U.S. patent application number 15/733194 was filed with the patent office on 2021-04-08 for aerosolizable structure.
The applicant listed for this patent is NICOVENTURES TRADING LIMITED. Invention is credited to Walid ABI AOUN, Andy DAVIS, Glen ELGAR.
Application Number | 20210100281 15/733194 |
Document ID | / |
Family ID | 1000005313940 |
Filed Date | 2021-04-08 |
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United States Patent
Application |
20210100281 |
Kind Code |
A1 |
ABI AOUN; Walid ; et
al. |
April 8, 2021 |
AEROSOLIZABLE STRUCTURE
Abstract
Disclosed is an aerosolizable structure for use in an article
for use with apparatus for heating aerosolizable material to
volatilize at least one component of the aerosolizable material.
The aerosolizable structure includes a gathered layered structure
having a first sheet including aerosolizable material and a second
sheet including heating material that is heatable by penetration
with a varying magnetic field to heat the aerosolizable material of
the first sheet. The second sheet is free from aerosolizable
material.
Inventors: |
ABI AOUN; Walid; (London,
GB) ; ELGAR; Glen; (London, GB) ; DAVIS;
Andy; (London, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NICOVENTURES TRADING LIMITED |
London |
|
GB |
|
|
Family ID: |
1000005313940 |
Appl. No.: |
15/733194 |
Filed: |
December 6, 2018 |
PCT Filed: |
December 6, 2018 |
PCT NO: |
PCT/EP2018/083795 |
371 Date: |
June 8, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24C 5/01 20200101; A24D
1/20 20200101; A24F 40/20 20200101; A24F 40/465 20200101; A24B 3/14
20130101 |
International
Class: |
A24D 1/20 20060101
A24D001/20; A24F 40/20 20060101 A24F040/20; A24F 40/465 20060101
A24F040/465; A24C 5/01 20060101 A24C005/01; A24B 3/14 20060101
A24B003/14 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 8, 2017 |
GB |
1720535.2 |
Claims
1. An aerosolizable structure for use in an article for use with an
apparatus for heating aerosolizable material to volatilize at least
one component of the aerosolizable material, the aerosolizable
structure comprising: a gathered layered structure comprising: a
first sheet comprising aerosolizable material; and a second sheet
comprising heating material that is heatable by penetration with a
varying magnetic field to heat the aerosolizable material of the
first sheet, wherein the second sheet is free from aerosolizable
material.
2. The aerosolizable structure of claim 1, wherein the
aerosolizable material is reconstituted, cellulosic, or in gel
form.
3. The aerosolizable structure of claim 2, wherein the
aerosolizable structure is free from any aerosolizable material
between the heating material and the reconstituted or cellulosic
aerosolizable material or the aerosolizable material in gel
form.
4. The aerosolizable structure of claim 2, wherein the
reconstituted or cellulosic aerosolizable material or the
aerosolizable material in gel form is in surface contact with the
heating material.
5. An aerosolizable structure for use in an article for use with
apparatus for heating aerosolizable material to volatilize at least
one component of the aerosolizable material, the aerosolizable
structure comprising: a gathered layered structure comprising: a
first sheet comprising aerosolizable material; a second sheet
comprising heating material; and a third sheet comprising
aerosolizable material; wherein the second sheet is located between
the first sheet and the third sheet, and wherein the heating
material is heatable by penetration with a varying magnetic field
to heat the aerosolizable material of the first sheet and the third
sheet.
6. The aerosolizable structure of claim 5, wherein the second sheet
is free from aerosolizable material.
7. The aerosolizable structure of claim 1, wherein the gathered
layered structure is crimped.
8. The aerosolizable structure of claim 1, claims 1 to 7, wherein
the heating material comprises one or more materials selected from
the group consisting of: an electrically-conductive material, a
magnetic material, and a magnetic electrically-conductive
material.
9. The aerosolizable structure of claim 1, wherein the heating
material comprises a metal or a metal alloy.
10. The aerosolizable structure of claim 1, wherein the heating
material comprises one or more materials selected from the group
consisting of: aluminum, gold, iron, nickel, cobalt, conductive
carbon, graphite, steel, plain-carbon steel, mild steel, stainless
steel, ferritic stainless steel, copper, and bronze.
11. The aerosolizable structure of any one of claims 1 to 10,
wherein the first sheet comprises reconstituted tobacco.
12. The aerosolizable structure of claim 1, wherein the second
sheet comprises aluminum aluminium foil.
13. The aerosolizable structure of claim 1, comprising a wrapper
wrapped around the gathered layered structure.
14. The aerosolizable structure of claim 1, wherein the
aerosolizable structure is substantially cylindrical.
15. An article for use with an apparatus for heating aerosolizable
material to volatilize at least one component of the aerosolizable
material, the article comprising the aerosolizable structure of
claim 1.
16. The article of claim 15, comprising a filter for filtering
aerosol released from the aerosolizable structure in use, and a
connector by which the filter is retained relative to the
aerosolizable structure.
17. A system for heating aerosolizable material to volatilize at
least one component of the aerosolizable material, the system
comprising: the article according to claim 15; and an apparatus for
heating the aerosolizable material of the article to volatilize at
least one component of the aerosolizable material, the apparatus
comprising: a heating zone for receiving the article, and a
magnetic field generator for generating the varying magnetic field
for penetrating the heating material of the article when the
article is located in the heating zone.
18. A method of manufacturing an aerosolizable structure for use in
an article for use with apparatus for heating aerosolizable
material to volatilize at least one component of the aerosolizable
material, the method comprising: providing a layered structure, the
layered structure having a first sheet comprising aerosolizable
material, and a second sheet comprising heating material that is
heatable by penetration with a varying magnetic field to heat the
aerosolizable material; and gathering the layered structure to form
a gathered layered structure.
19. The method of claim 18, wherein the second sheet is free from
aerosolizable material.
20. The method of claim 18, wherein the layered structure has a
third sheet comprising aerosolizable material, wherein the second
sheet is located between the first sheet and the third sheet, and
wherein the heating material is heatable by penetration with a
varying magnetic field to heat the aerosolizable material of the
first sheet and the third sheet.
21. The method of claim 18, wherein the gathering comprises feeding
the layered structure through a converging funnel.
22. The method of claim 18, wherein the gathering causes the
layered structure to become substantially cylindrical.
23. The method of claim 18, comprising crimping the layered
structure before the gathering.
24. The method of claim 18, wherein providing the layered structure
comprises causing the first sheet to come into contact with the
second sheet.
25. The method of claim 18, comprising wrapping a wrapper around
the gathered layered structure to form a wrapped gathered layered
structure.
26. The method of claim 25, comprising severing the wrapped
gathered layered structure to form a discrete wrapped gathered
layered structure.
27. A method of manufacturing an article for use with an apparatus
for heating aerosolizable material to volatilize at least one
component of the aerosolizable material, the method comprising:
performing the method of claim 18; and connecting a filter to the
gathered layered structure using a connector that retains the
filter relative to the gathered layered structure.
Description
PRIORITY CLAIM
[0001] The present application is a National Phase entry of PCT
Application No. PCT/EP2018/083795, filed Dec. 6, 2018, which claims
priority from GB Patent Application No. 1720535.2, filed Dec. 8,
2017, each of which is hereby fully incorporated herein by
reference.
TECHNICAL FIELD
[0002] The present disclosure relates to aerosolizable structures
for use in articles for use with apparatus for heating
aerosolizable material, methods of manufacturing an aerosolizable
structure, articles for use with apparatus for heating
aerosolizable material, methods of manufacturing an article for use
with apparatus for heating aerosolizable material, and systems
comprising such an article and such apparatus.
