Consumables

Abstract

The present invention relates to a consumable (100, 120, 130, 140, 150, 160, 170) for use with an aerosol delivery device. The consumable (100, 120, 130, 140, 150, 160, 170) comprises an outer tube (101), an inner member (102) inside the outer tube (101), and at least one support (103) that supports the inner member (102) relative to the outer tube (101) such that at least one gap (104) exists between the inner member (102) and the outer tube (101). The consumable (100, 120, 130, 140, 150, 160, 170) includes an aerosol-generating material (105) that can be heated to generate an aerosol within at least one cavity (104), and a layer (106) of granular material disposed between an outer tube (101) and an inner member (102).

Description

[Technical Field]

[0001] The present invention relates to consumables for use with aerosol delivery systems, and aerosol delivery systems including consumables. [Background technology]

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

[0003] In a first aspect of the present invention, there is provided a consumable for use with an aerosol delivery system, the consumable comprising an outer tube, an inner member inside the outer tube, and at least one support supporting the inner member against the outer tube such that there is at least one gap between the inner member and the outer tube, the consumable comprising an aerosol-generating material that can be heated to generate an aerosol in the at least one gap, the outer tube comprising a tube wall, the inner member comprising a member wall, and a layer of granular material provided between the tube wall of the outer tube and the member wall of the inner member.

[0004] In some embodiments, the layer of particulate material may be breathable.

[0005] In some embodiments, the particulate material may include silica.

[0006] In some embodiments, the particulate material may be an aerosol-forming material.

[0007] In some embodiments, the at least one support may include a component disposed at an axial end of the consumable.

[0008] In some embodiments, at least one of the inner member and the outer tube may include an aerosol-forming material.

[0009] In some embodiments, at least one of the inner member and the outer tube may comprise a layer of granular material.

[0010] In some embodiments, the inner member may comprise an aerosol-generating material and a layer of particulate material, and the layer of particulate material may be located closer to the inner member than the aerosol-generating material.

[0011] In some embodiments, the inner member may comprise an aerosol-forming material and a layer of particulate material, and the aerosol-forming material may be located closer to the inner member than the layer of particulate material.

[0012] In some embodiments, the outer tube may comprise a layer of aerosol-forming material and particulate material, and the layer of particulate material may be located closer to the outer tube than the aerosol-forming material.

[0013] In some embodiments, the outer tube may comprise a layer of aerosol-forming material and particulate material, and the aerosol-forming material may be located closer to the outer tube than the layer of particulate material.

[0014] In some embodiments, one of the outer tube and the inner member may include an aerosol-generating material, and the other of the outer tube and the inner member may include a layer of particulate material.

[0015] In some embodiments, at least one of the inner member and the outer tube may comprise a carrier, with the aerosol-forming material being fixed to the carrier.

[0016] In some embodiments, the aerosol-forming material may be an aerosol-forming film disposed on a carrier.

[0017] In some embodiments, the layer of particulate material may be a carrier.

[0018] In some embodiments, at least one of the inner member and the outer tube may be circular.

[0019] In some embodiments, at least one of the inner member and the outer tube may be non-circular.

[0020] In a second aspect of the present invention, there is provided a system comprising the consumable product of the first aspect and an aerosol delivery device. [Brief explanation of the drawings]

[0021] Embodiments of the present invention will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which: [Figure 1] 1 is a schematic cross-sectional end view of one embodiment of a consumable. [Figure 2] 1 is a schematic cross-sectional end view of one embodiment of a consumable. [Figure 3] 1 is a schematic cross-sectional end view of one embodiment of a consumable. [Figure 4] 1 is a schematic cross-sectional end view of one embodiment of a consumable. [Figure 5] 1 is a schematic cross-sectional end view of one embodiment of a consumable. [Figure 6] 1 is a schematic cross-sectional end view of one embodiment of a consumable. [Figure 7] 1 is a schematic cross-sectional end view of one embodiment of a consumable. [Figure 8] 1 shows a schematic diagram of a system including a consumable and an aerosol delivery device. DETAILED DESCRIPTION OF THE INVENTION

[0022] 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.

[0023] 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.

[0024] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0025] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system.

[0026] 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.

[0027] 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.

[0028] The present disclosure relates to consumables, sometimes referred to as articles throughout this disclosure, that include aerosol-generating materials and are configured for use with non-combustion aerosol delivery devices.

[0029] 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.

[0030] 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.

