Aerosol generating consumables

Abstract

Disclosed is a consumable (10) formed from a corrugated, gathered sheet material (20) having an aerosol-generating section (30) and one or two filter sections (40). The aerosol-generating section (30) is formed from an aerosol-generating material (31). The aerosol-generating material may include a film of aerosol-generating material applied, for example, by printing, to a portion of the surface of the corrugated, gathered sheet material (20). Corrugation may be applied only to the filter section (40), or to both the filter section (40) and the aerosol-generating section (30). The same level of corrugation may be applied to all sections, or different levels of corrugation may be applied to each section.

Description

Technical Field

[0001] The present disclosure relates to a consumable for use with an aerosol supply system, an aerosol supply system including the consumable, and a method of forming the consumable.

Background Art

[0002] Certain tobacco industry products generate an aerosol that is inhaled by a user during use. For example, a tobacco heating device forms an aerosol by heating an aerosol-forming substrate such as tobacco, rather than burning the substrate. Such tobacco industry products generally include a consumable containing an aerosol-forming material for use in a heating device.

Summary of the Invention

[0003] In a first aspect of the present invention, there is provided a consumable for use with a non-combustion aerosol supply device, the consumable comprising an aerosol generation section and a filter section, the aerosol generation section and the filter section being integrally formed from a crimped and gathered sheet material, the aerosol generation section containing an aerosol-forming material and the filter section substantially not containing the aerosol-forming material.

[0004] In some embodiments, the aerosol generation section comprises a portion of the crimped and gathered sheet material into which the aerosol-forming material is incorporated.

[0005] In some embodiments, the aerosol generation section comprises a film of the aerosol-forming material provided on a surface of a portion of the crimped and gathered sheet material. The aerosol-forming material may be printed on the crimped and gathered sheet material.

[0006] In some embodiments, the aerosol generation section is not waveformd. The aerosol generation section may substantially not include waveformization.

[0007] In some embodiments, the filter section and aerosol generation section of the corrugated and assembled sheet material are corrugated at the same level. In other embodiments, the filter section and aerosol generation section of the corrugated and assembled sheet material are corrugated at different levels. The level of corrugation may have a corrugation amplitude and / or corrugation interval.

[0008] The corrugation spacing may have the average spacing between adjacent furrows of the corrugated and assembled sheet material. In some embodiments, the average spacing of the corrugations in both the filter section and the aerosol generation section is about 0.1 mm to about 3 mm. In some embodiments, the adjacent grooves of the corrugated sheet material are separated by distances of at most 3 mm, preferably at most 2.5, 2, 1, 1.5, 0.7, 0.5, 0.2, or 0.1 mm.

[0009] In some embodiments, the average waveform interval of the aerosol generation section is smaller than the average waveform interval of the filter section. In other embodiments, the average waveform interval of the aerosol generation section is larger than the average waveform interval of the filter section.

[0010] The waveform amplitude may have the average height of the ridges in the corrugated and assembled sheet material. In some embodiments, the waveform amplitude of both the filter section and the aerosol generation section is about 0.1 mm to about 1 mm. In some embodiments, the sheet material is corrugated to a waveform amplitude of at least 0.1 mm, preferably at least 0.3 mm, 0.4 mm, or 0.5 mm. In some embodiments, the sheet material is corrugated to a waveform amplitude of at most 1 mm, preferably at most 0.8 mm, 0.6 mm, or 0.5 mm.

[0011] In some embodiments, the sheet material may have a waveform with a waveform amplitude smaller than 500 μm and a peak (or trough) spacing of at least 300 μm, at least 400 μm, or at least 500 μm.

[0012] In some embodiments, the waveform amplitude of the aerosol generation section is smaller than that of the filter section. In other embodiments, the waveform amplitude of the aerosol generation section is larger than that of the filter section.

[0013] In some embodiments, the corrugated and assembled sheet material is surrounded by a first packaging material. The first packaging material preferably has a basis weight of about 30 to about 75 gsm, or about 40 to about 65 gsm. Such a basis weight can help improve the roundness of the cross-section of the aerosol-generating section.

[0014] A second packaging material may be provided only around the filter section. The second packaging material preferably has a basis weight of about 70 gsm to about 120 gsm, more preferably about 80 gsm to about 110 gsm. Such a basis weight is desirable to achieve an acceptable overall level of rigidity.

