Consumables

Abstract

A consumable (100) for use with a non-combustion aerosol delivery device (200), the consumable (100) comprising a core, the core comprising a twisted rope-like structure of at least two strands of material (102), at least one strand of material (102) comprising an aerosol-generating material (105).

Description

[Technical Field]

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

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

[0003] In a first aspect of the present invention, there is provided a consumable for use with a non-combustion aerosol delivery device, the consumable comprising a core, the core comprising a twisted rope-like structure of at least two strands of material, at least one strand of material comprising an aerosol-generating material.

[0004] In a second aspect of the present invention, there is provided a method of producing the consumable product of the first aspect, comprising the steps of: providing at least two strands of material, at least one of the strands of material including an aerosol-generating material; forming a stranded rope-like structure of the at least two strands of material; A method is provided which includes:

[0005] In a third aspect of the present invention, there is provided a non-combustion aerosol delivery system comprising: a consumable product according to the first aspect; A non-combustion aerosol delivery system is provided, comprising: a non-combustion aerosol delivery device for heating a consumable aerosol-generating material to generate an aerosol, the non-combustion aerosol delivery device comprising an area for receiving the consumable; and an aerosol generator for causing the heating of the aerosol-generating material when the consumable is within the area.

[0006] Embodiments of the present invention will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0007] [Figure 1] 1 illustrates exemplary consumables. [Figure 2a] An example of a consumable item is shown in cross section. [Figure 2b] Another example of a consumable is shown in cross section. [Figure 2c] Another example of a consumable is shown in cross section. [Figure 2d] Another example of a consumable is shown in cross section. [Figure 2e] Another example of a consumable is shown in cross section. [Figure 3] FIG. 10 is a schematic diagram of another example of a consumable item. [Figure 4] 1 illustrates a schematic of a system including a consumable and a non-combustion aerosol delivery device. [Figure 5] Another example of a consumable item is shown. [Figure 6] 1 shows schematically the steps of a method for manufacturing a consumable product. [Figure 7] 1 illustrates a schematic cross-sectional view of a consumable product according to an example of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0008] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user, including non-combustion aerosol delivery systems that release compounds from an aerosol-forming material without burning the aerosol-forming material, such as electronic cigarettes, tobacco heating products, and hybrid systems that generate an aerosol using a combination of aerosol-forming materials.

[0009] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials (or components of those materials) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0010] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0011] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system.

[0012] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0013] The non-combustion aerosol delivery systems described herein include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0014] The present disclosure relates to consumables, sometimes referred to as articles throughout this disclosure, that include aerosol-forming materials and are configured for use with non-combustion aerosol delivery devices.

[0015] In some embodiments, a non-combustion aerosol delivery system, such as a non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, an electrical power source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol-generating material or a heat-transfer material proximate the heat-generating power source.

[0016] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0017] In some embodiments, a consumable for use with a non-combustion aerosol delivery device may include an aerosol-generating material, an aerosol-generating material storage region, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating region, a housing, a packaging material, a filter, a mouthpiece, and / or an aerosol modifier. The consumable may also include an aerosol generator, such as a heater, that generates heat upon use to cause the aerosol-generating material to generate an aerosol. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0018] In some embodiments, the substance to be delivered may be an aerosol-generating material or a material not intended to be aerosolized. Optionally, either material may include one or more active ingredients, one or more flavors, one or more aerosol-former materials, and / or one or more other functional materials.

[0019] In some embodiments, the substance to be delivered comprises an active agent.

[0020] As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. The active substance may be naturally derived or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another plant material.

[0021] In one embodiment, the active substance is a legally permitted recreational drug. In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0022] As described herein, the active substance may include one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

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

[0024] 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.

[0025] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0026] In some embodiments, the substance to be delivered comprises a flavor.

[0027] As used herein, the terms "flavor" and "flavoring agent" refer to materials that may be used, where local regulations permit, to create a desired taste, aroma, or other somatic sensation in products intended for adult consumers.They include naturally occurring flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, Tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, eggplant, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang ylang , sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, peppermint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, bay leaf, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damiento, maize The present invention may also include other additives such as joram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be of imitation, synthetic, or natural origin, or blends thereof. They may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

[0028] 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.

[0029] 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.

[0030] Aerosol-Generating Materials 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.

[0031] 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.

[0032] 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.

[0033] 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.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] 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.

