Heated tobacco systems, devices, and consumables

Abstract

A heated tobacco (HT) consumable is disclosed in which some of the electronic components are dispersed within the consumable. Advantageously, by inserting the consumable into the cavity of the HT device, the electronic components dispersed within the consumable can complete the circuit using the electronic components dispersed on the device. This enables stick recognition. For example, if the consumable is not properly installed, the circuit will not be completed, and the device cannot be activated. Automatic switching is also possible; inserting the consumable and completing the circuit initiates a smoking session, requiring no further user interaction (such as providing a button).

Description

Technical Field

[0001] The present invention relates to a smoking alternative system, and more particularly, but not limited thereto, to a smoking alternative system comprising a device and an aerosol-forming article. More specifically, it relates to a heated tobacco system comprising an electronic device and an insertable consumable, the consumable being heated to generate an inhalable aerosol.

Background Art

[0002] Smoking alternative systems include electronic aerosol generation systems that enable a user to simulate the act of smoking by generating an aerosol (also referred to as "vapor") that is inhaled from the mouth into the lungs and then exhaled.

[0003] One technological platform for smoking alternative systems is a group of products that use a "heated tobacco" ("HT") approach in which tobacco is heated or warmed to release vapor. In the HT approach, the tobacco is heated but not burned, i.e., the tobacco does not combust. The HT approach recognizes that there is no need to burn the tobacco to release components from the tobacco leaves. Rather, release is achieved at temperatures below about 350 degrees. Since HT systems do not combust the tobacco, the lower temperatures of HT systems are expected to result in emissions that are lower in chemical content or quantity than the smoke of combustible tobacco for exposure to the user. HT systems are well known in the industry. Although referred to herein as HT systems, they may also be known as heated tobacco products (HTP), Heat not Burn (HNB), and smokeless systems.

[0004] The HT product family is easily distinguishable from e-cigarettes (or vapes), which are a group of alternative smoking systems based on a technology platform that uses a device to heat a pod or cartridge filled with liquid (also called e-liquid). The main difference here is that HT systems generate an aerosol from tobacco leaves, while in e-cigarettes the aerosol is supplied from a liquid suspension.

[0005] A typical HT system includes an HT device and HT consumables, which consist of a tobacco stick that is replaced at the end of a smoking session. It will be understood herein that an HT system may be interchangeably referred to as "system," and similarly, an HT device may be interchangeably referred to as "device," and an HT consumable may be interchangeably referred to as "consumable." At a basic level, a consumable is inserted into the device to form a system, and the user operates the system to heat the consumable in a controlled manner, releasing flavor, aroma, and other components while vaporizing (without burning) the nicotine from the tobacco. The user can then inhale through the mouthpiece of the system to draw air through the tobacco. The released components and vaporized nicotine are drawn into the airflow, mixed, and cooled to create an aerosol. The aerosol is then inhaled by the user. A known HT device is marketed under the brand name Pulze® and used in combination with HT consumables marketed under the brand name iD®.

[0006] Known HT consumables comprise three parts arranged continuously from end to end to form a rod, including but not limited to a tobacco portion, a cooling portion, and a mouthpiece (or mouthpiece filter). Here, the tobacco portion forms the upstream end of the consumable, and the mouthpiece filters the downstream end of the consumable. In the iD® stick, the cooling portion comprises a continuously arranged bore filter and a paper tube, and the rod comprises the tobacco portion, bore filter, paper tube, and mouthpiece filter, arranged continuously from end to end, from the upstream end to the downstream end, to form a rod. In such consumables, the rod is held together by a combination of overlapping binding paper and tipping paper (i.e., overlapping region). In the iD® stick, the overlapping region is adjacent to the paper tube. In other words, the binding paper surrounds the tobacco portion, the hollow bore filter, and part of the paper tube (surrounding essentially involves a single wrap and any overlapping adhesive), while the tipping paper surrounds the mouth filter and part of the paper tube, with the tipping paper area surrounding the binding paper area. As a result, the diameter may increase along the overlapping areas compared to the rest of the rod. For example, the diameter of the consumable changes by 0.08 mm (twice the thickness of the tipping paper) from the upstream end to the downstream end.

[0007] It will be understood that as the diameter of consumables increases, the packing density of such consumables decreases. Those skilled in the art will recognize that lower packing density increases the packing volume of a typical consumable pack, thus increasing costs such as transportation. Furthermore, variations in diameter along a rod can affect the placement of consumables, for example, when they are packed together as in a typical consumable pack, and when they are moving within the manufacturing environment (for example, because consumables may be at a slight angle rather than in their intended true axial alignment). Those skilled in the art will recognize that misalignment of consumables can increase problems during manufacturing and detract from the aesthetics of the packaged consumables (i.e., the consumables may appear not to be properly packed).

[0008] HT consumables are typically manufactured, packaged, and prepared for transport on a single production line that processes thousands of consumables per minute. A typical production line, though not limited to these, includes multiple machines and stations, such as strip cutters, multiple buffers (e.g., one each for the tobacco portion, bore filter, paper tube, and mouthpiece filter), combiners, packaging machines, and transport case filling machines. Additional buffers may be provided between stations as needed.

[0009] When tobacco is formed from reconstituted tobacco leaves, the reconstituted tobacco leaves are first formed into a rod shape in a strip cutter. At this point, a reel of reconstituted tobacco may be fed into the production line. A continuous flow of reconstituted tobacco can be provided by splicing a new reel onto a nearly empty reel. The reconstituted tobacco is then cut into multiple strips of continuous length, similar to spaghetti, and these multiple strips are then formed into a rod shape. Optionally, flavorings such as menthol may be applied to the tobacco material at this stage. The strip cutter can also typically enclose the tobacco rod with wrapping paper, or optionally with lacquered foil laminate. Enclosing the tobacco with metallic foil prevents misuse of the HT consumable by using it as combustible tobacco (i.e., the metallic foil prevents, inhibits, or suppresses ignition). The multiple strips formed into the cylindrical rod are then cut to lengths for use in a combiner. As described below, to reduce processing time, each cylindrical tobacco rod is cut to form tobacco portions twice its length. In other words, the tobacco material is formed into a rod long enough to form two consumables when cut in half. The double tobacco portions are then transferred to a storage buffer, where multiple double tobacco portions may be tightly packed together.

[0010] Similarly, twice the length of each component of the cooling section and mouthpiece filter are stored tightly packed in their respective buffers. For example, in some configurations, twice the length of each of the tobacco section, bore filter, paper tube, and mouthpiece filter are stored in buffers for supply to the combiner.

[0011] If necessary, twice the length of each component is supplied to the combiner. Inside the combiner, twice the length of the paper tube can be cut in half to form a single-length paper tube. Then, twice the length of the bore filter may be sandwiched between each single-length paper tube to form a first unit. Then, the first unit can be cut in half (through the center of the twice-length bore filter) to form two second units (each having a single-length bore filter adjacent to a single-length paper tube). Then, twice the length of the tobacco portion is sandwiched between each second unit to form a third unit.

[0012] A double-width binding paper (where the width is formed along the length of the consumable or along the longitudinal axis) may be fed into the combiner. Similar to the reassembled tobacco reels, the binding paper reels can also be unwound by joining a new reel to a nearly empty reel via a splicing unit, creating a continuous flow of binding paper. Adhesive may be applied to the binding paper within the combiner. The adhesive-coated binding paper may then be wound around a third unit. The adhesive may be allowed to set before the wound third unit is cut into two fourth units (through the center of the double-length tobacco portion). That is, the cut forms the distal upstream end of the HT consumable, and since the cut is made through the binding paper and tobacco portion, the distal end has a plane at the same height as the tobacco and binding paper. At this stage, each fourth unit may have a tobacco portion adjacent to a bore filter, which is adjacent to a paper tube surrounded by binding paper. Because the width of the binding paper is shorter than the length of the fourth unit, the binding paper can surround the third unit such that the end of the binding paper is at the same height as the end of the tobacco portion, and the paper tube protrudes from the opposite end of the binding paper. Next, each of the fourth units is inverted so that the paper tubes are adjacent to each other and the tobacco portion faces outwards. Then, to form the fifth unit, a mouthpiece filter twice the length is inserted between the fourth units.

[0013] Twice the width of the tipping paper is fed into the combiner. Similar to the binding paper reels, the tipping paper reels can also be rewound by joining a new reel to a nearly used reel, creating a continuous flow of tipping paper. Inside the combiner, adhesive is applied to the tipping paper. The adhesive-coated tipping paper is then wound around the center of the fifth unit. The tipping paper has a width such that an overlapping area is formed where the tipping paper surrounds the paper tube and the binding paper. The adhesive is then allowed to set before the fifth unit is cut in half (through the center of the twice-length mouthpiece filter) to form two consumables. A laser is then typically used to punch holes in the tipping paper and paper tube near the mouthpiece end of each consumable, completing the binding process. Here, the holes are distributed radially and circumferentially to provide ventilation downstream of the tobacco material to introduce ventilation air.

[0014] The consumables are then transferred to a packaging machine, where individual consumables are packaged into consumable packs. Here, first, multiple consumables (perhaps 20) are arranged in an array with a standard number of rows and columns, and then the array of consumables is placed into packaging (e.g., plastic packaging and cardboard presentation boxes). It is noteworthy that, since the combiner and packaging machine process the same number of consumables per minute, the number of packs discharged from the packaging machine per minute is significantly reduced compared to the number of consumables discharged from the combiner per minute (necessarily reduced to 1 / 20th based on the number of consumables in each pack). Each pack is then wrapped in cellophane or similar material, and multiple packs are packaged together by a transport case filling machine.

[0015] Those skilled in the art will recognize that this manufacturing process may require not only the precise orientation of the consumables along their longitudinal axis, but also the need to tightly pack multiple units and consumables. Consequently, maintaining a consistent and uniform outer diameter of the consumables is crucial, as variations in outer diameter negatively impact the packaging configuration, leading to reduced packaging density and increased packaging volume of consumables and intermediate units, as well as reduced fit and alignment in the packaging, potentially affecting the visual impression of the packaged consumables to the end user. Furthermore, variations in diameter can cause misalignment of consumables across multiple machines during the manufacturing process, potentially leading to inconsistencies in the production of consumables.

[0016] As described above, in existing consumables, the rod comprises an upstream tobacco end and a downstream mouthpiece end on the opposite side. The mouthpiece end (also called the mouthpiece or mouth end) is defined by the end face of the mouthpiece filter, and the tobacco end is defined by the end face of the tobacco portion. Furthermore, the mouthpiece end is at the same height as the edge of the tipping paper, and the tobacco end is at the same height as the edge of the binding paper. Thus, the tobacco material is exposed at the end of the consumable. Those skilled in the art will recognize that the tobacco material tends to fall out or be pulled out of the consumable during use (for example, into the cavity of the device used to heat the consumable). If the device is not cleaned, the tobacco material can adhere to the heater, resulting in a stronger odor and reduced performance. Tobacco material remaining in the cavity is also undesirable from the user's perspective, as tobacco particles can contaminate the user's pockets or bags, which are typically used when carrying the HT device. Furthermore, tobacco particles or fibers that fall out of the consumable during the manufacturing process can contaminate the machine, potentially requiring downtime for maintenance and cleaning.

[0017] Known heater devices have a cavity for housing heater consumables, with the heater positioned in or around the cavity. Thus, the device further comprises a power source (e.g., a battery) and control electronics for connecting the power source and the heater, appropriately via a user interface. Of course, the device also typically includes a charging port and control electronics that control not only the discharge of power to the heater (i.e., starting the heater) but also the recharging of the power source.

[0018] Pulze® devices define a cavity and provide a housing for accommodating a power supply, control electronics, and a user interface (i.e., a power button). The housing generally has a longitudinal shape, and its longitudinal axis is aligned with the cavity, so that when consumables are inserted, the consumables and the device share a common axis. Here, the housing has an electronics compartment at the upstream end of the device and a cavity at the downstream end. That is, consumables are inserted into the cavity from downstream to upstream. A charging connector is provided at the upstream end of the housing, and a power button is provided on the side. The housing defines an airflow path to the upstream end of the cavity (i.e., the bottom of a closed cavity). In Pulze® devices, the airflow is provided to the bottom of the cavity through a gap formed between the housing and a retractable cap containing the cavity.

[0019] To use the HT system, the device and consumables are physically coupled by first inserting the upstream tobacco portion and then inserting the consumable into the cavity. Once the consumable is fully inserted into the cavity, the mouthpiece filter protrudes from the cavity of the device, with the end of the tobacco portion adjacent to the closed end of the cavity.

[0020] As is well known, the user can activate the HT device via the power button on the user interface. When the HT device is activated, the heater turns on and a predetermined smoking session (e.g., heater on time) begins. During use, the heating element of the device heats the tobacco material, and the airflow through the tobacco material releases moisture within the tobacco material as vapor. The airflow through the tobacco is provided through the device by an air channel to the closed lower end of the cavity. The airflow then travels along the consumable, entraining the vapor formed by the tobacco material and any flavorings, in addition to the volatile compounds released from the tobacco as it passes through the tobacco portion. The airflow then continues through the cooling section, entraining a flow of cool air that enters the consumable through the holes in the tipping paper and paper tube. The cooled airflow finally continues through the mouthpiece filter, which acts to cool the vapor to a comfortable temperature for inhalation, and is then discharged from the consumable through the mouthpiece filter at the downstream end of the consumable and out of the system.

[0021] Various heaters are known for HT systems. Pulze™ devices use a resistance heating rod as the heating element, with a resistance heating wire placed on the heating rod. When power is supplied from a power source, the wire generates heat. The resistance heating wire conducts heat to the tobacco near or in contact with the heating wire. Here, the heating rod is arranged coaxially within a cavity, and when the consumable is inserted into the cavity, the heating rod penetrates the tobacco, heating the tobacco from the inside. Flat blades are also used for heating from the inside out. During use, when the heater penetrates the tobacco portion, force is applied to the tobacco, and the relative movement between the heating element and the consumable may cause the tobacco portion to move or shift in an undesirable direction. Furthermore, this penetration may disturb the tobacco material, and when the consumable is removed from the device, the tobacco material may fall into the device's cavity. For example, when the heating element is withdrawn, the tobacco can be pulled out of the consumable.