[0031] 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.

[0032] 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.

[0033] In some embodiments, the substance to be delivered comprises an active agent.

[0034] 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.

[0035] In one embodiment, the active substance is a legally permitted recreational drug.

[0036] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0037] 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.

[0038] The active substance can be CBD or a derivative thereof

[0039] As described herein, an active substance may comprise or be derived from one or more botanical substances or their components, derivatives, or extracts. As used herein, the term "botanical substance" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, or shells. Alternatively, the material may comprise a synthetically derived active compound naturally present in the botanical substance. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, or sheets. Examples of plants include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, and saffron. , lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiento, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following mint varieties: Mentha americana, Mentha cv, Egyptian mint, peppermint, eau de cologne mint, candy mint, curly mint, Kentucky kernel mint, horse mint, pineapple mint, pennyroyal mint, green mentha, and apple mint.

[0040] 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.

[0041] 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.

[0042] 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.

[0043] In some embodiments, the substance to be delivered comprises a flavor.

[0044] As used herein, the terms "flavor" and "flavoring agent" refer to materials that may be used, where local regulations permit, to create a desired taste, aroma, or other somatic sensation in products intended for adult consumers.They include naturally occurring flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, Tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, eggplant, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang ylang , sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, peppermint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, bay leaf, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damiento, maize The present invention may also include other additives such as joram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be imitation, synthetic, or natural sources, 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.

[0045] 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.

[0046] In some embodiments, the flavor may include a sensation eliciting agent intended to achieve somatic sensations typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the aroma or taste nerves, and may include agents that produce heating, cooling, tingling, and numbing effects. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol, WS-3.

[0047] An aerosol-forming material is a material that can generate an aerosol when, for example, heated, irradiated, or energized in any other manner. The aerosol-forming material may be, for example, in solid, liquid, or semi-solid (such as a gel) form, which may or may not contain an active agent and / or flavoring.

[0048] The aerosol-generating materials may include one or more active agents and / or flavorings, one or more aerosol former materials, and optionally one or more other functional materials.

[0049] 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.

[0050] 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.

[0051] The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be within the range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

[0052] The aerosol-forming material may include two or more films, and the thicknesses described herein may refer to the combined thickness of the films.

[0053] 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.

[0054] 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. 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.

[0055] The slurry may be heated to remove at least about 60%, 70%, 80%, 85%, or 90% by weight of the solvent.

[0056] An aerosol-generating material may include or be an "amorphous solid." In some embodiments, the aerosol-generating material includes an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid." The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material that may retain some fluid, such as a liquid, within the amorphous solid. In some embodiments, the amorphous solid may comprise, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0057] The amorphous solid may be substantially free of plant material.The amorphous solid may be substantially free of tobacco.

[0058] 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.

[0059] 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.

[0060] The aerosol-generating material may be on or in a support, forming a substrate. The support may be or comprise, for example, paper, card, paperboard, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support includes a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0061] The susceptor is a material that can be heated by penetration by a conveying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that penetration of the conductive material by a 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 a 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.

[0062] 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 in an aerosol modifier-releasing component operable to selectively release the aerosol modifier.

[0063] 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.

[0064] 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.

[0065] 1-7, there are shown schematic cross-sectional end and side views of example consumables 100, 120, 130, 140, 150, 160, 170 according to an embodiment of the present invention. Consumable 100 is for use with an aerosol delivery device 200 for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, such as device 200 shown in FIG. 8 and described below.

[0066] The consumable 100 comprises an outer tube 101 and an inner member 102 inside the outer tube 101. The consumable 100 further comprises at least one support 103. The at least one support 103 supports the inner member 102 relative to the outer tube 101 such that at least one void 104 exists between the inner member 102 and the outer tube 101.

[0067] The consumable 100 further includes an aerosol-generating material 105 that can be heated to generate an aerosol within the at least one void 104. The outer tube 101 includes a tube wall 111. The inner member 102 includes a member wall 113. The consumable 100 further includes a layer 106 of granular material disposed between the outer tube 101 and the inner member 102. That is, the layer 106 of granular material is disposed between the tube wall 111 of the outer tube 101 and the member wall 113 of the inner member 102, as will be described in more detail below.

