Aerosol generating apparatus

Abstract

Disclosed is a consumable for an aerosol generating apparatus, comprising a homogeneous hydrogel article comprising aerosol carrier material and less than 5 wt% tobacco. The homogeneous hydrogel article provides gradual release of aerosol carrier material on heating. An aerosol generating apparatus, a method of generating aerosol, and a method of manufacturing a consumable are also described.

Description

[0001] P01550

[0002] AEROSOL GENERATING APPARATUS

[0003] This application claims priority from EP24194657.3 filed 14 August 2024, the contents and elements of which are herein incorporated by reference for all purposes.

[0004] FIELD

[0005] The present disclosure relates to a consumable for aerosol generating apparatus, an aerosol generating system comprising the consumable, a method of generating aerosol, and a method of manufacturing such a consumable.

[0006] BACKGROUND

[0007] A typical aerosol generating apparatus may comprise a power supply, an aerosol generating unit that is driven by the power supply, an aerosol precursor, which in use is aerosolised by the aerosol generating unit to generate an aerosol, and a delivery system for delivery of the aerosol to a user.

[0008] One approach for an aerosol generating system is the “heated tobacco” (“HT”) or “heat-not-burn” (“HNB”) approach in which a solid substrate aerosol precursor such as tobacco is heated or warmed to release vapour. The precursor material may be leaf tobacco or reconstituted tobacco. The vapour may contain nicotine and / or flavourings. In the HT approach the intention is that the precursor material, such as tobacco, is heated but not burned, i.e. the precursor material does not undergo combustion.

[0009] A typical HT system may include a heating system and a consumable. The consumable may include the precursor material. In use, the precursor material is heated by the heating system, wherein airflow through the precursor material causes moisture in the precursor material to be released as vapour. A vapour may also be formed from a carrier in the precursor material (this carrier may for example include propylene glycol and / or vegetable glycerine) and additionally volatile compounds released from the precursor material. The released vapour may be entrained in the airflow drawn through the precursor material.

[0010] There is a general desire to improve the overall quality of the vapour generated by such systems, while minimising (or entirely avoiding) any burning of the precursor material. In spite of the effort already invested in the development of aerosol generating apparatuses / systems further improvements are desirable.

[0011] SUMMARY

[0012] In a first aspect the present disclosure provides a consumable for an aerosol generating apparatus that comprises a homogeneous hydrogel article. In some examples, the consumable is a heat-not-burn consumable. In some examples, the homogeneous hydrogel article comprises an aerosol carrier material. In some examples the homogeneous hydrogel article comprises less than 5 wt% of precursor material, e.g. tobacco or tobacco extract, relative to the total weight of the homogeneous hydrogel article.

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[0015] Including aerosol carrier material in the form of a homogeneous hydrogel article provides increased levels of aerosol carrier material to the consumable relative to typical consumables which only contain aerosol carrier material within the precursor substrate. The aerosol carrier material is released from the hydrogel article on melting. This avoids the manufacturing difficulties and detriment to visual quality that can be caused by including free aerosol carrier material. It also ensures that the aerosol carrier material is only released during use. For example, free aerosol carrier material can leach material onto combiner paper or, for example, affect the tobacco content of a tobacco-containing precursor substrate, if included in other manners.

[0016] Providing increased levels of aerosol carrier material increases session aerosol content mass (ACM) beyond what can be achieved by using precursor substrates alone. Increasing aerosol carrier material results in increased cloud vapour. In this way, for example, nicotine delivery may also be improved.

[0017] In at least some cases, depletion of volatile materials in the consumable can be quick, particularly for aerosol generating systems using outside-in heating systems compared to aerosol generating systems using inside-out heating systems. Quick depletion of volatile materials leads to sensory factor degradation as the session progresses (e.g., reduced flavour, vapour, mouth feel, and throat feel). By providing the homogeneous hydrogel article the amount of available volatile material is increased so that this does not occur.

[0018] Additionally, the ingredients and positioning of the homogeneous hydrogel article can be controlled to tune the timing of the aerosol carrier material release from the homogeneous hydrogel article. Delayed release of additional material can be advantageous, to “rewet” the substrate as it become depleted due to aerosol release, rather than requiring heating of all materials at once initially.

[0019] The homogeneous nature of the hydrogel article allows gradual melting and release of aerosol carrier material as the article is heated. In this way a controlled release of additional aerosol carrier material is provided. This helps to provide a cooler and smoother experience to the user, particularly when the consumable is used with outside-in heating devices which can cause the consumable to reach high temperatures. This differs from core-shell hydrogel structures which release the entire contents of the core on breach of the shell (e.g. by melting). As used herein, the term “homogeneous hydrogel” is used to define a hydrogel with a substantially uniform composition throughout its shape. The hydrogel article of the present invention is not a hydrogel shell with a liquid core, or other core-shell type hydrogel.

[0020] Suitable aerosol carrier materials include, but are not limited to, glycerine (such as vegetable glycerine), polyols (such as erythritol, sorbitol, glycerol, xylitol), glycols (such as propylene glycol, triethylene glycol), monohydric alcohols, high boiling point hydrocarbons, acids (such as lactic acid), glycerol derivatives, esters (such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, myristates (such as ethyl myristate, isopropyl myristate), aliphatic carboxylic acid esters (such as methyl stearate, dimethyl dodecanedioate, dimethyl tetradecanedioate). In some examples, the aerosol carrier material comprises glycerine. In some examples, the aerosol carrier material comprises propylene glycol. In

[0021] 2

[0022] 008823239 P01550 some examples, the aerosol carrier material consists essentially of or consists of glycerine and / or propylene glycol. In some examples, the aerosol carrier material consists essentially of or consists of glycerine.