[0015] In some embodiments, the consumables are substantially cylindrical in shape.

[0016] The length of the aerosol generation section may be in the range of approximately 25 mm to approximately 50 mm, more preferably in the range of approximately 30 mm to 45 mm, and even more preferably in the range of approximately 30 mm to 40 mm. The length of the filter section may be in the range of approximately 5 mm to approximately 50 mm.

[0017] In some embodiments, the closed pressure drop between the ends of the consumable is 30 to 90 mmWG, preferably 35 to 70 mmWG.

[0018] The closed pressure drop between the ends of the filter section can be approximately 0.5 to 20 mmWG. The closed pressure drop between the ends of the filter section can be approximately 1.5 to 8.6 mmWG per 1 mm of filter section length, or approximately 3 to 6 mmWG per 1 mm of filter section length.

[0019] The closed pressure drop between the two ends of the aerosol generation section can be approximately 29 to 70 mmWG.

[0020] In some embodiments, the aerosol-generating material comprises an aerosol-forming agent, a binder, optionally a filler, and optionally an activator and / or flavoring agent.

[0021] In some embodiments, the consumable comprises an aerosol generating section and one filter section. In other embodiments, the consumable comprises an aerosol generating section and two filter sections, one on each side of the aerosol generating section.

[0022] In a second aspect of the present invention, A method for forming consumables for use with a non-combustible aerosol supply device, The steps include preparing the sheet material and The steps include applying an aerosol-generating material to a sheet material in separate sections to alternately form an aerosol-generating section and a filter section that substantially does not contain the aerosol-generating material, The steps include: the step of corrugating the sheet material, The steps include: gathering sheet material together to form a roughly cylindrical rod, The rod is separated into individual consumables, each having an aerosol generation section and a filter section. A method including this is provided.

[0023] In some embodiments of the second aspect, different levels of corrugation are applied to the aerosol generation section and the filter section. In some embodiments of the second aspect, no corrugation is applied to the aerosol generation section.

[0024] In a third aspect of the present invention, A method of forming a consumable for use with a non-combustion aerosol supply device, comprising: Providing a continuous sheet material having discrete sections containing an aerosol-forming material, the discrete sections being spaced equidistantly along the length of the continuous sheet material; Applying a corrugated pattern to the continuous sheet material; Gathering the continuous sheet material including the corrugated pattern; Wrapping the gathered continuous sheet material in at least one packaging material to form a consumable A method is provided that includes.

[0025] In some embodiments of the third aspect, the step of applying a corrugated pattern includes applying a first level of corrugation to the discrete sections and a second level of corrugation to the sections between the discrete sections.

[0026] In a fourth aspect of the present invention, A non-combustion aerosol supply system for heating an aerosol-forming material to volatilize at least one component of the aerosol-forming material, comprising: A consumable according to the first aspect, And a non-combustion aerosol supply device, The non-combustion aerosol supply device includes an aerosol generator configured to heat the consumable to generate an aerosol when the consumable and the device are combined during use. A non-combustion aerosol supply system is provided.

[0027] A fifth aspect of the present invention provides a consumable for use with a non-combustible aerosol supply device, the consumable comprising a first end and a second end, the consumable comprising a suction port downstream of the first end, an aerosol generating section downstream of the first end and upstream of the suction port, and a blocking member (or plug) positioned upstream of the aerosol generating section, wherein the aerosol generating section and the blocking member are formed collectively from corrugated and / or slit and assembled sheet material, and the aerosol generating section comprises an aerosol generating material.

[0028] In some embodiments of the fifth aspect, the blocking member allows airflow but prevents the outflow of aerosol-generating material from the consumables. Therefore, in some embodiments, the blocking member is permeable.

[0029] A sixth aspect of the present invention provides a consumable for use with a non-combustible aerosol supply device, the consumable comprising an aerosol generating section and a filter section, the aerosol generating section and the filter section being formed collectively from corrugated and / or slit and assembled sheet material, the aerosol generating section containing an aerosol generating material, and the filter section substantially containing no aerosol generating material.

[0030] In some embodiments of the sixth aspect, the slits may be replaced by the corrugations of the other embodiments. The material may be slit by a plurality of separate slits or perforations.