[0068] The layer of granular material 106 disposed between the tube wall 111 of the outer tube 101 and the member wall 113 of the inner member 102 reduces the volume available for airflow through the at least one gap 104 defined between the tube wall 111 of the outer tube 101 and the member wall 113 of the inner member 102. Thus, providing the layer of granular material 106 between the tube wall 111 of the outer tube 101 and the member wall 113 of the inner member 102 increases the pressure drop through the consumable product 100. This provides the user with an experience more similar to that felt when inhaling from a conventional cigarette.

[0069] At least one gap 104 may have a width in the range of 1 mm to 4 mm. That is, the distance between the tube wall 111 of the outer tube 101 and the member wall 113 of the inner member 102 may be in the range of 1 mm to 4 mm. In some embodiments, at least one gap 104 may have a width in the range of 2 mm to 2.5 mm.

[0070] The layer of particulate material 106 may be breathable. In some embodiments, the layer of particulate material 106 may be formed from an aerosol-forming material, such as reconstituted tobacco. In some embodiments, the layer of particulate material 106 may be formed from a non-aerosol-forming material, such as silica or sand. The layer of particulate material 106 may be formed from, for example, but not limited to, tobacco granules, reconstituted tobacco, or any other particulate material, such as silica or sand.

[0071] The layer of granular material 106 may have an average particle size ranging, for example, but not limited to, from 10 microns to 150 microns. In some embodiments, the layer of granular material 106 may have an average particle size ranging, for example, but not limited to, from 30 microns to 120 microns. The layer of granular material 106 may create a pressure drop ranging, for example, but not limited to, from about 30 to 90 mmWg. In some embodiments, the layer of granular material 106 may create a pressure drop ranging, for example, but not limited to, from about 40 to 60 mmWg. In some embodiments, the layer of granular material 106 may create a pressure drop ranging, for example, but not limited to, from about 10 to 40 mmWg.

[0072] In some embodiments, the consumable 100 may be combined with a filter section (not shown) located at the mouth end of the consumable 100. The filter section may create a pressure drop, for example, but not limited to, in the range of about 15 mmWg to 20 mmWg. In such a consumable, the layer of granular material 106 may create a pressure drop, for example, but not limited to, in the range of about 10 to 40 mmWg.

[0073] Thus, the layer of granular material 106 may be configured to achieve a desired user experience in terms of taste and draw resistance. Additionally, the layer of granular material 106 may be configured to provide the consumable product 100 with a structure that is more resistant to shattering, as described in more detail below.

[0074] At least one support 103 may connect the inner member 102 to the outer tube 101. In some embodiments, the inner member 102 may include a hollow inner tube 102. The hollow inner tube 102 may define a passageway 107 therein. However, in other embodiments, the inner member 102 may be other than tubular, such as a solid rod.

[0075] The consumable 100 in the illustrated exemplary embodiment has circular inner and outer cross-sectional shapes. Additionally, both the outer tube 101 and the inner member 102 are shown as being circular. For example, the outer tube 101 may have a diameter ranging from about 10 mm to about 15 mm. In some embodiments, the outer tube 101 may have a diameter of about 13 mm. However, in other embodiments, one or each of the outer tube 101 and the inner member 102 is non-circular, such as, but not limited to, an oval, polygon, rectangle, square, triangle, or star shape. In some embodiments, the outer tube 101 and / or the inner member 102 are corrugated.

[0076] In this embodiment, the consumable 100 extends along an axis A. Axis A is a central axis that extends along the length of the consumable 100. In this embodiment, the consumable 100 is elongated in the direction of axis A, however, in other embodiments, the width or diameter of the consumable 100 may be equal to or greater than the dimension of the consumable 100 in the direction of axis A such that the consumable 100 is not elongated.

[0077] In this embodiment, the inner member 102 and the outer tube 101 are substantially concentric and each is centered on the axis A. However, in other embodiments, the inner member 102 may be non-concentric with the outer tube 101, and the center of one or each of the inner member 102 and the outer tube 101 may be spaced apart from the axis A.

[0078] As shown in FIG. 1 , the consumable 100 includes at least one support 103. In this embodiment, the consumable 100 includes three supports 103. However, it will be understood that the consumable 100 may include more or fewer supports 103. The supports 103 may be circumferentially spaced apart from one another by gaps 104. In some embodiments, the supports 103 may extend along the entire length of the consumable 100. In some embodiments, the supports 103 may extend along only a portion of the length of the consumable 100.