BACKGROUND
[0003] Smoking articles such as cigarettes, cigars and the like
burn tobacco during use to create tobacco smoke. Attempts have been
made to provide alternatives to these articles by creating products
that release compounds without combusting. Examples of such
products are so-called "heat not burn" products or tobacco heating
devices or products, which release compounds by heating, but not
burning, material. The material may be, for example, tobacco or
other non-tobacco products, which may or may not contain
nicotine.
SUMMARY
[0004] A first aspect of the present disclosure provides an
aerosolizable structure for use in an article for use with
apparatus for heating aerosolizable material to volatilize at least
one component of the aerosolizable material, the aerosolizable
structure comprising: a gathered layered structure having: a first
sheet comprising aerosolizable material; and a second sheet
comprising heating material that is heatable by penetration with a
varying magnetic field to heat the aerosolizable material of the
first sheet, wherein the second sheet is free from aerosolizable
material.
[0005] In an exemplary embodiment, the aerosolizable material is
reconstituted, cellulosic, or in gel form.
[0006] In an exemplary embodiment, the aerosolizable structure is
free from any aerosolizable material between the heating material
and the reconstituted or cellulosic aerosolizable material or the
aerosolizable material in gel form.
[0007] In an exemplary embodiment, the reconstituted or cellulosic
aerosolizable material or the aerosolizable material in gel form is
in surface contact with the heating material.
[0008] In an exemplary embodiment, the second sheet consists of the
heating material only.
[0009] In an exemplary embodiment, the layered structure is
crimped.
[0010] In an exemplary embodiment, the heating material comprises
one or more materials selected from the group consisting of: an
electrically-conductive material, a magnetic material, and a
magnetic electrically-conductive material.
[0011] In an exemplary embodiment, the heating material comprises a
metal or a metal alloy.
[0012] In an exemplary embodiment, the heating material comprises
one or more materials selected from the group consisting of:
aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite,
steel, plain-carbon steel, mild steel, stainless steel, ferritic
stainless steel, copper, and bronze.
[0013] In an exemplary embodiment, the first sheet comprises
reconstituted tobacco.
[0014] In an exemplary embodiment, the second sheet comprises
aluminium foil.
[0015] In an exemplary embodiment, the aerosolizable structure
comprises a wrapper wrapped around the gathered layered
structure.
[0016] In an exemplary embodiment, the aerosolizable structure is
substantially cylindrical.
[0017] A second aspect of the present disclosure provides an
aerosolizable structure for use in an article for use with
apparatus for heating aerosolizable material to volatilize at least
one component of the aerosolizable material, the aerosolizable
structure comprising: a gathered layered structure having: a first
sheet comprising aerosolizable material; a second sheet comprising
heating material; and a third sheet comprising aerosolizable
material; wherein the second sheet is located between the first and
third sheets, and wherein the heating material is heatable by
penetration with a varying magnetic field to heat the aerosolizable
material of the first and third sheets.
[0018] In an exemplary embodiment, the second sheet is free from
aerosolizable material.
[0019] In an exemplary embodiment, the second sheet consists of the
heating material only.
[0020] In an exemplary embodiment, the layered structure is
crimped.
[0021] In an exemplary embodiment, the heating material comprises
one or more materials selected from the group consisting of: an
electrically-conductive material, a magnetic material, and a
magnetic electrically-conductive material.
[0022] In an exemplary embodiment, the heating material comprises a
metal or a metal alloy.
[0023] In an exemplary embodiment, the heating material comprises
one or more materials selected from the group consisting of:
aluminum , gold, iron, nickel, cobalt, conductive carbon, graphite,
steel, plain-carbon steel, mild steel, stainless steel, ferritic
stainless steel, copper, and bronze.
[0024] In an exemplary embodiment, the aerosolizable material of
the first sheet is reconstituted, cellulosic, or in gel form.
[0025] In an exemplary embodiment, the first sheet comprises
reconstituted tobacco.
[0026] In an exemplary embodiment, the second sheet comprises
aluminum foil.
[0027] In an exemplary embodiment, the aerosolizable material of
the third sheet is reconstituted, cellulosic, or in gel form.
[0028] In an exemplary embodiment, the third sheet comprises
reconstituted tobacco.
[0029] In an exemplary embodiment, the aerosolizable structure
comprises a wrapper wrapped around the gathered layered
structure.
[0030] In an exemplary embodiment, the aerosolizable structure is
substantially cylindrical.
[0031] A third aspect of the present disclosure provides an article
for use with apparatus for heating aerosolizable material to
volatilize at least one component of the aerosolizable material,
the article comprising the aerosolizable structure of the first
aspect of the present disclosure or the aerosolizable structure of
the second aspect of the present disclosure.
[0032] In an exemplary embodiment, the article comprises a filter
for filtering aerosol released from the aerosolizable structure in
use, and a connector by which the filter is retained relative to
the aerosolizable structure.
[0033] A fourth aspect of the present disclosure provides a system
for heating aerosolizable material to volatilize at least one
component of the aerosolizable material, the system comprising: an
article according to the third aspect of the present disclosure;
and apparatus for heating the aerosolizable material of the article
to volatilize at least one component of the aerosolizable material,
the apparatus comprising: a heating zone for receiving the article,
and a magnetic field generator for generating the varying magnetic
field for penetrating the heating material of the article when the
article is located in the heating zone.
[0034] A fifth aspect of the present disclosure provides a method
of manufacturing an aerosolizable structure for use in an article
for use with apparatus for heating aerosolizable material to
volatilize at least one component of the aerosolizable material,
the method comprising: providing a layered structure, the layered
structure having a first sheet comprising aerosolizable material,
and a second sheet comprising heating material that is heatable by
penetration with a varying magnetic field to heat the aerosolizable
material; and gathering the layered structure to form a gathered
layered structure.
[0035] In an exemplary embodiment, the second sheet is free from
aerosolizable material.
[0036] In an exemplary embodiment, the second sheet consists of the
heating material only.
[0037] In an exemplary embodiment, the second sheet comprises
aluminum foil.
[0038] In an exemplary embodiment, the aerosolizable material of
the first sheet is reconstituted, cellulosic, or in gel form.
[0039] In an exemplary embodiment, the first sheet comprises
reconstituted tobacco.
[0040] In an exemplary embodiment, the layered structure has a
third sheet comprising aerosolizable material, the second sheet is
located between the first and third sheets, and the heating
material is heatable by penetration with a varying magnetic field
to heat the aerosolizable material of the first and third
sheets.
[0041] In an exemplary embodiment, the aerosolizable material of
the third sheet is reconstituted, cellulosic, or in gel form.
[0042] In an exemplary embodiment, the third sheet comprises
reconstituted tobacco.
[0043] In an exemplary embodiment, the gathering comprises feeding
the layered structure through a converging funnel.
[0044] In an exemplary embodiment, the gathering causes the layered
structure to become substantially cylindrical.
[0045] In an exemplary embodiment, the method comprises crimping
the layered structure before the gathering.
[0046] In an exemplary embodiment, the providing the layered
structure comprises causing the first sheet to come into contact
with the second sheet.
[0047] In an exemplary embodiment, the providing the layered
structure comprises causing the third sheet to come into contact
with the second sheet.
[0048] In an exemplary embodiment, the method comprises wrapping a
wrapper around the gathered layered structure to form a wrapped
gathered layered structure.
[0049] In an exemplary embodiment, the method comprises severing
the wrapped gathered layered structure to form a discrete wrapped
gathered layered structure.