[0023] Propylene glycol may act as a hydrating solvent, such that the polymer element thickens by hydration with propylene glycol and / or water to form the hydrogel article. Use of propylene glycol may be beneficial to limit the amount of water in the hydrogel and thus reduce the impact of inhaling hot water vapour on the user.

[0024] In some examples, the homogeneous hydrogel article may be considered non-liquid at room temperature, for example at 20°C. By non-liquid it is considered that the homogeneous hydrogel article can support its own weight and hold its shape, i.e. , the homogeneous hydrogel article may be a semisolid such as a gel or a solid at room temperature. In some examples, the homogeneous hydrogel article may be considered solid at room temperature, for example at 20°C. In this way, the consumable has increased levels of glycerine but leaching of the additional material is reduced or prevented, the composition of the precursor substrate is not affected, and the release of the additional material may be timed by controlling the melting of the homogeneous hydrogel article.

[0025] In some examples, the homogeneous hydrogel article is substantially free from precursor material, for example, tobacco or tobacco extract. In some examples, the homogeneous hydrogel article is free from precursor material. In this way the homogeneous hydrogel article may be provided separately to a precursor substrate, e.g. a tobacco-containing substrate, and the additional material of the hydrogel does not affect the composition of the precursor substrate. Thus, the homogeneous hydrogel article may act as a ‘non tobacco’ delivery vehicle. This may provide an additional vehicle for flavour, which is separate to any precursor substrate.

[0026] In some examples, the homogeneous hydrogel article comprises a polymer element and aerosol carrier material. The polymer element may be a hydrocolloid, a protein, or a lipid. Aerosol carrier material facilitates vapour cloud formation.

[0027] In some examples, the polymer element is a hydrocolloid. For example, the polymer element may be starch, hydroxypropyl cellulose, alginate, gum (such as guar gum), or carrageenan. In some examples, the polymer element is selected from guar gum and carrageenan.

[0028] The total amount of polymer element in the homogeneous hydrogel article is not particularly restricted but ensures that the hydrogel article can form with a non-liquid consistency.

[0029] In some examples, the homogeneous hydrogel article comprises at least 10 wt%, at least 20 wt%, at least 30 wt%, at least 40 wt%, or at least 50 wt% of aerosol carrier material relative to the total weight of the homogeneous hydrogel article. This may enable efficient delivery of additional aerosol carrier material to the consumable.

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[0032] In some examples, the consumable comprises a total aerosol carrier material content (including any aerosol carrier material in the precursor substrate) of 0.05 to 0.3 g, or 0.05 to 0.2 g. In some examples, the consumable comprises a total aerosol carrier material content of 30 to 100 % compared to the weight of precursor substrate in the consumable.

[0033] In some examples, the homogeneous hydrogel article comprises water. In some examples, the homogeneous hydrogel article comprises less than 60 wt%, less than 50 wt%, less than 40 wt%, less than 35 wt%, less than 30 wt%, less than 25 wt%, less than 20 wt%, or less than 15 wt% of water relative to the total weight of the homogeneous hydrogel article. It may be beneficial to limit the amount of water in the homogeneous hydrogel article to reduce the impact of inhaling hot water vapour on the user of the aerosol generating apparatus.

[0034] In some examples, the total combined aerosol carrier material and water content of the homogeneous hydrogel article is 70 wt% or more relative to the total weight of the homogeneous hydrogel article. In some examples the total combined aerosol carrier material and water content is 80 wt% or more, 85 wt% or more, or 88 wt% or more, relative to the total weight of the homogeneous hydrogel article.

[0035] In some examples, the homogeneous hydrogel article comprises a flavourant. In this way, flavour may be introduced to the consumable separately to any tobacco. The aerosol carrier material may act as a carrier for the flavourant. Alternatively, in some examples, the homogeneous hydrogel article does not contain a flavourant.

[0036] In some examples, the homogeneous hydrogel article may comprise residual ions. For example, metal or salt ions (such as potassium and chloride ions), from use of a salt to form the hydrogel.

[0037] In some examples, the homogeneous hydrogel article comprises an additional active agent. For example, the homogeneous hydrogel article may comprise a nicotinic compound such as nicotine, nicotine salt(s), nicotine complex(es), and nicotine solvate(s). In this way an additional active agent can be delivered to the user separately to any tobacco or other precursor material in the precursor substrate. The aerosol carrier material may act as a carrier for the additional active agent.

[0038] In some examples, the homogeneous hydrogel article comprises up to 5 wt% of an additional active agent. In some examples, the homogeneous hydrogel article does not comprise an additional active agent. In some examples, the homogeneous hydrogel article is free from nicotinic compounds.

[0039] In some examples, the homogeneous hydrogel article consists essentially of a polymer element, aerosol carrier material, and optionally, water, a flavourant, residual ions, and / or an additional active agent.

[0040] In some examples, the homogeneous hydrogel article consists of a polymer element, aerosol carrier material, and optionally, water, a flavourant, residual ions, and / or an additional active agent.

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[0043] In some examples, the homogeneous hydrogel article consists of a polymer element, aerosol carrier material, and water.

[0044] The size and shape of the homogeneous hydrogel article is not particularly limited. The rate of aerosol carrier material release can be controlled by changed the components and component ratios in the hydrogel article as well as the surface area and volume of the hydrogel article. For example, a plurality of smaller hydrogel articles will melt more rapidly than an identical hydrogel article formed into one larger similarly proportioned shape.

[0045] In some examples, the homogeneous hydrogel article is a 3D shape, as opposed to a shape that may be considered 2D such as a sheet. The 3D shape may be a bead, a sphere, an ovoid, a cuboid, a cylinder or rod, a prism, a pyramid, or other 3-dimensional shape. The 3D shape enables gradual release of aerosol carrier material from the homogeneous hydrogel article as it melts towards the centre on heating.

