Consumable for aerosol generating apparatus

Abstract

A consumable (70) for use with an aerosol generating apparatus comprising: a solid aerosol precursor arrangement (6) and a mouthpiece (71) downstream of the solid aerosol precursor arrangement (6), the solid aerosol precursor arrangement (6) having an axial length extending from an upstream end (72) to a downstream end (73) of the solid aerosol precursor arrangement (6), wherein the solid aerosol precursor arrangement (6) includes a plurality of bodies, including a first body (74) and a second body (75); wherein: the bodies are separated by a plane of weakness, and wherein the plane of weakness is orientated substantially parallel to a flow path of the heat-not-burn consumable; or a gap (76) is formed between the first body (74) and the second body (75) and the gap (76) extends along the entire axial length of the solid precursor arrangement (6).

Description

[0001] P01589

[0002] 1

[0003] CONSUMABLE FOR AEROSOL GENERATING APPARATUS FIELD

[0004] The present disclosure relates in particular but not exclusively to a consumable for an aerosol generating apparatus, an aerosol-forming element for a consumable, a consumable comprising the aerosol-forming element, an aerosol-generating system comprising the consumable, use of the aerosolforming element and a method of preparing an aerosol-forming element.

[0005] BACKGROUND

[0006] A heat-not-burn (HNB) device, also known as a heated tobacco device, is a type of aerosol-generating system in which an aerosol-forming material (e.g., a solid aerosol-precursor such as tobacco) is heated by a heating system to produce an aerosol that can be inhaled by the user.

[0007] A typical aerosol generating apparatus or device 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. Aerosol precursors may be formed by injection of the aerosol forming material into a card tube.

[0008] A drawback with at least some known aerosol precursors is that the injection process can result in aerosol precursors with variable shapes. As a result, the pressure drop across the consumable may be different between consumables, thereby providing an inconsistent and possibly inferior experience. For example, for some consumables there may be a comparatively low pressure drop across the precursor if there is a void which allows air to pass through the precursor. This also results in poor aerosol formation as most of the precursor is bypassed by airflow. On the other hand, for some consumables the precursor may have a comparatively high pressure drop if a solid plug forms as a result of injection, since air cannot easily pass through the precursor.

[0009] In addition, during use in a HNB device, volatile components are removed from the aerosol-forming material by heating. As a result, the content of water, liquid aerosol former and other volatile components are reduced. This can cause the aerosol-forming material to change its structure and shape.

[0010] In particular, where a body of aerosol-forming material is used inside a card tube or wrapper, the aerosol-forming material may shrink and pull away from the sides of the card tube or wrapper. This may result in the aerosol-forming material coming loose within the consumable, as it detaches from the card tube or wrapper, and can even lead to the aerosol-forming material falling out of the HNB consumable during or after use.

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[0012] 2

[0013] A body of aerosol-forming material can also warp during heating, especially if the heating is uneven or the volatile components within the aerosol-forming material are not homogenously dispersed. The warping of the aerosol-forming material can cause the HNB consumable to deform or break.

[0014] The present invention has been devised in light of the above considerations.

[0015] SUMMARY

[0016] In a first aspect the present disclosure provides a consumable that may comprise a solid aerosol precursor arrangement and a mouthpiece.

[0017] The mouthpiece may be downstream of the solid aerosol precursor arrangement. In use, a user may engage the mouthpiece to create an airflow through the consumable. In particular, the airflow may flow from the solid aerosol precursor arrangement to the mouthpiece, and may exit from the consumable at the mouthpiece. Generally, the terminology upstream and downstream may be used in accordance with the airflow when the consumable is in use. As such, the mouthpiece may be at the downstream end of the consumable and airflow through the consumable, e.g. through the precursor arrangement, may be towards the mouthpiece in a downstream direction.

[0018] The terms “precursor”, “solid precursor arrangement” and “aerosol-forming element” are generally used synonymously herein, and may be formed of aerosol-forming material. Similarly, the terms “consumable” and “aerosol generating article” are generally used synonymously herein.

[0019] In some examples, the solid aerosol precursor arrangement (or aerosol-forming element) has an upstream end and a downstream end. In use, the airflow may flow from the upstream end to the downstream end. The upstream end and the downstream end may delimit an axial length of the solid aerosol precursor arrangement.

[0020] In some examples, the solid aerosol precursor arrangement / aerosol-forming element includes a plurality of precursor bodies, which may include a first precursor body and a second precursor body.

[0021] In some examples, the first and second bodies may be separate bodies. In such cases a gap may formed between the first precursor body and the second precursor body, the gap extending along the entire axial length of the solid aerosol precursor arrangement. In other words, in some examples, the bodies may be separate from one another, i.e. comprise separate bodies. In this case, the separate bodies do not contact one another. In such cases , the gap may comprise a void or an air-gap, allowing for airflow inside the gap and between the bodies. In other words, the gap between separate bodies may be substantially empty of solid material and / or may provide an air channel. The airflow in such an air channel may comprise aerosol released from the precursor bodies.

[0022] P152693PC00 P01589

[0023] 3

[0024] In another example, the solid aerosol precursor arrangement (or aerosol-forming element) comprises two or more bodies of aerosol-forming material separated by one or more planes of weakness. The planes of weakness may be orientated substantially parallel to a flow path of the heat-not-burn consumable. In some examples, bodies of aerosol-forming material separated by one or more planes of weakness may be referred to as sub-bodies.

[0025] The provision of the separate precursor bodies and arranging these to form a gap may enhance airflow through the solid aerosol precursor arrangement. In particular, the separate bodies can be arranged so as to provide the gap along the entire axial length of the solid aerosol precursor arrangement to thereby enhance airflow through the solid aerosol precursor arrangement. This may improve the consistency of the pressure drop across different consumables, e.g. since arrangement of the precursor bodies and formation of the gap may be more easily controllable than an injection processes. Additionally, the gap may improve flavour delivery, because the solid aerosol precursor bodies may have a higher density compared with a single-segment solid aerosol precursor arrangement. This is because the gap will occupy some volume of the consumable, such that the mass of the precursor material (i.e. aerosol forming material) will occupy a reduced volume and hence have a higher density. A higher density of precursor material may result in more intense and longer-lasting flavour delivered by the solid aerosol precursor arrangement to the user.

[0026] Conversely, planes of weakness present in the solid aerosol precursor arrangement / extruded aerosolforming material allow for a solid plug of aerosol-forming material to be provided (referred to as a compound body herein) which may be less prone to warping or fall out of the consumable during use. The aerosol-forming material can fracture or cleave along the planes of weakness, to account for shape changes and shrinkage of the aerosol-forming material during use. As a result, the aerosol-forming material is more easily retained within the consumable. The consumable is also less liable to change shape during use.

[0027] The planes of weakness allow the aerosol-forming material to fracture in a controlled way. In use, as the aerosol-forming material dries out and shrinks, the aerosol-forming material preferentially fractures along the planes of weakness. This allows the aerosol-forming material to better tolerate changes in moisture / volatile content, and consequently changes in shape (e.g., shrinking / warping). By fracturing along the planes of weakness, the aerosol-forming material does not pull away from the walls of the consumable (e.g., an envelope, such as a wrapper or card tube which circumscribes the aerosolforming material around its perimeter) and does not deform the consumable. This means the aerosolforming material is less likely to come loose and fall out of the consumable.

[0028] Fracturing along the planes of weakness may also allow air gaps or air channels to open up during use, to change the resistance to draw during a session and provide increased penetration of air flow through the aerosol-forming element, especially towards the end of a session. In some examples, the planes of weakness may comprise (e.g. be partially formed of) voids, which may provide air gaps and / or at least

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[0030] 4 in part, air channels. The air flow in air channels may comprise aerosol released from the precursor bodies. In some examples, air channels may alternatively or additionally be provided outside of the region containing a plane of weakness. The plane(s) of weakness may be provided as a result of an extrusion process, or as a result of cutting an extrudate soon after extrusion.

[0031] In some examples, the first precursor body and the second precursor body each have the shape of a cylinder segment. For example, the first precursor body and the second precursor body may each have the shape of a semi-cylinder. For example, the first body and the second body may each have the shape of a quarter-cylinder.

[0032] In some examples, the bodies are arranged in the consumable such that the solid aerosol precursor arrangement / aerosol-forming material has a generally cylindrical overall shape.

[0033] In some examples, the solid aerosol precursor arrangement / aerosol-forming material further includes a third body. In some such examples, a second gap or plane of weakness is formed between the second body and the third body, and a third gap or plane of weakness is formed between the third body and the first body. In other words, when the solid aerosol precursor arrangement includes three bodies, three gaps or three planes of weakness may be formed. The second and third gap or plane of weakness may each extend along the entire axial length of the solid aerosol precursor arrangement.

[0034] In some examples, the solid aerosol precursor arrangement further includes a third and a fourth body. In these examples, a second gap or plane of weakness is formed between the second body and the third body, a third gap or plane of weakness is formed between the third body and the fourth body, and a fourth gap or plane of weakness is formed between the fourth body and the first body. In other words, when the solid aerosol precursor arrangement includes four bodies, four gaps or planes of weakness may be formed. The second, third and fourth gap / plane of weakness may each extend along the entire axial length of the solid aerosol precursor arrangement.

[0035] In some examples, the solid aerosol precursor arrangement includes up to and including ten bodies, such as up to and including eight bodies, such as up to and including six bodies. That is, in some examples, the solid aerosol precursor arrangement includes two to ten bodies, such as two to eight bodies, such as two to six bodies. In other examples, the solid aerosol precursor arrangement includes three to ten bodies, such as fourto ten bodies, such as six to ten bodies. In these examples, the number of gaps or planes of weakness that form between the bodies may be equal to the number of bodies. Each of the gaps / planes of weakness may extend along the entire axial length of the solid aerosol precursor arrangement.

[0036] In some examples, all the bodies have the shape of a cylinder segment. In these examples, the bodies may be arranged in the consumable such that the solid aerosol precursor arrangement has a generally cylindrical overall shape. For example, in examples where the solid aerosol precursor arrangement

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[0038] 5 further comprises a third and fourth body, the first and second bodies and the third and the fourth bodies each may have the shape of a cylinder segment, such as the shape of a quarter-cylinder.

[0039] The plurality of bodies of the solid aerosol precursor arrangement may enhance airflow through the solid aerosol precursor arrangement since the bodies can be arranged so as to provide gaps which may extend along the entire axial length of the solid aerosol precursor arrangement. The airflow through the solid aerosol precursor arrangement may be more reliable and consistent and / or may result in improved consistency of the pressure drop across different consumables. Consequently, this may improve the amount and consistency of aerosol and flavour delivered to the user from the precursor arrangement between different consumables. As noted above, in some examples, planes of weakness may also open up in use to provide air channels.

[0040] Additionally, the shaping of the solid aerosol precursor arrangement (e.g. by way of the provision of a plurality of separate bodies) may allow for greater customisability and flexibility of design. In other words, the solid aerosol precursor arrangement may be shaped depending on, for example, the composition of the precursor, the types and amounts or quality of flavourant present in the solid aerosol precursor arrangement or the desired pressure drop. These factors maybe varied by changing the number of bodies present in the precursor arrangement.

[0041] In some examples, the solid aerosol precursor arrangement may be disposed in an envelope. The solid aerosol precursor arrangement and the mouthpiece may be disposed in the envelope. For example, the aerosol precursor arrangement and the mouthpiece may both be held by the envelope.

[0042] As used herein, the term “envelope” may define a covering or containing structure or layer. The envelope may be arranged around the solid aerosol precursor arrangement and may extend along the axial length of the solid aerosol precursor arrangement, and / or may be arranged around and extend along the entire mouthpiece. In some examples, the envelope extends along the entire axial length of the solid aerosol precursor arrangement. In some examples, the envelope surrounds the whole of the solid aerosol precursor arrangement, and / or may surround the whole of the mouthpiece. In this way, the envelope may encase the solid aerosol precursor arrangement and improve handleability of the solid aerosol precursor arrangement before it is assembled into a consumable for an aerosol generating apparatus.

[0043] The envelope may be made from any suitable material and may have any suitable shape. In some examples, the envelope may comprise a rigid material such as card. In some examples, the envelope may be a tube, such as a card tube. In other examples, the envelope may comprise a less rigid material, or a flexible material such as paper, foil or foil-paper laminate. In some examples, the envelope may be a wrapper, such as a foil-paper laminate wrapper.

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[0045] 6

[0046] The envelope may have an outside surface and may have an inside surface. The inside surface is the surface of the envelope facing the solid aerosol precursor arrangement when the arrangement is disposed in an envelope. The outside surface is the surface of the envelope facing away from the solid aerosol precursor arrangement when the arrangement is disposed in an envelope. In some examples, the bodies of the solid aerosol precursor arrangement are adhered to the inside surface of the envelope. In some examples, the bodies have a peripheral surface. The peripheral surface may be a surface of the bodies which is adjacent the envelope, e.g. the inside surface, when the solid aerosol precursor arrangement is disposed in the envelope. In some examples, the peripheral surface of each of the bodies is adhered to the envelope.

[0047] Adhesion of the bodies to the inside surface of the envelope maintains the arrangement of the bodies in the consumable. In other words, adhesion of the bodies to the inside surface of the envelope may maintain a gap formed between each body in the consumable, leading to enhanced airflow, and therefore improved consistency of aerosol and flavour delivered to the user across different consumables.

[0048] In some examples, the gap or plane of weakness extends across the entire aerosol precursor arrangement, when viewed in cross-section (e.g. perpendicular to the downstream direction). For example, the gap / plane of weakness may extend from the inside surface of the envelope on one side to the inside surface on the other side. In other examples, multiple gaps / planes of weakness may be provided, these gaps / planes of weakness may meet centrally and the gaps may extend in different transverse directions to the inside surface of the envelope.

[0049] In some examples, the gap or plane of weakness formed between the first body and the second body extends across the solid aerosol precursor arrangement from a first region on the inside surface of the envelope to a second region on the inside surface of the envelope. The first region and the second region may be on opposite sides of the solid aerosol precursor arrangement. That is, in some examples, the gap or plane of weakness formed between the first body and the second body extends across the solid aerosol precursor arrangement in a direction from a first region on the inside surface of the envelope to a second region on the inside surface of the envelope.

[0050] In some examples, the solid aerosol precursor arrangement has a central axis. The central axis of the solid aerosol precursor arrangement extends along the axial length of the solid aerosol precursor arrangement. The upstream end and the downstream end may delimit the solid aerosol precursor arrangement along the central axis. Where the solid aerosol precursor arrangement is generally cylindrical, the central axis may be a cylinder axis. The solid aerosol precursor arrangement may be rotationally symmetric with respect to the central axis. In some examples, the central axis may be a central axis for the whole consumable.

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[0053] In some examples, the gap or plane of weakness formed between the first body and the second body extends in a first transverse direction from the central axis to the inside surface of the envelope. In some examples, a second gap or plane of weakness extends in a second transverse direction from the central axis to the inside surface of the envelope. In these examples, the first transverse direction is different from the second transverse direction; the first transverse direction and the second transverse direction may be perpendicular to the downstream direction and / or the central axis.

[0054] In some examples, further gaps or planes of weakness extend in transverse directions from the central axis to the inside surface of the envelope. In these examples, the transverse direction of each gap / plane of weakness is different to the transverse direction of other gaps / planes of weakness. For example, a third gap / plane of weakness may extend in a third transverse direction from the central axis to the inside surface of the envelope, where the third transverse direction is different from the first and second transverse directions, and a fourth gap / plane of weakness may extend in a fourth transverse direction from the central axis to the inside surface of the envelope, where the fourth transverse direction is different from the first, second and third directions. In some examples, the bodies may be arranged such that the gaps / plane of weakness form the shape of a cross or of an asterisk.

[0055] In examples where the solid aerosol precursor arrangement further includes a third body such that a second gap or plane of weakness is formed between the second body and the third body, and a third gap or plane of weakness is formed between the third body and the first body, the gap / plane of weakness formed between the first body and the second body extends in a first transverse direction from the central axis to the inside surface of the envelope, the second gap / plane of weakness formed between the second body and the third body extends in a second transverse direction from the central axis to the inside surface of the envelope and the third gap / plane of weakness formed between the third body and the first body extends in a third transverse direction from the central axis to the inside surface of the envelope, where the first, second and third transverse directions are all different.

