Method of preparing consumable for aerosol generating apparatus

Abstract

The present invention provides a method of preparing a precursor element for a heat-not-burn consumable. In some examples, the method comprises adding a first portion of raw material into an extrusion machine (401), adding a second portion of raw material into the extrusion machine (402) at a different part of the extrusion machine to the first portion, wherein the composition of the second portion is different to the composition of the first portion, mixing the first and second portions in the extrusion machine to form a precursor bulk material (403), and extruding the precursor bulk material to form a precursor element.

Description

[0001] 008529836

[0002] 1

[0003] METHOD OF PREPARING CONSUMABLE FOR AEROSOL GENERATING APPARATUS

[0004] FIELD

[0005] The present disclosure relates to a method of preparing a precursor element for consumable for an aerosol generating apparatus, particularly to a heat-not-burn consumable. The present disclosure also relates to a method of preparing a heat-not-burn consumable, and a heat-not-burn consumable obtained or obtainable by such a method.

[0006] BACKGROUND

[0007] A typical process for preparing an aerosol generating apparatus may comprise preparing the consumable / precursor using a batch process. Typically, such batch processes comprise mixing the raw materials in various vessels, which are then decanted for filling tubes using syringes to form precursors.

[0008] A drawback with such known processes is inconsistency of the precursor between products, which arises due to variations in quality between batches. Furthermore, batch processes involve stopping and starting the manufacture processes between each batch, potentially leading to long period of downtime. These processes therefore do not have high production or cost efficiency.

[0009] The present invention has been devised in light of the above considerations.

[0010] SUMMARY

[0011] In a first aspect the present disclosure provides a method of preparing a precursor element for a heat- not-burn (HNB) consumable.

[0012] In some examples, the method comprises i) adding a first portion of raw material into an extrusion machine, ii) adding a second portion of raw material into the extrusion machine at a different part of the extrusion machine to the first portion. In some examples, the second portion has a different composition to the first portion, and the method comprises iii) mixing the first and second portions in the extrusion machine to form a precursor bulk material. In some examples, the method comprises iv) extruding the precursor bulk material to form a precursor element. In some examples, the steps i) and ii) are carried out simultaneously. In some examples, after steps i) and ii) are performed, steps iii) and iv) are performed in the order of iii), then iv).

[0013] In this way, a precursor element comprising a homogenous precursor bulk material may be provided. Separate addition of the first and second portions of the raw material to the extrusion machine at different parts of the extrusion machine and mixing of the raw materials in the extrusion machine may result in increased homogeneity of the precursor bulk material, and consequently of the precursor element. This may improve the consistency of the precursor element between products. Furthermore, extrusion of the precursor bulk material may result in several benefits. Extrusion may allow for less

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[0015] 2 solvent to be used in the bulk material. A lower solvent content in the precursor may give the heat-not- burn consumable improved shelf life and may reduce the amount of liquid that may leach from the precursor. Additionally, extrusion may provide continuous production capability. Extrusion processes may produce long lengths of precursor element without interruption, and may lead to higher production efficiency and / or reduced downtime. A continuous production method may reduce costs, energy consumption and material waste. The need for frequent handling of the product may be reduced in an extrusion process, which may decrease the risk of damage or contamination during production. In some examples, the method may allow the production of a solid precursor having a specific cross-sectional shape and / or a consistent, continuous length whilst maintaining a specific formulation. The solid precursor herein may be homogeneous, or substantially homogeneous.

[0016] In some examples, the extrusion machine comprises at least two inlets, a barrel and an outlet. In some examples, the inlets may comprise one or more of a feeder, a hopper, or a funnel. In some examples, one or more of the inlets may be equipped with apparatus for measuring out raw materials, such as a balance or a pump. In some examples, a ram or screw is contained within the barrel. In some examples, the outlet comprises a die or aperture. The raw materials may be added to the extrusion machine into the barrel from the inlets. The raw materials may be pushed through the barrel and expelled from the outlet by the screw or ram.

[0017] In some examples, the extrusion machine is a single screw extruder. In other examples, the extrusion machine is a twin screw extruder. Other kinds of extruder may be suitable.