[0050] A sixth aspect of the present disclosure provides a method
of manufacturing an article for use with apparatus for heating
aerosolizable material to volatilize at least one component of the
aerosolizable material, the method comprising: performing the
method of the fifth aspect of the present disclosure; and
connecting a filter to the gathered layered structure using a
connector that retains the filter relative to the gathered layered
structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] Embodiments of the disclosure will now be described, by way
of example only, with reference to the accompanying drawings, in
which:
[0052] FIG. 1 shows a schematic side view of an example of an
aerosolizable structure for use in an article for use with
apparatus for heating aerosolizable material to volatilize at least
one component of the aerosolizable material.
[0053] FIG. 2 shows a schematic cross-sectional view of the
aerosolizable structure of FIG. 1.
[0054] FIG. 3 shows a partial schematic cross-sectional view of an
example of a layered structure of an aerosolizable structure for
use in an article for use with apparatus for heating aerosolizable
material to volatilize at least one component of the aerosolizable
material.
[0055] FIG. 4 shows a partial schematic cross-sectional view of an
example of a layered structure of another aerosolizable structure
for use in an article for use with apparatus for heating
aerosolizable material to volatilize at least one component of the
aerosolizable material.
[0056] FIG. 5 shows a partial schematic cross-sectional view of an
example of a layered structure of a further aerosolizable structure
for use in an article for use with apparatus for heating
aerosolizable material to volatilize at least one component of the
aerosolizable material.
[0057] FIG. 6 shows a partial schematic cross-sectional view of an
example of a layered structure of a still further aerosolizable
structure for use in an article for use with apparatus for heating
aerosolizable material to volatilize at least one component of the
aerosolizable material.
[0058] FIG. 7 shows a schematic cross-sectional side view of an
example of another aerosolizable structure for use in an article
for use with apparatus for heating aerosolizable material to
volatilize at least one component of the aerosolizable
material.
[0059] FIG. 8 shows a schematic cross-sectional side view of an
example of an article for use with apparatus for heating
aerosolizable material to volatilize at least one component of the
aerosolizable material.
[0060] FIG. 9 shows a schematic cross-sectional side view of an
example of another article for use with apparatus for heating
aerosolizable material to volatilize at least one component of the
aerosolizable material.
[0061] FIG. 10 shows a schematic cross-sectional side view of an
example of a system comprising the article of FIG. 9 and apparatus
for heating aerosolizable material of the article to volatilize at
least one component of the aerosolizable material.
[0062] FIG. 11 shows a flow diagram showing an example of a method
of manufacturing an aerosolizable structure for use in an article
for use with apparatus for heating aerosolizable material to
volatilize at least one component of the aerosolizable
material.
[0063] FIG. 12 shows a flow diagram showing an example of another
method of manufacturing an aerosolizable structure for use in an
article for use with apparatus for heating aerosolizable material
to volatilize at least one component of the aerosolizable
material.
[0064] FIG. 13 shows a flow diagram showing an example of a method
of manufacturing an article for use with apparatus for heating
aerosolizable material to volatilize at least one component of the
aerosolizable material.
DETAILED DESCRIPTION
[0065] As used herein, the term "aerosolizable material" includes
materials that provide volatilized components upon heating,
typically in the form of vapor or an aerosol. "Aerosolizable
material" may be a non-tobacco-containing material or a
tobacco-containing material. "Aerosolizable material" may, for
example, include one or more of tobacco per se, tobacco
derivatives, expanded tobacco, reconstituted tobacco, tobacco
extract, homogenized tobacco or tobacco substitutes. The
aerosolizable material can be in the form of ground tobacco, cut
rag tobacco, extruded tobacco, reconstituted tobacco, reconstituted
aerosolizable material, liquid, gel, gelled sheet, powder, or
agglomerates, or the like. "Aerosolizable material" also may
include other, non-tobacco, products, which, depending on the
product, may or may not contain nicotine. "Aerosolizable material"
may comprise one or more humectants, such as glycerol or propylene
glycol.
[0066] As used herein, the term "sheet" denotes an element having a
width and length substantially greater than a thickness
thereof.
[0067] As used herein, where it is stated that a sheet is "free
from aerosolizable material", this means that the sheet itself does
not comprise or consist of aerosolizable material, and is not
coated or impregnated with aerosolizable material. However, it does
not mean that the sheet may not be adjacent (directly or
indirectly) to, or adhered to, a sheet that does comprise
aerosolizable material.
[0068] As used herein, the term "gathered" includes wrinkled,
folded, creased, or otherwise convoluted in shape, whether in a
regular or an irregular manner. Correspondingly, as used herein,
the term "gathering" includes wrinkling, folding, creasing, or
otherwise convoluting in shape, whether in a regular or an
irregular manner.
[0069] As used herein, the term "crimped" includes having a
plurality of substantially parallel corrugations, or ridges and
troughs, therein.
[0070] As used herein, the term "heating material" or "heater
material" refers to material that is heatable by penetration with a
varying magnetic field.
[0071] Induction heating is a process in which an
electrically-conductive object is heated by penetrating the object
with a varying magnetic field. The process is described by
Faraday's law of induction and Ohm's law. An induction heater may
comprise an electromagnet and a device for passing a varying
electrical current, such as an alternating current, through the
electromagnet. When the electromagnet and the object to be heated
are suitably relatively positioned so that the resultant varying
magnetic field produced by the electromagnet penetrates the object,
one or more eddy currents are generated inside the object. The
object has a resistance to the flow of electrical currents.
Therefore, when such eddy currents are generated in the object,
their flow against the electrical resistance of the object causes
the object to be heated. This process is called Joule, ohmic, or
resistive heating. An object that is capable of being inductively
heated is known as a susceptor.
[0072] It has been found that, when the susceptor is in the form of
a closed electrical circuit, magnetic coupling between the
susceptor and the electromagnet in use is enhanced, which results
in greater or improved Joule heating.
[0073] Magnetic hysteresis heating is a process in which an object
made of a magnetic material is heated by penetrating the object
with a varying magnetic field. A magnetic material can be
considered to comprise many atomic-scale magnets, or magnetic
dipoles. When a magnetic field penetrates such material, the
magnetic dipoles align with the magnetic field. Therefore, when a
varying magnetic field, such as an alternating magnetic field, for
example as produced by an electromagnet, penetrates the magnetic
material, the orientation of the magnetic dipoles changes with the
varying applied magnetic field. Such magnetic dipole reorientation
causes heat to be generated in the magnetic material.
[0074] When an object is both electrically-conductive and magnetic,
penetrating the object with a varying magnetic field can cause both
Joule heating and magnetic hysteresis heating in the object.
Moreover, the use of magnetic material can strengthen the magnetic
field, which can intensify the Joule and magnetic hysteresis
heating.
[0075] In each of the above processes, as heat is generated inside
the object itself, rather than by an external heat source by heat
conduction, a rapid temperature rise in the object and more uniform
heat distribution can be achieved, particularly through selection
of suitable object material and geometry, and suitable varying
magnetic field magnitude and orientation relative to the object.
Moreover, as induction heating and magnetic hysteresis heating do
not require a physical connection to be provided between the source
of the varying magnetic field and the object, design freedom and
control over the heating profile may be greater, and cost may be
lower.
[0076] Referring to FIGS. 1 and 2, there are shown schematic side
and cross-sectional views of an example of an aerosolizable
structure according to an embodiment of the disclosure. The
aerosolizable structure 1 is for use in an article for use with
apparatus for heating aerosolizable material to volatilize at least
one component of the aerosolizable material, such as the article
100 shown in FIG. 8 and described below.
