Consumables and non-combustible aerosol supply systems

Abstract

A consumable (100) for use with an aerosol supply device (200). The consumable comprises an open airflow channel (111) extending between several open ends (112, 113) of the consumable, and an aerosol generating section configured to generate an aerosol in at least a portion of the open airflow channel during use. The pressure drop across the consumable is greater than about 50 mmWg at a volumetric flow rate of about 17.5 ml / s. A non-combustible aerosol supply system comprising such a consumable is also disclosed.

Description

[Technical Field]

[0001] This disclosure relates to components for an aerosol supply system or an article for use as an aerosol supply system, an article for use in an aerosol supply system or an aerosol supply system, and methods for forming components for an aerosol supply system or an article for use as an aerosol supply system. [Background technology]

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

[0003] In a first aspect of the present invention, a consumable is provided for use with an aerosol supply device, the consumable comprising an open airflow channel extending between a plurality of open ends of the consumable, and an aerosol generating section configured to generate an aerosol in at least a portion of the open airflow channel during use, wherein the pressure drop across the consumable is greater than about 50 mmWg at a volumetric flow rate of about 17.5 ml / s.

[0004] A second aspect of the present invention provides a non-combustible aerosol supply system comprising a consumable of the first aspect and a non-combustible aerosol supply 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 in the area.

[0005] Next, embodiments of the present invention will be described with reference to the accompanying drawings, merely as non-limiting examples. [Brief explanation of the drawing]

[0006] [Figure 1] A schematic diagram of a system including consumables and a non-combustible aerosol supply device is shown. [Figure 2] This shows a cross-section of a consumable item projected onto a plane parallel to its longitudinal axis. [Figure 3] This shows a cross-section of a consumable item projected onto a plane perpendicular to its longitudinal axis. [Figure 4] This shows a cross-section of a consumable item projected onto a plane perpendicular to its longitudinal axis. [Figure 5] This shows a cross-section of a consumable item projected onto a plane parallel to its longitudinal axis. [Figure 6] This shows crimped sheet material. [Figure 7] This is a flowchart illustrating an example of a method for manufacturing consumables. [Modes for carrying out the invention]

[0007] As used herein, the term “delivery system” is intended to encompass a system for delivering at least one substance to a user, and includes non-combustion aerosol delivery systems that release compounds from aerosol-generating materials without burning the materials, such as hybrid systems that generate aerosols using a combination of electronic cigarettes, tobacco heating products, and aerosol-generating materials.

[0008] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the aerosol-generating materials (or their components) that make up the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0009] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0010] In some embodiments, the non-combustion aerosol supply system is an aerosol-generating material heating system, also known as a non-combustion heating system.

[0011] In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates aerosols 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 the form of a solid, liquid, or gel, 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.

[0012] The non-combustible aerosol supply system described herein comprises a non-combustible aerosol supply device and consumables for use with the non-combustible aerosol supply device.

[0013] This disclosure relates to consumables comprising aerosol-generating materials and configured for use with non-combustible aerosol supply devices. These consumables may be referred to as articles throughout this disclosure.

[0014] In some embodiments, a non-combustible aerosol supply system, such as a non-combustible aerosol supply device, may include a power source and a controller. The power source may be, for example, an electrical power source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that can be energized to distribute power in the form of heat to an aerosol-generating material or heat-transferring material adjacent to the heat-generating power source.

[0015] In some embodiments, the non-combustible aerosol supply system may include an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, a suction port, a filter, and / or an aerosol modifier.

[0016] In some embodiments, the consumables for use with a non-combustible aerosol supply device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a packaging material, a filter, a suction port, and / or an aerosol modifier. The consumables may also include an aerosol generator such as a heater that generates heat during use to generate an aerosol from the aerosol generating material. The heater may include, for example, a combustible material, a material that can be heated by electrical conduction, or a susceptor.

[0017] In some embodiments, the substance to be delivered may be an aerosol generating material or a material not intended to be aerosolized. If desired, any material may include one or more active components, one or more flavoring agents, one or more aerosol forming materials, and / or one or more other functional materials.

