Consumable

Abstract

Disclosed herein is a consumable for use in a device for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the consumable including a hollow tube containing a carrier and an aerosolizable material including an amorphous solid coated on the carrier.

Description

Technical Field

[0001] The present invention relates to a consumable used in an apparatus for heating an aerosolizable material, a method of manufacturing a consumable used in an apparatus for heating an aerosolizable material, a system including a consumable having an aerosolizable material, and an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material.

Background Art

[0002] Smoking articles such as cigarettes and cigars burn tobacco during use to generate smoke. Attempts have been made to create products that release compounds without combustion as an alternative to these articles. Examples of such products include so-called "non-combustion heating" products or tobacco heating devices or products that release compounds by heating the material without combustion. The material may be, for example, tobacco or other tobacco products, which may or may not contain nicotine.

Summary of the Invention

[0003] A first aspect of the present invention provides a consumable for use in an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the consumable including a hollow tube including a carrier and an aerosolizable material including an amorphous solid coated on the carrier.

[0004] In an exemplary embodiment, the consumable is non-combustible.

[0005] In an exemplary embodiment, at least a portion of the aerosolizable material is located radially inward of the carrier.

[0006] In an exemplary embodiment, the aerosolizable material forms at least a portion of the surface of the hollow tube. In an exemplary embodiment, the surface is the innermost surface of the hollow tube.

[0007] In an exemplary embodiment, the aerosolizable material forms at least a majority of the innermost surface of the hollow tube.

[0008] In an exemplary embodiment, the aerosolizable material forms all of the innermost surface of the hollow tube.

[0009] In an exemplary embodiment, at least a portion of the aerosolizable material is located radially outward of the carrier.

[0010] In an exemplary embodiment, the aerosolizable material forms at least a portion of the outermost surface of the hollow tube.

[0011] A second aspect of the present invention provides a consumable for use in an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the consumable including a hollow tube including a carrier and an aerosolizable material including an amorphous solid fixed to the carrier, the aerosolizable material forming at least a portion of the innermost surface of the hollow tube.

[0012] In an exemplary embodiment, the aerosolizable material forms at least a majority of the innermost surface of the hollow tube.

[0013] In an exemplary embodiment, the aerosolizable material forms all of the innermost surface of the hollow tube.

[0014] In an exemplary embodiment, the carrier does not include a heating material that can be heated by transmission of a varying magnetic field.

[0015] In an exemplary embodiment, the consumable does not include a heating material that can be heated by penetration of a varying magnetic field.

[0016] In an exemplary embodiment, the carrier is tubular.

[0017] In an exemplary embodiment, the carrier includes a rolled strip.

[0018] In an exemplary embodiment, the aerosolizable material is tubular.

[0019] In an exemplary embodiment, the consumable is heatable by the penetration of a variable magnetic field, and includes a heating element that heats the aerosolizable material thereby.

[0020] In an exemplary embodiment, the heating element includes one or more materials selected from the group consisting of a conductive material, a magnetic substance, and a magnetoconductive material.

[0021] In an exemplary embodiment, the heating element includes a metal or a metal alloy.

[0022] In an exemplary embodiment, the heating element includes one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper, and bronze.

[0023] In an exemplary embodiment, the carrier includes a heating element.

[0024] In an exemplary embodiment, the carrier includes a closed circuit of a heating element.

[0025] In an exemplary embodiment, the carrier consists of or consists essentially of a heating element.

[0026] In an exemplary embodiment, the heating element has a substantially constant cross-sectional area axially spaced along the consumable.

[0027] In an exemplary embodiment, the carrier includes a first layer and a second layer, the first layer includes a heating element, the second layer is not heated by penetration by a variable magnetic field, and the first layer is located between the aerosolizable material and the second layer.

[0028] In an exemplary embodiment, the second layer includes one or more materials selected from the group consisting of paper, cardboard, paperboard, corrugated board, recycled tobacco, and plastic material.

[0029] In an exemplary embodiment, the carrier forms at least a part of the surface of the consumable.

[0030] In an exemplary embodiment, the carrier forms at least a majority of the surface of the consumable.

[0031] In an exemplary embodiment, the carrier forms all of the surface of the consumable.

[0032] In an exemplary embodiment, the surface of the consumable is the outermost surface of the consumable.

[0033] In an exemplary embodiment, the surface of the consumable is the innermost surface of the consumable.

[0034] In an exemplary embodiment, the carrier has one or more holes extending through the carrier to allow an aerosol generated from the aerosolizable material to pass to the surface of the consumable while the carrier is heating the aerosolizable material during use.

[0035] In an exemplary embodiment, the consumable includes a porous body of material for containing an aerosol for containing an aerosol generated from the aerosolizable material while the aerosolizable material is being heated during use. In an exemplary embodiment, the aerosolizable material is located radially between the carrier and the porous body of material containing the aerosol.

[0036] In an exemplary embodiment, the aerosolizable material has a thickness of 0.1 millimeter to 5 millimeters in a direction orthogonal to the axial direction of the consumable.

[0037] A third aspect of the present invention provides a system for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the system comprising a consumable of the first aspect or the second aspect of the present invention, and a device for heating the aerosolizable material of the consumable to volatilize at least one component of the aerosolizable material, the device comprising a heating region for accommodating the consumable, and a device for heating the aerosolizable material when the consumable is in the heating region.

[0038] In an exemplary embodiment, the device includes a magnetic field generator that generates a variable magnetic field for entering the heating region when the consumable is in the heating region.

[0039] In an exemplary embodiment, the device includes a heating element including a heating material, the heating element being in thermal contact with the heating region, and the device includes a magnetic field generator that generates a variable magnetic field that enters the heating element to heat the heating region.

[0040] In an exemplary embodiment, the device for heating the aerosolizable material when the consumable is in the heating region is configured to independently heat different sections of the heating region.

[0041] A fourth aspect of the present invention provides a method for manufacturing a consumable for use in a device for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the method including providing a hollow tube including a carrier and an aerosolizable material including an amorphous solid fixed to the carrier.

[0042] In an exemplary embodiment, providing the hollow tube includes fixing the aerosolizable material to the carrier and then forming the hollow tube.

[0043] In an exemplary embodiment, fixing includes coating the aerosolizable material on the carrier.

[0044] In an exemplary embodiment, the coating comprises spraying or casting an aerosolizable material onto a carrier.

[0045] In an exemplary embodiment, the aerosolizable material forms at least a portion of the innermost surface of the hollow tube.

[0046] A further aspect of the invention provides for the use of a consumable of the first or second aspect of the invention in the generation of an inhalable aerosol.

[0047] The embodiments of the invention will be described by way of example only with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0048]

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Mode for Carrying Out the Invention

[0049] In this specification, the term "aerosolizable material" includes materials that, when heated, provide volatile components, typically in the form of an aerosol. The "aerosolizable material" may be a non-tobacco-containing material or a tobacco-containing material. The "aerosolizable material" may include, for example, one or more of tobacco itself, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco extracts, homogenized tobacco, or tobacco substitutes.

[0050] The aerosolizable materials described herein include "amorphous solids", which may also be referred to separately as "monolithic solids" (i.e., non-fibrous) or "dry gels". An amorphous solid is a solid material that holds a fluid such as a liquid inside it. In some cases, the aerosolizable material may contain from about 50 wt%, 60 wt% or 70 wt% amorphous solid to about 90 wt%, 95 wt% or 100 wt% amorphous solid. In some cases, the aerosolizable material consists of an amorphous solid.

[0051] The "aerosolizable material" may include other non-tobacco products that contain or do not contain nicotine depending on the product. The "aerosolizable material" may include one or more wetting agents such as glycerin or propylene glycol.

[0052] The amorphous solid may be formed as a sheet. It may be incorporated into a sheet-like consumable. In some cases, the aerosolizable material may be contained as a flat sheet, a bunch or gathered sheet, a crimped sheet or a roll sheet (i.e., tubular). In some such cases, the amorphous solid of these embodiments may be contained in a consumable or system as a sheet such as a sheet surrounding a rod (e.g., a cigarette) made of an aerosolizable material. In some other cases, the aerosolizable material may be formed as a sheet and then scored and incorporated into a consumable. In some cases, the scored sheet may be mixed with cut tobacco scraps and incorporated into a consumable.

[0053] In some cases, the amorphous solid may contain 1 to 60 wt% of a gelling agent, and these weights are calculated on a dry weight basis.

[0054] Preferably, the amorphous solid may contain about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt% or 27 wt% of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may contain 1 to 50 wt%, 5 to 40 wt%, 10 to 30 wt% or 15 to 27 wt% of a gelling agent.

[0055] In some embodiments, the gelling agent comprises a hydrophilic colloid. In some embodiments, the gelling agent comprises one or more compounds selected from alginates, pectins, starches (and derivatives), celluloses (and derivatives), rubbers, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum acacia, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. Optionally, the gelling agent comprises alginate and / or pectin, and may be mixed with a curing agent (such as a calcium source) during the formation of the amorphous solid. Optionally, the amorphous solid may comprise alginate crosslinked with calcium and / or pectin crosslinked with calcium.

[0056] In some embodiments, the gelling agent comprises an alginate, and the alginate is included in the amorphous solid in an amount of 10-30 wt% (calculated on a dry weight basis) of the amorphous solid. In some embodiments, the alginate is the only gelling agent included in the amorphous solid. In other embodiments, the gelling agent comprises an alginate and a further gelling agent such as at least one pectin.

[0057] In some embodiments, the amorphous solid may comprise a gelling agent comprising carrageenan.

[0058] Preferably, the amorphous solid may contain from about 5 wt%, 10 wt%, 15 wt% or 20 wt% to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt% or 35 wt% (calculated on a dry weight basis) of an aerosol generating agent. The aerosol generating agent may act as a plasticizer. For example, the amorphous solid may contain from 10 to 60 wt%, 15 to 50 wt% or 20 to 40 wt% of an aerosol generating agent. In some cases, the aerosol generating agent contains one or more compounds selected from erythritol, propylene glycol, glycerin, triacetin, sorbitol and xylitol. In some cases, the aerosol generating agent contains glycerin, consists essentially of glycerin or consists of glycerin. The inventor has confirmed that if the content of the plasticizer is too high, the amorphous solid will absorb water and become a material that does not produce a suitable consumption experience during use. The inventor has confirmed that if the content of the plasticizer is too low, the amorphous solid will become brittle and easily breakable. The amount of plasticizer specified herein provides flexibility to the amorphous solid, enabling the amorphous solid sheet to be wound around a bobbin useful for the manufacture of aerosol generating articles.

[0059] In some cases, the amorphous solid may contain a flavorant. Preferably, the amorphous solid may contain up to about 60 wt%, 50 wt%, 40 wt%, 30 wt%, 20 wt%, 10 wt% or 5 wt% of a flavorant. In some cases, the amorphous solid may contain at least about 0.1 wt%, 0.5 wt%, 1 wt%, 2 wt%, 5 wt%, 10 wt%, 20 wt% or 30 wt% of a flavorant (calculated on a dry weight basis). For example, the amorphous solid may contain from 0.1 to 60 wt%, 1 to 60 wt%, 5 to 60 wt%, 10 to 60 wt%, 20 to 50 wt% or 30 to 40 wt% of a flavorant. In some cases, the flavorant (if included) contains menthol, consists essentially of menthol or consists of menthol. In some cases, the amorphous solid does not contain a flavorant.