[0077] The aerosolizable structure 1 is substantially cylindrical
with a substantially circular cross section (see FIG. 2), but in
other embodiments the aerosolizable structure 1 may have an oval or
elliptical cross section or be other than cylindrical. In some
embodiments, the aerosolizable structure 1 may have a polygonal,
quadrilateral, rectangular, square, triangular, star-shaped, or
irregular cross section, for example. In this embodiment, the
aerosolizable structure 1 is a rod. In some other embodiments, the
aerosolizable structure may be tubular with a hollow inner
region.
[0078] In this embodiment, the aerosolizable structure 1 is
elongate and has a longitudinal axis A-A. A length of the
aerosolizable structure 1 in the direction of the longitudinal axis
A-A may fall within the range of 40 millimeters to 150 millimeters,
such as 70 millimeters to 120 millimeters. In other embodiments,
the aerosolizable structure 1 may not be elongate. In some such
other embodiments, the aerosolizable structure 1 still has an axial
direction A-A that is perpendicular to the cross section of the
aerosolizable structure 1 shown in FIG. 2. A width of the
aerosolizable structure 1 perpendicular to the axial direction A-A
may fall within the range of 4 millimeters to 10 millimeters, such
as 5 millimeters to 8 millimeters. A circumference of the
aerosolizable structure 1 perpendicular to the axial direction A-A
may fall within the range of 12 millimeters to 30 millimeters, such
as 16 millimeters to 25 millimeters.
[0079] The aerosolizable structure 1 comprises a layered structure
10. FIG. 3 shows a partial schematic cross-sectional view of the
layered structure 10 of the aerosolizable structure 1. The layered
structure 10 comprises a first sheet 11 and a second sheet 12. In
some embodiments, the layered structure 10 is a laminate. In some
embodiments, the first sheet 11 is bonded to the second sheet 12,
such as by an adhesive or by a chemical bond. Examples adhesives
are polyvinyl acetate (PVA) and ethylene-vinyl acetate (EVA). In
other embodiments, the first sheet 11 may be unbonded to the second
sheet 12.
[0080] In this embodiment, the first sheet 11 comprises
aerosolizable material. The aerosolizable material of the first
sheet 11 may be any of the aerosolizable materials discussed
herein, such as reconstituted aerosolizable material (e.g.
reconstituted tobacco) or in the form of a gel. The first sheet 11
may comprise a substrate, such as a paper, that is impregnated or
coated with an aerosolizable material, such as a gel. The
aerosolizable material of the first sheet 11 may be cellulosic
aerosolizable material.
[0081] In this embodiment, the second sheet 12 comprises heating
material that is heatable by penetration with a varying magnetic
field. More specifically, the heating material is heatable by
penetration with the varying magnetic field to heat the
aerosolizable material of the first sheet 11. That is, the heating
material is in thermal contact with the aerosolizable material.
Since the first and second sheets 11, 12 are part of the same
layered structure 10, the heat generated in the second sheet 12 by
the penetration with the varying magnetic field is proximate to the
first sheet 11 and so relatively efficient heating of the
aerosolizable material of the first sheet 11 may be achieved. In
some embodiments, the aerosolizable material of the first sheet 11
is in surface contact with the heating material of the second sheet
12. Thus, heat may be conducted directly from the heating material
to the aerosolizable material. This can help to further increase
the efficiency of heating of the aerosolizable material of the
first sheet 11. In other embodiments, the heating material may be
kept out of surface contact with the aerosolizable material. For
example, in some embodiments, a thermally-conductive barrier that
is free from heating material and aerosolizable material may space
the heating material from the aerosolizable material. In some
embodiments, the thermally-conductive barrier may be a coating on
the first sheet 11 or on the second sheet 12. The provision of such
a barrier may be advantageous to help to dissipate heat to
alleviate hot spots in the heating material.
[0082] In some embodiments in which the aerosolizable material of
the first sheet 11 is reconstituted, cellulosic or in gel form, the
aerosolizable structure 1 may be free from any aerosolizable
material between the reconstituted, cellulosic or gel-form
aerosolizable material of the first sheet 11 and the heating
material of the second sheet 12. In some embodiments, a benefit of
this is that a greater proportion of the heat generated in the
second sheet 12 by penetrating the heating material with the
varying magnetic field is usable to heat the aerosolizable material
of the first sheet 11.
[0083] In this embodiment, the heating material is aluminum , and
the second sheet 12 is a sheet of aluminum foil. However, in other
embodiments, the heating material may be any one or more of those
described herein and/or the sheet 12 comprising heating material
may take any of the forms described herein. In this embodiment, the
second sheet 12 is free from aerosolizable material. In some
embodiments, the second sheet 12 consists of the heating material
only. In other embodiments, such as will be described below with
reference to FIGS. 5 and 6, this may not be the case. In some
embodiments, a benefit of omitting aerosolizable material from the
second sheet 12 in this way is that a greater proportion of the
heat generated in the second sheet 12 by penetrating the heating
material with the varying magnetic field is usable to heat the
aerosolizable material of the first sheet 11.
[0084] As is best seen in FIG. 2, the layered structure 10 of the
aerosolizable structure 1 is a gathered layered structure 10. In
other words, the layered structure 10 has been gathered. Example
methods for gathering the layered structure 10 are described in
more detail below. This gathering of the layered structure 10
enables a greater proportion of the second sheet 12 comprising
heating material to be proximate to the first sheet 11 comprising
the aerosolizable material to be heated, as compared to, for
example, wrapping the second sheet 12 comprising heating material
just around the outside of a plug or gathering of the aerosolizable
material or locating a blade or bar of heating material in a
relatively concentrated way in a plug or gathering of the
aerosolizable material. Accordingly, improved efficiency of heating
of the aerosolizable material of the first sheet 11 may be
achieved. Moreover, a sheet comprising aerosolizable material can
have a relatively high surface area to volume ration, and gathering
a sheet comprising aerosolizable material can leave a large
proportion of a surface area of the sheet exposed for release of
aerosol in use. Furthermore, the gathered sheet can define one or
more flow paths along which aerosol generated in use is able to
escape from the aerosolizable structure.
[0085] In a variation to the embodiment of FIGS. 1 to 3, the
layered structure may be crimped. FIG. 4 shows a partial schematic
cross-sectional view of an example of a gathered layered structure
of another aerosolizable structure according to an embodiment of
the disclosure, in which embodiment the layered structure is
crimped. The gathered layered structure 20 of FIG. 4 again
comprises a first sheet 21 comprising aerosolizable material, and a
second sheet 22 comprising heating material that is heatable by
penetration with a varying magnetic field to heat the aerosolizable
material of the first sheet 21. Still further, the second sheet 22
is again free from aerosolizable material. In some embodiments, the
second sheet 22 consists of the heating material only. In some
variations to this embodiment, the first and second sheets 21, 22
may have any of the optional or alternative features described
herein in relation to the first and second sheets 11, 12 shown in
FIGS. 2 and 3.
[0086] Such crimping can aid gathering of the layered structure 20,
and/or dictate how the layered structure 20 becomes gathered,
during manufacture of the aerosolizable structure. For example, the
distance by which the layered structure 20 is crimped can help to
determine the path that the convolutions of the layered structure
20 will take when gathered, and may help to determine a porosity of
the resultant gathered layered structure 20. Additionally, or
alternatively, such crimping can further increase the proportion of
the second sheet 22 that is proximate to the first sheet 21, which
in turn helps to increase the efficiency with which the
aerosolizable material of the first sheet 21 is heated in use.
