Aerosol-generating consumables

Abstract

Disclosed is a consumable (10) formed from a corrugated, gathered sheet material (20) having an aerosol-generating section (30) and one or two filter sections (40). The aerosol-generating section (30) is formed from an aerosol-generating material (31). The aerosol-generating material may include a film of aerosol-generating material applied, for example, by printing, to a portion of the surface of the corrugated, gathered sheet material (20). Corrugation may be applied only to the filter section (40), or to both the filter section (40) and the aerosol-generating section (30). The same level of corrugation may be applied to all sections, or different levels of corrugation may be applied to each section.

Description

[Technical Field]

[0001] SUMMARY The present disclosure relates to consumables for use with aerosol delivery systems, aerosol delivery systems including consumables, and methods of forming 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 a non-combustion aerosol delivery device, the consumable comprising an aerosol-generating section and a filter section, the aerosol-generating section and the filter section being integrally formed from a crimped gathered sheet material, the aerosol-generating section comprising aerosol-generating material and the filter section being substantially free of aerosol-generating material.

[0004] In some embodiments, the aerosol-generating section comprises a portion of corrugated gathered sheet material having aerosol-generating material entrained therein.

[0005] In some embodiments, the aerosol-generating section includes a film of aerosol-generating material disposed on a portion of the corrugated gathered sheet material. The aerosol-generating material may be printed on the corrugated gathered sheet material.

[0006] In some embodiments, the aerosol-generation section is not corrugated. The aerosol-generation section may be substantially free of corrugations.

[0007] In some embodiments, the filter section and the aerosol-generation section of the corrugated gathered sheet material are corrugated at the same level. In other embodiments, the filter section and the aerosol-generation section of the corrugated gathered sheet material are corrugated at different levels. The level of corrugation may include corrugation amplitude and / or corrugation spacing.

[0008] The corrugation spacing may be the average spacing between adjacent ridges of the corrugated gathered sheet material. In some embodiments, the average spacing of the corrugations in both the filter section and the aerosol-generation section is from about 0.1 mm to about 3 mm. In some embodiments, adjacent flutes of the corrugated sheet material are separated by a distance of at most 3 mm, preferably at most 2.5, 2, 1, 1.5, 0.7, 0.5, 0.2, or 0.1 mm.

[0009] In some embodiments, the average spacing of the corrugations in the aerosol-generation section is less than the average spacing of the corrugations in the filter section, while in other embodiments, the average spacing of the corrugations in the aerosol-generation section is greater than the average spacing of the corrugations in the filter section.

[0010] The corrugation amplitude can be the average height of the ridges of the corrugated gathered sheet material. In some embodiments, the corrugation amplitude in both the filter section and the aerosol-generation section is from about 0.1 mm to about 1 mm. In some embodiments, the sheet material is corrugated to a corrugation amplitude of at least 0.1 mm, preferably at least 0.3 mm, 0.4 mm, or 0.5 mm. In some embodiments, the sheet material is corrugated to a corrugation amplitude of at most 1 mm, preferably at most 0.8 mm, 0.6 mm, or 0.5 mm.

[0011] In some embodiments, the sheet material may have corrugations with a corrugation amplitude of less than 500 μm and a spacing between peaks (or valleys) of at least 300 μm, at least 400 μm, or at least 500 μm.

[0012] In some embodiments, the waveform amplitude in the aerosol-generation section is less than the waveform amplitude in the filter section, while in other embodiments, the waveform amplitude in the aerosol-generation section is greater than the waveform amplitude in the filter section.

[0013] In some embodiments, the corrugated and gathered sheet material is surrounded by a first packaging material. The first packaging material preferably has a basis weight of about 30 to about 75 gsm, or about 40 to about 65 gsm. Such a basis weight can help improve the circularity of the cross-section of the aerosol-generating section.

[0014] A second packaging material may be provided only around the filter section. The second packaging material preferably has a basis weight of about 70 gsm to about 120 gsm, more preferably about 80 gsm to about 110 gsm. Such a basis weight is desirable to achieve an acceptable overall level of stiffness.

[0015] In some embodiments, the consumable is generally cylindrical.

[0016] The length of the aerosol-generation section may be in the range of about 25 mm to about 50 mm, more preferably in the range of about 30 mm to 45 mm, and even more preferably in the range of about 30 mm to 40 mm. The length of the filter section may be in the range of about 5 mm to about 50 mm.

