Heat-not-burn hybrid consumable article, device, and system

Abstract

A heat-not-burn hybrid consumable article (1) includes a tubular body (49) extending from an upstream end (3) to a downstream end (2). The tubular body (49) defines a cavity. A capsule (14) is contained within the cavity. The capsule (14) contains dry powder. An aerosol forming substrate (9) is contained within the cavity, downstream of the capsule (14). The aerosol forming substrate (9) defines an open airflow channel (10) to fluidly connect the upstream end (3) to the downstream end (2) of the tubular body (49). A mouthpiece element (6) is downstream from the aerosol forming substrate (9). The mouthpiece element (6), aerosol forming substrate (9), and capsule (14) are in serial arrangement and axial alignment.

Description

[0001] HEAT-NOT-BURN HYBRID CONSUMABLE ARTICLE, DEVICE, AND SYSTEM

[0002] The present disclosure relates to a heat-not-burn hybrid consumable article, device and system for generating an airflow that contains aerosol generated from an aerosol forming substrate and dry powder from a capsule, for inhalation by a user. The heat-not-burn hybrid consumable article contains an aerosol forming substrate which produces aerosol when heated (and then cooled). The aerosol is captured in an airflow through the consumable article and is delivered, via the airflow, to the user. The hybrid consumable article also contains a capsule which contains dry powder. The capsule containing dry powder is pierced to release dry powder into the airflow as the airflow travels through the heat-not-burn hybrid consumable article. This airflow containing dry powder is combined with aerosol produced from heated aerosol forming substrate to provide an aerosol containing aerosolized substrate and dry powder to a user.

[0003] Electronic aerosol generating devices may be configured to receive a consumable having an aerosol forming substrate. The aerosol forming substrate is heated when the consumable article is inserted into an electronic aerosol generating device which has a heater. Air flows through the consumable containing the aerosol forming substrate. When the aerosol forming substrate is heated, it releases particles into the heated air, creating vapor. As that vapor cools, aerosol is formed. The aerosol may be visible aerosol. Airflow containing aerosolized substrate is delivered to the user. Users must wait for the electronic device to heat up and wait for the aerosol forming substrate in the consumable to heat sufficiently to release particles into the heated air before aerosolized substrate can be inhaled. After use of the consumable or depletion of the aerosol forming substrate, the consumable article may be removed from the device and replaced with a fresh consumable article. The dose of pharmaceutically active compounds delivered to the user is limited by the aerosol generated by heating the aerosol forming substrate for the time of the heating cycle.

[0004] Dry particle inhaler articles may contain a capsule containing dry powder. To release the dry powder from a capsule and to introduce dry powder into an airflow so that the dry powder can be delivered to a user, the capsule may be pierced. The pierced capsule releases its dry powder contents into airflow as the air flows past the pierced capsule. The inhaler article is depleted when the contents of the capsule have been released into the airflow. The dose of pharmaceutically active compounds is limited by the contents of the capsule. The dose of pharmaceutically active compounds is also limited by the degree to which all the contents of the capsule can be released from the capsule and delivered to the user.

[0005] Non-electronic systems, such as dry powder inhalers, offer certain advantages, as their consumption may be more discreet and convenient for some individuals or situations, making them a preferred choice. Their convenience is further enhanced by the fact that they do not require battery charging and operate using the inhalation of the consumer. Additionally, non-electronic devices can potentially be used in locations where the use of conventional or electronic aerosolgenerating devices may not be permitted. On the other hand, electronic systems are often better at accurately replicating the flavor of tobacco, potentially delivering a more satisfying experience.

[0006] In this sense, current nicotine delivery options present a significant limitation, as users seeking varied experiences are required to carry multiple devices, which is inconvenient. Furthermore, a significant issue with both electronic and non-electronic systems is the inability to adjust the amount of delivered nicotine. This limitation means that users desiring a stronger experience from nicotine, for instance, do not have the option to modify the intensity of their consumption.

[0007] It would be desirable to provide a consumable article that incorporates an aerosol forming substrate segment and a capsule containing dry powder segment in a heat-not-burn hybrid consumable article. This heat-not-burn hybrid consumable article provides for the benefits of both a dry powder inhaler article and a heat-not-burn aerosol forming article in a single article. Consumers can enjoy the accuracy and flavor replication of electronic systems while also having the option for a more discreet, non-electronic consumption experience.

[0008] It would be desirable to provide a heat-not-burn hybrid consumable article and corresponding heating device adapted for suitably heating the aerosol forming substrate segment (tobacco segment), to enabling a consumer to selectively activate the release of powdered nicotine from the heat-not-burn hybrid consumable article. The consumer may release the powdered nicotine before, during, or following the heating and release of aerosol from the aerosol forming substrate segment.

[0009] It would be desirable to provide a puncturing mechanism on the heating device to enable consumers to selectively release the powdered nicotine within the heat-not-burn hybrid consumable article. This feature enables the device to function as a standard heat-not-burn tobacco heating product, a nicotine powder inhaler, or to combine both functionalities. Such an innovation eliminates the necessity of switching between different devices.

[0010] It would be desirable to provide a heat-not-burn hybrid consumable article that can provide a satisfying dose of nicotine with a reduced wait time. It would be desirable to provide a heat-not- burn hybrid consumable article that provides a dry powder dose of nicotine in a first puff while the consumable article is heating to a temperature sufficient to release aerosol from the aerosol forming substrate segment.

[0011] It would be desirable to provide a heat-not-burn hybrid consumable article that can provide a satisfying dose of nicotine while requiring less heat, including lower peak temperature and shorter heating profile over several puffs. Requiring less heat means that there is less power drawn from batteries in the aerosol generating device that receives the consumable article. If less heat is required, a smaller battery could be utilized, or the battery could last longer. Lower peak temperature or shorter heating profile, each or in combination, may allow for the use of a smaller battery or provide prolonged battery life. In addition, reducing the peak temperature results in a device that has a lower peak temperature when the device is held by a user. It would be desirable to provide a consumable article, device and system that can provide a longer nicotine delivery experience.

[0012] It may be desirable to provide consumable articles which provide larger doses of pharmaceutically active compounds, such as nicotine. It would be desirable to provide a long smoking experience, but with a lower temperature profile, limiting risks of users being burned by hot air coming out of the device (“warm mitigation issue”) as well as decreasing the battery consumption, allowing for a smaller battery (lowering the bulk and cost of the devices) or reducing the time between recharging the battery.

[0013] Provided herein is a heat-not-burn hybrid consumable article which can provide both an aerosol, from the aerosol forming substrate segment when heated, and dry powder released from a capsule. The consumable article having a capsule segment and a heated aerosol forming substrate segment downstream of the capsule segment is referred to herein as a ‘heat-not-burn hybrid consumable article.’ The heat-not-burn hybrid consumable article may be defined by an elongated tubular body resembling a conventional cigarette. The heat-not-burn hybrid consumable article may be stick-shaped and may be inserted into a device having a recess shaped to receive the stick-shaped consumable.

[0014] This heat-not-burn hybrid consumable article has at least several advantages. The heat- not-burn hybrid consumable article having a combination of an aerosol forming substrate and dry powder may provide an inhalation experience that provides a satisfying dose of pharmaceutically active compounds (such as nicotine) to the user from the first “puff” to the last “puff” in a series of puffs. A series of puffs is an inhalation experience. The heat-not-burn hybrid consumable article having a combination of an aerosol forming substrate and dry powder may allow the device to be used without a long heat-up cycle because a first “puff” may be taken before the heater is fully heated, as the dry powder may provide a satisfying dose of pharmaceutically active compound in the first puff.

[0015] Another advantage of the heat-not-burn hybrid consumable article and system includes it combines the benefits of both electronic and non-electronic systems. Users can enjoy the accuracy and flavor replication of electronic systems while also having the option for a more discreet, non-electronic consumption experience. The heat-not-burn hybrid consumable article and system may also eliminate the need to carry multiple devices for different experiences. This innovation serves as a versatile solution, offering varied nicotine delivery experiences within a single, compact unit. The heat-not-burn hybrid consumable article and system may also offer a non-electronic mode that does not rely on battery power, enhancing convenience for users who may not have regular access to charging facilities or prefer a simpler, more straightforward usage method.

[0016] Further advantages of the heat-not-burn hybrid consumable article may include the heat- not-burn hybrid consumable article has a combination of a heatable aerosol forming substrate and dry powder provides an article that may require a shorter heating cycle while still delivering the same dose of pharmaceutically active compound (such as nicotine) compared to an aerosolgenerating article without dry powder. The heat-not-burn hybrid consumable article having a combination of an aerosol forming substrate and dry powder provides an article that may require heating to a lower peak temperature while still providing the same dose of pharmaceutically active compound (such as nicotine) to the user. Heating the aerosol forming substrate to a lower peak temperature may also reduce the production of undesirable compounds when heating the aerosol forming substrate. The heat-not-burn hybrid consumable article having a combination of an aerosol forming substrate and dry powder provides an article that can provide a longer experience because pharmaceutically active compounds (such as nicotine) may be provided by the aerosol forming substrate as well as dry powder. The heat-not-burn hybrid consumable article having a combination of aerosol forming substrate and dry powder provides an enhanced dose of pharmaceutically active compounds (such as nicotine) to be delivered to the user. The heat-not- burn hybrid consumable article having a combination of an aerosol forming substrate and dry powder provides a safer experience since the peak temperature required to deliver a peak dose of pharmaceutically active compounds is lower. The heat-not-burn hybrid consumable article having a combination of an aerosol forming substrate and dry powder provides a device that can be used through more cycles before requiring charging because it may require heating to a lower peak temperature or heating in a shorter heating cycle. The heat-not-burn hybrid consumable article having a combination of an aerosol forming substrate and dry powder may allow for a device that requires a smaller battery. The heat-not-burn hybrid consumable article having a combination of an aerosol forming substrate and dry powder provides a system that provides the same dose of pharmaceutically active compounds in fewer consumables. The heat-not-burn hybrid consumable article having a combination of an aerosol forming substrate and dry powder may allow the device to be used without a long heat-up cycle because a first “puff” may be taken before the heater is fully heated, as the dry powder may provide a satisfying dose of pharmaceutically active compound in the first puff.