Some, most or all of the plurality of substantially parallel
corrugations, or ridges and troughs, present in the layered
structure 20 as a result of the crimping may be parallel to an
axial direction A-A of the aerosolizable structure in which the
layered structure 20 is comprised.
[0087] In each of the embodiments shown in FIGS. 1 to 3 and FIG. 4
and described herein, the gathered layered structure 10, 20
comprises two sheets 11, 12, 21, 22. However, in some embodiments,
the gathered layered structure may comprise more than two sheets.
FIG. 5 shows a partial schematic cross-sectional view of an example
of a gathered layered structure 30 of a further aerosolizable
structure according to an embodiment of the disclosure.
[0088] The gathered layered structure 30 of FIG. 5 has a first
sheet 31, a second sheet 32, and a third sheet 33. The second sheet
32 is located between the first sheet 31 and the third sheet 33.
Each of the first and second sheets 31, 33 comprises aerosolizable
material. The aerosolizable material of the first sheet 31 may be
any of the aerosolizable materials discussed herein, such as
reconstituted tobacco or in the form of a gel. Similarly, the
aerosolizable material of the third sheet 33 may be any of the
aerosolizable materials discussed herein, such as reconstituted
tobacco or in the form of a gel. One or each of the first and third
sheets 31, 33 may be cellulosic aerosolizable material.
[0089] The second sheet 32 comprises heating material that is
heatable by penetration with a varying magnetic field to heat the
aerosolizable material of the first and third sheets 31, 33.
Locating the second sheet 32 between the first and third sheets 31,
33 enables a greater proportion of the total area of the surfaces
of the second sheet 32 to be proximate to a sheet 31, 33 comprising
aerosolizable material. In turn, this permits heat energy emitted
from both surfaces of the second sheet 32 in use to heat
aerosolizable material of the layered structure 30.
[0090] In some embodiments, the second sheet 32 is free from
aerosolizable material. In some embodiments, the second sheet 32
consists of the heating material only. However, in other
embodiments, the second sheet 32 itself may comprise aerosolizable
material, such as through the provision of a coating of
aerosolizable material, or the impregnation or interweaving of the
second sheet 32 with aerosolizable material. In some variations to
this embodiment, one or each of the first and third sheets 31, 33
may have any of the optional or alternative features described
herein in relation to the first sheet 11 shown in FIGS. 2 and 3. In
some variations to this embodiment, the second sheet 32 may have
any of the optional or alternative features described herein in
relation to the second sheet 12 shown in FIGS. 2 and 3.
[0091] In a variation to the embodiment of FIG. 5, the layered
structure may be crimped.
[0092] FIG. 6 shows a partial schematic cross-sectional view of an
example of a gathered layered structure of a still further
aerosolizable structure according to an embodiment of the
disclosure. The gathered layered structure 40 of FIG. 6 is the same
as the gathered layered structure 30 of FIG. 5, except that the
gathered layered structure 40 of FIG. 6 is crimped. The layered
structure 40 of FIG. 6 again comprises first and third sheets 41,
43 comprising aerosolizable material, and again comprises a second
sheet 42 therebetween comprising heating material that is heatable
by penetration with a varying magnetic field to heat the
aerosolizable material of the first and third sheets 41, 43. Any of
the herein-described possible variations to the embodiment of FIG.
5 may be made to the embodiment of FIG. 6 to form further
embodiments.
[0093] FIG. 7 shows a schematic cross-sectional side view of an
example of another aerosolizable structure according to an
embodiment of the disclosure. The aerosolizable structure 5 of FIG.
7 is again substantially cylindrical with a substantially circular
cross section and a longitudinal axis A-A. A length and/or a width
of the aerosolizable structure 5 may, for example, be any one of
those discussed herein for the aerosolizable structure 1 of FIGS. 1
to 3. In other embodiments, the aerosolizable structure 5 may have
a different cross section, such as any of those discussed herein,
or be other than cylindrical, or not be elongate.
[0094] The aerosolizable structure 5 of FIG. 7 comprises a gathered
layered structure 50. The gathered layered structure 50 may be the
same as any one of the gathered layered structures 10, 20, 30, 40
discussed above, or any of the variants thereof discussed
herein.
[0095] The aerosolizable structure 5 also comprises a wrapper 51
that is wrapped around the gathered layered structure 50. The
wrapper 51 encircles the gathered layered structure 50, may help to
avoid or prevent unravelling or ungathering of the layered
structure 50, and helps to protect the gathered layered structure
50 from damage during transport and use. During use, the wrapper 51
may also help to direct the flow of air into and through the
gathered layered structure 50, and may help to direct the flow of
vapor or aerosol through and out of the gathered layered structure
50.
[0096] In this embodiment, the wrapper 51 is wrapped around the
gathered layered structure 50 so that free ends of the wrapper 51
overlap each other. The wrapper 51 may form all of, or a majority
of, a circumferential outer surface of the aerosolizable structure
5. The wrapper 51 could be made of any suitable material, such as
paper, card, reconstituted aerosolizable material (e.g.
reconstituted tobacco), or heating material (e.g. a metal or metal
alloy foil, such as aluminum foil). The wrapper 51 may also
comprise an adhesive (not shown) that adheres the overlapped free
ends of the wrapper 51 to each other. The adhesive may comprise one
or more of, for example, gum Arabic, natural or synthetic resins,
starches, and varnish. The adhesive helps prevent the overlapped
free ends of the wrapper 51 from separating. In other embodiments,
the adhesive may be omitted or the wrapper 51 may take a different
from to that described. Any one of these types of wrapper may be
applied to the other aerosolizable structures described or
illustrated herein to form further embodiments.
[0097] Any one of the aerosolizable structures described or
illustrated herein may itself be employed as an article for use
with apparatus for heating aerosolizable material to volatilize at
least one component of the aerosolizable material, such as the
apparatus 500 shown in FIG. 10 and described below. However, in
other embodiments, the article may comprise an aerosolizable
structure along with one or more further components.
[0098] For example, FIG. 8 shows a schematic cross-sectional side
view of an example of an article according to an embodiment of the
disclosure. The article 100 of FIG. 8 comprises the aerosolizable
structure 1 of FIGS. 1 to 3. However, in other embodiments, the
aerosolizable structure of the article may be any other one of the
aerosolizable structures described herein, for example.
[0099] The article 100 is substantially cylindrical with a
substantially circular cross section, but in other embodiments the
article 100 may have an oval or elliptical cross section or be
other than cylindrical. In some embodiments, the article 100 may
have a polygonal, quadrilateral, rectangular, square, triangular,
star-shaped, or irregular cross section, for example. In this
embodiment, the article 100 is a rod. In some other embodiments,
the article may be tubular with a hollow inner region.
[0100] In this embodiment, the article 100 is elongate and has a
longitudinal axis B-B. The longitudinal axis B-B of the article 100
is coincident with the longitudinal axis A-A of the aerosolizable
structure 1. A length of the article 100 in the direction of the
longitudinal axis B-B may fall within the range of 40 millimeters
to 150 millimeters, such as 70 millimeters to 120 millimeters. In
other embodiments, the article 100 may not be elongate. In some
such other embodiments, the article 100 still has an axial
direction B-B that is perpendicular to the cross section of the
article 100. A width of the article 100 perpendicular to the axial
direction B-B may fall within the range of 4 millimeters to 10
millimeters, such as 5 millimeters to 8 millimeters. A
circumference of the aerosolizable structure 1 perpendicular to the
axial direction B-B may fall within the range of 12 millimeters to
30 millimeters, such as 16 millimeters to 25 millimeters.