[0038] The slurry may be heated to remove at least about 60%, 70%, 80%, 85%, or 90% by weight of the solvent.

[0039] The aerosol-forming material may include an aerosol-forming agent, a binder, optionally a filler, and optionally an active agent and / or a flavoring agent.

[0040] 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.

[0041] 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.

[0042] 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.

[0043] 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.

[0044] An aerosol modifier is a substance, typically located downstream of the aerosol-generation area, configured to modify the generated aerosol, for example, by changing the taste, flavor, acidity, or another property of the aerosol. The aerosol modifier may be provided within an aerosol modifier-releasing component operable to selectively release the aerosol modifier.

[0045] 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.

[0046] 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.

[0047] Figure 1 shows a consumable 100 for use with a non-combustion aerosol delivery device, such as non-combustion aerosol delivery device 200 shown schematically in Figure 4. Consumable 100 comprises a core 101 comprising a twisted rope-like structure of at least two strands 102 of material. At least one of the strands 102 of material includes an aerosol-generating material 105.

[0048] Non-combustion aerosol delivery device 200 comprises an area 201 for receiving consumable product 100 and an aerosol generator 202. Aerosol generator 202 is configured to heat aerosol-generating material 105 of consumable product 100 when consumable product 100 is received within area 201 to generate an aerosol for inhalation by a user, as described further below.

[0049] 2a-2e illustrate an exemplary consumable 100 in cross section. Each cross section is projected onto a plane that bisects the consumable 100 perpendicular to its longitudinal axis. In each example, the core 101 of each consumable 100 includes three strands 102; however, it will be understood that any of the examples may include only two strands 102, or more than two strands 102, such as four or five strands 102. While the illustrated strands 102 include circular cross sections, it will be understood that other cross-sectional shapes may be used as long as the resulting strands can be twisted together to form a rope-like structure. In some examples described herein, the diameter of each strand 102 is between 0.1 mm and 5 mm, or between 1 mm and 3 mm. In one example, the diameter of each strand 102 is approximately 2 mm.

[0050] In the example of FIG. 2a, each strand is formed from an absorbent material 104. The absorbent material 104 is provided with an aerosol-generating material 105. For example, the aerosol-generating material 105 may be provided as an additive to the absorbent material 104. In some examples, the absorbent material 104 may be doped with the aerosol-generating material 105 in liquid form so that the aerosol-generating material 105 is absorbed by the absorbent material 104. The absorbent material 104 may be any material suitable for absorbing the aerosol-generating material 105 described herein. The absorbent material 104 may be a fibrous material or may be plant-based. In one example, the absorbent material 104 is crimped and gathered paper. The aerosol-generating material 105 may include an aerosol-former material, as defined above. Thus, when the consumable product 100 is heated during use, the aerosol-former material evaporates to form an aerosol for inhalation by the user. The aerosol-generating material 105 may include one or more active substances, one or more flavors, and / or one or more other functional materials, as defined above. In one example, the absorbent material 104 is provided with the aerosol-generating material 105 including an aerosol former material including glycerol, a flavor, and an active substance including nicotine. Optionally, the absorbent material 104 is a reconstituted tobacco material formed as absorbent tobacco paper. Thus, the absorbent material 104 further provides flavor to the aerosol former material when the consumable is heated during use.

[0051] When strands 102 of reconstituted tobacco material are used, the strands 102 may be provided in strips of reconstituted tobacco material. The reconstituted tobacco strands may be longitudinal strips. The reconstituted tobacco material may be, for example, band-cast reconstituted tobacco material or paper reconstituted tobacco material. In some embodiments, the strands are provided as flat strips of reconstituted tobacco. The strips may have widths of 0.25 mm to 2 mm, thicknesses of 30 to 1000 μm, or 30 to 300 μm, and densities ranging from about 20 to 250 grams per square meter. The strips may have width-to-thickness ratios of 0.25 to 70, or 1 to 10.