[0022] For the reasons stated above, the design of the HT system needs to be improved to enhance the user experience and to improve the manufacturing and transportation of such consumables and the methods thereof. With the above in mind, the aspects and embodiments were devised. [Overview of the project]

[0023] Another aspect of the present invention provides a heated tobacco (HT) consumable in which, in the most common case, some electronic components are dispersed within the consumable. Advantageously, by inserting the consumable into a cavity in the HT device, the electronic components dispersed within the consumable can complete the circuit using the electronic components dispersed on the device. This enables stick recognition. For example, if the consumable is not properly installed, the circuit will not be completed, and the device cannot be activated. Automatic switching is also possible, and a smoking session begins by inserting the consumable and completing the circuit, requiring no further user interaction (such as providing a button).

[0024] In the exemplary embodiments and claims of heated tobacco consumables described herein, the heated tobacco consumable comprises an aerosol-generating substrate. As described above, an aerosol-generating substrate is a solid (not liquid) substrate that, upon heating, can release at least one volatile compound capable of forming an aerosol. Tobacco leaves are one such substrate, and it will be understood that an aerosol is produced by inhalation through a heated substrate. However, those skilled in the art will recognize that heated tobacco systems can also be easily configured to heat non-tobacco organic materials such as other plant materials (e.g., cannabis leaves). Consequently, heated tobacco consumables are intended, in their broadest sense, to include an aerosol-generating substrate comprising at least one volatile compound, which is intended to evaporate / aerosolize and, upon inhalation, may provide the user with recreational and / or medical effects. Suitable chemically and / or physiologically active volatile compounds include nicotine, cocaine, caffeine, THC, CBD, opiates and opioids, catine and cathinone, cannabinoids, kavalactone, mysticine, beta-carborin alkaloids, salvinorin A, and any combination of the aforementioned, functionally equivalents, and / or synthetic substitutes.

[0025] Accordingly, in the exemplary HT consumables described and claimed herein, the aerosol-generating substrate of the HT consumable appropriately comprises plant material. The plant material includes Amaranthus dubius, bearberry, thistle poppy, Amica, European mugwort, yellow tea, Kalea ternifolia, Canavalia maritima (baby bean), Cecropia mexicana (Guamura), night jasmine, Cynoglossum virginianum (wild comfrey), broom, damiana, Entada rheedii, California poppy, red oak, star thistle, Japanese hop, hop (Humulus lupulus) (Hops), wild lettuce (opium lettuce), Laggera alata, Leonotis, Motherwort, Honeyweed, Lobelia, Lobelia ciphilitica, Catnip, Nicotiana species (tobacco), White Lily, Nymphaea caerulea (Blue Lily), Poppy, Passionflower, Pedicularis densiflora (Indian Warrior), Pedicularis It may comprise at least one plant material selected from a list including groenlandica (elephant's head), Salvia divinorum, Salvia doli (tobacco sage), Salvia species (sage), marsh skullcap, blue skullcap, dwarf skullcap, Scutellaria species (skullcap), Fern Acta (wireweed), Kingojika, Silene capensis, clove, mint marigold (Mexican tarragon), Tarchonanthus camphoratus, Turnera diffuse (Damiana), Mullein (Mullein), Zamia latifolia (Maconha Brava), as well as any combination of the aforementioned, functionally equivalents, and / or synthetic substitutes.

[0026] However, in particularly suitable exemplary embodiments, it will be understood that the plant material is tobacco. Herein, in the exemplary HT consumables described and claimed herein, all kinds of tobacco may be used. This includes, but is not limited to, hot-air dried tobacco, Burley tobacco, Maryland tobacco, dark-air dried tobacco, Oriental tobacco, dark-fire tobacco, Perique tobacco, and Rustica tobacco. It also includes blends of the above tobaccos.

[0027] Tobacco may comprise one or more of the following: leaf tobacco, stem tobacco, tobacco powder, tobacco ash, tobacco derivatives, expanded tobacco, homogenized tobacco, shredded tobacco, extruded tobacco, cut rag tobacco, and / or reconstituted tobacco (e.g., slurry recon or paper recon). In any case, the aerosol generating substrate is formed from a rod-shaped material, for example, referred to herein as a tobacco rod. The aerosol generating substrate (i.e., the tobacco rod) is appropriately formed to be substantially cylindrical so that the article / consumable resembles a conventional cigarette. The diameter of the aerosol generating substrate may be between 5 and 10 mm (e.g., between 6 and 9 mm, or between 6 and 8 mm, e.g., about 7 mm). The aerosol generating substrate may have an axial length between 10 and 25 mm (e.g., between 11 and 14 mm, e.g., about 12 mm or 13 mm).

[0028] In an exemplary embodiment comprising a reconstituted tobacco, the aerosol generating substrate may comprise an assembly sheet of homogenized reconstituted tobacco, or an assembly piece / strip formed from such a sheet. Here, the plurality of strips may be substantially aligned in a row. Further, the plurality of strips parallel to each other may be substantially parallel to the longitudinal axis of the rod. In addition to this, the plurality of strips may be tightly packed. Those skilled in the art will recognize that the plurality of strips of the reconstituted tobacco are fragile, and thus, during use, especially after use, the tobacco material may fall off from the consumable. Therefore, the problem associated with the tobacco falling off from the consumable still exists in order to provide greater resistance to the reconstituted tobacco being pulled out from the consumable, and further, the risk increases when using other types of tobacco such as cut rag tobacco. As a result, the closed-end HT consumable aspects and embodiments are beneficial for consumables containing reconstituted tobacco as the aerosol generating substrate, and may be particularly beneficial for HT consumables formed with an aerosol generating substrate comprising non-reconstituted tobacco.

[0029] In the exemplary aspects and embodiments described and claimed herein, the aerosol generating substrate may comprise one or more additives selected from a humectant, a flavorant, a filler, an aqueous / non-aqueous solvent, and a binder. Here, the flavorant may be provided in a solid form or in a liquid form. It may include menthol, licorice, chocolate, fruit flavors (including, for example, citrus, cherry, etc.), vanilla, spices (such as ginger, cinnamon), and tobacco flavors. The flavorant may be uniformly dispersed throughout the aerosol generating substrate, or provided at isolated locations and / or at different concentrations throughout the aerosol generating substrate.

[0030] All of the exemplary aspects and embodiments described and claimed herein comprise HT consumables that are specially adapted for use with an HT device (either a known device or an HT device described and claimed herein). In particular, combustible tobacco is not particularly adapted for use with an HT device. The main reason is that inserting combustible tobacco into an HT device and then operating the HT device does not produce an adequate amount of vapor to be consumed by the user. In particular, an inadequate amount of aerosol vapor is produced. Thus, in an exemplary embodiment of an HT consumable described and claimed herein, one specific adaptation for use with an HT device is to incorporate a carrier into the tobacco material. Here, during use, a first vapor is produced from the tobacco material that volatilizes nicotine (or other active substances as described above), and a second vapor is produced from the evaporation of the carrier. Any known or suitable carrier is contemplated. For example, a carrier added to an aerosol-generating substrate (such as a plant material like tobacco) suitably comprises polyglycol (PG), propylene glycol, and / or vegetable glycerin (VG).

[0031] In embodiments of the exemplary HT consumables described and claimed herein, in addition to the aerosol-generating substrate, further components or elements known in the art and described and claimed herein, which are combined with the aerosol-generating substrate, may also be provided. Thus, the exemplary HT consumables may include an aerosol-generating substrate combined with one or more further components or elements by binding paper, where the binding paper surrounds the aerosol-generating substrate and further components and is known in the art and is bonded or attached to form a homogeneous component or rod, as described in the background art section above. Thus, additions or combinations of features of the described and claimed consumables and embodiments are expressly considered unless they are incompatible. Furthermore, the term binding paper as used herein is intended in its broadest sense to include any suitable substrate that can surround the components of the consumable and can be used to bind or wrap one or more of the components. Suitable substrates are envisioned to be thin and flexible, such as paper or similar materials. Therefore, the packaging substrates used herein are interchangeable to refer to binding paper in its broadest sense, even when, for example, the binding paper does not bind the components together.

[0032] As will become clear, the described or claimed embodiments and models are suitable for use in HT systems, and the HT consumables are intended to be used as described in the background art section above. That is, the consumables are inserted into a cavity at the downstream end of the HT device. Or, to put it another way, the consumables are insertable into the cavity in a downstream-to-upstream direction. In this specification, such an arrangement may be referred to as a “downstream” consumable, where the aerosol generating substrate is located at the upstream end, and the distal downstream end of the HT consumable comprises a mouthpiece. For example, a mouthpiece filter (e.g., a terminal filter arrangement) is one such arrangement. In this case, the mouthpiece filter may appropriately comprise a monoacetate filter or a hollow bore filter. In some arrangements, the hollow bore filter may be, for example, a triple-pore filter having three holes arranged in an equilateral triangle around a central axis. Alternatively, the mouthpiece filter may be composed of cellulose acetate or polypropylene tow. Further alternatively, the mouthpiece filter element (e.g., a terminal filter element) may be composed of activated carbon or paper. In any case, the mouthpiece filter element is preferably surrounded at least partially (for example, preferably but not necessarily all) by a plug wrap, such as a paper plug wrap. In some arrangements of downstream HT consumables, the mouthpiece filter may contain a fragrance. For example, the mouthpiece filter may be formed of a crushable capsule (e.g., equipped with a crush ball) that can be crushed by the user to release vapor or liquid, as is known in the art.

[0033] In an exemplary downstream HT consumable, the mouthpiece filter (the downstream end of the consumable) is formed by a surrounding tipping layer, such as a tipping paper layer, and is appropriately bonded to an upstream element containing at least an aerosol-generating substrate. The axial length of the tipping paper is longer than the axial length of the end filter element, so that the tipping paper completely encloses the end filter element and the packaging layer surrounding the adjacent upstream element.

[0034] As described, the HT consumables of the described and claimed embodiments may comprise further components and elements. For example, in exemplary downstream HT consumables, further elements may be positioned between the aerosol generating substrate and the mouthpiece filter. Non-downstream embodiments may not necessarily include a mouthpiece filter, but further elements may be provided on either side of the aerosol generating substrate. For example, in some embodiments, the consumable comprises an aerosol cooling element adapted to cool the aerosol generated from the aerosol generating substrate (by heat exchange) before it is inhaled by the user. That is, in such a consumable, the cooling element regulates the temperature of the vapor. In some exemplary arrangements, the cooling element appropriately comprises a bore filter and a paper tube, each of which regulates the temperature of the vapor during use. In some arrangements, the bore filter may be a hollow bore filter. In some arrangements, the paper tube may be a spiral paper tube. In other words, the paper tube may be a spirally wound continuous paper tube, or the paper tube may be a corrugated cardboard tube. In exemplary embodiments, the paper tube itself is impermeable to air but may have multiple holes formed, for example, by a laser. The multiple holes are distributed circumferentially around the paper tube, and their number and position correspond to multiple holes in the tipping paper to provide ventilation to the internal cavity of the paper tube.

[0035] In most common cases, one aspect of the present invention provides a heated tobacco (HT) consumable having a closed end. By closing the end and preventing the tobacco portion from being exposed at the tip, the consumable is provided which advantageously reduces the risk or possibility of the tobacco falling out or being pulled out of the consumable during use, transport, and / or during the manufacturing process.

[0036] In one exemplary embodiment, a closed-end consumable is manufactured by first forming a recess at the distal end of a partially processed consumable. In other words, the distal end of the partially processed consumable has a distal end formed by a plane of the hollow portion of the packaging substrate, and the end face of the aerosol-generating substrate (i.e., cigarette) is recessed from the plane containing the distal end of the packaging substrate. Advantageously, the recessed distal end of the partially processed HT consumable allows for a further processing step to close the end face of the aerosol-generating substrate; that is, to cover the aerosol-generating substrate so that it is not exposed through the distal end of the consumable, as in the case of known forming processes. As understood, if the packaging substrate encloses two components (i.e., an aerosol-generating substrate and a further component such as a hollow tube), the packaging substrate is sometimes referred to as binding paper. Although the term binding paper is used herein, the use of the term binding paper does not implicitly require that the packaging substrate combines further components, unless necessary. In exemplary embodiments, the recess is formed by placing a first single-length aerosol generating substrate on the binding paper and a second single-length aerosol generating substrate on the binding paper. The binding paper is wound simultaneously around the first and second single-length aerosol generating substrates to produce a unit, the binding paper surrounding the first and second single-length aerosol generating substrates and also surrounding the twice-length recess formed between each aerosol generating substrate. The binding paper is preferably cut along the center of the recess between each aerosol generating substrate to produce two partially processed consumables, each partially processed consumable having a recess at its distal end.

[0037] Accordingly, a method for manufacturing HT consumables is provided, comprising the steps of providing a width of binding paper and arranging a first aerosol generating substrate and a second aerosol generating substrate on the binding paper, wherein the aerosol generating substrates are spaced apart. Since the first and second aerosol generating substrates are separate components, spacing them apart creates a space or gap between the substrates. The method comprises the step of wrapping the binding paper around the aerosol generating substrates and the gaps between them. The method then includes the step of cutting the binding paper through the portion of binding paper surrounding the gaps to form two partially processed HT consumables, each partially processed HT consumable having a recessed distal end. That is, each partially processed HT consumable comprises a distal end portion including the end face of the aerosol generating substrate and an overhang length of binding paper. For example, in an imagined exemplary embodiment, the aerosol generating substrate is a rod, and therefore the overhang binding paper is a hollow cylinder extending from the end face of the aerosol generating substrate. Advantageously, this method provides an improved manufacturing process for forming recessed distal ends that can be easily used with minimal modifications to existing processing machinery. For example, existing combiners can be easily adapted to position separate first and second aerosol-generating substrates on the binding paper.