[0017] In some embodiments, the closing pressure drop across the consumable is between 30 and 90 mmWG, preferably between 35 and 70 mmWG.

[0018] The closing pressure drop across the filter section can be about 0.5 to about 20 mmWG, about 1.5 to about 8.6 mmWG per mm of filter section length, or about 3 to about 6 mmWG per mm of filter section length.

[0019] The closure pressure drop across the aerosol-generation section can be from about 29 to about 70 mmWG.

[0020] In some embodiments, the aerosol-forming material comprises an aerosol-forming agent, a binder, optionally a filler, and optionally an active agent and / or a flavoring agent.

[0021] In some embodiments, the consumable comprises an aerosol-generation section and a filter section, while in other embodiments, the consumable comprises an aerosol-generation section and two filter sections, one on each side of the aerosol-generation section.

[0022] In a second aspect of the present invention, 1. A method of forming a consumable for use with a non-combustion aerosol delivery device, comprising: providing a sheet material; applying an aerosol-generating material to the sheet material in distinct sections to form alternating aerosol-generating sections and filter sections that are substantially free of the aerosol-generating material; corrugating the sheet material; gathering the sheet material together to form a generally cylindrical rod; Separating the rod into individual consumables each having an aerosol-generating section and a filter section; A method is provided which includes:

[0023] In some embodiments of the second aspect, the aerosol-generation section and the filter section are provided with different levels of corrugation. In some embodiments of the second aspect, the aerosol-generation section is not provided with corrugation.

[0024] In a third aspect of the present invention, 1. A method of forming a consumable for use with a non-combustion aerosol delivery device, comprising: providing a continuous sheet material having distinct sections containing aerosol-generating material, the distinct sections being equally spaced along a length of the continuous sheet material; applying a corrugated pattern to a continuous sheet of material; gathering a continuous sheet of material containing a corrugated pattern; wrapping the gathered continuous sheet material in at least one packaging material to form a consumable product; A method is provided which includes:

[0025] In some embodiments of the third aspect, the step of applying a corrugation pattern comprises applying a first level of corrugation to the separate sections and applying a second level of corrugation to sections between the separate sections.

[0026] In a fourth aspect of the present invention, 1. A non-combustion aerosol delivery system for heating an aerosol-forming material to volatilize at least one component of the aerosol-forming material, comprising: a consumable product according to a first aspect; a non-combustion aerosol delivery device; the non-combustion aerosol delivery device comprising an aerosol generator configured to, in use, heat the consumable to generate an aerosol when the consumable and the device are combined; A non-combustion aerosol delivery system is provided.

[0027] In a fifth aspect of the present invention, there is provided a consumable for use with a non-combustion aerosol delivery device, the consumable having a first end and a second end, a mouthpiece downstream of the first end, an aerosol-generation section downstream of the first end and upstream of the mouthpiece, and a blocking member (or plug) positioned upstream of the aerosol-generation section, wherein the aerosol-generation section and the blocking member are formed together from corrugated and / or slit and gathered sheet material, and the aerosol-generation section contains aerosol-generating material.

[0028] In some embodiments of the fifth aspect, the blocking member allows air flow but prevents escape of aerosol-forming material from the consumable. Thus, in some embodiments, the blocking member is breathable.

[0029] In a sixth aspect of the present invention, there is provided a consumable for use with a non-combustion aerosol delivery device, the consumable comprising an aerosol-generating section and a filter section, the aerosol-generating section and the filter section being integrally formed from a corrugated and / or slit and gathered sheet material, the aerosol-generating section comprising aerosol-generating material and the filter section being substantially free of aerosol-generating material.

[0030] In some embodiments of the sixth aspect, the slits may replace the corrugations of other embodiments. The material may be slit by a plurality of separate slits or perforations.

[0031] In some embodiments of the sixth aspect, the aerosol-generating section is slit and the filter section is corrugated. The corrugated filter section can help retain the aerosol-generating material within the consumable.

[0032] In some embodiments, the corrugations and / or slits extend longitudinally along the consumable.