[0018] In some examples, an extrusion path may be defined along a longest or axial length of the barrel, from an inlet which is furthest upstream, to the outlet. In some examples, the outlet corresponds with the furthest downstream position. In some examples, inlets are located along the extrusion path such that at least one is further upstream, and at least one is further downstream (where upstream and downstream may be set in accordance with the direction of travel of the raw materials through the extrusion machine). Accordingly, in some examples, adding a second portion to the extrusion machine at a different part of the extrusion machine to the first portion corresponds with adding a second portion to the extrusion machine at a different position along the extrusion path to the first portion. In some examples, the extrusion path corresponds with the barrel, so that the first and second portions are added at different positions along the barrel.

[0019] In some examples, the second portion of raw material is added into the extrusion machine downstream of the first portion. In some examples, the first portion of raw material and the second portion of raw material are added to different parts along the barrel of the extrusion machine, such that mixing occurs in the barrel. For example, the second portion may be added into a downstream part of the barrel of the extrusion machine relative to the first portion. Upstream and downstream may be set in accordance with the direction of travel of the raw materials through the extrusion machine.

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[0022] Separate addition of the first and second portions of raw material may allow for improved consistency and homogeneity of the precursor element since mixing is performed by the extruder. This is because variations in quality which may occur in traditional batch production of precursors due to changes between batches may be avoided or reduced.

[0023] In some examples, steps iii) and / or iv) are performed at room temperature, which may be between 20- 30°C, such as 22-27°C. In some examples, steps iii) and / or iv) are performed without any applied heat. In some examples, the first portion of raw material and the second portion of raw material are mixed at room temperature, which may be between 20-30°C, such as 22-27°C. In some examples, during mixing, the first portion of raw material and the second portion of raw material are maintained at a temperature of 30 °C or less.

[0024] In some examples, the precursor bulk material is extruded without any applied heat. In some examples, the precursor bulk material is extruded at room temperature. In some examples, the precursor bulk material is extruded at an elevated temperature. In some examples, the precursor bulk material is extruded at a reduced temperature (under cooling).

[0025] In some examples, the extrusion machine comprises one or more heating or cooling elements. Typical heating and cooling elements are known to the skilled person. In some examples, the heating element is a heated jacket that is fitted to the extrusion machine. In some examples, the heating element is a heated fluid.

[0026] Subjecting the raw materials and / or precursor bulk material to both pressure and heat during the mixing and extrusion process may allow for the flowability of the precursor bulk material to be improved. In some examples, the pressure is applied by the screw or ram of the extrusion machine.

[0027] In some examples, the bulk material is shaped during extrusion. That is, the formed precursor element may be shaped as a result of the extrusion process. In some examples, the shape of the precursor element is achieved by extruding the bulk material through a shaped die or shaped aperture. In some examples, the precursor element is cylindrical in shape. In some examples, the die or aperture may be located at an outlet end of an extruder barrel from which the extrudate is expelled. In some examples, the shape of the precursor element is achieved through a shaped barrel in addition to a shaped die or aperture.

[0028] In this way, a wide range of products with different shapes and sizes may be produced. Further, the designs may quickly be adapted to meet changing market demands.

[0029] In some examples, the raw materials are the components of the precursor bulk material which forms the precursor element. In some examples, the raw materials are added to the extrusion machine in two or more separate portions. In some examples, the raw materials are added to the extrusion machine

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[0031] 4 in two portions, a first and a second portion respectively. 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 extrusion machine (extruder). In some examples, downstream refers to a position closer to the outlet of the extruder.

[0032] In some examples, the raw materials 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 one or more of the dry ingredients and the second portion comprises one or more of 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.

[0033] In some examples, the first portion comprises one or more dry ingredients and is added upstream of the second portion comprising one or more wet ingredients. In such examples, where there is more than one dry ingredient in the first portion, the dry ingredients may have time to mix independently of wet ingredient(s) in the extrusion machine, before becoming mixed with the wet ingredient(s). In some examples, the first portion comprises one or more dry ingredients and is added downstream of the second portion comprising one or more wet ingredients.

[0034] In some examples, a dry ingredient may comprise one or more of a filler, and a non-tobacco particle. In some examples, a wet ingredient may comprise one or more of a solvent, humectant, thickening agent and / or binder, and a (liquid) flavourant.