[0038] In exemplary embodiments, each aerosol generating substrate is of a single length. That is, the length of the aerosol generating substrate is intended to be suitable for forming a single HT consumable. Furthermore, in the step of arranging the first and second aerosol generating substrates, each substrate is arranged axially aligned. That is, each aerosol generating substrate has a longitudinal axis, and when placed on the binding paper, the longitudinal axes are aligned and coincide. Preferably, the first aerosol generating substrate may be a cylindrical rod, where the cylindrical rod has opposing end faces. Each of the end faces is a plane. That is, the end faces are said to be planes along the main plane of the aerosol generating substrate, although they may be formed from the ends of multiple strands in a common plane. Thus, in the example of a tobacco rod, the tobacco rod has planes at each end, even though the end faces may be formed from the ends of multiple tobacco strands with gaps between them. The cylindrical rod has a longitudinal axis, and the end faces are appropriately perpendicular to the longitudinal axis. Furthermore, preferably, the second aerosol generating substrate is an element of the same type as the first aerosol generating substrate. In other words, the first and second aerosol-generating substrates are independent and separate components, yet they may otherwise be substantially identical. Here, "identical" is understood to include variations due to the randomness of the aerosol-generating substrates.

[0039] In exemplary embodiments, the step of wrapping the binding paper around a first aerosol generating substrate, a second aerosol generating substrate, and the gap comprises the step of cutting the binding paper and bonding or adhering the binding paper as known in the art. Preferably, the step of cutting the binding paper through the portion having the gap comprises the step of cutting through the center of the gap such that two partially processed HT consumables are formed having binding paper overhangs of the same size. As understood, the cutting is preferably performed perpendicular to the longitudinal axis of the binding paper.

[0040] The length of the gap or space between the first aerosol-generating substrate and the second aerosol-generating substrate is predetermined. In some exemplary embodiments, the space is relatively large, for example, equal to or greater than the diameter of the aerosol-generating substrate. That is, when cut in half, the overhang length is greater than or equal to the radius of the aerosol-generating substrate. Thus, if the diameter of the aerosol-generating substrate is appropriately between 5 and 10 mm, the gap between the first aerosol-generating substrate and the second aerosol-generating substrate will also be 5 to 10 mm or greater accordingly. Here, the method further comprises the step of folding the binding paper to close the distal end portion of the HT consumable, if appropriate. In alternative exemplary embodiments, the space is relatively small, for example, less than the diameter of the aerosol-generating substrate. That is, when cut in half, the overhang length is less than the radius of the aerosol-generating substrate. Thus, if the diameter of the aerosol-generating substrate is appropriately between 5 and 10 mm, the gap between the first aerosol-generating substrate and the second aerosol-generating substrate will also be less than 5 to 10 mm accordingly. Herein, the method further comprises the step of inserting a film into a recess to appropriately close the distal end portion of the HT consumable.

[0041] In most common cases, the present invention provides heated tobacco (HT) consumables having closed ends. By closing the ends and preventing the tobacco portion from being exposed at the tip, the consumables are provided that advantageously reduce the risk or possibility of the tobacco falling out or being pulled out of the consumable during use, transport, and / or during the manufacturing process.

[0042] Accordingly, in a further exemplary embodiment, a method is provided for manufacturing an HT consumable, comprising the steps of providing a width for a packaging substrate and arranging a first aerosol generating substrate and a second aerosol generating substrate on the packaging substrate, with each aerosol generating substrate spaced apart. The method comprises the step of wrapping the packaging substrate around the aerosol generating substrates and the gaps between them. The method then comprises the step of cutting the packaging paper through the portion of the binding substrate surrounding the gaps to form two partially processed HT consumables, each partially processed HT consumable having a recessed distal end. That is, the method comprises the exemplary embodiments described above and herein. However, in this embodiment, the method further comprises the step of folding the packaging substrate to close or cover the end faces of the aerosol generating substrates after creating the recessed distal ends. Thus, advantageously, an improved method for forming an HT consumable is provided. To be understood, when a packaging substrate encloses two components (i.e., an aerosol-generating substrate and a further component such as a hollow tube), the packaging substrate is sometimes referred to as binding paper. Although the term binding paper is used herein, the use of the term binding paper does not implicitly require that the packaging substrate combines further components, unless necessary.

[0043] In exemplary embodiments, the binding paper folded on the end face is perforated. When used herein, perforation includes, for example, mechanically puncturing the substrate by laser drilling or ablation (i.e., small holes by micro-drilling), and porous substrates (i.e., having porosity through which air is drawn). Thus, HT consumables are further provided comprising binding paper surrounding an aerosol-generating substrate, wherein a continuous portion of the binding paper is perforated and folded on the end face of the aerosol-generating substrate. Advantageously, the HT consumable has a closed end, thereby reducing the risk of particles or fibers of the aerosol-generating substrate falling out of or being pulled out of the consumable while maintaining communication with the aerosol-generating substrate and airflow through the end of the consumable. Furthermore, the external dimensions of the consumable are not affected by being formed from a continuous portion of binding paper. HT consumables can be adequately formed using the exemplary methods described above and herein.

[0044] Appropriately, the exemplary method comprises the step of perforating the binding paper before cutting the binding paper in the gap region. Here, the binding paper may be perforated before providing it. Alternatively, the binding paper may be perforated after it has been wrapped around each aerosol generating substrate. In either case, holes are formed so that air can flow through the closed distal end; that is, holes are formed in the folded-over portion of the distal end of the binding paper. Here, as understood, the holes are formed in the portion of the binding paper surrounding the gap between the first aerosol generating substrate and the second aerosol generating substrate.

[0045] The holes are appropriately formed using laser ablation techniques. For example, in the background information section, laser ablation is described as being used to create holes in tipping paper, but the same process and techniques can be readily adapted to create holes in bonded paper. Thus, exemplary HT consumables may include holes having multiple holes. The holes are made to be sized such that they allow airflow through the bonded paper but prevent the passage of aerosol-generating substrates or the movement of their particles.

[0046] In some exemplary embodiments, the recessed end of a partially processed consumable is formed from a generally cylindrical portion of binding paper that extends from the end of the aerosol generating substrate. In one embodiment, the cylinder is flattened to randomly fold the extended binding paper onto the end face of the aerosol generating substrate. Alternatively, some exemplary methods include the step of folding the extended binding paper by creasing the binding paper to form a predetermined folded shape, such as a letterbox fold. The binding paper may also be creasing before being provided, and the crease lines correspond to the intended folds when the binding paper is wrapped and cut. Additionally or alternatively, the binding paper may have cuts and / or removed segments in the portion of the binding paper that encloses a gap or space between two aerosol generating substrates. Here, the binding paper remains as a whole until the gap is cut. Once cut, the cut portion or removed segment forms a shape profile that facilitates folding. For example, once cut, the extended portion of the binding paper forms multiple fingers. Herein, the method comprises the step of folding each finger to cover a portion of the end face of the aerosol generating substrate. Preferably, the fingers can be folded continuously in an iris pattern so as to substantially cover the end face of the aerosol generating substrate.

[0047] As described above, the binding paper can have pre-formed cuts and removals to provide a predetermined folded shape. In some embodiments, for example, if the consumable is intended for use in an HT device where the heater does not need to penetrate the aerosol generating substrate, the method and the HT consumable may be configured such that the folded binding paper substantially covers the entire end face of the aerosol generating substrate; however, if the consumable is intended for use in a device where the aerosol generating substrate penetrates, the binding paper may be folded to maintain an open portion corresponding to the size of accommodating the penetrating heater. That is, the binding paper of a partially processed consumable with a recessed end is composed of cuts or removed segments of the binding paper, which form an opening when folded. The formed opening exposes a portion of the end face of the aerosol generating substrate.

[0048] In most common cases, the present invention provides heated tobacco (HT) consumables having closed ends. By closing the ends and preventing the tobacco portion from being exposed at the tip, the consumables are provided that advantageously reduce the risk or possibility of the tobacco falling out or being pulled out of the consumable during use, transport, and / or during the manufacturing process.

[0049] In further exemplary embodiments, an HT consumable and a method for manufacturing an HT consumable are provided, wherein a film is adhered to the inner surface of an overhang portion of a packaging substrate wrapped around an aerosol generating substrate. The film covers the end face of the aerosol generating substrate. Advantageously, the film prevents the aerosol generating substrate from flowing out of the consumable. Furthermore, since the film is adhered to the inner surface of the overhang, the outer diameter of the consumable is unaffected; that is, the outer surface of the consumable remains that of the packaging substrate. In fact, the overhanging binding paper plays a role in restraining the film to ensure alignment within the recess. Thus, a method for manufacturing an HT consumable is provided, comprising the steps of wrapping an aerosol generating substrate with a packaging substrate and forming a recessed end, wherein a continuous portion of the packaging substrate overhangs the end face of the aerosol generating substrate. The method further comprises the step of adhering a film to the inner surface of the overhanging packaging substrate. Subsequently, an HT consumable is also provided in which the packaging substrate is wrapped around an aerosol generating substrate and the film covers the end face of the aerosol generating substrate. The film is adhered to the inner surface of the overhanging portion of the packaging substrate. To be understood, when a packaging substrate encloses two components (i.e., an aerosol-generating substrate and a further component such as a hollow tube), the packaging substrate is sometimes referred to as binding paper. Although the term binding paper is used herein, the use of the term binding paper does not implicitly require that the packaging substrate combines further components, unless necessary.

[0050] As can be understood, the protruding portion of the binding paper may be formed by compressing the end of the tobacco, or by adhering or properly attaching another binding paper on top of the first binding paper surrounding an aerosol generating substrate without protrusion, or by using an oversized binding paper that protrudes from the end face when wound. However, compressing the tobacco changes the density of the tobacco at the distal end, which can locally alter the airflow or other properties. Furthermore, adhering additional binding paper increases the outer diameter, creating potential misalignment. Also, using an oversized binding paper prevents the formation of two partially processed consumables by cutting the binding paper, reducing production throughput. Therefore, in exemplary embodiments, the protrusion can be formed as described above and herein; that is, the protrusion can be formed by forming a partially processed consumable with a recessed distal end. Thus, the method further comprises the steps of providing the width of the binding paper and arranging a first aerosol generating substrate and a second aerosol generating substrate on the binding paper, with each aerosol generating substrate spaced apart. The method comprises the step of wrapping binding paper around aerosol generating substrates and in the gaps between them. The method then comprises the step of cutting the binding paper through the portion of binding paper surrounding the gaps to form two partially processed HT consumables, each partially processed HT consumable having a recessed distal end.

[0051] In exemplary embodiments, the membrane is preferably perforated to allow air to flow through the membrane to and from the distal end of an aerosol-generating substrate (where perforation is mechanically puncturing the substrate, for example, by laser drilling or ablation, and includes porous substrates). The perforations are preferably an array of holes through the membrane. The array of holes may be laser ablation holes as described herein, and in particular may relate to holes formed through tipping paper to allow airflow to a cooling segment. Alternatively, an array of holes can be provided by utilizing a mesh material as the membrane, in which case the mesh openings are sized to substantially prevent the passage of the aerosol-generating material but allow airflow.

[0052] Instead of perforating the membrane, holes can be made on the circumferential side of the binding paper to allow airflow between aerosol-generating substrates through the sides rather than the distal end of the consumable. Alternatively, holes passing through the circumferential side may be provided in addition to the perforated membrane. As is understood, whether side holes are necessary or essential is determined by the structure of the HT device in which the consumable is intended to be used, for example, by where the airflow channels are located. Furthermore, similar logic applies to whether a perforated membrane is necessary, for example, if the HT device in which the consumable is intended to be used provides airflow at the distal end.

[0053] In exemplary embodiments, the film is a sheet material such as paper or foil. Here, the method may comprise the step of supplying an oversized sheet material (i.e., film) to an aerosol generating substrate, where the diameter of the sheet material is greater than the diameter of the aerosol generating substrate. Here, the sheet material is pressed into the binding paper so that its edges are folded and in contact with the inner wall of the overhanging binding paper. Here, the method comprises the step of applying an adhesive to the edge region of the sheet material, where the edge region is the oversized portion of the sheet material outside the diameter of the aerosol generating substrate, and therefore, when the sheet material is pressed into the binding paper, that portion is folded inward.

[0054] In exemplary embodiments, the membrane is an oversized sheet member, and the membrane may be pre-formed to assist in folding its sides against an inner circumferential surface. For example, the membrane may be made of notches and / or cuts and / or removed portions. Preferably, the membrane is pre-formed to have tabs around a central region, where the central region may substantially correspond to the size of the end face of the aerosol generating substrate. In embodiments in which the membrane is perforated, it will be understood that the central region has holes. The pre-formed tabs are configured to fold against the inner circumferential surface of the overhanging binding paper. Adhesive may be appropriately applied to the tabs before pressing the membrane into the recessed end of the partially processed consumable.

[0055] In some exemplary embodiments, the membrane has a central opening for housing a heater. That is, in embodiments of consumables configured for use in HT devices having a heater configured to penetrate the consumable (particularly an aerosol generating substrate), the membrane includes a through-hole to facilitate the heater entering the aerosol generating substrate. The hole is assumed to be larger than the pore, thus providing a path for particles to be discharged from the consumable, although the heater is generally significantly smaller than the diameter of the aerosol generating substrate. Thus, the membrane further reduces the risk of aerosol generating particles being pulled out or falling out of the consumable.

[0056] The membrane is preferably a sheet material. For example, the membrane is a flexible sheet material. In some examples, the flexible sheet material is paper or foil (e.g., aluminum foil). However, the membrane may be other planar members such as a disc having considerable thickness. Here, the disc having considerable thickness allows for the application of adhesive between the circumferential surface of the extended binding paper and the thickness of the disc. Examples of suitable discs include bore filters (one or more bore filters known in the art) or other filter elements. For example, the membrane may be a disc made of cellulose acetate or polypropylene tow. In some arrangements, as described herein, the exemplary HT consumable is configured as an upstream consumable. That is, the exemplary HT consumable is a consumable used in an HT device having a cavity for housing the consumable at the upstream end and an air passage through the device to the mouthpiece at the downstream end. Here, in embodiments where the membrane is a disc, the disc may comprise a filter containing a fragrance (e.g., provided in a crush ball known in the art).