[0056] In examples where the solid aerosol precursor arrangement includes more than three bodies, such as up to and including ten bodies, the gaps / planes of weakness that form between each of the bodies may each extend in a transverse direction from the central axis to the inside surface of the envelope, where the transverse direction of each gap / plane of weakness is different from the transverse directions of the other gaps / planes of weakness. In some examples, the bodies may be arranged such that the gaps / planes of weakness form the shape of a cross or of an asterisk.

[0057] When the bodies each have the shape of a cylinder segment, the gaps / planes of weakness formed between the bodies may extend radially in transverse directions from the central axis of the solid aerosol precursor arrangement to the inside surface of the envelope, where the transverse direction of each gap / plane of weakness is different.

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[0060] In this way, the airflow through the solid aerosol precursor arrangement may be enhanced since the gap(s) / plane(s) of weakness extends both along the axial length of the solid precursor arrangement and in a transverse direction from the central axis to the inside surface of the envelope such that there is no contact between any of the bodies.

[0061] In some examples in which gaps are provided, the gap or gaps have approximately constant width in the transverse direction from the central axis all the way to the inside surface of the envelope. In other examples, the width of the gap or gaps varies in the transverse direction from the central axis to the inside surface of the envelope. In some examples, the width of the gap or gaps decreases along the transverse direction from the central axis to the inside surface of the envelope. In other words, the width of the gap or gaps is narrower nearer the peripheral surface of the bodies (i.e., at the inside surface of the envelope), expanding to the widest at the central axis of the solid aerosol precursor arrangement. In other examples, the width of the gap or gaps increases along the transverse direction from the central axis to the inside surface of the envelope. In other words, the width of the gap or gaps is wider nearer a peripheral surface of bodies (i.e., at the inside surface of the envelope).

[0062] In some examples, the gap or gaps are provided as one or more of a channel, a groove, a cut, a hollow bore, or a perforation. These may take any form, for example the channel may be a spiral shaped channel. In some examples, each gap is delineated by the surfaces of the bodies bounding the gap, so as to produce for example a conical, cylindrical, cuboid such as rectangular cuboid, or pyramidal shape of gap.

[0063] In some examples, the gap or gaps is / are arranged to receive a penetrative heater, such as a blade heater or a pin heater. For example, a solid precursor arrangement may be configured to receive the penetrative heater exclusively into the gap or gaps and without penetrating any of the bodies.

[0064] In some examples, when the gap or gaps extends in a transverse direction from the central axis of the solid aerosol precursor arrangement to the inside surface of the envelope, the penetrative heater may be located at the centre of the consumable. In some examples, the penetrative heater is located along the central axis of the solid aerosol precursor arrangement, and extends along the central axis. The penetrative heater may heat the solid aerosol precursor arrangement by conductive heat transfer, and generate an aerosol which is inhaled by the user. Particularly, the use of a penetrative heater may be beneficial for, for example, influencing the airflow through the solid precursor, which may be beneficial for improving the pressure drop across different consumables during use. The effect of the penetrative heater on the airflow may be dependent on, for example, the proximity of the heater to the solid aerosol precursor arrangement and the density of the bodies. Additionally, where the heater is received within the gap or gaps of the solid aerosol precursor arrangement the need for cleaning of the apparatus may be reduced.

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[0066] 9

[0067] In some examples, the bodies of the solid precursor arrangement comprise a precursor composition, where the precursor composition is or comprises an agglomeration of particles, such as is an agglomeration of particles.

[0068] In some examples, the first body and the second body have the same precursor composition. In some examples, the first body and the second body have a precursor composition comprising an agglomeration of particles. In examples where the solid precursor arrangement comprises more than two bodies, each of the bodies may have the same precursor composition. In these examples, each of the bodies may have a precursor composition comprising an agglomeration of particles.

[0069] In some examples, the precursor composition comprises plant materials. For example, these may comprise non-tobacco particles, such as cellulose particles and / or tea particles. In some examples, the tea particles comprise oolong tea. In other examples, the tea particles comprise green tea. In some examples, the tea particles comprise a mixture of oolong and green tea. In some examples, the precursor composition is free or substantially free of tobacco particles. By substantially free, it is meant that the precursor composition comprises no dry mass tobacco in accordance with regulatory standards. As used herein, dry mass tobacco does not encompass tobacco extract or tobacco essence.

[0070] In some examples, the precursor composition comprises up to about 60 weight% (wt%) non-tobacco particles relative to the total weight of the precursor composition (the total weight of the precursor composition being 100 wt%). In some examples, the precursor composition comprises up to about 55 wt% non-tobacco particles, or up to about 50 wt% non-tobacco particles relative to the total weight of the precursor composition. In some examples, the precursor composition comprises about 40 wt% or more non-tobacco particles, such as about 45 wt% or more non-tobacco particles, such as about 50 wt% or more non-tobacco particles relative to the total weight of the precursor composition.

[0071] In some examples, the precursor composition comprises an amount of non-tobacco particles selected from a range with the upper and lower amounts selected from the values given above. In some examples, the precursor composition comprises 40 to 60 wt% non-tobacco particles, such as 50 to 60 wt% non-tobacco particles, such as 55 to 60 wt% non-tobacco particles relative to the total weight of the precursor composition. In other examples, the precursor composition comprises 40 to 50 wt% non-tobacco particles relative to the total weight of the precursor composition. In some examples, the precursor composition comprises up to and including 60 wt% non-tobacco particles relative to the total weight of the precursor composition.

[0072] For example, when the precursor composition comprises cellulose particles and tea particles, the precursor composition is 20 to 25 wt% cellulose particles and 20 to 25 wt% tea particles relative to the total weight of the precursor composition. In some examples, the precursor composition comprises up to about 25 wt% cellulose particles, such as up to about 24 wt% cellulose particles, such as up to about 23 wt% cellulose particles relative to the total weight of the precursor composition. In some examples,

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[0074] 10 the precursor composition comprises about 20 wt% or more cellulose particles, such as about 21 wt% or more, such as about 22 wt% or more relative to the total weight of the precursor composition. In some examples, the precursor composition comprises cellulose particles in a range with the upper and lower amounts selected from the values given above. In some examples, the precursor composition comprises up to about 25 wt% tea particles, such as up to about 24 wt% tea particles, such as up to about 23 wt% tea particles relative to the total weight of the precursor composition. In some examples, the precursor composition comprises about 20 wt% or more tea particles, such as about 21 wt% or more, such as about 22 wt% or more relative to the total weight of the precursor composition. In some examples, the precursor composition comprises an amount of tea particles selected from a range with the upper and lower amounts selected from the values given above.

[0075] In some examples, the amounts of cellulose particles and tea particles in the precursor composition are equal. In other examples, the amounts of cellulose particles and tea particles in the precursor composition are not equal.

[0076] In some examples, the plant material may comprise or be formed of tobacco. Any type of tobacco may be used, including, but is not limited to, flue-cured tobacco, burley tobacco, Virginia tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco, rustica tobacco. This also includes blends of the above mentioned tobaccos. Any suitable parts of the tobacco plant may be used, including leaves, stems, roots, bark, seeds and flowers. 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). For example, the aerosolforming material may comprise a gathered sheet of homogenised (e.g. paper / slurry recon) tobacco or gathered shreds / strips formed from such a sheet.

[0077] The tobacco may be processed tobacco, steam treated stems or shredded dried stems. The tobacco material may be fermented, cured, uncured, toasted, or otherwise pre-treated. The tobacco may be unprocessed and / or untreated.

[0078] 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), Oestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia califomica (California Poppy), Fittonia albivenis, Hippobroma longi flora, 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 (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

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[0081] (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombi folia, 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.

[0082] In some examples, the precursor composition comprises a flavourant, such as tobacco extract or other plant extracts. In some examples, the flavourant may provide flavour and odour to the solid precursor. In some examples, the precursor composition comprises a tobacco extract. In some examples, the precursor composition comprises other plant extracts such as fig, maple, or acer saccharum extract. In some examples, the precursor composition comprises up to about 40 weight (wt%) flavourant, such as up to about 35 wt% flavourant, such as up to about 30 wt% flavourant relative to the total weight of the precursor composition. In some examples, the precursor composition comprises about 20 wt% or more flavourant, such as about 25 wt% or more flavourant, such as about 30 wt% or more flavourant relative to the total weight of the precursor composition. In some examples, the precursor composition comprises an amount of flavourant selected from a range with the upper and lower amounts selected from the values given above. In some examples, the precursor composition comprises 20 to 40 wt% flavourant, such as 25 to 40 wt%, such as 30 to 40 wt%, such as 35 to 40 wt% relative to the total weight of the precursor composition. In some examples, the precursor composition comprises up to and including 40 wt% flavourant relative to the total weight of the precursor composition.

[0083] In some examples, the precursor composition comprises a humectant. In some examples, the humecant may comprise propylene glycol (PG) and / or glycerol (VG). In some examples, the amount of humectant present in the precursor composition is up to about 30 weight% (wt%), such as up to about 25 wt%, such as up to about 20 wt% relative to the total weight of the precursor composition. In some examples, the amount of humectant present in the precursor composition is about 20 wt% or more, such as about 25 wt% or more, such as about 30 wt% or more relative to the total weight of the precursor composition. In some examples, the precursor composition comprises an amount of humectant selected from a range with the upper and lower amounts selected from the values given above. In some examples, the amount of humectant present in the precursor composition is about 20 to 30 wt%, such as 25 to 30 wt%, such as up to and including 30 wt% relative to the total weight of the precursor composition.

[0084] In some examples, the precursor composition comprises a binding agent, which in some examples may act as a thickening agent, or may comprise a thickening agent. In some examples, the binding and / or thickening agent is selected from one or more of microcrystalline cellulose (MCC), Konjac Mannan, carrageenan, starches such as corn starch, gelatine, pectin, gums such as guar or xanthan gum, or alginates. In some examples, the binding and / or thickening agent is Konjac Mannan. In some examples, the binding and / or thickening agent is a water-independent thickening agent. A water-

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[0086] 12 independent thickening agent may be a thickening agent which does not require water for activation. In some examples, the precursor composition comprises up to about 5 weight% (wt%) binding and / or thickening agent, such as up to about 4 wt% binding and / or thickening agent, such as up to about 3 wt% binding and / or thickening agent relative to the total weight of the precursor composition. In some examples, the precursor composition comprises about 1 wt% or more binding and / or thickening agent, such as about 2 wt% or more binding and / or thickening agent, such as about 3 wt% or more binding and / or thickening agent relative to the total weight of the precursor composition. In some examples, the precursor composition comprises an amount of binding and / or thickening agent selected from a range with the upper and lower amounts selected from the values given above. In some examples, the precursor composition comprises 1 to 5 wt% binding and / or thickening agent, such as 2 to 5%, such as 3 to 5% relative to the total weight of the precursor composition. In some examples, the precursor composition comprises up to and including 5 wt% binding and / or thickening agent relative to the total weight of the precursor composition.

[0087] In some examples, the precursor composition comprises a solvent. In some examples the solvent is aqueous. In some examples, the amount of solvent present in the precursor composition is up to about 75 weight% (wt%), such as up to about 60 wt%, such as up to about 50 wt% relative to the total weight of the precursor composition. In some examples, the amount of solvent present in the precursor composition is up to about 45 wt%, such as up to about 40 wt% relative to the total weight of the precursor composition. In some examples, the amount of solvent present in the precursor composition is about 5wt% or more, such as 10 wt% or more, such as 20 wt% or more, such as 30 wt% or more relative to the total weight of the precursor composition. In some examples, the amount of solvent present in the precursor composition may be selected from a range with the upper and lower amounts selected from the values given above. In some examples, the amount of solvent present in the precursor composition is about 20 to 50 wt%, such as 20 to 45 wt%, such as 20 to 40 wt% relative to the total weight of the precursor composition. In some examples, the amount of solvent present in the precursor composition is about 25 to 50 wt%, such as 30 to 50 wt% relative to the total weight of the precursor composition.

[0088] In some examples, the amount of water (as the solvent) present in the precursor composition is up to about 75 weight% (wt%), such as up to about 60 wt%, such as up to about 50 wt% relative to the total weight of the precursor composition. In some examples, the amount of water present in the precursor composition is up to about 45 wt%, such as up to about 40 wt% relative to the total weight of the precursor composition. In some examples, the amount of water present in the precursor composition is about 5 or more weight% (wt%), such as 10 wt% or more, such as 15 wt% or more, such as 20 wt% or more, such as 30 wt% or more relative to the total weight of the precursor composition. In some examples, the amount of water present in the precursor composition may be selected from a range with the upper and lower amounts selected from the values given above. In some examples, the amount of water present in the precursor composition is about 20 to 50 wt%, such as 20 to 45 wt%, such as 20 to 40 wt% relative to the total weight of the precursor composition. In some examples, the amount of

[0089] P152693PC00 P01589

[0090] 13 water present in the precursor composition is about 25 to 50 wt%, such as 30 to 50 wt% relative to the total weight of the precursor composition. In some examples, the amount of water present in the precursor composition is up to and including 20 wt% relative to the total weight of the precursor composition. In other examples, the amount of water present in the precursor composition is less than 10 wt% relative to the total weight of the precursor composition.

[0091] When the solvent content (for example, water content) is less than 10 wt% relative to the total weight of the precursor composition, this may require a higher amount of other wet ingredients in the precursor composition, such as an increased amount of humectant. A low solvent content may increase the viscosity of the precursor bulk material which is advantageous for the extrusion process (see below).

[0092] The precursor composition may comprise one or more additives selected from vapour generators, carrier agents, humectants, flavourants, fillers, aqueous / non-aqueous solvents and binders.

[0093] The precursor composition may comprise propylene glycol (PG) and / or vegetable glycerin (VG). Propylene glycol (PG) and vegetable glycerin (VG) are typically used as base materials that act as aerosol generators (alternatively referred to as aerosol-formers), carrier agents, and / or humectants. The precursor composition may comprise, alternatively or in addition, other substances that function as one or more of aerosol generators, carrier agents, and humectants.

[0094] The humectant content of the precursor composition may have a lower limit of at least 5 wt %, such as at least 10 wt %. The humectant content of the combustible material of the smoking body may have an upper limit of at most 50 % by weight of the plant material, such as at most 40 wt %. [Conventional cigarettes typically have a humectant content of 1-5 wt%]

[0095] Flavourants may be provided in solid form, liquid form, gel form, or a combination thereof. Flavourants may include one or more of menthol (e.g. peppermint (mentha piperita), spearmint (mentha spicata), wild mint (Mentha Arventis), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), applemint (Mentha suaveolens), pennyroyal (Mentha pulegium)), liquorice, chocolate / cocoa, fruit flavour (including e.g. apple, citrus, cherry, banana (Isoamyl acetate)), rose, vanilla (Ethylvanillin), spice (e.g. ginger, clove, cinnamon, star anise), tobacco extract / flavour, marijuana, hemp, cannabinoid compounds, citronella, orange, lemon, geraniol, thyme, fennel, green tea, black tea, coffee, salvia dorrii, salvia, passiflora incarnata, arctostaphylos uva-ursi, lobelia inflata, matcha, Yerba mate, lemon grass, flax, cedar wood, coumarin, helio, eucalyptus, ginkgo biloba, hazel, hibiscus, laurel, chamomile, rosemary, lavender, rooibos, or combinations thereof. The flavourant may be evenly dispersed throughout the precursor composition or may be provided in isolated locations and / or varying concentrations throughout the precursor composition.

[0096] The cannabinoid compounds may be selected from the non-exhaustive list comprising: tetrahydrocannabinol (THC), cannabidiol (CBD), cannabinol (CBN).

[0097] P152693PC00 P01589

[0098] 14

[0099] Fillers can strengthen the precursor composition. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g. wood fibres), jute fibres and combinations thereof.

[0100] Binders can act to bind together the components forming the precursor composition. Binders may comprise starches and / or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxy propyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and / or locust bean gum, organic acids and their salts such as alginic acid / sodium alginate, agar and pectins.

[0101] In some examples, the precursor composition has a composition according to Table 1 .