[0079] In some embodiments, the at least one support 103 may additionally or alternatively comprise a component disposed at an axial end of the consumable 100. The component may be disposed, for example, against the axial end faces of the outer tube 101 and the inner member 102, or two supports may be disposed at the axial ends of the outer tube 101 and the inner member 102, respectively. Such a component may be an end piece. The component may be made of any suitable material, such as, for example, cellulose acetate, paper, or a plastic material. The end piece may have features for receiving the outer tube 101 and the inner member 102, respectively, and may be configured to hold the inner member 102 relative to the outer tube 101.

[0080] The supports 103 may extend from the inner member 102 to the outer member 101 such that each of the supports 103 extends in a generally radial direction. Each of the supports 103 may extend in a radial direction perpendicular to the axis A of the consumable 100. Each of the supports 103 may take the form of a spoke or a fin. Each of the supports 103 may be substantially planar. In some embodiments, the supports 103 may be non-planar, such as curved or corrugated.

[0081] In some embodiments, the at least one support 103 may be formed from a layer 106 of granular material. The layer 106 of granular material may be formed to include at least one channel 109 (see FIG. 7 ) extending through the at least one void 104 of the consumable 170. Alternatively, the layer 106 of granular material may be formed such that there are no defined channels 109 extending through the at least one void 104, except for small air pathways extending through the air-permeable layer 106 of granular material.

[0082] In some embodiments, at least one of the outer tube 101 and the inner member 102 includes an aerosol-generating material 105. That is, the aerosol-generating material 105 contacts the outer tube 101 or the inner member 102 directly or indirectly through another component. For example, the aerosol-generating material 105 may contact the inner member 102 directly or indirectly through the layer of particulate material 106. In some embodiments, the aerosol-generating material 105 may extend along the entire length of the consumable 100. In some embodiments, the aerosol-generating material 105 may extend along only a portion of the length of the consumable 100.

[0083] Additionally, in some embodiments, at least one of the outer tube 101 and the inner member 102 includes a layer of granular material 106. That is, the layer of granular material 106 contacts the outer tube 101 or the inner member 102 directly or indirectly through other components. For example, the layer of granular material 106 may contact the inner member 102 directly or indirectly through the aerosol-generating material 105. In some embodiments, the layer of granular material 106 may extend along the entire length of the consumable 100. In some embodiments, the layer of granular material 106 may extend along only a portion of the length of the consumable 100.

[0084] Thus, in some embodiments, such as shown in Figure 3, the outer tube 101 includes the aerosol-generating material 105 and the layer of particulate material 106. That is, the aerosol-generating material 105 and the layer of particulate material 106 may be layered on the surface of the outer tube 101. In other embodiments, such as shown in Figure 4, the inner member 102 includes the aerosol-generating material 105 and the layer of particulate material 106. That is, the aerosol-generating material 105 and the layer of particulate material 106 may be layered on the surface of the inner member 102.

[0085] In some embodiments, both the outer tube 101 and the inner member 102 include an aerosol-generating material 105 and a layer of particulate material 106. In some embodiments, such as that shown in Figure 1, the outer tube 101 includes a layer of particulate material 106, and the inner member 102 includes an aerosol-generating material 105. In some embodiments, such as that shown in Figure 2, the outer tube includes an aerosol-generating material 105, and the inner member 102 includes a layer of particulate material 106.

[0086] 1 , there is shown a first embodiment of a consumable product 100 according to the present invention. An outer tube 101 comprises a layer 106 of granular material. The outer tube 101 comprises a tube wall 111 having an inner surface 112. The tube wall 111 may be formed from, for example, but not limited to, a paper or plastic material. The layer 106 of granular material may be disposed on the inner surface 112 of the tube wall 111. Thus, the layer 106 of granular material may comprise an inner surface 117 of the outer tube 101 that defines an edge or boundary of at least one void 103.

[0087] The inner member 102 includes an aerosol-generating material 105. The inner member 102 includes a member wall 113 having an outer surface 114. The member wall 115 may be formed, for example, but not limited to, from a paper or plastic material. The aerosol-generating material 105 may be disposed on the outer surface 114 of the member wall 113. Thus, the aerosol-generating material 105 may include an outer surface 116 that defines an edge or boundary of at least one void 103.

[0088] The inner member 102 may optionally further include a carrier 119. The aerosol-generating material 105 may be fixed to the carrier 119. Thus, the carrier 119 may be disposed on the outer surface 114 of the member wall 113. The carrier 119 may be disposed on the inner surface 115 of the aerosol-generating material 105 and on the outer surface 114 of the member wall 113. The aerosol-generating material 105 may be an aerosol-generating film provided on the carrier 119. However, it will be understood that the carrier 119 may be omitted, and the inner surface 115 of the aerosol-generating material 105 may be in direct contact with the outer surface 114 of the member wall 113.