[0060] In some cases, the amorphous solid contains an active substance. For example, in some cases, the amorphous solid contains tobacco material and / or nicotine. For example, the amorphous solid may contain powdered tobacco and / or nicotine and / or a tobacco extract. In some cases, the amorphous solid may contain from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 70 wt%, 50 wt%, 45 wt% or 40 wt% (calculated on a dry weight basis) of the active substance. In some cases, the amorphous solid may contain from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt% or 40 wt% (calculated on a dry weight basis) of tobacco material and / or nicotine.

[0061] In some cases, the amorphous solid contains an active substance such as a tobacco extract. In some cases, the amorphous solid may contain from 5 to 60 wt% (calculated on a dry weight basis) of the tobacco extract. In some cases, the amorphous solid may contain from about 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 55 wt%, 50 wt%, 45 wt% or 40 wt% (calculated on a dry weight basis) of the tobacco extract. For example, the amorphous solid may contain from 5 to 60 wt%, from 10 to 55 wt% or from 25 to 55 wt% of the tobacco extract. The tobacco extract may contain nicotine at a concentration such that the amorphous solid contains from 1 wt%, 1.5 wt%, 2 wt% or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt% or 4 wt% (calculated on a dry weight basis) of nicotine. In some cases, there is no nicotine in the amorphous solid other than that obtained from the tobacco extract.

[0062] In some embodiments, the amorphous solid does not contain tobacco material but contains nicotine. In some such cases, the amorphous solid may contain from about 1 wt%, 2 wt%, 3 wt% or 4 wt% to about 20 wt%, 15 wt%, 10 wt% or 5 wt% (calculated on a dry weight basis) of nicotine. For example, the amorphous solid may contain from 1 to 20 wt% or from 2 to 5 wt% of nicotine.

[0063] In some cases, the total content of the active substance and / or flavoring may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt% or 30 wt%. In some cases, the total content of the active substance and / or flavoring may be less than about 80 wt%, less than 70 wt%, less than 60 wt%, less than 50 wt% or less than 40 wt% (all calculated on a dry weight basis).

[0064] In some cases, the total content of the tobacco material, nicotine and flavoring may be at least about 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt% or 30 wt%. In some cases, the total content of the tobacco material, nicotine and flavoring may be less than about 80 wt%, less than 70 wt%, less than 60 wt%, less than 50 wt% or less than 40 wt% (all calculated on a dry weight basis).

[0065] In some cases, the amorphous solid contains about 1 wt% to about 15 wt% or about 5 wt% to about 15 wt% of water calculated on a wet weight basis. Preferably, the moisture content of the amorphous solid is about 5 wt%, 7 wt% or 9 wt% to about 15 wt%, 13 wt% or 11 wt% (WWB), and most preferably about 10 wt%.

[0066] In some embodiments, the amorphous solid is a hydrogel and contains less than about 20 wt% of water calculated on a wet weight basis. In some cases, the hydrogel may contain less than about 15 wt%, less than 12 wt% or less than 10 wt% of water (WWB) calculated on a wet weight basis. In some cases, the hydrogel may contain at least about 2 wt% or at least about 5 wt% of water (WWB).

[0067] The amorphous solid may be made from a gel, and the gel may contain a solvent additionally contained in an amount of 0.1 to 50 wt%. However, the inventor has confirmed that adding a solvent in which the flavoring is soluble reduces the stability of the gel and the flavoring crystallizes out of the gel. Therefore, in some cases, the gel does not contain a solvent in which the flavoring is soluble.

[0068] In some embodiments, the amorphous solid contains less than 60 wt%, for example 1 wt% to 60 wt% or 5 wt% to 50 wt% or 5 wt% to 30 wt% or 10 wt% to 20 wt% of a filler.

[0069] In other embodiments, the amorphous solid contains less than 20 wt%, preferably less than 10 wt% or less than 5 wt% of a filler. In some cases, the amorphous solid contains less than 1 wt% of a filler and in some cases contains no filler.

[0070] If a filler is included, it may include one or more of suitable inorganic adsorbents such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate and molecular sieves. The filler may include one or more organic fillers such as wood pulp, cellulose and cellulose derivatives. In certain cases, the amorphous solid does not contain calcium carbonate such as chalk.

[0071] In certain embodiments containing a filler, the filler is fibrous. For example, the filler may be a fibrous filler such as wood pulp, hemp fiber, cellulose or cellulose derivative. Without wishing to be bound by any theory, it has been confirmed that incorporating a fibrous filler into the amorphous solid increases the tensile strength of the material. This is particularly advantageous in examples where the amorphous solid is provided as a sheet, such as when the amorphous solid sheet surrounds a rod made of an aerosolizable material.

[0072] In some embodiments, the amorphous solid does not contain tobacco fiber. In certain embodiments, the amorphous solid does not contain fibrous material.

[0073] In some embodiments, the aerosol generating material does not contain tobacco fiber. In certain embodiments, the aerosol generating material does not contain fibrous material.

[0074] In some embodiments, the aerosol generating substrate does not contain tobacco fiber. In certain embodiments, the aerosol generating substrate does not contain fibrous material.

[0075] In some embodiments, the consumable does not contain tobacco fibers. In certain embodiments, the consumable does not contain fibrous materials.

[0076] In some cases, the amorphous solid consists essentially of or consists of a gelling agent, an aerosol generating agent, a tobacco material and / or a nicotine source, water and optionally a flavorant.

[0077] A method of manufacturing an aerosolizable material may include (a) forming a slurry comprising an amorphous solid or a precursor thereof, (b) forming a layer of the slurry, (c) curing the slurry to form a gel, and (d) drying to form an amorphous solid.

[0078] Forming the layer of the slurry in step (b) may include, for example, spraying, casting or extruding the slurry. In some cases, the layer is formed by electrospraying the slurry. In some cases, the layer is formed by casting a sleeve.

[0079] In some cases, the slurry is applied to a carrier.

[0080] In some cases, steps (b) and / or (c) and / or (d) may be performed at least partially simultaneously (e.g., during electrospraying). In some cases, these steps may be performed sequentially.

[0081] The step (c) of curing the gel may include adding a curing agent to the slurry. For example, the slurry may include sodium alginate, potassium alginate or ammonium alginate as a gel precursor and a calcium source (such as calcium chloride), and may include a curing agent added to the slurry to form a calcium alginate gel.

[0082] The total amount of the curing agent such as a calcium source may be 0.5 to 5 wt% (calculated on a dry weight basis). The inventor has discovered that if the addition amount of the curing agent is too small, the resulting amorphous solid cannot stabilize the amorphous solid components, and as a result, these components will spill out of the amorphous solid. The inventor has discovered that if the addition amount of the curing agent is too large, the resulting amorphous solid will be sticky and difficult to handle.

[0083] Alginates are derivatives of alginic acid and are typically high molecular weight polymers (10 - 600 kDa). Alginic acid is a copolymer in which β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) are linked by (1,4)-glycosidic bonds to form a polysaccharide. The addition of calcium crosslinks the alginate to form a gel. The inventor has discovered that alginates with a high G monomer content easily form gels by adding a calcium source. Therefore, in some cases, the gel precursor may contain an alginate in which at least 40%, 45%, 50%, 55%, 60% or 70% of the monomer units of the alginic acid copolymer are α-L-guluronic acid (G) units.

[0084] The drying process may reduce the thickness of the cast material by at least 80%, preferably 85% or 87%. For example, the slurry may be cast at a thickness of 2 mm, and the resulting dried amorphous solid may have a thickness of 0.2 mm.

[0085] The amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Preferably, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. The inventor has discovered that a material with a thickness of 0.2 mm is particularly suitable. The amorphous solid may include two or more layers, and the thickness described herein means the total thickness of these layers.

[0086] In some cases, the slurry solvent may consist essentially of water or alternatively may consist of water. In some cases, the slurry may contain about 50 wt%, 60 wt%, 70 wt%, 80 wt% or 90 wt% of the solvent (WWB).

[0087] When the solvent consists of water, the content by dry weight of the slurry coincides with the content by dry weight of the amorphous solid. Accordingly, the considerations in this specification regarding the solid composition are to be taken as being clearly disclosed in combination with the slurry aspect of the present invention.

[0088] In some examples, the slurry has a viscosity of about 10 to about 20 Pa·s at 46.5 °C, for example about 14 to 16 Pa·s at 46.5 °C.

[0089] The aerosolizable material containing the amorphous solid is 30 g / m 2 ~120 g / m 2 and may have any suitable areal density, such as. In some embodiments, the aerosolizable material may have an areal density of about 30 to 70 g / m 2 or about 40 to 60 g / m 2 In some embodiments, the amorphous solid may have an areal density of about 80 to 120 g / m 2 or about 70 to 110 g / m 2 or particularly about 90 to 110 g / m 2 Such areal densities are particularly suitable when the aerosol generating material is contained as a sheet-like consumable or in a system or in an engraved sheet (described further below).

[0090] In some examples, the sheet-like amorphous solid may have a tensile strength of from about 200 N / m to about 900 N / m. In some examples where the amorphous solid does not contain a filler, the amorphous solid may have a tensile strength of 200 N / m to 400 N / m or 200 N / m to 300 N / m or about 250 N / m. Such tensile strength is particularly suitable when the aerosolizable material is formed as a sheet, then scored, and incorporated into a consumable. In some examples where the amorphous solid contains a filler, the amorphous solid may have a tensile strength of 600 N / m to 900 N / m or 700 N / m to 900 N / m or about 800 N / m. Such tensile strength is contained in a consumable or system in the form of a rolled sheet, preferably a tube, of the aerosolizable material.

[0091] In certain particular cases, the carrier may be a foil supported on paper, the layer of paper being in contact with the amorphous solid layer, and the properties described in the above paragraph are made possible by this contact. The backing of the foil is substantially impermeable and controls the flow path of the aerosol. The backing of the metal foil also serves to transfer heat to the gel.

[0092] In another case, the foil layer of the foil supported on paper is in contact with the amorphous solid. The foil is impermeable, thereby preventing water provided in the amorphous solid from being absorbed by the paper which may weaken the structural integrity of the paper.

[0093] In some cases, the carrier is formed from or includes a metal foil such as aluminum foil. The metal carrier can transfer thermal energy better through the amorphous solid. Additionally or alternatively, the metal foil may function as a susceptor for an induction heating system. In certain embodiments, the carrier includes a metal foil layer and a support layer such as cardboard. In these embodiments, the metal foil layer has a thickness of less than 20 μm, for example from about 1 μm to about 10 μm, preferably about 5 μm.