[0046] In some examples, the homogeneous hydrogel article is substantially spherical. In some examples, the homogeneous hydrogel article is a sphere. In this way, as it is heated the homogeneous hydrogel article can melt gradually in a consistent manner to provide a smooth release of additional aerosol carrier material. In this way, the user is provided with a cool and smooth experience when using the aerosol carrier apparatus. In some examples, the homogeneous hydrogel article is substantially cylindrical or rod shaped. In some examples, the homogeneous hydrogel article is a cylinder or rod. These shapes may be particularly easy to manufacture with rolling / extrusion methods or hydrogel precipitation methods.

[0047] In some examples, the homogeneous hydrogel article has a thickness or diameter of 0.5 to 7 mm, 0.5 to 3 mm, or 1 to 2 mm.

[0048] In some examples, the consumable comprises a housing substrate which houses the homogeneous hydrogel article. In some examples the housing substrate is a porous material. The housing substrate may be a fibrous material, in particular a naturally occurring fibrous material, or other organic wicking material. For example, the housing substrate may be fibrous bamboo or cotton. In this way the homogeneous hydrogel article can easily be kept in position within the consumable. As the hydrogel article melts during use the aerosol carrier material may be released and permeate the housing substrate. In this way vaporisation of the additional aerosol carrier material is facilitated, to provide a smoother experience for the user. Wicking materials can ensure that the aerosol carrier material is distributed for efficient vaporisation.

[0049] In some examples, the consumable comprises a precursor substrate (this may also be known as an aerosol generating substrate). In some examples the precursor substrate is a tobacco-containing substrate.

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[0052] In some examples, the consumable comprises a precursor substrate and a housing substrate. In some examples, the housing substrate abuts the precursor substrate within the consumable as opposed to the homogeneous hydrogel article being positioned within the precursor substrate. In this way, it may be easier to control the melting of the homogeneous hydrogel sphere as it is not directly heated by surrounding precursor substrate. The housing substrate may also absorb the aerosol carrier material as the homogeneous hydrogel article melts to disperse it for vaporisation or more evenly distribute it to the precursor substrate.

[0053] In some examples, the homogeneous hydrogel article is positioned or located within the precursor substrate. Optionally the homogeneous hydrogel article is positioned within a housing substrate which is then positioned or located within the precursor substrate. The homogeneous hydrogel article may be surrounded by the precursor substrate. In some examples, the homogeneous hydrogel article is positioned or located in direct contact with a precursor substrate. In this way, when the homogeneous hydrogel article melts during use, the aerosol carrier material released may ‘rewet’ the precursor substrate. In some examples there may be a plurality of homogeneous hydrogel articles positioned within the precursor substrate.

[0054] In some examples, the homogeneous hydrogel article is positioned downstream of the precursor substrate. In this way, when the consumable is held in an upright orientation during use with the downstream end above the upstream end, the aerosol carrier material released from the hydrogel article permeates downwards under gravity to the precursor substrate.

[0055] The precursor substrate may comprise a precursor material. The precursor substrate may comprise leaf material (e.g., tobacco leaf material). The precursor substrate may comprise reconstituted tobacco.

[0056] In a second aspect the present disclosure provides an aerosol generating system comprising a consumable and a heating system, wherein the consumable comprises a homogeneous hydrogel article, wherein the homogeneous hydrogel article comprises aerosol carrier material and less than 5 wt% precursor material (e.g. tobacco) relative to the total weight of the homogeneous hydrogel article, and wherein the heating system is arranged to heat the homogeneous hydrogel article. In this way, the heating system can be used to melt the homogeneous hydrogel article in a controlled manner to release additional aerosol carrier material to the consumable. The consumable may be a heat-not-burn consumable.

[0057] The heating system may comprise one or more heaters. The heater may be configured to at least partly surround the consumable in use. In this respect, the heater may be referred to as an external heater. This may be referred to as ‘outside-in’ heating. The heater may be tubular. The heaters may take other forms. For example, the heater may be configured to extend into (i.e. penetrate) the consumable in use (e.g. may be an internal heater). This may be referred to as ‘inside-out’ heating. For example, the

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[0059] 008823239 P01550 heater may be a rod or a blade. In the present proposals, outside-in heating systems may provide enhanced user experience compared to inside out systems and therefore may be preferred.

[0060] The heating system may form part of an aerosol generating apparatus. The aerosol generating apparatus may be configured for releasable engagement with the consumable. For example, the aerosol generating apparatus may comprise a consumable-receiving cavity for receipt of the consumable. The heating system may be disposed in and / or at least partly surround the consumablereceiving cavity. The heating system may, in some embodiments, at least partly define the cavity.

[0061] In some examples, the heating system is configured to heat the homogeneous hydrogel article and a precursor containing portion separately e.g. with different heating elements. In this way the release of aerosol carrier material can be controlled or delayed.

[0062] In a third aspect the present disclosure provides a method of generating aerosol, the method comprising heating a consumable comprising a homogeneous hydrogel consumable to melt the homogeneous hydrogel article such that it provides a controlled release of aerosol carrier material, wherein the homogeneous hydrogel article comprises aerosol carrier material and less than 5 wt% precursor material (e.g. tobacco) relative to the total weight of the homogeneous hydrogel article. In this way, aerosol is generated in a manner which feels smooth to the user due to the additional aerosol carrier material released to the consumable. The consumable may be a heat-not-burn consumable.

[0063] The consumable may be as otherwise described above with respect to the first aspect. The heating may be performed by a heating system as described above with the respect to the second aspect.

[0064] In a fourth aspect, the present disclosure provides a method of manufacturing a consumable for an aerosol generating apparatus comprising the steps of:

[0065] (i) providing a homogeneous hydrogel article, wherein the homogeneous hydrogel article comprises aerosol carrier material and less than 5 wt% precursor material (e.g. tobacco),

[0066] (ii) inserting the homogeneous hydrogel article into a consumable.