[0101] The article 100 of FIG. 8 also comprises a filter 1b. The
filter 1b is for filtering aerosol or vapor released from the
aerosolizable structure 1 of the article 100 in use. The filter 1b
could be of any type used in the tobacco industry. For example, the
filter 1b may be made of cellulose acetate. In this embodiment, the
filter 1b is substantially cylindrical with a substantially
circular cross section and a longitudinal axis. In other
embodiments, the filter 1b may have a different cross section, such
as any of those discussed herein for aerosolizable structures, or
be other than cylindrical, or not be elongate.
[0102] In this embodiment, the filter 1b abuts a longitudinal end
of the aerosolizable structure 1 and is axially aligned with the
aerosolizable structure 1. In other embodiments, the filter 1b may
be spaced from the aerosolizable structure, such as by a gap and/or
by one or more further components of the article 100. Example
further component(s) are an additive or flavor source (such as an
additive- or flavor-containing capsule or thread), which may be
held by a body of filtration material or between two bodies of
filtration material, for example.
[0103] The article 100 also comprises a wrap 1c that is wrapped
around the aerosolizable structure 1 and the filter 1b to retain
the filter 1b relative to the aerosolizable structure 1. The wrap
1c encircles the aerosolizable structure 1 and the filter 1b, may
help to avoid or prevent unravelling or ungathering of the layered
structure of the aerosolizable structure 1, and helps to protect
the gathered layered structure from damage during transport and
use. During use, the wrap 1c may also help to direct the flow of
air into and through the aerosolizable structure 1, and may help to
direct the flow of vapor or aerosol through and out of the
aerosolizable structure 1.
[0104] In this embodiment, the wrap 1c is wrapped around the
aerosolizable structure 1 and the filter 1b so that free ends of
the wrap 1c overlap each other. The wrap 1c may form all of, or a
majority of, a circumferential outer surface of the article 100.
The wrap 1c could be made of any suitable material, such as paper,
card, or reconstituted aerosolizable material (e.g. reconstituted
tobacco). The wrap 1c may also comprise an adhesive (not shown),
such as one of those discussed elsewhere herein, that adheres the
overlapped free ends of the wrap 1c to each other. The adhesive
helps prevent the overlapped free ends of the wrap 1c from
separating. In other embodiments, the adhesive may be omitted or
the wrap 1c may take a different from to that described. In other
embodiments, the filter 1b may be retained relative to the
aerosolizable structure 1 by a connector other than the wrap 1c,
such as an adhesive.
[0105] FIG. 9 shows a schematic cross-sectional side view of an
example of another article according to an embodiment of the
disclosure. The article 200 of FIG. 9 is the same as that of FIG.
8, except that the article 200 has the aerosolizable structure 5 of
FIG. 7 in place of the aerosolizable structure 1. Accordingly, the
wrap 1c of the article 200 of FIG. 9 is wrapped around the wrapper
51 of the aerosolizable structure 5 and the filter 1b to retain the
filter 1b relative to the aerosolizable structure 5. Any of the
possible variations to the article 100 of FIG. 8 discussed herein
may be made to the article 200 of FIG. 9 to form further
embodiments.
[0106] In some embodiments, the article may be provided together
with the apparatus for heating the aerosolizable material of the
article to volatilize at least one component of the aerosolizable
material. The apparatus may comprise a heating zone for receiving
the article, and a magnetic field generator for generating a
varying magnetic field for penetrating the heating material of the
article when the article is located in the heating zone, thereby to
heat the aerosolizable material of the article.
[0107] For example, FIG. 10 shows a schematic cross-sectional side
view of an example of a system according to an embodiment of the
disclosure . The system 1000 comprises the article 200 of FIG. 9
and apparatus 500 for heating aerosolizable material of the article
200 to volatilize at least one component of the aerosolizable
material. In other embodiments, the article 200 may be replaced by
any of the other articles described herein. In this embodiment, the
apparatus 500 is a tobacco heating product (also known in the art
as a tobacco heating device or a heat-not-burn device).
[0108] Broadly speaking, the apparatus 500 comprises a heating zone
511 for receiving the article 200, and a magnetic field generator
512 for generating the varying magnetic field for penetrating the
heating material of the article 200 when the article 200 is located
in the heating zone 511.
[0109] More specifically, the apparatus 500 of this embodiment
comprises a body 510 and a mouthpiece 520. The mouthpiece 520 may
be made of any suitable material, such as a plastics material,
cardboard, cellulose acetate, paper, metal, glass, ceramic, or
rubber. The mouthpiece 520 defines a channel 522 therethrough. The
mouthpiece 520 is locatable relative to the body 510 so as to cover
an opening into the heating zone 511. When the mouthpiece 520 is so
located relative to the body 510, the channel 522 of the mouthpiece
520 is in fluid communication with the heating zone 511. In use,
the channel 522 acts as a passageway for permitting volatilized
material to pass from aerosolizable material of an article inserted
in the heating zone 511 to an exterior of the apparatus 500. In
this embodiment, the mouthpiece 520 is releasably engageable with
the body 510 so as to connect the mouthpiece 520 to the body 510.
In other embodiments, the mouthpiece 520 and the body 510 may be
permanently connected, such as through a hinge or flexible member.
In some embodiments, such as embodiments in which the article
itself comprises a mouthpiece, the mouthpiece 520 of the apparatus
500 may be omitted.
[0110] The apparatus 500 may define an air inlet (not shown) that
fluidly connects the heating zone 511 with the exterior of the
apparatus 500. Such an air inlet may be defined by the body 510
and/or by the mouthpiece 520. A user may be able to inhale the
volatilized component(s) of the aerosolizable material by drawing
the volatilized component(s) through the channel 522 of the
mouthpiece 520. As the volatilized component(s) are removed from
the article 200, air may be drawn into the heating zone 511 via the
air inlet of the apparatus 500.
[0111] In this embodiment, the body 510 comprises the heating zone
511. In this embodiment, the heating zone 511 comprises a recess
511 for receiving at least a portion of the article 200. In other
embodiments, the heating zone 511 may be other than a recess, such
as a shelf, a surface, or a projection, and may require mechanical
mating with the article in order to co-operate with, or receive,
the article. In this embodiment, the heating zone 511 is elongate,
and is sized and shaped to accommodate the whole article 200. In
other embodiments, the heating zone 511 may be dimensioned to
receive only a portion of the article 200.
[0112] In this embodiment, the magnetic field generator 512
comprises an electrical power source 513, a coil 514, a device 516
for passing a varying electrical current, such as an alternating
current, through the coil 514, a controller 517, and a user
interface 518 for user-operation of the controller 517.
[0113] The electrical power source 513 of this embodiment is a
rechargeable battery. In other embodiments, the electrical power
source 513 may be other than a rechargeable battery, such as a
non-rechargeable battery, a capacitor, a battery-capacitor hybrid,
or a connection to a mains electricity supply.
[0114] The coil 514 may take any suitable form. In this embodiment,
the coil 514 is a helical coil of electrically-conductive material,
such as copper. In some embodiments, the magnetic field generator
512 may comprise a magnetically permeable core around which the
coil 514 is wound. Such a magnetically permeable core concentrates
the magnetic flux produced by the coil 514 in use and makes a more
powerful magnetic field. The magnetically permeable core may be
made of iron, for example. In some embodiments, the magnetically
permeable core may extend only partially along the length of the
coil 514, so as to concentrate the magnetic flux only in certain
regions. In some embodiments, the coil may be a flat coil. That is,
the coil may be a two-dimensional spiral. In this embodiment, the
coil 514 encircles the heating zone 511. The coil 514 extends along
a longitudinal axis that is substantially aligned with a
longitudinal axis of the heating zone 511. The aligned axes are
coincident. In a variation to this embodiment, the aligned axes may
be parallel or oblique to each other.