[0031] In some embodiments of the sixth aspect, the aerosol-generating section is slit and the filter section is corrugated. The corrugated filter section can help retain the aerosol-generating material within the consumable.

[0032] In some embodiments, the corrugations and / or slits extend longitudinally along the consumable.

[0033] Next, embodiments of the present invention will be described with reference to the accompanying drawings, merely as non-limiting examples. [Brief explanation of the drawing]

[0034] [Figure 1A] This is a schematic diagram of an exemplary consumable made from corrugated and assembled sheet material, having an aerosol generation section and one filter section. [Figure 1B] This is a schematic diagram of an exemplary consumable made from corrugated and assembled sheet material, having an aerosol generation section and two filter sections. [Figure 2A] Figure 1B is a schematic diagram of the consumables, with waveforms applied only to the filter section. [Figure 2B] Figure 1B is a schematic diagram of the consumables, showing the filter section and aerosol generation section with waveforms applied. [Figure 2C] Figure 1B is a schematic diagram of the consumables, showing that the filter section and the aerosol generation section are subjected to different levels of waveform processing. [Figure 3A] This figure shows the amplitude and interval of a single waveform. [Figure 3B] This figure shows the amplitude and interval of a different waveform configuration. [Figure 4A] Figure 1A is a schematic diagram of the consumable with additional packaging material. [Figure 4B] Figure 1B is a schematic diagram of the consumables with additional packaging materials. [Figure 5] This figure shows a schematic process configuration for corrugating sheet material during the manufacturing of consumables. [Figure 6] This diagram schematically shows a system comprising consumables and a non-combustible aerosol supply device. [Modes for carrying out the invention]

[0035] As used herein, the term “delivery system” is intended to encompass a system for delivering at least one substance to a user, and includes non-combustion aerosol delivery systems that release compounds from aerosol-generating materials without burning the materials, such as hybrid systems that generate aerosols using a combination of electronic cigarettes, tobacco heating products, and aerosol-generating materials.

[0036] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the constituent aerosol-generating materials (or components of those materials) of the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0037] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0038] In some embodiments, the non-combustion aerosol supply system is an aerosol-generating material heating system, also known as a non-combustion heating system.

[0039] In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates aerosols using a combination of one or more aerosol-generating materials that can be heated. Each of the aerosol-generating materials may be in the form of, for example, a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0040] The non-combustible aerosol supply system described herein comprises a non-combustible aerosol supply device and consumables for use with the non-combustible aerosol supply device.

[0041] This disclosure relates to consumables comprising aerosol-generating materials and configured for use with non-combustible aerosol supply devices. These consumables may be referred to as articles in this disclosure.

[0042] In some embodiments, a non-combustible aerosol supply system, such as a non-combustible aerosol supply device, may include a power source and a controller. The power source may be, for example, an electrical power source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that can be energized to distribute power in the form of heat to an aerosol-generating material or heat-transferring material adjacent to the heat-generating power source.

[0043] In some embodiments, the non-combustible aerosol supply system may include a consumable receiving area, an aerosol generator, an aerosol generating area, a housing, a suction port, a filter, and / or an aerosol modifier.

[0044] In some embodiments, consumables for use with a non-combustible aerosol supply device may include aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, packaging material, a filter, a suction nozzle, and / or an aerosol modifier. The consumables may also include an aerosol generator, such as a heater, which generates heat during use to cause the aerosol generating material to produce an aerosol. The heater may include, for example, a flammable material, an electrically conductive material, or a susceptor.

[0045] In some embodiments, the delivered substance may be an aerosol-generating material or a material not intended to be aerosolized. Optionally, any of the materials may include one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0046] active substance In some embodiments, the delivered substance includes an active substance.

[0047] The active substances used herein may be physiologically active materials, which are materials intended to achieve or enhance a physiological response. Active substances may be selected from, for example, dietary supplements, nootropics, and psychostimulants. Active substances may be naturally occurring or obtained synthetically. Active substances may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or their components, derivatives, or combinations. Active substances may also include one or more components, derivatives, or extracts of tobacco, cannabis, or other plant substances.

[0048] In one embodiment, the active substance is a legally permissible recreational drug.