[0094] The active substance used in the present invention is a physiologically active material intended to achieve or enhance a physiological reaction. The active substance may be selected, for example, from nutraceuticals, nootropics, and psychotropic drugs. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or mixtures thereof. The active substance may include one or more of the components, derivatives, or extracts of tobacco, cannabis, or other plants.

[0095] In some embodiments, the active substance includes nicotine.

[0096] In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0097] As described herein, the active substance may include one or more of the components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0098] Cannabinoids are a group of natural or synthetic compounds that act on cannabinoid receptors within cells (i.e., CB1 and CB2) to suppress neurotransmitter release in the brain. Cannabinoids can be naturally occurring in plants such as cannabis (phytocannabinoids), or naturally occurring in animals (zoocannabinoids), or artificially produced (synthetic cannabinoids). Cannabis seeds exhibit at least 85 different phytocannabinoids and are divided into subclasses including cannaguerols, cannabinochromenes, cannabidiols, tetrahydrocannabinols, cannabinols, cannabinodiols, and other cannabinoids. Cannabinoids found in the genus Cannabis include, but are not limited to, cannabigerol (CBG), cannabinochromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabinochromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabinotriol (CBO), tetrahydrocannabinolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A).

[0099] As described herein, the active substance may include or be derived from plants or their components, derivatives, or extracts. The term "plant" as used herein includes, but is not limited to, any material derived from plants such as extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, pods, etc. Alternatively, the material may include active compounds naturally present in plants obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, pieces, strips, sheets, etc. Examples of plants include tobacco, eucalyptus, camphor tree, mugwort, cocoa, cannabis, aster, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, nettles, hibiscus, laurel, licorice, matcha, mate tea, orange peel, papaya, rose, sage, green tea or black tea, thyme, star anise, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, bilberry, nasturtium flower, vanilla, koji, chrysanthemum, turmeric, saffron, sandalwood, silantro, bergamot, neroli, ylang-ylang, blackcurrant, bugbane, allspice, mace, damiana, carnation, olive, lemon balm, lemon basil, chive, aster, vervain, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint may be selected from mint species such as peppermint, Moroccan mint, Egyptian mint, peppermint, odoratum mint, candy mint, curly mint, Kentucky colonel mint, horsemint, pineapple mint, pennyroyal mint, curly mint, and apple mint.

[0100] In some embodiments, the plant is selected from eucalyptus, camphor tree, cocoa, and hemp.

[0101] In some embodiments, the plant is selected from rooibos and aster.

[0102] As used herein, the terms "flavoring agent" and "flavor enhancer" are permitted by local regulations and are used to produce tastes, odors or other somatic sensory stimuli desired by adult consumers.

[0103] They include naturally occurring flavor materials, plants, plant extracts, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, phoebe leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, kojic acid, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, radish, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, damson, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, chat, naswar, kinma, shisha, pine, honey extract, rose oil, vanilla, lemon oil, orange oil, neroli, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, perilla, wasabi, pimento, ginger, coriander, coffee, mugwort, peppermint oil from any species of the genus Mentha, eucalyptus, Japanese aralia, cocoa, lemongrass, rooibos, flax, ginkgo, hashish, hibiscus, laurel, mate tea, orange peel, rose, tea such as green tea or black tea, thyme, byakushin, nasturtium flower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, chrysanthemum, curcuma, silantro, ginger lily, blackcurrant, butterbur, pimento, mace, damiana, sweet william, olive, lemon balm, lemon basil, chive, perilla, verbena, tarragon, limonene, thymol, camphene), seasonings, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, mannitol, etc.), and other additives such as charcoal, chlorophyll, minerals, plants, or odor suppressants.These materials may be imitation, synthetic or natural components, or blends thereof. They may be in any suitable form, such as a liquid like an oil, a solid like a powder, or a gas.

[0104] The flavoring preferably includes one or more mint flavorings and preferably includes peppermint oil from any species of the Mentha genus. The flavoring preferably contains, consists essentially of, or consists of menthol.

[0105] In some embodiments, the flavoring includes menthol, spearmint and / or peppermint.

[0106] In some embodiments, the flavoring includes flavor components of cucumber, blueberry, citrus and / or redberry.

[0107] In some embodiments, the flavoring includes eugenol.

[0108] In some embodiments, the flavoring includes flavor components extracted from tobacco.

[0109] In some embodiments, the flavoring includes flavor components extracted from cannabis.

[0110] In some embodiments, the flavoring may include a sensory stimulant, which is chemically induced and recognized by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of olfactory or gustatory nerves, and they may include agents that give a heating, cooling, tingling, or numbing sensation. Suitable heat agents include, but are not limited to, vanillyl ethyl ether, and suitable cooling agents include, but are not limited to, eucalyptol, WS-3.

[0111] In this specification, the term "aerosol generating agent" means an agent that promotes the generation of an aerosol. The aerosol generating agent may promote the generation of an aerosol by promoting the initial vaporization of a gas and / or the aggregation of a solid and / or liquid aerosol into an inhalable form. The aerosol generating agent may promote the generation of an aerosol by promoting the initial vaporization and / or the condensation of a gas into an inhalable solid and / or liquid aerosol.

[0112] Suitable aerosol generating agents include polyols such as erythritol, sorbitol, glycerin and glycols such as propylene glycol or triethylene glycol, monohydric alcohols, high boiling point hydrocarbons, acids such as lactic acid, glycerin derivatives, diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, ethyl myristate and myristic acid esters including isopropyl myristate, methyl stearate, dimethyl dodecanedioate and dimethyl tetradecanedioate and other esters such as aliphatic carboxylic acid esters, but are not limited thereto. The aerosol generating agent preferably has a composition that does not dissolve menthol. The aerosol generating agent preferably contains glycerin, consists essentially of glycerin or consists of glycerin.

[0113] In this specification, the term "tobacco material" means any material including tobacco or its derivatives. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may include one or more of powdered tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco stalks, reconstituted tobacco and / or tobacco extracts.

[0114] The tobacco used to make the tobacco material may be any suitable tobacco, including single grades or blends containing Virginia and / or Burley and / or Oriental, shredded scraps or whole leaves. It may also be other processed leaf stalk materials such as tobacco particles "fine powder" or dust, expanded tobacco, leaf stalks, expanded leaf stalks and cut and rolled leaf stalks. The tobacco material may be powdered tobacco or recycled tobacco material. The recycled tobacco material may be tobacco fibers and may be formed by casting, the Ford linear papermaking method with subsequent addition of tobacco extract or extrusion.

[0115] In some embodiments, the amorphous solid contains menthol.

[0116] Certain embodiments containing a menthol-containing amorphous solid are particularly suitable for inclusion in a consumable or system as an etched sheet. In such embodiments, the amorphous solid has a composition (DWB) of a gelling agent (preferably including alginate, more preferably including alginate and pectin) in an amount of about 20 wt% to about 40 wt% or about 25 wt% to 35 wt%, menthol in an amount of about 35 wt% to about 60 wt% or about 40 wt% to 55 wt%, and an aerosol generating agent (preferably including glycerin) in an amount of about 10 wt% to about 30 wt% or about 15 wt% to about 25 wt% (DWB).

[0117] In one embodiment, the amorphous solid contains about 32 - 33 wt% of an alginate / pectin gelling agent blend, about 47 - 48 wt% of a flavorant, and about 19 - 20 wt% of a glycerin aerosol generating agent (DWB).

[0118] As described above, the amorphous solids of these embodiments may be contained in a consumable or system as an etched sheet. The etched sheet may be provided to a consumable or system blended with shredded tobacco. Alternatively, the amorphous solid may be provided as an unetched sheet. Preferably, the etched or unetched sheet has a thickness of about 0.015 mm to about 1 mm, preferably about 0.02 mm to about 0.07 mm.

[0119] Certain embodiments of the menthol-containing amorphous solid are particularly suitable for inclusion in a consumable or system as a sheet, such as a sheet that surrounds a rod (e.g., a cigarette) made of an aerosolizable material. In these embodiments, the amorphous solid has a composition (DWB) of about 5 wt% to about 40 wt% or about 10 wt% to 30 wt% of a gelling agent (preferably including alginate, more preferably including alginate and pectin), about 10 wt% to about 50 wt% or about 15 wt% to 40 wt% of menthol, about 5 wt% to about 40 wt% or about 10 wt% to about 35 wt% of an aerosol generating agent (preferably including glycerin), and up to 60 wt%, such as 5 wt% to 20 wt% or about 40 wt% to 60 wt% (DWB) of any filler.

[0120] In one of these embodiments, the amorphous solid includes about 11 wt% of an alginate / pectin gelling agent blend, about 56 wt% of a wood pulp filler, about 18% of a menthol flavorant, and about 15 wt% of glycerin (DWB).

[0121] In another example of these embodiments, the amorphous solid includes about 22 wt% of an alginate / pectin gelling agent blend, about 12 wt% of a wood pulp filler, about 36 wt% of a menthol flavorant, and about 30 wt% of glycerin (DWB).

[0122] As described above, the amorphous solid of these embodiments may be contained as a sheet. In one embodiment, the sheet is provided on a carrier including paper. In one embodiment, the sheet is provided on a carrier including a metal foil, preferably an aluminum metal foil. In this embodiment, the amorphous solid abuts the metal foil.

[0123] In one embodiment, the sheet forms part of a laminate material having layers (preferably including paper) attached to the top and bottom surfaces of the sheet. Preferably, the sheet of the amorphous solid has a thickness of about 0.015 mm to about 1 mm.

[0124] In some embodiments, the amorphous solid comprises a flavorant that does not include menthol. In these embodiments, the amorphous solid has a composition (DWB) such as a gelling agent (preferably including alginate) in an amount of about 5 wt% to about 40 wt%, or about 10 wt% to 35 wt%, or about 20 wt% to about 35 wt%, a flavorant in an amount of about 0.1 wt% to about 40 wt, about 1 wt% to about 30 wt%, or about 1 wt% to about 20 wt%, or about 5 wt% to about 20 wt%, an aerosol generating agent (preferably including glycerin) in an amount of about 15 wt% to about 75 wt%, or about 30 wt% to about 70 wt%, or about 50 wt% to about 65 wt%, and an optional filler (preferably wood pulp) in an amount of less than about 60 wt%, or less than about 20 wt%, or less than about 10 wt%, or about 5 wt% (preferably the amorphous solid does not include a filler).

[0125] In one of these embodiments, the amorphous solid comprises about 27 wt% of an alginate gelling agent, about 14 wt% of a flavorant, and about 57 wt% of a glycerin aerosol generating agent (DWB).

[0126] In another example of these embodiments, the amorphous solid comprises about 29 wt% of an alginate gelling agent, about 9 wt% of a flavorant, and about 60 wt% of glycerin (DWB).

[0127] The amorphous solid of these embodiments may be contained in a consumable or system as a scored sheet and, if desired, blended with shredded tobacco. Alternatively, the amorphous solid of these embodiments may be contained in a consumable or system as a sheet such as a sheet surrounding a rod (e.g., a tobacco) made of an aerosolizable material. Alternatively, the amorphous solid of these embodiments may be contained in a consumable or system as a layer portion disposed on a carrier.