[0052] To form the core 101, the strips are arranged in parallel and gathered into a bundle before twisting into a rope-like structure according to method 60 described below with reference to FIG. 6. While any number of strands can be used, in some instances, 100 to 300 strands can be used to form the core. In some instances, the core is made of a material having a density of 0.1 g / cm 3 ~0.9g / cm 3 The density may be

[0053] An advantage of twisting strips of reconstituted tobacco material into a rope-like structure is that the strips are interlocked and do not easily displace. This is particularly beneficial when the consumable is used with a non-combustion aerosol delivery device 200 that includes a pin or blade heater that extends into the area 201 for receiving the consumable 100. The pin or blade heater is configured to penetrate the consumable 100 along its axis to heat the aerosol-generating material 105. It has been found that consumables that include strands of reconstituted tobacco material that are not twisted into a rope-like structure tend to be displaced by such heaters, leaving debris in the area 201 for receiving the consumable. During longer-term use of the device, this debris can accumulate, compromising heater efficiency and hygiene.

[0054] In another example shown in FIG. 2b, each strand 102 includes a homogenized structure 106 of aerosol-generating material 105, which includes an aerosol-forming agent, a binder, optionally a filler, and optionally an active agent and / or a flavoring. In the illustrated example, each strand 102 is a monolithic solid; that is, each strand is cast as a single piece. For example, each strand 102 may be an extruded portion of aerosol-generating material 105. When the consumable product 100 is heated during use, volatile components of the aerosol-generating material 105 evaporate to form an aerosol for inhalation by the user.

[0055] The exemplary consumable 100 shown in FIG. 2c is the same as the example of FIG. 2b, except that each strand 102 further includes a material 107 heatable by penetration by a varying magnetic field, referred to herein as a susceptor 107. In the illustrated example, the susceptor 107 is embedded in each strand 102 of the consumable 100. Such exemplary consumable 100 is configured for use with a device 200 including an aerosol generator 202 configured to generate a varying magnetic field that penetrates an area 201 for receiving the consumable 100, as described further below. Thus, when the consumable 100 is used with such a device 200, the varying magnetic field heats the susceptor 107 of each strand 102, thereby heating the aerosol-generating material 105 and forming an aerosol for inhalation by a user. In the illustrated example, the susceptor 107 of each strand 102 includes a twisted rope-like structure. However, it will be understood that the susceptor 207 may take any form suitable for integration into the strands 102. Thus, the susceptors 207 are preferably formed from a resilient, flexible material that allows them to follow the helical path of the strands 102 in which they are embedded. In the illustrated example, each susceptor 107 is substantially centrally embedded within the strands 102. Such an exemplary consumable 100 can be formed by extruding strands 102 of aerosol-generating material 105 around a continuous length of susceptor 107. Each strand 102 is then cut to length and twisted around at least one other such strand 102 to form the rope-like structure of the core 101, as described further below.

[0056] In another example, not shown, each strand 102 includes a susceptor 107 embedded in the strand 102 formed from a material other than the homogenizing structure 106 of the aerosol-generating material 105. It will be understood that the susceptor 207 may be embedded in any of the strands 102 described herein. For example, the susceptor 207 may be embedded in a strand 102 of absorbent material, such as the strand 102 described in connection with FIG. 2a. Such an exemplary strand 102 may be formed by gathering absorbent material 104 around a continuous length of susceptor 107. Each resulting strand 102 is then cut to length and twisted around at least one other such strand 102 to form the rope-like structure of the core 101, as further described below with reference to the method of FIG. 6.

[0057] The exemplary consumable product shown in FIG. 2d further includes an outer wrapping material 108 surrounding the core 101. The illustrated strands 102 represent any of the strands 102 described above, including strands 102 of absorbent material 104 and strands including a homogenized structure 106 of aerosol-generating material 105. In such an example, the consumable product 100 has a smooth, generally cylindrical appearance. The outer wrapper 108 forms the outer surface of the consumable product 100. Thus, by encasing the core 101 in the outer wrapper 108, a user does not need to directly handle the core 101. This can be beneficial in preventing any of the aerosol-generating material 105 from transferring to the user where the user touches the consumable product 100. An additional benefit of the outer wrapper 108 is that air flow channels 109 are formed between the outer wrapper 108 and the core 101. The air flow channels 109 follow the spiral grooves formed between the strands 102 of the rope-like structure. The air flow channels 209 form a helical airflow path that extends from the distal end 100" of the consumable to the mouth end 100'. Due to their helical shape, the length of the helical airflow path formed by the air flow channels 209 is longer than if the airflow path were straight. That is, the length of the helical airflow path is longer than a straight airflow path extending over the same axial length of the consumable 100. Thus, the residence time of air drawn through the consumable 100 is longer than if the airflow path were straight. This causes more of the components of the aerosol formed during use to be entrained in the air drawn along the airflow path. Another effect of a helical airflow path is that the pressure drop across the consumable is greater than if the airflow path were straight.