[0067] The homogeneous hydrogel article may be provided by mixing a polymer element with an aerosol carrier material and optionally water. The mixture may be heated e.g. to 50-60 °C. The homogeneous hydrogel article may form on cooling. The homogeneous hydrogel article may form by precipitation of the mixture e.g. after addition of a salt such as KCI.

[0068] The homogeneous hydrogel article may be positioned in a specific location within the consumable. For example, it may be beneficial to position the homogeneous hydrogel article in a radially central position to allow the aerosol carrier material to be released radially outwards into surrounding precursor substrate. In some examples, the homogeneous hydrogel article may be positioned in a radially central position and surrounded radially by precursor substrate. In some examples, the homogeneous hydrogel article may be positioned in a region that is longitudinally separated from a precursor substrate region.

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[0070] 008823239 P01550

[0071] In some examples, the homogeneous hydrogel article may be positioned in such a way as to be spatially close to a heater element when the consumable is inserted into a heating device. For example, if the heater surrounds or contacts the outside of the consumable, the homogeneous hydrogel article may be positioned radially towards the outside of the consumable; whereas if the heater penetrates into the consumable, the homogeneous hydrogel article may be positioned in an appropriate radial and longitudinal position to ensure close proximity to the heater when it is inserted.

[0072] The homogeneous hydrogel article may be as described above with respect to the first aspect. The consumable may be as otherwise described above with respect to the first aspect.

[0073] The present disclosure may provide a use of a homogeneous hydrogel article comprising aerosol carrier material and less than 5 wt% precursor material (e.g. tobacco) relative to the total weight of the homogeneous hydrogel article, for an aerosol generating apparatus. The homogeneous hydrogel article can provide a controlled release of aerosol carrier material to the consumable of an aerosol generating apparatus.

[0074] The preceding summary is provided for purposes of summarizing some examples to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the above-described features should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and / or proceeding examples may be combined in any suitable combination to provide further examples, except where such a combination is clearly impermissible or expressly avoided. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following text and the accompanying drawings.

[0075] BRIEF DESCRIPTION OF THE FIGURES

[0076] Aspects, features and advantages of the present disclosure will become apparent from the following description of examples in reference to the appended drawings in which like numerals denote like elements.

[0077] Fig. 1 is a block system diagram showing an example aerosol generating apparatus.

[0078] Fig. 2 is a block system diagram showing an example implementation of the apparatus of Fig. 1 , where the aerosol generating apparatus is configured to generate aerosol from a solid precursor.

[0079] Fig. 3 is a schematic diagram showing an example implementation of the apparatus of Fig. 2.

[0080] Fig. 4 is section view showing a heat-not-burn consumable for use with an aerosol generating apparatus.

[0081] Fig. 5 is a section view of an aerosol generating system according to a first embodiment including the consumable of Fig. 4.

[0082] Fig. 6 is a section view of an aerosol generating system according to a second embodiment including the consumable of Fig. 4.

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[0085] DETAILED DESCRIPTION OF EMBODIMENTS

[0086] Before describing several examples implementing the present disclosure, it is to be understood that the present disclosure is not limited by specific construction details or process steps set forth in the following description and accompanying drawings. Rather, it will be apparent to those skilled in the art having the benefit of the present disclosure that the systems, apparatuses and / or methods described herein could be embodied differently and / or be practiced or carried out in various alternative ways.

[0087] Unless otherwise defined herein, scientific and technical terms used in connection with the presently disclosed inventive concept(s) shall have the meanings that are commonly understood by those of ordinary skill in the art, and known techniques and procedures may be performed according to conventional methods well known in the art and as described in various general and more specific references that may be cited and discussed in the present specification.

[0088] Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.

[0089] All examples implementing the present disclosure can be made and executed without undue experimentation in light of the present disclosure. While particular examples have been described, it will be apparent to those of skill in the art that variations may be applied to the systems, apparatus, and / or methods and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit, and scope of the inventive concept(s). All such similar substitutions and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the inventive concept(s) as defined by the appended claims.

[0090] The use of the term “a” or “an” in the claims and / or the specification may mean “one,” as well as “one or more,” “at least one,” and “one or more than one.” As such, the terms “a,” “an,” and “the,” as well as all singular terms, include plural referents unless the context clearly indicates otherwise. Likewise, plural terms shall include the singular unless otherwise required by context.

[0091] The use of the term “or” in the present disclosure (including the claims) is used to mean an inclusive “and / or” unless explicitly indicated to refer to alternatives only or unless the alternatives are mutually exclusive. For example, a condition “A or B” is satisfied by any of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0092] As used in this specification and claim(s), the words “comprising, “having,” “including,” or “containing” (and any forms thereof, such as “comprise” and “comprises,” “have” and “has,” “includes” and “include,” or “contains” and “contain,” respectively) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[0093] Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, examples, or claims prevent such a combination, the features of examples disclosed herein, and of the claims, may be integrated together in any suitable arrangement, especially ones where there is a

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[0095] 008823239 P01550 beneficial effect in doing so. This is not limited to only any specified benefit, and instead may arise from an “ex post facto” benefit. This is to say that the combination of features is not limited by the described forms, particularly the form (e.g. numbering) of example(s), embodiment(s), or dependency of claim(s). Moreover, this also applies to the phrase “in one embodiment,” “according to an embodiment,” and the like, which are merely a stylistic form of wording and are not to be construed as limiting the following features to a separate embodiment to all other instances of the same or similar wording. This is to say, a reference to ‘an,’ ‘one,’ or ‘some’ embodiment(s) may be a reference to any one or more, and / or all embodiments, or combination(s) thereof, disclosed. Also, similarly, the reference to “the” embodiment may not be limited to the immediately preceding embodiment. Further, all references to one or more embodiments or examples are to be construed as non-limiting to the claims.