[0017] It may be desirable to provide heat-not-burn hybrid consumable articles having a combination of an aerosol forming substrate and dry powder where the aerosol forming substrate is downstream of the dry powder. Providing heat-not-burn hybrid consumable articles having a combination of an aerosol forming substrate and dry powder where the aerosol forming substrate is downstream of the dry powder may make it easier to pierce the capsule from the upstream end of the consumable article. Nicotine may be contained in the aerosol forming substrate. Nicotine may be contained in the dry powder. Nicotine may be contained in both the aerosol forming substrate and the dry powder.

[0018] Providing heat-not-burn hybrid consumable articles having a combination of an aerosol forming substrate and dry powder where the aerosol forming substrate is downstream of the dry powder may prevent the flow of hot and humid aerosol passing through the dry powder. Exposure of the dry powder to hot and humid airflow may cause the dry powder to change its dry powder characteristics. Exposure of the dry powder to hot and humid airflow may cause the dry powder to agglomerate. Exposure of the dry powder to hot and humid airflow may change the delivery characteristics of the dry powder delivered to the user. Providing heat-not-burn hybrid consumable articles having a combination of an aerosol forming substrate and dry powder where the aerosol forming substrate is downstream of the dry powder may improve the release of dry powder from a capsule containing dry powder. The rotation of the capsule containing dry powder may be more easily induced by the device when the capsule is close to the upstream end of the consumable article. Providing heat-not-burn hybrid consumable articles having a combination of an aerosol forming substrate and dry powder where the aerosol forming substrate is downstream of the dry powder may allow the aerosol forming substrate to be used as a retention element. Providing heat-not-burn hybrid consumable articles having a combination of an aerosol forming substrate and dry powder where the aerosol forming substrate is downstream of the dry powder may stop the capsule containing dry powder from moving downstream in response to pressure on the upstream end of the capsule when the capsule is pierced, for example.

[0019] Providing heat-not-burn hybrid consumable articles having a combination of an aerosol forming substrate and dry powder where the aerosol forming substrate is downstream of the dry powder may allow dry powder to flow along or through the aerosol forming substrate allowing the dry powder to mix with aerosol formed from heating the aerosol forming substrate to deliver a mixed aerosol containing both dry powder and aerosol formed from heating the aerosol forming substrate to the consumer. Providing heat-not-burn hybrid consumable articles having a combination of an aerosol forming substrate and dry powder where the aerosol forming substrate is downstream of the dry powder may allow dry powder to flow along or through the aerosol forming substrate allowing the dry powder to mix with aerosol formed from heating the aerosol forming substrate to provide a satisfactory dose of combined dry powder and aerosol formed from the an aerosol forming substrate to the consumer. Nicotine is preferably contained in both the aerosol forming substrate and dry powder.

[0020] It may be desirable to provide a heat-not-burn hybrid device including a housing defining a consumable article receiving cavity, a heating element disposed along the consumable article receiving cavity, a piercing element disposed at a bottom of the consumable article receiving cavity, and a power source in electrical connection with a controller, the controller in electrical connection with the heating element. Providing heat-not-burn hybrid devices that includes both a heating element and a separate capsule piercing element allows the consumer to independently activate the release of dry powder and aerosol from the aerosol forming substrate contained within a heat-not-burn hybrid consumable article.

[0021] It may be desirable to provide a heat-not-burn hybrid device that further includes a sensor configured to sense the position of the piercing element and electronically coupled to the device controller. The position sensor and device controller may modify the operation of the heater based on the position of the piercing element.

[0022] It may be desirable to provide a heat-not-burn system for use with the heat-not-burn hybrid consumable article where the system includes a heat-not-burn hybrid device and a heat-not-burn hybrid consumable article. The device may have a cavity to receive the heat-not-burn hybrid consumable article. The device may also have a heater. The heater may be a resistive heater or an inductive heater. The heater may provide heat that is external to the heat-not-burn hybrid consumable article received in the cavity of the device. The heater may provide heat that is internal to the heat-not-burn hybrid consumable article received in the cavity of the device. In addition, the device may provide a piercing mechanism to pierce the capsule contained in the heat-not-burn hybrid consumable article. Advantageously, the device having a heater and a piercing mechanism provides a safe and predictable way to provide heat to the heat-not-burn hybrid consumable article. Providing a piercing mechanism in the same device allows the consumer to pierce the capsule (or not) when using the heat-not-burn hybrid consumable article without having to use or carry a separate piercing device. This reduces the steps required by the user to use the system, reduces the number of devices required by the consumer to use the heat- not-burn hybrid consumable article, and provides a safe piercing mechanism inside the device so that the consumer does not need to handle a needle to pierce the capsule.

[0023] Other objects and advantages of the present invention will be evident to those of skill in the art upon reading and understanding the present disclosure, which includes the claims that follow and the accompanying drawings.

[0024] As used herein, the singular forms “a,” “an,” and “the” also encompass embodiments having plural referents, unless the content clearly dictates otherwise.

[0025] As used herein, “have”, “having”, “include”, “including”, “comprise”, “comprising” or the like are used in their open-ended sense, and generally mean “including, but not limited to”. It will be understood that “consisting essentially of”, “consisting of”, and the like are subsumed in “comprising,” and the like.

[0026] The words “preferred” and “preferably” refer to embodiments of the invention that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful and is not intended to exclude other embodiments from the scope of the disclosure, including the claims.

[0027] Any direction referred to herein such as “top”, “bottom”, “left”, “right”, upper”, “lower”, and other directions or orientations are described herein for clarity and brevity but are not intended to be limiting of an actual device or system. Devices and systems described herein may be used in a number of directions and orientations.

[0028] As used herein, “downstream” and “proximal” mean the mouthpiece end of the aerosolgenerating device. “Downstream” and “proximal” mean the end of the aerosol-generating device intended to be contacted by the mouth of a user. “Upstream” and “distal” mean the opposite end of the aerosol-generating device.

[0029] As used herein, “average particle size” refers to mass median aerodynamic diameter as measured by a cascade impactor.

[0030] As used herein, “tobacco” means plant material, such as leaves, stems, or other portions of any of several plants belonging to the genus Nicotiana, such as of the species N. tabacum. Preferably, tobacco includes leaves, stems, or leaves and stems.

[0031] As used herein, “aerosol” means visible particles in air. “Aerosol” includes smoke generated from heated (and then cooled) aerosol forming substrate. “Aerosol” also includes particles of pharmaceutically active compound entrained in airflow. “Aerosol” also includes dry particles of pharmaceutically active compound released from a capsule of a heat-not-burn hybrid consumable article, entrained in airflow. “Aerosol” preferably includes nicotine.

[0032] As used herein “hybrid” means a device that combines two sources of inhalable material, a capsule containing dry powder which can be inhaled and an aerosol forming substrate which can provide aerosol which can also be inhaled.

[0033] As used herein, a “controller” is one or more hardware devices, one or more software or firmware programs, or one or more hardware devices and software or firmware programs that manages or directs flow of data between two or more entities. The controller may include a memory, an Application-Specific Integrated Circuit (ASIC) state machine, a digital signal processor, a gate array, a microprocessor, or equivalent discrete or integrated logic circuitry. A controller may include memory that contains instructions that cause one or more components of the circuitry to carry out a function of the controller. Functions attributable to a controller in this disclosure may be embodied as one or more of software, firmware, and hardware. The controller may include a microprocessor. The operation of one or more controller of a system may be coordinated by an overarching system controller.

[0034] The term “aerosol” is used here to refer to a suspension of solid particles or liquid droplets, or a combination of solid particles and liquid droplets in a gas. The gas may be air. The solid particles or liquid droplets may comprise one or more volatile flavor compounds. Aerosol may be visible or invisible. Aerosol may include substances that are ordinarily liquid or solid at room temperature. Aerosol may include substances that are ordinarily liquid or solid at room temperature, in combination with solid particles or in combination with liquid droplets or in combination with both solid particles and liquid droplets. The aerosol preferably comprises nicotine.

[0035] This disclosure is directed to a heat-not-burn hybrid consumable article containing an aerosol forming substrate which produces aerosol when heated, and a capsule which contains pharmaceutically active dry powder so that the heat-not-burn hybrid article provides both aerosol from the aerosol forming substrate combined with pharmaceutically active dry powder to a consumer during use. Pharmaceutically active dry powder preferably comprises nicotine.

[0036] This disclosure is directed to a heat-not-burn hybrid consumable article containing an aerosol forming substrate which produces aerosol when heated, and a capsule which contains pharmaceutically active dry powder so that the heat-not-burn hybrid article may independently provide aerosol from the aerosol forming substrate and pharmaceutically active dry powder to a consumer during use. The heat-not-burn hybrid consumable article may release dry powder or aerosol from the aerosol forming substrate. The heat-not-burn hybrid consumable article may serially release dry powder and aerosol from the aerosol forming substrate, in either order. The heat-not-burn hybrid consumable article may first release dry powder and then release both dry powder and aerosol from the aerosol forming substrate. The heat-not-burn hybrid consumable article may first release aerosol from the aerosol forming substrate and then release both dry powder and aerosol from the aerosol forming substrate.

[0037] In embodiments, the present disclosure provides a heat-not-burn hybrid consumable article comprising a tubular body extending from an upstream end to a downstream end and, the tubular body defining a cavity; a capsule contained within the cavity, the capsule containing dry powder; an aerosol forming substrate contained within the cavity and downstream of the capsule, the aerosol forming substrate defining an open airflow channel to fluidly connect the upstream end to the downstream end of the tubular body; and a mouthpiece element downstream from the aerosol forming substrate, the mouthpiece element, aerosol forming substrate, and capsule in serial arrangement and axial alignment. Such an article provides the advantages described above.