[0018] In some embodiments, the substance to be delivered includes an active substance.

[0019] As used herein, the active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological reaction. The active substance may be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. The active substance may be naturally occurring or obtained synthetically. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or their components, derivatives, or combinations. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another plant substance.

[0020] In one embodiment, the active substance is a legally acceptable recreational drug.

[0021] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes 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.

[0024] As described herein, the active substance may include or be derived from one or more plant substances or their components, derivatives, or extracts. As used herein, the term “plant substance” includes, but is not limited to, any material derived from a plant, including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, exoskeletons, shells, etc. Alternatively, the material may include naturally occurring active compounds in plant substances or synthetically obtained active compounds. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, flakes, strips, sheets, etc. Examples of plant-based substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay leaf, licorice, matcha, mate, orange peel, papaya, rose, sage, tea (such as green or black tea), thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. Dar, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiana, 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 arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0025] In some embodiments, the active substance comprises or is derived from one or more plant substances or their components, derivatives, or extracts, the plant substance being tobacco.

[0026] In some embodiments, the active substance comprises or is derived from one or more plant substances or their components, derivatives, or extracts, the plant substances being selected from eucalyptus, star anise, cocoa, and hemp.

[0027] In some embodiments, the active substance comprises or is derived from one or more plant substances or their components, derivatives, or extracts, the plant substances being selected from rooibos and fennel.

[0028] In some embodiments, the substance delivered includes a flavoring agent.

[0029] As used herein, the terms “flavoring agents” and “flavorings” refer to materials that may be used to create a desired taste, aroma, or other somatosensory effect in products intended for adult consumers, where permitted by local regulations.These are naturally occurring flavorings, plant substances, extracts of plant substances, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes). 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, kurt, eggplant, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-yi Orchid, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, peppermint oil from any of the Mentha species, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazelnut, hibiscus, bay leaf, 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, blackcurrant, valerian, pimento, mace, damien, maji It may also contain other additives such as chollum, 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), as well as charcoal, chlorophyll, minerals, plant-derived substances, or breath fresheners.They may be imitations, synthetics, or natural raw materials, or blends thereof. They may be in any suitable form, such as a liquid like an oil, a solid like a powder, or a gas.

[0030] In some embodiments, the flavoring agent includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring agent includes flavor components of cucumber, blueberry, citrus, and / or red berry. In some embodiments, the flavoring agent includes eugenol. In some embodiments, the flavoring agent includes flavor components extracted from tobacco. In some embodiments, the flavoring agent includes flavor components extracted from cannabis.

[0031] In some embodiments, the flavoring agent may include a sensory stimulant, which is intended to achieve somatosensory perception that is normally 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 these may include agents that produce heating, cooling, tingling, or numbing effects. A suitable thermal agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol or WS-3.

[0032] Aerosol-generating materials are materials that can generate aerosols when energy is supplied, for example, by heating, irradiation, or any other method. Aerosol-generating materials may be in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain active substances and / or flavorings.

[0033] The aerosol-generating material may include one or more active substances and / or flavoring agents, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0034] 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 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-based materials. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0035] The aerosol-generating material may include an aerosol-generating film, or may 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 delivered substance and / or fillers may also be present. The aerosol-generating film may not contain substantially any plant material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco-free.

[0036] The aerosol-generating film may have a thickness of approximately 0.015 mm to approximately 1 mm. The aerosol-generating film may also have a maximum thickness of 0.5 mm, preferably 0.05 mm to 0.5 mm microns. For example, the thickness may be in the range of approximately 0.05 mm, 0.1 mm, or 0.15 mm to approximately 0.5 mm or 0.3 mm.

[0037] The aerosol-generating film may be continuous. For example, the film may include a continuous sheet of material, or may be a continuous sheet of material. The sheet may be in the form of packaging paper, may be gathered to form a gathered sheet, or may be shredded to form a shredded sheet. The shredded sheet may include one or more strands or strips of the aerosol-generating material.

[0038] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may include one or more individual parts or regions of aerosol-generating material, such as dots, stripes, or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.