[0058] It will be appreciated that the length of the airflow path can be affected by the pitch P of the helix formed by each strand 102 of the core 101. The pitch P of the helix formed by each strand 102 of the core is defined as the length of one complete turn of the strand 102, measured parallel to the longitudinal axis XX of the consumable 100. FIG. 1 shows a pitch P for a core 101 with three strands 102. Increasing the pitch P decreases the pressure drop of the consumable 100 and the residence time of air drawn through the consumable. In one example, the pitch P is 0.2 to 1.5 times the diameter D of the helix formed by each strand 102.

[0059] The outer wrapper 108 may extend along the entire length of the core 101, as shown in FIG. 5, or may extend only partially along the length of the core 101. In the example of FIG. 5, the outer wrapper 108 extends from the mouth end 100′ of the consumable 100 over a portion of the length of the core 101. The mouth end 101′ of the consumable 100 is defined herein as the portion of the consumable 100 that is positioned between a user's lips so that the user can draw on the consumable 100. Thus, the user's lips do not come into contact with the aerosol-generating material 105 during use. Alternatively, the device 200 may include a mouthpiece (not shown) that movably surrounds an area 201 for receiving the consumable 100. In such an example, when the consumable 100 is inserted into said area 201, the mouthpiece may be moved to surround said area 201 and positioned between the user's lips so that the user can draw on the mouthpiece and inhale the aerosol generated during use of the device 200. Advantageously, the outer wrapper 108 may be omitted entirely from a consumable 100 configured for use with a mouthpiece-equipped device 200. The consumable 100 may be sized to fit closely against the wall 207 of the area for receiving the consumable, such that when the consumable 100 is inserted into said area 201, an air flow path is instead formed between the core 101 of the consumable 100 and the wall 207.

[0060] The outer wrapper 108 may be made of any suitable wrapping material, such as cigarette paper.

[0061] The exemplary consumable product 100 shown in FIG. 2e is the same as the example of FIG. 2d, except that the outer wrapper 108 is a laminate including first and second layers 110, 111. The first layer is the outer layer 110 and includes paper, such as cigarette paper. The second layer 111 is an inner layer and includes a material that can be heated by penetration by a varying magnetic field. The inner layer is referred to herein as a susceptor 111. Such exemplary consumable product 100 is configured for use with a device 200 including an aerosol generator 202 configured to generate a varying magnetic field that penetrates a region 201 for receiving the consumable product 100, as described further below. Thus, when the consumable product 100 is used with such a device 200, the susceptor 111 is heated by the varying magnetic field, heating the aerosol-generating material 105 of the adjacent strands 102 and forming an aerosol for inhalation by a user.

[0062] In the examples described herein, the pitch circle diameter PCD of the strands 102 is about 4 mm to 12 mm, or about 5 mm to 11 mm, or about 6 mm to 9 mm. In one example, the pitch circle diameter PCD of the strands 102 is about 7 mm, or about 8 mm, or about 9 mm, or about 10 mm.

[0063] By "pitch circle diameter PCD" is meant the diameter of a circle passing through the center C of each strand 102. This is shown schematically in Figure 7. By "center C of each strand" is meant the centerline C that follows the helical path of each strand 102. Selecting the pitch circle diameter PCD according to the above example can ensure that the consumable provides adequate retraction resistance during use and that the above-mentioned helical airflow path is sized to generate an adequate amount of aerosol therein when the consumable is heated.

[0064] The consumable 100 can include any number of additional components 90 for attachment to any of the stranded rope-like cores 101 described above. Alternatively, the consumable 100 may consist solely of the core 101 (e.g., if the consumable 100 is configured for use with a device 200 that includes a mouthpiece). If the consumable 100 includes additional components 90, the additional components 90 may be, for example, a filter component 91, as shown in the exemplary consumable 100 of FIG. 3 . Other components 90 may include a cooling section or other sections containing aerosol-generating material, as known in the art. The filter component 91 may be a paper filter component or a cellulose filter component. Preferably, any additional component 90 has substantially the same outer diameter as the core 101 to which it is attached. Thus, the additional component 90 may be attached by overlapping layers of wrapping material, such as the outer wrapping material 108.