[0096] The present disclosure may be better understood in view of the following explanations, wherein the terms used that are separated by “or” may be used interchangeably:

[0097] As used herein, an "aerosol generating apparatus" (or “electronic(e)-cigarette ’) may be an apparatus configured to deliver an aerosol to a user for inhalation by the user. The apparatus may additionally / alternatively be referred to as a “smoking substitute apparatus”, if it is intended to be used instead of a conventional combustible smoking article. As used herein a combustible “smoking article” may refer to a cigarette, cigar, pipe or other article, that produces smoke (an aerosol comprising solid particulates and gas) via heating above the thermal decomposition temperature (typically by combustion and / or pyrolysis). An aerosol generated by the apparatus may comprise an aerosol with particle sizes of 0.2 - 7 microns, or less than 10 microns, or less than 7 microns. This particle size may be achieved by control of one or more of: heater temperature; cooling rate as the vapour condenses to an aerosol; flow properties including turbulence and velocity. The generation of aerosol by the aerosol generating apparatus may be controlled by an input device. The input device may be configured to be user-activated, and may for example include or take the form of an actuator (e.g. actuation button) and / or an airflow sensor.

[0098] Each occurrence of the aerosol generating apparatus being caused to generate aerosol for a period of time (which may be variable) may be referred to as an “activation” of the aerosol generating apparatus. The aerosol generating apparatus may be arranged to allow an amount of aerosol delivered to a user to be varied per activation (as opposed to delivering a fixed dose of aerosol), e.g. by activating an aerosol generating unit of the apparatus for a variable amount of time, e.g. based on the strength / duration of a draw of a user through a flow path of the apparatus (to replicate an effect of smoking a conventional combustible smoking article).

[0099] The aerosol generating apparatus may be portable. As used herein, the term "portable" may refer to the apparatus being for use when held by a user.

[0100] As used herein, an "aerosol generating system" may be a system that includes an aerosol generating apparatus and optionally other circuitry / components associated with the function of the apparatus, e.g. one or more external devices and / or one or more external components (here “external” is intended to mean external to the aerosol generating apparatus).

[0101] 10

[0102] 008823239 As used herein, an “external device” and “external component” may include one or more of a: a charging device, a mobile device (which may be connected to the aerosol generating apparatus, e.g. via a wireless or wired connection); a networked-based computer (e.g. a remote server); a cloud-based computer; any other server system.

[0103] An example aerosol generating system may be a system for managing an aerosol generating apparatus. Such a system may include, for example, a mobile device, a network server, as well as the aerosol generating apparatus.

[0104] As used herein, an "aerosol" may include a suspension of precursor, including as one or more of: solid particles; liquid droplets; gas. Said suspension may be in a gas including air. An aerosol herein may generally refer to / include a vapour. An aerosol may include one or more components of the precursor.

[0105] As used herein, a “precursor” may include one or more of a: liquid; solid; gel; loose leaf material; other substance. The precursor may be processed by an aerosol generating unit of an aerosol generating apparatus to generate an aerosol. The precursor may include one or more of: an active component; a carrier; a flavouring. The active component may include one or more of nicotine; caffeine; a cannabidiol oil; a non-pharmaceutical formulation, e.g. a formulation which is not for treatment of a disease or physiological malfunction of the human body. The active component may be carried by the carrier, which may be a liquid, including propylene glycol and / or glycerine. The term “flavouring” may refer to a component that provides a taste and / or a smell to the user. The flavouring may include one or more of: Ethylvanillin (vanilla); menthol, Isoamyl acetate (banana oil); or other. The precursor may include a substrate, e.g. reconstituted tobacco to carry one or more of the active component; a carrier; a flavouring.

[0106] As used herein, a “substrate” may refer to a solid precursor (e.g. loose leaf precursor material or a “stick” of precursor material such as tobacco), or an absorbent material (e.g. fibrous non-precursor material, such as cotton or hemp).

[0107] As used herein, a “precursor material” may be tobacco, a cannabis derivative, tea, or any substrate or extract containing an active ingredient for the purpose of pharmacological, nutritional or stimulation benefits (such as nicotine, a cannabidiol oil, caffeine, cocaine, THC, CBD, opiates and opioids, cathine and cathinone, cannabinoids, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A, together with any combinations, functional equivalents to, and / or synthetic alternatives of the foregoing).

[0108] Consequently, the precursor substrate may comprise a plant material. The plant material may comprise at least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia califomica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian- tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba

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[0111] (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and / or synthetic alternatives of the foregoing.

[0112] It will however be appreciated that in particularly suitable exemplary embodiments, the plant material is tobacco. Here, any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above-mentioned tobaccos.

[0113] The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and / or reconstituted tobacco (e.g., slurry recon or paper recon). In each case, the aerosol-generating substrate may be formed into a rod of material. For instance, as termed herein, a tobacco rod. The precursor substrate (e.g. tobacco rod) may be formed into a substantially cylindrical shape such that the article / consumable resembles a conventional cigarette. The precursor substrate may have a diameter of between 5 and 10 mm (e.g., between 6 and 9 mm or 6 and 8 mm e.g., around 7 mm). The precursor substrate may have an axial length of between 10 and 25 mm (e.g., between 11 and 14 mm, such as around 12 or 13 mm).

[0114] In exemplary embodiments comprising recon tobacco, the precursor substrate may comprise a gathered sheet of homogenised recon tobacco or gathered shreds / strips formed from such a sheet. Here, the plurality of strips may be substantially aligned. Moreover, the plurality of strips, parallel to one another, may be substantially parallel to a longitudinal axis of the rod. In addition to this, the plurality of strips may be tightly packed together.