[0039] An aerosol-generating film can 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 components 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 to form an aerosol-generating film.

[0040] The slurry may be heated to remove at least about 60% by weight, 70% by weight, 80% by weight, 85% by weight, or 90% by weight of the solvent.

[0041] The aerosol-generating material may include an amorphous solid. In some embodiments, the aerosol-generating material includes an aerosol-generating film which 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 which may hold some fluid, such as a liquid, within the amorphous solid. In some embodiments, the amorphous solid may include, for example, about 50% by weight, 60% by weight, or 70% by weight of amorphous solid, or about 90% by weight, 95% by weight, or 100% by weight of amorphous solid.

[0042] The amorphous solid does not need to contain substantially any plant-based material. The amorphous solid does not need to contain substantially any tobacco.

[0043] The aerosol-forming material may comprise one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material may comprise 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, a mixture of diacetins, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0044] One or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0045] The aerosol-generating material may be present on or within a support that forms the substrate. The support may be, for example, paper, cardboard, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy, or may comprise these. 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.

[0046] A susceptor is a material that can be heated by penetration of a fluctuating magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, and as a result, penetration by the fluctuating magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, and as a result, magnetic hysteresis heating of the heating material occurs when the fluctuating magnetic field penetrates the heating material. The susceptor may be both conductive and magnetic, and as a result, the susceptor can be heated by both heating mechanisms. A device configured to generate a fluctuating magnetic field is referred to herein as a magnetic field generator.

[0047] Aerosol modifiers are typically substances located downstream of the aerosol generation area and are configured to modify the generated aerosol by altering, for example, the taste, flavor, acidity, or other properties of the aerosol. The aerosol modifier may be contained within an aerosol modifier release component that is operable to selectively release the aerosol modifier.

[0048] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may contain, for example, one or more of the following: flavorings, colorants, water, and carbon adsorbents. 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, thread, or granules. The aerosol modifier does not need to contain a filter material.

[0049] 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 supply thermal energy to the aerosol-generating material so that it releases one or more volatile substances from the material to form an aerosol.

[0050] Figure 1 shows a non-combustible aerosol supply system comprising consumables 100 and a non-combustible aerosol supply device 200. The device comprises an area 201 for receiving consumables 100 and an aerosol generator 202.

[0051] Figure 2 shows a cross-section of the consumable 100. The cross-section is projected onto a plane that bisects the consumable in the longitudinal direction. The consumable 100 includes an aerosol generating section 101. The aerosol generating section 101 includes a wall 102 surrounding an air gap 103 that forms part of an open airflow channel 111 extending between several open ends 112, 113 of the consumable 100. The aerosol generating section 101 is configured to generate an aerosol in the air gap 103 when heated by a non-combustible aerosol supply device for inhalation by the user.

[0052] The open airflow channel 111 (hereinafter simply referred to as "channel 111") is free of obstructions, meaning that a straight airflow channel 114 is provided through channel 111 between the open ends 112 and 113 of the consumable 100. Because the airflow channel 114 is straight, less of the aerosol components generated during the heating of the consumable 100 accumulate when the user inhales the consumable 100 than if the path were non-linear. For example, if the consumable instead had a permeable material that closed one end of the consumable, then when the user inhales the consumable, the resulting air stream passing through the consumable would have to take a winding path through the permeable material, thereby blocking components of the aerosol by that material. This is, of course, the principle of a cigarette filter. However, in the examples described herein, such obstructions are avoided in order to allow more components of the aerosol generated during the heating of the consumable 100 to reach the user.

[0053] The consumable 100 is configured to produce a pressure drop over the consumable 100 greater than approximately 50 mmWg. Having a pressure drop over the consumable 100 greater than approximately 50 mmWg ensures sufficient suction resistance. "Sufficient suction resistance" means that when a user suctions the consumable 100, the suction resistance is similar to that of a cigarette. The pressure drop is measured using industry standard techniques well known to those skilled in the art. In short, the pressure drop is measured by sealing one of the open ends 112, 113 to a pressure drop measuring device (e.g., Borgwaldt A11) configured to draw a set volumetric flow rate of approximately 17.5 ml / s through the consumable 100. The open ends 112, 113 selected for attachment to the pressure drop measuring device are the ends of the consumable 100 that the user suctions during use of the consumable 100, and are hereafter referred to as the suction end ME. In the example in Figure 2, the suction end ME is at the same end of the consumable as the open end 112.