[0033] 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]

[0034] [Figure 1A] FIG. 1 is a schematic diagram of an exemplary consumable formed from a corrugated gathered sheet material having an aerosol-generation section and one filter section. [Figure 1B] FIG. 1 is a schematic diagram of an exemplary consumable formed from a corrugated gathered sheet material having an aerosol-generation section and two filter sections. [Figure 2A] FIG. 1C is a schematic diagram of the consumable of FIG. 1B, with corrugation applied to the filter section only. [Figure 2B] FIG. 1C is a schematic diagram of the consumable of FIG. 1B, with corrugations in the filter section and the aerosol-generation section. [Figure 2C] FIG. 1C is a schematic diagram of the consumable of FIG. 1B with different levels of corrugation in the filter section and the aerosol-generation section. [Figure 3A] FIG. 1 illustrates the amplitude and spacing of one waveform morphology. [Figure 3B] FIG. 10 illustrates the amplitude and spacing of another waveform morphology. [Figure 4A] FIG. 1B is a schematic diagram of the consumable product of FIG. 1A with additional packaging material. [Figure 4B] FIG. 1C is a schematic diagram of the consumable product of FIG. 1B with additional packaging material. [Figure 5] FIG. 1 illustrates a schematic process configuration for corrugating sheet material during the manufacture of consumable products. [Figure 6] FIG. 1 is a schematic diagram of a system including a consumable product and a non-combustion aerosol delivery device. DETAILED DESCRIPTION OF THE INVENTION

[0035] 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.

[0036] 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.

[0037] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0038] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system.

[0039] 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 aerosol-generating material 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.

[0040] 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.

[0041] The present disclosure relates to consumables, sometimes referred to as articles in this disclosure, that include aerosol-generating materials and are configured for use with non-combustion aerosol delivery devices.

[0042] In some embodiments, a non-combustion aerosol delivery system, such as a non-combustion aerosol delivery device, may include a power source and a controller. The power source may 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 to the heat generating power source.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] active substance In some embodiments, the substance to be delivered comprises an active agent.

[0047] As used herein, the term "active substance" may refer to 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 psychoactive substances. The active substance may be naturally occurring 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.

[0048] In one embodiment, the active substance is a legally permitted recreational drug.

[0049] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0050] 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. The active substance may be CBD or a derivative thereof.

[0051] As described herein, an active substance may include 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, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, the material may include synthetically derived active compounds naturally occurring in the botanical substance. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, sheets, etc. Exemplary botanicals include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, rabe The mint may be selected from the following mint varieties: Mentha acuta, Mentha cv, Egyptian mint, Mentha piperita, Eau de Cologne mint, Candy mint, Curcuma officinalis, Curcuma longa, Curcuma longa, Sandalwood, Cilantro, Bergamot, Orange blossom, Myrtle, Cassis, Valerian, Pimento, Mace, Damian, Marjoram, Olive, Lemon balm, Lemon basil, Chive, 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 acuta, Mentha cv, Egyptian mint, Peppermint, Eau de Cologne mint, Candy mint, Curly mint, Kentucky Kernel mint, Horse mint, Pineapple mint, Pennyroyal mint, Green mint, and Apple mint.

[0052] 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.

[0053] 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 eucalyptus, star anise, cocoa, and hemp.

[0054] 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.

[0055] Flavor In some embodiments, the substance delivered comprises a flavor.

[0056] 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 may be 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, tomato, etc.). 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 Orchids, sage, fennel, wasabi, bell peppers, 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, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damien, maji The present invention may include other additives such as cholams, olives, 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 other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be imitation, synthetic, or natural raw materials, 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.

[0057] 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.

[0058] In some embodiments, the flavor may include a sensory elicitor intended to achieve somatic sensations typically chemically evoked and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the aroma or gustatory nerves, and may include agents that produce heating, cooling, tingling, or numbing effects. Suitable thermal effect agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucalyptol, WS-3.

[0059] Aerosol-Generating Materials An aerosol-forming material is a material that can generate an aerosol when, for example, heated, irradiated, or otherwise energized. The aerosol-forming material may be in solid, liquid, or semi-solid (such as a gel) form, which may or may not contain active substances and / or flavorings.

[0060] 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.

[0061] The aerosol-generating material may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a delivery substance and / or a bulking agent 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.

[0062] 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 delivery substance and / or a filler 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.

[0063] The aerosol-generating film may have a thickness of from about 0.015 mm to about 1 mm. For example, the thickness may be within the range of from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.3 mm or 0.5 mm.

[0064] In some embodiments, 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.

[0065] The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with one or more other ingredients, such as a solvent, such as water, an aerosol-forming agent, and 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.

[0066] The slurry can be heated to remove at least about 60%, 70%, 80%, 85%, or 90% by weight of the solvent.

[0067] The 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 can 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.