[0049] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0050] As described herein, the active substance may comprise one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes. The active substance may be CBD or a derivative thereof.

[0051] As described herein, the active substance may include or be derived from one or more plant substances or their components, derivatives, or extracts. As used herein, the term “plant substance” includes, but is not limited to, any material derived from a plant, including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, exoskeletons, shells, etc. Alternatively, the material may include synthetically obtained active compounds naturally present in plant substances. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, flakes, strips, sheets, etc. Examples of plant-based substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay leaf, licorice, matcha, mate, orange peel, papaya, rose, sage, tea (such as green or black tea), thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and rabbi. The herbs are mint, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following mint varieties: peppermint, mint cv, Egyptian mint, European mint, eau de cologne mint, candy mint, curly mint, Kentucky colonel mint, horse mint, pineapple mint, pennyroyal mint, green mint, and apple mint.

[0052] In some embodiments, the active substance comprises or is derived from one or more plant substances, or their components, derivatives, or extracts, the plant substance being tobacco.

[0053] In some embodiments, the active substance comprises or is derived from one or more plant substances, or their components, derivatives, or extracts, the plant substances being selected from eucalyptus, star anise, cocoa, and hemp.

[0054] In some embodiments, the active substance comprises or is derived from one or more plant substances, or their components, derivatives, or extracts, the plant substances being selected from rooibos and fennel.

[0055] Flavor In some embodiments, the delivered substance includes flavorings.

[0056] As used herein, the terms “flavoring” and “flavoring agent” refer to materials that may be used to create a desired taste, aroma, or other somatosensory effect in products intended for adult consumers, where permitted by local regulations.These are naturally occurring flavorings, plant substances, extracts of plant substances, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes, etc.). Tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, kurt, eggplant, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-yi Orchid, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, peppermint oil from any of the Mentha species, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazelnut, hibiscus, bay leaf, mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damien, maji It may contain other additives such as chollum, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), as well as charcoal, chlorophyll, minerals, plant-based substances, or breath fresheners.They may be imitations, synthetics, or natural raw materials, or blends thereof. They may be in any suitable form, such as a liquid like an oil, a solid like a powder, or a gas.

[0057] In some embodiments, the flavor includes menthol, spearmint, and / or peppermint. In some embodiments, the flavor includes cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavor includes eugenol. In some embodiments, the flavor includes flavor components extracted from tobacco. In some embodiments, the flavor includes flavor components extracted from cannabis.

[0058] In some embodiments, the flavor may include a sensory stimulant, which is intended to achieve somatosensation that is normally chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to, or instead of, aromatic or gustatory nerves, and these may include agents that produce heating, cooling, tingling, or numbing effects. Preferred thermal agents are not limited to vanillyl ethyl ether, and preferred cooling agents are not limited to eucalyptol or WS-3.

[0059] Aerosol generating materials Aerosol-generating materials are materials that can generate aerosols when energy is supplied, for example, by heating, irradiation, or any other method. Aerosol-generating materials may be in the form of a solid, liquid, or semi-solid (such as a gel), and may or may not contain active substances and / or flavorings.

[0060] The aerosol-generating material may include one or more active substances and / or flavorings, one or more aerosol-forming agent materials, and optionally one or more other functional materials.

[0061] The aerosol-generating material may include a binder such as a gelling agent and an aerosol-forming agent. Optionally, a delivered substance and / or filler may also be present. Optionally, a solvent such as water may also be present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant-based materials. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0062] The aerosol-generating material may include or be in the form of an aerosol-generating film. The aerosol-generating film may include a binder such as a gelling agent and an aerosol-forming agent. Optionally, a delivered substance and / or filler may also be present. The aerosol-generating film may not contain substantially any plant material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco-free.

[0063] The aerosol-generating film may have a thickness of approximately 0.015 mm to approximately 1 mm. For example, the thickness may be in the range of approximately 0.05 mm, 0.1 mm, or 0.15 mm to approximately 0.3 mm or 0.5 mm.

[0064] In some embodiments, the aerosol-generating film may be discontinuous. For example, the aerosol-generating film may include one or more separate parts or regions of aerosol-generating material, such as dots, stripes, or lines, which can be supported on a support. In such embodiments, the support may be planar or non-planar.