[0054] The channel dimensions are selected accordingly to produce the required pressure drop. When the air gap 103 forms part of the channel 111, and when aerosols are generated in the air gap 103 during use, that portion of the channel 111 containing the air gap 103 must have a sufficient volume to accommodate a sufficient amount of generated aerosols. If the air gap 103 is too small, insufficient aerosols will be generated during heating of the consumable 100. Therefore, the channel 111 includes a first region 115 having a first cross-sectional area and a second region 116 having a second cross-sectional area, the second cross-sectional area being smaller than the first cross-sectional area. When the user aspirates the consumable 100, the second cross-sectional area 116 causes a limit, which increases the pressure drop of the consumable 100. The first region 115 forms part of the channel 111 containing the air gap 103 and has an optimal cross-sectional area for aerosol generation.

[0055] The first cross-sectional area is approximately 5 mm². 2 ~about 20mm 2 It may be the case that the second cross-sectional area is approximately 0.5 mm². 2 ~about 3.5mm 2 That's fine.

[0056] In one example, the first cross-sectional area is approximately 7.1 mm². 2 The second cross-sectional area is approximately 1.8 mm². 2 In such an example, the length of the first region 115 may be approximately 60 mm, and the length of the second region 116 may be approximately 20 mm. In this example, the pressure drop across the combined first region 115 and second region 116 is approximately 70 mmWg, with the second region 116 contributing approximately 40 mmWg and the first region 115 contributing approximately 30 mmWg.

[0057] In another example, the first cross-sectional area is approximately 19.6 mm². 2 The second cross-sectional area is approximately 0.8 mm². 2In this example, the length of the first region 115 may be approximately 60 mm, and the length of the second region 116 may be approximately 20 mm. In this example, the pressure drop across the combined first region 115 and second region 116 is approximately 72 mmWg, with the second region 116 contributing approximately 60 mmWg and the first region 115 contributing approximately 12 mmWg.

[0058] The ratio of the first cross-sectional area to the second cross-sectional area is approximately 20:1 to 7:3, and in one example, it is approximately 20:1 to 3.5:1.

[0059] The length of the first region 115 may be approximately 40 mm to 80 mm, and the length of the second region 116 may be approximately 15 mm to 25 mm. In one example, the length of the first region 115 is approximately 60 mm, and the length of the second region 116 is approximately 20 mm.

[0060] The second region 116 may contribute at least 40% of the total pressure drop of the combined first region 115 and the second region 116, which in an embodiment may be the total pressure drop across the consumable 100. For example, the second region 116 may contribute at least 50%, or at least 60%, or at least 70%, or at least 80% of the total pressure across the consumable 100.

[0061] Figure 3 shows a cross-section of the aerosol-generating section 101 of the consumable 100 described herein, projected onto a plane that bisects the aerosol-generating section 101 perpendicular to its longitudinal direction. Figure 3 shows further details of the wall 102 of the aerosol-generating section 101. In this example, the wall 102 further comprises a support 104 and a film of aerosol-generating material 105 provided on the support 104. The film of aerosol-generating material 105 forms the inner surface of the wall 102. The support 104 forms the outer surface of the wall 102, which in this example is covered by packaging material 110 for attaching the aerosol-generating section 101 to further components of the consumable. In other examples, the outer surface of the wall 2 may be the outermost surface of the consumable 100, such as in the example of Figure 5, which is illustrated and described below. The support may be made from any suitable material, such as paper or cardboard.