[0035] In some examples, there are more than two portions of raw materials, and each portion is added at a different part of the extrusion machine, or at different stages along the extrusion path.

[0036] 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.

[0037] In some examples, the precursor bulk material comprises a filler, which may be a fibrous or particulate filler. In some examples, the filler of the precursor bulk material comprises non-tobacco particles, such as cellulose particles and / or tea particles. In some examples, the tea particles may comprise oolong tea. In other examples, the tea particles may comprise green tea. In some examples, the tea particles may comprise a mixture of oolong and green tea. In some examples, the precursor bulk material 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.

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[0040] In some examples, the precursor bulk material comprises up to about 60 weight% (wt%) non-tobacco particles relative to the total weight of precursor bulk material. In some examples, the precursor bulk material 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 bulk material. In some examples, the precursor bulk material 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 bulk material.

[0041] In some examples, the precursor bulk material 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 bulk material 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 bulk material. In other examples, the precursor bulk material comprises 40 to 50 wt% non-tobacco particles relative to the total weight of the precursor bulk material. In some examples, the precursor bulk material comprises up to and including 60 wt% non-tobacco particles relative to the total weight of the precursor bulk material.

[0042] For example, when the precursor bulk material comprises cellulose particles and tea particles, the precursor bulk material may be 20 to 25 wt% cellulose particles and 20 to 25 wt% tea particles relative to the total weight of the precursor bulk material. In some examples, the precursor bulk material 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 bulk material. In some examples, the precursor bulk material 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 bulk material. In some examples, the precursor bulk material comprises cellulose particles selected from a range with the upper and lower amounts selected from the values given above. In some examples, the precursor bulk material 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 bulk material. In some examples, the precursor bulk material 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 bulk material. In some examples, the precursor bulk material comprises an amount of tea particles selected from a range with the upper and lower amounts selected from the values given above.

[0043] In some examples, the amounts of cellulose particles and tea particles in the precursor bulk material are equal. In other examples, the amounts of cellulose particles and tea particles in the precursor bulk material are not equal.

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[0046] In some examples, the precursor bulk material comprises a flavourant, such as tobacco extract or other plant extracts. The function of the flavourant is to provide flavour and odour to the solid precursor. In some examples, the flavourant is a liquid. In some examples, the precursor bulk material comprises a tobacco extract. In some examples, the precursor bulk material comprises other plant extracts such as fig, maple, or acer saccharum extract. In some examples, the precursor bulk material 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 bulk material. In some examples, the precursor bulk material 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 bulk material. In some examples, the precursor bulk material 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 bulk material 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 bulk material. In some examples, the precursor bulk material comprises up to and including 40 wt% flavourant relative to the total weight of the precursor bulk material. Where more than one flavourant is included, the above amounts may correspond with the total amount of flavourants. For example, total flavourants may be up to about 40 wt%, and so on.

[0047] In some examples, the precursor bulk material 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 bulk material 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 bulk material. In some examples, the amount of humectant present in the precursor bulk material 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 bulk material. In some examples, the precursor bulk material 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 bulk material 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 bulk material. Where more than one humectant is included, the above amounts may correspond with the total amount of humectants. For example, total humectants may be up to about 30 wt%, and so on.

[0048] In some examples, the precursor bulk material comprises a binding agent, that may in some examples 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 waterindependent binding and / or thickening agent may be a thickening agent which does not require water for activation. In some examples, the precursor bulk material comprises up to about 5 weight% (wt%)

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[0050] 7 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 bulk material. In some examples, the precursor bulk material 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 bulk material. In some examples, the precursor bulk material 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 bulk material 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 bulk material. In some examples, the precursor bulk material comprises up to and including 5 wt% binding and / or thickening agent, relative to the total weight of the precursor bulk material. Where more than one binding and / or thickening agent is included, the above amounts may correspond with the total amount of binding and / or thickening agents. For example, total binding and / or thickening agents may be up to about 5 wt%, and so on.