[0102] Table 1

[0103] In some examples, the bodies of the solid aerosol precursor arrangement are formed or formable by extrusion. Advantageously, extrusion may allow for a lower or more consistent water content of the solid precursor between different samples, particularly at the point of manufacture. Extrusion may also result in better process control and may allow for continuous production. Continuous production may be beneficial for high speed and large-scale manufacturing. Material waste, costs and lead times may also be reduced. Further beneficially, extrusion may result in an extrudate which may be portioned, cut, wrapped and assembled with minimal handling and increased automation.

[0104] In some examples, the mouthpiece of the consumable comprises a filter element. In use, a user may engage the mouthpiece to create an airflow through the consumable. In particular, the airflow may flow from the solid aerosol arrangement to the mouthpiece, and may exit from the consumable at the mouthpiece. Therefore, when the mouthpiece comprises a filter element, the airflow may pass through the filter element before exiting from the consumable at the mouthpiece, thereby removing any particulates and preventing their inhalation by the user.

[0105] In some examples, the consumable comprises a hollow element, where the hollow element is downstream of the solid aerosol precursor arrangement and upstream of the mouthpiece. The hollow element may be a portion of the consumable comprising no segment. In some examples, the hollow element is bounded by or comprises a paper tube. Advantageously, the hollow element may function

[0106] P152693PC00 as a mixing container, allowing for cooling and mixing of the generated vapour from the solid aerosol precursor arrangement during use. In this way, overheating of the mouthpiece may be prevented or reduced.

[0107] In some examples, the hollow element contains a frangible capsule. In some examples, the frangible capsule is heat activated. In some examples, the heat-activated frangible capsule comprises a capsule shell which may be melted to release the contents of the capsule. In some examples, the frangible capsule is mechanically activated. In some examples, the mechanically activated frangible capsule may be crushed during use to release the contents of the capsule. In this way, flavour delivered to the user may be enhanced since the frangible capsule may contain one or more additional flavourants which may be released during use. The frangible capsule may be held in position adjacent the mouthpiece of the consumable by a support structure. In some examples, the support structure is a paper roll.

[0108] In a second aspect the present disclosure provides a method of preparing the consumable of the first aspect.

[0109] In some examples, the method comprises extruding a precursor slurry to form an extrudate, dividing the extrudate to form at least two extruded bodies, drying the at least two extruded bodies to form a solid aerosol precursor arrangement comprising at least two bodies, and assembling the solid aerosol precursor arrangement into a consumable for an aerosol generating apparatus.

[0110] In this way the uniformity of the solid aerosol precursor arrangement may be improved, and may result in more consistent porosity within the solid precursor arrangement and more consistent shape of the solid precursor arrangement. This may result in a more consistent pressure drop across the precursor arrangement during use across different consumables. Extrusion may also allow for lower and more consistent water content of the bodies, particularly at point of manufacture, as well as potentially resulting in better process control. Further, extrusion may allow for continuous production of the consumable. This may have advantages of high speed and large-scale manufacturing, and reduction in material waste, costs and lead times. Further, extrusion may allow for reduced handing and increased automation of the stick manufacturing process.

[0111] In some examples, the extrudate is divided to form at least two extruded bodies at a mouth of the extruder. A “mouth of the extruder” may be an aperture of the extruder from which the extrudate is expelled. In some examples, the extrudate is divided by a mesh located over the mouth of the extruder, where the pattern of the mesh defines the portions into which the extrudate is separated or divided. During the extrusion process, the precursor slurry is introduced into the extruder and is forced out of the mouth of the extruder, past the mesh. As the slurry passes the mesh, the resulting extrudate is divided into at least two extruded bodies, the extruded bodies corresponding to the pattern of the mesh.

[0112] P152693PC00 16

[0113] In some examples, a die of the extruder is adapted to divide the extrudate as it is expelled.

[0114] In some examples, extrusion and division of the extrudate to form at least two extruded bodies occur simultaneously. In other examples, the extrudate is divided to form at least two extruded bodies in a downstream process separate from the extrusion process.

[0115] In some examples, the precursor slurry comprises dry ingredients and wet ingredients. In some examples, the dry ingredients and the wet ingredients are mixed using an extruder to form the precursor slurry. The dry ingredients of the precursor slurry may comprise a fibrous or particulate filler, such as cellulose and / or tea particles. The wet ingredients of the precursor slurry may comprise humectant, flavourants, binding and / or thickening agents and solvent.

[0116] In some examples, the amount of fibrous or particulate filler in the precursor slurry is about 50 wt%. In some examples, the precursor slurry comprises non-tobacco particles in an amount as described herein in relation to the precursor composition of the first aspect.

[0117] In some examples, the humectant includes glycerol (VG) and / or propylene glycol (PG). In some examples, the amount of humectant present in the precursor slurry is as described herein in relation to the precursor composition of the first aspect.

[0118] In some examples, the amount of solvent present in the precursor slurry is as described herein in relation to the precursor of the first aspect. In some examples, the solvent is aqueous. In some examples, the solvent is water.

[0119] When the solvent content (for example, water content) is less than 10 wt% relative to the total weight of the precursor slurry, this may require a higher amount of other wet ingredients in the precursor slurry, such as an increased amount of humectant. A low solvent content may increase the viscosity of the slurry which may be advantageous for the extrusion process.

[0120] The extrusion process may be any extrusion process known to the skilled person. In some examples, the extrusion process may use a single screw extruder. In other examples, the extrusion process may use a twin-screw extruder.

[0121] In some examples, the wet and dry ingredients of the precursor slurry are added to the extruder at different points in the extrusion process. For example, the ingredients may be introduced into the extruder at different points along a barrel of the extruder. In this way, although the ingredients may be introduced into the extruder simultaneously in time, mixing of the ingredients may be staggered as it may take time for the most upstream ingredients to be transported along the barrel such that they can be mixed with the downstream ingredients. Upstream and downstream may be set in accordance with the direction of travel of the precursor slurry in the extruder. In some examples, the raw materials of

[0122] P152693PC00 P01589

[0123] 17 the precursor slurry may be separated into dry ingredients and wet ingredients as the first and second portions of raw material. In some examples, the first portion comprises the dry ingredients and the second portion comprises the wet ingredients. In some examples, the second portion of raw material is added into the extrusion machine downstream of the first portion of raw material. In some examples, the first portion of raw material is added to the extrusion machine downstream of the second portion of raw material. This staggered approach may ensure complete mixing of the wet and dry ingredients separately. In some examples, such an approach may prevent or reduce or minimise blockages in the extruder.

[0124] In some examples, the first portion comprises dry ingredients and is added upstream of the second portion comprising wet ingredients. In such examples, the dry ingredients have time to mix independently of wet ingredients in the extrusion machine, before becoming mixed with the wet ingredients.

[0125] In some examples, the first portion comprises dry ingredients and is added downstream of the second portion comprising wet ingredients.

[0126] In some examples, the ingredients are introduced into the extruder in the following order, starting from the most upstream to the most downstream: filler, thickening and / or binding agent, solvent, humectant, and finally flavourant. In some examples, the solvent and humectant are added in the same portion.

[0127] In some examples, the precursor slurry is extruded without any applied heat. That is, in some examples, the precursor slurry is extruded at room temperature, which may be between 20-30°C such as 22-26°C. In some examples, the precursor slurry is extruded at an elevated temperature. In this way, the flowability of the precursor slurry may be improved. In some examples, the precursor slurry is extruded at a reduced temperature (under cooling).

[0128] In some examples, the at least two extruded bodies are inserted into an envelope before drying the at least two extruded bodies to form a solid aerosol precursor arrangement comprising at least two bodies. As used herein, the term “envelope” defines a covering or containing structure or layer. In some examples, during drying, the peripheral surface of the at least two extruded bodies adhere to the envelope. In some examples, an adhesive is used to adhere the peripheral surface of the at least two extruded bodies to the envelope. In some examples, a binder in the material which forms the solid aerosol precursor may provide or act as an adhesive. Adhesion of the bodies to the inside surface of the envelope maintains the arrangement of the bodies in the consumable. In some examples, the envelope comprises a rigid material such as card. In some examples, the envelope is a rigid tube, such as a card tube. In some examples, during drying, the at least two extruded bodies of the extrudate shrink to form a gap between the bodies, where the gap extends along the entire axial length of the solid aerosol precursor arrangement. In this way the air flow route through the precursor arrangement

[0129] P152693PC00 P01589

[0130] 18 may be enhanced, resulting in improved consistency of the pressure drop across the solid aerosol precursor arrangement during use across different consumables.

[0131] In other examples, the at least two extruded bodies are dried to form a solid aerosol precursor arrangement comprising at least two bodies before the solid aerosol precursor arrangement is encased in an envelope. In some examples, the envelope is a wrapper. In these examples, the envelope comprises a less rigid material such as paper, foil or foil-paper laminate. In this way, leaching of water into the envelope may be reduced or avoided. Encasing the solid aerosol precursor arrangement may be carried out by any method known to the skilled person. In some examples, the envelope may be a foil-paper laminate. In some examples, the envelope is paper. In some examples, during drying, the peripheral surface of the at least two extruded bodies adhere to the paper. In some examples, an adhesive is used to adhere the peripheral surface of the at least two extruded bodies to the envelope. In some examples, a binder in the material which forms the solid aerosol precursor may provide or act as an adhesive. In some examples, the envelope comprises a single piece of wrapping which may be folded around the solid aerosol precursor arrangement. In some examples, the envelope comprises two or more pieces of wrapping which may be used to spiral wrap the solid aerosol precursor arrangement. Advantageously, spiral wrapping the precursor arrangement may reduce the amount of overlap of the wrapping (compared with the single piece of wrapping) and so thickness control of the wrapping may be improved. Excessive overlap of the wrapping may lead to an air flow path which may negatively affect the pressure drop across the solid aerosol precursor arrangement.

[0132] In some examples, the method may comprise rejoining the two or more bodies of aerosol-forming material into a compound body of solid aerosol-forming material, the compound body comprising one or more planes of weakness within the body along the planes where the bodies are rejoined. For example, the bodies may be placed in contact with one another, for example before during or after drying, to form a composite body with planes of weakness along the plane(s) the join. The bodies may be somewhat sticky and adhere to one another (for example, but virtue of a binder therein), or an adhesive may be used.

[0133] In some examples, drying the at least two extruded bodies comprises heating the extruded bodies at a temperature of up to 70 °C, such as up to 60 °C, such as up to 50 °C. In some examples, drying the at least two extruded bodies comprises heating the extruded bodies at a temperature of at least 30°C, such as at least 35 °C or at least 40 °C. Any of these may be combined to form a suitable range. In some examples, drying the at least two extruded bodies comprises heating the extruded bodies to within a range of 40 to 70 °C, such as 40 to 60 °C, such as 40 to 50 °C. In this way, the solvent / water content of the extruded bodies may be reduced, whilst retaining the other components of the precursor composition. In some examples, drying the at least two extruded bodies comprises drying the extruded bodies in line. In some examples, solvent / water content of the extrudate after drying is about 5 to 10 wt% relative to the total weight of the extrudate.

[0134] P152693PC00 P01589

[0135] 19

[0136] In some examples, extruding the precursor slurry, dividing the extrudate to form at least two extruded bodies, and drying the at least two extruded bodies to form a solid aerosol precursor arrangement comprising at least two bodies is a continuous process. That is, the extruded bodies may be dried continuously straight after extrusion and division of the extrudate, for example the extruded bodies may be dried continuously in line.

[0137] In some examples, the extrudate is cylindrical. In some examples, the cylindrical extrudate has a diameter of about 6 mm at the point of extrusion. In some examples, the solid aerosol precursor arrangement obtained from a cylindrical extrudate has a total diameter of 6.95-7.00 mm. The increase in diameter of the solid aerosol precursor arrangement compared with the cylindrical extrudate may be due to the compressible nature of the precursor slurry. In the extruder, the precursor slurry may be compressed and the resultant cylindrical extrudate therefore may have the same diameter as the aperture of the mouth of the extruder (for example, 6 mm). Once the extrudate has been expelled from the extruder, the extrudate may expand. Since the extrudate is divided into at least two extruded bodies, as it expands, a gap between the extruded bodies may form. The gap may further increase in size during the drying process forming the solid aerosol precursor arrangement, in which ‘shrinking back’ of the extruded bodies may be observed. This therefore results in a solid aerosol precursor arrangement with a larger diameter than the cylindrical extrudate from which it is derived from.

[0138] In a third aspect the present disclosure provides a consumable obtained or obtainable by the method of the second aspect.

[0139] In a fourth aspect the present disclosure provides an aerosol generating system comprising a consumable of the first aspect and an aerosol generating unit comprising a heating element, wherein the heating element is configured to heat at least a part of the solid precursor.

[0140] In some examples, the heating element is a penetrative heater configured to penetrate the gap extending between the bodies of the solid aerosol precursor arrangement. Particularly, in examples where the solid aerosol precursor arrangement comprises a plurality of bodies and therefore a plurality of gaps and where the gaps extend in a transverse direction from the central axis of the solid aerosol precursor arrangement to the inside surface of the envelope, the penetrative heater may be located at the centre of the consumable. In some examples, the penetrative heater may be located along the central axis of the solid aerosol precursor arrangement, and extend along the central axis. The penetrative heater may heat the solid aerosol precursor arrangement by conductive heat transfer, and generate an aerosol which is inhaled by the user. Particularly, the use of a penetrative heater may be beneficial for, for example, influencing the airflow through the solid precursor, which may be beneficial for improving the pressure drop across different consumables during use. The effect of the penetrative heater on the airflow may be dependent on, for example, the proximity of the heater to the solid aerosol precursor arrangement and the density of the bodies. Additionally, the use of a penetrative heater may

[0141] P152693PC00 P01589

[0142] 20 reduce the need for cleaning of the consumable since the heater is enclosed within the solid aerosol precursor arrangement.

[0143] The present disclosure may provide a method of generating an aerosol, which may implement any one or more features disclosed herein. The method may comprise heating the heat-not-burn consumable of the first aspect.

[0144] The present disclosure may provide a use of solid precursor for improving the pressure drop of an aerosol generating segment during use. In some examples, the solid precursor is as described for the first aspect.

[0145] In a fifth aspect, the present disclosure provides an aerosol-forming element for a heat-not-burn consumable. In some examples, the aerosol-forming element comprises a compound body of a solid aerosol-forming material. In some examples, the aerosol-forming element comprises one or more planes of weakness. In some examples, the compound bodies of solid aerosol-forming material comprise the one or planes of weakness within the body. In some examples, the planes of weakness are orientated substantially parallel to a flow path of the heat-not-burn consumable.

[0146] As noted above, the terms “precursor” and “an aerosol-forming element” are generally used synonymously herein. In particular, an aerosol-forming element may alternatively be referred to as solid aerosol precursor arrangement.

[0147] In some examples, the aerosol-forming element comprises a compound body of a solid aerosol-forming material, wherein the compound body of solid aerosol-forming material comprises two or more bodies (e.g. sub-bodies or regions) of aerosol-forming material separated by one or more planes of weakness, and wherein the planes of weakness are orientated substantially parallel to a flow path of the heat-not- burn consumable.

[0148] The present disclosure also provides an aerosol-forming element comprising a compound body of aerosol-forming material having one or more planes of weakness within the compound body, where during heating of the aerosol-forming element the compound body fractures along the one or more planes of weakness.

[0149] The present disclosure also provides an aerosol-forming element comprising a compound body of aerosol-forming material having one or more planes of weakness within the compound body, where during aerosol-formation the compound body fractures along the one or more planes of weakness.

[0150] The planes of weakness present in the extruded aerosol-forming material, allow for a solid plug of aerosol-forming material to be provided, but which is unlikely to warp or fall out of the consumable during use. The aerosol-forming material can fracture or cleave along the planes of weakness, to account for shape changes and shrinkage of the aerosol-forming material during use. As a result, the

[0151] P152693PC00 P01589

[0152] 21 aerosol-forming material is more easily retained within the consumable. The consumable is also less liable to change shape during use.

[0153] The planes of weakness allow the aerosol-forming material to fracture in a controlled way. In use, as the aerosol-forming material dries out and shrinks, the aerosol-forming material preferentially fractures along the planes of weakness. This allows the aerosol-forming material to better tolerate changes in moisture / volatile content, and consequently changes in shape (e.g., shrinking / warping). By fracturing along the planes of weakness, the aerosol-forming material does not pull away from the walls of the consumable (e.g., an envelope, such as a wrapper or card tube which circumscribes the aerosolforming material around its perimeter) and does not deform the consumable. This means the aerosolforming material is less likely to come loose and fall out of the consumable.