[0068] The amorphous solid may be substantially free of plant material. The amorphous solid may be substantially free of tobacco.

[0069] The aerosol-generating material may include or be in the form of granules or beads, which may be trapped within the consumable when the sheet material is brought together to form the consumable.

[0070] Aerosol-forming materials 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.

[0071] functional materials 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.

[0072] Base material The aerosol-generating material may be present on or in a support, forming a substrate. The support may be or include, 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.

[0073] Susceptor 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.

[0074] Aerosol Modifiers An aerosol modifier is a substance typically located downstream of the aerosol-generation region and configured to modify the generated aerosol, for example, by changing the taste, flavor, acidity, or other properties of the aerosol. The aerosol modifier may be provided within an aerosol modifier-releasing component operable to selectively release the aerosol modifier.

[0075] 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.

[0076] Aerosol Generator 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.

[0077] 1A and 1B show schematic diagrams of an exemplary consumable 10 formed from a corrugated, gathered sheet material 20 having an aerosol-generation section 30 and one or two filter sections 40. The aerosol-generation section 30 is formed by an aerosol-generating material 31. In FIG. 1A, the aerosol-generation section 30 is located at one end of the consumable such that one filter section 40 is provided. In FIG. 1B, the aerosol-generation section 30 is located in the center of the consumable such that two filter sections 40 are provided.

[0078] The sheet material 20 may be formed from or include paper, card, paperboard, cardboard, or reconstituted materials. Other materials for the sheet 20 may be as described above with respect to the substrate / support.

[0079] The aerosol-generating material 31 is configured to generate an aerosol when heated by an aerosol generator of the non-combustion aerosol-delivery device, as described further below. The aerosol-generating material 31 may be formed from or include any of the materials described above. The consumable may further include a metallic material to act as a susceptor for heating the aerosol-generating material 31.

[0080] Figures 2A, 2B, and 2C show schematic diagrams of the consumable of Figure 1B with different configurations of corrugation 50. Those skilled in the art will understand that different configurations of corrugation are equally applicable to the consumable of Figure 1A.

[0081] In FIG. 2A, only the filter section 40 has corrugation 50 applied.

[0082] In Figure 2B, the filter section 40 and the aerosol-generation section 30 have corrugations 50. All sections have the same level of corrugation.

[0083] In Figure 2C, different levels of corrugation are provided in filter section 40 and aerosol-generation section 30. Filter section 40 is provided with a first level of corrugation 51, and aerosol-generation section 30 is provided with a second level of corrugation 52. A "level" of corrugation may be defined as amplitude and / or spacing, as further explained below in relation to Figure 4.

[0084] The spacing of the corrugations 51 applied to the filter section 40 may be greater or less than the spacing of the corrugations 52 applied to the aerosol-generation section 30 .

[0085] The amplitude of the corrugations 51 applied to the filter section 40 may be greater or less than the amplitude of the corrugations 52 applied to the aerosol-generation section 30. Both the spacing and the amplitude may be different between the filter section 40 and the aerosol-generation section 30.

[0086] 3A and 3B show the amplitude A and spacing S of two different waveform forms, including a sine wave and a triangular wave, respectively. Waveforms of other shapes, such as a square, may also be employed.

[0087] 4A and 4B show schematic diagrams of the consumable of FIGS. 1A and 1B with additional packaging material. A first packaging material 60 is provided around the entire consumable 10, which helps to hold the corrugated and gathered material 20 in a cylindrical form. A second packaging material 70 is provided around one or two filter sections 40. In FIG. 4B, the second packaging material 70 may be provided around one or both filter sections 40. The first and second packaging materials may be formed from tipping paper.

[0088] A filter component may be included within the filter section 40, or, if two filter sections 40 are present, within one or both filter sections 40. The filter component preferably allows for finer control of the closing pressure drop or resistance to draw of the consumable 10. For example, the closing pressure drop may be controlled by setting the density of the filter material in the filter component or by increasing or decreasing the axial length of the filter component. The filter component may include additional filter material. The filter component may include a capsule.

[0089] 5 shows a schematic process configuration for corrugating sheet material during the manufacture of a consumable product. A bobbin 90 comprises a (what may be considered a substantially continuous) roll of sheet material 20 that is corrugated and gathered to form the consumable product. The sheet material 20 in the bobbin 90 is pre-printed with sections of aerosol-generating material 31. Alternatively, the aerosol-generating material 31 may be printed or otherwise applied in a line to the sheet material 20 after it is unwound from the bobbin 90.