[0051] In some examples, the precursor bulk material comprises a solvent. In some examples, the solvent is aqueous. In some examples, the amount of solvent present in the precursor bulk material is up to about 75 weight% (wt%), such as up to about 60 wt%, such as up to about 50wt% relative to the total weight of the precursor bulk material. In some examples, the amount of solvent present in the precursor bulk material is up to about 45 wt%, such as up to about 40 wt% relative to the total weight of the precursor bulk material. In some examples, the amount of solvent present in the precursor bulk material is about 10 wt% or more, such as about 20 wt% or more, such as about 30 wt% or more relative to the total weight of the precursor bulk material. 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 around 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 around 25 to 50 wt%, such as 30 to 50 wt% relative to the total weight of the precursor composition. Where more than one solvent is included, the above amounts may correspond with the total amount of solvents. For example, total solvents may be up to about 75 wt%, and so on.

[0052] In some examples, the amount of water (as the solvent) present in the precursor bulk material 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 bulk material. In some examples, the amount of solvent present in the precursor bulk material is up to about 45 wt%, such as up to about 40 wt% relative to the total weight of the precursor bulk material. In some examples, the amount of water present in the precursor bulk material is about 10 wt% or more, such as about 20 wt% or more, such as about 30 wt% or more relative to the total weight of the precursor bulk material. In some examples, the amount of water present in the precursor slurry 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 slurry is around

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[0055] 20 to 50 wt%, such as 20 to 45 wt%, such as 20 to 40 wt% relative to the total weight of the precursor slurry. In some examples, the amount of water present in the extrudate is around 25 to 50 wt%, such as 30 to 50 wt% relative to the total weight of the precursor slurry. In some examples, the amount of water present in the precursor slurry is up to and including 20 wt% relative to the total weight of the precursor slurry. In other examples, the amount of water present in the precursor slurry is less than 10 wt% relative to the total weight of the precursor slurry.

[0056] When the solvent content (for example, water content) is less than 10 wt% relative to the total weight of the precursor bulk material, this may require a higher amount of other wet ingredients in the precursor bulk material, 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.

[0057] In some examples, the first portion of raw material comprises non-tobacco particles, such as cellulose particles and / or tea particles. In some examples, the first portion of raw material comprises non-tobacco particles in an amount as described above.

[0058] In some examples, the second portion of raw material comprises a binding and / or thickening agent. In some examples, the second portion of raw material comprises a binding and / or thickening agent in an amount as described above. In some examples, the second portion of raw material comprises a humectant, such as propylene glycol (PG) and / or glycerol (VG). In some examples, the second portion of raw material comprises a humectant in an amount as described above. In some examples, the second portion of raw material comprises a flavourant, such as tobacco extract or other plant extracts. In some examples, the second portion of raw material comprises a flavourant in an amount as described above. In some examples, the second portion of raw material comprises a solvent. In some examples, the second portion of raw materials comprises a solvent in an amount as described above.

[0059] In some examples, the second portion of raw material comprises one or more of a humectant, a flavourant and a solvent. In some examples, the second portion of raw material comprises the one or more of a humectant, a flavourant and a solvent in the amounts as described above. In some examples, the second portion of raw material comprises all of a humectant, a flavourant and a solvent in the amounts as described above.

[0060] In some examples, the second portion of raw material comprises one or more of a binding and / or thickening agent, a humectant, a flavourant and a solvent. In some examples, the second portion of raw material comprises one or more of a binding and / or thickening agent, a humectant, a flavourant and a solvent in the amounts as described above. In some examples, the second portion of raw material comprises all of a binding and / or thickening agent, a humectant, a flavourant and a solvent in the amounts as described above.

[0061] In some examples, the precursor bulk material has a composition according to Table 1 after mixing.

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[0064] Table 1

[0065] In a second aspect the present disclosure provides a method of preparing a heat-not-burn consumable comprising providing a precursor element by the method of the first aspect and assembling the precursor element into a heat-not-burn consumable.

[0066] In some examples, assembling the precursor element comprises inserting the element into a tube, and drying to form a solid precursor. In some examples, assembling the precursor element comprises drying the precursor element to form a solid precursor and wrapping the solid precursor. In some examples, the precursor element is inserted into a tube directly from the extrusion machine. That is, in some examples, the precursor element is inserted into a tube at or near the mouth of the extruder. A ‘mouth of the extruder’ may be the outlet, or an aperture of the extruder from which the extrudate is expelled. In some examples, the precursor element is injected into a tube. In some examples, the precursor element is injected into a tube in a secondary filling process separate to the extrusion process. In some examples, the secondary filing process is a syringe filling process. In some examples, during drying, the precursor element adheres to the tube. In some examples, an adhesive is used to adhere the precursor element to the tube. In some examples, the tube is a card tube. In some examples, in order to facilitate injection of the precursor element into a tube, the precursor element is in the form of a flowable paste or slurry.