[0154] Fracturing along the planes of weakness may also allow air gaps to open up during use, to change the resistance to draw during a session and provide increased penetration of air flow through the aerosolforming element, especially towards the end of a session.

[0155] The planes of weakness may be provided as a result of the extrusion process, or as a result of cutting an extrudate soon after extrusion.

[0156] The aerosol-forming material may be prepared by extrusion. As noted above, extrusion of the aerosolforming material allows for a lower and more consistent water content in the aerosol-forming material, especially at the point of manufacture. Extrusion is also thought to give better process control, as it operates as a continuous process and the formulation may be made more reliable and consistent. The extrusion process may also allow for greater customisability and flexibility in design.

[0157] Extrusion typically results in a solid rod of aerosol-forming material, which can be portioned, cut, wrapped and assembled into a HNB consumable, for example as described above. This allows for reduced handling, increased automation and continuous manufacturing.

[0158] The present disclosure describes to an aerosol-forming element where there are planes of weakness built into the aerosol-forming element. The planes of weakness may also be known as cleavage planes. A compound body of solid aerosol-forming material is connected across the cleavage planes. The compound body of solid aerosol-forming material is in contact across the cleavage planes.

[0159] The planes of weakness are typically orientated parallel within the longitudinal direction of the consumable. The planes of weakness may be parallel to and intersect the axis of rotation of the consumable.

[0160] The planes of weakness may define bodies (or sub-bodies) of the compound body of solid aerosolforming material, where the bodies of the aerosol-forming material are in partial or full contact along the planes of weakness. In some examples, the bodies are in contact over the plane of weakness, such as in contact over each plane of weakness. In some examples, the bodies are in contact over part of the plane of weakness, such as in contact over part of each plane of weakness.

[0161] P152693PC00 P01589

[0162] 22

[0163] The planes of weakness may be where the compound body has been rejoined.

[0164] The planes of weakness are internal to the compound body of aerosol-forming material.

[0165] A plane of weakness is a plane where the strength of the solid aerosol-forming material is less than the rest of the solid aerosol-forming material. The strength of the rest of the solid-aerosol-forming material may refer to the strength of another plane which is not the plane of weakness. The strength of the rest of the solid-aerosol-forming material may refer to the average strength of another plane which is not the plane of weakness. Alternatively, the strength of the rest of the solid aerosol-forming material may refer to the strength, or average strength, of an aerosol-forming material which does not include a plane of weakness.

[0166] The plane of weakness is a plane where the strength of the solid aerosol-forming material is less than the rest of the solid aerosol-forming material. The strength of the rest of the solid-aerosol-forming material may refer to the strength of another plane which is not the plane of weakness.

[0167] The plane of weakness may be substantially weaker than the rest of the aerosol-forming material. The plane of weakness may be 10% or more weaker than the rest of the aerosol-forming material, such as 20% or more, such as 40% or more, such as 60% or more, such as 80% or less.

[0168] The plane of weakness may be less strong than the rest of the aerosol-forming material. The plane of weakness may have a strength which is 90% or less than the rest of the aerosol-forming material, such as 80% or less, such as 60% or less, such as 40% or less, such as 20% or less.

[0169] In some examples, the planes of weakness have an ultimate tensile strength which is less than the ultimate tensile strength of the aerosol-forming material. In some examples, the planes of weakness have an ultimate tensile strength which is 90% or less than the ultimate tensile strength of the aerosolforming material, such as 80% or less, such as 60% or less, such as 40% or less, such as 20% or less.

[0170] In some examples, the strength of the aerosol-forming material refers to the tensile strength (e.g., breaking strength or fracture strength), such as the ultimate tensile strength. The ultimate tensile strength is the maximum stress that a material can withstand while in tension before breaking. The ultimate tensile strength may be determined by increasing the tension across the aerosol-forming material until the aerosol-forming material breaks. The force applied just before the material breaks is the ultimate tensile strength. The ultimate tensile strength may be measured according to any suitable method, such as according to ASTM D828.

[0171] In some examples, the plane of weakness may have an ultimate tensile strength which is 90% or less than the ultimate tensile strength of the aerosol-forming material, such as 80% or less, such as 60% or less, such as 40% or less, such as 20% or less.

[0172] The strength, such as the ultimate tensile strength, of the plane of weakness of the aerosol-forming material is measured by testing the ultimate tensile strength normal to the plane of weakness.

[0173] P152693PC00 P01589

[0174] 23

[0175] The strength, such as the ultimate tensile strength, of the aerosol-forming material refers to the inherent strength of the material, where a plane of weakness is not present. This may be tested by measuring the strength, such as the ultimate tensile strength of a sample of the material without a plane of weakness. It may also be measured by testing the tensile strength parallel to the plane of weakness.

[0176] By providing the plane of weakness, when the aerosol-forming material fractures it fractures at the plane of weakness and not at a random point in the aerosol-forming material. As the planes of weakness extend from the upstream to the downstream end of the aerosol-forming element, the planes of weakness also assist in providing a complete break within the aerosol-forming element. That is, the aerosol-forming element may fracture from a compound body into two or more bodies (e.g. sub-bodies) along the plane of weakness. The bodies (or sub-bodies) may remain attached to HNB consumable (e.g., by adhesion to the envelope), and are thus retained within the HNB consumable even after fracturing along the planes of weakness.

[0177] In addition, fracturing along the planes of weakness may prevent distortion of the overall shape of the aerosol-forming element during heating. Where the aerosol-forming element may previously have warped during heating, due to changes in shape caused by a change in liquid content of the solid aerosol-forming material and / or uneven heating, the planes of weakness can fracture to elevate stress which may have built up during deformation of the aerosol-forming material. In this way, the fracturing along the planes of weakness can help to prevent distortion and warping of the aerosol-forming element.

[0178] Where the compound body of aerosol-forming material factures along the planes of weakness it may form two or more separated bodies. The shape of the bodies may be such that the bodies lock together within the aerosol-forming element. For example, the bodies may have the shape as described herein. The bodies may lock into place by an interference fit with other bodies and / or the envelope (e.g., wrapper or card tube which circumscribes the perimeter of the aerosol-forming material.

[0179] In some examples, the planes of weakness extend from an upstream end of the aerosol-forming element to a downstream end of the aerosol-forming element, and / or the one or more planes of weakness extend across the radial width of the aerosol-forming element.

[0180] The planes of weakness may have a different structure to the rest of the aerosol-forming material. The difference in structure results in the plane of weakness.

[0181] As mentioned above, the planes of weakness may be at least partially formed by, or comprise, voids. The voids may be known as air gaps. The voids typically do not include any aerosol-forming material or component of the aerosol-forming material.

[0182] The planes of weakness may be a collection of voids and / or air gaps, that together form the plane of weakness. In some examples, the voids may comprise the gaps of the first, second or fourth aspects of the invention. A void or airgap may provide at least part of an air channels in some examples. The compound body may alternatively or additionally include air channels in at least one region other than

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[0184] 24 the region including a plane of weakness. The air flow in air channels may comprise aerosol released from the bodies.

[0185] The aerosol-forming material as a whole may include voids. The voids in the aerosol-forming materials are typically distributed homogeneously. However, the planes of weakness may include a higher concentration of voids than the bulk of the aerosol-forming material. In some examples, the planes of weakness may include a greater concentration of voids than the bulk of the aerosol-forming material.

[0186] In some examples, the planes of weakness may include a greater concentration of voids than the bulk of the aerosol-forming material, where concentration is determined on a volume basis. The volume basis may be based on the total volume of the voids per unit volume of the aerosol-forming material. In some examples, the planes of weakness may include a greater volume of voids than the bulk of the aerosol-forming material

[0187] In some examples, the concentration of voids at the planes of weakness is 10% or more greater than the concentration of voids in the bulk of the aerosol-forming material, such as 20% or more, such as 30% or more, such as 50% or more.

[0188] In some examples, the planes of weakness may include a greater concentration of voids than the bulk of the aerosol-forming material, where concentration is determined on a number basis. The number basis may be based on the total number of voids per unit volume of the aerosol-forming material.

[0189] The voids may be formed by a process of dividing the body into bodies, and rejoining the bodies into a compound body. As the body is divided along a plane, this introduces voids into the space between the divided bodies, which are then at least partially retained as the bodies are rejoined to form the compound body of aerosol-forming material. The voids are thought to reduce the contact between the bodies either side of the plane of weakness, thus reducing the strength in the plane of weakness.

[0190] In some examples, the solid aerosol-forming material comprises a fibrous filler and / or a binder, wherein fibres of the filler and / or binder do not extend across the planes of weakness.

[0191] In some examples, the solid aerosol-forming material comprises fibrous filler, wherein the fibrous filler does not extend across the planes of weakness, optionally wherein fibres of the fibrous filler terminate at the planes of weakness

[0192] In some examples, 50% or more of the fibres present at the planes of weakness do not extend across the planes of weakness, such as 60% or more, such as 70% or more, such as 80% or more, such as 90% or more. The % of fibres is based on the number of fibres present at the plane of weakness, such as intersecting the plane of weakness.

[0193] In some examples, the fibres of the filler and / or binder terminate at the planes of weakness.

[0194] In some examples, 50% or more of the fibres present at the planes of weakness terminate at the planes of weakness, such as 60% or more, such as 70% or more, such as 80% or more, such as 90% or more.

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[0196] 25

[0197] The % of fibres is based on the number of fibres present at the plane of weakness, such as intersecting the plane of weakness.

[0198] If there are fibres orientated perpendicular to the plane of weakness, then these fibres may terminate at the plane of weakness. In some examples, 50% or more of the fibres orientated perpendicular to the planes of weakness terminate at the planes of weakness, such as 60% or more, such as 70% or more, such as 80% or more, such as 90% or more. The % of fibres is based on the number of fibres present at the plane of weakness, such as intersecting the plane of weakness.

[0199] A fibre may be perpendicular to the plane of weakness if the fibre at the plane of weakness is substantially perpendicular to the plane. This may also be known as normal to the plane of weakness. A fibre may be perpendicular to the plane of weakness if the longitudinal direction of the fibre is within 40° or the normal of the plane of weakness, such as within 30°, such as within 20°, such as within 10°.

[0200] The number of fibres at the planes of weakness may be determined using microscopy techniques, such as optical microscopy or SEM. The number of fibres may be counted across the entire plane of weakness. Alternatively, the number of fibres may be counted across a sample portion of the plane of weakness, and then extrapolated to the full plane of weakness.

[0201] In some examples, the solid aerosol-forming material comprises a fibrous filler and / or a binder, wherein at the planes of weakness the fibres of the filler and / or binder are oriented parallel to the plane of weakness.

[0202] A fibre may be parallel to the plane of weakness if the fibre at the plane of weakness is substantially parallel to the plane. This may also be known as in line with the plane of weakness. A fibre may be parallel to the plane of weakness if the longitudinal direction of the fibre is within 40° or the plane, such as within 30°, such as within 20°, such as within 10°.

[0203] The fibres at the plane of weakness refers to fibres which are within 2 mm of the plane of weakness, such as within 1 mm of the plane of weakness, such as within 0.5 mm, such as within 0.2 mm.

[0204] The planes of weakness may be formed by an absence of fibrous fillers and / or binders. The planes of weakness may be formed by an absence of fibrous fillers and / or binders spanning a plane in the material.

[0205] The absence of fibrous fillers and / or binders may be caused by a process of dividing and rejoining the bodies, and thereby forming the plane of weakness. As the body is divided along a plane, this removes any filler (e.g., fibrous filler) or binder from the space between the divided bodies, so there is no filler or binder spanning the plane. As the bodies are rejoined, although the filler and binder in different bodies may come back into contact, there is no filler (e.g., fibrous filler) or binder spanning the plane. This is thought to reduce the strength in the plane of weakness.

[0206] As a result, binding between the rejoined segments is weaker and the aerosol-forming material will preferentially fracture along these planes during use.

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[0208] 26

[0209] In some examples, the one or more planes of weakness extend along the entire axial length of the aerosol-forming element. In some examples, the one or more planes of weakness extend along the entire flow path of the aerosol-forming element. In some examples, the one or more planes of weakness extend from an upstream end to a downstream end of the solid aerosol-forming material.

[0210] In some examples, at least one plane of weakness extends along the entire axial length of the aerosolforming element. In some examples, at least one plane of weakness extends along the entire flow path of the aerosol-forming element. In some examples, at least one plane of weakness extends from an upstream end to a downstream end of the solid aerosol-forming material.

[0211] In some examples, the one or more planes of weakness extend across the radial width of the aerosolforming element. In some examples, at least one plane of weakness extends across the radial width of the aerosol-forming element.

[0212] In some examples, the aerosol-forming element is cylindrical. The aerosol-forming element may be rod-shaped.

[0213] In some examples, the planes of weakness intersect the central axis of the aerosol-forming element. The central axis typically refers to the axis of rotation.

[0214] In some examples, the planes of weakness extend from the central axis of the aerosol-forming element to the perimeter of the aerosol-forming element.

[0215] The planes of weakness may be arranged to form a single line, a cross shape, or an asterisk shape. The planes of weakness may be arranged to have line shaped cross-section, a cross-shaped crosssection, or an asterisk shaped cross-section. In this way, the bodies may have the cross-sectional shape of a semi-circle, a quarter circle, or a sixth of a circle.

[0216] In some examples, the planes of weakness are formed by cutting the aerosol-forming material. The aerosol-forming material may be cut at the point of extrusion to form separate bodies. The aerosolforming material may be cut with a mesh, at least one wire, at least one knife or the like.

[0217] The separate bodies formed at the point of extrusion are reconnected, at least partially, when forming the compound body of the aerosol-forming element. The cutting and reconnection of the aerosolforming material results in the planes of weakness within the compound body of material.

[0218] In some examples, the planes of weakness are flat. In some examples, the planes of weakness are two-dimensional. In some examples, the planes of weakness extend in two directions, such as an axial direction (a direction parallel with the central axis of the aerosol-forming element) and a radial direction (a direction perpendicular to the central axis of the aerosol-forming element).

[0219] In some examples, the compound body of solid aerosol-forming material comprises two or more bodies of aerosol-forming material (which may be referred to as sub-bodies in some examples).

[0220] In some examples, the bodies are at least partially connected along the planes of weakness.

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[0222] 27

[0223] In some examples, the compound body of solid aerosol-forming material comprises two or more bodies of aerosol-forming material, wherein the two or more bodies are at least partially in contact along the planes of weakness.

[0224] In some examples, the bodies are joined at at least one point along the planes of weakness. In some examples, the bodies are separable.

[0225] Typically, there is not a continuous gap between the bodies. In some examples, there is a gap between parts of the bodies, such as a discontinuous gap between the bodies. In this way, a compound body is provided which includes the planes of weakness. A continuous gap may be formed between the bodies during use, along the planes of weakness.

[0226] In some examples, one or more planes of weakness define bodies of solid aerosol-forming material. In some examples, bodies are joined at one or more points along the planes of weakness. In some examples, bodies are joined along 10% or more of the planes of weakness, calculated on an area basis.

[0227] In some examples, the compound body comprises two or more bodies, such as four or more bodies, such as six or more bodies, such as eight or more bodies.

[0228] In some examples, the compound body comprises twelve or less bodies, such as ten or less bodies, such as eight or less bodies, such as six or less bodies, such as four or less bodies.

[0229] In some examples, the compound body comprises from two to twelve bodies, such as from four to ten bodies, such as from six to eight bodies.

[0230] In some examples, the aerosol-forming element is cylindrical.

[0231] In some examples, the bodies have the shape of a segment of a cylinder. In some examples, each of the bodies have substantially the same shape. In some examples, the cross-section of the bodies collectively appear to be segments of a cylinder, such as equal segments of a cylinder.

[0232] In some examples, the bodies each have the shape of a segment of a semi-cylinder or a quartercylinder.

[0233] In some examples, each of the bodies have substantially the same cross-sectional shape, optionally wherein each of the bodies have the shape of a segment of a cylinder.

[0234] In some examples, the aerosol-forming element comprises one or more channels extending from an upstream end of the aerosol-forming element to a downstream end of the aerosol-forming element. The channels may be present in addition to the planes of weakness. The one or more channels may be arranged such that a compound body of aerosol-forming element is present.