[0062] Figure 4 shows another exemplary aerosol-generating section 101 with similar features that retain the same reference numerals. Similar to Figure 3, Figure 4 is a cross-section projected onto a plane that bisects the aerosol-generating section 101 perpendicular to its longitudinal direction. In the example of Figure 4, the support 104 further includes a first layer 106 and a second layer 107, the first layer 106 located between the aerosol-generating material 105 and the second layer 107. The first layer 106 is a susceptor 106, which is heatable by penetration by a fluctuating magnetic field. The second layer 107 is not heatable by penetration by a fluctuating magnetic field and may be any suitable material included within this standard, such as paper or cardboard. The aerosol-generating material 105 is provided directly on the susceptor 106. However, in other examples, further material may be provided between the aerosol-generating material 105 and the susceptor 106.

[0063] In the example shown in Figure 2, the first region 115 is provided by the aerosol generating section 101, and the second region 116 is provided by a separate component 109, referred to herein as a throttling 109. The throttling 109 is positioned coaxially with the aerosol generating section 101 and is attached to the aerosol generating section 101 by packaging material 110 that surrounds both the throttling 109 and the aerosol generating section 101. The throttling 109 has an opening 117 that forms the second region of the airflow channel 111.

[0064] Figure 5 shows another exemplary consumable 100 having similar features that retain the same reference numerals. The example in Figure 5 is substantially the same as the example in Figure 2, except that the packaging material 110 is omitted and instead a constrictor 109' is attached to the aerosol generating section 101 by insertion into the end of the aerosol generating section 101. In the illustrated example, the end is the suction end ME of the consumable 100. The constrictor 109' is provided with overall dimensions that are substantially the same as, or slightly smaller than, the internal dimensions of the aerosol generating section 101 so that the constrictor 109' fits snugly within the aerosol generating section 101. As described above, the constrictor 109' has an opening that forms a second cross-sectional area of ​​the airflow channel 111.

[0065] In the illustrated example, the aerosol-generating section 101 is tubular, i.e., includes an annular cross-section. However, it should be understood that other cross-sectional shapes may be used. For example, the wall 102 may be a prism with a polygonal cross-section. The exemplary polygonal cross-sections may include, but are not limited to, octagons, hexagons, heptagons, or squares.

[0066] In the illustrated example, the apertures 109 and 109' are located at the mouthpiece end ME of the consumable 100. However, in other examples, the apertures 109 and 109' may be located at the distal end, i.e., the end opposite the mouthpiece end ME. Since the airflow exiting the apertures 109 and 109' is supplied with turbulent energy, the position of the apertures can affect the user's sensory experience. For example, by placing the apertures 109 and 109' at the distal end of the consumable 100, further mixing of the aerosol generated in the air gap 103 is promoted, which can increase the flavor intensity of the aerosol delivered to the user. Alternatively, placing the apertures 109 and 109' at the mouthpiece end ME results in the aerosol being delivered to the user's mouth at a faster rate, causing further mixing and a different sensory experience in the user's mouth.

[0067] In the illustrated example, the second region 116 of the channel 111 is provided by a single component 109, 109' having a constant cross-sectional area. However, it will be understood that the invention can be achieved by the second region 116 being formed from multiple components having different cross-sectional areas or from a single component having a varying cross-sectional area. Regardless of the arrangement of the second region 116, it is important that the consumable 100 is provided with a channel 111 having a straight air passage 114 between multiple open ends of the consumable 100, and that the pressure drop across the consumable is as defined herein.

[0068] The consumable 100 may be provided with any number of additional components for attachment to the aerosol generation section 101 described above. However, importantly, any additional components must have openings that do not obstruct the straight air passage 114.

[0069] The apertures 109, 109' described in this specification can be formed from a gather sheet of material. "Formed from a gather sheet of material" means gathering the sheet material to form the shape of the apertures 109, 109'. Similarly, the support 104 of the exemplary consumable described in this specification can be formed from a gather sheet of material. In an example, the sheet material is a fibrous sheet material such as paper. In an example, the sheet material is crimped before gathering it to form the shape of the apertures 109, 109' or the support 104. Thus, the apertures 109, 109' or the support 104 can be formed from a gather sheet of crimped material.