[0065] An aerosol-generating film can be formed by combining a binder, such as a gelling agent, with one or more other components, such as a solvent like water, an aerosol-forming agent, and one or more substances to be delivered, to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent to form an aerosol-generating film.

[0066] The slurry may be heated to remove at least about 60% by weight, 70% by weight, 80% by weight, 85% by weight, or 90% by weight of the solvent.

[0067] The aerosol-generating material may include or may be an amorphous solid. In some embodiments, the aerosol-generating material includes an aerosol-generating film which is an amorphous solid. The amorphous solid may be a monolithic solid. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material capable of holding some fluid, such as a liquid, within the amorphous solid. In some embodiments, the amorphous solid may include, for example, about 50% by weight, 60% by weight, or 70% by weight of amorphous solid to about 90% by weight, 95% by weight, or 100% by weight of amorphous solid.

[0068] The amorphous solid does not need to contain substantially any plant-based material. The amorphous solid does not need to contain substantially any tobacco.

[0069] The aerosol-generating material may contain granules or beads, or be in the form thereof. The granules or beads may be trapped within the consumable when the sheet material is assembled and the consumable is formed.

[0070] Aerosol-forming agent materials The aerosol-forming agent material may contain one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming agent material may contain one or more of the following: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetins, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0071] functional materials One or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0072] Base material The aerosol-generating material may be present on or within a support that forms the substrate. The support may be, for example, paper, cardboard, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy, or may include these. In some embodiments, the support includes a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0073] Susceptor A susceptor is a material that can be heated by penetration through a fluctuating magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, and consequently, penetration through the conductive material by the fluctuating magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, and consequently, penetration through the magnetic material by the fluctuating magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, and consequently, the susceptor can be heated by both heating mechanisms. A device configured to generate a fluctuating magnetic field is referred to herein as a magnetic field generator.

[0074] Aerosol modifier Aerosol modifiers are typically substances located downstream of the aerosol-generating region and are configured to modify the generated aerosol, for example, by altering the taste, flavor, acidity, or other properties of the aerosol. The aerosol modifier may be provided within an aerosol modifier release component that is operable to selectively release the aerosol modifier.

[0075] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may contain, for example, one or more of the following: flavorings, colorings, water, and carbon adsorbents. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, thread, or granules. The aerosol modifier does not need to contain a filter material.

[0076] aerosol generator An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to supply thermal energy to the aerosol-generating material so as to release one or more volatile substances from the aerosol-generating material to form an aerosol.

[0077] Figures 1A and 1B show schematic diagrams of exemplary consumables 10 formed from corrugated and aggregated sheet material 20, having an aerosol generating section 30 and one or two filter sections 40. The aerosol generating section 30 is formed from aerosol generating material 31. In Figure 1A, the aerosol generating section 30 is located at one end of the consumable so that one filter section 40 is provided. In Figure 1B, the aerosol generating section 30 is located in the center of the consumable so that two filter sections 40 are provided.

[0078] The sheet material 20 may be formed from or contain paper, cardboard, cardboard, thick paper, or reconstructed material. Other materials of the sheet 20 may be as described above with respect to the substrate / support.

[0079] The aerosol-generating material 31 is configured to generate an aerosol when heated by the aerosol generator of a non-combustion aerosol supply device, as will be further described below. The aerosol-generating material 31 may be formed from or contain any of the materials described above. The consumables may further include a metallic material to function as a susceptor for heating the aerosol-generating material 31.

[0080] Figures 2A, 2B, and 2C show schematic diagrams of the consumable of Figure 1B having different configurations of waveform 50. Those skilled in the art will understand that the different configurations of waveform are equally applicable to the consumable of Figure 1A.

[0081] In Figure 2A, waveform conversion 50 is applied only to the filter section 40.

[0082] In Figure 2B, waveform 50 is applied to both the filter section 40 and the aerosol generation section 30. The same level of waveform 50 is applied to all sections.

[0083] In Figure 2C, the filter section 40 and the aerosol generation section 30 are subjected to different levels of waveformization. The filter section 40 is provided with a first level of waveformization 51, and the aerosol generation section 30 is provided with a second level of waveformization 52. The "level" of waveformization can be defined as amplitude and / or interval, as will be further explained below in relation to Figure 4.