[0057] In most common cases, the present invention provides a heated tobacco (HT) system comprising a heated tobacco (HT) consumable with an end closed by a disc, and a heated tobacco (HT) device having a heating zone that does not heat the end region of the consumable with the disc. By closing the end and preventing the tobacco portion from being exposed at the tip, a consumable is provided that advantageously reduces the risk or possibility of the tobacco falling out or being pulled out of the consumable during use, transport, and / or the manufacturing process. Furthermore, the device is configured not to heat the disc.

[0058] In exemplary embodiments of HT consumables where the membrane is a disk, it is preferable that the disk is not heated. That is, in both upstream and downstream consumables, the HT device can be configured not to heat the distal end region of the consumable including the disk. Thus, in further exemplary embodiments, an HT system comprising an HT consumable and an HT device is provided. The HT consumable comprises an aerosol-generating substrate and a disk assembled at the distal end of the aerosol-generating substrate, which is intended to be inserted into a device. Preferably, the disk is assembled to the aerosol-generating substrate by wrapping a packaging substrate around the element. The disk and aerosol-generating substrate may be formed by arranging the disk adjacent to the aerosol-generating substrate on the packaging substrate before wrapping the packaging substrate around the element, but preferably, the method and consumable comprises other embodiments and methods and consumables as described herein. As understood, when the packaging substrate encloses two components (i.e., an aerosol-generating substrate and further components such as a hollow tube), the packaging substrate may be called binding paper. Although binding paper is used in this specification, unless necessary, the use of the term binding paper does not implicitly require the packaging substrate to combine with further components. The HT device comprises a housing having a cavity for housing a consumable. The distal end of the cavity is provided with a stopper into which the consumable is pushed. Thus, when the consumable is adjacent to the stopper, it indicates that the consumable is fully or correctly inserted into the cavity. The housing of the device houses a heater. The heater defines a heating zone, which is the region of the cavity to which the heater supplies heat. Here, the heating zone is positioned toward the entrance of the cavity, spaced apart from the stopper.

[0059] In one exemplary embodiment, the heater is a resistance heater comprising a rod or blade extending into a cavity, where the rod or blade is intended to be inserted into an aerosol generating substrate through a disk. Preferably, the rod or blade comprises an insulating portion and a heating portion, where the insulating portion is positioned between a stopper and the heating portion. Thus, in this case, the heating region of the resistance heater is spaced apart from the stopper by the insulating portion, and the insulating portion can correspond to the disk to prevent unnecessary heating of the disk.

[0060] Other heaters are also envisioned. For example, in some embodiments, a resistance heater or an infrared heater is envisioned to be positioned to heat the sides of the consumable. Here, the heater can be positioned to heat an area away from the stopper; that is, the heater can be positioned so as not to heat the distal end portion of the cavity corresponding to the area to be occupied by the disk. Alternatively, embodiments in which the heater is distributed throughout the consumable are also envisioned. For example, in the case of an induction heater, a susceptor is provided within the consumable and an electromagnetic wave source is provided around the cavity. Here, the heating zone is defined by the susceptor, and in exemplary embodiments, the susceptor is positioned around the aerosol generating substrate and does not extend beyond or into the disk.

[0061] Ideally, the stopper is formed by the closed end of the cavity. However, in some embodiments, the stopper is envisioned to be provided as a projection or ridge within the cavity. In particular, in embodiments including an HT device having a cavity at its upstream end through which air is drawn in via an aerosol generating substrate and a disk, the device may be configured to provide airflow from the distal end of the cavity to a mouthpiece downstream of the device. Here, the distal end of the cavity may include a passage. For example, the passage may be formed in the center of the projection. Here, preferably, a mesh may be provided at the distal end of the cavity.

[0062] In most common cases, the present invention provides a plurality of heated tobacco (HT) consumables having closed ends, wherein once the consumables are arranged in an array, the ends are closed by pressing a membrane into the consumables with a packaging machine. By closing the ends and preventing the tobacco portion from being exposed at the tip, the consumables are provided that advantageously reduce the risk or possibility of the tobacco falling out or being pulled out of the consumable during use, transport, and / or the manufacturing process.

[0063] In a further exemplary embodiment, a method is provided for manufacturing multiple HT consumables, in which the film is pressed into the partially processed consumables. Advantageously, the multiple HT consumables are first assembled and arranged in a matrix. It will be understood that this corresponds to a process on a packaging machine in which the consumables are assembled for packaging preparation. Thus, in the exemplary embodiment, the method step is completed by the packaging machine. Here, after arranging the multiple partially processed consumables in a matrix array, the array of film is simultaneously pressed into each of the partially processed consumables. Advantageously, by simultaneously pressing the film into multiple consumables in the array as part of a processing step performed, for example by the packaging machine, the consumables move at a slower speed within the machine, and a more convenient opportunity is provided in the processing of the consumables to accommodate the pressing of the film.

[0064] Since the placement and pressing steps are performed by the packaging machine, multiple consumables can be kept in the placed state after the membrane is pressed in and until the consumables are packaged.

[0065] Preferably, the step of pressing a film into a partially processed consumable comprises a step of pressing a film according to a method of other embodiments described herein. The process of pressing a film may create a recess at the end of the partially processed consumable by compressing the tobacco, but a particularly preferred method comprises a step of first creating a recessed end of the partially processed consumable, as described in other embodiments herein.

[0066] In most common cases, the present invention provides a heated tobacco (HT) system comprising a heated tobacco (HT) consumable with its ends closed by a foil film, and a heated tobacco (HT) device having an infrared heater positioned at the distal end of a cavity for housing the consumable. By closing the ends and preventing the tobacco portion from being exposed at the tip, a consumable is provided that advantageously reduces the risk or possibility of the tobacco falling out or being pulled out of the consumable during use, transport, and / or the manufacturing process. Furthermore, it is considered that the infrared heating of the consumable can be improved by closing the ends with foil in combination with an infrared heater positioned at the distal end of the cavity.

[0067] In further exemplary embodiments, an HT system is provided comprising an HT device and an HT consumable. The heated tobacco consumable comprises a closed-end consumable having a foil film formed across the distal end of the consumable and closing the distal end of the consumable, where the foil is positioned relative to the end face of the aerosol generating substrate. It will be understood that a preferred method for forming the closed-end consumable with the foil film is as described herein. Thus, the aforementioned method and consumable features are optional features in embodiments of the invention. The HT device includes a housing that defines a cavity for housing the consumable. The cavity has a closed distal end against which the consumable is pressed. This closed distal end forms an infrared heater, where the closed distal end comprises a material that transmits infrared heat. On the opposite side from which the heater is pressed is an infrared heating element. The infrared heating element is an element that generates infrared radiation upon being supplied with electricity. For example, the infrared heating element may be configured such that more infrared radiation is generated passing through the material forming the closed distal end of the cavity than thermal radiation conducted through the same material. Infrared heating is known as a known alternative to HT devices with resistance heating elements, but infrared heating from the distal end tends to generate excessive heat in the consumable. However, it has been found that better heating of the aerosol-generating substrate can be achieved by using a consumable with its distal end closed by a foil film. The foil film is thought to act to reduce the heating effect and improve infrared heating. Furthermore, since the heater operates by utilizing infrared radiation absorbed from the outside by the consumable, in HT devices there is no need for any part of the heater to penetrate the consumable. Thus, closed-end consumables are particularly beneficial both by closing the distal end of the consumable and by reducing the risk of the aerosol-generating substrate falling out or being pulled out of the consumable.

[0068] In some embodiments, an HT device having an infrared (IR) heater at the closed distal end of a cavity provides a passage for airflow between the closed distal end and the external environment. Here, the foil closing the distal end is appropriately perforated. In the example of a downstream consumable, this airflow becomes an intake, and the HT device supplies airflow to the user through the device, the end face of the aerosol generating material, and the downstream end filter of the consumable. Alternatively, as described herein, the HT device has a cavity at the upstream end, into which air is drawn through the aerosol generating substrate and foil, and the airflow from the closed distal end of the cavity becomes an outlet, providing airflow to the mouthpiece downstream of the device. As understood, the foil can be perforated as described herein in relation to the aforementioned embodiments.

[0069] Instead of perforating the foil, holes can also be made in the circumferential sidewalls of the consumable (i.e., the sides of the binding paper surrounding the aerosol generating substrate). Here, the HT device is configured to provide airflow channels on the sides of the cavity. In some embodiments, the airflow channels may be provided by channels or grooves provided in the walls of the cavity. Alternatively, the airflow channels may be provided through the housing.

[0070] In most common cases, another aspect of the present invention provides a heated tobacco (HT) consumable in which the end of the aerosol generating substrate is closed by applying a liquid to the distal end face of the aerosol generating substrate and curing it. By closing the end and preventing the tobacco portion from being exposed at the tip, a consumable is provided that advantageously reduces the risk or possibility of the tobacco falling out or being pulled out of the consumable during use, transport, and / or during the manufacturing process.

[0071] In most common cases, another aspect of the present invention provides a heated tobacco (HT) consumable in which the end of the aerosol generating substrate is closed by applying and curing a liquid to at least a portion of the end face of the aerosol generating substrate. By closing the end face and preventing the tobacco portion from being exposed at the tip, a consumable is provided that advantageously reduces the risk or possibility of the tobacco falling out or being pulled out of the consumable during use, transport, and / or the manufacturing process. In exemplary embodiments, the liquid is applied only to a portion of the distal end face of the aerosol generating substrate, in particular leaving open voids through the cured liquid and the aerosol generating substrate. Here, in some exemplary embodiments, the liquid is applied by means of a brush or doctor blade, etc., and the liquid is not applied to the voids at the end face of the aerosol generating substrate. That is, the end face of the aerosol generating substrate has voids between the fibers and particles, allowing air to be drawn through the aerosol generating substrate. The liquid is applied to the tips of the fibers or particles without filling the voids between the fibers or particles at the end face. As a result, air channels are maintained through the cured liquid and the aerosol generating substrate. Alternatively, the liquid can be applied in a pattern. For example, the liquid can be applied by spraying. In this case, the spray pattern does not completely cover the end face. Because the voids within the aerosol generating substrate and the areas not covered by the spray pattern are random, the probability of coating a sufficient number of voids within the aerosol generating substrate with liquid and substantially blocking the airflow through the end face is considered minimal.

[0072] Accordingly, a method is provided for manufacturing an HT consumable having an aerosol generating substrate having end faces, the method comprising the step of applying a liquid to a portion of the end face and curing the liquid. Advantageously, the cured liquid acts to hold together the particles and fibers of the aerosol generating substrate, thereby reducing the risk of particles or fibers falling off the consumable. Here, preferably, the aerosol generating substrate is wrapped around a packaging substrate (i.e., binding paper, which may bind further components only if otherwise required). The binding paper restrains the circumferential walls of the aerosol generating substrate. Thus, an HT consumable having an aerosol generating substrate having end faces is also provided, in which a liquid is cured on a portion of the end face.

[0073] In exemplary embodiments, the liquid is an adhesive. Preferably, the adhesive covers at least 50%, at least 60%, at least 70%, and at least 80% of the distal end of the aerosol-forming substrate, while simultaneously leaving at least 50%, at least 60%, at least 70%, and at least 80% of the voids at the end face of the aerosol-generating substrate open.

[0074] In some exemplary embodiments, once the adhesive is applied, a disc or the like can be pressed against the edge of a consumable. Here, holes are made in the disc to allow airflow. The holes are also positioned to reduce the risk of the majority of the opening being covered by the adhesive.

[0075] Another aspect of the present invention provides a heated tobacco (HT) consumable in which, in the most common case, some electronic components are distributed in the consumable. Advantageously, by inserting the consumable into the cavity of the HT device, the electronic components distributed in the consumable can complete the circuit using the electronic components distributed on the device. This enables stick recognition. For example, if the consumable is not properly installed, the circuit will not be completed, and the device cannot be started. Automatic switching is also possible, and a smoking session is initiated by inserting the consumable and completing the circuit, requiring no further user interaction (such as providing a button). Thus, an HT system is provided comprising a heater circuit, the heater circuit comprising a battery, a heater, and an electrical connection for connecting the battery to the heater. The HT system comprises an HT device and an HT consumable, the device including electrical contacts that contact the corresponding electrical contacts of the consumable when the consumable is inserted into the cavity of the device. The heater circuit is distributed in both the device and the consumable. The electrical contacts of the consumable and the device constitute part of the heater circuit. That is, the heater circuit comprises a heater, a battery, an electrical connection, and electrical contacts.

[0076] In some exemplary embodiments, the heater is provided on a consumable and the battery is provided on a device. In other embodiments, the battery is provided on a consumable and the heater is provided on a device. In further embodiments, the heater and battery are provided on the same one of the device and consumable, and the electrical connection is provided on the other of the device or consumable. In embodiments where the heater and battery are provided on the same component, there may be four corresponding electrical contacts on each of the device and consumable. However, appropriately, the requirement that one of the anodes or cathodes of the battery and the heater are directly connected to the same component, and therefore only two electrical contacts are required on each component, is maintained.

[0077] As is known in the art, the electrical circuit may include a user interface, such as a push button, for the user to control the system's functions, for example, to start a smoking session or select smoking session parameters such as heater temperature. However, the system may be configured to automatically supply power from the battery to the heater when the circuit is complete. That is, the heater circuit is completed by establishing an electrical connection between the device's contacts and the corresponding contacts of the consumables, and the battery begins to discharge to the heater.