[0089] At least one support 103 may extend between the outer tube 101 and the inner member 102. Thus, the at least one support 103 extends from the inner surface 117 of the layer of particulate material 106 to the outer surface 116 of the aerosol-forming material 105.

[0090] 2, there is shown a second embodiment of a consumable 120 in accordance with the present invention. The second embodiment of the consumable 120 is similar to the first embodiment of the consumable 100 described above in connection with FIG. 1 and will not be described in detail again. Furthermore, like features and components retain their terminology and reference numerals.

[0091] The primary difference between this embodiment and the embodiment shown in FIG. 1 is the location of the aerosol-generating material 105 and the layer of particulate material 106. The outer tube 101 contains the aerosol-generating material 105. The outer tube 101 includes a tube wall 121 having an inner surface 122. The tube wall 121 may be formed, for example, but not limited to, from a paper or plastic material. The aerosol-generating material 105 may be disposed on the inner surface 122 of the tube wall 121. Thus, the aerosol-generating material 105 may include an inner surface 125 of the outer tube 101 that defines the edge or boundary of at least one void 103.

[0092] The outer tube 101 may optionally further include a carrier 129. The aerosol-generating material 105 may be fixed to the carrier 129. Thus, the carrier 129 may be disposed on the inner surface 122 of the tube wall 121. The carrier 129 may be disposed on the outer surface 126 of the aerosol-generating material 105. The aerosol-generating material 105 may be an aerosol-generating film disposed on the carrier 129. However, it will be understood that the carrier 129 may be omitted, and the outer surface 126 of the aerosol-generating material 105 may be in direct contact with the inner surface 122 of the tube wall 121.

[0093] The inner member 102 comprises a layer of granular material 106. The inner member 102 comprises a member wall 123 having an outer surface 124. The member wall 123 may be formed from, for example, but not limited to, a paper or plastic material. The layer of granular material 106 may be disposed on the outer surface 124 of the member wall 123. Thus, the layer of granular material 106 may include an outer surface 128 that defines an edge or boundary of at least one void 103.

[0094] At least one support 103 may extend between the outer tube 101 and the inner member 102. Thus, the at least one support 103 extends from the inner surface 125 of the aerosol-forming material 105 to the outer surface 128 of the layer of particulate material 106.

[0095] 3, there is shown a third embodiment of a consumable 130 in accordance with the present invention. The third embodiment of the consumable 130 is similar to the first and second embodiments of the consumables 100, 120 described above in connection with FIGS. 1 and 2, and therefore will not be described in detail here. Furthermore, like features and components retain their terminology and reference numerals.

[0096] The main difference between this embodiment and the embodiment shown in Figures 1 and 2 is the location of the aerosol-forming material 105 and the layer 106 of particulate material.

[0097] Outer tube 101 includes aerosol-generating material 105 and layer of granular material 106. Outer tube 101 includes a tube wall 131 having an inner surface 132. Tube wall 131 may be formed from, for example, but not limited to, a paper or plastic material. Layer of granular material 106 may be disposed on inner surface 132 of tube wall 131. Layer of granular material 106 may have an inner surface 137.

[0098] The aerosol-generating material 105 may be disposed on the inner surface 137 of the layer of particulate material 106. Thus, the aerosol-generating material 105 may comprise the inner surface 135 of the outer tube 101 that defines the edge or boundary of the at least one void 103.

[0099] Optionally, the outer tube 101 may further include a carrier 139, as shown in FIG. 3 . The aerosol-generating material 105 may be fixed to the carrier 139. Thus, the carrier 139 may be disposed on the inner surface 137 of the layer of granular material 106. The carrier 139 may be disposed on the outer surface 136 of the aerosol-generating material 105. The aerosol-generating material 105 may be an aerosol-generating film disposed on the carrier 139. However, it will be understood that the carrier 139 may be omitted, and the outer surface 135 of the aerosol-generating material 105 may be in direct contact with the inner surface 137 of the layer of granular material 106.

[0100] The inner member 102 may include a member wall 133 having an outer surface 134. The member wall 133 may be formed from, for example, but not limited to, a paper or plastic material. The outer surface 134 of the member wall 133 may define an edge or boundary of at least one void 103.

