of the air gap 103 of the consumable 100. This narrows the air gap 103, which consequently affects the pressure drop across the consumable 100 when a user draws on the consumable 100. By configuring the system so that the protrusions occupy 20% to 80% of the cross-sectional area of ​​at least a portion of the air gap 103, the system can be configured to provide sufficient resistance to draw. In certain examples, the system may be configured to replicate the resistance to draw of more traditional aerosol delivery devices, such as cigarettes. In other examples, the system may be configured such that the protrusions occupy 30% to 70%, 40% to 60%, or approximately 50% of the cross-sectional area of ​​at least a portion of the air gap 103. In particular examples, the system may be configured such that the protrusion occupies about 50%, about 60%, about 70%, about 80%, or about 85% of the cross-sectional area of ​​at least a portion of the air gap 103. In the particular example of FIG. 7, where a protrusion having a hexagonal protrusion is inscribed in the circular wall 102 of the consumable, the protrusion occupies 82% to 83% of that portion of the air gap 103. Other examples of protrusions 206 having polygonal cross-sections inscribed by the circular wall 102 of the consumable are also considered within the scope of the present disclosure.

[0062] The protrusion 206 may have a constant cross-sectional area along its length, or the cross-sectional area may vary along its length. In one example, the cross-sectional area of ​​the protrusion decreases along its length, i.e., the cross-sectional area decreases with distance from the base of the region 201 for receiving the consumable 100. In other words, the protrusion 206 may be tapered, as shown schematically in FIG. 9 . In such an example, the percentage of the cross-sectional area of ​​the air gap 103 occupied by the protrusion 206 when the consumable 100 is fully inserted into the region 201 varies along the length of the hollow section 101 of the consumable 100. In one example, the percentage of the cross-sectional area of ​​the air gap 103 occupied by the protrusion 206 near the base of the region 201 may be approximately 80% and approximately 10% near the tip 208 of the protrusion 206. In another example, the protrusion 206 has a constant cross-sectional area along its length and is configured to extend only partially along the length of the hollow section 101 when the consumable 100 is fully inserted into the region 201. Thus, the protrusion 206 occupies a constant percentage of the cross-sectional area of ​​the air gap 103 only where the protrusion extends, and the air gap 103 extends beyond the protrusion 206, with at least a portion of the air gap 103 being free of the protrusion 206.

[0063] The aerosol generator 202 includes any suitable means for heating the aerosol-forming material 105 of the consumable 100 received in the region 201 of the device 200. Power for the aerosol generator 202 is provided by a power source 203, which in the illustrated example is a power source 203 such as a battery 203.

[0064] In one example, the aerosol generator 202 comprises a magnetic field generator configured to generate a varying magnetic field that penetrates the region 201 for receiving the consumable 100. Thus, the device 200 is configured for use with a consumable 100 that includes a susceptor 106, such as the consumable illustrated by FIG. 3. The varying magnetic field heats the susceptor 106 by magnetic hysteresis. When the consumable 100 is placed in the device 200 and the aerosol generator 202 is activated, the varying magnetic field penetrates the susceptor 106 of the consumable 100, heating the aerosol-generating material 105 in thermal contact with the susceptor and generating an aerosol for inhalation by the user.

[0065] In another example, the aerosol generator 202 includes a susceptor in thermal contact with the region 201 for receiving the consumable 100 and a magnetic field generator for generating a varying magnetic field that penetrates the susceptor. The varying magnetic field heats the susceptor by magnetic hysteresis. The susceptor then heats the region 201 for receiving the consumable. Thus, when the consumable 100 is placed in the device 200 and the aerosol generator 202 is activated, the varying magnetic field penetrates the susceptor and heats the region 201 for receiving the consumable 100. The heat is transferred to the aerosol-generating material 105 of the consumable 100, generating an aerosol for inhalation by the user. In such an example, the wall 207 of the region 201 for receiving the consumable 100 can include a susceptor. The consumable 100 can be configured to be in direct contact with the wall 207 for efficient heat transfer. Alternatively or additionally, the protrusion 206 can include a susceptor. For example, either or both of the wall 207 and the protrusion 206 may be made from a material that can be heated by penetration by a varying magnetic field.