[0065] The inclusion of the filter component 91 advantageously allows for more precise control of the closing pressure drop or resistance to draw of the consumable 100. For example, the closing pressure drop can be controlled by setting the density of the filter material within the filter component or by increasing or decreasing the axial length of the filter component 91. The filter component 91 may be attached to either the mouth end 100' or the distal end 100", as shown in FIG. 3.

[0066] In one example, the closed pressure drop of the consumable 100 is in the range of approximately 30-90 mmWg. In another example, the closed pressure drop of the consumable 100 is in the range of approximately 40-60 mmWg.

[0067] 6 schematically illustrates a method 60 of forming an example consumable product 100 described herein. The method includes providing 61 at least two strands of material 102, at least one of the strands including an aerosol-generating material 105, and forming 62 a stranded rope-like structure of the at least two strands of material 102. In some examples, the method further includes wrapping 63 the stranded rope-like structure 101 with a wrapping material 108.

[0068] In some examples, providing 61 at least two strands of material 102 includes providing at least two strands of absorbent material 104 and doping 64 each strand of absorbent material with an aerosol-forming material. Doping 64 may include doping 64 with a liquid aerosol-forming material such that absorbent material 104 absorbs liquid aerosol-forming material 105.

[0069] In some examples, providing 61 at least two strands 102 includes extruding 65 strands 102 of aerosol-forming material 105, including an aerosol-forming agent, a binder, optionally a filler, and optionally an active agent and / or a flavoring. In such examples, the aerosol-forming material 105 may be a homogenized structure 106 of aerosol-forming material 105.

[0070] In some examples, forming 62 the stranded rope-like structure includes bundling strands 102 next to one another and twisting the ends of the bundles to form helical strands 102 that extend around one another. It should be understood that such stranded rope-like structures differ from other common rope-like structures, such as braided structures. Braided structures differ from stranded structures in that the individual strands are interwoven in a braided structure but not in a twisted structure. It should be further understood that braided structures do not provide the helical flow paths described above. Any such flow paths are destroyed by weaving such braided structures.

[0071] 4 shows a system including a consumable 100 and a non-combustion aerosol delivery device 200. The device includes a power source 203, a controller 204, and a puff sensor 205. In use, a user inserts the consumable 100 into area 201 for receiving the consumable and activates aerosol generator 202 to generate an aerosol for inhalation. The user can then inhale the aerosol by drawing on the consumable 100, or alternatively, on a mouthpiece (not shown) of device 200. In the illustrated example, consumable 100 and device 200 are configured such that mouthpiece end 100' of consumable 100 protrudes from area 201 for receiving consumable 100 when fully inserted into device 200. Thus, consumable 100 is available to be placed between a user's lips while the user is holding device 200.

[0072] The puff sensor 205 is configured to detect when a user is inhaling the consumable 100 in the device 200 and send a signal to the controller 204 to activate the aerosol generator 202. Thus, aerosol is generated simultaneously when the user inhales the consumable 100. Alternatively, the device 200 may be provided with a user interface, such as a button (not shown), that the user can interact with to cause activation of the aerosol generator 202.

[0073] The area 201 for receiving the consumable 100 is provided with an inlet (not shown) that allows air to enter the area 201 for passage through the consumable 100 when a user inhales on the mouth end 100' of the consumable 100. Thus, when a user inhales on the consumable 100, a flow of air is directed through the consumable 100. More specifically, the air flow is directed along the airflow path of the consumable 100. The air flow entrains an aerosol generated by the aerosol-generating material 105 of the consumable 100 when heated by the aerosol generator 202.

[0074] Aerosol generator 202 includes any suitable means for heating consumable aerosol-generating material 105 received in said region 201 of device 200. Power for aerosol generator 202 is provided by power source 203, which in the illustrated example is a power source 203 such as a battery 203.

[0075] In one example, the aerosol generator 202 comprises a magnetic field generator configured to generate a varying magnetic field that penetrates the region 201 for receiving the consumable 100. The varying magnetic field heats the susceptors 107, 111 disposed within the region 201 for receiving the consumable 100 by magnetic hysteresis. Thus, this example can be used with a consumable 100 that includes a material that can be heated by a varying magnetic field, as described above. Thus, when such a consumable 100 is placed within the device 200 and the aerosol generator 202 is activated, the varying magnetic field penetrates the material of the consumable 100, heating the aerosol-generating material 105 in thermal contact with the material and generating an aerosol for inhalation by a user.