[0038] In embodiments, the tubular body has an outer diameter and an inner diameter. The difference between the outer diameter of the tubular body and the inner diameter of the tubular body is the thickness of the material of the tubular body. The tubular body is formed from, for example, cardboard, paper, or the like.

[0039] The aerosol forming substrate may define a hollow cylinder extending along a longitudinal axis a length from an upstream substrate end to a downstream substrate end. The aerosol forming substrate has an outer diameter and an inner diameter. The difference between the outer diameter of the aerosol forming substrate and the inner diameter of the aerosol forming substrate is the thickness of the material of the tubular body.

[0040] The thickness of the cylindrical aerosol forming substrate may be from about 2% to about 25% of the outer diameter of the cylindrical aerosol forming substrate. The cylindrical aerosol forming substrate may define a central channel or opening extending from the upstream end to the downstream end of the cylindrical aerosol forming substrate. The central channel or opening may be from about 95% to about 40% outer diameter of the cylindrical aerosol forming substrate.

[0041] In embodiments, the outer diameter of the cylindrical aerosol forming substrate may be from about 4 mm to about 8 mm. The thickness of the cylindrical aerosol forming substrate may be from about 0.2 mm to about 2.5 mm. The central channel or opening may be from about 7.2 mm to about 2 mm.

[0042] The aerosol forming substrate may include nicotine and an aerosol former. The aerosol forming substrate is a heat-not-burn substrate. The aerosol forming substrate releases an aerosol containing nicotine when it is heated. The aerosol forming substrate may include a tobacco material and an aerosol former. The aerosol forming substrate may include a tobacco material and glycerine. The aerosol forming substrate may further include a susceptor material configured to heat up with induction coupling. The tobacco material may be in the form of cut filler. The tobacco material may be in the form of cast leaf. The tobacco material may be a homogenized material. The tobacco material may be in the form of film tobacco.

[0043] The aerosol forming substrate fits inside the tubular body. That is, the aerosol forming substrate has an outer diameter that is equal to or slightly less than the inner diameter of the tubular body so that the aerosol forming substrate fits inside the tubular body. The aerosol forming substrate fits inside the tubular body downstream of the capsule.

[0044] The heat-not-burn hybrid consumable article tubular body may comprise the mouthpiece element. In embodiments, the mouthpiece element comprises filter material. The heat-not-burn hybrid consumable article tubular body may be formed of an aerosol forming substrate segment separating a capsule segment from the mouthpiece segment. The capsule segment, aerosol forming substrate segment, and mouthpiece segment may be axially aligned in serial arrangement from the upstream end to the downstream end of the heat-not-burn hybrid consumable. The mouthpiece segment may separate the aerosol forming substrate segment or aerosol forming substrate from the upstream end of the heat-not-burn hybrid consumable article.

[0045] In embodiments, the dry powder comprises nicotine particles. In embodiments the nicotine particles have an average particle size of between about 0.5 and about 200 micrometers in diameter, preferably between about 0.5 and 10 micrometers in diameter, more preferably from 0.5 to 5 micrometer in diameter. As used herein, “average particle size” refers to mass median aerodynamic diameter as measured by a cascade impactor. The advantage of providing nicotine particles in this size range is to provide particles that are delivered to the lungs of a user during use, rather than being deposited in the mouth of the user when inhaled. In embodiments, the capsule contains flavor particles. These flavor particles may provide additional flavor to the aerosol and the powder to the user. These flavor particles may be sized to deposit in the mouth of the consumer. In embodiments the flavor particles have an average particle size of between about 20 and about 200 micrometers in diameter, preferably between about 50 and 150 micrometers in diameter.

[0046] The aerosol forming substrate may prevents the capsule from falling out of the downstream end of the consumable article. In embodiments, the heat-not-burn hybrid consumable article may also comprise a porous retainer element between the capsule and the aerosol forming substrate to prevent the capsule from falling out of the downstream end of the heat-not-burn hybrid consumable article. The porous retainer element may be fixed in the tubular body and separating the capsule segment from the aerosol forming substrate segment. In embodiments, the porous retainer element orients and holds the capsule so that it can be pierced efficiently. The porous retainer element comprises a plurality of apertures to allow dry powder to flow from the capsule segment to the aerosol forming substrate segment.

[0047] In embodiments, the heat-not-burn hybrid consumable article comprise an endpiece element defining the upstream end of the heat-not-burn hybrid consumable article tubular body. The endpiece element and the porous retainer element define the upstream end and downstream end of the capsule cavity. The capsule is contained within the capsule cavity.

[0048] The endpiece element may be configured to create or form inlet swirling airflow into the capsule cavity when the consumer inhaled on the mouthpiece element. This swirling airflow causes the capsule to rotate along the capsule longitudinal axis. When the capsule is pierced with a single aperture through an upstream end cap of the capsule, dry powder is uniformly released into the swirling inhalation airflow and flows downstream through the aerosol forming substrate segment, and then through the mouthpiece element or segment to the consumer.

[0049] In embodiments, the endpiece element comprises angles air inlets configured to create swirling airflow into the capsule cavity to rotate the capsule within the capsule cavity. The endpiece element may further comprises a linear piercing channel to allow a piercing element to pass through the channel and pierce the capsule.

[0050] The heat-not-burn hybrid consumable article described herein may be utilized with a complimentary heat-not-burn hybrid device, forming a heat-not-burn hybrid system. The heat-not- burn hybrid device is configured to independently release dry powder and aerosol from the aerosol forming substrate. The heat-not-burn hybrid device is configured to pierce the capsule and heat the aerosol forming substrate.

[0051] The heat-not-burn hybrid device includes a housing defining a consumable article receiving cavity, a heating element disposed along the consumable article receiving cavity, a piercing element disposed at a bottom of the consumable article receiving cavity, a power source in electrical connection with a controller. The controller is in electrical connection with the heating element. The piercing element is separated from the heating element.

[0052] The heat-not-burn hybrid device includes an airflow path to allow air to flow through the device and the heat-not-burn hybrid consumable article mated with the heat-not-burn hybrid device to deliver dry powder and aerosol to the user. When the heat-not-burn hybrid consumable article is inserted into the consumable article receiving cavity, the heating element along the consumable article receiving cavity is aligned with the aerosol forming substrate of the heat-not- burn hybrid consumable article. When the heat-not-burn hybrid consumable article is inserted into the consumable article receiving cavity, the piercing element disposed at a bottom of the consumable article receiving cavity is aligned with the capsule end cap of the not-burn hybrid consumable article. The heating element of the device is separated from the device piercing element by the heat-not-burn hybrid consumable article capsule cavity. The piercing element is not a heating element.

[0053] The piercing element may be configured to move between a retracted position and protracted position. The piercing element forms a single hole in the capsule as the piercing element moved from the retracted position and protracted position. Once the hole is formed in the capsule, the piercing element is moved to the retracted position so that dry powder may flow out of the capsule and be entrained in the swirling inhalation airflow.

[0054] The heat-not-burn hybrid device may include a bias element configured to apply a bias force to move the piercing element from the protracted position to the retracted position. The bias element may comprise a spring.

[0055] The piercing element may further include a slider element coupled to the piercing element. The slider element extends through the housing. The slider element may provide a visual indication to the consumer of the position of the piercing element. The slider element may be manipulated by the consumer to move the piercing element from the retracted position to the protracted position.

[0056] The housing may comprise a guiding slot. The slider element may include a guiding post mating with the guiding slot. The guiding slot may define the path from the protracted position to the retracted position of the piercing element.

[0057] The heat-not-burn hybrid device may include a position sensor adjacent to the piercing element to sense the position of the piercing element. The position sensor is electrically coupled to the controller. The controller may be configured to modify the operation of the heater element based on a position of the piercing element.

[0058] The heat-not-burn hybrid device heats the aerosol forming substrate of the heat-not-burn hybrid consumable article after the heat-not-burn hybrid consumable article is received in the heat-not-burn hybrid device. Air flows into the device and through the heat-not-burn hybrid consumable article. When aerosol forming substrate is heated, it releases vapor. As the vapor cools, aerosol is formed. This aerosol is captured in the airflow through the heat-not-burn hybrid consumable article. Airflow containing aerosolized aerosol forming substrate is delivered to the user. After use of the heat-not-burn hybrid consumable article or depletion of the aerosol forming substrate and dry powder, the consumable may be removed from the device and replaced with a fresh consumable. The dose of pharmaceutically active compounds delivered to the user is limited by the aerosol generated by heating the aerosol forming substrate for the time of the heating cycle.

[0059] A number of prior art documents disclose aerosol-generating articles and devices for heating aerosol-generating articles to produce aerosol for inhalation by a consumer. Such devices may be, for example, electrically heated aerosol generating devices in which an aerosol is generated by the transfer of heat from one or more electrical heating elements of the aerosol generating device to the aerosol forming substrate received by the aerosol-generating device. One advantage of such electrical smoking systems is that they may provide aerosol to a user without burning or combusting the aerosol forming substrate, thereby reducing unwanted compounds being delivered to the user. By way of example, the electrical heating system may heat the aerosol forming substrate by induction or by resistive heating. In an induction heating system, Eddy currents are created into a susceptor by an alternating electromagnetic field generated in the device, and these Eddy currents heat a susceptor by Joules law. The susceptor heats the aerosol forming substrate. In a resistive heating device, a resistive element is heated according to Joules law and the resistive element heats the aerosol forming substrate. In addition, the electrical heating system may be internal or external. In an internal heating system, the aerosol forming substrate is heated from the inside of the aerosol forming substrate toward the outside, for example by providing a heated blade that is inside the aerosol forming substrate. In an external heating system, the heat is provided from the outside of the aerosol forming substrate and heat travels from the outside toward the inside of the aerosol forming substrate. For example, heat could be provided by portions of the inner walls of the heating chamber of the device into which the consumable is inserted.