[0115] In exemplary aspects and embodiments described herein, the precursor substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous / non-aqueous solvents and binders. Here, the flavourant may be provided in solid or liquid form. It may be selected from one or more of menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the precursor substrate or may be provided in isolated locations and / or varying concentrations throughout the precursor substrate

[0116] As used herein, a "storage portion" may be a portion of the apparatus adapted to store the precursor. It may be implemented as fluid-holding reservoir or carrier for solid material depending on the implementation of the precursor as defined above.

[0117] 12

[0118] 008823239 P01550

[0119] As used herein, a "flow path" may refer to a path or enclosed passageway through an aerosol generating apparatus, e.g. for delivery of an aerosol to a user. The flow path may be arranged to receive aerosol from an aerosol generating unit. When referring to the flow path, upstream and downstream may be defined in respect of a direction of flow in the flow path, e.g. with an outlet being downstream of an inlet.

[0120] As used herein, a "delivery system" may be a system operative to deliver an aerosol to a user. The delivery system may include a mouthpiece and a flow path.

[0121] As used herein, a "flow" may refer to a flow in a flow path. A flow may include aerosol generated from the precursor. The flow may include air, which may be induced into the flow path via a puff by a user.

[0122] As used herein, a “puff” (or "inhale" or “draw”) by a user may refer to expansion of lungs and / or oral cavity of a user to create a pressure reduction that induces flow through the flow path.

[0123] As used herein, an "aerosol generating unit" may refer to a device configured to generate an aerosol from a precursor. The aerosol generating unit may include a unit to generate a vapour directly from the precursor (e.g. a heating system or other system) or an aerosol directly from the precursor (e.g. an atomiser including an ultrasonic system, a flow expansion system operative to carry droplets of the precursor in the flow without using electrical energy or other system). A plurality of aerosol generating units to generate a plurality of aerosols (for example, from a plurality of different aerosol precursors) may be present in an aerosol generating apparatus.

[0124] As used herein, a “heating system” may refer to an arrangement of at least one heating element, which is operable to aerosolise a precursor once heated. The at least one heating element may be electrically resistive to produce heat from the flow of electrical current therethrough. The at least one heating element may be arranged as a susceptor to produce heat when penetrated by an alternating magnetic field. The heating system may be configured to heat a precursor to below 300 or 350 degrees C, including without combustion.

[0125] As used herein, a "consumable" may refer to a unit that includes a precursor. The consumable may include an aerosol generating unit, e.g. it may be arranged as a cartomizer. The consumable may include a mouthpiece. With solid material implementations of the precursor, e.g. tobacco or reconstituted tobacco formulation, the consumable may be referred to as a “stick” or “package” or “heat- not-burn consumable”. In a heat-not-burn consumable, the mouthpiece may be implemented as a filter and the consumable may be arranged to carry the precursor. The consumable may be implemented as a dosage or pre-portioned amount of material, including a loose-leaf product.

[0126] As used herein, an "information carrying medium" may include one or more arrangements for storage of information on any suitable medium. Examples include: a computer readable medium; a Radio Frequency Identification (RFID) transponder; codes encoding information, such as optical (e.g. a bar code or QR code) or mechanically read codes (e.g. a configuration of the absence or presents of cutouts to encode a bit, through which pins or a reader may be inserted).

[0127] 13

[0128] 008823239 P01550

[0129] As used herein “heat-not-burn” (or “HNB” or “heated precursor”) may refer to the heating of a precursor, typically tobacco, without combustion, or without substantial combustion (i.e. localised combustion may be experienced of limited portions of the precursor, including of less than 5% of the total volume).

[0130] As used herein, the term “flavourant” may denote a compound having a desirable taste, aroma or both. Suitable flavourants include coffee, eucalyptus, menthol, liquorice, peppermint, spearmint, chocolate, fruit flavour (including e.g. citrus, cherry etc.), vanilla, spice (e.g. ginger, cinnamon) and tobacco flavour.

[0131] As used herein, the term “hydrogel” may denote a hydrophilic 3-dimensional cross-linked polymer network.

[0132] Referring to Fig. 1 , an example aerosol generating apparatus 1 includes a power supply 2, for supply of electrical energy. The apparatus 1 includes an aerosol generating unit 4 that is driven by the power supply 2. The power supply 2 may include an electric power supply in the form of a battery and / or an electrical connection to an external power source. The apparatus 1 includes a precursor s, which in use is aerosolised by the aerosol generating unit 4 to generate an aerosol. The apparatus 2 includes a delivery system 8 for delivery of the aerosol to a user.

[0133] Electrical circuitry (not shown in figure 1) may be implemented to control the interoperability of the power supply 4 and aerosol generating unit 6.

[0134] In variant examples, which are not illustrated, the power supply 2 may be omitted since, e.g. an aerosol generating unit implemented as an atomiser with flow expansion may not require a power supply.

[0135] Fig. 2 shows an implementation of the apparatus 1 of Fig. 1 , where the aerosol generating apparatus 1 is configured to generate aerosol by a-heat not-burn process.

[0136] In this example, the apparatus 1 includes a device body 50 and a consumable 70.

[0137] In this example, the body 50 includes the power supply 4 and a heating system 52. The heating system 54 includes at least one heating element 54. The body may additionally include any one or more of electrical circuitry 56, a memory 58, a wireless interface 60, one or more other components 62.

[0138] The electrical circuitry 56 may include a processing resource for controlling one or more operations of the body 50, e.g. based on instructions stored in the memory 58.

[0139] The wireless interface 60 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.

[0140] The other component(s) 62 may include an actuator, one or more user interface devices configured to convey information to a user and / or a charging port, for example (see e.g. Fig. 3).

[0141] The body 50 is configured to engage with the consumable 70 such that the at least one heating element 54 of the heating system 52 penetrates into the solid precursor 6 of the consumable. In use, a user may activate the aerosol generating apparatus 1 to cause the heating system 52 of the body 50 to cause the at least one heating element 54 to heat the solid precursor 6 of the consumable (without combusting it) by conductive heat transfer, to generate an aerosol which is inhaled by the user.