[0084] The interval of the waveform 51 applied to the filter section 40 may be greater than or less than the interval of the waveform 52 applied to the aerosol generation section 30.

[0085] The amplitude of the waveform 51 applied to the filter section 40 may be greater than or less than the amplitude of the waveform 52 applied to the aerosol generation section 30. Both the interval and amplitude may differ between the filter section 40 and the aerosol generation section 30.

[0086] Figures 3A and 3B show the amplitude A and interval S of two different waveform shapes, including a sine wave and a triangular wave, respectively. Other waveform shapes, such as a square, may also be used.

[0087] Figures 4A and 4B show schematic diagrams of the consumables of Figures 1A and 1B with additional packaging material. A first packaging material 60 is provided around the entire consumable 10, which helps to hold the corrugated and assembled material 20 in a cylindrical shape. A second packaging material 70 is provided around one or two filter sections 40. In Figure 4B, the second packaging material 70 may be provided around one or both filter sections 40. The first and second packaging materials may be formed from chip paper.

[0088] A filter component may be included within a filter section 40, or, if there are two filter sections 40, within one or both of the filter sections 40. The filter component preferably allows for finer control of the closing pressure drop or suction resistance of the consumable 10. For example, the closing pressure drop can be controlled by setting the density of the filter material in the filter component, or by increasing or decreasing the axial length of the filter component. The filter component may include additional filter material. The filter component may include a capsule.

[0089] Figure 5 shows a schematic process configuration for corrugating sheet material during the manufacture of consumables. The bobbin 90 contains a roll (which can be considered substantially continuous) of sheet material 20 that is corrugated and assembled to form the consumables. Sections of aerosol-generating material 31 are pre-printed on the sheet material 20 in the bobbin 90. Alternatively, the aerosol-generating material 31 may be printed linearly onto the sheet material 20 after it has been unwound from the bobbin 90, or applied in other ways.

[0090] The corrugated roller 91 corrugates the sheet material. This corrugation may be continuous or discontinuous, depending on the required corrugation configuration. The corrugation configuration may be one of the corrugation configurations shown in Figure 2. After corrugation, the corrugated sheet 20 having the aerosol-generating material 31 is fed into a rod-making machine where sheets are assembled by conventional means to form a rod. The rod may also be packaged in one or more packaging materials, or in other configurations as needed, as shown in Figure 4, for example. The rod is then separated into individual consumables, for example, by cutting.

[0091] Figure 6 shows a system comprising a consumable 100, which may be one of the consumables 10 according to the present invention described above, and a non-combustible aerosol supply device 200. The device comprises a region 201 for receiving the consumable 100 and an aerosol generator 202. The aerosol generator is configured to heat the aerosol-generating material 31 of the consumable 100 when the consumable 100 is received into the region 201 to generate an aerosol for inhalation by the user. The device further comprises a power supply 203, a controller 204, and a puff sensor 205. When in use, the user first inserts the distal end 102 of the consumable 100 into the region 201 for receiving the consumable and activates the aerosol generator 202 to generate an aerosol for inhalation. The user can then inhale the aerosol by sucking on the mouthpiece end 101 of the consumable, or alternatively, the mouthpiece of the device 200 (not shown). In the illustrated example, the consumable 100 and device 200 are configured such that the mouthpiece end 101 protrudes from the area 201 for receiving the consumable 100 when fully inserted into the device 200. Thus, the mouthpiece end 101 is available to be positioned between the user's lips while the user is holding the device.

[0092] The puff sensor 205 is configured to detect when the user is inhaling the inhalation tip 101 of the consumable in the device 200 and to send a signal to the controller 204 to activate the aerosol generator 202. Thus, an aerosol is generated simultaneously with the user inhaling the consumable. Alternatively, the device 200 may be provided with a user interface such as a button (not shown) that the user can press to activate the aerosol generator 202.

[0093] The area 201 for receiving the consumable 100 is provided with an inlet (not shown) for introducing air into the area and passing through the consumable when the user inhales the mouthpiece end 101 of the consumable 100. Thus, when the user inhales the consumable 100, an airflow is directed through the consumable 100. When heated by the aerosol generator 202, the airflow carries the aerosol generated by the aerosol-generating material 31 of the consumable.