[0060] Aerosol delivery systems that comprise an aerosol forming substrate and an inductive heating device are known or have been described. The inductive heating device comprises an induction source, which produces an alternating electromagnetic field that induces a heat generating eddy current and / or hysteresis losses in a susceptor material. The susceptor material is in thermal proximity of the aerosol forming substrate. The heated susceptor material in turn heats the aerosol forming substrate, which comprises a material, which is capable of releasing volatile compounds that can form an aerosol.

[0061] An example of an aerosol generating device including an inductive heating element is disclosed in U.S. Patent Application Publication No. US2017 / 0055580. The inductive heating element is attached to a body of the aerosol generating device and surrounded by a magnetic field generator including coils. An additional example of an aerosol generating substrate is disclosed in PCT Patent Application Publication No. WO 2015 / 177294. The internal heating element is inserted into the aerosol forming substrate such that the internal heating element is in contact with the aerosol forming substrate. For example, the aerosol forming substrate may be surrounding the internal heating element. Direct contact between an internal heating element of an aerosol-generating device and the aerosol forming substrate of an aerosol-generating article can provide an efficient means for heating the aerosol forming substrate to form an inhalable aerosol.

[0062] An example of a resistive heating element can be found in, for example, EP4176746. As disclosed therein, the resistive heating element may be an internal heater, such as a blade which inserts into the aerosol-generating consumable article. Or the electrically resistive heating element may surround the cavity and may be an external heater. The electrically resistive heating element may be powered by a power supply and controlled by control electronics. The power supply may be any suitable power supply, for example a DC voltage source such as a battery. In one embodiment, the power supply is a lithium-ion battery. Alternatively, the power supply may be a nickel-metal hydride battery, a nickel cadmium battery, or a lithium-based battery, for example a lithium-cobalt, a lithium-iron-phosphate, lithium titanate or a lithium- polymer battery.

[0063] The device may further include a control element preferably coupled to, or comprising, a monitor or means for monitoring the DC current provided by the DC power source. The DC current may provide an indirect indication of the apparent resistance of a heating blade located in the electromagnetic field, which in turn may provide for detection of a Curie transition in the heating blade. The control element may be a simple switch. Alternatively, the control element may be electric circuitry and may comprise one or more microprocessors or microcontrollers.

[0064] The heating element may comprise an electrically resistive material. Suitable electrically resistive materials include but are not limited to semiconductors such as doped ceramics, electrically “conductive” ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys and composite materials made of a ceramic material and a metallic material. Such composite materials may comprise doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbides. Examples of suitable materials include titanium zirconium, tantalum platinum, gold and silver. Examples of suitable metal alloys include stainless steel, nickel-, cobalt-, tungsten-, tin-, gallium-, manganese-, gold- and iron-containing alloys, and super alloys based on nickel, iron, cobalt, stainless steel, Timetai® and iron- manganese-aluminium based alloys. In composite materials, the electrically resistive material may optionally be embedded in, encapsulated or coated with an insulating material or vice-versa, depending on the kinetics of energy transfer and the external physicochemical properties required. The heat-not-burn hybrid device is an electronic device that includes a cavity to receive heat-not-burn hybrid consumable article. The heat-not-burn hybrid device also comprises a power supply or power source, and controller or control electronics.

[0065] As used herein, an “electronic device” is a device that has one or more electrical components. At least some of the one or more electrical components control generation or delivery of an aerosol from an aerosol generating substrate to a user. The electrical components may include the heating element of the heating component, which may include, for example, one or more inductive elements or one or more resistive heating elements. The electrical components may also control heating of the heating element. Preferably, the controller or control electronics control heating of the heating element such that the heating element heats an aerosol forming substrate to an extent sufficient to generate an aerosol from the substrate but to avoid combustion of the substrate.

[0066] Control electronics or a controller may be provided in any suitable form and may, for example, include a controller and a memory. The controller may include one or more of an Application Specific Integrated Circuit (ASIC) state machine, a digital signal processor, a gate array, a microprocessor, or equivalent discrete or integrated logic circuitry. The controller may include memory that contains instructions that cause one or more components of the controller to carry out a function or aspect of the controller. Functions attributable to controller in this disclosure may be embodied as one or more of software, firmware, and hardware.

[0067] Any suitable consumable comprising an aerosol forming substrate and a dry powder capsule may be used with heat-not-burn hybrid device of the present invention. Aerosol forming substrate is a substrate capable of releasing volatile compounds that can form an aerosol. The volatile compounds are released by heating the sensorial media. Volatile compounds are released into airflow flowing past the aerosol forming substrate. These volatile compounds in heated air forms vapor. As the airflow continues to move through the consumable, the air cools. As the air cools the particles of volatile compounds become larger, forming visible aerosol. Aerosol may be visible as “smoke”. Dry particles entrained in an airflow are also aerosol. Dry particles entrained in an airflow may combine with aerosol produced from the heated aerosol forming substrate to form aerosol.

[0068] The aerosol forming substrate may be solid or liquid or comprise both solid and liquid components. In embodiments, the aerosol forming substrate is solid. The aerosol forming substrate may comprise plant-based material. The aerosol forming substrate preferably comprises tobacco. The tobacco containing material contains volatile tobacco flavor compounds, which are released from the aerosol forming substrate upon heating. The aerosol forming substrate preferably comprises nicotine.

[0069] The aerosol forming substrate may comprise homogenized tobacco material. Homogenized tobacco material may be formed by agglomerating particulate tobacco. The aerosol forming substrate may comprise, for example, one or more of: powder, granules, pellets, shreds, spaghettis, strips or sheets containing one or more of: herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted tobacco, homogenized tobacco, extruded tobacco and expanded tobacco. In embodiments, the aerosol forming substrate is formed in a shape that fits inside the tubular body of the heat-not-burn hybrid consumable article. In embodiments, the aerosol forming substrate defines a hollow cylinder, where the hollow portion is the airflow channel through the aerosol forming substrate. In embodiments, the aerosol forming substrate comprises film. In embodiments, the aerosol forming substrate comprises gel. In embodiments, the aerosol forming substrate comprises botanical material. In embodiments, the aerosol forming substrate comprises tobacco. In embodiments, the aerosol forming substrate comprises cut fill tobacco. In embodiments, the aerosol forming substrate comprises cast leaf tobacco. In embodiments, the aerosol forming substrate comprises film tobacco. In embodiments, the aerosol forming substrate comprises homogenized tobacco. In embodiments, the aerosol forming substrate comprises tobacco that is extruded. In embodiments, the aerosol forming substrate comprises tobacco that is pressed into the shape of hollow cylinder.

[0070] In embodiments, the aerosol forming substrate may be formed from reconstituted tobacco. In embodiments, the aerosol forming substrate may be formed from homogenised tobacco. In embodiments, the aerosol forming substrate may be formed from extruded tobacco. In embodiments, the aerosol forming substrate may be formed from cast leaf tobacco. In embodiments, the sensorial media may be formed from expanded tobacco. The aerosol forming substrate may be in loose form or may be compressed. Homogenised tobacco refers to material formed by agglomerating particulate tobacco. Homogenised tobacco may be in the form of a sheet. Homogenized tobacco may have an aerosol-former content of greater than 5% on a dry weight basis. Homogenised tobacco material may alternatively have an aerosol former content of between 5% and 30% by weight on a dry weight basis. Sheets of homogenised tobacco material may be formed by agglomerating particulate tobacco obtained by grinding or otherwise combining one or both of tobacco leaf lamina and tobacco leaf stems. Alternatively, or in addition, sheets of homogenised tobacco material may comprise other additives including, but not limited to, tobacco and non-tobacco fibers, aerosol-formers, humectants, plasticisers, flavorants fillers, aqueous and non-aqueous solvents and combinations thereof. In embodiments, the aerosol forming substrate is made from tobacco cast leaf. Tobacco cast leaf is a paper-like sheet of tobacco compound which can be shaped or folded into an empty core tube. Or the aerosol forming substrate can be extruded from a tobacco compound slurry and formed into a desired shape. The desired shape may be a tube having a central aperture to form the plug airpath or a cylindrical rod having peripheral plug airpath(s). The tube of aerosol forming substrate may be structured and arranged to fit within the cavity of the internal tube body of the consumable article. The advantage of such option is that the at least one air path can be made directly by forming it into the aerosol forming substrate shape. An additional advantage of this option is that the surface roughness of the aerosol forming substrate material can be controlled by the extrusion. That is, the surface roughness can be controlled to provide a substrate material having a surface consistent that can interact with powder as desired.

[0071] The aerosol forming substrate may comprise at least one aerosol former. The aerosol former may be any suitable known compound or mixture of compounds that, when heated, facilitates formation of a dense and stable aerosol and that is substantially resistant to thermal degradation at the operating temperature of the aerosol generating device. Suitable aerosolformers are well known in the art and include, but are not limited to: polyhydric alcohols, such as triethylene glycol, 1 ,3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. Particularly preferred aerosol formers are polyhydric alcohols or mixtures thereof, such as triethylene glycol, 1 ,3-butanediol and, most preferred, glycerine. The aerosol forming substrate may comprise other additives and ingredients, such as flavorants. The aerosol forming substrate preferably comprises nicotine and at least one aerosol former. In a particularly preferred embodiment, the aerosol former is glycerine. Where present, the homogenized tobacco material may have an aerosol-former content of equal to or greater than 5% on a dry weight basis, and preferably between greater than 5% and 30% by weight on a dry weight basis.