[0066] In the examples described herein, the system may be configured such that the protrusions 206 occupy 50% to 80% of the volume of the air gap 103 when the consumable 100 is fully inserted into the region 201 for receiving the consumable 100. By configuring the system such that the protrusions occupy 50% to 80% of the volume of the air gap 103, the system can be configured to provide sufficient resistance to suction. In certain examples where the protrusions 206 comprise susceptors, configuring the system such that the protrusions occupy 50% to 80% of the volume of the air gap 103 ensures a good balance between resistance to suction and the level of heating provided within the air gap 103. In other examples, the system may be configured such that the protrusions occupy approximately 50%, approximately 60%, approximately 70%, approximately 80%, or approximately 85% of the volume of the air gap 103 when the consumable 100 is fully inserted into the device 200.

[0067] 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.

[0068] In any of the above examples of aerosol generator 202, aerosol generator 202 may be configured for zonal or localized heating of consumable 100. By "zonal or localized heating," it is meant that aerosol generator 202 is configured to heat distinct portions of aerosol-generating material 105 separately, i.e., at different times. Zonal heating can be provided to device 200 with protrusions 206 having varying cross-sectional areas along their lengths, as described above.

[0069] An exemplary consumable 100 in combination with a tapered protrusion 206 is shown in cross section in FIG. 10 , with other features of the device 200 omitted for clarity. The device 200 is configured for zonal heating. The device is configured to heat the first individual section 103a of the consumable air gap 103 before the second individual section 103b, or the second individual section 103b before the first individual section 103a. Whether the first or second individual section 103a, 103b is heated first may depend on user input or may be inherent to the configuration of the device 200. The first individual section 103a is axially spaced from the second individual section 103b and may contain the same or a different aerosol-generating material 105. The first individual section 103a is relatively closer to the base of the protrusion 206 than the second individual section 103b. Because the protrusions 206 occupy a larger proportion of the volume of the first individual section 103a than the second individual section 103b, the first individual section 103a may heat up faster than the second individual section 103b. Also, due to the difference in the volumes of the first and second individual sections 103a, 103b occupied by the protrusions 206, the aerosol formed in the first individual section 103a when heated may be different from the aerosol formed in the second individual section 103b when heated. The aerosol-generating materials 105 provided in the first and second individual sections 103a, 103b may be appropriately selected to take full advantage of these different aerosol-generating characteristics. Thus, the non-combustion aerosol delivery system may be designed to provide a user with a varying experience during heating of the consumable product 100. In particular, the user's experience of the consumable product 100 during heating of the first discrete section 103a may be different from the user's experience of the consumable product 100 during heating of the second discrete section 103b.

[0070] While the above example describes zonal heating of two separate sections 103a, 103b of the consumable 100, it will be appreciated that zonal heating may be applied to any number of separate sections as desired. Those skilled in the art will appreciate that the consumable 100 may be divided into any number of separate sections and the device 200 may be configured accordingly to heat each of said separate sections separately.

[0071] The consumable 100 may be provided with any number of additional components for attachment to the hollow section 101 described above. Importantly, however, any additional components should not interfere with insertion of the protrusion 206 into the air gap 103 when the consumable 100 and device 200 are combined. An exemplary consumable 100 with additional components is shown in FIG. 5; in this example, the consumable includes a filter plug 108 and two locator components 109, 109′ in addition to the hollow section 101. The additional components 108, 109, 109′ include substantially the same outer diameter as the hollow section 101 and are axially aligned and connected thereto by wrapping material 110. The consumable includes a mouth end 111 and a distal end 112. The distal end 112 is configured for insertion into the region 201 for receiving the consumable 100. In all examples of the consumable 100 within the scope of this disclosure, the distal end 112 includes an opening 113 that allows the protrusion 206 to enter the air gap 103 of the hollow section 101. This opening may be, for example, an open end of the hollow section 101 without any additional components, or it may be an opening 113 in an additional component. In the example of FIG. 5 , a locator component 109 is provided at the distal end 112 of the consumable and includes an opening 113 for the protrusion 206. The opening 113 in the locator component 109 is preferably sized to closely contact the outer surface of the protrusion 206 when the consumable and device 200 are combined. Thus, the wall 102 of the hollow section 101 may be spaced from the outer surface of the protrusion 206 all around the longitudinal axis of the consumable 100 at the location where the locator component 109 is provided. The locator component 109 also negates the need for the outermost surface of the consumable 100 to be in close proximity to the wall 207 of the area 201 for receiving the consumable 100. In the example of Figure 5, an additional locator component 109' is positioned at the mouth end 111 of the consumable 100 between the hollow section 101 and the filter plug 108. The filter plug 108 and locator components 109, 109' can be made from cellulose acetate or a paper material.When the consumable item 100 is fully inserted into the area 201, the mouth end protrudes from the area 201, allowing a user to suck on the consumable item 100 during use.