[0094] The aerosol generator 202 includes any suitable means for heating the consumable aerosol-generating material 31 received within the region 201 of the device 200. Power for the aerosol generator 202 is supplied by a power supply 203, which in the illustrated example is a battery 203.

[0095] In one example, the aerosol generator 202 includes a magnetic field generator configured to generate a fluctuating magnetic field that penetrates a region 201 for receiving a consumable 100. The fluctuating magnetic field heats a susceptor placed within the region for receiving the consumable by magnetic hysteresis. This example is used when the consumable 100 includes a susceptor that is in thermal contact with an aerosol-generating material 31, such as the aforementioned metallic material. Thus, when such a consumable 100 is placed in the device 200 and the aerosol generator 202 is activated, the fluctuating magnetic field penetrates the susceptor of the consumable 100, heating the aerosol-generating material 31 that is in thermal contact with the susceptor to generate an aerosol for inhalation by the user.

[0096] In another example, the aerosol generator 202 comprises a susceptor that is in thermal contact with a region 201 for receiving a consumable, and a magnetic field generator for generating a fluctuating magnetic field that penetrates the susceptor. The fluctuating magnetic field heats the susceptor by magnetic hysteresis. The susceptor then heats the region 201 for receiving the consumable. Thus, when the consumable 100 is placed inside the device 200 and the aerosol generator 202 is activated, the fluctuating magnetic field penetrates the susceptor and heats the region 201 in which the consumable 100 is received. The heat is transferred to the aerosol-generating material 31 of the consumable 100, generating an aerosol for inhalation by the user. In such an embodiment, the susceptor may be the wall of the region 201 for receiving the consumable 100, and the consumable 100 may be configured to be in direct contact with the wall for efficient heat transfer. Alternatively, the susceptor may comprise one or more protrusions (not shown) that stand upright within the region 201 for receiving the consumable 100. Therefore, the susceptor may be directly placed within the consumable 100.

[0097] In another example, the aerosol generator 202 comprises an electrically conductive material, which is provided in thermal contact with a region 201 for receiving a consumable 100. Thus, when the consumable 100 is placed within the device 200 and the aerosol generator 202 is activated, an electric current is passed through the material to heat the region 201 where the consumable 100 is received. The heat is transferred to the aerosol-generating material 31 of the consumable 100, generating an aerosol for inhalation by the user. In such an embodiment, the material may also be the wall of the region 201 for receiving the consumable 100, and the consumable 100 may be configured to be in direct contact with the wall for efficient heat transfer. Alternatively, the aerosol generator 202 may be in the form of a blade or pin inserted into the aerosol-generating material 31 when the consumable 100 is placed within the device. When the aerosol generator 202 is activated, the heat is transferred directly to the aerosol-generating material 31, generating an aerosol for inhalation by the user.

Claims

1. A consumable for use with a non-combustible aerosol supply device, wherein the consumable comprises an aerosol generating section and a filter section, the aerosol generating section and the filter section being formed collectively from a corrugated and assembled sheet material, the aerosol generating section containing an aerosol generating material, and the filter section substantially containing no aerosol generating material.

2. The consumable according to claim 1, wherein the aerosol generating section includes a portion of the corrugated and assembled sheet material mixed with the aerosol generating material.

3. The consumable according to claim 1, wherein the aerosol generating section includes a film of aerosol generating material provided on the surface of a portion of the corrugated and assembled sheet material.

4. The consumable according to any one of claims 1 to 3, wherein the aerosol generation section is not waveformd.

5. The consumable according to any one of claims 1 to 3, wherein the filter section and the aerosol generation section of the corrugated and assembled sheet material are corrugated at the same level or at different levels.

6. The consumable according to claim 5, wherein the level of corrugation has a corrugation interval, and the corrugation interval has the average interval between adjacent furrows of the corrugated and assembled sheet material.

7. The consumable according to claim 6, wherein the average interval of the waveforms in both the filter section and the aerosol generation section is about 0.1 mm to about 3 mm.

8. The consumable according to claim 6, wherein the filter section and the aerosol generating section of the corrugated and assembled sheet material have different levels of corrugation, and the average interval of the corrugation of the aerosol generating section is smaller than the average interval of the corrugation of the filter section, or the average interval of the corrugation of the aerosol generating section is larger than the average interval of the corrugation of the filter section.