[0072] Preferably, the aerosol forming substrate comprises about 40% water by weight or less, such as about 30% or less, about 25% or less or about 20% or less. For example, the aerosol forming substrate may comprise 5% to about 30% water by weight.

[0073] Preferably, the aerosol forming substrate is in solid form rather than in a fluid form. Preferably the solid aerosol forming substrate holds its shape. The solid aerosol forming substrate may be in loose form or may be provided in a suitable consumable such as container or cartridge.

[0074] Preferably, the heat-not-burn hybrid consumable article is in the form of an elongated cylinder that resembles a cigarette. The hybrid consumable article may be in the form of a stick or tube in which the aerosol forming substrate, preferably comprising tobacco, and the dry powder capsule are contained within a paper or cardboard tube or wrapper. The heat-not-burn hybrid consumable article may be in the form of a “heat stick”. The term “heat stick” refers to, for example Marlboro IQOS HeatSticks (known in some markets under the trademark name “HEETS”®) that may be used with an IQOS® heating device and system.

[0075] In preferred embodiments the heat-not-burn hybrid device comprises a DC power source, such as a rechargeable battery, for providing a DC supply voltage and a DC current, power supply electronics comprising a DC / AC inverter for converting the DC current into an AC current for supply to the inductor. The heat-not-burn hybrid device may further comprise an impedance matching network between the DC / AC inverter and the inductor to improve power transfer efficiency between the inverter and the inductor.

[0076] The heat-not-burn hybrid device may be a portable or handheld aerosol generating device that is comfortable for a user to hold between the fingers of a single hand. The heat-not-burn hybrid device may be substantially cylindrical in shape. The aerosol generating device may have a length of between approximately 70 millimetres and approximately 120 millimetres.

[0077] An alternative way of delivering pharmaceutically active compounds by inhalation is with dry powder inhalers. Dry powder inhalers have been disclosed, for example, in WO2017 / 109626. Dry powder inhalers are used to treat respiratory diseases by delivering pharmaceutically active dry power compounds to the lungs of a user. A capsule containing dry powder may be pierced. The user provides an airflow through the dry powder inhaler. The airflow agitates the pierced capsule, releasing the dry powder contained therein. The released dry powder particles are entrained in the airflow and inhaled by the user.

[0078] Dry powder inhalers or consumable articles containing a capsule can be inserted into a device prior to use. The device may have a piercing element. When the consumable article is inserted into the device, the piercing element may extend into the consumable article to pierce the capsule. The device may also have airflow control to provide airflow to the pierced capsule inside the consumable article and to the downstream or mouthpiece end of the consumable article to deliver dry powder entrained in the airflow to the user. Dry powder inhaler devices do not require a heater because heat is not required to release powder from a capsule.

[0079] The heat-not-burn hybrid device includes a piercing mechanism to perforate the capsule. Such piercing mechanism includes a piercing element such as a needle or other sharp object that can be activated to move in relation to the capsule, pierce the capsule, then move away from the capsule, leaving the capsule with one or more holes inside the consumable article. The piercing mechanism may extend to pierce the capsule from the upstream end of the capsule. The piercing element may use a needle that goes along the longitudinal axis of the cavity into which is inserted the capsule and the sensorial media, and which can be moved along this axis up to the position where the capsule is expected to be. The piercing mechanism may be a slide that allows the user to advance a needle to pierce a capsule in the heat-not-burn hybrid consumable article, and then withdraw the needle from the capsule. A needle is a sharp object which can be hollow or solid, suitable for piercing a capsule in the context of this system. The piercing mechanism may have a spring to bias piercing element and automatically withdraw the piercing element or needle from the capsule. The piercing mechanism may be electronic. That is, the piercing mechanism may be a solenoid controlled by the controller. The user may activate this solenoid by pressing a button on the device, for example. In response to this activation, the solenoid may advance a piercing element to pierce the capsule and then withdraw the piercing element from the capsule. In additional embodiments, the capsule may be pierced by a piercing element that is separate from the device, before the consumable article is inserted into a device. Or, in embodiments, the capsule may be pierced by a piercing element that is separate from the device, thus the capsule may be pierced before the capsule is inserted into the tube body of the consumable article.

[0080] In embodiments, a heat-not-burn hybrid device for use with the disclosed heat-not-burn hybrid consumable article having an aerosol forming substrate and a capsule includes a heating element for heating the aerosol forming substrate, and power and a controller as described above, as well as a mechanism for piercing a capsule contained in the heat-not-burn hybrid consumable article. The heat-not-burn hybrid device may include a position sensor configured to sense the position of the piercing element and electrically connected to the controller.

[0081] The controller may modify the operation of the heating element based on the sensed position of the piercing element. For example, the controller may activate the heating element once the position sensor senses the piercing element travels from the protracted position to the retracted position. The controller may also prevent activation of the heating element when the piercing element is in the protracted position.

[0082] The heat-not-burn hybrid device may have an airflow management system. The heat-not- burn hybrid device air flow management system may direct inlet air into the heat-not-burn hybrid consumable article at the upstream end of the hybrid consumable article to the downstream end or mouthpiece end of the heat-not-burn hybrid consumable article. The heat-not-burn hybrid device may have a device air inlet in fluid connection with the upstream end of the heat-not-burn hybrid consumable article, so that air is drawn into the heat-not-burn hybrid consumable article at the upstream end of the heat-not-burn hybrid consumable article. In an embodiment, the device airflow system may create swirling air flow effect that picks up the particles from the (pierced) capsule and shakes and rotates the capsule held inside the heat-not-burn hybrid consumable article, helping deplete the capsule of its contents.

[0083] According to embodiments, this swirling air flow management system may be contained in the heat-not-burn hybrid consumable article. In embodiments an endpiece element may be in the heat-not-burn hybrid consumable article upstream of the capsule. Ambient air entering the heat-not-burn hybrid consumable article upstream of the capsule enters the cavity of the heat- not-burn hybrid consumable article at an angle through an angled air inlet of the endpiece element. The endpiece element may have twist tubes which direct the air at an angle and generate twisted or spiral or angled airflow into the cavity of the heat-not-burn hybrid consumable article. Once the airflow enters these twist tubes, it is then directed toward the capsule at an angle. In this manner, as the airflow passes past the capsule, it agitates the capsule by inducing twisted or swirling airflow. This agitating airflow helps to agitate and empty the capsule during use. This agitating airflow helps to agitate and empty the capsule as air flows through the heat-not-burn hybrid consumable article. The hybrid aerosol and powder heat-not-burn hybrid consumable article and system disclosed herein comprises both an aerosol forming substrate which, when heated, generates aerosol containing desirable compounds for inhalation and a capsule containing dry powder desirable for inhalation in a single hybrid consumable article. This hybrid, or combination consumable article provides the advantages described above and throughout this disclosure.

[0084] The dimensions and configuration of the heat-not-burn hybrid consumable article are adapted to interact with the desired heat-not-burn hybrid device. And the heat-not-burn hybrid device is adapted to interact with the dimensions and configuration of the heat-not-burn hybrid consumable articles. For example, the diameter, length and size of its aerosol forming substrate is adapted to match the size of the heating element, whether the heater is internal or external, inductive or resistive. The placement of the aerosol forming substrate may be adapted to fit into a recess in the device so that the aerosol forming substrate is exposed to the heating element of the device. In addition, the capsule is provided in the heat-not-burn hybrid consumable article to present to the piercing element and airflow structure of the heat-not-burn hybrid device.

[0085] Heat-not-burn hybrid consumable articles may be assembled as sub-elements held together by wrapping materials. These sub-elements may be small cylinders axially aligned end to end from upstream to downstream, and held together by a wrapper, for example. These subelements may be, for example, three successive main elements, from upstream to downstream: a capsule segment, an aerosol forming segment and a mouthpiece segment. The mouthpiece segment may be configured to cool the heated air or vapor and for allowing the air to cool to form aerosol. Optionally, a filter sector for removing unwanted contaminants from the airflow containing aerosol prior to inhalation by the user may be present downstream of the cooling region of the mouthpiece segment.

[0086] Consumable articles having aerosol forming substrate but not dry powder, may be formed of three elements: the aerosol forming substrate segment, a cooling segment and a filter segment. The cooling and filter segments may be desirable because of the high temperature profile of the electronic device. The reasons for such a high temperature profile comes from a desired utility of these systems. It is desirable to provide minimal wait time before the first puff so the device and the consumable need to heat quickly. It is desirable to provide a minimum quantity of aerosol per puff, including that first puff. It is desirable to provide a consistent quantity of aerosol per puff. In order to provide these desirable qualities, it may be desirable to begin a heating cycle with a relatively high temperature so that a sufficient large amount of aerosol is generated from the aerosol forming substrate. That is, it may be desirable to begin a heating cycle with a relatively high temperature so that the aerosol forming substrate can reach the proper aerosolization temperature as soon as possible. Furthermore, an expected time duration of (and / or number of puffs during) the smoking experience implies that the consumable holds a certain quantity of aerosol forming substrate. In order to maintain the device cost low and the consumables easy to handle and provide a pleasant taste and feel of the aerosol in the mouth of the user, the aerosol forming substrate (and so the device’s heating chamber) has a preferred length and diameter to contain this expected amount of aerosol forming substrate. In order to efficiently heat the aerosol forming substrate in a large diameter cylinder, the temperature provided by the device may be relatively high after the start of the device. This leads to a relatively high temperature profile during the smoking experience. Because of this relatively high temperature profile, a cooling sector in the consumable is usually needed because of the large amount of heat that the device provides to the consumable. The cooling sector allows for the reduction of temperature as airflow passes from the aerosol forming substrate and protects the user from air and aerosol exiting the consumable article being too hot. The filter sector, although less needed than for conventional cigarettes, may be useful because part of the aerosol forming substrate could be overheated (due to the high temperature profile), possibly generating potentially harmful constituents.