[0067] In some examples, assembling the precursor element further comprises assembling other components into the tube. Other components to be assembled in the tube may include a frangible capsule configured to deliver additional flavourant(s) to the user, a support structure such as a paper rod for holding the frangible capsule in place, and / or a mouthpiece filter.

[0068] In some examples, before drying the precursor element, the precursor element is sterilised using a microwave. In this way, contamination of the precursor may be minimised, reduced or avoided.

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[0071] In some examples, drying the precursor element comprises heating the extrudate 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 two or more sectors of the extrudate comprises heating the extrudate at a temperature of 40 to 70 °C, such as 40 to 60 °C, such as 40 to 50 °C, such as 50 °C. In this way, the water content of the precursor element may be reduced, whilst retaining the other components of the precursor element. In some examples, drying the precursor element comprises drying the element in line.

[0072] In some examples, the precursor element is dried for up to around 5 hours, such as up to around 4 hours, such as up to around 3 hours. In some examples, the precursor element is dried for around 30 minutes or more, such as around 1 hour or more, such as around 2 hours or more. In some examples, such as when the precursor element is dried at around 70 °C, the precursor element is dried for between around 30 minutes and around 4 hours. In some examples, the precursor element is dried until the element has a target water content. In some examples, the target water content is 5 to 10 weight% (wt%) relative to the total weight of the dried precursor element such as 7 to 10 wt%, such as 9 to 10 wt% relative to the total weight of the precursor element. In some examples, the target water content is up to about 10 wt% relative to the total weight of the precursor element, such as up to about 9 wt% relative to the total weight of the precursor element. In some examples, the target water content is 5 wt% or more, such as 7 wt% or more relative to the total weight of the precursor element.

[0073] In some examples, the precursor element is divided (separated) into two or more sectors before assembling the precursor element into a heat-not-burn consumable. In some examples, a die of the extruder is adapted to divide the precursor bulk material as it is expelled. In some examples, the precursor element is divided in a downstream process separate from the extrusion process.

[0074] In some examples, assembling the precursor element comprises drying the two or more sectors to form a solid precursor and wrapping the solid precursor. In this way, leaching of solvent e.g., water into the wrapping may be avoided. Wrapping of the solid precursor may be carried out by any method known to the skilled person. In some examples, the wrapping is a foil-paper laminate. In some examples, the wrapping is paper. In some examples, the wrapping comprising a single piece of wrapping which may be folded around the solid precursor. In some examples, the wrapping comprising two or more pieces of wrapping which may be used to spiral wrap the solid precursor. Advantageously, spiral wrapping the precursor 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 precursor.

[0075] In some examples, extruding the precursor bulk material and drying the precursor element is a continuous process. That is, the cylindrical extrusion may be dried continuously straight after extrusion, for example the cylindrical extrusion may be dried continuously in line.

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[0078] In some examples, the precursor element is divided into two or more sectors before cooling and assembling the precursor element into a heat-not-burn consumable. In this way, the precursor element may be sized or cut to the desired length. In some examples, the precursor element may be divided into sections having a length of 8 to 12 mm, such as 8 to 11 mm, such as 8 to 10 mm. In some examples, the precursor element may be divided into sections having a length of around 120 mm, such as around 115 mm, such as around 110 mm. In some examples, the sections of the precursor element may be further divided in a subsequent process.

[0079] In some examples, such as examples in which heating is applied to form the precursor element, the precursor element is cooled before assembling into a heat-not-burn consumable. For example, the precursor element may be cooled using an air-cooling method or a water-cooling method. Cooling the precursor element after extrusion and before assembling may allow the precursor element to maintain its shape. In some examples, cooling of the precursor element is carried out by the extrusion machine. In some examples, there is no separate cooling apparatus or independent cooling step. In some examples, cooling is effected rapidly.