[0078] Preferably, the electrical connections of a consumable can be a first electrical connection and a second electrical connection. For example, the electrical connections of a consumable are an electric anode and an electric cathode. Preferably, each electrical connection of a consumable substantially surrounds the consumable. For example, each electrical connection is provided as a contact band or contact ring around the consumable. Appropriately, the band or ring is positioned perpendicular to the longitudinal axis of the consumable. The first electrical contact band is appropriately spaced at a predetermined distance from the second electrical contact band. Thus, it is not necessary to change the orientation of the consumable around the longitudinal axis and relative to the device in order to make an electrical connection. The simplest method is to surface screen print strips of metal anode and metal cathode onto the outer surface of the consumable. For example, conductive bands can be provided on the binding paper forming the outer surface of the consumable by printing or other deposition or attachment techniques. Here, the conductive bands are connected to the respective batteries and / or heaters and / or electrical connections. In some embodiments, the electrical connections are appropriately covered with a paper layer or other insulating layer before packaging. Here, the user removes the cover before inserting the consumable into the cavity. Advantageously, the cover prevents unintended electrical connections to the contacts.

[0079] Preferably, the electrical connections of the device have corresponding first and second electrical contacts provided at a predetermined distance from a stopper, where the stopper provides an adjacent portion to which the consumable is pressed when inserted into the cavity. As understood, the distance between the stopper and the respective first and second electrical contacts of the device may correspond to the distance between the end of the consumable and the corresponding first and second electrical contacts of the consumable. Thus, by pressing the consumable against the stopper, the respective electrical connections can be aligned and coupled. As described in other embodiments, the stopper may be the closed end or shoulder of the cavity, and the features of the stopper described in those embodiments are also applicable to this embodiment. For example, the stopper may include an opening to an air passage, and appropriately the opening may be covered with a mesh or filter. In some embodiments, the electrical contacts of the device are rings or bands. Alternatively, each electrical contact of the device has a spring-loaded connection, such as a pogo pin, and the connection is pressed against the electrical contact of the consumable by elastic spring bias. In other words, spring-loaded connections are prone to wear because they can be prevented from moving axially relative to the cavity. Each electrical connection may have multiple spring-loaded connections. For example, if the contacts of a consumable are a band containing one or more bridges, and the band forms a perfect circle around the binding paper except for the bridges, then the appropriate spacing of two or more spring-loaded connections ensures that even if one of the spring-loaded connectors is rotatably aligned with the bridge (and therefore no electrical connection is made), the other is not aligned with the bridge, and thus an electrical connection is established.

[0080] In some embodiments, the battery is provided in the consumable. Here, a suitable battery comprises a biodegradable cellulose paper battery. Preferably, the battery is a paper battery wrapped around the consumable (e.g., spirally wound to create an airflow channel). That is, the paper battery may be formed on binding paper, or the paper battery may be formed as a rod (i.e., wound into a rod shape) and bonded by binding paper to the aerosol generating substrate or other elements of the consumable. Advantageously, the airflow channel through the wrapped battery may form part of the airflow channel through the system. If the battery is located upstream of the aerosol generating substrate of the consumable, the battery may act to preheat the incoming air. However, as can be seen, the device may also be configured to provide an airflow channel on the side of the consumable, and corresponding holes through the side of the consumable (i.e., holes in the binding paper) can provide an intake airflow to the aerosol generating substrate while bypassing the battery (i.e., without flowing over or around the battery).

[0081] In exemplary embodiments of the device having a heater, the heater may be a resistance heater. For example, the heater may include a rod or blade positioned within a cavity and inserted into the consumable during insertion (so-called inside-out resistance heating). Alternatively, the heater may have a resistance track around the sides of the cavity (so-called outside-in resistance heating). However, it is assumed that the heater for exciting the consumable susceptor may also take alternative forms, such as an infrared heater or an electromagnetic wave source (inductive heater).

[0082] In exemplary embodiments, a heater is provided on the consumable, and preferably the heater comprises a resistance track. The resistance track may be wrapped around the consumable. Preferably the resistance track is provided on the inside of the binding paper of the consumable. For example, the resistance track can be printed or deposited on the inner surface of the binding paper wrapping the aerosol generating substrate, and it can also be combined with further elements as described herein. Alternatively, the resistance track may be formed, for example, as a separate sheet element, where the separate element can be placed on the binding paper before being wrapped around the aerosol generating substrate. Preferably, the resistance track can be wrapped multiple times around the aerosol generating substrate to generate “wind”. However, preferably, the resistance track is wrapped around the aerosol-generating substrate so as to substantially surround it (i.e., a single layer, but allowing for adhesive overlap), or alternatively, the resistance track can be formed in a zigzag or other corrugated pattern along the length of the consumable such that when wrapped around the consumable, the resistance track forms multiple loops, each loop encircling the consumable in a partial circle, then reversing direction and moving around the consumable in a partial circle in the opposite direction. Alternatively, the resistance track can form a corrugated pattern across the width of the consumable so that when wrapped around the aerosol-generating substrate, the track moves longitudinally in one direction along the consumable, then reverses direction and moves longitudinally in the opposite direction.

[0083] In preferred embodiments where the resistance track is formed inside the binding paper enclosing the aerosol generating substrate, the electrical contacts are preferably formed by exposing them through the binding paper. Here, the electrical contacts may be an extension of the resistance track. Furthermore, the electrical contacts can be appropriately positioned such that they substantially surround the aerosol generating substrate when wrapped around it. In some embodiments, the contacts are exposed by mechanically removing a portion of the binding paper. Preferably, the mechanical exposure may involve removing a portion of the binding paper, i.e., the binding paper can be removed by laser ablation (e.g., ablating the binding paper over the electrical contacts). Alternatively, the binding paper can be removed by scraping it away from the electrical contacts. In some embodiments, the electrical contacts may be exposed through pre-formed openings in the binding paper. In any case, the resistance track remains covered by the binding paper, and only the electrical contacts are exposed.

[0084] Therefore, in the most common case, another aspect of the present invention provides a heated tobacco (HT) consumable in which an electronic component is positioned between packaging substrates enclosing an aerosol generating substrate, and the electrical contacts of the electronic component are exposed through the packaging substrates. As understood, when a packaging substrate encloses two components (i.e., an aerosol generating substrate and a further component such as a hollow tube), the packaging substrate is sometimes referred to as binding paper. Although the term binding paper is used herein, the use of the term binding paper does not implicitly require that the packaging substrate combines further components, unless necessary.

[0085] In a further embodiment, an HT consumable is provided comprising an aerosol generating substrate wrapped around a binding paper, with a track positioned between the aerosol generating substrate and the binding paper. Preferably, the track is a conductive track, where electrical contacts are the portion of the track exposed through the binding paper. Since only the electrical contacts are exposed through the binding paper (i.e., the resistive track connecting the contacts remains between the binding paper and the aerosol generating substrate), the binding paper covers and protects the conductive track. Preferably, the electrical contacts are exposed through a band of binding paper. The band may completely surround the binding paper, or it may substantially surround the binding paper so that one or more bridges are maintained through the band. Preferably, the bands are concentric and spaced apart from one another. The track may also be part of a resistive heater, in which case the conductive track may be a resistive track that generates heat when the battery is discharged, or the conductive track may be part of a battery such as a paper battery.

[0086] A method for manufacturing HT consumables is also provided, comprising the steps of providing binding paper, then placing a resistance track on the binding paper, and then placing an aerosol generating substrate on the resistance track. The method then comprises the step of wrapping the binding paper around the aerosol generating substrate. The method further comprises the step of exposing the electrical contacts of the resistance track through the binding paper. Preferably, the step of exposing the electrical contacts may comprise the step of mechanically removing the binding paper covering the electrical contacts. Alternatively, openings may be pre-formed in the binding paper, and the step of placing the resistance track comprises the step of aligning the electrical contacts of the resistance track with the openings, so that when wrapped around the aerosol generating substrate, the electrical contacts are exposed through the pre-formed openings in the binding paper.

[0087] The exemplary embodiment of the consumable is applicable to downstream consumables (i.e., when the consumable includes a downstream mouthpiece and is inserted into the cavity in a downstream-to-upstream direction). The exemplary embodiment is also applicable to upstream consumables (i.e., when the device includes a downstream mouthpiece and is inserted into the consumable in a upstream-to-downstream direction), and thus the exemplary consumable can also form an exemplary system comprising the consumable and an HT device of the following embodiments.

[0088] In most common cases, another aspect of the present invention provides a heated tobacco (HT) device in which a cavity is provided at the upstream end. Here, the HT device includes a mouthpiece and a cavity, the mouthpiece being interconnected with the cavity via an air passage through the device. The cavity is located at the upstream end of the device, and the mouthpiece forms the downstream end of the device. Preferably, the upstream end is opposite the downstream end. For example, preferably, the device has a generally elongated shape with a longitudinal axis, and the mouthpiece and cavity are concentric with the longitudinal axis. In other words, the provision of the cavity at the upstream end of the device means that consumables are inserted into the cavity in an upstream-to-downstream direction. On the other hand, the HT device described in the background art section may also be called a downstream device, in which consumables are inserted into the cavity in the opposite direction from downstream to upstream, and the consumables include a mouthpiece. Advantageously, by configuring the HT device as an “upstream” device, the mouthpiece is provided in the device, and the device provides a downstream air passage from the aerosol generating substrate. Therefore, the device can be configured to have more or different airflow options than those available in the downstream configuration where the airflow downstream from the aerosol generating substrate is supplied to the consumables.

[0089] Accordingly, an HT device is provided having a mouthpiece, a cavity, and a housing that defines an airflow channel interconnecting the mouthpiece and the cavity. Here, the cavity is configured to accommodate the consumable by inserting the consumable into the cavity in an upstream-to-downstream direction. An HT system comprising the HT device and HT consumables is also provided. The HT consumables include an aerosol generating substrate and may be consumables according to the embodiments described above, or combinations of interchangeable features of the embodiments described above. In embodiments of the invention where the consumable is upstream, a consumable having a closed end is particularly important because the airflow entering the airflow channel through the consumable acts to draw aerosol generating particles away from the distal end of the consumable or deflect them. Furthermore, the consumable does not require a mouthpiece.

[0090] In exemplary embodiments, the mouthpiece is shaped for comfortable inhalation by the user. Preferably, the mouthpiece includes an outlet from the airflow channel. The outlet may be located in the center of the mouthpiece.

[0091] In exemplary embodiments, the air passage is sealed by a housing between the mouthpiece and the cavity. Preferably, the air passage may communicate with the closed distal end of the cavity. Here, consumables having a hole passing through the closed distal end are particularly important. Also, preferably, the air passage is substantially linear, preferably coinciding with the overall longitudinal axis of the body. Alternatively, the air passage may communicate with the side walls (i.e., circumferential walls) of the cavity. Here, the passage may include bends or curves such as bends, so that not all parts of the air passage are substantially coaxial or parallel to the generally longitudinal axis of the body. Downstream air passages provided in the device act to cool and regulate the generated aerosol. Therefore, the device may include baffles and the like. Furthermore, the device may include means for inserting capsules, such as flavor capsules, into the air passage.

[0092] In exemplary embodiments, the device cavity includes a stopper. As in previous embodiments, the stopper serves as a cradle into which the consumable is pushed for complete and correct insertion. Thus, the stopper can provide a reference point for precisely positioning the respective features of the device and consumable in the longitudinal direction. The stopper may be the closed distal end of the cavity, or it may be a projection, etc. Thus, the stopper may correspond to stoppers of other embodiments, and their features are assumed to be relevant to this embodiment. In particular, in embodiments where the stopper is a projection defining an inlet to an airflow channel (i.e., a closed distal end with a central opening that forms the stopper as an annular projection), a mesh is preferably provided to cover the inlet. That is, the inlet is an opening (e.g., a central opening), and the mesh is positioned to cover the opening. Here, the mesh serves to suppress aerosol-generating particles that are being drawn into the device by the airflow. The mesh may also be similar to the mesh of other embodiments. Furthermore, instead of a mesh, the closed distal end of the cavity may be perforated with multiple openings. For example, the closed distal end of the cavity may be an array or matrix of small openings for replicating the mesh. However, a mesh may be preferable because it can be removed for cleaning or replacement.

[0093] In exemplary embodiments of the upstream device, the system is provided by a combination of an HT device and consumables. The consumables appropriately have closed ends. Therefore, the closed ends may conform to other embodiments. In particular, the closed ends may have a membrane. In these embodiments, since the consumables do not require a mouthpiece filter, both ends of the aerosol generating substrate may be finished with the same component or connected to the same component. For example, both ends may have folded closed ends or membranes that close the ends.

[0094] Accordingly, the present invention provides a heated tobacco (HT) system comprising, in the most common case, heated tobacco (HT) consumables having end-to-end symmetry, and a heated tobacco (HT) device having a cavity for housing the consumables from upstream to downstream.

[0095] Accordingly, according to one embodiment, a consumable having end-to-end symmetry is provided. That is, the consumable is configured to operate the same way regardless of which end is inserted into the device. End-to-end symmetry simplifies use by eliminating the need for the user to identify the correct end to insert (i.e., the upstream or downstream end of the consumable). Appropriately, both ends of the consumable are closed. In this specification, “closed end” of the consumable refers to a state in which the end face of the aerosol generating substrate is not exposed. That is, the end face of the aerosol generating substrate is closed.

[0096] Of course, if the consumable has an elongated shape, preferably a rod shape (i.e., the consumable forms a substantially cylindrical outer shape), preferably the upstream and downstream ends of the consumable are air permeable to allow axial airflow through the consumable. Thus, in exemplary embodiments, both closed ends are air permeable, where the ends are appropriately closed by being perforated or by a mesh-type feature, as described herein.

[0097] In the exemplary HT devices, with respect to HT consumables and the HT devices in which such consumables are intended to be used, the HT devices may have any one or more of the following exemplary features, unless those features are incompatible with the embodiments in which they are disclosed. This applies to both HT devices having cavities configured to allow insertion of consumables in the upstream and downstream directions.