[0090] Corrugating rollers 91 apply corrugations to the sheet material. These may be continuous or discontinuous corrugations, depending on the desired corrugation configuration. The corrugation configuration may be one of those shown in FIG. 2. After corrugation, the corrugated sheet 20 with aerosol-generating material 31 is fed into a rod-making machine where the sheet is gathered by conventional means to form a rod. The rod may also be packaged in one or more packaging materials, as shown in FIG. 4, or in another configuration as desired. The rod is then separated into individual consumables, for example, by cutting.

[0091] 6 shows a system including a consumable 100, which may be one of the consumables 10 according to the present invention described above, and a non-combustion aerosol delivery device 200. The device includes an area 201 for receiving the consumable 100 and an aerosol generator 202. The aerosol generator is configured to heat the aerosol-generating material 31 of the consumable 100 when the consumable 100 is received in 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 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 101 of the consumable, or alternatively, on the mouthpiece (not shown) of the device 200. In the illustrated example, consumable 100 and device 200 are configured such that mouth end 101 protrudes from area 201 for receiving consumable 100 when fully inserted into device 200. Mouth end 101 is therefore available to be placed between a user's lips while the user is holding the device.

[0092] 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.

[0093] The area 201 for receiving the consumable product 100 is provided with an inlet (not shown) for admitting air into the area and through the consumable product when a user inhales on the mouth end 101 of the consumable product 100. Thus, when a user inhales on the consumable product 100, a flow of air is directed through the consumable product 100. When heated by the aerosol generator 202, the air flow entrains the aerosol generated by the aerosol-generating material 31 of the consumable product.

[0094] The aerosol generator 202 includes any suitable means for heating the consumable aerosol-generating material 31 received within 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.

[0095] In one example, the aerosol generator 202 includes 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 includes a susceptor in thermal contact with an aerosol-generating material 31, such as the metallic material described above. Thus, when such a consumable 100 is placed within the device 200 and the aerosol generator 202 is activated, the varying magnetic field penetrates the susceptor of the consumable 100 and heats the aerosol-generating material 31 in thermal contact with the susceptor, generating an aerosol for inhalation by a user.

[0096] 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 31 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. Alternatively, the susceptor may include one or more protrusions (not shown) that stand up within the region 201 for receiving the consumable 100. Thus, the susceptor may be directly positionable within the consumable 100 .

[0097] 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 region 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 is passed through the material to heat the region 201 for receiving the consumable 100. The heat is transferred to the aerosol-generating material 31 of the consumable 100, generating an aerosol for inhalation by the user. In such an embodiment, the material 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. Alternatively, the aerosol generator 202 may be in the form of a blade or pin that is inserted into the aerosol-generating material 31 when the consumable 100 is placed in the device. When the aerosol generator 202 is activated, heat is transferred directly to the aerosol-generating material 31, generating an aerosol for inhalation by the user.

Claims

1. 1. A consumable for use with a non-combustion aerosol delivery device, the consumable comprising an aerosol-generating section and a filter section, the aerosol-generating section and the filter section being integrally formed from a corrugated and gathered sheet material, the aerosol-generating section comprising aerosol-generating material, and the filter section being substantially free of aerosol-generating material.

2. The consumable of claim 1 , wherein the aerosol-generating section comprises a portion of the corrugated gathered sheet material having an aerosol-generating material entrained therein.

3. The consumable product of claim 1 , wherein the aerosol-generating section comprises a film of aerosol-generating material disposed on a portion of the corrugated gathered sheet material.

4. The consumable product according to any one of claims 1 to 3, wherein the aerosol-generation section is not corrugated.

5. A consumable product according to any one of claims 1 to 3, wherein the filter section and the aerosol-generating section of the corrugated gathered sheet material are corrugated to the same level.

6. 4. A consumable product according to any one of claims 1 to 3, wherein the filter section and the aerosol-generating section of the corrugated gathered sheet material are corrugated to different levels.

7. The consumable product according to claim 5 or 6, wherein the level of corrugation comprises a corrugation amplitude and / or a corrugation interval.

8. 8. The consumable of claim 7, wherein the corrugation spacing comprises an average spacing between adjacent ridges of the corrugated gathered sheet material.

9. 9. The consumable product of claim 8, wherein the average spacing of the corrugations in both the filter section and the aerosol-generation section is between about 0.1 mm and about 3 mm.