[0101] At least one support 103 may extend between the outer tube 101 and the inner member 102. Thus, the at least one support 103 extends from the inner surface 135 of the aerosol-forming material 105 to the outer surface 134 of the member wall 133.

[0102] 4, there is shown a fourth embodiment of a consumable 150 in accordance with the present invention. The fourth embodiment of the consumable 140 is similar to the third embodiment of the consumable 130 described above in connection with FIG. 3 and will not be described in detail here. Furthermore, like features and components retain their terminology and reference numerals.

[0103] The main difference between this embodiment and the embodiment shown in FIG. 3 is the order of the layers 106 of aerosol-forming material 105 and particulate material.

[0104] Outer tube 101 includes layer 106 of granular material and aerosol-generating material 105. Outer tube 101 includes a tube wall 141 having an inner surface 142. Tube wall 141 may be formed from, for example, but not limited to, a paper or plastic material. Aerosol-generating material 105 may be disposed on inner surface 142 of tube wall 141. Aerosol-generating material 105 may have inner surface 145.

[0105] The outer tube 101 may optionally further include a carrier 149. The aerosol-generating material 105 may be fixed to the carrier 149. Thus, the carrier 149 may be disposed on the inner surface 142 of the tube wall 141. The carrier 149 may be disposed on the outer surface 146 of the aerosol-generating material 105. The aerosol-generating material 105 may be an aerosol-generating film disposed on the carrier 149. However, it will be understood that the carrier 149 may be omitted, and the outer surface 146 of the aerosol-generating material 105 may be in direct contact with the inner surface 142 of the tube wall 141.

[0106] The layer of particulate material 106 may be disposed on an interior surface 145 of the aerosol-generating material 105. Thus, the layer of particulate material 106 may include an interior surface 147 that defines an edge or boundary of at least one void 103.

[0107] The inner member 102 may include a member wall 143 having an outer surface 144. The member wall 143 may be formed from, for example, but not limited to, a paper or plastic material. The outer surface 144 of the member wall 143 may define an edge or boundary of at least one void 103.

[0108] At least one support 103 may extend between the outer tube 101 and the inner member 102. Thus, the at least one support 103 extends from the inner surface 147 of the layer of particulate material 106 to the outer surface 144 of the member wall 143.

[0109] 5, there is shown a fifth embodiment of a consumable 150 in accordance with the present invention. The fifth embodiment of the consumable 150 is similar to the third and fourth embodiments of the consumables 130, 140 described above in connection with Figures 3 and 4, and therefore will not be described in detail here. Furthermore, like features and components retain their terminology and reference numerals.

[0110] The main difference between this embodiment and the embodiment shown in FIGS. 3 and 4 is that the aerosol-forming material 105 and layer of particulate material 106 form part of the inner member 102 rather than the outer tube 101 .

[0111] The outer tube 101 includes a tube wall 151 having an inner surface 152. The tube wall 151 may be formed from, for example, but not limited to, a paper or plastic material. The inner surface 152 of the tube wall 151 defines an edge or boundary of at least one void 103.

[0112] The inner member 102 may include an aerosol-generating material 105 and a layer of particulate material 106. The inner member 102 may include a member wall 153 having an outer surface 154. The member wall 153 may be formed from, for example, but not limited to, a paper or plastic material. The aerosol-generating material 105 may be disposed on the outer surface 154 of the member wall 153. The aerosol-generating material 105 may have an outer surface 156.

[0113] 5, the inner tube 102 may optionally further include a carrier 159. The aerosol-generating material 105 may be fixed to the carrier 159. Thus, the carrier 159 may be disposed on the outer surface 154 of the member wall 153. The carrier 159 may be disposed on the inner surface 155 of the aerosol-generating material 105. The aerosol-generating material 105 may be an aerosol-generating film provided on the carrier 159. However, it will be understood that the carrier 159 may be omitted, and the inner surface 155 of the aerosol-generating material 105 may be in direct contact with the outer surface 154 of the member wall 153.

[0114] The layer of particulate material 106 may be disposed on an outer surface 156 of the aerosol-generating material 105. Thus, the layer of particulate material 106 may include an outer surface 158 that defines an edge or boundary of at least one void 103.

[0115] At least one support 103 may extend between the outer tube 101 and the inner member 102. Thus, the at least one support 103 may extend from the inner surface 152 of the tube wall 151 of the outer tube 101 to the outer surface 158 of the layer of granular material 106 of the inner member 102.