[0142] 14

[0143] 008823239 Fig. 3 shows an example implementation of the aerosol generating device 1 of Fig. 2.

[0144] As depicted in Fig. 3, the consumable 70 is implemented as a stick, which is engaged with the body 50 by inserting the stick into an aperture at a top end 53 of the body 50, which causes the at least one heating element 54 of the heating system 52 to penetrate into the solid precursor 6.

[0145] The consumable 70 includes the solid precursor 6 proximal to the body 50, and a filter distal to the body 50. The filter serves as the mouthpiece of the consumable 70 and thus the apparatus 1 as a whole. The solid precursor 6 may be a reconstituted tobacco formulation.

[0146] In this example, the at least one heating element 54 is a rod-shaped element with a circular transverse profile. Other heating element shapes are possible, e.g. the at least one heating element may be bladeshaped (with a rectangular transverse profile) or tube-shaped (e.g. with a hollow transverse profile).

[0147] In this example, the body 50 includes a cap 51. In use the cap 51 is engaged at a top end 53 of the body 50. Although not apparent from Fig. 3, the cap 51 is moveable relative to the body 50. In particular, the cap 51 is slidable and can slide along a longitudinal axis of the body 50.

[0148] The body 50 also includes an actuator 55 on an outer surface of the body 50. In this example, the actuator 55 has the form of a button.

[0149] The body 50 also includes a user interface device configured to convey information to a user. Here, the user interface device is implemented as a plurality of lights 57, which may e.g. be configured to illuminate when the apparatus 1 is activated and / or to indicate a charging state of the power supply 4. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.

[0150] The body may also include an airflow sensor which detects airflow in the aerosol generating apparatus 1 (e.g. caused by a user inhaling through the consumable 70). This may be used to count puffs, for example.

[0151] In this example, the consumable 70 includes a flow path which transmits aerosol generated by the at least one heating element 54 to the mouthpiece of the consumable.

[0152] In this example, the aerosol generating unit 4 is provided by the above-described heating system 52 and the delivery system 8 is provided by the above-described flow path and mouthpiece of the consumable 70.

[0153] Referring to Figure 4, a heat-not-burn consumable 70, which may be implemented in any of the preceding examples, is shown. In this example, the consumable 70, which is for use with a heat-not- burn aerosol generating apparatus, comprises first 101 and second 102 sections arranged along an elongate axis of the consumable 70 extending between upstream 103 and downstream 104 ends of the consumable 70. The first section 101 and second section 102 are formed of different materials. The first section comprises a precursor substrate 105 and the second section comprises a second substrate (or housing substrate) 109. In particular, the first section 101 comprises tobacco in the form of a reconstituted tobacco substrate 105. In this example, the second section 102 of the consumable 70 comprises a homogeneous hydrogel article 106. The reconstituted tobacco 105 and homogeneous

[0154] 15

[0155] 008823239 hydrogel article 106 can be considered to provide the precursor 6 of the consumable 70 in that each of these contribute to the aerosol that is ultimately formed when the consumable 70 is heated.

[0156] In some examples, the homogeneous hydrogel article 6 is instead arranged within or abutting the first section 101 and the second section 102 is not required.

[0157] The homogeneous hydrogel 106 is non-liquid (at room temperature). In examples where the homogeneous hydrogel 106 is housed in the second section 102, the homogeneous hydrogel 106 is supported within a cylindrical porous (e.g. fibrous) second substrate 109, that is positioned directly downstream of the precursor substrate 105 (so as to be adjacent to the precursor substrate 105).

[0158] In use, aerosol carrier material is gradually released from the homogeneous hydrogel article 106 to ‘wet’ the precursor substrate and / or to be vaporised as a user inhales from the consumable 70. To facilitate this, the homogeneous hydrogel article 106 is configured to melt gradually when heated by an aerosol generating apparatus (the homogeneous hydrogel article 106 may, for example, be configured to melt at a temperature that is lower than a temperature at which aerosol carrier material is typically vapourised). In examples where the homogeneous hydrogel article 106 is housed in a second section 102, when the hydrogel article 106 melts, aerosol carrier material is released so as to flow into the pores of the second substrate 109. The porous nature of the second substrate 109 means that it wicks the aerosol carrier material such that the aerosol carrier material is distributed throughout the second substrate 109. In examples where the homogeneous hydrogel article is housed in the first section 101 , the aerosol carrier material is released to the precursor substrate 105. The homogeneous nature of the hydrogel article 106 means that there is a gradual controlled release of aerosol carrier material. In some examples, the homogeneous hydrogel article 106 may be configured and arranged to provide a delayed release of aerosol carrier material to the precursor substrate 105 or the second substrate 109. In particular the aerosol carrier material may be released after the consumable 70 has been heated for a chosen period so that the aerosol carrier material may ‘rewet’ the precursor substrate after any depletion of materials from use of the consumable 70.

[0159] At the downstream end 104, the consumable 70 comprises a terminal filter element 110. The terminal filter element 110 is formed of cellulose acetate tow with a paper plug wrapper (not shown). The terminal filter element 110 is spaced downstream from the second substrate 109, such that a space 111 (which may promote mixing and / or cooling of vapour) is defined between the second substrate 109 and the terminal filter element 110.

[0160] The precursor substrate 105, second substrate 109, space 111 and terminal filter 110 are all circumscribed by a paper wrapping layer 112. This holds the components of the consumable 70 together and provides a protective outer layer.

[0161] Referring now to Figure 5, the consumable 70 is shown engaged in a consumable-receiving cavity 113 of an aerosol generating apparatus 50. Together, the consumable 70 and aerosol generating apparatus 50 form an aerosol generating system 1 .