[0070] FIG. 6 shows a cross-section of a crimp pattern of an exemplary crimped sheet material 6 that can be used to form the apertures 109, 109' or the support 104. The crimp pattern includes a plurality of ridges and valleys within the sheet material 6, and the crimp amplitude "A" is the depth of the valleys measured from those ridges. The crimping can form a "zigzag" configuration or another shape. Adjacent grooves of the crimped sheet material can be separated by a distance or pitch "P" within the range of 0.3 to 2 mm, preferably within the range of 0.4 to 1 mm. In an example, adjacent grooves of the crimped sheet material 6 are separated by at least 0.4 mm, or at least 0.5, 0.6, 0.7 or 0.8 mm. In other examples, adjacent grooves of the crimped sheet material 6 are separated by at most 1.5 mm, preferably at most 1.4, 1.3, 1.2, 1.1 or 1.0 mm. The crimped sheet material 6 can have a crimp amplitude of less than 0.5 mm.

[0071] The stretched width of the crimped sheet material can be selected to provide a gather sheet material having a density of about 0.1 mg / mm 3 ~0.3 mg / mm 3 of the exemplary consumable described in this specification can be formed from a gather sheet of material. In an example, the sheet material is a fibrous sheet material such as paper. In an example, the sheet material is crimped before gathering it to form the shape of the apertures 109, 109' or the support 104. Thus, the apertures 109, 109' or the support 104 can be formed from a gather sheet of crimped material.

[0072] Referring again to Figure 1, the aerosol generator 202 is configured to heat the aerosol-generating material 105 of the consumable 100 when the consumable 100 is received in the area 201 for receiving the consumable. The device further comprises a power source 203, a controller 204, and a puff sensor 205. In use, the user inserts the consumable 100 into the area 201 for receiving the consumable and activates the aerosol generator 202 to generate an aerosol for inhalation. The user can then inhale the aerosol by sucking on the mouthpiece end ME of the consumable 100, or alternatively, the mouthpiece of the device 200 (not shown). In the illustrated example, the consumable 100 and device 200 are configured such that when the consumable 100 is fully inserted into the device 200, the mouthpiece end ME is part of the consumable 100 protruding from the area 201. Thus, the mouthpiece end ME is available for the user to suck on the mouthpiece end while the user is holding the device 200.

[0073] The puff sensor 205 is configured to detect when the user is inhaling the mouthpiece end of the consumable in the device 200 and to send a signal to the controller 204 to activate the aerosol generator 202. Thus, an aerosol is generated simultaneously with the user inhaling the consumable. Alternatively, the device 200 may be provided with a user interface, such as a button (not shown) that the user can press to trigger the activation of the aerosol generator 202.

[0074] An inlet (not shown) is provided in the area 201 for receiving the consumable 100, allowing air to enter the area 201 before passing through the consumable 100 when the user inhales the mouthpiece end 101 of the consumable 100. Thus, when the user inhales the consumable 100, an airflow is guided through the consumable 100. Specifically, the air is guided through the airflow channel 111 of the consumable 100. The airflow is accompanied by an aerosol generated by the aerosol-generating material 105 of the consumable for inhalation by the user.

[0075] The aerosol generator 202 comprises any suitable means for heating the aerosol-generating material 105 of the consumable 100 received in the area 201 of the device 200. Power for the aerosol generator 202 is supplied by a power source 203, which in the illustrated example is a power source 203 such as a battery 203.

[0076] In one example, the aerosol generator 202 includes a magnetic field generator configured to generate a fluctuating magnetic field that enters an area 201 for receiving the consumable 100. Thus, the device 200 is configured to be used with the consumable 100 which includes a susceptor, such as the susceptor 106 illustrated by Figure 4. The fluctuating magnetic field heats the susceptor 106 by magnetic hysteresis. When the consumable 100 is placed inside the device 200 and the aerosol generator 202 is activated, the fluctuating magnetic field enters the susceptor 106 of the consumable 100, heating the aerosol-generating material 105 that is in thermal contact with the susceptor and generating an aerosol for inhalation by the user.