[0128] In some embodiments, the amorphous solid contains tobacco extract. In these embodiments, the amorphous solid has a composition (DWB) of a gelling agent (preferably including alginate) in an amount of about 5 wt% to about 40 wt% or about 10 wt% to 30 wt% or about 15 wt% to about 25 wt%, a tobacco extract in an amount of about 30 wt% to about 60 wt or about 40 wt% to 55 wt% or about 45 wt% to about 50 wt%, and an aerosol generating agent (preferably including glycerin) in an amount of about 10 wt% to about 50 wt% or about 20 wt% to about 40 wt% or about 25 wt% to about 35 wt% (DWB).

[0129] In one embodiment, the amorphous solid includes about 20 wt% of an alginate gelling agent, about 48 wt% of a Virginia tobacco extract, and about 32 wt% of glycerin (DWB).

[0130] The amorphous solids of these embodiments may have any suitable moisture content. For example, the amorphous solid may have a moisture content of about 5 wt% to about 15 wt%, or about 7 wt% to about 13 wt%, or about 10 wt%.

[0131] The amorphous solids of these embodiments may be contained in a consumable or system as a scored sheet and, if necessary, blended with cut tobacco. Alternatively, the amorphous solids of these embodiments may be contained in a consumable or system as a sheet such as a sheet surrounding a rod (e.g., tobacco) made of aerosolizable material. Alternatively, the amorphous solids of these embodiments may be contained in a consumable or system as a layer portion disposed on a carrier. Preferably, in any of these embodiments, the amorphous solid has a thickness of about 50 μm to about 200 μm or about 50 μm to about 100 μm, or about 60 μm to about 90 μm, preferably about 77 μm.

[0132] The slurry for forming this amorphous solid may also form part of the present invention. In some cases, the slurry may have an elastic modulus (also referred to as storage elastic modulus) of about 5 to 1200 Pa, and in some cases, the slurry may have a viscosity coefficient (also referred to as loss coefficient) of about 5 to 600 Pa.

[0133] The weight percentages (expressed as wt%) described herein are calculated on a dry weight basis unless otherwise specified. All weight ratios are also calculated on a dry weight basis. The weight shown on a dry weight basis means the total of extracts other than water, slurries, or amounts of materials, and may include components that are liquid at room temperature and room pressure, such as glycerol. In other words, the weight ratio on a wet weight basis means all components including water.

[0134] As used herein, the term "sheet" means a member having a width and length that are substantially longer than the thickness. The sheet may be, for example, a strip.

[0135] As used herein, the term "heating material" or "heater material" means a material that can be heated by the penetration of a variable magnetic field.

[0136] Induction heating is a process of heating an object by causing a variable magnetic field to penetrate the conductive object. This process is explained by Faraday's law of electromagnetic induction and Ohm's law. An induction heater can include an electromagnet and a device for passing a variable current, such as an alternating current, through the electromagnet. When the object to be heated and the electromagnet are arranged in an appropriate relative position such that the variable magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are generated in the object. The object has a resistance to the flow of current. Therefore, when such eddy currents are generated in the object, the eddy currents flow against the electrical resistance of the object, thereby heating the object. This process is called Joule heating, Ohmic heating, or resistance heating. An object that can be induction heated is known as a susceptor.

[0137] When the susceptor is in the form of a closed circuit, it has been found that the magnetic coupling between the susceptor and the electromagnet during use becomes stronger, and as a result, Joule heating increases or is improved.

[0138] Magnetic hysteresis heating is a process of heating an object made of a magnetic material by allowing an alternating magnetic field to penetrate the object. A magnetic material can be considered to contain many atomic-scale magnets, i.e., magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipoles align along the magnetic field. Therefore, when an alternating magnetic field, such as a fluctuating magnetic field generated by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes according to the applied fluctuating magnetic field. Due to such reorientation of the magnetic dipoles, heat is generated within the magnetic material.

[0139] When an object has both conductivity and magnetism, introducing a fluctuating magnetic field into the object can cause both Joule heating and magnetic hysteresis heating in the object. Furthermore, using a magnetic material can strengthen the fluctuating magnetic field, thereby strengthening Joule heating.

[0140] In each of the above processes, heat is generated not by heat conduction from an external heat source but inside the object itself, so a rapid temperature rise within the object and a more uniform heat distribution can be achieved. This can be achieved particularly by appropriately selecting the material and geometry of the object and appropriately selecting the magnitude and direction of the fluctuating magnetic field for the object. Furthermore, in induction heating and magnetic hysteresis heating, there is no need to provide a physical connection between the source of the fluctuating magnetic field and the object, so the design freedom and the controllability of the heating profile can be increased while reducing costs.

[0141] Referring to FIGS. 1 and 2, these show schematic side and end cross-sections of an example of a consumable according to an embodiment of the present invention. The consumable 1 is shown in FIG. 8 and is for use in an apparatus that heats an aerosolizable material, such as the apparatus 100 described below, to volatilize at least one component of the aerosolizable material.

[0142] The consumable 1 includes a hollow tube that includes a carrier 16 and an aerosolizable material 14 that includes an amorphous solid coated on the carrier 16. The aerosolizable material 14 may be considered a coating on the carrier 16. The aerosolizable material 14 may be, for example, sprayed, electrosprayed, cast, or bandcast onto the carrier 16. The hollow tube is located around the void 10 of the consumable 1. In this embodiment, the void 10 is formed by a through hole that extends from one longitudinal end of the consumable 1 to the other longitudinal end. In other embodiments, the void 10 may be formed by a blind hole that extends only partially from one longitudinal end of the consumable 1 towards the opposite longitudinal end of the consumable 1.

[0143] The hollow tube of the consumable 1 extends along axis A-A. Axis A-A is a central axis that extends along the void 10, but in other embodiments, the structure of the hollow tube may be such that axis A-A is offset from the void 10. In this embodiment, the hollow tube is elongated in the direction of axis A-A, but in other embodiments, the width or diameter of the hollow tube may be longer than or equal to the dimension of the hollow tube in the direction of axis A-A such that the hollow tube is not elongated. The hollow tube of this embodiment has a circular inner and outer cross-sectional shape. In other embodiments, one or both of the inner and outer cross-sectional shapes of the hollow tube may be other than circular, for example, elliptical, polygonal, rectangular, square, triangular, or star-shaped.

[0144] In some embodiments, the carrier 16 forms at least a portion of a surface, such as the outer surface of a hollow tube or of the entire consumable. In some embodiments, the carrier 16 forms at least a majority, such as all, of the surface. In this embodiment, the carrier 16 forms the outer surface of the hollow tube and of the consumable 1. This helps to prevent the user's finger or hand from contacting the aerosolizable material 14 during operation of the consumable, such as when inserting or removing the consumable from the device with which it is used. This also helps to prevent the aerosolizable material 14 from contacting the walls that define the heating region of the device, thereby helping to keep the device relatively clean. However, in other embodiments, such as the embodiments described below with reference to FIG. 3, the carrier 16 further or alternatively forms the inner surface of the hollow tube and / or of the consumable.

[0145] The carrier 16 of this embodiment is tubular. Further, in this embodiment, the carrier 16 surrounds the aerosolizable material 14 and the void 10, and the aerosolizable material 14 is located between the carrier 16 and the void 10. In some other embodiments, the carrier 16 may be other than tubular. For example, in some embodiments, the carrier 16 may have axially extending slots or other features formed in the carrier such that the carrier 16 is discontinuous in the circumferential direction and thus does not form a complete tube.

[0146] Carrier 16 may be made of any suitable material. Carrier 16 needs to have sufficient heat resistance to withstand the temperatures to which consumable 1 is exposed during normal use, such as the temperatures described later in this specification. Carrier 16 helps impart rigidity to consumable 1. In some embodiments, the carrier is impermeable to the aerosol generated from aerosolizable material 14 during use. In some embodiments, carrier 16 includes one or more materials selected from the group consisting of paper, cardboard, paperboard, corrugated board, recycled tobacco, plastic materials, metals, and metal alloys. For example, in some embodiments, carrier 16 includes a rolled sheet or strip, such as paper or paperboard or recycled tobacco. In some embodiments, carrier 16 includes a laminate consisting of two of the above materials, such as paper and metal or metal alloy. In other embodiments, carrier 16 may include an extrusion of a material including one or more plastic materials or metals or metal alloys. In some embodiments, carrier 16 includes or consists of a tobacco material such as a sheet of recycled tobacco.

[0147] The surface of the carrier in contact with aerosolizable material 14 may be porous in some cases. For example, in some cases, carrier 16 includes paper. The inventor has found that a porous carrier such as paper is particularly suitable for the present invention, and the porous layer contacts and adheres strongly to aerosolizable material 14. The amorphous solid of aerosolizable material 14 is formed by drying a gel. Without being limited by any theory, it is believed that the slurry in which the gel is formed partially impregnates a porous carrier (such as paper) so that the carrier binds to the gel partially when the gel hardens and forms crosslinks. This strongly binds between the gel and the carrier (and between the dried gel and the carrier). The porous layer (such as paper) may be used to carry flavorings. In some cases, the porous layer may preferably include paper and have a porosity of 0 to 300 Cobb units (CU), preferably 5 to 100 CU or 25 to 75 CU.

[0148] Furthermore, it contributes to the strength of the adhesion between the aerosolizable material 14 and the carrier 16. The inventors have found that the roughness of the paper (the surface in contact with the aerosolizable material) is in the range of 50 to 1000 Bekk seconds, preferably 50 to 150 Bekk seconds, and more preferably 100 Bekk seconds (measured at an air pressure interval of 50.66 to 48.00 kPa). (The Bekk smoothness tester is a device used to measure the smoothness of the paper surface where air leaks between a smooth glass surface and a paper sample at a specific pressure, and the time (seconds) for a predetermined amount of air to seep through between these surfaces is the "Bekk smoothness".)

[0149] In some embodiments, at least a portion of the aerosolizable material 14 is located radially inward of the carrier 16. In some embodiments such as those shown in FIGS. 1 and 2, all of the aerosolizable material 14 is located radially inward of the carrier 16. In other embodiments, a portion of the aerosolizable material 14 may be located other than radially inward, such as on one longitudinal end face of the carrier 16 or on two opposing longitudinal end faces of the carrier 16. In some embodiments such as those described below with reference to FIG. 3, at least a portion of the aerosolizable material 14 is located radially outward of the carrier 16.

[0150] In some embodiments, the aerosolizable material 14 forms at least a portion of a surface, such as the innermost surface of a hollow tube. The aerosolizable material 14 forms at least a majority of the surface of the hollow tube, such as all of the surface of the hollow tube. In this embodiment, the aerosolizable material 14 forms the outermost surface of the hollow tube. This allows the aerosol to be delivered to the user through the void 10 during use. And this helps to reduce or avoid the deposition of condensate within the device during use. However, in other embodiments, such as the embodiment described below with reference to FIG. 3, the aerosolizable material 14 further or alternatively forms the outermost surface of the hollow tube. In some embodiments, the aerosolizable material 14 does not even form a portion of the innermost surface of the hollow tube. For example, in some variations of the embodiments shown in FIGS. 1 and 2, the hollow tube forms the innermost surface of the hollow tube and may include another layer (not shown) that is permeable to the aerosol emitted from the aerosolizable material 14 during use.