[0235] In some examples, the one or more channels are disposed at the perimeter of the aerosol-forming element. In some examples, the two or more channels, such as three or more, such as four or more, are disposed at the perimeter of the aerosol-forming element.

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[0237] 28

[0238] In some examples, the one or more channels are disposed at the centre of the aerosol-forming element. The channel may be a hollow bore.

[0239] In some examples, the bodies are each made of the same solid aerosol-forming material. That is, the aerosol-forming material has the same composition throughout the aerosol-forming element.

[0240] In some examples, the compound body of solid aerosol-forming material is or comprises an agglomeration of particles, such as an agglomeration of non-tobacco particles.

[0241] In some examples, the bodies have the same aerosol-forming material composition. In some examples, a first body and the second body include a solid aerosol-forming material comprising an agglomeration of particles. In examples where the solid aerosol-forming material comprises more than two bodies, each of the bodies may have the same composition. In these examples, each of the bodies may have a composition comprising an agglomeration of particles.

[0242] In some examples, the solid aerosol-forming material comprises non-tobacco particles, such as cellulose particles and / or tea particles as described above. The aerosol-forming material may comprise plant material. The non-tobacco particles may comprise plant material. The non-tobacco particles may be plant material.

[0243] The aerosol-forming material may be absent of tobacco and / or nicotine.

[0244] In some examples, the solid aerosol-forming material of the fifth aspect of the invention has any or any combination of the attributes of the precursor composition of the first aspect of the invention (e.g. (wt%) of non-tobacco particles relative to the total weight of the solid aerosol-forming material, wt% cellulose particles and wt% tea particles, relative amounts of cellulose particles and tea particles in the solid aerosol-forming material).

[0245] In some examples, the solid aerosol-forming material comprises a flavourant, such any flavourant or flavourant combination described in relation to the precursor composition of the first aspect of the invention.

[0246] In some examples, the solid aerosol-forming material comprises a humectant such any of the humectant or humectant combination described in relation to the precursor composition of the first aspect of the invention

[0247] In some examples, the solid aerosol-forming material comprises a binding agent, such any of the binding agent or binding agent combination described in relation to the precursor composition of the first aspect of the invention.

[0248] In some examples, the solid aerosol-forming material comprises a solvent such any of the solvent or solvent combination described in relation to the precursor composition of the first aspect of the invention.

[0249] In some examples, the solid aerosol-forming material has a composition according to Table 1 above.

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[0251] 29

[0252] The aerosol-forming material may comprise one or more additives selected from vapour generators, carrier agents, humectants, flavourants, fillers, aqueous / non-aqueous solvents and binders.

[0253] In some examples, the compound body of solid aerosol-forming material is disposed in an envelope.

[0254] In some examples, the envelope is arranged around the compound body of solid aerosol-forming material and extends along the axial length of the compound body of solid aerosol-forming material. In some examples, the envelope is arranged around the perimeter of the compound body of solid aerosolforming material. In some examples, the envelope is not disposed over the ends of the solid aerosolforming material.

[0255] In some examples, the compound body of solid aerosol-forming material is adhered to the inside surface of the envelope. The envelope may circumscribe the aerosol-forming material.

[0256] As used herein, the term “envelope” defines a covering or containing structure or layer. In some examples, during drying, the peripheral surface of the compound body adheres to the envelope. In some examples, an adhesive is used to adhere the peripheral surface of the compound body to the envelope. In some examples, a binder in the material which forms the solid aerosol precursor may provide or act as an adhesive. Adhesion of the body to the inside surface of the envelope maintains the arrangement of the body in the consumable.

[0257] In some examples, the envelope comprises a rigid material such as card. In some examples, the envelope is a rigid tube, such as a card tube. In some examples, the envelope is a wrapper. In these examples, the envelope comprises a less rigid, or flexible, material such as paper, foil or foil-paper laminate, The wrapper may have any attribute and / or be configured as described for the wrapper of the first aspect of the invention.

[0258] Any element(s) (e.g. filter elements), cooling elements), spacer elements)) downstream of the aerosol-forming material may be at least partially (e.g. entirely) circumscribed by the wrapping layer. Accordingly, the wrapping layer may alternatively be referred to as a ‘combining layer’. The wrapping layer may at least partially (e.g. entirely) circumscribe elements upstream of the terminal filter element.

[0259] The terminal filter element (at the downstream end of the article / consumable) may be joined to the upstream elements forming the article / consumable by a circumscribing tipping layer e.g. a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

[0260] Any elements) (e.g. filter elements), cooling element(s), spacer element(s)) may be further circumscribed by a respective plug wrap e.g. a paper plug wrap.

[0261] In a sixth aspect of the disclosure, there is provided a heat-not-burn consumable comprising the aerosol-forming element of the fifth aspect.

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[0263] 30

[0264] In a related aspect, there is provided a heat-not-burn consumable comprising an aerosol-forming element, wherein the aerosol-forming element comprises a compound body of aerosol-forming material, wherein the compound body of aerosol-forming material comprises one or more planes of weakness within the body, and wherein the planes of weakness are orientated substantially parallel with a flow path of the heat-not-burn consumable.

[0265] The present disclosure also provides a heat-not-burn consumable comprising an aerosol-forming element comprising a body of aerosol-forming material having one or more planes of weakness within the body, where during heating of the aerosol-forming element the body is configured to fracture along the one or more planes of weakness.

[0266] The present disclosure also provides a heat-not-burn consumable comprising an aerosol-forming element comprising a body of aerosol-forming material having one or more planes of weakness within the body, where during aerosol-formation the body fractures along the one or more planes of weakness.

[0267] The heat-not-burn consumable may comprise a filter element.

[0268] A “filter element” is defined as a porous element configured to remove one or more components of the fluid passing therethrough, e.g. solid particles from a liquid or gas passed through the filter.

[0269] The filter elements may be formed from materials including cellulose acetate, polypropylene tow, activated charcoal, paper, extruded plant material, and like materials. The filter elements may be circumscribed with a plug wrap, e.g. a paper plug wrap, to help maintain the form of the filter element.

[0270] The filter elements may be solid. The filter elements may be hollow bore filter elements comprising one or more bores extending longitudinally through the filter element. The filter elements may retain flavorant elements, such as granules, pellets, strips, capsules or other objects

[0271] The heat-not-burn consumable may comprise a supporting element.

[0272] As used herein, a “supporting element” relates to an element configured to provide support to the consumable, e.g. support the wrapping layer(s) of the consumable. The supporting element may be an inactive element insofar as it is configured not to generate a vapour, even if heated.

[0273] The supporting element may comprise an internal cavity. The internal cavity may be substantially empty and extend along the length of the cooling element to provide a substantially unrestricted air flow therethrough. The walls of the internal cavity may be substantially impermeable to aerosol such that the supporting element does not filter aerosol flowing therethrough. The internal cavity may define a mixing zone for aerosols therein. For instance, the turbulent flow resulting from pressure changes as air enters and exits the internal cavity can enhance aerosol mixing.

[0274] The supporting element may be provided in the form of a hollow tube, such that the internal cavity has a substantially constant cross-sectional area. The supporting element may have a high void fraction (cavity volume per total volume), for example having a porosity greater than 0.5, greater than 0.7, or greater than 0.9.

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[0276] 31

[0277] The supporting element may be formed of cardboard, paper, cellulose acetate, or other like material.

[0278] The supporting element may be configured to reduce the temperature of the aerosol generated during the heating process - and thus can be referred to as a “cooling element”. As the aerosol passes through the cooling element, the temperature of the aerosol can be reduced due to transfer of thermal energy to the cooling element. In particular, the cooling element has a large surface area and low resistance to draw compared to upstream and / or downstream sections of the consumable.

[0279] In a seventh aspect of the disclosure, there is provided an aerosol generating system comprising the consumable of the first or the sixth aspect and an aerosol generating unit.

[0280] In some examples, the aerosol generating unit includes a heating element. The heat element is configured to heat at least a part of the solid aerosol-forming material.

[0281] In some examples, the heating element is a penetrative heater configured to penetrate the aerosolforming element. The penetrative heater may penetrate the centre of the aerosol-forming element, such as the axial centre of the aerosol-forming element. The penetrative heater may penetrate along the planes of weakness of the solid aerosol-forming material. Particularly, in examples where the aerosol-forming element comprises a bodies separated by the panes of weakness, and the planes of weakness extend in a transverse direction from the central axis of the solid aerosol the aerosol-forming element to the perimeter of the aerosol-forming element, the penetrative heater may be located at the centre of the consumable. In some examples, the penetrative heater may be located along the central axis of the aerosol-forming element, and extend along the central axis. The penetrative heater may heat the aerosol-forming element by conductive heat transfer, and generate an aerosol which is inhaled by the user. Particularly, the use of a penetrative heater may be beneficial for, for example, influencing the airflow through the aerosol-forming element, which may be beneficial for improving the pressure drop across different consumables during use. The effect of the penetrative heater on the airflow may be dependent on, for example, the proximity of the heater to the aerosol-forming element and the density of the solid aerosol-forming material. Additionally, the use of a penetrative heater may reduce the need for cleaning of the consumable since the heater is enclosed within the aerosol-forming element.

[0282] The present disclosure may provide a method of generating an aerosol, which may implement any one or more features disclosed herein. The method may comprise heating the aerosol-forming element of the fifth aspect or the heat-not-burn consumable of the first or sixth aspect.

[0283] In an eight aspect of the disclosure, there is provided a use of aerosol-forming element of the fifth aspect to form an aerosol, where the aerosol-forming element fractures along the one or more planes of weakness.

[0284] During use, the aerosol-forming material may ‘shrink back’ and break along the planes of weakness. This may open up channels along the planes of weakness. Opening up the channels can reduce the

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[0286] 32 resistance to draw during a session and provide increased penetration of air flow through the aerosolforming element, especially towards the end of a session.

[0287] In use, such as during heating of the aerosol-forming element, the body may fracture along the one or more planes of weakness.

[0288] In use, such as during aerosol-formation from the aerosol-forming element, the body may fracture along the one or more planes of weakness.

[0289] In a ninth aspect of the disclosure there is provided a method of preparing an aerosol-forming element for a heat-not-burn consumable, the method comprising: forming a body of aerosol-forming material; dividing the body of aerosol-forming material into two or more bodies of aerosol-forming material; rejoining the two or more bodies of aerosol-forming material into a compound body of solid aerosol-forming material, the compound body comprising one or more planes of weakness within the body along the planes where the bodies are rejoined.

[0290] The present disclosure also provides an aerosol-forming element obtained or obtainable by the method of the ninth aspect.

[0291] In some examples, the step of forming a body of aerosol-forming material comprises extruding a body of aerosol-forming material. The aerosol-forming material may be extruded from a slurry. During extrusion, a slurry enters the extruder, is pressurised, and is forced to exit the extruder through a die. As the pressure is released from the slurry, the body of aerosol-forming material expands The extruder die typically has a diameter of about 6 mm. As the pressure is released from the slurry, the body of aerosol-forming material expands to about 6.95-7.00mm. The slurry may be extruded as a rod of material. In some examples, the body of aerosol-forming material is cylindrical.

[0292] The extrusion may be carried out using known extrusion equipment. The extruder may be a single or twin screw extruder. The extrusion may take place at elevated temperatures, to improve flowability of the slurry.

[0293] In some examples, the extruder has different sections, which are adapted to mix different types of ingredient (e.g., dry / wet) and transport (extrude) the aerosol-forming material slurry.

[0294] In some examples, materials are added at different points through the extruder. For example, the materials may be added in order of:

[0295] Dry powder (tea, cellulose, tobacco)

[0296] Binder / fixing agent (e.g., Guar gum)

[0297] Liquid solvents and aerosol formers (e.g., VG / PG + water)

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[0300] Liquid flavours (e.g., nicotine -10% cone, and flavours dissolved in VG)

[0301] In some examples, the extrusion may produce a continuous rod of aerosol-forming material.

[0302] The slurry may include less than 10-20 wt.% water, at point of extrusion. Alternatively, the slurry may include less than 10 wt.% water, at the point of extrusion. Typically, where the slurry includes less than 10 wt.% water a higher amount of other liquid components, such as humectants, are present. The water content of the slurry may be low, to increase viscosity for extrusion.

[0303] In some examples, the step of dividing the body of aerosol-forming material into two or more bodies uses a die or mandrel. The die or mandrel cut the body, such as an extruded body, to divide it into the bodies. The bodies are formed at point of extrusion by cutting the aerosol-forming material (e.g, with a wire / blade or mesh as described above), and the material then expands to close the gaps between the segments and form the planes of weakness. The outer circumference of the rod is adhered to the card tube / combining paper. In some examples, a rod of extrudate is formed and extruded over a mesh, to divide the rod into bodies.

[0304] The step of rejoining the two or more bodies may be passive or active. In a passive step, the bodies are allowed to come back into contact and rejoin as they move through the extrusion process. In an active step, the bodies are forced back into contact by a guide or mould. The guide or mould may push the bodies together to rejoin the bodies into a compound body.

[0305] In some examples, the bodies are rejoined when the bodies are wrapped in a combining paper. The wrapping of the bodies in a combining paper may cause the bodies to rejoin to form a compound body of aerosol-forming material.

[0306] In some examples, the bodies are rejoined when they are extruded into a card tube. The extrudate typically expands after extrusion, and so the expansion into the confined space of the card tube may causes the bodies to rejoin (e.g., as the extrudate expands).

[0307] Where the segments are divided and then ‘rejoined’ is weaker - and so this leads to the formation of the planes of weakness.

[0308] The process may include a further step of drying the aerosol-forming material. The aerosol-forming material may be dried continuously in line with the extruder. The aerosol-forming material may be dried immediately after extrusion. The material may be dried at from 40 to 60 °C. The drying may- remove water, but retain the majority of humectants within the aerosol-forming material.

[0309] In some examples, the aerosol-forming material is extruded directly into card tubes during consumable preparation.

[0310] In some examples, the method comprises extruding a slurry to form an extrudate, dividing the extrudate to form at least two extruded bodies, rejoining the at least two extruded bodies to form a compound body of solid aerosol-forming material comprising a plane of weakness.

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[0313] In some examples, the extrudate is divided to form at least two extruded bodies at a mouth of the extruder. A “mouth of the extruder” may be an aperture of the extruder from which the extrudate is expelled. In some examples, the extrudate is divided by a wire, wires or mesh located over the mouth of the extruder, where the pattern of the wire(s) / mesh defines the portions into which the extrudate is separated or divided. During the extrusion process, the slurry is introduced into the extruder and is forced out of the mouth of the extruder, past the mesh. As the slurry passes the mesh, the resulting extrudate is divided into at least two extruded bodies, the extruded bodies corresponding to the pattern of the mesh.

[0314] In some examples, a die of the extruder is adapted to divide the extrudate as it is expelled.

[0315] In some examples, extrusion and division of the extrudate to form at least two extruded bodies occur simultaneously. In other examples, the extrudate is divided to form at least two extruded bodies in a downstream process separate from the extrusion process.

[0316] In some examples, the slurry comprises dry ingredients and wet ingredients. In some examples, the dry ingredients and the wet ingredients are mixed using an extruder to form the slurry. The dry ingredients of the slurry may comprise a fibrous or particulate filler, such as cellulose and / or tea particles. The wet ingredients of the slurry may comprise humectant, flavourants, binding and / or thickening agents and solvent. The components are as described herein.

[0317] In some examples, the amount of fibrous or particulate filler in the slurry is about 50 wt%. In some examples, the slurry comprises non-tobacco particles in an amount as described herein in relation to the precursor material of the first aspect.

[0318] In some examples, the humectant includes glycerol (VG) and / or propylene glycol (PG). In some examples, the amount of humectant present in the slurry is as described herein in relation to the aerosolforming element composition of the first aspect.

[0319] In some examples, the amount of solvent present in the slurry is as described herein in relation to the aerosol-forming element of the first aspect. In some examples, the solvent is aqueous. In some examples, the solvent is water.

[0320] When the solvent content (for example, water content) is less than 10 wt% relative to the total weight of the slurry, this may require a higher amount of other wet ingredients in the slurry, such as an increased amount of humectant. A low solvent content may increase the viscosity of the slurry which may be advantageous for the extrusion process.

[0321] The extrusion process may be any extrusion process known to the skilled person. In some examples, the extrusion process may use a single screw extruder. In other examples, the extrusion process may use a twin-screw extruder.