[0098] Appropriately, the device may comprise an elongated housing (also called a body). One end of the elongated body may be configured to engage with a consumable. For example, the body is configured to engage with a heated tobacco consumable. An exemplary device comprises a cavity configured to house (i.e., engage with) at least a portion of the consumable. As described, an aerosol-forming article is of the type comprising an aerosol-forming body (e.g., carried by an aerosol-generating substrate).

[0099] An exemplary device includes a heater for heating an aerosol generating substrate.

[0100] In exemplary embodiments, the heater (and thus the heating element) is securely attached to the body. The heating element may be elongated to define a longitudinal axis and, for example, have a substantially circular cross-sectional profile (i.e., transverse to the longitudinal axis of the heating element) (i.e., the heating element may generally be cylindrical). Alternatively, the heating element may have a rectangular cross-sectional profile (i.e., the heater may be a “blade heater”). The heating element may also be tubular in shape (i.e., the heater may be a “tube heater”). The heating element may take other shapes (for example, the heating element may have an elliptical cross-sectional profile). The shape and / or size (e.g., diameter) of the cross-sectional profile of the heating element may generally be consistent over the entire length (or substantially the entire length) of the heating element.

[0101] In exemplary embodiments, the length of the heating element is between 15 mm and 25 mm, for example between 18 mm and 20 mm, and for example, about 19 mm in length. The diameter of the heating element is between 1.5 mm and 2.5 mm, for example between 2 mm and 2.3 mm, and may have a diameter of, for example, about 2.15 mm.

[0102] The heating element may be formed of ceramic. The heating element may have a core made of Al2O3 (for example, a ceramic core). The diameter of the heating element's core may be 1.8 mm to 2.1 mm, for example, 1.9 mm to 2 mm. The heating element may have an outer layer made of Al2O3 (for example, an outer ceramic layer). The thickness of the outer layer may be between 160 μm and 220 μm, for example, between 170 μm and 190 μm, for example, about 180 μm. The heating element may have a heating track, which may extend longitudinally along the heating element. The heating track may be sandwiched between the outer layer and the core of the heating element. The heating track may be made of tungsten and / or rhenium. The thickness of the heating track may be about 20 μm.

[0103] In exemplary embodiments, the heating element may be located in a cavity (of the device) and extend from the internal base of the cavity (i.e., the distal end) toward the opening of the cavity (for example, along the longitudinal axis). The length of the heating element (i.e., the length of the heater along the longitudinal axis) may be shorter than the depth of the cavity. Thus, the heating element may extend only a portion of the length of the cavity; that is, the heating element must not extend through (or beyond) the opening of the cavity.

[0104] Optionally, the heater includes a heating element in the form of a rod or blade extending from the body into the cavity. That is, the heating element extends from an end of the body configured to engage with a consumable. Here, the heating element is configured to be inserted into the aerosol-forming article (e.g., an HT consumable) when the aerosol-forming article is housed in the cavity. In this regard, the distal end of the heating element (i.e., distal to the base to which the heating element is attached to the device) may have a tapered portion, which may facilitate insertion of the heating element into the aerosol-forming article. The heating element can penetrate the aerosol-forming article completely when the aerosol-forming article is housed in the cavity; that is, the entire length, or substantially the entire length, of the heating element can be housed in the aerosol-forming article.

[0105] The heating element may be shorter than or substantially the same length as the axial length of the aerosol-generating substrate that forms part of the aerosol-forming article (e.g., an HT consumable). Therefore, when such an aerosol-forming article engages with the device, the heating element may penetrate only the aerosol-generating substrate and not other components of the aerosol-forming article. The heating element may penetrate the aerosol-forming substrate over substantially the entire axial length of the aerosol-forming substrate of the aerosol-forming article. Thus, upon penetration by the heating element, heat can be transferred from the heating element (e.g., the circumferential surface of the heating element) to the surrounding aerosol-generating substrate. That is, heat can be transferred radially outward (in the case of a cylindrical heating element).

[0106] Alternatively, the heater may be configured to transfer heat radially inward (in the case of a tube heater). In an exemplary embodiment where the heater is a tube heater, the heating element of the tube heater may surround at least a portion of the cavity. When a portion of the aerosol-forming article (i.e., HT consumable) is housed in the cavity, the heating element surrounds the portion of the aerosol-forming article (i.e., to heat that portion of the aerosol-forming article, e.g., the aerosol-generating substrate). In particular, the heating element may surround the aerosol-generating substrate of the aerosol-forming article. That is, when the aerosol-forming article engages with the device, the aerosol-generating substrate of the aerosol-forming article may be positioned adjacent to the inner surface of the (tubular) heating element. When the heating element is activated (by discharging the battery throughout the heater), heat is transferred radially inward from the inner surface of the heating element to heat the aerosol-forming substrate.

[0107] In exemplary embodiments where the heater is a tube heater, the cavity comprises walls (or multiple walls) (e.g., circumferentially), and the (tubular) heating element extends around at least a portion of the walls. Thus, the walls may be positioned between the inner surface of the heating element and the outer surface of the aerosol-forming article. The walls (or multiple walls) of the cavity may be formed from a thermally conductive material (e.g., metal) to allow heat conduction from the heating element to the aerosol-forming article. Thus, heat is conducted from the heating element through the walls (or multiple walls) of the cavity to the aerosol-generating substrate of the aerosol-forming article contained within the cavity. Alternatively, the heating element may be an infrared (IR) heating element. A tubular IR heating element may be configured to radiate more IR radiation across the walls (or multiple walls) than is transmitted by conduction. Thus, the walls (or multiple walls) adequately transmit the radiated IR radiation. The combination of walls (or multiple walls) and a tubular IR heating element is sometimes referred to as an IR heating tube. That is, in exemplary embodiments, the cavity may be formed from an IR heating tube.

[0108] The device further comprises equipment, preferably mechanical means, for entering a cavity. For example, an O-ring configured to be slightly compressed over the inserted consumable, thereby gripping the consumable and providing resistance to pulling it out (and, in relation to a cavity configured upstream, preventing the consumable from falling out due to gravity during use). In embodiments comprising an electrical connection between the device and the consumable, the electrical connection can provide resistance to pulling out the consumable or further assist in pulling it out.

[0109] In some exemplary embodiments, the device comprises a cap positioned at the end of a body configured to engage with a consumable. If the device comprises a heater having a heating element configured to be inserted into the consumable, the cap may at least partially enclose the heating element. The cap may be movable between an open position that provides access to the heating element and a closed position in which the cap at least partially encloses the heating element. The cap may be slidably engaged (i.e., slide-engaged) with the body of the device, or slidably (i.e., able to slide) between the open and closed positions. Alternatively, instead of opening and closing a cavity, or in addition to that, the sliding between the open and closed positions may act to lift the consumable away from the heating element.

[0110] In exemplary embodiments, the cap defines at least a portion of the device cavity. That is, the cavity may be entirely defined by the cap, or the cap and the body may each define a portion of the cavity. If the cap completely defines the cavity, the cap may have an opening (when the cap is in the closed position) for housing a heating element in the cavity. The cap may have an opening to the cavity. The opening may be configured to accommodate at least a portion of a consumable (preferably at least a portion including an aerosol generating substrate). That is, the consumable can be inserted into the cavity through the opening (to engage with the device).

[0111] In exemplary embodiments, the cap is configured such that only a portion of the consumable is housed in the cavity when the consumable is engaged with the device (e.g., housed in the cavity). That is, a portion of the consumable (the portion not housed in the cavity) may protrude from the opening (i.e., extend beyond the opening). In embodiments where the cavity is an upstream cavity, this (protruding) portion of the consumable is the end of the consumable (e.g., the mouth) that is placed in the user's mouth for the purpose of inhaling the aerosol formed by the system.

[0112] In exemplary embodiments, the device may have a power supply or be connectable to a power supply (e.g., a power supply separate from the device), where the power supply is electrically connectable to a heater. In this regard, changing (e.g., switching) the power supply's electrical connection to the heater may affect the heater's state. For example, switching the power supply's electrical connection to the heater can switch the heater between an on and off state (e.g., PWM control). The power supply may be an energy storage device. For example, the power supply may be a battery or a rechargeable battery (e.g., preferably a lithium-ion battery).

[0113] In exemplary embodiments, the device includes an input connection (e.g., a USB port, a Micro USB port, a USB-C port, etc.). The input connection may be configured to connect to an external power source, such as a mains outlet. In some cases, the input connection may be used as a substitute for an internal power source (e.g., a battery, or a rechargeable battery). That is, the input connection may be electrically connectable to a heater (to supply power to a heater). Thus, in some forms, the input connection may form at least part of the device's power supply. If the power supply includes a rechargeable power source (such as a rechargeable battery), the input connection may be used to charge and recharge the power supply.

[0114] In exemplary embodiments, the device includes a user interface (UI). In some embodiments, the UI may include input means for receiving operation commands from the user. The UI's input means allows the user to control at least one aspect of the device's operation. In some embodiments, the input means may include a power button for switching the device on and off. In some embodiments, the UI may additionally or alternatively include output means for communicating information to the user. In some embodiments, the output means may include a light for indicating the state of the device (and / or aerosol-forming article) to the user. The state of the device (and / or aerosol-forming article) indicated to the user may include a state indicating the operation of a heater. For example, the state may include whether the heater is off or on. In some embodiments, the UI unit may include at least one of the following: a button, a display, a touchscreen, a switch, a light, etc. For example, the output means may include one or more (e.g., two, three, four, etc.) light-emitting diodes ("LEDs") that can be located on the body of the device. In some exemplary embodiments, the device may further include a puff sensor (e.g., an airflow sensor) that forms part of the UI's input means. The puff sensor may be configured to detect user inhalation at the end of the system (i.e., the end of the terminal (mouth)). The puff sensor may be, for example, a pressure sensor or a microphone. The puff sensor may be configured to generate a signal indicating a puff state. The signal may be, for example, in the form of a binary signal, indicating that the user has inhaled (aerosol from the consumable). Alternatively or additionally, the signal may indicate characteristics of the inhalation (e.g., the flow rate of inhalation, the length of time of inhalation, etc.).

[0115] In exemplary embodiments, the device may include a controller or be connectable to a controller which can be configured to control at least one function of the device. The controller may include a microcontroller which can be mounted on a printed circuit board (PCB), for example. The controller may also include memory, such as non-volatile memory. The memory may contain instructions which, when implemented, may cause the controller to perform steps of a particular task or method. If the device has input connections, the controller may be connected to the input connections. The controller may be configured to control the operation of a heater (and, for example, a heating element). Thus, the controller may be configured to control the evaporation of an aerosol-forming portion of an aerosol-forming article engaged with the device. The controller may be configured to control the voltage applied to the heater by a power supply. For example, the controller may be configured to switch between a state in which the full output voltage (of the power supply) is applied to the heater and a state in which no voltage is applied to the heater. Alternatively or additionally, the control unit may implement more complex heater control protocols. In exemplary embodiments, the controller includes a voltage regulator which adjusts the output voltage supplied by the power supply to form a regulated voltage. The regulated voltage may then be applied to the heater.

[0116] In some embodiments, if the device includes a UI, the controller may be operably connected to one or more components of the UI. The controller may be configured to receive command signals from input means of the UI. The controller may be configured to control a heater in response to a command signal. For example, the controller may be configured to receive "on" and "off" command signals from the UI and, accordingly, control the heater to the corresponding on or off state. The controller may be configured to transmit output signals to components of the UI. The UI may be configured to communicate information to the user via output means in response to such output signals (received from the controller). For example, if the device includes one or more LEDs, the LEDs may be operably connected to the controller. Thus, the controller may be configured to control the illumination of the LEDs (for example, in response to an output signal). For example, the controller may be configured to control the illumination of the LEDs in response to the state of the heater (for example, on or off).

[0117] If the device includes a sensor (e.g., a puff sensor / airflow sensor), the controller may be operably connected to the sensor. The controller may be configured to receive signals from the sensor (e.g., signals indicating the state of the device and / or engaged aerosol-forming article). The controller may be configured to control an aspect of the heater or output means based on the signals from the sensor.

[0118] In some exemplary embodiments, the device may have a wireless interface configured to communicate wirelessly with an external device (for example, via Bluetooth (e.g., Bluetooth Low Energy Connection) or Wi-Fi). Similarly, an input connection may be configured for a wired connection to an external device to provide communication between the device and the external device. The external device may be a mobile device. For example, the external device may be a smartphone, tablet, smartwatch, or smart car. An application (e.g., an app) may be installed on the external device (e.g., the mobile device). This application may facilitate communication between the device and the external device via a wired or wireless connection. The wireless or wired interface may be configured to transfer signals between the external device and the device's controller. In this regard, the controller may control aspects of the device in response to signals received from the external device. Alternatively, or additionally, the external device may respond to signals received from the device (e.g., signals received from the device's controller).

[0119] As used herein, the terms “upstream” and “downstream” are intended to refer to the direction of vapor / aerosol flow; i.e., the downstream end of an article / consumable is the mouth or outlet from which the aerosol exits the consumable and is inhaled by the user. The upstream end of an article / consumable is typically the end opposite the downstream end. That is, if the airflow through the component or system is substantially straight, the upstream end will be opposite the downstream end. If an air intake is provided on the side of the component, the downstream end is defined by the outlet from which the aerosol is discharged to the user, and the upstream end is typically the area opposite the intake.