[0087] The present disclosure provides a heat-not-burn hybrid consumable article which contains both a capsule containing dry powder and an aerosol forming substrate. The dry powder may comprise particles comprising nicotine. The aerosol forming substrate may also contain nicotine. For example, the aerosol forming substrate may comprise tobacco and an aerosol former. The capsule and the aerosol forming substrate are contained in a tubular body. Because the heat-not- burn hybrid consumable article of the present disclosure provides a capsule containing dry powder, which can be nicotine, the first puff of from the heat-not-burn hybrid consumable article may be primarily dry powder. This allows the device to deliver a first puff having a desired dose of nicotine without the need for rapid heating for a consumable article that doesn’t provide a capsule containing dry powder. This reduces the need for a cooling segment and filter element at the downstream end of the article as described above. That is, in embodiments, the heat-not-burn hybrid consumable article does not have a filter.

[0088] The heat-not-burn hybrid consumable article containing both dry powder and aerosol forming substrate provides the user with a consumable that can deliver the experience of inhaling aerosol generated from heated tobacco and the experience of inhaling nicotine powder. Surprisingly, the combination of these two sources of nicotine combine to provide an enhanced experience.

[0089] Providing a heat-not-burn hybrid consumable article may allow the for provision of the same dose of pharmaceutically active compound with a reduced amount of aerosol forming substrate. Providing a heat-not-burn hybrid consumable article may allow for provision of the same dose of nicotine when nicotine is the pharmaceutically active compound, with a reduced amount of aerosol forming substrate. The lower quantity of aerosol forming substrate allows for lower temperature profile for the device. Less media requires less energy to heat to a temperature sufficient to generate aerosol. This pulls less energy from the battery, reduces the risk of delivering harmful or potentially harmful constituents to the user, and reduces the risk of burning the user, as discussed above. These advantages are provided without shortening the experience or limiting the overall delivery of pharmaceutically active agents such as, for example, nicotine as the pharmaceutically active dry powder provides additional pharmaceutically active agent to replace reduced pharmaceutically active agent in the aerosol produced by heating the aerosol forming substrate. This improves both the reactivity and the duration of the smoking experience. The aerosol forming substrate having an air passage or airflow path in its body also allows potentially the use of the full substrate, as the heating system can be designed or controlled to take advantage of this geometry of the aerosol forming substrate to extract the maximum dose of nicotine from aerosol generated by heating the aerosol forming substrate.

[0090] Providing a heat-not-burn hybrid consumable article and device provides various options for the users who can chose to consume one or both aerosol forming substrate and dry powder simultaneously or sequentially. For example, the consumer can choose when to pierce the capsule. The consumer can choose to pierce the capsule before, during or after heating the aerosol forming substrate with the heating device.

[0091] Providing a heat-not-burn hybrid consumable article and device allows the first puff to deliver a higher dose of nicotine compared to a consumable article having only aerosol forming substrate. When consuming simultaneously aerosol forming substrate and dry powder, the quantity of delivery, at least at the start of the experience, can be higher than with aerosol forming consumables or with usual nicotine dry powder consumables, as both aerosols may be provided at the same time. Also, when consuming simultaneously aerosol generated from the aerosol forming substrate and dry powder, the taste of the dry powder can be improved by the aerosol provided by the aerosol forming substrate. The combination of flavor from nicotine particles and aerosol may allow particles of nicotine to be provided without flavor particles in the capsule. This simplifies the manufacture of capsules containing nicotine dry powder.

[0092] In embodiments, the capsule contains dry powder. In embodiment, the dry powder may be nicotine particles. In embodiments, the capsule contains pharmaceutically acceptable nicotine salt or nicotine salt hydrate. Useful nicotine salts or nicotine salt hydrates include nicotine bitartrate, nicotine salicylate, nicotine fumarate, nicotine mono-pyruvate, nicotine glutamate or nicotine hydrochloride, for example.

[0093] In embodiments, the nicotine powder can have any useful size distribution for inhalation delivery into the lungs of a user. The dry particles comprising nicotine may have an average particle size of between about 0.5 and 200 micrometers in diameter. In embodiments, the dry particles comprising nicotine have an average particle size of between 0.5 and 10 micrometers in diameter. In embodiments, the dry particles comprising nicotine have an average particle size of between 0.5 and 5 micrometres in diameter. In embodiments, the dry particles comprising nicotine have an average particle size of between 1 and 7 microns in diameter. In embodiments, at least about 90 wt% of the dry particles comprising nicotine has a particle size of about 10 micrometers or less. In embodiments, at least about 90 wt% of the dry particles comprising nicotine has a particle size of between 0.5 and 5 micrometers. In embodiments, at least about 90 wt% of the dry particles comprising nicotine has a particle size of between 1 and 7 micrometers.

[0094] In embodiments, the capsule may contain at least about 1 mg of nicotine powder. In embodiments, the capsule may contain at least about 2 mg of nicotine powder. In embodiments the capsule may contain at least about 3 mg of nicotine powder. In embodiments the capsule may contain at least about 4 mg of nicotine powder. In embodiments the capsule may contain at least about 5 mg of nicotine powder. In embodiments the capsule may contain at least about 10 mg of nicotine powder. In embodiments the capsule may contain between 1 and 10 mg of nicotine powder. In embodiments the capsule may contain between 1 and 5 mg of nicotine powder. In embodiments the capsule may contain between 2 and 6 mg of nicotine. In embodiments the capsule may contain between 2.5 and 7.5 mg of nicotine powder. In embodiments, the capsule may further comprise flavor particles, in addition to nicotine powder, the flavor particles are sized to be deposited in the mouth of the consumer, preferably from about 50 micrometers to 150 micrometers.

[0095] In embodiments, the heat-not-burn hybrid consumable article is “filter less”, meaning there is no filter plug downstream of the aerosol forming substrate. Air flows through a central passageway or channel defined by the cylindrical aerosol forming substrate. In use, air that flows along or through the aerosol forming substrate contains powder entrained in the air flow from the punctured capsule upstream of the aerosol forming substrate. Aerosol formed by the aerosol forming substrate then combines with the dry powder entrained air and flows through the mouthpiece to the consumer.

[0096] In order for the heating system to have a correct heating efficiency, the aerosol forming substrate may be close to the heat element. Furthermore, the dry powder particles of the capsule may be degraded if they are heated. For these reasons, the air path of the heat-not-burn hybrid consumable article into which the dry powder particles are drawn should be as far as possible from the heating element of the heat-not-burn hybrid device.

[0097] In addition, because of the low temperature profile allowed by the heat-not-burn hybrid consumable configuration, harmful and potentially harmful constituents are much less likely to be generated as the aerosol forming substrate is heated, thus there is no real need for a filter element downstream of the aerosol forming substrate. A consumable article that does not require an additional filter plug has fewer parts. This decreases the cost complexity of the consumable.

[0098] In embodiments, the downstream portion of the heat-not-burn hybrid consumable article, the mouthpiece segment is sufficient to act as a “cooling sector”. The mouthpiece segment can act as a cooling sector by allowing heat transfer to the ambient air through the tubular wall. In embodiments, this cooling is sufficient because of the low temperature profile used to heat the aerosol forming substrate. This provides a cooling segment which is simplified and low cost. In addition, infusion air inlets could be provided downstream through the tubular body into the mouthpiece segment. Infusion air inlet may advantageously help the cooling and nucleation of the aerosol coming from the heated aerosol forming substrate.

[0099] In embodiments, there is a porous retainer element between the capsule and the aerosol forming substrate. In embodiments, the porous retainer element functions to prevent the capsule from falling out of the downstream end of the device and holds the capsule in place as it is pierced. This porous retainer element could be inside the tubular part containing the capsule. The porous retainer element may be between the capsule and the aerosol forming substrate. The porous retainer element blocks the capsule movements when a piercing element is introduced at the downstream end of the consumable toward the capsule and helps to hold the capsule in place to ensure correct piercing of the capsule’s shell. In embodiments, the porous retainer element has a structure with large holes or apertures allowing the powder contained in the capsule to pass through it carried by the air drawn by the user in the consumable.

[0100] Regardless of the type of consumable or aerosol generating device, the aerosol forming substrate may be heated to release volatile flavor compounds, without combustion of the aerosol forming substrate. The released volatile compounds may then be conveyed within an aerosol to the user. In use, volatile compounds are released from the aerosol forming substrate by heat transfer from a heating element and are entrained in air drawn through the hybrid consumable article. As the released compounds cool, they condense to form an aerosol that is inhaled by the user.

[0101] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ±(10%) of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

[0102] The invention is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0103] Example Ex1 : Disclosed herein is a heat-not-burn hybrid consumable article comprising: a tubular body extending from an upstream end to a downstream end and, the tubular body defining a cavity; a capsule contained within the cavity, the capsule containing dry powder; an aerosol forming substrate contained within the cavity and downstream of the capsule, the aerosol forming substrate defining an open airflow channel to fluidly connect the upstream end to the downstream end of the tubular body; and a mouthpiece element downstream from the aerosol forming substrate, the mouthpiece element, aerosol forming substrate, and capsule in serial arrangement and axial alignment.

[0104] Example Ex2: Further disclosed herein is the heat-not-burn hybrid consumable article of Ex1 , wherein the aerosol forming substrate comprises nicotine and an aerosol former.

[0105] Example Ex3: Further disclosed herein is the heat-not-burn hybrid consumable article of Ex1 or Ex2, wherein the aerosol forming substrate comprises tobacco material and an aerosol former, preferably the aerosol former comprises glycerine.

[0106] Example Ex4: Further disclosed herein is the heat-not-burn hybrid consumable article of any one of Ex1 to Ex3, wherein the aerosol forming substrate forms an aerosol comprising nicotine when heated.

[0107] Example Ex5: Further disclosed herein is the heat-not-burn hybrid consumable article of any one of Ex1 to Ex4 wherein the aerosol forming substrate comprises a susceptor element.