[0116] 6, there is shown a sixth embodiment of a consumable 160 in accordance with the present invention. The sixth embodiment of the consumable 160 is similar to the fifth embodiment of the consumable 150 described above in connection with FIG. 5 and will not be described in detail again. Furthermore, like features and components retain their terminology and reference numerals.

[0117] The main difference between this embodiment and the embodiment shown in FIG. 6 is the order of the layers 106 of aerosol-forming material 105 and particulate material.

[0118] The outer tube 101 includes a tube wall 161 having an inner surface 162. The tube wall 161 may be formed from, for example, but not limited to, a paper or plastic material. The inner surface 162 of the tube wall 161 defines an edge or boundary of at least one void 103.

[0119] The inner member 102 may include an aerosol-generating material 105 and a layer of granular material 106. The inner member 102 may include a member wall 163 having an outer surface 164. The member wall 163 may be formed from, for example, but not limited to, a paper or plastic material. The layer of granular material 106 may be disposed on the outer surface 164 of the member wall 163. The layer of granular material 106 may have an outer surface 168.

[0120] The aerosol-generating material 105 may be disposed on an outer surface 168 of the layer of particulate material 106. Thus, the aerosol-generating material 105 may have an outer surface 166 that defines an edge or boundary of at least one void 103.

[0121] The inner tube 102 may optionally further include a carrier 169. The aerosol-generating material 105 may be fixed to the carrier 169. Thus, the carrier 169 may be disposed on the outer surface 168 of the layer of granular material 106. The carrier 169 may be disposed on the inner surface 165 of the aerosol-generating material 105. The aerosol-generating material 105 may be an aerosol-generating film provided on the carrier 169. However, it will be understood that the carrier 169 may be omitted, and the inner surface 165 of the aerosol-generating material 105 may be in direct contact with the outer surface 168 of the layer of granular material 106.

[0122] 8 illustrates a system including consumables 100, 120, 130, 140, 150, 160, 170 and a non-combustion aerosol delivery device 200. Non-combustion aerosol delivery device 200 includes an area 201 for receiving consumable 100 and an aerosol generator 202. Aerosol generator 202 is configured to heat aerosol-generating material A of consumable 100 when consumable 100 is received within area 201 to generate an aerosol for inhalation by a user.

[0123] Non-combustion aerosol delivery device 200 further comprises power source 203, controller 204, and puff sensor 205. In use, a user first inserts distal end B of consumable 100 into an area for receiving consumable 201 and activates aerosol generator 202 to generate an aerosol for inhalation. The user may then draw on mouth end C of consumable 100, or alternatively, draw on a mouthpiece (not shown) of non-combustion aerosol delivery device 200 to inhale the aerosol.

[0124] In the illustrated example, consumable 100 and non-combustion aerosol delivery device 200 are configured so that mouth end C protrudes from area 201 for receiving consumable 100 when mouth end C is fully inserted into non-combustion aerosol delivery device 200. Thus, mouth end C is available to be placed between a user's lips while the user is holding the device.

[0125] Puff sensor 205 is configured to detect when a user inhales on mouth end C of consumable 100 in non-combustion aerosol delivery device 200 and send a signal to controller 204 to activate aerosol generator 202. Thus, aerosol is generated simultaneously with the user inhaling the consumable. Alternatively, non-combustion aerosol delivery 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.

[0126] Aerosol generator 202 includes any suitable means for heating aerosol-generating material A of consumable 100 received within region 201 of non-combustion aerosol delivery device 200. Power for aerosol generator 202 is provided by power source 203, which in the illustrated example is a power source 203 such as a battery 203.

[0127] 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 201 for receiving the consumable 100. This example is used when the consumable 100 includes a susceptor that is in thermal contact with an aerosol-generating material A. Thus, when such a consumable 100 is placed within the non-combustion aerosol-delivery device 200 and the aerosol generator 202 is activated, the transport magnetic field penetrates the susceptor of the consumable 100 and heats the aerosol-generating material A that is in thermal contact with the susceptor, generating an aerosol for inhalation by a user.

[0128] 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 non-combustion aerosol delivery device 200 and the aerosol generator 202 is activated, the varying magnetic field penetrates the susceptor and heats the region 201 where the consumable 100 is received. The heat is transferred to the aerosol-generating material A of the consumable 100, generating an aerosol for inhalation by the user.