[0080] In a third aspect the present disclosure provides a heat-not-burn consumable obtained or obtainable by the method of the second aspect.

[0081] In this way, a heat-not-burn consumable with a precursor having improved homogeneity may be provided. Furthermore, the heat-not-burn consumable may have a better shelf life due to the reduced solvent content of the precursor element, as well as the capability to be manufactured by a continuous production process which may have numerous advantages as discussed herein.

[0082] In a fourth aspect the present disclosure provides a use of an extrusion machine for mixing a first portion of raw material and a second portion of raw material, wherein the second portion has a different composition to the first portion, and wherein the first portion is added to the extrusion machine at a different part of the extrusion machine to the second portion, in the production of a precursor element for a heat-not-burn consumable. Such use may provide for a heat-not-burn consumable with a precursor having improved homogeneity and / or a better shelf life and / or the capability to be manufactured by a continuous production process as discussed herein.

[0083] In some examples, the extrusion machine and the production of the precursor element is as described above in relation to the first aspect. In some examples, the second portion of raw material is added into the extrusion machine downstream of the first portion. In some examples, the first portion of raw material and the second portion of raw material are added to different parts along the barrel of the extrusion machine, such that mixing occurs in the barrel. For example, the second portion may be added into a downstream part of the barrel of the extrusion machine relative to the first portion.

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[0086] Upstream and downstream may be set in accordance with the direction of travel of the raw materials through the extrusion machine.

[0087] 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.

[0088] BRIEF DESCRIPTION OF THE FIGURES

[0089] 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.

[0090] Fig. 1 is a block system diagram showing an example aerosol generating apparatus.

[0091] 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.

[0092] Fig. 3 is a schematic diagram showing an example implementation of the apparatus of Fig. 2.

[0093] Fig. 4 is a flow diagram representing a method of preparing a consumable of the apparatus of Fig. 2.

[0094] DETAILED DESCRIPTION OF EMBODIMENTS

[0095] 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.

[0096] 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.

[0097] Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.

[0098] 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

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[0100] 13 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.

[0101] 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.

[0102] The use of the term “or” in the present disclosure (including the claims) is used to mean an inclusive “and / or” unless explicitly indicated to refer to alternatives only or unless the alternatives are mutually exclusive. For example, a condition “A or B” is satisfied by any of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0103] 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.

[0104] 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), embodiments), 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.

[0105] 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:

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[0107] 14

[0108] 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.

[0109] 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).

[0110] 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.

[0111] 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.

[0112] As used herein, a “precursor” may include one or more of a: solid; gel; loose leaf material; other substance. The precursor may be processed by an aerosol generating unit of an aerosol generating apparatus to generate an aerosol. The precursor may include one or more of: an active component; a carrier; a flavouring. The active component may include one or more of nicotine; caffeine; a cannabidiol oil; a non-pharmaceutical formulation, e.g. a formulation which is not for treatment of a disease or physiological malfunction of the human body. The active component may be carried by the carrier, which may be a liquid, including propylene glycol and / or glycerine. The term “flavouring” may refer to a component that provides a taste and / or a smell to the user. The flavouring may include one or more of: Ethylvanillin (vanilla); menthol, Isoamyl acetate (banana oil); or other. The precursor may include a substrate, e.g. reconstituted tobacco to carry one or more of the active component; a carrier; a flavouring.

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[0114] 15

[0115] As used herein, a "storage portion" may be a portion of the apparatus adapted to store the precursor, such as a carrier for solid material.

[0116] 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 in the context of an aerosol generating apparatus, 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.

[0117] 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.

[0118] 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.

[0119] 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.

[0120] 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). 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.

[0121] 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.

[0122] As used herein, a "consumable" may refer to a unit that includes a precursor. The consumable may include an aerosol generating unit. The consumable may include a mouthpiece. The consumable may include an information carrying medium. 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. 008529836

[0123] 16

[0124] 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).

[0125] 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 and pastes, may be encompassed by “solid”.

[0126] 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.

[0127] As used herein “water-independent binding and / or thickening agent” may, in some examples, 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.