[0115] In this embodiment, the device 516 for passing a varying
current through the coil 514 is electrically connected between the
electrical power source 513 and the coil 514. In this embodiment,
the controller 517 also is electrically connected to the electrical
power source 513, and is communicatively connected to the device
516 to control the device 516. More specifically, in this
embodiment, the controller 517 is for controlling the device 516,
so as to control the supply of electrical power from the electrical
power source 513 to the coil 514. In this embodiment, the
controller 517 comprises an integrated circuit (IC), such as an IC
on a printed circuit board (PCB). In other embodiments, the
controller 517 may take a different form. In some embodiments, the
apparatus may have a single electrical or electronic component
comprising the device 516 and the controller 517. The controller
517 is operated in this embodiment by user-operation of the user
interface 518. In this embodiment, the user interface 518 is
located at the exterior of the body 510. The user interface 518 may
comprise a push-button, a toggle switch, a dial, a touchscreen, or
the like. In other embodiments, the user interface 518 may be
remote and connected to the rest of the apparatus wirelessly, such
as via Bluetooth.
[0116] In this embodiment, operation of the user interface 518 by a
user causes the controller 517 to cause the device 516 to cause an
alternating electrical current to pass through the coil 514. This
causes the coil 514 to generate an alternating magnetic field. The
coil 514 and the heating zone 511 of the apparatus 500 are suitably
relatively positioned so that, when the article 200 is located in
the heating zone 511, the varying magnetic field produced by the
coil 514 penetrates the heating material of the article 200. In
this embodiment, the heating material is an electrically-conductive
material, and so this penetration causes the generation of one or
more eddy currents in the heating material. The flow of eddy
currents in the heating material against the electrical resistance
of the heating material causes the heating material to be heated by
Joule heating. When the heating material is made of a magnetic
material, the orientation of magnetic dipoles in the heating
material changes with the changing applied magnetic field, which
causes heat to be generated in the heating material.
[0117] The apparatus 500 of this embodiment comprises a temperature
sensor 519 for sensing a temperature of the heating zone 511. The
temperature sensor 519 is communicatively connected to the
controller 517, so that the controller 517 is able to monitor the
temperature of the heating zone 511. On the basis of one or more
signals received from the temperature sensor 519, the controller
517 may cause the device 516 to adjust a characteristic of the
varying or alternating electrical current passed through the coil
514 as necessary, in order to ensure that the temperature of the
heating zone 511 remains within a predetermined temperature range.
The characteristic may be, for example, amplitude or frequency or
duty cycle. Within the predetermined temperature range, in use the
aerosolizable material within an article located in the heating
zone 511 is heated sufficiently to volatilise at least one
component of the aerosolizable material without combusting the
aerosolizable material. Accordingly, the controller 517, and the
apparatus 500 as a whole, is arranged to heat the aerosolizable
material to volatilize the at least one component of the
aerosolizable material without combusting the aerosolizable
material. In some embodiments, the temperature range is about
50.degree. C. to about 300.degree. C., such as between about
50.degree. C. and about 250.degree. C., between about 50.degree. C.
and about 150.degree. C., between about 50.degree. C. and about
120.degree. C., between about 50.degree. C. and about 100.degree.
C., between about 50.degree. C. and about 80.degree. C., or between
about 60.degree. C. and about 70.degree. C. In some embodiments,
the temperature range is between about 170.degree. C. and about
220.degree. C. In other embodiments, the temperature range may be
other than this range. In some embodiments, the upper limit of the
temperature range could be greater than 300.degree. C. In some
embodiments, the temperature sensor 519 may be omitted. In some
embodiments, the heating material may have a Curie point
temperature selected on the basis of the maximum temperature to
which it is desired to heat the heating material, so that further
heating above that temperature by induction heating the heating
material is hindered or prevented.
[0118] FIGS. 11 and 12 show flow diagrams showing respective
examples of methods of manufacturing an aerosolizable
structure.
[0119] The method of FIG. 11 is usable to manufacture any of the
aerosolizable structures described herein. The method comprises
providing 11a a layered structure, the layered structure having a
first sheet 11, 21, 31, 41 comprising aerosolizable material, and a
second sheet 12, 22, 32, 42 comprising heating material that is
heatable by penetration with a varying magnetic field to heat the
aerosolizable material; and gathering 11b the layered structure to
form a gathered layered structure 10, 20, 30, 40.
[0120] The second sheet 12, 22, 32, 42 may be free from
aerosolizable material. The second sheet 12, 22, 32, 42 may consist
of heating material only. In some embodiments, the second sheet
comprises aerosolizable material.
[0121] The gathering 11b may comprise feeding the layered structure
through a converging funnel. The gathering 11b may cause the
layered structure to become substantially cylindrical. The method
may comprise crimping the layered structure before the gathering
11b. The providing 11a the layered structure may comprise causing
the first sheet 11, 21, 31, 41 to come into contact with the second
sheet 12, 22, 32, 42. The method may comprise wrapping a wrapper
around the gathered layered structure to form a wrapped gathered
layered structure. In some embodiments, the method comprises
severing the wrapped gathered layered structure to form a discrete
wrapped gathered layered structure.
[0122] The method of FIG. 12 is useable in the manufacture of an
aerosolizable structure that has a gathered layered structure
comprising three sheets, such as those shown in FIGS. 5 and 6.
[0123] The method comprises providing a layered structure, the
layered structure having a first sheet 31, 41 comprising
aerosolizable material, a second sheet 32, 42 comprising heating
material that is heatable by penetration with a varying magnetic
field, and a third sheet comprising aerosolizable material, wherein
the second sheet 32, 42 is located between the first and third
sheets 31, 33, 41, 43, and wherein the heating material is heatable
by penetration with a varying magnetic field to heat the
aerosolizable material of the first and third sheets 31, 33, 41,
43.
[0124] In some embodiments, the second sheet 32, 42 is free from
aerosolizable material. In some embodiments, the second sheet 32,
42 consists of the heating material only. In some embodiments, the
second sheet comprises aerosolizable material.
[0125] In this embodiment, the providing comprises causing 12a the
first sheet 31, 41 to come into contact with the second sheet 32,
42. The first and second sheets 31, 41, 32, 42 may be drawn from
respective supplies, such as respective bobbins (not shown), before
being brought into contact with each other. In other embodiments,
the first and second sheets may already be in contact with each
other, and so the method does not include this causation. Rather, a
combination (such as a laminate) of the first and second sheets 31,
41, 32, 42 may be drawn from a supply, such as a bobbin (not
shown).
[0126] In this embodiment, the providing comprises causing 12b the
third sheet 33, 43 to come into contact with the second sheet 32,
42. The third sheet 33, 43 may be drawn from a supply, such as a
bobbin (not shown), before being brought into contact with the
second sheet 32, 42. In other embodiments, the second and third
sheets may already be in contact with each other, and so the method
does not include this causation. Rather, a combination (such as a
laminate) of the second and third sheets 32, 33, 42, 43 may be
drawn from a supply, such as a bobbin (not shown). Alternatively, a
combination (such as a laminate) of the first, second and third
sheets 31, 32, 33, 41, 42, 43 may be drawn from a supply, such as a
bobbin (not shown).