[0076] In another example, the aerosol generator 202 includes a susceptor in thermal contact with the region 201 for receiving the consumable and a magnetic field generator for generating a varying magnetic field that penetrates the susceptor. The varying magnetic field heats the susceptor by magnetic hysteresis. The susceptor then heats the region 201 for receiving the consumable. Thus, when the consumable 100 is placed in the device 200 and the aerosol generator 202 is activated, the varying magnetic field penetrates the susceptor and heats the region 201 for receiving the consumable 100. The heat is transferred to the aerosol-generating material 105 of the consumable 100, generating an aerosol for inhalation by the user. In such an embodiment, the susceptor may be a wall 207 of the region 201 for receiving the consumable 100, and the consumable 100 may be configured to be in direct contact with the wall 207 for efficient heat transfer.

[0077] In another example, the aerosol generator 202 includes a material that can be heated by electrical conduction, and the material is provided in thermal contact with the area 201 for receiving the consumable 100. Thus, when the consumable 100 is placed in the device 200 and the aerosol generator 202 is activated, an electric current passes through the material, heating the area 201 for receiving the consumable 100. The heat is transferred to the aerosol-generating material 105 of the consumable 100, generating an aerosol for inhalation by the user. In such an embodiment, the material may be a wall 207 of the area 201 for receiving the consumable 100, and the consumable 100 may be configured to be in direct contact with the wall 207 for efficient heat transfer.

Claims

1. A consumable for use with a non-combustion aerosol delivery device, the consumable comprising a core, the core comprising a twisted rope-like structure of at least two strands of material, at least one of the strands of material comprising an aerosol-generating material.

2. The consumable of claim 1 , wherein the core comprises three or more strands of material.

3. 3. The consumable of claim 1 or claim 2, wherein each strand of material comprises an absorbent material.

4. The consumable of claim 2 , wherein the absorbent material is mixed with an aerosol-forming material.

5. 3. The consumable product of claim 1 or claim 2, wherein each strand of material comprises an aerosol-forming material.

6. the aerosol-forming material is an aerosol former; and a binder; and optionally a filler; Optionally, an active agent and / or a flavoring agent; and 6. The consumable product of claim 5, comprising:

7. 7. The consumable of claim 6, wherein each strand of material consists solely of aerosol-forming material.

8. A consumable product according to any preceding claim, wherein each strand of material comprises a generally circular cross-section.

9. 9. The consumable of claim 8, wherein the diameter of each strand of material is between 0.1 mm and 5 mm.

10. 10. The consumable of claim 9, wherein each strand of material has a diameter of about 2 mm.

11. 6. The consumable product of any one of claims 1 to 5, wherein each strand comprises reconstituted tobacco material, optionally said reconstituted tobacco material comprising reconstituted tobacco paper, optionally said reconstituted tobacco paper having a thickness of 30 to 300 μm.

12. 12. The consumable of claim 11, wherein each strand comprises a strip having a width of between 0.25 mm and 2 mm.

13. The core is 0.1 g / cm ３ ~0.9 g / cm ３ 13. The consumable product of claim 11 or claim 12, comprising a density of:

14. The consumable product of any one of claims 1 to 13, wherein the core is enclosed in an outer wrapper to form a rod-shaped section comprising the core enclosed in the outer wrapper.

15. 15. The consumable product of claim 14, wherein the outer wrapper comprises a material that is heatable by penetration by a varying magnetic field.

16. A consumable product according to any one of the preceding claims, wherein at least one of the strands comprises a material that can be heated by penetration by a fluctuating magnetic field.

17. The consumable product of any one of claims 1 to 16, wherein the strands (102) have a pitch diameter of about 4 mm to 12 mm.

18. A method for producing a consumable product according to any one of claims 1 to 17, comprising the steps of: providing at least two strands of material, at least one of the strands of material comprising an aerosol-forming material; forming a stranded rope-like structure of the at least two strands of material; A method comprising:

19. 20. The method of claim 18, wherein the at least two strands of material are absorbent material, the method including doping each strand of material with an aerosol-forming material.

20. 20. The method of claim 18, wherein the at least one strand of material is formed by extruding an aerosol-forming material comprising a binder, a gelling agent, and an aerosol former material.

21. The method of any one of claims 18 to 20, further comprising the step of encasing the stranded rope-like structure in an outer wrapper.

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

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