[0072] 8, a flow diagram illustrating an example method 80 for manufacturing a consumable product 100 for use with the example systems described herein is shown. The method 80 of FIG. 8 can be used to manufacture any of the consumable products 100 described herein.

[0073] The method includes providing 81 a hollow section 101 including a support 104 and an aerosol-generating material 105 attached to the support 104, and optionally affixing any desired additional components thereto.

[0074] In some examples, providing 81 includes applying 82 the aerosol-generating material 105 to a substrate 104 and then forming 83 the hollow section 101. Thus, in some examples, the substrate 104 may be flat or generally flat at the time the aerosol-generating material 105 is applied. Then, in some examples, the substrate 104 and the aerosol-generating material 105 may be processed together during the formation of the hollow section 101. Such processing may include rolling or wrapping the combination of the substrate 104 and the aerosol-generating material 105 into a typically tubular section 101. However, it will be understood that the combination of the substrate 104 and the aerosol-generating material 105 may instead be folded into a section 101 having a non-circular cross-section. Such wrapping, wrapping, or folding may be, for example, around a mandrel. In other examples, the substrate 104 is provided in a tubular or generally tubular form, and then the aerosol-generating material 105 is applied to the substrate 104.

[0075] In some examples, the method includes manufacturing the support 104. For example, as described in some examples herein, the support 104 can include multiple layers 106, 107, and manufacturing the support 104 can include assembling the layers, such as by bonding, to form the support 104. At least one of the layers 106, 107 can be in the form of a sheet or strip.

[0076] In some examples, such as in some examples where applying 82 occurs before forming 83, applying 82 includes coating aerosol-generating material 105 onto substrate 104 to form a film of aerosol-generating material 105. Such coating may include, for example, spraying, electrospraying, casting, or band casting. Such casting may include providing the material (or the material that will ultimately form substrate 104) in liquid or other fluid form on the surface of substrate 104 and then at least partially solidifying or curing the material on the surface of substrate 104 to form a film-containing aerosol-generating material 105. The material in liquid or other fluid form may be an aerosol-generating form in that form, or may become an aerosol-generating form only after solidifying or curing.

[0077] In some examples, attaching 82 may include techniques other than coating. For example, attaching 82 may include adhering aerosol-generating material 105 to support 104 using an adhesive.

[0078] If additional components are required, such as those in the example of Figure 5, the components can be attached to hollow section 101 by first axially aligning and positioning each of the components to form an assembly of components, and then wrapping the components in wrapping material 110. In the example of Figure 5, the assembly comprises, in order, distal end locator component 109, hollow section 101, mouth end locator component 109', and filter plug 108. The assembly is then wrapped in wrapping material 110 to form consumable 100 of Figure 5.

[0079] The aerosol-generating material 105 of any of the examples described herein may include an aerosol-forming agent, a binder, optionally a filler, and optionally an active agent and / or a flavoring agent.

Claims

1. 1. A non-combustion aerosol delivery system comprising a consumable and a non-combustion aerosol delivery device, the non-combustion aerosol delivery device comprises an aerosol generator configured to heat the consumable product to generate an aerosol when the consumable product and the non-combustion aerosol delivery device are combined during use of the device; the consumable product includes a hollow section, the hollow section including a support and a film of aerosol-generating material coated on the support, the hollow section defining an air gap in the consumable product in which aerosol is generated during use; A non-combustion aerosol delivery system, wherein the device comprises a protrusion configured to insert into the air gap of the consumable when the device and the consumable are combined.