[0120] To enable understanding of the present invention and recognition of further aspects and features of the present invention, embodiments illustrating the principles of the present invention will be described in further detail with reference to the accompanying drawings. [Brief explanation of the drawing]

[0121] [Figure 1] This is a schematic plan view of the processing steps in the manufacturing of consumables. [Figure 2] This figure shows a cross-section of a partially processed consumable with a recessed end. [Figure 3] Figure 2 shows folding options a-c for folding the binding paper to close the ends of the consumables. [Figure 4] This is an end view of the recessed end face shown in Figure 2. [Figure 5] This is a perspective view showing the process of pressing a film onto the end of a consumable item. [Figure 6] This is a cross-sectional perspective view through an exemplary consumable. [Figure 7] This diagram shows exemplary consumables before electrical contacts are exposed. [Figure 8] This diagram shows the consumable part shown in Figure 7, with its electrical contacts exposed. [Figure 9] This diagram shows the consumables shown in Figure 7, without the binding paper. [Figure 10] This figure shows unwrapped bonded paper with a resistance track formed on it. [Figure 11] This is a perspective view of a system comprising a device and connected consumables. [Figure 12] Figure 11 is a schematic diagram of the system. [Figure 13] Figure 11 is a perspective view showing the consumables separated from the device. [Figure 14] Figures 11, 12, and 13 show the consumables. [Modes for carrying out the invention]

[0122] Next, aspects and embodiments of the present invention will be described below with reference to the accompanying drawings. Further aspects and embodiments will be apparent to those skilled in the art. All documents referenced herein are incorporated herein by reference.

[0123] Referring to Figures 1 to 4, a heated tobacco (HT) consumable 100 is shown, where the consumable comprises at least an aerosol-generating substrate 110. The aerosol-generating substrate is appropriately formed into a cylindrical rod. The cylindrical rod has a longitudinal axis. In exemplary embodiments, the aerosol-generating substrate 110 is a tobacco rod 110, and although the aerosol-generating substrate is referred to as a tobacco rod herein, the reference to the tobacco rod also applies equally to the aerosol-generating substrate, which is a more comprehensive general term. Preferably, the tobacco rod 110 is formed from reconstituted tobacco. The processing of tobacco material in the preparation of reconstituted tobacco (ricon) by papermaking processes is well known in the art, as exemplified in Canadian Patent No. 862,497, which is incorporated herein by reference. The process described therein is particularly advantageous for papermaking processes for preparing sheets of reconstituted tobacco material ("ricon"). A carrier to aid in aerosol formation is added to the ricon so that the consumable can be specifically adapted to operate as an HT consumable. The ricon is prepared in a strip maker and assembled into a rod. Therefore, as shown in Figure 4, the tobacco rod comprises multiple parallel strips 112 of cut ricon running parallel to the longitudinal axis. Thus, in Figure 4, only the cut ends of the strips 112 are shown. The strips are tightly packed, but gaps 114 remain between adjacent strips. As can be understood, the gaps provide air passages through the tobacco rod 110.

[0124] Figure 2 shows a partially processed consumable 102 in which a tobacco rod 110 is wrapped with binding paper 120. In some embodiments, the binding paper 120 may also wrap and bind further elements around the tobacco rod 110, but in Figure 2 it is shown only as surrounding the tobacco rod. As shown, the partially processed consumable 102 has a recessed end 104. Here it is shown that the end face 114 of the tobacco rod 110 is recessed relative to the end face of the binding paper 120; that is, a portion of the binding paper protrudes from the end face 114. Appropriately, the portion of the binding paper protruding from the end face 114 is cylindrical.

[0125] Referring to Figure 1, an exemplary method for manufacturing the partially processed consumable 102 shown in Figure 2 is illustrated. Here, a binding paper 120 is provided, and a first tobacco rod 110a and a second tobacco rod 110b are placed on the binding paper. The first and second tobacco rods are coaxially aligned but separated by a gap G. That is, the cut end face of one tobacco rod 110a is positioned longitudinally away from the cut end of the other tobacco rod 110b to create a gap or space between their respective end faces 114. In the exemplary embodiment, each tobacco rod is of a single length, i.e., the length of the tobacco rod intended for a single consumable.

[0126] The method comprises the step of wrapping binding paper around two tobacco rods 110 in order to wrap tobacco rods of twice their length, as is known in the art. For example, the wrapping step may include a step of bonding and curing to fix the binding paper 120 in place. Thus, a unit is formed comprising the binding paper and two spaced tobacco rods. By cutting the binding paper 120 through the gap G, the unit is transformed into two partially processed consumables (and preferably two identical partially processed consumables).

[0127] As shown in Figure 1, optionally, holes are made in the portion 122 of the binding paper that is aligned with the gap G, and preferably in the central portion. The binding paper may be pre-perforated. Alternatively, holes may be made after the unit has been formed by wrapping the binding paper around the tobacco rod. For example, holes can be formed by laser ablation, as is known in the art to form vents in a downstream cooling segment. Thus, there may be multiple holes of a size that prevents tobacco particles or fibers from passing through but allows airflow. The holes may be spaced longitudinally and axially along the portion 122 of the binding paper.

[0128] Once the unit is formed and a hole is made in portion 122, the method includes the step of cutting the binding paper in region 122. Thus, the unit is divided into two partially processed consumables 102, one of which is shown in Figure 2. Preferably, portion 122 is cut along the center of the gap so that the two partially formed consumables are substantially identical. Thus, it will be understood that the gap G is predetermined as twice the length of overhang required for each partially processed consumable 102.

[0129] The partially processed consumable 102 shown in Figure 2 is further processed to form the consumable 100 by closing the distal end portion. However, it will be understood that in exemplary embodiments, there may be further processing steps to combine further segments or elements, such as filters and cooling segments or tubes.

[0130] One exemplary embodiment for closing the partially processed consumable 102 shown in Figure 2 is to fold the overhanging binding paper over the end face 114. Several folding methods are envisioned here, as shown in Figure 3. Figure 3a shows an example where the overhanging binding paper is flattened and folded over the end face 114. In Figure 3b, the overhanging portion of the binding paper is folded in an "envelope" or "letterbox" fold, with the first edge folded, then the opposite edge folded, and finally the remaining edge folded. Here, the binding paper may be pre-creased before the wrapping step to provide fold lines for the envelope fold. In Figure 3c, the overhanging portion of the binding paper 120 is cut to generate multiple fingers 124. For example, an opening can be formed by cutting the binding paper and removing a segment of the binding paper before the packaging step. The removed segment is shaped such that fingers are formed when cut. The fingers can then be folded in sequence or in other sequences to create an "iris".

[0131] To cover the end face, the length of the overhang may be substantially the same as or longer than the radius of the tobacco rod 110. However, it will be understood that if the overhang is too long, there will be too much material to fold. Therefore, the length of the overhang may be less than 75%, or less than 70%, or less than 60%, or less than 55% of the diameter of the tobacco rod 110.

[0132] Adhesives may be used to prevent the binding paper from unfolding. Also, if the consumables are intended to be punctured by a heater during use, the protruding binding paper may be shaped so that an opening remains through the fold when folded. This opening may, appropriately, be a central opening.

[0133] Referring to Figure 5, an exemplary method for manufacturing a heated tobacco consumable 100 is shown. Here, a film 130 is pressed onto a partially processed consumable comprising binding paper 120 around which a tobacco rod 110 is wrapped, and the film 130 is adhered to the inner surface of the binding paper 120. The process of pressing the film 130 onto the partially processed consumable 102 acts to compress the tobacco at its distal end, and by compressing the tobacco, a portion of the binding paper 120 protrudes or bulges out from the end face of the tobacco (which is now being compressed). Alternatively, the film is pressed onto the partially processed consumable 102 as shown and described in Figures 1 to 4 above.

[0134] In Figure 5, the film 130 is shown as a sheet 131. For example, the sheet may be paper or foil. Since the tobacco rod 110 is cylindrical, the sheet is also shown as circular, and it will be understood that the central region of the sheet corresponds to the cross-sectional shape of the tobacco rod 110. The sheet is oversized relative to the tobacco rod 110. Therefore, the edge region 132 of the sheet extends beyond the diameter of the tobacco rod 110 when the tobacco rod 110 and the sheet are centered. Adhesive is applied to the edge region here. As a result, no adhesive is applied to the central region that covers and closes the end face 114 of the tobacco rod 110. When the oversized film is pressed onto a partially processed consumable, it will be understood that the edge region comes into contact with the binding paper. This causes the edge region to fold against the inner side of the binding paper. A push rod 140, and preferably a metal push rod, is shown pressing the sheet onto the protruding binding paper 120.

[0135] In some embodiments, the membrane 130 is perforated. For example, the membrane 130 may have an array of holes of a size that prevents tobacco fibers or particles from passing through the tobacco rod 110 but allows airflow. The array of holes is envisioned as a matrix substantially extending across the entire area of ​​the membrane. In other embodiments, additionally or alternatively, the membrane may have an opening for accommodating a heater. As understood, the opening is envisioned as a central opening and is sized to accommodate, for example, a resistance heating rod or blade.

[0136] The membranes may be pressed individually onto partially processed consumables 102, for example, on a combiner, but preferably, multiple membranes are pressed simultaneously onto partially processed consumables. Here, the multiple consumables are first arranged in an array. Since this corresponds to a step in a packaging machine, it is assumed that the step of pressing multiple membranes onto multiple partially processed consumables can be performed in a packaging machine. Here, the speed is slower than when the consumables are arranged individually on a combiner because they move together. Therefore, it is advantageous to complete the extrusion step on a packaging machine. In a hypothetical embodiment, the simultaneous extrusion step is completed by multiple pushers moving simultaneously and thereby arranging in the corresponding array.

[0137] Figure 6 shows an exemplary heated tobacco consumable 100. The consumable is intended to be inserted into a cavity in a downstream-to-upstream direction, with a mouthpiece 150 provided at the upstream end of the consumable, and a spacer 160 and a bore filter 170 positioned between the mouthpiece and the tobacco rod 110. As is known, the elements can be enclosed in various ways by binding paper 120 and tipping paper 152. In Figure 6, a membrane, indicated as a disc 135, is attached to the end face of the tobacco rod. Preferably, the disc 135 is a metal cap. However, other discs are also conceivable. For example, the disc may be a mesh or a bore filter, etc. Unlike when the membrane is paper or foil, the edges of the disc have sufficient thickness to allow adhesive to be applied directly. Furthermore, advantageously, the disc may be configured to have sufficient thickness to accommodate flavoring components such as a disintegrable liquid capsule.

[0138] As described above, the disc 135 is pressed against the end of the tobacco rod and adhered to the inner surface of the binding paper. This is done, for example, by compressing it when pressing the tobacco, or by pressing it into a partially processed consumable 102 which includes a recessed end, as described herein. Similarly, the advantages of simultaneous pressing into a baler also apply.

[0139] Alternatively, the disc 132 can be bonded to the end face 114 of the tobacco rod. Here, the adhesive is applied only to a portion of the end face so as not to fill the voids in the end face of the tobacco rod (see Figure 4). For example, the adhesive can be sprayed in droplet form. Alternatively, the adhesive can be applied by brushing, scraping, or other means to bond only to the tobacco fibers and not to filling the voids. The disc 135 is then pressed against the end to adhere. This may be done in addition to, or instead of, bonding to the inner circumferential surface, and if not bonded to the inner circumferential end, the disc may not be pressed into the binding paper. However, pressing the binding paper is considered beneficial to aid in alignment and limit the risk of the disc protruding from the outer contour of the binding paper. Furthermore, in some embodiments, the disc 135 is optional, and the presence of cured liquid adhesive is sufficient to bond the fibers together and reduce the risk of fibers or particles falling off the consumable.

[0140] In embodiments where the membrane 130 comprises a disk 135, the disk may be a filter such as a monoacetate filter or a bore filter. Here, the consumable is appropriately configured for use in a heated tobacco device, and the device is configured not to directly heat the disk 135. In these exemplary embodiments, the device comprises a cavity for housing the consumable. The consumable is inserted using the disk 135 first, in an upstream-to-downstream or downstream-to-upstream direction. The disk is pressed against a stopper in the cavity. For example, the stopper may be the bottom of the cavity, or it may be a protrusion against which the disk is pressed. Thus, the stopper functions as a register point in the cavity for determining the position of the end of the consumable, where the cavity includes a heater element having a heating zone. Heat is transferred to the consumable in this zone. Since the stopper provides a register for determining where the disk is located, the heating zone is configured not to heat the end of the cavity where the disk is located.

[0141] The heated tobacco consumable shown in Figure 6 is particularly advantageous when used in a device in which an infrared heater is positioned at the end of the cavity housing the consumable. Infrared heaters are known. However, it has been found that when used in combination with a metal film (i.e., foil or metal disc) at the end of the cavity, the heat can be controlled more effectively, and better heating is applied to the tobacco rod than when a metal film is not placed on the end face of the tobacco rod.

[0142] Referring to Figures 7 to 10, further exemplary consumables are shown. Consumable 100 includes a tobacco rod 110 at one end. The tobacco rod 110 is surrounded by binding paper 120. A resistance track 180 is sandwiched between the tobacco rod and the binding paper. The resistance track is positioned between a first electrical contact 181 and a second electrical contact 182. The resistance track is configured to provide a thin, elongated connection between the two electrical contacts. For example, the resistance track may be spirally wrapped around the tobacco rod. However, as shown in Figure 10, the resistance track and contacts are preferably coated onto the binding paper 120 before the tobacco rod 110 is placed on top and the binding paper is wrapped around it to surround the tobacco rod. Here, the resistance track can be deposited by printing or other methods, or the resistance track may be formed as another layer placed on top of the binding paper 120. Because the resistance track is wrapped around the tobacco rod using the binding paper, the resistance track may bend in a reciprocating pattern (displayed as a zigzag) around the radial direction. Alternatively, the reciprocating pattern may extend in the vertical direction (not shown). In either case, a similar spiral winding is formed.

[0143] Here, since part of the heater circuit is distributed across the consumable, an electrical connection is needed between the consumable and the device. The device is assumed to have electrical contacts, such as spring pins, that are biased to contact the electrical contacts of the consumable. As described above, the device may include a stopper at the bottom of the adjacent cavity in which the consumable resides. The stopper acts as a register for longitudinal positioning of the consumable within the cavity. It will be understood that this directional alignment ensures that the longitudinal alignment of the electrical contacts of the device and the consumable is ensured.