[0322] In some examples, the wet and dry ingredients of the slurry are added to the extruder at different points in the extrusion process. For example, the ingredients may be introduced into the extruder at different

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[0324] 35 points along a barrel of the extruder. In this way, although the ingredients may be introduced into the extruder simultaneously in time, mixing of the ingredients may be staggered as it may take time for the most upstream ingredients to be transported along the barrel such that they can be mixed with the downstream ingredients. Upstream and downstream may be set in accordance with the direction of travel ofthe slurry in the extruder. In some examples, the raw materials of the slurry may be separated into dry ingredients and wet ingredients as the first and second portions of raw material. In some examples, the first portion comprises the dry ingredients and the second portion comprises the wet ingredients. In some examples, the second portion of raw material is added into the extrusion machine downstream of the first portion of raw material. In some examples, the first portion of raw material is added to the extrusion machine downstream of the second portion of raw material. This staggered approach may ensure complete mixing of the wet and dry ingredients separately. In some examples, such an approach may prevent or reduce or minimise blockages in the extruder.

[0325] In some examples, the first portion comprises dry ingredients and is added upstream of the second portion comprising wet ingredients. In such examples, the dry ingredients have time to mix independently of wet ingredients in the extrusion machine, before becoming mixed with the wet ingredients.

[0326] In some examples, the first portion comprises dry ingredients and is added downstream of the second portion comprising wet ingredients.

[0327] In some examples, the ingredients are introduced into the extruder in the following order, starting from the most upstream to the most downstream: filler, thickening and / or binding agent, solvent, humectant, and finally flavourant. In some examples, the solvent and humectant are added in the same portion.

[0328] In some examples, the slurry is extruded without any applied heat. That is, in some examples, the slurry is extruded at room temperature, which may be between 20-30°C such as 22-26°C. In some examples, the slurry is extruded at an elevated temperature. In this way, the flowability ofthe slurry may be improved. In some examples, the slurry is extruded at a reduced temperature (under cooling).

[0329] In some examples, the bodies are inserted into an envelope before rejoining and / or drying to form a compound body of solid aerosol-forming material. As used herein, the term “envelope” defines a covering or containing structure or layer. In some examples, during drying, the peripheral surface of the at least two extruded bodies adhere to the envelope. In some examples, an adhesive is used to adhere the peripheral surface of the at least two extruded bodies to the envelope. In some examples, a binder in the material which forms the solid aerosol precursor may provide or act as an adhesive. Adhesion to the inside surface of the envelope maintains the arrangement of the bodies in the consumable. In some examples, the envelope comprises a rigid material such as card. In some examples, the envelope is a rigid tube, such as a card tube.

[0330] In other examples, the at least two bodies are dried to form a compound body of aerosol-forming material comprising at least two bodies, before the body is encased in an envelope. In some examples,

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[0332] 36 the envelope is a wrapper. In these examples, the envelope comprises a less rigid material such as paper, foil or foil-paper laminate. In this way, leaching of water into the envelope may be reduced or avoided. Encasing the aerosol-forming element may be carried out by any method known to the skilled person. In some examples, the envelope may be a foil-paper laminate. In some examples, the envelope is paper. In some examples, the envelope comprises a single piece of wrapping which may be folded around the aerosol-forming material. In some examples, the envelope comprises two or more pieces of wrapping which may be used to spiral wrap the solid aerosol-forming material. Advantageously, spiral wrapping the aerosol-forming material may reduce the amount of overlap of the wrapping (compared with the single piece of wrapping) and so thickness control of the wrapping may be improved.

[0333] In some examples, drying the at least two bodies comprises heating the bodies at a temperature of up to 70 °C, such as up to 60 °C, such as up to 50 °C. In some examples, drying the at least two bodies comprises heating the extruded bodies at a temperature of at least 30°C, such as at least 35 °C or at least 40 °C. Any of these may be combined to form a suitable range. In some examples, drying the at least two bodies comprises heating the bodies to within a range of 40 to 70 °C, such as 40 to 60 °C, such as 40 to 50 °C. In this way, the solvent / water content of the extruded bodies may be reduced, whilst retaining the other components of the aerosol-forming material. In some examples, drying the at least two extruded bodies comprises drying the extruded bodies in line. In some examples, solvent / water content of the extrudate after drying is about 5 to 10 wt% relative to the total weight of the extrudate.

[0334] In some examples, forming (e.g., extruding), dividing and rejoining the bodies to form the aerosolforming element is a continuous process.

[0335] 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.

[0336] BRIEF DESCRIPTION OF THE FIGURES

[0337] 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.

[0338] Fig. 1 is a block system diagram showing an example aerosol generating apparatus.

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[0340] 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.

[0341] Fig. 3 is a schematic diagram showing an example implementation of the apparatus of Fig. 2.

[0342] Figs. 4A and 4B are schematic diagrams showing examples of the consumable of the apparatus of

[0343] Fig. 2.

[0344] Fig. 5 shows a schematic diagram of the cross section of an example solid aerosol precursor arrangement of the consumable of the apparatus of Fig. 2, where the solid aerosol precursor arrangement comprises two bodies.

[0345] Fig. 6 shows a schematic diagram of the cross section of an example solid aerosol precursor arrangement of the consumable of the apparatus of Fig. 2, where the solid aerosol precursor arrangement comprises three bodies.

[0346] Fig. 7 shows a schematic diagram of the cross section of an example solid aerosol precursor arrangement of the consumable of the apparatus of Fig. 2, where the solid aerosol precursor arrangement comprises four bodies.

[0347] Fig. 8 shows a schematic diagram of the cross section of an example solid aerosol precursor arrangement of the consumable of the apparatus of Fig. 2, where the solid aerosol precursor arrangement comprises eight bodies.

[0348] Fig. 9 shows a schematic diagram of the cross section of an example solid aerosol precursor arrangement of the consumable of the apparatus of Fig. 2, where the solid aerosol precursor arrangement comprises four bodies and where the gaps separating the bodies vary in width.

[0349] Fig. 10A shows a schematic diagram of an extrusion process, a step in the method of preparing a consumable, where the extrudate is not divided during the extrusion process.

[0350] Fig. 10B shows a schematic diagram of an extrusion process, a step in the method of preparing the consumable of the apparatus of Fig. 2, where the extrudate is divided during the extrusion process to form at least two extruded bodies.

[0351] Figs. 11 A and 11 B are schematic diagrams showing examples of a heat-not-burn consumable.

[0352] Fig. 12 shows a schematic diagram of the cross section of an example aerosol-forming element, where the solid aerosol-forming material comprises two bodies divided by a plane of weakness.

[0353] Fig. 13 shows a schematic diagram of the cross section of an example aerosol-forming element, where the solid aerosol-forming material comprises three bodies divided by three planes of weakness.

[0354] Fig. 14 shows a schematic diagram of the cross section of an example aerosol-forming element, where the solid aerosol-forming material comprises four bodies divided by four intersecting planes of weakness.

[0355] Fig. 15 shows a schematic diagram of the cross section of an example aerosol-forming element, where the solid aerosol-forming material comprises six bodies divided by six intersecting planes of weakness. Fig. 16 shows a schematic diagram of the cross section of an example aerosol-forming element, where the solid aerosol-forming material comprises four bodies divided by four intersecting planes of weakness, and includes a hollow bore in the centre.

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[0357] 38

[0358] Fig. 17 shows a schematic diagram of the cross section of an example aerosol-forming element, where the solid aerosol-forming material comprises four bodies divided by four intersecting planes of weakness, and includes four channels at the perimeter of the aerosol-forming element.

[0359] Fig. 18 shows a schematic diagram of an extrusion process, a step in the method of preparing a consumable, where the extrudate body is divided during the extrusion process to form multiple bodies, and is rejoined to form a compound body with planes of weakness.

[0360] DETAILED DESCRIPTION OF EMBODIMENTS

[0361] 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.

[0362] 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.

[0363] Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.

[0364] 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.

[0365] 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.

[0366] 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

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[0368] 39 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).

[0369] 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.

[0370] 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 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.

[0371] 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:

[0372] As used herein, an "aerosol generating apparatus" (or “electron ic(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.

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[0374] 40

[0375] 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).

[0376] 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.

[0377] 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.

[0378] As used herein, a “precursor” may include one or more of a: solid; 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.

[0379] As used herein, a "storage portion" may be a portion of the apparatus adapted to store the precursor.

[0380] 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.

[0381] 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.

[0382] 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.

[0383] P152693PC00 P01589

[0384] 41

[0385] 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.

[0386] 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.

[0387] 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.

[0388] 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. The consumable may include an information carrying medium. The capsule / pod may include a storage portion, e.g. a reservoir or tank, for storage of the precursor. 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.

[0389] 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).

[0390] As used herein “solid” refers to a state of matter. It may distinguish from liquid forms such as slurries or solutions, and gaseous forms. Semi-solid forms, such as gels or pastes, may be encompassed by “solid”.

[0391] As used herein “slurry” refers to a suspension of solid particles in liquid. It may distinguish from a solution, which has dissolved solute rather than suspended particles.

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[0393] 42

[0394] As used herein “water-independent binding and / or thickening agent” may refer to a binding and / or thickening agent which does not require water for activation. That is, the presence of water may not be required for the binding and / or thickening agent to increase the viscosity of precursor composition.

[0395] As used herein “about” in relation to a value should be interpreted to include a disclosure of the value mentioned e.g. “about 20%” includes a disclosure of exactly 20%. The value may include up to ±5% of the mentioned value, such as up to ±2% or up to ±1 % of the mentioned value.

[0396] 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 solid aerosol precursor arrangement 6 (or consumable), which in use is aerosolised by the aerosol generating unit 4 to generate an aerosol. The apparatus 1 includes a delivery system 8 for delivery of the aerosol to a user.

[0397] Electrical circuitry (not shown in figure 1) may be implemented to control the interoperability of the power supply 4 and aerosol generating unit 6.

[0398] 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.

[0399] 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.

[0400] In this example, the apparatus 1 includes a device body 50 and a consumable 70.

[0401] In this example, the body 50 includes the power supply 4 and a heating system 52. The heating system 52 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.

[0402] 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. The device body 50 may include a printed circuit board (PCB) 25 on which components of the electrical circuitry, memory, wireless interface, and other components may be mounted.

[0403] The wireless interface 60 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.

[0404] The other components) 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).

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[0406] 43

[0407] The body 50 is configured to engage with the consumable 70, in this example such that the at least one heating element 54 of the heating system 52 penetrates into the solid aerosol precursor arrangement 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 aerosol precursor arrangement 6 of the consumable (without combusting it) by conductive heat transfer, to generate an aerosol which is inhaled by the user. In other words, the heating element 54 heats the solid aerosol precursor arrangement 6 to a temperature lower than its combustion temperature such that an aerosol can be formed by evaporation, torrefaction and pyrolysis.

[0408] Fig. 3 shows an example implementation of the aerosol generating apparatus 1 of Fig. 2.

[0409] 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 aerosol precursor arrangement 6.

[0410] The consumable 70 includes the solid aerosol precursor arrangement 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 aerosol precursor arrangement 6 may be a reconstituted tobacco formulation.

[0411] In this example, the at least one heating element 54 is a penetrative heating element. Other heating element shapes are possible, e.g. the at least one heating element may be blade-shaped (with a rectangular transverse profile) or tube-shaped (e.g. with a hollow transverse profile). For example, the heating element 54 may be configured to at least partially encircle the consumable 70, such that when the heating element 54 is activated, heat is transferred radially inward from the heating element 54 to the solid aerosol precursor arrangement 6. This may be referred to as an ‘outside-in’ heating arrangement.

[0412] 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.

[0413] 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.

[0414] 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.

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[0416] 44

[0417] Other user interface devices are possible, e.g. to convey information haptically or audibly to a user. The lights 57 may be configured to convey information to the user regarding the state of the apparatus 1 and / or consumable. It will be appreciated that the input element(s) may be provided in various forms such as touch screens, switches, and sensors, and the output element(s) may be provided in various forms such as display screens, speakers, or a haptic output generated by a vibration generator.

[0418] 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.

[0419] 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.

[0420] 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.

[0421] Fig. 4 shows examples of the consumable of the apparatus of Fig. 2 in some examples.

[0422] Referring to Fig. 4A, a consumable 70, which may be implemented in any of the preceding examples, comprises a solid aerosol precursor arrangement 6 and a mouthpiece 71 downstream of the precursor arrangement 6 (also referred to as aerosol forming element. The solid aerosol precursor arrangement 6 has an upstream end 72 and a downstream end 73, defining the axial length of the precursor arrangement 6. The solid aerosol precursor arrangement 6 includes a first body 74 and a second body 75. A gap 76 extends along the entire axial length of the solid aerosol precursor arrangement 6 between the first 74 and second 75 bodies. In use, a user may engage the mouthpiece 71 to create an airflow through the consumable 70. In particular, the airflow may flow from the solid aerosol precursor arrangement 6 to the mouthpiece 71 along a flow path, and may exit from the consumable 70 at the mouthpiece 71 . Aerosol may be entrained into the airflow as the airflow flows through a portion of the flow path which is formed by the solid aerosol precursor arrangement 6.

[0423] The solid aerosol precursor arrangement 6 is disposed in an envelope 79. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 79 is arranged around the solid aerosol precursor arrangement 6 and extends along the axial length of the arrangement 6 such that the envelope 79 surrounds the whole of the arrangement.

[0424] The first 74 and second 75 bodies and the mouthpiece 71 are adhered to the envelope 79.

[0425] The gap 76 between the first 74 and second 75 bodies extends across the solid aerosol precursor arrangement 6, when viewed in cross-section, from a first region on the inside surface of the envelope

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[0427] 45

[0428] 79 to a second region on the inside surface of the envelope 79. The first region and second region are on opposite sides of the solid aerosol precursor arrangement 6.

[0429] The first 74 and second 75 bodies may have the same precursor composition. The precursor composition is as described herein and may comprise an agglomeration of particles. The precursor composition may comprise non-tobacco particles. The precursor composition may also or alternatively be substantially free of tobacco particles.

[0430] In this example, the mouthpiece 71 of the consumable 70 comprises a filter element 77. The airflow in use passes through the filter element 77 before exiting from the consumable 70 at the mouthpiece 71 , thereby removing particulates and preventing their inhalation by the user.

[0431] In this example, the consumable 70 comprises a hollow element 78 downstream of the solid precursor arrangement 6 and upstream of the mouthpiece 71. The hollow element 78 may function as a mixing container, allowing for cooling and mixing of the generated vapour from the precursor arrangement 6 and preventing overheating of the mouthpiece 71.

[0432] Referring to Fig. 4B, a consumable 70, which may be implemented in any of the preceding examples, comprises a solid aerosol precursor arrangement 6 and a mouthpiece 71 downstream of the precursor arrangement 6. The solid aerosol precursor arrangement 6 has an upstream end 72 and a downstream end 73, defining the axial length of the precursor arrangement 6.

[0433] The solid aerosol precursor arrangement 6 includes a first body 74, a second body 75 and a third body 710. A gap 76 extends along the entire axial length of the solid aerosol precursor arrangement 6 between the first 74 and second 75 bodies. A second gap 711 extends along the entire axial length of the solid aerosol precursor arrangement 6 between the second 75 and third 710 bodies. Although not shown, a third gap extends along the entire axial length of the solid aerosol precursor 6 between the third 710 and first 74 bodies.

[0434] In this example, the solid aerosol precursor arrangement 6 is disposed in an envelope 79. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 79 is arranged around the solid aerosol precursor arrangement 6 and extends along the axial length of the arrangement 6 such that the envelope 79 surrounds the whole of the arrangement.

[0435] The first 74 and second 75 bodies may be adhered to the envelope 79.

[0436] The gap 76 between the first 74 and second 75 bodies and the second gap between the second 75 and third 710 bodies (and the third gap between the third 710 and first 74 bodies that is not shown) also extend across the solid aerosol precursor arrangement 6 from a first region on the inside surface of the

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[0438] 46 envelope 79 to a second region on the inside surface of the envelope 79. The first region and second region are on opposite sides of the solid aerosol precursor arrangement 6.

[0439] The first 74 and second 75 bodies may have the same precursor composition. The precursor composition is as described herein and may comprise an agglomeration of particles. The precursor composition may comprise non-tobacco particles. The precursor composition may also be substantially free of tobacco particles.