9. The consumable according to claim 5, wherein the level of corrugation has a waveform amplitude, and the waveform amplitude has the average height of the ridges of the corrugated and assembled sheet material.

10. The consumable according to claim 9, wherein the waveform amplitude of both the filter section and the aerosol generation section is approximately 0.1 mm to approximately 1 mm.

11. The consumable according to claim 9, wherein the filter section and the aerosol generating section of the corrugated and assembled sheet material have different corrugation levels, and the waveform amplitude of the aerosol generating section is smaller than the waveform amplitude of the filter section, or the waveform amplitude of the aerosol generating section is larger than the waveform amplitude of the filter section.

12. The consumable product according to any one of claims 1 to 3, wherein the corrugated and assembled sheet material is surrounded by a first packaging material.

13. The consumable according to claim 12, wherein the second packaging material is provided only around the filter section.

14. The consumable according to any one of claims 1 to 3, wherein the length of the aerosol generating section is about 25 mm to about 50 mm, and / or the length of the filter section is about 5 mm to about 50 mm.

15. The consumable product according to any one of claims 1 to 3, wherein the aerosol generating material comprises an aerosol forming agent and a binder.

16. The consumable according to any one of claims 1 to 3, wherein the consumable comprises one aerosol generating section and one filter section.

17. The consumable according to any one of claims 1 to 3, wherein the consumable comprises one aerosol generating section and two filter sections, one on each side of the aerosol generating section.

18. A method for forming consumables for use with a non-combustible aerosol supply device, The steps include preparing the sheet material and The steps include applying an aerosol-generating material to separate sections of the sheet material to alternately form aerosol-generating sections and filter sections substantially free of the aerosol-generating material, The steps of corrugating the sheet material and The steps include gathering the aforementioned sheet material together to form a roughly cylindrical rod, The rod is separated into individual consumables having an aerosol generation section and a filter section, respectively. A method that includes this.

19. The method according to claim 18, wherein the aerosol generation section and the filter section are subjected to different levels of waveformization.

20. The method according to claim 18, wherein the aerosol generation section is not subjected to waveform processing.

21. A method for forming consumables for use with a non-combustible aerosol supply device, A step of preparing a continuous sheet material having separate sections containing an aerosol-generating material, wherein the separate sections are arranged at equal intervals along the length of the continuous sheet material, The steps include applying a wave pattern to the continuous sheet material, The steps include: gathering together the continuous sheet material including the waveform pattern; The steps include: wrapping the assembled continuous sheet material in at least one packaging material to form the consumable product; A method that includes this.

22. The method according to claim 21, wherein the step of applying the waveform pattern includes the steps of applying a first level of waveformization to the separate sections and a second level of waveformization to the sections between the separate sections.

23. A non-combustion aerosol supply system for heating an aerosol generating material to volatilize at least one component of the aerosol generating material, A consumable item according to any one of claims 1 to 3, Equipped with a non-combustion aerosol supply device, A non-combustible aerosol supply system comprising an aerosol generator configured to heat the consumables and generate an aerosol when the non-combustible aerosol supply device and the non-combustible aerosol supply device are combined during use.

24. A consumable for use with a non-combustible aerosol supply device, wherein the consumable comprises a first end and a second end, The suction port downstream of the first end, Aerosol generation section downstream of the first end and upstream of the mouthpiece, A blocking member positioned upstream of the aerosol generation section and Equipped with, A consumable item wherein the aerosol generating section and the blocking member are formed collectively from corrugated and / or slit and assembled sheet material, and the aerosol generating section contains an aerosol generating material.

25. A consumable for use with a non-combustible aerosol supply device, wherein the consumable comprises an aerosol generating section and a filter section, the aerosol generating section and the filter section being formed collectively from corrugated and / or slit and assembled sheet material, the aerosol generating section containing an aerosol generating material, and the filter section substantially containing no aerosol generating material.

26. The consumable according to claim 25, wherein the aerosol generation section is slit and the filter section is corrugated.

27. ​​The consumable according to any one of claims 1 to 3, wherein the waveform extends longitudinally along the consumable.

28. The consumable according to any one of claims 24 to 26, wherein the waveform and / or slit extends longitudinally along the consumable.

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