[0151] As described above, the aerosolizable material 14 of this embodiment is affixed to the carrier 16 by being coated on the carrier 16. The coating may include spraying. The coating may include casting. Casting may involve providing a liquid or other fluid material on the surface of the carrier 16 (or ultimately the material that forms the carrier 16), and then at least partially solidifying or curing the material on the surface of the carrier 16 to form the aerosolizable material 14 that includes an amorphous solid. The aerosolizable material 14 of such an embodiment may itself be referred to as a "casting".

[0152] In other embodiments, the aerosolizable material 14 comprising the amorphous solid may be attached to the carrier by a mechanism other than casting. For example, in some embodiments, the aerosolizable material 14 may be attached to the carrier 16 by providing an adhesive between the aerosolizable material 14 and the carrier 16. The adhesive may include, for example, one or more of gum arabic, natural or synthetic resins, starches, polyvinyl acetate (PVA), and varnishes. In other embodiments, the attachment may be by providing a fastener or interference fit between the aerosolizable material 14 and the carrier 16 such that the aerosolizable material 14 is held in a predetermined position relative to the carrier 16. In some embodiments, the aerosolizable material 14 may be attached to the carrier 16 by being captured or sandwiched between two layers of the carrier 16 or between two carriers 16.

[0153] In this embodiment, the aerosolizable material 14 is tubular. More specifically, in this embodiment, the aerosolizable material 14 is attached along an annular path on the inner surface of the carrier 16 such that the aerosolizable material 14 surrounds the void 10. In this embodiment, the aerosolizable material 14 covers all or substantially all of the inner surface of the carrier 16. In other embodiments, only a portion of the inner surface of the carrier 16 may be covered by the aerosolizable material 14. For example, the aerosolizable material 14 may be coated or otherwise attached to the carrier 16 as one or more individual spaced-apart regions, such as a tube of the aerosolizable material 14. In some embodiments, the aerosolizable material 14 may be non-tubular, such as one or more patch shapes on the carrier 16.

[0154] The consumable 1 of this embodiment is suitable for insertion into the heating region of a device, such as the heating region 110 of the device 100 shown in FIG. 8, which has a device that causes heating of the aerosolizable material 14 when the consumable 1 is in the heating region. When entering the heating region 110, the device of the apparatus causes heating of the aerosolizable material 14 and volatilizes at least one component of the aerosolizable material 14. In some embodiments, the device is configured to apply thermal energy to the consumable 1, specifically to the aerosolizable material 14, via a carrier. In some such embodiments, the device may be a resistive heater, which is heated by electrically connecting the resistive heater to a power source. In some other embodiments, the device may include a magnetic field generator 112 that generates a varying magnetic field for entering the heating region when the consumable 1 is in the heating region 110, and the carrier 16 of the consumable 1 includes a heating material that can be heated by the penetration of the varying magnetic field. As a result, in these other embodiments, the device is configured to generate heat in the heating material such that electromagnetic energy is applied to the heating material of the consumable 1, and then the thermal energy is applied from the carrier 16 to the aerosolizable material 14. In some embodiments, the consumable 1 may include a heating material that is partially or completely embedded in the aerosolizable material 14. In yet another embodiment, the device 100 has a heating element 120 that includes a heating material, the heating element 120 is in thermal contact with the heating region 110, and the magnetic field generator 112 is for generating a varying magnetic field that penetrates the heating element 120 and thus causes heating of the heating region 110. In any case, thereafter, one or more volatilized components of the aerosolizable material 14 pass from the aerosolizable material 14 into the void 10, where the component forms an aerosol, from which it exits the consumable 1 by user suction at the consumable 1 or the mouthpiece (if provided) of the device 100.

[0155] Therefore, as a matter of course, in some embodiments, the carrier 16 includes a heating material that can be heated by the intrusion of a variable magnetic field. The heating material may be, for example, any one or more of those described herein. The carrier 16 consists of or substantially consists of the heating material. Although it is preferred but not essential for the carrier 16 to include a closed circuit made of the heating material. The heating material has a substantially constant cross-sectional area axially spaced along the consumable 1. However, in other embodiments, the carrier 16 may not include such a heating material. Of course, in some embodiments, the entire consumable may not include such a heating material.

[0156] FIG. 3 is a schematic end cross-sectional view of an example of a consumable according to another embodiment of the present invention. The consumable 2 is for use in an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, such as the apparatus 100 shown in FIG. 8 and described below. The consumable 2 includes a hollow tube including a carrier 16 and an aerosolizable material 14 including an amorphous solid coated on the carrier 16. The hollow tube is located around the void 10 of the consumable 2.

[0157] It should be noted that the consumable 2 in FIG. 3 is similar to the consumable 1 in FIGS. 1 and 2, and the same reference numerals are assigned to similar members. For the sake of brevity, the consumable 2 in FIG. 3 will be mainly considered with an eye on the differences between these two consumables 1 and 2. However, it should be noted that any possible modifications of the consumable 1 (or a part thereof) in FIGS. 1 and 2 described herein can also be made to the consumable 2 (or its corresponding part) in FIG. 3, further constituting another embodiment.

[0158] Although not clearly shown in FIG. 3, in this embodiment, the hollow tube of the consumable 2 is elongated in the direction of the central axis A-A extending along the gap 10 here, and the hollow tube has a circular inner and outer cross-sectional shape. However, in this embodiment, the aerosolizable material 14 is located radially outward of the carrier 16. In some embodiments, such as those shown in FIG. 3, all of the aerosolizable material 14 is located radially outward of the carrier 16. In other embodiments, a portion of the aerosolizable material 14 may be located other than radially outward of the carrier 16, such as on one end face in the longitudinal direction of the carrier 16 or on two opposing end faces in the longitudinal direction of the carrier 16.

[0159] The aerosolizable material 14 is attached to the carrier 16 by being coated on the carrier 16. The coating may include spraying or casting. In this embodiment, the carrier 16 forms the innermost surface of the hollow tube of the consumable 2, and the aerosolizable material 14 forms the outermost surface of the hollow tube and the consumable 2. The aerosolizable material 14 of this embodiment is tubular. Further, in this embodiment, the aerosolizable material 14 surrounds the carrier 16 and the gap 10, and the carrier 16 is located between the aerosolizable material 14 and the gap 10. In this embodiment, the aerosolizable material 14 covers all or substantially all of the outer surface of the carrier. In other embodiments, only a portion of the outer surface of the carrier 16 may be covered by the aerosolizable material 14. For example, the aerosolizable material 14 may be coated on the carrier 16 as one or more individually spaced regions, such as a tube made of the aerosolizable material 14. In some embodiments, the aerosolizable material 14 may be non-tubular, such as one or more patch shapes on the carrier 16.

[0160] The consumable 2 of this embodiment is suitable for insertion into the heating region of the device, and the device has a device that causes heating of the aerosolizable material 14 when the consumable 2 is in the heating region. When entering the heating region, the device of the device causes heating of the aerosolizable material 14 using any of the heating techniques described herein to volatilize at least one component of the aerosolizable material 14. In some embodiments, the device of the device may protrude into the void 10 of the consumable 2 when the consumable 2 is in the heating region, and the device may be configured to apply thermal energy to the aerosolizable material 14 via the carrier 16. When volatilized, one or more components of the aerosolizable material 14 then move radially outward from the aerosolizable material 14 and the consumable 2, where they form an aerosol, and the user inhales through the consumable 2 or the mouthpiece of the device to aspirate the one or more volatilized components or the aerosol.

[0161] Figure 4 shows a schematic end cross-section of another example of a consumable according to another embodiment of the present invention. The consumable 3 is for use in a device that heats an aerosolizable material to volatilize at least one component of the aerosolizable material, such as the device 100 shown in FIG. 8 and described below. The consumable 3 includes a hollow tube that includes a carrier 16 and an aerosolizable material 14 that includes an amorphous solid coated on the carrier 16. The hollow tube is located around the void 10 of the consumable 3.

[0162] The consumable 3 of FIG. 4 is the same as the consumables of FIGS. 1 and 2 except for the shape of the carrier 16. Accordingly, similar members are given the same reference numerals, and for the sake of brevity, the consumable 3 of FIG. 4 will be considered mainly with an eye to the differences between these two consumables 1, 3. Note that any of the possible variations of the consumable 1 (or a part thereof) of FIGS. 1 and 2 described herein can also be made for the consumable 3 (or its corresponding part) of FIG. 4, constituting yet another embodiment.

[0163] The consumable 3 of this embodiment and more specifically the carrier 15 includes a heating material that can be heated by the intrusion of a variable magnetic field to heat the aerosolizable material 14. The heating material may be any one or more of those described herein, for example.

[0164] More specifically, the carrier 16 includes a first layer 18 and a second layer 20 that contain a heating material. The carrier 16 may be a laminate. It is preferable but not essential that the carrier 16 (for example, its first layer) includes a heating material such as a closed circuit made of the heating material. The heating material may be any one or more of those described herein, for example. In this embodiment, the second layer 20 is not heatable by the intrusion of a variable magnetic field, but in other embodiments, the second layer 20 may also contain the same or different heating materials as the heating material of the first layer 18. The second layer may include one or more materials selected from the group consisting of, for example, paper, cardboard, paperboard, corrugated board, recycled tobacco, and plastic materials.

[0165] In this embodiment, the first layer 18 is located between the aerosolizable material 14 and the second layer 20. The aerosolizable material 14 is coated on the first layer 18, and the second layer 20 forms the outermost surface of the tubular member and the consumable 3.

[0166] In other embodiments, the second layer 20 may be located between the aerosolizable material 14 and the first layer 18 that includes a heating material. In some such embodiments, the aerosolizable material 14 may be coated on the second layer 20, and the first layer 18 may form the outermost surface of the tubular member and the consumable 3. In yet another embodiment, the carrier 16 may include one or more additional layers (not shown), at least one of which forms the outermost surface of the tubular member and optionally the consumable 3. In some such embodiments, the first layer 18 that includes a heating material is located between the second layer 20 and the one or more additional layers. In still some such embodiments, the aerosolizable material 14 may be coated on the second layer 20 and / or on one or more of its additional layers. Still other configurations will be apparent to those skilled in the art. In each variation of the above-described embodiments, the aerosolizable material 14 may be attached to the carrier 16 by a mechanism other than a coating, such as any of the techniques described herein with respect to the consumable 1 of FIGS. 1 and 2.

[0167] The consumable 3 of this embodiment is suitable for insertion into the heating region of an apparatus having a device that causes the aerosolizable material 14 to be heated when the consumable 3 is in the heating region. Upon entering the heating region, the device of the apparatus causes heating of the aerosolizable material 14 using any of the heating techniques described herein to volatilize at least one component of the aerosolizable material 14. Thereafter, one or more volatilized components of the aerosolizable material 14 pass from the aerosolizable material 14 into the void 10, where they form an aerosol from which they exit the consumable 3 by user suction at the consumable 3 or the mouthpiece (if provided) of the apparatus.