10. 10. The consumable product of claim 8 or 9, wherein the average spacing of the corrugations in the aerosol-generation section is smaller than the average spacing of the corrugations in the filter section, or the average spacing of the corrugations in the aerosol-generation section is greater than the average spacing of the corrugations in the filter section.

11. A consumable product according to any one of claims 7 to 10, wherein the corrugation amplitude has an average height of the ridges of the corrugated gathered sheet material.

12. 12. The consumable product of claim 11, wherein the waveform amplitude in both the filter section and the aerosol-generation section is between about 0.1 mm and about 1 mm.

13. 13. The consumable product of claim 11 or 12, wherein the waveform amplitude of the aerosol-generation section is smaller than the waveform amplitude of the filter section, or the waveform amplitude of the aerosol-generation section is larger than the waveform amplitude of the filter section.

14. A consumable product according to any preceding claim, wherein the corrugated gathered sheet material is surrounded by a first packaging material.

15. 15. The consumable product of claim 14, wherein a second packaging material is provided only around the filter section.

16. The consumable product according to any one of claims 1 to 15, wherein the aerosol-generation section has a length of about 25 mm to about 50 mm and / or the filter section has a length of about 5 mm to about 50 mm.

17. the aerosol-forming material is an aerosol forming agent; a binder; and optionally a filler; Optionally with active agents and / or flavorings The consumable product of any one of claims 1 to 16, comprising:

18. The consumable according to any one of the preceding claims, wherein the consumable comprises an aerosol-generation section and a filter section.

19. The consumable according to any one of the preceding claims, wherein the consumable comprises an aerosol-generation section and two filter sections, one on each side of the aerosol-generation section.

20. 1. A method of forming a consumable for use with a non-combustion aerosol delivery device, comprising: providing a sheet material; applying an aerosol-forming material to the sheet material in distinct sections to form alternating aerosol-generating sections and filter sections that are substantially free of aerosol-generating material; corrugating the sheet material; gathering the sheet material together to form a generally cylindrical rod; separating the rod into individual consumables each having an aerosol-generating section and a filter section; A method comprising:

21. 21. The method of claim 20, wherein the aerosol-generation section and the filter section are provided with different levels of corrugation.

22. 21. The method of claim 20, wherein the aerosol-generation section is not corrugated.

23. 1. A method of forming a consumable for use with a non-combustion aerosol delivery device, comprising: providing a continuous sheet material having distinct sections containing an aerosol-forming material, the distinct sections being equally spaced along a length of the continuous sheet material; applying a corrugated pattern to the continuous sheet material; gathering the continuous sheet material containing the corrugated pattern; wrapping the gathered continuous sheet material in at least one packaging material to form the consumable product; A method comprising:

24. 24. The method of claim 23, wherein the step of applying the corrugation pattern comprises applying a first level of corrugation to the distinct sections and applying a second level of corrugation to sections between the distinct sections.

25. 1. A non-combustion aerosol delivery system for heating an aerosol-forming material to volatilize at least one component of the aerosol-forming material, comprising: A consumable product according to any one of claims 1 to 19; a non-combustion aerosol delivery device; A non-combustion aerosol delivery system, wherein the non-combustion aerosol delivery device comprises an aerosol generator configured to heat the consumable and generate an aerosol when the consumable and the device are combined in use.

26. 1. A consumable for use with a non-combustion aerosol delivery device, the consumable having a first end and a second end, the consumable comprising: a mouthpiece downstream of the first end; an aerosol-generation section downstream of the first end and upstream of the mouthpiece; a blocking member disposed upstream of the aerosol-generation section; Equipped with The consumable article, wherein the aerosol-generating section and the blocking member are integrally formed from a corrugated and / or slit gathered sheet material, and the aerosol-generating section contains an aerosol-generating material.

27. 1. A consumable for use with a non-combustion aerosol delivery device, the consumable comprising an aerosol-generating section and a filter section, the aerosol-generating section and the filter section being integrally formed from a corrugated and / or slit and gathered sheet material, the aerosol-generating section comprising aerosol-generating material, and the filter section being substantially free of aerosol-generating material.

28. 28. The consumable product of claim 27, wherein the aerosol-generation section is slit and the filter section is corrugated.

29. The consumable product of any one of claims 1 to 19 or 26 to 28, wherein the corrugations and / or slits extend longitudinally along the consumable product.

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