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[0163] 008823239 P01550

[0164] The consumable-receiving cavity 113 of the apparatus 50 is defined by a housing 114 of the apparatus 50. Housed within the housing 114 is a heating system 52 that includes a heating element 54. In the illustrated embodiment, the heating element 54 is a tubular heating element that circumferentially surrounds the consumable-receiving cavity 113 (and thus the consumable 70 when received therein).

[0165] The heating system 52 is configured to heat the first section 101 (and thus the reconstituted tobacco substrate 105) and second section 102 (including the homogeneous hydrogel article 106) of the consumable 70.

[0166] In use, the user may initiate a usage session, or ‘session’ in which the apparatus 50 operates the heating system to cause aerosol generation. The heating element 54 may be heated to different temperatures throughout a session. The heating element 54 may be heated to a higher temperature, e.g. exceeding 300°C, for a first period of the session. The first period may also be referred to as a pre-heating period, and may last no longer 30 seconds. During a second period of the session, which is after the first period, the heating element 54 may be heated to a lower temperature, for example of around 200°C.

[0167] Figure 6 shows an aerosol generating apparatus 50’ that is a variation of the apparatus 50 of Figure 5. Many of the features of the aerosol generating apparatus 50’ remain the same, and therefore the same reference numerals have been used. In the present apparatus 50’ the heating system comprises two heating elements, a first heating element 54a and a second first heating 54b. Otherwise the only change is that the heating element 54a is a rod heater rather than a tube heater. Thus, the heating element 54a is configured to penetrate the tobacco substrate 105 and heat the tobacco substrate 105 internally.

[0168] EXAMPLES

[0169] Method of preparation

[0170] Also disclosed herein is an exemplary method of preparing a homogeneous hydrogel article according to the present invention:

[0171] (i) mixing propylene glycol e.g. with an overhead stirrer,

[0172] (ii) dispersing a hydrocolloid powder (e.g. hydroxy propyl cellulose) into the mixture with vigorous mixing,

[0173] (iii) heating the mixture to 50-60 °C e.g. on a hotplate,

[0174] (iv) adding any additional ingredients (e.g. vegetable glycerin, flavour) sequentially with simultaneous mixing or mixing between ingredients,

[0175] (v) mixing at least until a homogeneous mixture is produced,

[0176] (vi) either : a. adding salt (e.g., KCI) to precipate the hydrogel article, or

[0177] 17

[0178] 008823239 P01550 b. adding the hot mixutre to a plastic mould and cooling to room temprature to form the hydrogel article.

[0179] This method should not be taken as limiting and any suitable alternative method may be used to prepare the homogeneous hydrogel article of the invention.

[0180] Alternative methods include thoroughly mixing all ingredients until a homogeneous mixture is produced and then cooling and rolling or extruding the hydrogel article into shape.

[0181] Example Formulation 1

[0182] An example homogeneous hydrogel article was formed by dispersing guar gum in propylene glycol and glycerine. The mixture was added to water to hydrate for 10 minutes. The mixture was mixed at 40 °C. The hydrogel article formed on cooling.

[0183] Example Formulation 2

[0184] An example homogeneous hydrogel article was formed by dispersing carrageenan in glycerine, then adding water and potassium chloride. The mixture was mixed vigorously at 70 °C. The hydrogel article formed on cooling.

[0185] 008823239

Claims

P01550CLAIMS1 . A consumable for an aerosol generating apparatus, comprising: a homogeneous hydrogel article comprising aerosol carrier material, wherein the homogeneous hydrogel article comprises less than 5 wt% tobacco.

2. The consumable according to claim 1 , wherein the aerosol carrier material comprises glycerine and / or propylene glycol.

3. The consumable according to claims 1 or 2, wherein the homogeneous hydrogel article comprises the aerosol carrier material, a polymer element, water, and optionally a flavourant.

4. The consumable according to claim 3, wherein the polymer element is a hydrocolloid.

5. The consumable according to any preceding claim wherein the total combined aerosol carrier material and water content of the homogeneous hydrogel article is 70 wt% or more relative to the total weight of the homogeneous hydrogel article.

6. The consumable according to any preceding claim, wherein the homogeneous hydrogel article consists of a polymer element, aerosol carrier material, and water.

7. The consumable according to any preceding claim, wherein the homogeneous hydrogel article comprises less than 60 wt% water.

8. The consumable according to any preceding claim, wherein the homogeneous hydrogel article is substantially spherical or cylindrical.

9. The consumable according to any preceding claim, comprising a housing substrate which houses the homogeneous hydrogel article, optionally wherein the housing substrate is a porous material.

10. The consumable according to claim 9, comprising a precursor substrate and the housing substrate, wherein the precursor substrate abuts the housing substrate.

11. The consumable according to any of claim 1 to 8, comprising a precursor substrate, wherein the homogeneous hydrogel article is positioned within or directly abutting the precursor substrate.

12. The consumable according to any preceding claim, comprising a precursor substrate, wherein the homogeneous hydrogel article is positioned downstream of the precursor substrate.19008823239P0155013. An aerosol generating system comprising a consumable and a heating system, wherein the consumable comprises a homogeneous hydrogel article, wherein the homogeneous hydrogel article comprises aerosol carrier material and less than 5 wt% tobacco, and wherein the heating system is arranged to heat the homogeneous hydrogel article.

14. A method of generating aerosol, the method comprising heating a consumable comprising a homogeneous hydrogel article to melt the homogeneous hydrogel article such that it provides a controlled release of aerosol carrier material, wherein the homogeneous hydrogel article comprises aerosol carrier material and less than 5 wt% tobacco.

15. A method of manufacturing a consumable for an aerosol generating apparatus comprising the steps of:(i) providing a homogeneous hydrogel article, wherein the homogeneous hydrogel article comprises aerosol carrier material and less than 5 wt% tobacco, (ii) inserting the homogeneous hydrogel article into a consumable.20008823239

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