[0168] As described above, the consumable 3 in FIG. 4 is the same as the consumables in FIGS. 1 and 2 except for the shape of the carrier 16. Similarly, in some embodiments, the consumable may be the same as the consumable 2 in FIG. 3 except for the shape of the carrier 16. For example, in some embodiments, the consumable 2 in FIG. 3 may be modified such that the carrier 16 includes a first layer and a second layer including a heating material. The heating material may be, for example, any one or more of those described herein. In some embodiments, the second layer may not be heatable by the intrusion of a variable magnetic field. In other embodiments, the second layer may include the same or different heating material as the heating material of the first layer. The second layer may include, for example, one or more materials selected from the group consisting of paper, cardboard, paperboard, corrugated board, recycled tobacco, and plastic materials. In some embodiments, the first layer is located between the aerosolizable material 14 and the second layer. In some embodiments, the aerosolizable material 14 is coated on the first layer, and the second layer forms a tubular member and the innermost surface of the consumable. In other embodiments, the second layer is located between the aerosolizable material 14 and the first layer including the heating material. In some such embodiments, it may be coated on the aerosolizable material 14. The second layer and the first layer may form a tubular member and the innermost surface of the consumable. In yet another embodiment, the carrier 16 may include one or more additional layers (not shown), at least one of which forms a tubular member and optionally the outermost surface of the consumable. In some such embodiments, the first layer including the heating material may be located between the second layer and the one or more additional layers. In yet some such embodiments, the aerosolizable material 14 may be coated on the second layer and / or on the one or more additional layers. Further alternative configurations will be apparent to those skilled in the art.

[0169] FIG. 5 is a schematic end cross-sectional view of an example of a consumable according to another embodiment of the present invention. The consumable 4 is for use in an apparatus that heats an aerosolizable material to volatilize at least one component of the aerosolizable material, such as the apparatus 100 shown in FIG. 8 and described below. The consumable 4 includes a hollow tube that includes a carrier 16 and an aerosolizable material 14 that includes an amorphous solid coated on the carrier 16. The hollow tube is located around the void 10 of the consumable 4.

[0170] It should be noted that the consumable 4 in FIG. 5 is similar to the consumable 2 in FIG. 3, and the same reference numerals are assigned to similar members. For the sake of brevity, the consumable 4 in FIG. 5 will be considered mainly by focusing on the differences between these two consumables 2 and 4. However, it should be noted that any of the possible variations of the consumable 2 (or a part thereof) in FIG. 3 described herein can also be made for the consumable 4 (or its corresponding part) in FIG. 5, further constituting another embodiment. For example, the carrier 16 may be in any form of the carrier 16 described herein such that in some embodiments the carrier 16 includes a heating material that can be heated by the penetration of a variable magnetic field to heat the aerosolizable material 14. The heating material may be, for example, any one or more of those described herein. In other embodiments, the carrier 16 may not include such a heating material. Of course, in some embodiments, the entire consumable 4 may not include such a heating material.

[0171] The consumable 4 includes a porous material body 11 that houses an aerosol. In this embodiment, the hollow tube includes a porous material body 11 that houses an aerosol. More specifically, in this embodiment, the aerosolizable material 14 is located radially between the carrier 16 and the porous material body 11 that houses the aerosol. Even more specifically, in this embodiment, the porous material body 11 that houses the aerosol is located radially outward of the aerosolizable material 14. In some embodiments, at least a portion of the porous material body 11 that houses the aerosol may be located on one longitudinal end face of the aerosolizable material 14 or on two opposing longitudinal end faces of the aerosolizable material 14.

[0172] The porous material body 11 that houses the aerosol is for housing the aerosol generated from the aerosolizable material 14 during heating of the aerosolizable material 14 during use. The porous aerosol housing 11 helps to ensure that the volatilized material generated from the aerosolizable material 14 during use does not liquefy on the surface of the device 100 where the consumable 4 is used. In some embodiments, providing the porous material body 11 that houses the aerosol helps to increase the surface area formed by the aerosol generated from the aerosolizable material 14 within the consumable 4 during use. In some embodiments, such a porous material body 11 that houses the aerosol helps to increase the amount of visible aerosol emitted from the aerosolizable material 14 during use and may thus improve the consumer experience.

[0173] In some embodiments, the porous material body 11 that houses the aerosol does not include an aerosolizable material. In some embodiments, the porous aerosol housing 11 includes one or more materials selected from the group consisting of packing cotton, fleece, non-woven material, non-woven fleece, woven material, knitted material, nylon, foam, polystyrene, polyester, polyester filament, polypropylene, and blends of polyester and polypropylene. In other embodiments, the porous material body 11 that houses the aerosol may include an aerosolizable material.

[0174] In this embodiment, the aerosolizable material 14 is in contact with the porous material body 11 that houses the aerosol. However, in other embodiments, there may be another material layer between the aerosolizable material 14 and the porous material body 11 that houses the aerosol. Such an additional material layer increases the rigidity or robustness of the consumable 4, helps to maintain the relative positions of the aerosolizable material 14 and the porous aerosol-containing material 11, and / or helps to hold together different regions of the aerosolizable material 14. Such an additional material layer needs to be permeable so that the aerosol generated from the aerosolizable material 14 can reach the porous aerosol-containing material 11.

[0175] In this embodiment, the porous material body 11 that houses the aerosol is tubular. Further, in this embodiment, the porous material body 11 that houses the aerosol surrounds the aerosolizable material 14, the carrier 16, and the void 10, and the aerosolizable material 14 is located between the carrier 16 and the porous material body 11 that houses the aerosol. In some other embodiments, the porous material body 11 that houses the aerosol may be other than tubular. For example, in some embodiments, the porous material body 11 that houses the aerosol may have axially extending slots or other features formed in the material body such that the porous material body 11 that houses the aerosol is discontinuous in the circumferential direction and thus does not form a complete tube.

[0176] The consumable 4 of FIG. 5 also includes an outer cover 12. In this embodiment, the outer cover 12 is tubular. Further, in this embodiment, the outer cover 12 surrounds the porous material body 11 that houses the aerosol, and the porous material body 11 that houses the aerosol is located between the outer cover 12 and the aerosolizable material 14.

[0177] The outer cover 12 may be made of any suitable material. The outer cover 12 needs to have sufficient heat resistance to withstand the temperatures to which it is exposed during normal use, such as the temperatures described later in this specification. In some embodiments, the outer cover 12 is impermeable to the aerosol emitted from the aerosolizable material 14 during use. For example, in some embodiments, during use, the volatile material emitted from the aerosolizable material 14 and contained in the porous material body 11 that houses the aerosol is guided by the outer cover 12 to pass through the consumable 4 through the axial end of the porous material body 11 that houses the aerosol.

[0178] In some embodiments, the outer cover 12 includes one or more materials selected from the group consisting of paper, cardboard, paperboard, corrugated board, recycled tobacco, plastic materials, metals, and metal alloys. For example, in some embodiments, the outer cover 12 may include, for example, a rolled sheet or strip of paper or cardboard or recycled tobacco. In other embodiments, the outer cover 12 may include, for example, an extrusion of a plastic material or a material containing one or more metals.

[0179] In some other embodiments, the outer cover 12 may be other than tubular or may be omitted from the consumable 4.

[0180] In a modification of the embodiments of FIGS. 1-4, the consumables 1, 2, 3 may include a porous material body 11 that houses the aerosol generated from the aerosolizable material 14 during heating of the aerosolizable material 14 during use. In some such modifications, the aerosolizable material 14 may be located radially between the carrier 16 and the porous material body 11 that houses the aerosol. In some such embodiments, the consumables 1, 2, 3 also include a cover 12, and the porous material body 11 that houses the aerosol is located between the cover 12 and the aerosolizable material 14.

[0181] FIG. 6 is a schematic end cross-sectional view of an example of a consumable according to another embodiment of the present invention. The consumable 5 is for use in an apparatus that heats an aerosolizable material to volatilize at least one component of the aerosolizable material, such as the apparatus 100 shown in FIG. 8 and described below. The consumable 5 includes a hollow tube that includes a carrier 16 and an aerosolizable material 14 that includes an amorphous solid coated on the carrier 16. The consumable 5 includes a hollow tube that includes a carrier 16 and an aerosolizable material 14 that includes an amorphous solid coated on the carrier 16. The hollow tube is located around the void 10 of the consumable 5.

[0182] It should be noted that the consumable 5 in FIGS. 5 and 6 is similar to the consumable 2 in FIG. 3, and the same reference numerals are assigned to similar members. For the sake of brevity, the consumable 5 in FIG. 6 will be considered mainly by focusing on the differences between these two consumables 2 and 5. However, it should be noted that any of the possible variations of the consumable 2 (or a part thereof) in FIG. 3 described herein can also be made for the consumable 5 (or its corresponding part) in FIG. 6, further constituting another embodiment. For example, the carrier 16 may be in any form of the carrier 16 described herein such that in some embodiments the carrier 16 includes a heating material that can be heated by the penetration of a variable magnetic field to heat the aerosolizable material 14. The heating material may be, for example, any one or more of those described herein. In other embodiments, the carrier 16 may not include such a heating material. Of course, in some embodiments, the entire consumable 5 may not include such a heating material.

[0183] The carrier 16 of this embodiment forms the innermost surface of the consumable 5. In other embodiments, the carrier 16 may form only a part of the innermost surface. The carrier 16 of this embodiment has a plurality of holes 16a extending therethrough, which are for allowing the aerosol generated from the aerosolizable material 14 during heating of the aerosolizable material 14 to reach the innermost surface of the consumable 5 during use. In other embodiments, there may be only one such hole. These or each hole 16a may be in any suitable form such as a perforation of the carrier 16.

[0184] The consumable 5 of this embodiment has an outer cover 12. In this embodiment, the outer cover 12 surrounds the aerosolizable material 14, and the aerosolizable material 14 is located between the outer cover 12 and the carrier 16. The outer cover 12 may be in any of the forms described herein for the outer cover 12 of the consumable 4 in FIG. 5. However, in some embodiments, the outer cover 12 is impermeable to the aerosol emitted from the aerosolizable material 14 during use. For example, in some embodiments, the volatilized material emitted from the aerosolizable material 14 is guided by the outer cover 12 to pass through the consumable 4 substantially radially inwards to the void through one or more holes 16a extending through the carrier 16. From the void 10, the aerosol exits through the consumable 5 of the device 100 or through the consumable 5 by suction of the user at the mouthpiece (if provided).

[0185] In other embodiments, the cover 12 guides the volatilized material generated from the aerosolizable material 14 to pass through the consumable 4 through one or more holes 16a extending through the carrier 16 substantially radially outward and the arrangement of the carrier 16 and the cover 12 may be reversed.