[0440] In this example, the mouthpiece 71 of the consumable 70 comprises a filter element 77. In use, a user may engage the mouthpiece 71 to create an airflow through the consumable 70. In particular, the airflow may flow from the solid aerosol precursor arrangement 6 to the mouthpiece 71 , and may exit from the consumable 70 at the mouthpiece 71 . Therefore, when the mouthpiece 71 comprises a filter element 77, the airflow may pass through the filter element 77 before exiting from the consumable 70 at the mouthpiece 71 , thereby removing particulates and preventing their inhalation by the user.

[0441] In this example, the consumable 70 further comprises a hollow element 78 downstream of the solid precursor 6 and upstream of the mouthpiece 71. In this example, the hollow element 78 contains a frangible capsule 712 which is held in position adjacent the mouthpiece 71 by a support structure 713. The frangible capsule 712 may be heat activated or mechanically activated in order to release the contents of the capsule to deliver flavour to the user during use. In this example, the support structure 713 is a paper roll.

[0442] Figs. 5 to 9 show cross sections of example solid aerosol precursor arrangements. In each of these examples, the bodies of each solid aerosol precursor arrangement may have the same precursor composition. The precursor composition is as described herein and may comprise an agglomeration of particles. The precursor composition may comprise non-tobacco particles. The precursor composition may also or alternatively be substantially free of tobacco particles.

[0443] Referring to Fig. 5, the solid aerosol precursor arrangement 6 comprises a first body 74 and a second body 75 and a gap 76 between the first 74 and second 75 body. The first 74 and second 75 body each have the shape of a semi-cylinder. Therefore, in this example, the solid aerosol precursor arrangement 6 has an overall shape of a cylinder.

[0444] In this example, the solid aerosol precursor arrangement 6 is disposed in an envelope 79. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 79 is arranged around the solid aerosol precursor arrangement 6 and extends along the axial length of the arrangement 6 such that the envelope 79 surrounds the whole of the arrangement.

[0445] The first 74 and second 75 bodies are adhered to the envelope 79 and are held by the envelope 79 so that the solid aerosol precursor arrangement 6 has an overall shape of a cylinder. Additionally, adhering

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[0447] 47 the first 74 and second 75 bodies to the envelop 79 maintains the gap 76 between the first 74 and second 75 bodies is maintained.

[0448] The gap 76 between the first 74 and second 75 bodies also extends across the solid aerosol precursor arrangement 6 from a first region 715 on the inside surface of the envelope 79 to a second region 716 on the inside surface of the envelope 79.

[0449] Referring to Fig. 6, the solid aerosol precursor arrangement 6 comprises a first body 74, a second body 75 and a third body 710. The solid aerosol precursor arrangement 6 also comprises a gap 76 between the first 74 and second 75 bodies, a second gap 71 1 between the second 75 and third 710 bodies, and a third gap 717 between the third 710 and first 74 bodies. In this example, the solid aerosol precursor arrangement 6 has an overall shape of a cylinder. In this example, the solid aerosol precursor arrangement 6 is disposed in an envelope 79. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 79 is arranged around the solid aerosol precursor arrangement 6 and extends along the axial length of the arrangement 6 such that the envelope 79 surrounds the whole of the arrangement. The bodies 74, 75, 710 may be adhered to the envelope 79. In this way, the first 76, second 711 and third 717 gaps between the bodies may be maintained. The first 76, second 711 and third 717 gaps extend in different transverse directions from the central axis 714 of the solid aerosol precursor arrangement 6 to the envelope 79. In this example, the width of each gap along the transverse direction from the central axis to the envelope 79 is constant.

[0450] Referring to Fig. 7, the solid aerosol precursor arrangement 6 comprises a first body 74, a second body 75, a third body 710 and a fourth body 718. The solid aerosol precursor arrangement 6 also comprises a gap 76 between the first 74 and second 75 bodies, a second gap 71 1 between the second 75 and third 710 bodies, a third gap 717 between the third 710 and fourth 718 bodies and a fourth gap 719 between the fourth 718 and first 74 bodies. The first 74, second 75, third 710 and fourth 718 bodies each have the shape of a quarter-cylinder. Therefore, in this example, the solid aerosol precursor arrangement 6 has an overall shape of a cylinder. In this example, the solid aerosol precursor arrangement 6 is disposed in an envelope 79. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 79 is arranged around the solid aerosol precursor arrangement 6 and extends along the axial length of the arrangement 6 such that the envelope 79 surrounds the whole of the arrangement. The bodies 74, 75, 710, 718 may be adhered to the envelope 79. In this way, the first 76, second 711 , third 717 and fourth 719 gaps may be maintained. The first 76, second 71 1 , third 717 and fourth 719 gaps extend in different transverse directions from the central axis of the solid aerosol precursor arrangement 6 to the envelope 79 to result in a “cross” shape. In this example, the width of each gap along the transverse direction from the central axis to the envelope 79 is constant.

[0451] P152693PC00 P01589

[0452] 48

[0453] Referring to Fig. 8, the solid aerosol precursor arrangement 6 comprises eight bodies and eight gaps, where the gaps extend between the bodies. In this example, the solid aerosol precursor arrangement 6 has an overall shape of a cylinder. In this example, the solid aerosol precursor arrangement 6 is disposed in an envelope 79. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 79 is arranged around the solid aerosol precursor arrangement 6 and extends along the axial length of the arrangement 6 such that the envelope 79 surrounds the whole of the arrangement. The bodies may be adhered to the envelope 79. In this way, the gaps between the bodies may be maintained. The gaps extend in different transverse directions from the central axis of the solid aerosol precursor arrangement 6 to the envelope 79 to results in an “asterisk” shape. In this example, the width of each gap along the transverse direction from the central axis to the envelope 79 is constant.

[0454] Referring to Fig. 9, the solid aerosol precursor arrangement 6 comprises a first body 74, a second body

[0455] 75, a third body 710 and a fourth body 718. The solid aerosol precursor arrangement 6 also comprises a gap 76 between the first 74 and second 75 bodies, a second gap 71 1 between the second 75 and third 710 bodies, a third gap 717 between the third 710 and fourth 718 bodies and a fourth gap 719 between the fourth 718 and first 74 bodies. In this example, the solid aerosol precursor arrangement 6 has an overall shape of a cylinder. In this example, the solid aerosol precursor arrangement 6 is disposed in an envelope 79. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 79 is arranged around the solid aerosol precursor arrangement 6 and extends along the axial length of the arrangement 6 such that the envelop 79 surrounds the whole of the arrangement. The bodies 74, 75, 710, 718 may be adhered to the envelope 79. In this way, the first 76, second 711 , third 717 and fourth 719 gaps may be maintained. The first

[0456] 76, second 711 , third 717 and fourth 719 gaps extend in different transverse directions from the central axis of the solid aerosol precursor arrangement 6 to the envelope 79. In this example, the width of each gap along the transverse direction decreases from the central axis towards the envelope 79. In other words, each gap is wider at the central axis of the solid aerosol precursor arrangement 6 and narrower at the envelope 79. The width of the gaps at the envelope 79 may be such that the bodies are in contact at the envelope.

[0457] Fig. 10 shows schematic diagrams of an extrusion process, which may be used in a step in the method of preparing the consumable of Fig. 4.

[0458] Referring to Fig. 10A an extruder 80 is used to extrude the precursor slurry to form an extrudate 81 . In this example, the extrudate 81 is cylindrical and unitary. The cylindrical shape of the extrudate 81 may be imparted by the shape of the mouth 82 of the extruder, or by a die. Other shapes of extrudate 81 are possible and known to the skilled person. That is, the cylindrical extrudate 81 is not divided into at least two extruded bodies. In this case, separation of the extrudate 81 to form at least two extruded bodies may be achieved in a downstream process separate from the extrusion process. The extruded bodies are then dried to form a solid aerosol precursor arrangement 6 comprising at least two bodies

[0459] P152693PC00 P01589

[0460] 49

[0461] 74, 75, before being assembled into a consumable 70 for an aerosol generating apparatus. Assembly of the at least two bodies 74,75 into a consumable may involve adhering the bodies to an envelope 79, such that a gap or gaps between the at least two bodies 74, 75 and the overall cylindrical shape of the solid aerosol precursor arrangement is maintained.

[0462] Referring to Fig. 10B an extruder 80 is used to extrude the precursor slurry to form an extrudate 81 . In this example, the extrudate 81 is cylindrical. The cylindrical shape of the extrudate 81 may be imparted by the shape of the mouth 82 of the extruder 80, or by a die. Other shapes of extrudate 81 are possible and known to the skilled person. In this example, a mesh 83 is located over the mouth 82 of the extruder 80. This results in a cylindrical extrudate 81 which is divided to form at least two extruded bodies 84. In this example, the division occurs at the point the extrudate 81 is expelled from the mouth 82 of the extruder 80. During the extrusion process, the precursor slurry is introduced into the extruder 80 and is forced out of the mouth 82 of the extruder 80, past the mesh 83. As the slurry passes the mesh 83, the resulting cylindrical extrudate 81 is divided into at least two extruded bodies 84, the extruded bodies corresponding to the pattern of the mesh. In this example, the extrudate 81 is divided into four extruded bodies 84. Each extruded body 84 has the shape of a quarter cylinder. In this example, the extruded bodies 84 are then dried to form a solid aerosol precursor arrangement 6 comprising at least two bodies 74, 75 as described above, before being assembled into a consumable 70 for an aerosol generating apparatus. Assembly of the at least two bodies 74, 75 into a consumable may involve adhering the bodies to an envelope 79, such that a gap or gaps between the at least two bodies 74, 75 and the overall cylindrical shape of the solid aerosol precursor arrangement is maintained.

[0463] The provision of at least two bodies in the solid aerosol precursor arrangement 6 may provide an air flow route through the precursor arrangement 6 since the bodies may be arranged so as to provide gaps between the bodies as described herein.

[0464] Referring to Fig. 11A, a consumable 170 comprises an aerosol-forming element 106 and a mouthpiece 171 downstream of the aerosol-forming element 106. The aerosol-forming element 106 has an upstream end 172 and a downstream end 173, defining the axial length of the aerosol-forming element 106. The aerosol-forming element 106 may alternatively be referred to as solid aerosol precursor arrangement. The aerosol-forming element 106 includes a compound body of a solid aerosol-forming material 174, formed of partially connected bodies. A plane of weakness 176 extends along the entire axial length of the aerosol-forming element 106 between the bodies. In use, a user may engage the mouthpiece 171 to create an airflow through the consumable 170. In particular, the airflow may flow from the solid aerosol-forming element 106 to the mouthpiece 171 along a flow path, and may exit from the consumable 170 at the mouthpiece 171. Aerosol may be entrained into the airflow as the airflow flows through a portion of the flow path which is formed by the aerosol-forming element 106.

[0465] The aerosol-forming element 106 is disposed in an envelope 179. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 179 is

[0466] P152693PC00 P01589

[0467] 50 arranged around the aerosol-forming element 106 and extends along the axial length of the aerosolforming material 106 such that the envelope 179 surrounds the whole of the material.

[0468] The compound body of solid aerosol-forming material 174 and the mouthpiece 171 are adhered to the envelope 179.

[0469] The plane of weakness 176 between the bodies of the solid aerosol-forming material 174 extends across the aerosol-forming element 106, when viewed in cross-section, from a first region on the inside surface of the envelope 179 to a second region on the inside surface of the envelope 179. The first region and second region are on opposite sides of the aerosol-forming element 106.

[0470] The solid aerosol-forming material has the same composition either side of the plane of weakness 176. The solid aerosol-forming material is as described herein and may comprise an agglomeration of particles. The solid aerosol-forming material may comprise non-tobacco particles. The solid aerosolforming material may also or alternatively be substantially free of tobacco particles.

[0471] In this example, the mouthpiece 171 of the consumable 170 comprises a filter element 177. The airflow in use passes through the filter element 177 before exiting from the consumable 170 at the mouthpiece 171 , thereby removing particulates and preventing their inhalation by the user.

[0472] In this example, the consumable 170 comprises a hollow element 178 downstream of the aerosolforming element 106 and upstream of the mouthpiece 171. The hollow element 178 may function as a mixing container, allowing for cooling and mixing of the generated vapour from the aerosol-forming element 106 and preventing overheating of the mouthpiece 171 .

[0473] Referring to Fig. 11 B, a consumable 170, which may be implemented in any of the preceding examples, comprises an aerosol-forming element 106 and a mouthpiece 171 downstream of the aerosol-forming element 106. The aerosol-forming element 106 has an upstream end 172 and a downstream end 173, defining the axial length of the aerosol-forming element 106. The aerosol-forming element 106 may alternatively be referred to as solid aerosol precursor arrangement.

[0474] The aerosol-forming element 106 includes a solid aerosol-forming material, including at least partially connected bodies 174, 175, 910 (which may also be referred to as ‘sub-bodies’). A plane of weakness 176 extends along the entire axial length of the aerosol-forming element 106 between the bodies 174, 175 of the aerosol-forming material. A second plane of weakness 911 extends along the entire axial length of the solid aerosol-forming element 106 between the bodies of the aerosol-forming material 175, 910. Although not shown, a third plane of weakness extends along the entire axial length of the solid aerosol-forming element 106 between the bodies of the aerosol-forming material 910, 174.

[0475] P152693PC00 P01589

[0476] 51

[0477] In this example, the aerosol-forming element 106 is disposed in an envelope 179. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 179 is arranged around the aerosol-forming element 106 and extends along the axial length of the element 106 such that the envelope 179 surrounds the whole of the solid aerosol-forming material.

[0478] The compound body of solid aerosol-forming material formed of the at least partially connected bodies 174, 175, 910 may be adhered to the envelope 179.

[0479] The plane of weakness 176 between the first 174 and second 175 bodies and the second plane of weakness between the second 175 and third 910 bodies (and the third plane of weakness between the third 910 and first 174 bodies that is not shown) also extend across the aerosol-forming element 106 from a first region on the inside surface of the envelope 179 to a common central point in the aerosolforming material.

[0480] The bodies 174, 175, 910 of the aerosol-forming material may have the same composition. The solid aerosol-forming material is as described herein and may comprise an agglomeration of particles. The solid aerosol-forming material may comprise non-tobacco particles. The solid aerosol-forming material may also be substantially free of tobacco particles.

[0481] In this example, the mouthpiece 171 of the consumable 170 comprises a filter element 177. In use, a user may engage the mouthpiece 171 to create an airflow through the consumable 170. In particular, the airflow may flow from the aerosol-forming element 106 to the mouthpiece 171 , and may exit from the consumable 170 at the mouthpiece 171. Therefore, when the mouthpiece 171 comprises a filter element 177, the airflow may pass through the filter element 177 before exiting from the consumable 170 at the mouthpiece 171 , thereby removing particulates and preventing their inhalation by the user.

[0482] In this example, the consumable 170 further comprises a hollow element 178 downstream of the solid aerosol-forming element 106 and upstream of the mouthpiece 171 . In this example, the hollow element 178 contains a frangible capsule 912 which is held in position adjacent the mouthpiece 171 by a support structure 913. The frangible capsule 912 may be heat activated or mechanically activated in order to release the contents of the capsule to deliver flavour to the user during use. In this example, the support structure 913 is a paper roll.

[0483] Figs. 12 to 17 show cross sections of example aerosol-forming elements 106. The aerosol-forming elements 106 may alternatively be referred to as solid aerosol precursor arrangement. In each of these examples, the solid aerosol-forming material of each aerosol-forming elements may have the same composition. The solid aerosol-forming material is as described herein and may comprise an agglomeration of particles. The solid aerosol-forming material may comprise non-tobacco particles. The solid aerosol-forming material may also or alternatively be substantially free of tobacco particles.

[0484] P152693PC00 P01589

[0485] 52

[0486] Referring to Fig. 12, the aerosol-forming element 106 comprises a compound body of solid aerosolforming material including a first body 174 and a second body 175 and a plane of weakness 176 between the first 174 and second 175 bodies. The first 174 and second 175 bodies each have the shape of a semi-cylinder. Therefore, in this example, the aerosol-forming element 106 has an overall shape of a cylinder.