2. 2. The non-combustion aerosol delivery system of claim 1, wherein the support is a portion of a wall of the hollow section surrounding the air gap, and the aerosol-forming material forms an interior surface of the wall.

3. 4. The non-combustion aerosol delivery system of claim 2 or claim 3, wherein the hollow section is a hollow tube.

4. 4. The non-combustion aerosol delivery system of claim 3, wherein the support is a tubular wall of the hollow tube.

5. The non-combustion aerosol delivery system of any one of claims 1 to 4, wherein the support forms at least a portion of a surface of the consumable.

6. The non-combustion aerosol delivery system of claim 5 , wherein the surface of the consumable is an outermost surface of the consumable.

7. The non-combustion aerosol delivery system of claim 6 , wherein the aerosol-forming material forms an interior surface of the hollow section.

8. 8. The non-combustion aerosol delivery system of claim 7, wherein the device and consumable are configured such that an outer surface of the protrusion is spaced apart from the inner surface of the hollow section of the consumable when the device and the consumable are combined.

9. 9. A non-combustion aerosol delivery system as described in any one of claims 1 to 8, wherein a cross-sectional area of ​​at least a portion of the protrusion occupies 20% to 80% of the cross-sectional area of ​​at least a portion of the air gap when the device and the consumable are combined.

10. 10. The non-combustion aerosol delivery system of claim 1, wherein the protrusion is configured to occupy 50% to 80% of the volume of the air gap when the device and the consumable are combined.

11. The non-combustion aerosol delivery system according to any one of claims 1 to 10, wherein the aerosol generator comprises the protrusion.

12. 12. The non-combustion aerosol delivery system of claim 11, wherein the protrusions are configured to be heated during use.

13. 13. The non-combustion aerosol delivery system of claim 12, wherein the protrusion comprises a susceptor, and the aerosol generator further comprises a magnetic field generator for generating a varying magnetic field penetrating the protrusion.

14. 14. The non-combustion aerosol delivery system of claim 1, wherein the consumable comprises a susceptor, and the aerosol generator comprises a magnetic field generator for generating a varying magnetic field that penetrates the susceptor.

15. The non-combustion aerosol delivery system of claim 14 , wherein the support comprises the susceptor.

16. 16. The non-combustion aerosol delivery system of claim 15, wherein the support comprises a first layer and a second layer, the first layer comprising the susceptor, the second layer not being heatable by penetration by a fluctuating magnetic field, and the first layer being positioned between the aerosol-generating material and the second layer.

17. 17. The non-combustion aerosol delivery system of claim 16, wherein the second layer is outside the first layer.

18. 18. The non-combustion aerosol delivery system of claim 17 when dependent on claim 6, wherein the second layer forms at least a portion of the outermost surface of the consumable.

19. 19. A non-combustion aerosol delivery system according to any one of claims 14 to 18 when dependent on claim 11, wherein the protrusion comprises a magnetic field generator for generating a fluctuating magnetic field that penetrates the susceptor.

20. 20. The non-combustion aerosol delivery system of claim 13, wherein the susceptor comprises one or more materials selected from the group consisting of an electrically conductive material, a magnetic material, and a magnetically conductive material.

21. 12. The non-combustion aerosol delivery system of claim 11, wherein the protrusions are configured to be heated by electrical resistance.

22. 22. The non-combustion aerosol delivery system of any one of claims 1 to 21, wherein the cross-sectional area of ​​the protrusion varies along its length.

23. 23. The non-combustion aerosol delivery system of any one of claims 1 to 22, wherein the air gap of the consumable comprises a plurality of individual sections, and the aerosol generator is configured to sequentially heat each of the plurality of individual sections.

24. the aerosol-forming material is an aerosol former; and a binder; and optionally a filler; Optionally, an active agent and / or a flavoring agent; and 24. The non-combustion aerosol delivery system of any one of claims 1 to 23, comprising:

25. 25. The non-combustion aerosol delivery system of claim 24, wherein the aerosol-forming material comprises an aerosol-forming film, the aerosol-forming 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.

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