[0144] In exemplary embodiments, as shown in Figure 8, the electrical contacts are exposed through the binding paper by applying contacts 181 and 182 to the inside of the binding paper. Preferably, the electrical contacts are exposed by mechanically removing a portion of the binding paper 120. For example, the electrical contacts are exposed by laser ablation or mechanical scraping of the binding paper. Figure 7 shows the consumables before mechanical removal of the binding paper. Preferably, the contacts are formed and exposed to create contact bands. The bands are shown as being spaced longitudinally. It will also be understood that the electrical contacts may be anode or cathode contacts. Only the electrical contacts are exposed, and the rest of the resistance track is not exposed, thus protected / insulated by the binding paper.

[0145] The consumables described herein are suitable for use in devices having a cavity into which the consumables are inserted from downstream to upstream. Here, the consumables typically include a cooling segment and a mouthpiece arranged continuously downstream of the tobacco rod 110. However, these features are also applicable to a device described later, which has a cavity into which the consumables are inserted from upstream to downstream. Here, since the user inhales from a mouthpiece provided in the device, a mouthpiece is not required for the consumables. An experienced reader will understand the possible modifications. Furthermore, because a mouthpiece filter is not required, it is possible to provide symmetry on both sides of the tobacco rod. For example, both ends may be closed by folding, by a membrane, or by a disc, as described herein. Achieving end-to-end symmetry allows the consumables to be inserted in either direction without affecting performance.

[0146] Referring to Figure 11, an exemplary heated tobacco system 10 is shown. The system 10 comprises a consumable 100 and a device 200. The device 200 is an electrical device for heating the consumable 100. For example, generally, the device 200 includes a housing or body 202 having a cavity 210 for housing the consumable, a compartment for electronic equipment, and a mouthpiece 220. In contrast to known devices in which the consumable is inserted into the consumable from downstream to upstream (i.e., against the airflow), the consumable 100 is inserted into the device from upstream to downstream (i.e., along the airflow). Thus, the device 200 is provided with a mouthpiece. Thus, the body also defines an air passage 230 (see Figure 12) between the cavity 210 and the mouthpiece 220.

[0147] The device 200 is generally elongated and comprises a cylindrical body portion 204 extending along the central axis from the upstream end 205. The cylindrical body is intended to be held in a manner similar to that of a burning cigarette. The mouthpiece 220 is shown as an integral part of the body 202 and extends between the cylindrical body portion 204 and the downstream end 206 of the device. The outer surface of the mouthpiece 220 is shaped at the top to be a comfortable mouthpiece shape for easy user inhalation. For example, the mouthpiece is scaled down to the size of the body portion and flattened into a non-circular cross-section. The mouthpiece provides an outlet 222 for the air passage 230.

[0148] The main body 202 of device 200 may include user interface buttons and / or user feedback means such as LEDs to inform the user of the device status (i.e., power on, charge level, etc.). However, as described, the embodiments shown in Figures 12 and 13 include stick recognition, which allows the heater to be automatically turned on and a smoking session to begin by inserting the consumable 100. This reduces the amount of electronic equipment held within the compartment, allowing the compartment and device 200 to be made slimmer or smaller.

[0149] The cavity 210 is generally shown in Figure 13 as a cylindrical bore extending from the downstream end of the housing 202. The cylindrical bore of the cavity 210 is generally sized to fit snugly with the consumable 100, that is, it has a diameter similar to that of the consumable. However, because it must be large enough to accommodate the consumable, and because insertion from upstream to downstream during use and the user holding the device 200 may cause gravity to act to pull the consumable 100 out of the device 200, further means may be provided to grip the consumable to prevent it from falling out. Further means may be a mechanically activated gripper or a closable lid. However, it is preferable that a compressible element within the cavity be used. For example, one or more O-rings (not shown) positioned to protrude into the cavity compress the consumable when it is inserted, acting to grip the consumable 100 into the device 200.

[0150] As can be understood, the cavity is positioned to coincide with the central axis of the cylindrical body portion 204. The central bore of the cavity 210 extends along the central axis to a distance sufficient to accommodate at least the aerosol generating substrate 110 (i.e., the tobacco rod) of the consumable 100. As is known in the art, the system includes a heater and a battery to power the heater. The heating element of the heater can be any known heating element, such as a resistance heating element penetrating the consumable for heating from the inside out, or a resistance heating element surrounding the cavity for heating from the outside in, or an electromagnetic generator used with the consumable's susceptor for inductive heat generation. However, in Figure 12, the heating element is appropriately shown as an infrared element. As is known, an infrared element emits infrared radiation through gaps or spaces (or, if passing through a permeable material forming the cavity). Thus, at least a portion of the wall of the cavity 210 is shown as an infrared heating tube 212.

[0151] As shown in Figure 12, the air passage 230 is provided through the device 200 from the cavity to the mouthpiece outlet 206. The air passage can be positioned to communicate with the side walls of the cavity (depending on the consumables, particularly where the airflow from the tobacco rod 110 is drawn), but is shown to communicate with the axial end of the cavity 210, where the air passage coincides with the central axis of the device 200. The air passage 230 extends substantially linearly from the cavity to the mouthpiece. Thus, the air passage 230 is a central air passage. However, one advantage of having the cavity formed at the upstream end and the mouthpiece at the downstream end of the device is that the device provides the air passage 230 downstream from the tobacco rod 110. Thus, it is conceivable that the air passage 230 may include a baffle or equipment for introducing flavor (such as a cavity for inserting flavor capsules, etc., into the air passage), or an airflow sensor, etc., for regulating and cooling the aerosol generated before inhalation through the mouthpiece 220.

[0152] The main body 202 can define air intakes to the air passage 230 and the cavity 210. Otherwise, the air passage 230 is substantially sealed. For example, an intake may be provided in the air passage 230 downstream of the cavity for introducing cooling air, and / or, if air is not configured to be drawn in through the upstream end of the consumable, an intake may be provided in the cavity upstream of the location where the tobacco rod 110 is intended to be positioned for introducing air into the consumable.

[0153] The electronics compartments are located within the main body 202 and around the cavities and airflow 230. In Figure 12, the airflow 230 is shown as a compartment 208 located around the airflow. That is, the airflow 230 passes through compartment 208. Compartment 208 is shown as housing a PCBA, but in an optional embodiment it may contain a battery for a heater circuit.

[0154] The device 200 includes a stopper 240 within the cavity 210. The stopper provides a register point by providing an adjacent portion against which the consumable is pressed to prevent further insertion of the consumable into the cavity. That is, if other parts or elements of the device need to be longitudinally aligned with respect to the inserted consumable, they can be spaced a predetermined distance from the stopper corresponding to the distance at which cooperating features or elements on the consumable are spaced from the distal end. The stopper 240 may be the closed end of the cavity. Alternatively, the stopper may be provided as a projection protruding into the cavity. In either case, as described above, the intake port to the air passage 230 is provided in the stopper, preferably in the center. The intake port may be covered with a mesh that acts as a filter to prevent tobacco particles or fibers from entering the air passage. The mesh may be provided instead of, or in addition to, the closed end of the consumable. However, the closed end of the consumable alone may be sufficient. In the case of the upstream cavity embodiment, since the airflow has the effect of drawing or attracting particles into the airflow channel, it is particularly important to prevent tobacco particles or fibers from entering the airflow channel.

[0155] It will be understood that the stopper or consumables, including combinations of features, are substantially as described herein. For example, in Figure 12, the consumables are shown together with the distal membrane 130.

[0156] Figure 13 shows an exemplary consumable 100 for use with device 200. Here, consumable 100 comprises an aerosol generating substrate 110 (i.e., a tobacco rod) enclosed in packaging paper 120. As can be understood, the tobacco rod is located at the downstream end of the consumable. The membrane 130 closes the distal downstream end of the consumable and covers the end face of the tobacco rod. Advantageously, the closed end of the consumable acts to prevent the passage of tobacco particles but to allow airflow. Upstream of the tobacco rod 110 is a spacing tube. In the exemplary embodiment shown in Figure 13, the upstream end of the consumable comprises a cellulose paper battery. The cellulose paper battery 190 is incorporated into the consumable by, for example, binding paper or tipping paper. The cellulose paper battery 190, by being spirally wound, provides airflow from the upstream end axially to the spacing tube, allowing inhalation to proceed through the tobacco rod 110 to the mouthpiece 220.

[0157] Therefore, by providing a battery in the consumable, the system's heater circuit is distributed across device 200 and consumable 100. Electrical contacts are provided on the consumable and device so that they can work together to make an electrical connection when inserted. Because the battery is distributed across the consumable (and other components of the heater circuit, such as heating elements and / or electrical connections, are also assumed to be additionally or alternatively distributed across the consumable), the heating circuit is not complete until the consumable is inserted into the cavity. Thus, the distribution of the heating circuit across the consumable enables stick recognition. That is, while sensors can be included to recognize when the consumable has been inserted into the cavity, the completion of the heater circuit connecting the heating elements and battery can be utilized to recognize the insertion of the consumable and automatically initiate a predetermined heating cycle (i.e., a smoking session).

[0158] As shown in Figure 14, the consumable electrical contacts 181 and 182 may be exposed contact bands. Two contact bands corresponding to the anode and cathode connections are shown. The electrical contacts on the device may be corresponding bands, or they may be elements such as spring pins or bias pins.

[0159] The features disclosed in the preceding description, the following claims, or the accompanying drawings may be expressed as appropriate in their specific forms, or in terms of means for performing the disclosed functions, or methods or processes for obtaining the disclosed results, and such features may be used individually or in any combination to realize the present invention in a variety of forms.

[0160] While the present invention has been described in relation to the exemplary embodiments described above, many equivalent modifications and changes will be apparent to those skilled in the art upon reading this disclosure. Therefore, the exemplary embodiments of the present invention described above are illustrative and not limiting. Various modifications can be made to the described embodiments without departing from the spirit and scope of the invention.

[0161] To avoid any doubt, the theoretical explanations provided herein are provided for the purpose of improving the reader's understanding. The inventors do not wish to be bound by any of these theoretical explanations.

[0162] The section headings used herein are for organizational purposes only and should not be construed as limiting the subject matter described.

[0163] Throughout this Specification, including in subsequent claims, unless the context specifically requires otherwise, the words “have,” “comprise,” and “include,” as well as variations such as “having,” “comprises,” “comprising,” and “including,” shall be understood to imply that the specified integer or step, or group of integers or steps, is included, but not that any other integer or step, or group of integers or steps, is excluded.

[0164] It should be noted that the singular forms “a,” “an,” and “the” as used herein and in the appended claims also include multiple referents unless the context clearly indicates otherwise. In this specification, ranges may be expressed as “approximately” from one particular value and / or “approximately” to another particular value. Where such ranges are expressed, another embodiment includes one particular value and / or another particular value. Similarly, where a value is expressed as an approximation by the use of the antecedent “approximately,” it will be understood that a particular value forms another embodiment. The term “approximately” with respect to numbers is optional and means, for example, + / - 10%.

[0165] As used herein, the terms “preferred” and “preferably” refer to embodiments of the present invention that may provide particular benefits under certain circumstances. However, it should be understood that other embodiments may also be preferred under the same or different circumstances. Therefore, the enumeration of one or more preferred embodiments does not mean or imply that other embodiments are unhelpful, nor is it intended to exclude other embodiments from the scope of this disclosure or the claims.

Claims

1. A heated tobacco system comprising a heater circuit, a heated tobacco device, and heated tobacco consumables, The heater circuit comprises a battery, a heating element, an electrical connection for connecting the battery and the heating element, and a plurality of electrical contacts. The device comprises a cavity for housing the consumables, and the cavity includes at least one of the plurality of electrical contacts. The consumable part comprises at least one of the plurality of electrical contacts, A heated tobacco system in which, when the consumable is inserted into the cavity, the electrical contacts of the device and the consumable are electrically connected, completing the heater circuit to automatically connect the battery and the heating element.

2. The system according to claim 1, wherein when the circuit is completed by inserting the consumable into the cavity, the heating cycle is automatically started by supplying power from the battery to the heating element.

3. The system according to claim 1 or 2, wherein the battery is distributed among the consumables, and optionally the heating element is distributed among the device.

4. The system according to claim 1 or 2, wherein the heating element is dispersed in the consumable.

5. The system according to any one of claims 1 to 4, wherein each electrical connection of the consumable comprises a contact band substantially surrounding the consumable.

6. The system according to any one of claims 1 to 5, wherein the device comprises a stopper in the cavity, the stopper provides an adjacent portion against which the consumable is pressed when the consumable is fully inserted, and at least one feature of the device is spaced at a predetermined distance from the stopper based on the spacing of cooperating features on the consumable from the distal end of the consumable.

7. The system according to claim 6, wherein the stopper is provided with an air passage opening, and the air passage opening is covered with a mesh.

8. The system according to any one of claims 1 to 7, wherein at least a portion of the cavity is provided with an infrared heating tube.

9. The system according to any one of claims 1 to 8, wherein the cavity is configured to allow the consumables to be inserted from downstream to upstream.

10. The system according to any one of claims 1 to 8, wherein the device comprises a mouthpiece at the downstream end of the device, the cavity is located at the upstream end opposite the device, and the device defines an air passage between the cavity and the mouthpiece.

11. A heated tobacco consumable for use in a system according to any one of claims 1 to 10, wherein the consumable comprises a battery at its upstream end and a packaging substrate at its downstream end that surrounds an aerosol generating substrate, and at least one electrical contact of the battery is provided on or through the packaging substrate.

12. The consumable according to claim 11, wherein each electrical contact is provided with a contact band that substantially surrounds the consumable.

13. The consumable according to claim 11 or 12, wherein a film is disposed at the downstream end of the consumable.

14. A heated tobacco device for use in a system according to any one of claims 1 to 10, or for use with the consumables according to claims 11 to 13, wherein the device comprises a body housing some, but not all, of the components of a heater circuit from a component list of a battery, a heating element, and an electrical connection for connecting the battery to the heating element, the device comprising a cavity for housing a consumable, the cavity comprising at least one electrical contact configured to electrically connect with the consumable when the consumable is inserted into the cavity.

15. The device according to claim 13, wherein the electrical contact is flipped up radially with respect to the longitudinal direction of the cavity and biased.

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