[0077] In another example, the aerosol generator 202 comprises a susceptor that makes thermal contact with area 201 to receive a consumable 100, and a magnetic field generator for generating a fluctuating magnetic field that penetrates the susceptor. The fluctuating magnetic field heats the susceptor by magnetic hysteresis. The susceptor then heats area 201 for receiving the consumable. Thus, when the consumable 100 is placed inside device 200 and the aerosol generator 202 is activated, the fluctuating magnetic field penetrates the susceptor and heats area 201 where the consumable 100 is received. The heat is transferred to the aerosol-generating material 105 of the consumable 100, generating an aerosol for inhalation by the user. In such an example, the wall 207 of area 201 for receiving the consumable 100 may include a susceptor. The consumable 100 may be configured to make direct contact with the wall 207 for efficient heat transfer. Alternatively or additionally, the projection 206 may comprise a susceptor. For example, either or both of the wall 207 and the projection 206 may be made from a material that can be heated by penetration due to a fluctuating magnetic field.

[0078] In another example, the aerosol generator 202 includes an electrically conductive material, which is provided in thermal contact with an area 201 for receiving the consumable 100. Thus, when the consumable 100 is placed inside the device 200 and the aerosol generator 202 is activated, an electric current passes through the material, heating the area 201 where the consumable 100 is received. 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 also be the 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.

[0079] In any of the above examples of the aerosol generator 202, the aerosol generator 202 may be configured for strip- or partial heating of the consumable 100. "Strip- or partial heating" means that the aerosol generator 202 is configured to heat discontinuous portions of the aerosol generating material 105 separately, i.e., at different times.

[0080] Referring to Figure 7, a flowchart is shown illustrating an example of a method 80 for manufacturing a consumable 100 for use with the example system described herein. Method 80 in Figure 7 can be used to manufacture any of the consumables 100 described herein.

[0081] The method includes providing an aerosol generating section 101 which includes a support 104 and an aerosol generating material 105 attached to the support 104, and optionally attaching any desired additional components thereto.

[0082] In some examples, providing 81 includes attaching the aerosol-generating material 105 to the support 104 82, and then forming the aerosol-generating section 101 83. Thus, in some examples, the support 104 may be flat or substantially flat at the time the aerosol-generating material 105 is attached to the support 104. Subsequently, in some examples, the support 104 and the aerosol-generating material 105 may be processed together during the formation of the aerosol-generating section 101. Such processing may include winding or wrapping the combination of the support 104 and the aerosol-generating material 105 into a typically tubular section 101. However, it will be understood that the combination of the support 104 and the aerosol-generating material 105 may instead be folded into a section 101 having a non-circular cross-section. Such winding, wrapping, or folding may, for example, be done around a mandrel. In other examples, the support 104 is provided in a tubular or substantially tubular form, and then the aerosol-generating material 105 is attached to the support 104.

[0083] In some examples, the method includes manufacturing a support 104. For example, as described in some examples herein, the support 104 may include a plurality of layers 106, 107, and the manufacturing of the support 104 may include assembling these layers by adhesive or the like to form the support 104. At least one of the layers 106, 107 may be in the form of a sheet or strip.

[0084] In some examples, such as some where bonding 82 is performed before forming 83, bonding 82 includes coating the aerosol-generating material 105 onto the support 104 to form a film of the aerosol-generating material 105. Such coating may include, for example, spraying, electrospraying, casting, or band casting. Such casting may include providing a material in liquid or other fluid form (or the material that will ultimately form the support 104) on the surface of the support 104, and then allowing the material to solidify or harden at least partially on the surface of the support 104 to form the aerosol-generating material 105, which includes the film. The material in liquid or other fluid form may be an aerosol generated in that form, or an aerosol generated only after solidification or hardening.

[0085] In some examples, bonding 82 may include techniques other than coating. For example, bonding 82 may include using an adhesive to bond the aerosol-generating material 105 to the support 104.

[0086] If additional components are required, they can be attached to the aerosol generating section 101 by first aligning each component axially to form an assembly of components, and then packaging the components with packaging material 110. In the example of Figure 5, the assembly comprises, in order, a distal end locator component 109, an aerosol generating section 101, a mouthpiece end locator component 109', and a filter plug 108. The assembly is then packaged with packaging material 110 to form the consumable 100 of Figure 5.