[0108] Example Ex6: Further disclosed herein is the heat-not-burn hybrid consumable article of any one of Ex1 to Ex5 wherein the mouthpiece element separates the aerosol forming substrate from the upstream end.

[0109] Example Ex7: Further disclosed herein is the heat-not-burn hybrid consumable article of any one of Ex1 to Ex6 further comprising a porous retainer element separating the capsule from the aerosol forming substrate and an endpiece element at the upstream end of the tubular body, the porous retainer element and the endpiece element define a capsule cavity therebetween, the capsule is contained in the capsule cavity.

[0110] Example Ex8: Further disclosed herein is the heat-not-burn hybrid consumable article of Ex7 wherein the endpiece element comprises angles air inlets configured to create swirling airflow into the capsule cavity to rotate the capsule within the capsule cavity, the endpiece element further comprises a linear piercing channel to allow a piercing element to pass through the channel and pierce the capsule.

[0111] Example Ex9: Disclosed herein is a heat-not-burn hybrid device comprising: a housing defining a consumable article receiving cavity; a heating element disposed along the consumable article receiving cavity; a piercing element disposed at a bottom of the consumable article receiving cavity; and a power source in electrical connection with a controller, the controller in electrical connection with the heating element.

[0112] Example Ex10: Further disclosed herein is the heat-not-burn hybrid device of Ex9 wherein the piercing element is configured to move between a retracted position and protracted position, and a bias element applies a bias force to move the piercing element from the protracted position to the retracted position.

[0113] Example Ex11 : Further disclosed herein is the heat-not-burn hybrid device of any one of Ex9 or Ex10 further comprising a position sensor adjacent to the piercing element to sense the position of the piercing element, the position sensor electrically coupled to the controller.

[0114] Example Ex12: Further disclosed herein is the heat-not-burn hybrid device of any one of Ex9 to Ex11 wherein the piercing element further comprises a slider element coupled to the piercing element, and the slider element extends through the housing.

[0115] Example Ex13: Further disclosed herein is the heat-not-burn hybrid device of any one of Ex9 to Ex12 wherein the housing further comprise a guiding slot and the slider element comprises a guiding post mating with the guiding slot.

[0116] Example Ex14: Disclosed herein is a heat-not-burn hybrid system comprising: the heat- not-burn hybrid consumable article according to any of Ex1 to Ex8; and the heat-not-burn hybrid device according to any of Ex9 to Ex13; wherein the heat-not-burn hybrid consumable article is received in the consumable article receiving cavity of the heat-not-burn hybrid device.

[0117] Example Ex15: Further disclosed herein is the heat-not-burn hybrid system of Ex14 wherein the heating element of the heat-not-burn hybrid device mates with the aerosol forming substrate of the heat-not-burn hybrid consumable article, and the piercing element of the heat- not-burn hybrid device pierces the capsule of the heat-not-burn hybrid consumable article.

[0118] Example Ex16: Further disclosed herein is the heat-not-burn hybrid system of any one of Ex14 or Ex15 wherein the controller is configured to modify the operation of the heater element based on a position of the piercing element.

[0119] Referring now to the drawings, in which some aspects of the present invention are illustrated. It will be understood that other aspects not depicted in the drawings fall within the scope and spirit of the present invention. The drawings are schematic drawings and are not necessarily to scale. Like numbers used in the figures refer to like components, steps and the like. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labelled with the same number. In addition, the use of different numbers to refer to components in different figures is not intended to indicate that the different numbered components cannot be the same or similar to other numbered components.

[0120] FIG. 1 is a schematic diagram of an embodiment of a heat-not-burn hybrid consumable article.

[0121] FIG. 2A is a schematic diagram of an illustrative heat-not-burn hybrid consumable article and an illustrative heat-not-burn hybrid device forming a heat-not-burn hybrid system. FIG. 2B is a schematic diagram of the heat-not-burn hybrid system of FIG. 2A where the illustrative heat-not-burn hybrid consumable article is received in the illustrative heat-not-burn hybrid device.

[0122] FIG. 3A is a schematic diagram of an illustrative piercing mechanism in a retracted position.

[0123] FIG. 3B is a schematic diagram of an illustrative piercing mechanism in a protracted position.

[0124] FIG. 4 is a schematic diagram of the heat-not-burn hybrid system of FIG. 2B illustrating the airflow though the heat-not-burn hybrid system.

[0125] FIG. 1 is a schematic diagram of an embodiment of a heat-not-burn hybrid consumable article 1. The heat-not-burn hybrid consumable article 1 includes a tubular body 49 extending from an upstream end 3 to a downstream end 2. The tubular body 49 defining a cavity. A capsule 14 contained within the cavity. The capsule 14 containing dry powder. An aerosol forming substrate 9 contained within the cavity and downstream of the capsule 14. The aerosol forming substrate 9 defining an open airflow channel 10 to fluidly connect the upstream end 3 to the downstream end 2 of the tubular body 49. A mouthpiece element 6 downstream from the aerosol forming substrate 9. The mouthpiece element 6, aerosol forming substrate 9, and capsule 14 in serial arrangement and axial alignment.

[0126] The heat-not-burn hybrid consumable article 1 is formed with a cylindrical or tubular shape, extending longitudinally from a proximal end or downstream end 2 to a distal end or upstream end 3. The heat-not-burn hybrid consumable article 1 integrates three sequentially arranged and coaxially aligned tubular segments; starting from the distal end or upstream end 3 is a capsule segment 4, followed by an aerosol forming substrate segment 5, and ultimately, a hollow mouthpiece segment 6.

[0127] The mouthpiece element 6 separates the aerosol forming substrate 9 from the upstream end 2. A porous retainer element 11 separates the capsule 14 from the aerosol forming substrate 9. An endpiece element 12 is at the upstream end 3 of the tubular body 49. The porous retainer element 11 and the endpiece element 12 define a capsule cavity 13 therebetween. The capsule 14 is contained in the capsule cavity 13.

[0128] The endpiece element 12 comprises angles air inlets 8 configured to create swirling airflow into the capsule cavity 13 to rotate the capsule 14 within the capsule cavity 13. The endpiece element 12 further comprises a linear piercing channel 17 to allow a piercing element to pass through the channel 17 and pierce the capsule 14.

[0129] In an exemplary embodiment, the hollow mouthpiece element 6 is constructed as a rigid, paper-based tubular segment, forming an air channel 7. The aerosol forming substrate 9 is a solid annular element concentric with a longitudinal open central passage or airflow channel 10. The aerosol forming substrate 9 contains an aerosol generating medium, for example, a tobacco material, nicotine or its derivatives, such as reconstituted tobacco or tobacco fibers and an aerosol forming material. The capsule segment 4, also in tubular form, incorporates a downstream porous retainer element 11 and an endpiece element 12, which are spaced apart to create a capsule cavity 13 between them, designed to receive and hold a capsule 14 containing dry powder, for example, nicotine-containing powder. All segments are collectively contained axially aligned and joined together within a paper overwrap 15.

[0130] The porous retainer element 11 may have a plurality of openings defining a honeycomb cross-section that defines airways or channels to allow the flow of air between the capsule cavity 13 and the aerosol forming substrate 9 open central passage or airflow channel 10. The endpiece element 12 features angled air inlets 8 that create a swirling air flow pattern inside the capsule cavity 13, causing the capsule 14 to rotate or spin when air is drawn across the capsule cavity 13. A linear piercing channel 17 extends along a central axis of the endpiece element 12. An overall airpath is established across the interconnected segments 4, 5, 6. This design allows external air drawn into the capsule cavity 13, via the angled air inlets 8 to travel into the aerosol forming substrate 9 open central passage or airflow channel 10. From the aerosol forming substrate 9 open central passage or airflow channel 10 air is further directed across the mouthpiece element 6 to ultimately exit through a mouthpiece outlet or downstream end 2.

[0131] The heat-not-burn hybrid consumable article 1 may have a length of about 7 cm to about 8 cm and a diameter of about 6 mm to 9 mm. The mouthpiece element 6 may have a length of about 2 cm to about 4 cm, or about 3 cm. The aerosol forming substrate 9 may have a length of about 1 cm to about 1.5 cm, or about 1.25 cm. The capsule 14 may have a length of about 1 cm to about 1.5 cm. The porous retainer element 11 may have a length of about 0.5 cm to about 1 cm, or about 0.8 cm. The endpiece element 12 may have a length of about 0.5 cm to about 1.5 cm, or about 1 cm.

[0132] One feature of the present innovation is the design of a heating device that pairs with the heat-not-burn hybrid consumable article 1 . Once paired, the heating device enables the heat-not- burn hybrid consumable article 1 to function both as a heat-not-burn product by appropriately heating the aerosol forming substrate 9 and as a nicotine powder inhaler, by facilitating the release and dispensing of nicotine powder from the capsule 14 within the capsule cavity 13.

[0133] FIG. 2A is a schematic diagram of an illustrative heat-not-burn hybrid consumable article 1 and an illustrative heat-not-burn hybrid device 19 forming a heat-not-burn hybrid system. FIG. 2B is a schematic diagram of the heat-not-burn hybrid system of FIG. 2A where the illustrative heat-not-burn hybrid consumable article 1 is received in the illustrative heat-not-burn hybrid device 19. FIG. 3A is a schematic diagram of an illustrative piercing 37 mechanism in a retracted position. FIG. 3B is a schematic diagram of an illustrative piercing 37 mechanism in a protracted position. FIG. 4 is a schematic diagram of the heat-not-burn hybrid system of FIG. 2B illustrating the airflow though the heat-not-burn hybrid system. A heat-not-burn hybrid consumable device 19 comprises a housing 20 defining a consumable article receiving cavity 23 and a heating element 27 disposed along the consumable article receiving cavity 23. A piercing element 37 disposed at a bottom 25 of the consumable article receiving cavity 23. A power source 21 in electrical connection with a controller 22. The controller 22 in electrical connection with the heating element 27.