[0487] In this example, the aerosol-forming element 106 is disposed in an envelope 179. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 179 is arranged around the aerosol-forming element 106 and extends along the axial length of the aerosol-forming element 106 such that the envelope 179 surrounds the whole of the element 106. The first 174 and second 175 bodies are adhered to the envelope 79 and are held by the envelope 79 so that the aerosol-forming element 106 has an overall shape of a cylinder.

[0488] The plane of weakness 176 between the first 174 and second 175 bodies also extends across the aerosol-forming element 106 from a first region 915 on the inside surface of the envelope 79 to a second region 916 on the inside surface of the envelope 179.

[0489] Referring to Fig. 13, the aerosol-forming element 106 comprises a solid aerosol-forming material comprising a composite body including a first body 174, a second body 175 and a third body 910. The aerosol-forming element 106 also comprises a plane of weakness 176 between the first 174 and second 175 bodies, a second plane of weakness 911 between the second 175 and third 910 bodies, and a third plane of weakness 917 between the third 910 and first 174 bodies. In this example, the aerosol-forming element 106 has an overall shape of a cylinder. In this example, the aerosol-forming element 106 is disposed in an envelope 179. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 179 is arranged around the aerosol-forming element 106 and extends along the axial length of the element 106 such that the envelope 179 surrounds the perimeter of the element. The bodies 174, 175, 910 may be adhered to the envelope 179. The first 176, second 911 and third 917 planes of weakness extend in different transverse directions from the central axis 914 of the aerosol-forming element 106 to the envelope 179. In this example, the bodies 174, 175, 910 are in contact along substantially the full length of the planes of weakness. The planes of weakness are consistent throughout the aerosol-forming element.

[0490] Referring to Fig. 14, the aerosol-forming element 106 comprises a solid aerosol-forming material comprising a composite body including a first body 174, a second body 175, a third body 910 and a fourth body 918. The aerosol-forming element 106 also comprises a plane of weakness 176 between the first 174 and second 175 bodies, a second plane of weakness 911 between the second 175 and third 910 bodies, a third plane of weakness 917 between the third 910 and fourth 918 bodies and a fourth plane of weakness 919 between the fourth 918 and first 174 bodies. The first 174, second 175, third 910 and fourth 918 bodies each have the shape of a quarter-cylinder. Therefore, in this example, the aerosol-forming element 106 has an overall shape of a cylinder. In this example, the aerosol-

[0491] P152693PC00 P01589

[0492] 53 forming element 106 is disposed in an envelope 179. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 179 is arranged around the aerosol-forming element 106 and extends along the axial length of the element 106. The compound body of solid aerosol-forming material including bodies 174, 175, 910, 918 may be adhered to the envelope 179. The first 176, second 911 , third 917 and fourth 919 planes of weakness include voids 921 between the bodies. The bodies are partially connected along the planes of weakness, but also include voids 921 where the bodies are not connected. The first 176, second 911 , third 917 and fourth 919 planes of weakness extend in different transverse directions from the central axis of the aerosolforming element 106 to the envelope 179 to result in a “cross” shape in the cross-section. In this example, the distribution of the planes of weakness is circularly symmetrical around the central axis of the aerosol-forming element.

[0493] Referring to Fig. 15, the aerosol-forming element 106 comprises six bodies making up the compound body of solid aerosol-forming material, and six planes of weakness, where the planes of weakness extend between the bodies. In this example, the aerosol-forming element 106 has an overall shape of a cylinder. In this example, the aerosol-forming element 106 is disposed in an envelope 179. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 179 is arranged around the aerosol-forming element 106 and extends along the axial length of the element 106. The bodies may be adhered to the envelope 179. Some of the bodies are in contact over the whole area of the planes of weakness. Some other of the bodies are in partial contact over part of the planes of weakness, and include voids 921 over part of the plane of weakness.

[0494] The planes of weakness extend in different transverse directions from the central axis of the aerosolforming element 106 to the envelope 179 to result in an “asterisk” shape.

[0495] Referring to Fig. 16, the aerosol-forming element 106 comprises a compound body of aerosol-forming material including a body 174, a second body 175, a third body 910 and a fourth body 918. The aerosolforming element 106 also comprises a plane of weakness 176 between the first 174 and second 175 bodies, a second plane of weakness 911 between the second 175 and third 910 bodies, a third plane of weakness 917 between the third 910 and fourth 918 bodies and a fourth plane of weakness 919 between the fourth 918 and first 174 bodies. In this example, the aerosol-forming element 106 has an annular shape, including a hollow bore 923. In this example, the aerosol-forming element 106 is disposed in an envelope 179. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 179 is arranged around the aerosol-forming element 106 and extends along the axial length of the element 106. The bodies 174, 175, 910, 918 may be adhered to the envelope 179. The first 176, second 91 1 , third 917 and fourth 919 planes of weakness are arranged symmetrically around the central axis of the aerosol-forming element. In this example, the bodies along one of the planes of weakness are in contact over the whole area of the plane of weakness, but the bodies along three of the planes of weakness are in partial contact, and

[0496] P152693PC00 P01589

[0497] 54 include voids 921 along the plane of weakness where the bodies are not in full contact. In addition, a hollow bore 923 is present at the centre axis of the aerosol-forming element. The hollow bore is cylindrical and extends from an upstream end to a downstream end of the aerosol-forming element. The first 176, second 911 , third 917 and fourth 919 planes of weakness extend in different transverse directions from the perimeter of the hollow bore 923 to the envelope 179.

[0498] Referring to Fig. 17, the aerosol-forming element 106 comprises a compound body of aerosol-forming material including a body 174, a second body 175, a third body 910 and a fourth body 918. The aerosolforming element 106 also comprises a plane of weakness 176 between the first 174 and second 175 bodies, a second plane of weakness 911 between the second 175 and third 910 bodies, a third plane of weakness 917 between the third 910 and fourth 918 bodies and a fourth plane of weakness 919 between the fourth 918 and first 174 bodies. In this example, the aerosol-forming element 106 has an overall shape of a cylinder, with sections of the cylinder removed at the perimeter to form four channels 924. One channel 924 is present in each of the four bodies. In this example, the aerosol-forming element 106 is disposed in an envelope 179. The envelope may comprise a rigid material such as card, or a less rigid material such as a foil-paper laminate. The envelope 179 is arranged around the aerosolforming element 106 and extends along the axial length of the element 106. The bodies 174, 175, 910,

[0499] 918 may be adhered to the envelope 179, around where the channels 924 are present. The first 176, second 91 1 , third 917 and fourth 919 planes of weakness are arranged symmetrically around the central axis of the aerosol-forming element. In this example, the bodies along one of the planes of weakness are in contact over the whole area of the plane of weakness, but the bodies along three of the planes of weakness are in partial contact, and include voids 921 along the plane of weakness where the bodies are not in full contact. In addition, the channels 924 are distributed equally around the axis of the aerosol-forming element, adjacent to the envelope 179. The first 176, second 911 , third 917 and fourth

[0500] 919 planes of weakness extend in different transverse directions from the perimeter of the hollow bore 923 to the envelope 179.

[0501] An aerosol-forming element may as shown in any of Figures 1 1 to 17 may be generated using an extrusion process, and for example using an extruder as shown in Fig. 10A.

[0502] As described in relation to that Figure, separation of the extrudate 18 to form at least two bodies may be achieved in a downstream process separate from the extrusion process. The extruded bodies may then then dried to form an aerosol-forming element 106 comprising at least two bodies 174, 175 joined by a plane of weakness, before being assembled into a consumable 170 for an aerosol generating apparatus. Assembly into a consumable may involve adhering the bodies to an envelope 179, which gathers the bodies together whilst maintaining the plane of weakness between the bodies.

[0503] Fig. 18 shows schematic diagrams of the extrusion process, a step in the method of preparing an example consumable.

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[0505] 55

[0506] Referring to Fig. 18B an extruder 80 is used to extrude a slurry to form an extrudate 81 . In this example, the extrudate 81 is cylindrical. The cylindrical shape of the extrudate 81 may be imparted by the shape of the mouth 82 of the extruder 80, or by a die. Other shapes of extrudate 81 are possible and known to the skilled person. In this example, a pair of wires 83 are orientated orthogonal to each other are located over the mouth 82 of the extruder 180. This results in a cylindrical extrudate 81 which is divided to form four bodies 84 or sections. In this example, the division occurs at the point the extrudate 81 is expelled from the mouth 82 of the extruder 80. During the extrusion process, the slurry is introduced into the extruder 80 and is forced out of the mouth 82 of the extruder 180, past the pair of wires 83. As the slurry passes the pair of wires 83, the resulting cylindrical extrudate 81 is divided into four subbodies 84, the extruded bodies corresponding to the pattern of the pair of wires 83. Each body 84 has the shape of a quarter cylinder. In this example, the bodies 84 are then rejoined together to form a compound body of aerosol-forming material including four planes of weakness between the four bodies, before being assembled into a consumable 170 for an aerosol generating apparatus. Assembly into a consumable may involve adhering the compound body into an envelope 179. In this step, the bodies are gathered together whilst maintaining the plane of weakness between the bodies.

[0507] In some examples, the extrudate may be divided using any arrangement of wires or cutters. The arrangement of wires or cutters may be a mesh.

[0508] The provision of the planes of weakness in the aerosol-forming element 106 may allow the compound body to fracture into separate bodies during use, as the moisture content and volatile content of the aerosol-forming material is reduced during heating and vaporisation. The intentional fracturing along the planes of weakness is controlled, meaning the aerosol-forming element does not warp the consumable and is retained within the consumable during use (e.g., by adhesion to the envelope).

[0509] P152693PC00

Claims

1. P0158956CLAIMS1 . A consumable for use with an aerosol generating apparatus comprising: a solid aerosol precursor arrangement; and a mouthpiece downstream of the solid aerosol precursor arrangement, the solid aerosol precursor arrangement having an axial length extending from an upstream end to a downstream end of the solid aerosol precursor arrangement, wherein the solid aerosol precursor arrangement includes a plurality of bodies including a first body and a second body; wherein:(i) the bodies are separated by a plane of weakness, and wherein the plane of weakness is orientated substantially parallel to a flow path of the consumable; or(ii) a gap is formed between the first body and the second body and the gap extends along the entire axial length of the solid precursor arrangement.

2. The consumable of claim 1 , wherein the first body and the second body each have the shape of a cylinder segment.

3. The consumable of any one of claim 1 or claim 2, wherein the solid aerosol precursor arrangement further includes a third body, wherein a second gap or plane of weakness is formed between the second body and the third body and a third gap or plane of weakness is formed between the third body and the first body, wherein the second gap and the third gap, or the second plane of weakness and third plane of weakness extend along the entire axial length of the solid aerosol precursor arrangement, or wherein the solid aerosol precursor arrangement further includes a third body and a fourth body, wherein a second gap or plane of weakness is formed between the second body and the third body, a third gap or plane of weakness is formed between the third body and the fourth body, and a fourth gap or plane of weakness is formed between the fourth body and the first body, wherein the second, third and fourth gap, or the second, third and fourth zone of weakness, extend along the entire axial length of the solid precursor arrangement, optionally wherein the third body and the fourth body each have the shape of a quarter-cylinder.

4. The consumable of any one of claims 1 to 3, wherein the solid aerosol precursor arrangement is disposed in an envelope, wherein the envelope is arranged around the solid aerosol precursor arrangement and extends along the axial length of the solid aerosol precursor arrangement, optionally wherein bodies are adhered to the inside surface of the envelope.P152693PC00P01589575. The consumable of claim 4, wherein the gap or plane of weakness extends across the solid aerosol precursor arrangement from a first region on the inside surface of the envelope to a second region on the inside surface of the envelope, wherein the first region and the second region are on opposite sides of the solid aerosol precursor arrangement.

6. The consumable of claim 4, wherein the solid aerosol precursor arrangement has a central axis extending along the axial length of the solid aerosol precursor arrangement, wherein the gap or plane of weakness extends in a first transverse direction from the central axis to the inside surface of the envelope, wherein a second gap or plane of weakness extends in a second transverse direction from the central axis to the inside surface of the envelope, and wherein the first transverse direction is different from the second transverse direction.

7. The consumable of any preceding claim comprising at least one plane of weakness, wherein the plane(s) of weakness have an ultimate tensile strength which is less than the ultimate tensile strength of the aerosol-forming material.

8. The consumable of claim 7, wherein the plane(s) of weakness have an ultimate tensile strength which is 90% or less than the ultimate tensile strength of the aerosol-forming material, such as 80% or less, such as 60% or less, such as 40% or less, such as 20% or less.

9. The consumable of any preceding claim comprising: at least one plane of weakness, wherein the one or more planes of weakness comprise voids, such as a series of voids, and / or at least one gap comprising an air gap, wherein the air gap allows for airflow inside the gap and between the bodies.

10. The consumable of any preceding claim comprising at least one plane of weakness, wherein the plane(s) of weakness include a greater concentration of voids than a bulk of the aerosol-forming material, where concentration is determined on a volume basis, optionally wherein the concentration of voids at the planes of weakness is 10% or more greater than the concentration of voids in the bulk of the aerosol-forming material, such as 20% or more, such as 30% or more, such as 50% or more.

11. The consumable of any preceding claim comprising at least one plane of weakness, wherein the solid aerosol-forming material comprises a fibrous filler, wherein the fibrous filler does not extend across the plane(s) of weakness, optionally wherein fibres of the fibrous filler terminate at the plane(s) of weakness.P152693PC005812. The consumable of any preceding claim comprising at least one plane of weakness, wherein the one or more plane(s) of weakness extend from an upstream end of the aerosol-forming element to a downstream end of the aerosol-forming element, and / or the one or more planes of weakness extend across the radial width of the aerosol-forming element.

13. The consumable of any preceding claim comprising at least one plane of weakness, wherein the solid aerosol precursor arrangement comprises a compound body comprising four or more bodies, such as six or more bodies, such as eight or more bodies.

14. The consumable of any preceding claim, wherein each of the bodies have substantially the same cross-sectional shape, optionally wherein each of the bodies has the shape of a segment of a cylinder.

15. The consumable of any preceding claim, wherein the solid aerosol precursor arrangement comprises one or more channels extending from an upstream end of the aerosol-forming element to a downstream end of the aerosol-forming element, optionally wherein the one or more channels are disposed at the perimeter of the solid aerosol precursor arrangement.

16. The consumable of any preceding claim, wherein the bodies of the solid precursor arrangement comprise a precursor composition, wherein the precursor composition comprises an agglomeration of particles, optionally wherein the first body and the second body have the same precursor composition and / or optionally wherein the particles are non-tobacco particles, and / or wherein the solid aerosolforming material is substantially free of tobacco particles.

17. The consumable of any preceding claim, wherein the bodies of the solid precursor arrangement are formed or formable by extrusion.

18. A solid precursor arrangement configured to provide the solid precursor arrangement of the consumable of any preceding claim.

19. A method of preparing the consumable of any one of claims 1 to 17, the method comprising: extruding a precursor slurry to form an extrudate, dividing the extrudate to form at least two extruded bodies, drying the at least two extruded bodies to form a solid aerosol precursor arrangement comprising at least two bodies, andP152693PC00P0158959 assembling the solid aerosol precursor arrangement into a consumable for an aerosol generating apparatus, optionally wherein the extrudate is divided to form at least two extruded bodies at a mouth (82) of the extruder.

20. The method of claim 19 wherein the at least two extruded bodies are inserted into an envelope before drying the at least two extruded bodies to form a solid precursor arrangement comprising at least two bodies, or wherein the at least two extruded bodies are dried to form a solid aerosol precursor arrangement comprising at least two bodies before the solid aerosol precursor arrangement is encased in an envelope.21 . A method of preparing an aerosol-forming element for a heat-not-burn consumable, the method comprising: forming a body of aerosol-forming material; dividing the body of aerosol-forming material into two or more bodies of aerosolforming material; rejoining the two or more bodies of aerosol-forming material into a compound body of solid aerosol-forming material, the compound body comprising one or more planes of weakness within the body along the planes where the bodies are rejoined.

22. A consumable obtained or obtainable by the method of any one of claims 19 to 21 .

23. An aerosol generating system comprising the consumable of any one of claims 1 to 17 or claim 22 and an aerosol generating unit comprising a heating element, wherein the heating element is configured to heat at least a part of the solid precursor arrangement, optionally wherein the heating element is a penetrative heating element, configured to penetrate a gap extending through the solid aerosol precursor arrangement.P152693PC00

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