[0128] Referring to Fig. 1 , an example aerosol generating apparatus 1 includes a power supply 2, for supply of electrical energy. The apparatus 1 includes an aerosol generating unit 4 that is driven by the power supply 2. The power supply 2 may include an electric power supply in the form of a battery and / or an electrical connection to an external power source. The apparatus 1 includes a precursor 6, which in use is aerosolised by the aerosol generating unit 4 to generate an aerosol. The apparatus 2 includes a delivery system 8 for delivery of the aerosol to a user.

[0129] Electrical circuitry (not shown in figure 1) may be implemented to control the interoperability of the power supply 4 and aerosol generating unit 6.

[0130] 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.

[0131] In this example, the apparatus 1 includes a device body 50 and a consumable 70.

[0132] In this example, the body 50 includes the power supply 4 and a heating system 52. The heating system 54 includes at least one heating element 54. The body may additionally include any one or more of electrical circuitry 56, a memory 58, a wireless interface 60, one or more other components 62.

[0133] 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. 008529836

[0134] 17

[0135] The wireless interface 60 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.

[0136] The other component(s) 62 may include an actuator, one or more user interface devices configured to convey information to a user and / or a charging port, for example (see e.g. Fig. 3).

[0137] The body 50 is configured to engage with the consumable 70 such that the at least one heating element 54 of the heating system 52 penetrates into the solid precursor 6 of the consumable. In use, a user may activate the aerosol generating apparatus 1 to cause the heating system 52 of the body 50 to cause the at least one heating element 54 to heat the solid precursor 6 of the consumable (without combusting it) by conductive heat transfer, to generate an aerosol which is inhaled by the user.

[0138] Fig. 3 shows an example implementation of the aerosol generating device 1 of Fig. 2.

[0139] As depicted in Fig. 3, the consumable 70 is implemented as a stick, which is engaged with the body 50 by inserting the stick into an aperture at a top end 53 of the body 50, which causes the at least one heating element 54 of the heating system 52 to penetrate into the solid precursor 6.

[0140] The consumable 70 includes the solid precursor 6 proximal to the body 50, and a filter distal to the body 50. The filter serves as the mouthpiece of the consumable 70 and thus the apparatus 1 as a whole. The solid precursor 6 may be a reconstituted tobacco formulation.

[0141] In this example, the at least one heating element 54 is a rod-shaped element with a circular transverse profile. In other examples, 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).

[0142] 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.

[0143] 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.

[0144] The body 50 also includes a user interface device configured to convey information to a user. Here, the user interface device is implemented as a plurality of lights 57, which may e.g. be configured to illuminate when the apparatus 1 is activated and / or to indicate a charging state of the power supply 4. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.

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[0146] 18

[0147] 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.

[0148] 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.

[0149] 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.

[0150] Fig. 4 shows a flow diagram representing a method of preparing a consumable for the apparatus of Fig. 2.

[0151] In some examples, raw materials to be used in the consumable are selected. In some examples, the raw materials to be used in the consumable are prepared. In some examples, such preparation may include being measured out, and / or portioned into portions as desired.

[0152] In step 401 , the first portion of raw materials is added to the extrusion machine. The first portion of raw materials may comprise cellulose and / or tea particles.

[0153] In step 402, the second portion of raw materials, which is different in composition to the first portion, is added to the extrusion machine. This may be in a different part of the extrusion machine to where the first portion of raw materials has been added, such as downstream of the part of the extrusion machine to where the first portion of raw materials has been added. The second portion of raw materials may comprise propylene glycol and glycerol, tobacco extract and a solvent such as water. The second portion of raw materials may further comprise a binding and / or thickening agent such as Konjac Mannan.

[0154] In some examples, the first portion comprises dry raw materials and the second portion comprises wet raw materials. Such arrangement may allow mixing of dry raw materials before mixing with wet raw materials. This may increase homogeneity. The first portion of raw materials may be mixed by a part of the extrusion machine adapted to mixing the dry ingredients.

[0155] In step 403, the first and second portions of raw materials are mixed in the extrusion machine to form precursor bulk material. The two portions of raw materials may be mixed by a part of the extrusion machine adapted to mixing the dry and wet ingredients together.