[0087] Any aerosol-generating material 105 of the examples described herein may include an aerosol-forming agent, a binder, optionally a filler, and optionally an activator and / or flavoring agent.

[0088] In some examples described herein, the consumables do not contain tobacco, eliminating tobacco-specific nitrosamine levels and thereby eliminating the need for filters.

[0089] The various embodiments described herein are presented solely to aid in understanding and teaching the claimed features. These embodiments are provided only as representative examples of embodiments and are not exhaustive or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered limitations to the scope of the invention as defined by the claims or to equivalents of the claims, and it should be understood that other embodiments may be used and modified without departing from the scope of the claimed invention. Various embodiments of the invention may, may consist of, or may essentially consist of, appropriate combinations of disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. A consumable for use with an aerosol supply device, wherein the consumable comprises an open airflow channel extending between a plurality of open ends of the consumable, and an aerosol generating section configured to generate an aerosol in at least a portion of the open airflow channel during use, wherein the pressure drop across the consumable is greater than about 50 mmWg at a volumetric flow rate of about 17.5 ml / s.

2. The consumable according to claim 1, wherein the open airflow channel comprises a first region having a first pressure drop and a second region having a second pressure drop.

3. The consumable according to claim 2, wherein the first region has a first cross-sectional area, the second region has a second cross-sectional area, and the second cross-sectional area is smaller than the first cross-sectional area.

4. The consumable according to claim 3, wherein the second region is located downstream of the first region along the open airflow channel.

5. The consumable according to claim 3, wherein the first region is located downstream of the second region along the open airflow channel.

6. The consumable product according to claim 4 or 5, wherein the ratio of the first cross-sectional area to the second cross-sectional area is approximately 20:1 to 7:

3.

7. The consumable according to any one of claims 1 to 6, wherein the aerosol generation section includes a support and an aerosol generation material provided on the support.

8. The consumable according to claim 7, wherein the support is part of the wall of the aerosol-generating section surrounding at least a portion of the open airflow channel, and the aerosol-generating material forms the inner surface of the wall.

9. The consumable according to claim 8, wherein the support forms at least a portion of the surface of the consumable, and optionally the surface of the consumable is the outermost surface of the consumable.

10. The consumable product according to claim 9, wherein the aerosol generating material forms the inner surface of the aerosol generating section.

11. The aerosol generating material is Aerosol-forming agent and A binder and The filler and, Optionally, activators and / or flavorings, A consumable product according to any one of claims 7 to 10, including the consumable product according to any one of claims 7 to 10.

12. The consumable product according to any one of claims 7 to 11, wherein the aerosol generating material includes an aerosol generating film, and the aerosol generating film has a maximum thickness of approximately 1 mm, optionally a maximum thickness of 500 microns, or optionally a thickness of 50 to 500 microns.

13. The consumable product according to any one of claims 1 to 12, wherein the aerosol generating section is tubular.

14. The consumable according to any one of claims 2 to 13, wherein the second region of the open airflow channel is formed of a component separate from the aerosol generating section, and the separate component is attached to the aerosol generating section by a packaging material that surrounds both the aerosol generating section and the separate component.

15. The consumable according to claim 14, wherein the separate component has an internal surface that surrounds at least a portion of the open airflow channel.

16. The consumable according to claim 14 or 15, wherein the separate component comprises a material body surrounding the inner surface, and optionally the material body includes a gathered sheet material.

17. The consumable according to any one of claims 2 to 16, wherein the pressure drop across the second region contributes to at least 40% of the pressure drop across the consumable.

18. A consumable item according to any one of claims 1 to 17, A non-combustion aerosol supply device for generating an aerosol by heating an aerosol-generating material of a consumable, wherein the device comprises an area for receiving the consumable and an aerosol generator for causing the heating of the aerosol-generating material when the consumable is in the area, A non-combustion aerosol supply system equipped with the following features.

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