[0186] In some embodiments, the consumables 1, 2, 3, 4, 5 also include a filter (not shown). The filter may be for filtering aerosol or vapor released from the aerosolizable material 14 during use. Separately or in addition thereto, the filter may be for controlling the pressure drop across the length of the consumables 1, 2, 3, 4, 5. The filter may be of any type used in the tobacco industry. For example, the filter may be made of cellulose acetate. In some embodiments, the filter may be substantially cylindrical having a substantially circular cross-section and a longitudinal axis. In other embodiments, the filter may have a different cross-section or may not be elongate.

[0187] In some embodiments, the filter abuts against the longitudinal end of the hollow tube and is axially aligned with the hollow tube. In other embodiments, the filter may be spaced from the hollow tube by a gap and / or one or more additional members of the consumables 1, 2, 3, 4, 5. Examples of additional members include, for example, an additive or flavor source (additive or flavor-containing capsule or thread) held between a body made of filter material or between two bodies made of filter material.

[0188] Also, the consumables 1, 2, 3, 4, 5 may include a wrapper wound around the hollow tube and the filter to hold the filter against the hollow tube. The wrapper may surround the hollow tube and the filter. The wrapper may be wound around the hollow tube and the filter such that the free ends of the wrapper overlap each other. The wrapper may form part or all of the outer peripheral surface of the consumables 1, 2, 3, 4, 5. The wrapper can be made of any suitable material such as paper, cardboard, or recycled aerosolizable material (e.g., recycled tobacco). Also, the wrapper may include an adhesive (not shown) such as one described elsewhere in this specification that adheres the overlapping free ends of the wrapper to each other. The adhesive serves to keep the overlapping free ends of the wrapper from separating. In other embodiments, the adhesive may be omitted and the wrapper may take a shape different from that described. In other embodiments, the filter may be held against the hollow tube by a connector other than the wrapper, such as an adhesive.

[0189] In some embodiments, the consumables 1, 2, 3, 4, 5 may have an axial length of 30 millimeters to 150 millimeters, such as 70 millimeters to 120 millimeters.

[0190] In some embodiments, the hollow tube may have an internal dimension (e.g., inner diameter) in a direction orthogonal to the axial direction of 2 millimeters to 10 millimeters, such as 4 millimeters to 8 millimeters.

[0191] In some embodiments, the hollow tube may have an external dimension (e.g., outer diameter) in a direction orthogonal to the axial direction of 4 millimeters to 10 millimeters, such as 4.5 millimeters to 8 millimeters.

[0192] In some embodiments, the hollow tube may have a thickness in a direction orthogonal to the axial direction of 0.15 millimeters to 0.5 millimeters, such as 0.2 millimeters to 0.3 millimeters.

[0193] In some embodiments, the aerosolizable material 14 may have a thickness in a direction orthogonal to the axial direction of the consumable that is 1 millimeter or less, such as 0.5 millimeter or less, or 0.25 millimeter or less, or 0.2 millimeter or less, or 0.1 millimeter or less, or 0.05 millimeter or less. The thickness may be from 0.05 millimeter to 1.0 millimeter. In some embodiments, the aerosolizable material 14 containing an amorphous solid is provided as a thin film coated or fixed to the carrier 16.

[0194] FIG. 7 is a flow diagram showing an example of a method for manufacturing a consumable according to an embodiment of the present invention for use in an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material. The method of FIG. 7 is useful for manufacturing any of the consumables described herein.

[0195] The method of the present invention includes providing 72 a hollow tube including a carrier and an aerosolizable material containing an amorphous solid fixed to the carrier. The carrier may be any of the carriers 16 described herein, for example. Similarly, the aerosolizable material may be any of the aerosolizable materials 14 described herein, for example.

[0196] In some embodiments, providing 72 the tube includes fixing 74 the aerosolizable material 14 to the carrier 16 and then forming 76 the hollow tube. As a result, in some embodiments, the carrier 16 may be flat or substantially flat when the aerosolizable material 14 is fixed thereto. Thereafter, in some embodiments, the carrier 16 and the aerosolizable material 14 may be handled together during the formation of the hollow tube. Such handling may include rolling or wrapping the combination of the carrier 16 and the aerosolizable material 14 into a tube or substantially tube shape. Such rolling or wrapping may be performed, for example, around a mandrel. In other embodiments, the carrier is provided in a tube or substantially tube shape, and then the aerosolizable material is fixed to the carrier 16.

[0197] In some embodiments, the method of the present invention includes manufacturing carrier 16. For example, as described by some examples herein, carrier 16 may include multiple layers, and manufacturing carrier 16 may include assembling those layers with an adhesive or the like to form carrier 16. At least one of the layers may be in the form of a sheet or strip. At least one of the layers may include a heating material such as any one or more of the examples of heating materials described herein. At least one of the layers may not be heatable by the intrusion of a variable magnetic field itself.

[0198] In some embodiments, such as embodiments where the pasting 74 is performed before the forming 76, the pasting 74 includes coating the carrier 16 with the aerosolizable material 14. As described elsewhere herein, the coating may include, for example, spraying, electrospraying, casting, or band carriers. As described elsewhere herein, the casting includes providing a liquid or other fluid material on the surface of the carrier 16 (or the material that will ultimately form the carrier 16), and then at least partially solidifying or curing the material on the surface of the carrier 16 to form the aerosolizable material 14 including an amorphous solid. The liquid or other fluid material may be aerosolizable in its form, or may become aerosolizable only after being solidified or cured once.

[0199] In some embodiments, the pasting 74 may include techniques other than coating. For example, in some embodiments, the pasting 74 may include adhering the aerosolizable material 14 using an adhesive such as any of the adhesives described herein.

[0200] In some embodiments, the aerosolizable material 14 forms at least a part of the surface of a hollow tube. In some embodiments, the aerosolizable material 14 forms all of the surface of a hollow tube. In some embodiments, the surface is the innermost surface of the hollow tube.

[0201] FIG. 8 is a schematic diagram of an example of a system including a consumable and an apparatus for heating an aerosolizable material of the consumable to volatilize at least one component of the aerosolizable material according to an embodiment of the present invention.

[0202] The system 1000 of the present invention includes the consumable 1 of FIGS. 1 and 2 and an apparatus 100 for heating the aerosolizable material of the consumable 1 to volatilize at least one component of the aerosolizable material. In other embodiments, the consumable 1 may be replaced with any of the other consumables described herein, such as the consumables 2, 3, 4, 5 shown in FIGS. 3 to 6. In this embodiment, the apparatus 100 is a tobacco heating product (also known in the art as a tobacco heating device or a non-combustion heating device).

[0203] The apparatus includes a heating region 110 for accommodating the consumables 1, 2, 3, 4, 5, and a device 112 for causing heating of the aerosolizable material 14 when the consumables 1, 2, 3, 4, 5 are in the heating region 110.

[0204] The apparatus 100 may define an air inlet (not shown) that fluidly connects the heating region 110 to the exterior of the apparatus 100. The user can inhale one or more volatilized components of the aerosolizable material by drawing in one or more components volatilized from the heating region 110. When one or more volatilized components are removed from the heating region 110 and the consumables 1, 2, 3, 4, 5, air is drawn into the heating region 110 through the air inlet of the apparatus 100.

[0205] In this embodiment, the heating area 110 includes a recess for accommodating at least a part of the consumables 1, 2, 3, 4, 5. In other embodiments, the heating area 110 may be other than a recess such as a shelf, a surface or a protrusion, and may require a mechanical connection with the consumables 1, 2, 3, 4, 5 or to accommodate them. In this embodiment, the heating area 110 is elongate and is sized and shaped to accommodate the entire consumables 1, 2, 3, 4, 5. In other embodiments, the heating area 110 may be sized to accommodate only a part of the consumables 1, 2, 3, 4, 5.

[0206] In some embodiments, the device 112 includes a power source, a resistive heater that is heated by passing electricity through it, and a controller for controlling the electricity passing through this resistive heater. The resistive heater is configured to apply thermal energy to the heating area 110, and thus to the consumables 1, 2, 3, 4, 5 when the consumables are within the heating area 110. The resistive heater may be configured such that thermal energy is applied to the aerosolizable material 14 via the carrier 16. In some embodiments, the resistive heater may protrude into the heating area 110 such that it is located within the void 10 of the consumables when the consumables are within the heating area 110. For example, such a configuration may be used when the consumables are those of FIG. 3 or FIG. 5. In some other embodiments, the resistive heater may be located radially outward of the consumables when the consumables are within the heating area 110. For example, the resistive heater may at least partially define the heating area 110. Such a structure may be used when the consumables are one of those of FIGS. 1, 2, 4 and 6 for example. In some embodiments, the device may include a first resistive heater that is within the void 10 of the consumables when the consumables are within the heating area 110 and a second resistive heater that is located radially outward of the consumables when the consumables are within the heating area 110. For example, such a structure may be used when the consumables are the consumables of FIG. 5.

[0207] In some embodiments, such as the embodiment shown in FIG. 8, device 112 includes a magnetic field generator that generates a varying magnetic field that penetrates heating region 110 when a consumable is within heating region 110. Such an apparatus 100 is suitable for use when the consumable includes a heating material for use in heating aerosolizable material 14.

[0208] In this embodiment, magnetic field generator 112 includes a power source 113, a coil 114, a device 116 that passes a varying current, such as an alternating current, through coil 114, a controller 117, and a user interface 118 for a user to operate controller 117.

[0209] Power source 113 of this embodiment is a rechargeable battery. In other embodiments, power source 113 may be other than a rechargeable battery, such as a non-rechargeable battery, a capacitor, a battery-capacitor hybrid, or a connection to an electrical mains supply.

[0210] Coil 114 may be of any suitable shape. In some embodiments, coil 114 is a helical coil made of a conductive material such as copper. In some embodiments, the coil is a flat coil. That is, the coil may be a two-dimensional helix made of a conductive material such as copper. In some embodiments, coil 114 surrounds heating region 110. In some embodiments, coil 114 extends along a longitudinal axis that is substantially aligned with the longitudinal axis of heating region 110. These axes that are aligned may coincide. Alternatively, these axes that are aligned may be parallel or oblique to each other.

[0211] In this embodiment, a device 116 for passing an alternating current through coil 114 is electrically connected between a power source 113 and the coil. In this embodiment, a controller 117 is also electrically connected to the power source 113 and communicably connected to the device 116 to control the device 116. More specifically, in this embodiment, the controller 117 is for controlling the device 116 to control the supply of power from the power source 113 to the coil 114. In this embodiment, the controller 117 includes an integrated circuit (IC) such as an IC on a printed circuit board (PCB). In other embodiments, the controller 117 may take different forms. In some embodiments, the apparatus 100 may have a single electrical or electronic member including the device 116 and the controller 117. The controller 117 is operated in this embodiment by a user operating a user interface 118. The user interface 118 may include a push button, a toggle switch, a dial, a touch screen, and the like. In other embodiments, the user interface 118 may be wirelessly connected to the rest of the apparatus 100 remotely, for example via Bluetooth (registered trademark).