[0156] Separate addition of the first and second portions of the raw material to the extrusion machine at different parts along the extrusion machine, and mixing of the respective portions of raw materials in

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[0158] 19 the extrusion machine independently and / or together, may result in increased homogeneity of the precursor bulk material and consequently may increase homogeneity of the precursor element. This may improve the consistency of the precursor element between products.

[0159] In step 404, the precursor bulk material is extruded from the extrusion machine to form a precursor element. Extrusion may allow for less solvent to be used in the bulk material. A lower solvent content in the precursor may give the heat-not-burn consumable improved shelf life and may reduce the amount of liquid that may leach from the precursor. Additionally, extrusion may allow for continuous production capability. Extrusion processes may produce long lengths of precursor element without interruption, and may lead to higher production efficiency and / or reduced downtime. A continuous production method may reduce costs, energy consumption and material waste. Additionally, a continuous production method may increase consistency of the precursor bulk material used in different heat-not-burn consumables as compared with batch production methods. The need for frequent handling of the product may be reduced in an extrusion process, which may decrease the risk of damage or contamination during production. The precursor bulk material may be extruded by a part of the extrusion machine adapted to transport (extrude) the bulk material. The precursor bulk material may be extruded through a shaped die such that the resultant precursor element is shaped. In this way, a wide range of products with different shapes and sizes may be produced. Further, the designs may quickly be adapted to meet changing market demands.

[0160] Finally, in step 405, the precursor element is assembled into a heat-not-burn consumable. Optionally, the precursor element may be dried before being assembled into the heat-not-burn consumable. Drying may allow for control over the viscosity of the precursor element, so that a desired product may be achieved, and / or may improve handleability.

[0161] P01594

Claims

CLAIMS1. A method of preparing a precursor element for a heat-not-burn consumable, the method comprising: i) adding a first portion of raw material into an extrusion machine; ii) adding a second portion of raw material into the extrusion machine at a different part of the extrusion machine to the first portion, wherein the second portion has a different composition to the first portion; iii) mixing the first and second portions in the extrusion machine to form a precursor bulk material; and iv) extruding the precursor bulk material to form the precursor element, wherein the formed precursor element is shaped as a result of the extrusion process.

2. The method of claim 1, wherein the extrusion machine comprises a barrel having an axial length, and the second portion of raw material is added into the extrusion machine at a different position of the axial length along the barrel of the extrusion machine to the first portion.

3. The method of claim 1 or 2, wherein the second portion of raw material is added into the extrusion machine downstream of the first portion.

4. The method of claim any one of claims 1 to 3, wherein steps iii) and / or iv) are performed at room temperature.

5. The method of any one of claims 1 to 4, wherein steps iii) and / or iv) are performed without any applied heat.

6. The method of any one of claims 1 to 5, wherein the precursor bulk material is shaped during extrusion.

7. The method of any one of claims 1 to 6, wherein the first portion of raw material comprises non-tobacco particles, such as cellulose and / or tea particles.

8. The method of any one of claims 1 to 7, wherein the second portion of raw material comprises a thickening and / or binding agent, and / or a humectant and / or a flavourant.

9. The method of any one of claims 1 to 8, wherein the second portion of raw material comprises a solvent.

10. A method of preparing a heat-not-burn consumable comprising providing a precursor element by the method of any one of claims 1 to 9 and assembling the precursor element into a heat-not-burn consumable.11 . The method of claim 10, wherein assembling the precursor element comprises inserting the precursor element into a tube and then drying the precursor element to form a solid precursor, optionally wherein during drying the precursor element adheres to the tube.

12. The method of claim 10, wherein assembling the precursor element comprises drying the precursor element to form a solid precursor and then wrapping the solid precursor.

13. The method of any one of claims 10 to 12, wherein the precursor element is divided into two or more sectors before assembling the precursor element into a heat- not-burn consumable.

14. A heat-not-burn consumable obtained or obtainable by the method of any one of claims 10 to 13.

15. Use of an extrusion machine for mixing a first portion of raw material and a second portion of raw material, wherein the second portion has a different composition to the first portion, and wherein the first portion is added to the extrusion machine at a different part of the extrusion machine to the second portion, in the production of a precursor element for a heat-not-burn consumable, wherein the formed precursor element is shaped as a result of the extrusion process.

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