[0134] The piercing element 37 is configured to move between a retracted position (see FIG. 3A) and protracted position (See FIG. 3B). A bias element applies a bias force to move the piercing element 37 from the protracted position to the retracted position. The heat-not-burn hybrid consumable device may further include a position sensor adjacent to the piercing element 37 to sense the position of the piercing element 37. The position sensor is electrically coupled to the controller 22.

[0135] The piercing element 37 may include a slider element 29 coupled to the piercing element 37. The slider element 29 extends through the housing 20. The housing 20 may comprise a guiding slot 33 and the slider element 29 comprises a guiding post 34 mating with the guiding slot 33.

[0136] The illustrative heat-not-burn hybrid device 19 incorporates a housing 20 containing a power source 21 , such as a rechargeable battery, which is in electrical communication with a controller or control circuitry 22. The housing 20 is designed with a tubular consumable article receiving cavity 23 to accommodate a heat-not-burn hybrid consumable article 1. In a specific embodiment, a tubular consumable article receiving cavity 23 that narrows into an elongated air channel 24 with a reduced cross-section compared to consumable article receiving cavity 23. This transition forms a bottom 25 within the consumable article receiving cavity 23, thereby establishing the lowermost insertion depth for the heat-not-burn hybrid consumable article 1. The elongated air channel 24, is aligned coaxially with the consumable article receiving cavity 23 and may be constructed either as a substantially tubular section of the housing 20 or as a separate piece. The elongated air channel 24 extends further across the housing 20, ultimately connecting to an external inlet airflow port 26.

[0137] Surrounding a portion of the consumable article receiving cavity 23 is a heating element 27, powered by the electric current from the power source 21. Specifically, the heat-not-burn hybrid consumable article 1 is designed for vertical insertion from above into a top opening 28 of the consumable article receiving cavity 23. Upon insertion, as shown in FIG. 2B, the capsule segment 4 is adjacent the chamber bottom 25, while the aerosol forming segment 5 aligns with the heating element 27 along the tubular consumable article receiving cavity 23 sidewall.

[0138] The heating element 27 may vary in design. In a specific embodiment, the heating element 27 incorporates a heat source that warms an inserted heat-not-burn hybrid consumable article 1 aerosol forming substrate 9 through conduction. For example, the heating element 27 could be one or more flexible heating foils on a dielectric substrate, such as polyimide, shaped to match the chamber perimeter. Furthermore, a heat conductive element, receiving thermal energy from the heating element 27, may be positioned to directly contact the surface of a heat-not-burn hybrid consumable article 1 within the consumable article receiving cavity 23.

[0139] The heating element 27 may also include a heat sink or heat reservoir, comprising a material that absorbs, stores, and gradually releases heat. This heat sink might be made of a suitable metal or ceramic material. Additionally, the heating element 27 may incorporate an insulating material layer to prevent heat transfer to the housing 20.

[0140] In a further aspect illustrated in FIG. 3A, a slider element 29 is designed as a T-shaped component extending across a lateral cutout 30 on the housing 20. The slider element 29 is formed with an outer gripping portion 31 , located externally to the housing 20, which terminates with an inner needle support 32, positioned within the elongated air channel 24. A guiding slot 33 on the housing wall 20, exerts a slight compressive retention against a corresponding post 34 on the slider, enabling its displacement between a bottom or retracted position 35 and an upper or protracted position 36. As illustrated, the needle support 32 mounts a piercing element or needle 37 with its tip oriented upwards, ensuring it is coaxially aligned with both the consumable article receiving cavity 23 and, consequently, with the piercing channel 17 of an inserted heat-not-burn hybrid consumable article 1 in the consumable article receiving cavity 23.

[0141] This design allows a user to manipulate the piercing element or needle 37 via the slider element 29 between a retracted position, as depicted in FIG. 3A, and a protracted position, as in FIG. 3B, which enables the piercing element or needle 37 to perforate the capsule 14 within the heat-not-burn hybrid consumable article 1. As the piercing element or needle 37 approaches the capsule 14, it first passes through the piercing channel 17. The piercing channel 17 may incorporate a resealable element (not shown) that forms an airtight seal or barrier along the channel when not occupied by the piercing element or needle 37. In this case, air is still enabled to enter the capsule cavity 13 through the angled air inlets 8. Once past the piercing channel 17, the piercing element or needle 37 contacts the capsule bottom wall 40, creating an aperture. This opening allows the powdered contents of the capsule 14 to be released.

[0142] In some embodiments, the slider element 29 may be returned to its initial position by a bias or spring element (not shown), such as a coiled spring attached to the housing 20, providing a biasing force that resets the slider after piercing. Alternatively, the guiding slot 33 may be designed with press-fit ends 43 that retain the slider element 29 into place, and visual indicators that inform the user to return the slider to the initial position before inhalation. In such an embodiment, an additional switching circuitry may, for instance, detect the slider element position and prevent device operation if not in the retracted position. The switching circuit, connected to the controller 22, may enable device operation after detecting capsule puncturing and confirming both the heat-not-burn hybrid consumable article 1 insertion and slider element 29 actuation. As illustrated in FIG. 4, during use, a user drawing from the mouthpiece 6 of the heat-not- burn hybrid consumable article 1 forces external air 47 into the capsule cavity 13, causing rotation of the capsule 14 and the subsequent release of its powdered content. The drawn air 47 then conveys the released particles into an aerosol stream 48 that travels upwards into the aerosol forming substrate 9. Given that the heating element 27 is operating as well, vaporized substances from the aerosol forming substrate 9 are conveyed into the aerosol stream 48, which is guided further for delivery from the mouthpiece outlet 18.

[0143] It is understood that the heat-not-burn hybrid device 19 may be configured with various operation modes specifically designed to control the nicotine delivery rate of the heat-not-burn hybrid consumable article 1 combined functionality. This is particularly relevant since the heat- not-burn hybrid consumable article 1 can offer a selectively greater nicotine delivery rate when both functions are combined. For instance, the controller 22 might adjust the heating profile associated with the heating element 27 depending on whether the capsule 14 is perforated or not. A higher temperature setting could be used when there is no perforated capsule, enhancing the vaporization of the aerosol forming substrate 9 for a more intense experience. In contrast, when the capsule 14 is perforated, allowing for the release of powdered nicotine, a lower temperature setting might be employed to balance the combined delivery of nicotine.

Claims

CLAIMS1. A heat-not-burn hybrid consumable article comprising: a tubular body extending from an upstream end to a downstream end, the tubular body defining a cavity; a capsule contained within the cavity, the capsule containing dry powder; an aerosol forming substrate contained within the cavity and downstream of the capsule, the aerosol forming substrate comprises nicotine and an aerosol former, the aerosol forming substrate defining an open airflow channel to fluidly connect the upstream end to the downstream end of the tubular body; and a mouthpiece element downstream from the aerosol forming substrate, the mouthpiece element, aerosol forming substrate, and capsule in serial arrangement and axial alignment.

2. The heat-not-burn hybrid consumable article according to claim 1, wherein the aerosol forming substrate comprises tobacco material and an aerosol former, preferably the aerosol former comprises glycerine.

3. The heat-not-burn hybrid consumable article according to any preceding claim, wherein the aerosol forming substrate comprises a susceptor element.

4. The heat-not-burn hybrid consumable article according to any preceding claim, wherein the mouthpiece element separates the aerosol forming substrate from the upstream end.

5. The heat-not-burn hybrid consumable article according to any preceding claim, further comprising a porous retainer element separating the capsule from the aerosol forming substrate and an endpiece element at the upstream end of the tubular body, the porous retainer element and the endpiece element define a capsule cavity therebetween, the capsule is contained in the capsule cavity.

6. The heat-not-burn hybrid consumable article according to claim 5, wherein the endpiece element comprises angles air inlets configured to create swirling airflow into the capsule cavity to rotate the capsule within the capsule cavity, the endpiece element further comprises a linear piercing channel to allow a piercing element to pass through the linear piercing channel and pierce the capsule.

7. A heat-not-burn hybrid device comprising:a housing defining a consumable article receiving cavity; a heating element disposed along the consumable article receiving cavity; a piercing element disposed at a bottom of the consumable article receiving cavity; and a power source in electrical connection with a controller, the controller in electrical connection with the heating element.

8. The heat-not-burn hybrid device according to claim 7, wherein the piercing element is configured to move between a retracted position and protracted position, a bias element applies a bias force to move the piercing element from the protracted position to the retracted position.

9. The heat-not-burn hybrid device according to claim 7 or 8, further comprising a position sensor adjacent to the piercing element to sense the position of the piercing element, the position sensor electrically coupled to the controller.

10. The heat-not-burn hybrid device according to any one of claims 7 to 9, wherein the piercing element further comprises a slider element coupled to the piercing element, the slider element extends through the housing.

11. The heat-not-burn hybrid device according to claim 10, wherein the housing further comprise a guiding slot and the slider element comprises a guiding post mating with the guiding slot.

12. A heat-not-burn hybrid system comprising: the heat-not-burn hybrid consumable article according to any of claims 1 to 6; and the heat-not-burn hybrid device according to any of claims 7 to 11 ; wherein the heat-not-burn hybrid consumable article is received in the consumable article receiving cavity of the heat-not-burn hybrid device.

13. The heat-not-burn hybrid system according to claim 12, wherein the heating element of the heat-not-burn hybrid device mates with the aerosol forming substrate of the heat-not-burn hybrid consumable article, and the piercing element of the heat-not-burn hybrid device is aligned to pierce the capsule of the heat-not-burn hybrid consumable article.

14. The heat-not-burn hybrid system according to claim 12 or 13, wherein the controller is configured to modify the operation of the heater element based on a position of the piercing element.

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