[0129] 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. Thus, the susceptor may be directly positionable within the consumable 100.

[0130] The susceptor may be positionable within one or more of the outer channels 13 or directly within the central channel 14, depending on the configuration of the susceptor. In one example, the susceptor includes protrusions configured for positioning within the outer channels 13. In such an example, the susceptor is optimized for use with a consumable 100 including section 1, as shown in the example of FIG. 1 or FIG. 3a. In another example, the susceptor includes protrusions configured for positioning only within selected outer channels 13. In such an example, the susceptor is optimized for use with a consumable 100 including section 1, as shown in the example of FIG. 4a. In particular, the protrusions may be configured for positioning only within the outer channel 14 adjacent to the outer channel 14 containing the aerosol-generating material 15. In another example, the susceptor includes protrusions configured for positioning within the central channel 14. In such an example, the susceptor is optimized for use with a consumable 100 including section 1, as shown in the example of FIG. 4a, FIG. 5a, or FIG. 6a.

[0131] It will be appreciated that in each of the exemplary susceptor configurations described above, the susceptor is configured to be positioned in proximity to, but prevented from direct contact with, aerosol-forming material A.

[0132] 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 is placed in the non-combustion aerosol delivery device 200 and the aerosol generator 202 is activated, an electric current is passed through the material to heat the area 201 for receiving the consumable 100. The heat is transferred to the aerosol-generating material A of the consumable 100, generating an aerosol for inhalation by the user. In such an embodiment, the material may be a wall of the area 201 for receiving the consumable 100, and the consumable 100 may be configured to be in direct contact with the wall for efficient heat transfer.

[0133] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be construed as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it should be understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. A consumable for use with an aerosol delivery device, the consumable comprising: An outer tube; an inner member inside the outer tube; at least one support supporting the inner member relative to the outer tube such that at least one gap exists between the inner member and the outer tube; Including, the consumable includes an aerosol-forming material that can be heated to generate an aerosol in the at least one void; the outer tube having a tube wall and the inner member having a member wall; A consumable article, wherein a layer of granular material is disposed between the tube wall of the outer tube and the member wall of the inner member.

2. The consumable of claim 1 , wherein the layer of granular material is breathable.

3. The consumable product of claim 1 or claim 2, wherein the particulate material comprises silica.

4. 3. The consumable product of claim 1 or claim 2, wherein the particulate material is an aerosol-forming material.

5. The consumable according to any one of claims 1 to 4, wherein the at least one support comprises a component located at an axial end of the consumable.

6. The consumable product of any one of claims 1 to 5, wherein at least one of the inner member and the outer tube comprises an aerosol-forming material.

7. The consumable product of claim 6 , wherein at least one of the inner member and the outer tube comprises a layer of the granular material.

8. The consumable product of claim 7 , wherein the inner member includes a layer of the aerosol-forming material and the granular material, the layer of granular material being located closer to the inner member than the aerosol-forming material.

9. The consumable product of claim 7 , wherein the inner member includes a layer of the aerosol-forming material and the granular material, the aerosol-forming material being located closer to the inner member than the layer of granular material.

10. 10. The consumable product of claim 7, wherein the outer tube comprises a layer of the aerosol-forming material and the granular material, the layer of granular material being located closer to the outer tube than the aerosol-forming material.

11. The consumable product of any one of claims 7 to 9, wherein the outer tube comprises a layer of the aerosol-forming material and the particulate material, the aerosol-forming material being located closer to the outer tube than the layer of particulate material.

12. The consumable product of claim 7 , wherein one of the outer tube and the inner member includes an aerosol-forming material, and the other of the outer tube and the inner member includes the layer of granular material.

13. The consumable product of any one of claims 6 to 12, wherein at least one of the inner member and the outer tube comprises a carrier, and the aerosol-forming material is fixed to the carrier.

14. 14. The consumable product of claim 13, wherein the aerosol-forming material is an aerosol-forming film disposed on the carrier.

15. 15. A consumable product according to claim 13 or claim 14, wherein the layer of particulate material is the carrier.

16. The consumable product of any one of claims 1 to 15, wherein at least one of the inner member and the outer tube is circular.

17. The consumable product of any one of claims 1 to 15, wherein at least one of the inner member and the outer tube is non-circular.

18. 1. A system comprising: A consumable product according to any one of claims 1 to 17; an aerosol delivery device; A system comprising:

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