[0212] In this embodiment, the operation of the user interface 118 by the user causes the device to pass an alternating current through the coil. Thereby, the coil 114 generates an alternating magnetic field. The coil 114 of the apparatus 100 and the heating region 110 are preferably relatively arranged such that when the consumable is located within the heating region, the alternating magnetic field generated by the coil penetrates into the heating material of the consumable, for example, the heating material of the carrier 16 of the consumable. When the heating material is conductive, this penetration generates one or more eddy currents in the heating material. As the eddy currents flow through the heating material against the electrical resistance of the heating material, the heating material is heated by Joule heating. When the heating material is made of a magnetic material, the orientation of the magnetic dipoles in the heating material changes in response to the change in the applied magnetic field, thereby generating heat in the heating material.

[0213] The device 100 of this embodiment includes a temperature sensor 119 for detecting the temperature of the heating region 110. The temperature sensor 119 is communicably connected to the controller 117, and as a result, the controller 117 can monitor the temperature of the heating region 110. The controller 117 can adjust, as needed, the characteristics of the alternating current or fluctuating current flowing through the coil 114 to the device 112 based on one or more signals received from the temperature sensor 119 in order to reliably maintain the temperature of the heating region 110 within a predetermined temperature range. These characteristics can be, for example, amplitude or frequency or duty cycle. In use, the aerosolizable material 14 within the consumable disposed within the heating region 110 is heated within a predetermined temperature range to volatilize at least one component of the aerosolizable material 14 without burning the aerosolizable material 14. Thus, the controller 117 and the device 100 as a whole are configured to heat the aerosolizable material 14 to volatilize at least one component of the aerosolizable material 14 without burning the aerosolizable material 14. In some embodiments, the temperature range is from about 50°C to about 300°C, for example, from about 100°C to about 300°C or from about 120°C to about 350°C or from about 140°C to about 250°C or from about 200°C to about 270°C. In other embodiments, the temperature range may be outside this range. In some embodiments, the upper limit of the temperature range can exceed 350°C. In some embodiments, the consumable may be non-combustible, for example, within these temperature ranges. In some embodiments, the temperature sensor 119 may be omitted.

[0214] In some embodiments, device 112 includes a heating element 120 that includes a heating material, the heating element 120 is in thermal contact with the heating region 110, and the magnetic field generator is for generating a varying magnetic field that penetrates the heating element 120 and thus causes heating of the heating region 110. Such a device 100 is suitable when the consumable itself does not include a heating material for use in heating the aerosolizable material 14. In some embodiments, the heating element 120 protrudes into the heating region 110 and is positioned within the void 10 of the consumable when the consumable is in the heating region 110. In some other embodiments, the heating element 120 may be positioned radially outward of the consumable when the consumable is in the heating region. For example, the heating element 120 may at least partially define the heating region 110.

[0215] In use, in some cases, substantially all of the amorphous solid is less than about 4 mm, less than 3 mm, less than 2 mm or less than 1 mm away from the heater (i.e., the heating element 120 or the resistive heater). In some cases, the solid is about 0.010 mm to 2.0 mm away from the heater, preferably about 0.02 mm to 1.0 mm, preferably 0.1 mm to 0.5 mm. These minimum distances may, in some cases, reflect the thickness of the carrier supporting the amorphous solid. In some cases, the surface of the amorphous solid may be in direct contact with the heater.

[0216] In some embodiments, the device 112 that causes heating of the aerosolizable material when the consumable is within the heating region 110 is configured to heat in such a way as to include independently controllable heating elements 120 for different sections of the heating region 110 independently of each other.

[0217] In some embodiments, the heating material of the consumables 1, 2, 3, 4, 5 or the heating element of the apparatus 100 is aluminum. However, in other embodiments, the heating material may include one or more materials selected from the group consisting of conductive materials, magnetic materials, and magnetoconductive materials. In some embodiments, the heating material may include a metal or a metal alloy. In some embodiments, the heating material may include one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, plain carbon steel, stainless steel, ferritic stainless steel, copper, and bronze. One or more other heating materials may be used in other embodiments.

[0218] In some embodiments, such as those where the heating material includes iron or aluminum such as steel (e.g., mild steel or stainless steel), the heating material may be coated to prevent corrosion or oxidation of the heating material during use. Such coatings may include, for example, nickel plating, gold plating, or coatings of ceramics or inert polymers.

[0219] In some embodiments, the consumables 1, 2, 3, 4, 5 may include a heating material partially or completely embedded in an aerosolizable material 14. In some embodiments, the aerosolizable material 14 may include a heating material. In some embodiments, the aerosolizable material 14 may not include a heating material.

[0220] In some embodiments, the aerosolizable material includes tobacco. However, in other embodiments, the aerosolizable material consists of tobacco, consists substantially entirely of tobacco, may include tobacco, may include aerosolizable materials other than tobacco, or may not include tobacco. In some embodiments, the aerosolizable material may include a vapor or an aerosol former or a wetting agent such as glycerin, propylene glycol, triacetin, or diethylene glycol.

[0221] In some embodiments, the consumable is non-combustible. In some embodiments, the consumable is configured to not become combustible during use.

[0222] In some embodiments, when all or substantially all of the volatile components of the aerosolizable material 14 within consumables 1, 2, 3, 4, 5 are consumed, the user may remove consumables 1, 2, 3, 4, 5 from the heating region 110 of the device 100 and discard consumables 1, 2, 3, 4, 5. The user may then reuse the device 100 with another set of consumables 1, 2, 3, 4, 5. However, in other corresponding embodiments, the device 100 and consumables 1, 2, 3, 4, 5 may be discarded together when one or more of the volatile components of the aerosolizable material 14 are consumed.

[0223] In some embodiments, consumables 1, 2, 3, 4, 5 are sold, supplied, or otherwise provided separately from the device 100 that can be used with consumables 1, 2, 3, 4, 5. However, in some embodiments, the device 100 and one or more consumables 1, 2, 3, 4, 5 may be provided together as a system, such as in a kit or assembly, and optionally with additional components such as cleaning implements.

[0224] To avoid misunderstanding, when "comprises" is used in this specification to define the invention or a feature of the invention, embodiments are also disclosed in which the invention or feature can be defined using "consists essentially of" or "consists of" instead of "comprises". When a particular feature is said to "comprise" a material, it means that those features are contained, included, or held in that material.

[0225] For addressing various problems and for the development of technologies, the present disclosure as a whole exemplarily shows various embodiments, in which the claimed invention is practiced, a consumable for use in an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, a method of manufacturing a consumable for use in an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, and a system including such a consumable and such an apparatus can be provided. The advantages and features of the present disclosure are merely representative specific examples of the embodiments and are neither comprehensive nor exclusive. They are provided merely as an aid to the understanding and teaching of the claimed features. Of course, the advantages, embodiments, specific examples, functions, features, structures, and / or other aspects of the present disclosure should not be considered to limit the present disclosure to what is defined in the claims or to equivalents of the claims, but other embodiments may be utilized and modified without departing from the scope and / or spirit of the present disclosure. The various embodiments may appropriately comprise, consist of, or essentially consist of the disclosed components, elements, features, parts, steps, means, and other combinations. The present disclosure also includes other inventions that are not currently claimed but may be claimed in the future.

Claims

1. A consumable for use in an apparatus that heats an aerosolizable material to volatilize at least one component of the aerosolizable material, the consumable includes a hollow tube containing a carrier and an aerosolizable material including an amorphous solid coated on the carrier, the consumable includes a heating material that can be heated by the intrusion of a variable magnetic field and thereby heats the aerosolizable material, the carrier forms at least a part of the surface of the consumable, and the consumable has one or more holes extending through the carrier to allow an aerosol generated from the aerosolizable material to pass to the surface of the consumable while the carrier is heating the aerosolizable material during use.

2. The consumable according to claim 1, wherein at least a part of the aerosolizable material is located radially inward of the carrier.

3. The consumable according to claim 1 or 2, wherein the carrier is tubular.

4. The consumable according to any one of claims 1 to 3, wherein the aerosolizable material is tubular.

5. The consumable according to any one of claims 1 to 4, wherein the heating material includes one or more materials selected from the group consisting of a conductive material, a magnetic substance, and a magnetoconductive material.

6. The consumable according to any one of claims 1 to 5, wherein the heating material includes a metal or a metal alloy.

7. The consumable according to any one of claims 1 to 6, wherein the heating material includes one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper, and bronze.

8. The consumable according to any one of claims 1 to 7, wherein the carrier includes the heating material.

9. The consumable according to claim 8, wherein the carrier includes a closed circuit of the heating material.

10. The consumable according to any one of claims 1 to 9, wherein the carrier includes a first layer and a second layer, the first layer includes the heating material, the second layer is not heated by the intrusion of a variable magnetic field, and the first layer is located between the aerosolizable material and the second layer.

11. The consumable according to any one of claims 1 to 10, characterized by comprising a porous material body that contains an aerosol containing an aerosol generated from an aerosolizable material while heating the aerosolizable material during use.

12. The consumable according to claim 11, characterized in that the aerosolizable material is located radially between the carrier and the porous material body that contains the aerosol.

13. The consumable according to any one of claims 1 to 12, characterized in that the aerosolizable material has a thickness of 0.1 millimeter to 5 millimeters in a direction orthogonal to the axial direction of the consumable.

14. A system for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, wherein this system includes a consumable that includes a hollow tube containing a carrier and an aerosolizable material including an amorphous solid coated on the carrier, the consumable includes a heating material that can be heated by the intrusion of a variable magnetic field and thereby heats the aerosolizable material, the carrier forms at least a part of the surface of the consumable, the carrier has one or more holes extending through the carrier to allow an aerosol generated from the aerosolizable material to pass to the surface of the consumable while heating the aerosolizable material during use, and a device for heating the aerosolizable material to volatilize at least one component of the aerosolizable material, and this device includes a heating region for accommodating the consumable and a device for heating the aerosolizable material when the consumable is in the heating region.

15. The system according to claim 14, characterized in that the device includes a magnetic field generator that generates a variable magnetic field for intruding into the heating region when the consumable is in the heating region.

16. The system according to claim 14 or 15, characterized in that the device includes a heating element including a heating material, the heating element is in thermal contact with the heating region, and the device includes a magnetic field generator that generates a variable magnetic field for intruding into the heating element to heat the heating region.

17. A method for manufacturing a consumable for use in a device for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, This method includes providing a heating element that can be heated by the intrusion of a variable magnetic field and thereby heats a material that can be aerosolized by this heating; providing a hollow tube containing a carrier and an aerosolizable material including an amorphous solid fixed to the carrier; forming one or more holes extending through the carrier for allowing an aerosol generated from the aerosolizable material to pass to the surface of the consumable while the carrier forms at least a part of the surface of the consumable and heats the aerosolizable material during use. **Claim 18** The method according to claim 17, characterized in that providing a hollow tube includes fixing an aerosolizable material to a carrier and then forming the hollow tube. **Claim 19** The method according to claim 18, characterized in that fixing includes coating the aerosolizable material on the carrier. **Claim 20** The method according to claim 19, characterized in that coating includes spraying or casting the aerosolizable material on the carrier.

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