[0127] In embodiments in which the aerosolizable structure being
manufactured is to have a crimped layered structure, such as that
shown in FIG. 6, the method comprises crimping 12c the provided
layered structure. The crimping may be performed by transporting
the layered structure between a pair of co-operable crimping
rollers, which engage and crimp the layered structure as it passes.
In other embodiments, in which the aerosolizable structure being
manufactured is to have an uncrimped layered structure, such as
that shown in FIG. 5, the crimping may be omitted.
[0128] The method comprises gathering 12d the layered structure to
form a gathered layered structure 30, 40. In embodiments in which
the layered structure is to be crimped, the crimping 12c may occur
before the gathering 12d. The gathering 12d may comprise
transporting the layered structure 30, 40 through a converging
funnel. In other embodiments, the gathering 12d may involve an
alternative process, such as squeezing the layered structure 30, 40
between bodies or plates that are movable relative to each other,
or such as twisting (e.g. into a helical form). In embodiments in
which the layered structure is crimped, the gathering may occur in
a direction substantially perpendicular to that of the
corrugations, or ridges and troughs, present in the layered
structure as a result of the crimping.
[0129] The gathering 12d may cause the layered structure 30, 40 to
become substantially cylindrical. This may be caused by the shape
of the converging funnel, if used. In other embodiments, the
gathering 12d may cause the layered structure 30, 40 to adopt a
shape other than cylindrical.
[0130] In this embodiment, the method comprises wrapping 12e a
wrapper 51 around the gathered layered structure 30, 40 to form a
wrapped gathered layered structure. The wrapper 51 may be drawn
from a supply (such as a bobbin) and enveloped around the gathered
layered structure 30, 40 by a garniture or endless belt conveyor.
The wrapper 51 may comprise adhesive, which may be applied thereto
before or during the wrapping 12e, so that when opposite free ends
of the wrapper 51 overlap each other the adhesive adheres the
opposite free ends to each other. The method may involve passing
the wrapped gathered layered structure through or past a dryer to
dry the adhesive. As discussed herein, in some embodiments such a
wrapper may be omitted. That is, the gathered layered structure may
be free from a wrapper. As such, the method of may not include such
wrapping 12e.
[0131] In this embodiment, the method comprises severing 12e the
wrapped gathered layered structure to form a discrete wrapped
gathered layered structure for use in an article, the article being
for use with apparatus for heating aerosolizable material to
volatilize at least one component of the aerosolizable material. In
embodiments in which the wrapping 12e is omitted, the method may
comprise severing 12e the gathered layered structure to form a
discrete gathered layered structure for use in the article. The
severing may comprise cutting, such as by a rotary cutter. In some
further other embodiments, the severing 12e may be omitted. For
example, in some embodiments, the gathered, or wrapped gathered,
layered structure produced so far according to the method may
already be dimensioned to suit use in the article without requiring
severing.
[0132] FIG. 13 shows a flow diagram showing an example of a method
of manufacturing an article for use with apparatus for heating
aerosolizable material to volatilize at least one component of the
aerosolizable material. The method of FIG. 13 comprises performing
13a the method of FIG. 11 or FIG. 12 (or any of the variants
thereof described herein), and connecting 13b a filter to the
gathered layered structure using a connector that retains the
filter relative to the gathered layered structure. The filter may,
for example, be the filter 1b discussed above. The connector may,
for example, be any of the connectors discussed herein, such as one
of the described wraps 1c.
[0133] In some embodiments, the heating material is aluminum.
However, in other embodiments, the heating material may comprise
one or more materials selected from the group consisting of: an
electrically-conductive material, a magnetic material, and a
magnetic electrically-conductive material. In some embodiments, the
heating material may comprise a metal or a metal alloy. In some
embodiments, the heating material may comprise one or more
materials selected from the group consisting of: aluminum, gold,
iron, nickel, cobalt, conductive carbon, graphite, steel,
plain-carbon steel, mild steel, stainless steel, ferritic stainless
steel, copper, and bronze. Other heating material(s) may be used in
other embodiments.
[0134] In some embodiments, the sheet comprising heating material
is a free from holes or discontinuities. In some embodiments, the
sheet comprising heating material comprises a foil, such as a metal
or metal alloy foil, e.g. aluminum foil. However, in some
embodiments, the sheet comprising heating material may have holes
or discontinuities. For example, in some embodiments, the sheet
comprising heating material may comprise a mesh, a perforated
sheet, or a perforated foil, such as a metal or metal alloy
perforated foil, e.g. perforated aluminum foil.
[0135] In some embodiments, such as those in which the heating
material comprises iron, such as steel (e.g. mild steel or
stainless steel) or aluminum, the sheet comprising heating material
may be coated to help avoid corrosion or oxidation of the heating
material in use. Such coating may, for example, comprise nickel
plating, gold plating, or a coating of a ceramic or an inert
polymer. In some embodiments, the sheet comprising heating material
comprises or consists of nickel plated aluminum foil.
[0136] The heating material may have a skin depth, which is an
exterior zone within which most of an induced electrical current
and/or induced reorientation of magnetic dipoles occurs. By
providing that the heating material has a relatively small
thickness, a greater proportion of the heating material may be
heatable by a given varying magnetic field, as compared to heating
material having a depth or thickness that is relatively large as
compared to the other dimensions of the heating material. Thus, a
more efficient use of material is achieved and, in turn, costs are
reduced.
[0137] In some embodiments, the aerosolizable material comprises
tobacco. However, in other embodiments, the aerosolizable material
may consist of tobacco, may consist substantially entirely of
tobacco, may comprise tobacco and aerosolizable material other than
tobacco, may comprise aerosolizable material other than tobacco, or
may be free from tobacco. In some embodiments, the aerosolizable
material may comprise a vapor or aerosol forming agent or a
humectant, such as glycerol, propylene glycol, triacetin, or
diethylene glycol. In some embodiments, the aerosolizable material
is non-liquid aerosolizable material, and the apparatus is for
heating non-liquid aerosolizable material to volatilize at least
one component of the aerosolizable material.
[0138] In some embodiments, the article 100, 200 is a consumable
article. Once all, or substantially all, of the volatilizable
component(s) of the aerosolizable material in the article 100, 200
has/have been spent, the user may remove the article 100, 200 from
the heating zone 511 of the apparatus 500 and dispose of the
article 100, 200. The user may subsequently re-use the apparatus
500 with another of the articles 100, 200. However, in other
respective embodiments, the article may be non-consumable, and the
apparatus and the article may be disposed of together once the
volatilizable component(s) of the aerosolizable material has/have
been spent.
[0139] In some embodiments, the article 100, 200 is sold, supplied
or otherwise provided separately from the apparatus 500 with which
the article 100, 200 is usable. However, in some embodiments, the
apparatus 500 and one or more of the articles 100, 200 may be
provided together as a system, such as a kit or an assembly,
possibly with additional components, such as cleaning utensils.
[0140] In order to address various issues and advance the art, the
entirety of this disclosure shows by way of illustration and
example various embodiments in which the claimed invention may be
practiced and which provide for superior aerosolizable structures
for use in articles for use with apparatus for heating
aerosolizable material, articles for use with apparatus for heating
aerosolizable material to volatilize at least one component of the
aerosolizable material, methods of manufacturing an aerosolizable
structure for use in an article for use with apparatus for heating
aerosolizable material to volatilize at least one component of the
aerosolizable material, methods of manufacturing an article for use
with apparatus for heating aerosolizable material to volatilize at
least one component of the aerosolizable material, and systems
comprising such an article and such apparatus. The advantages and
features of the disclosure are of a representative sample of
embodiments only, and are not exhaustive and/or exclusive. They are
presented only to assist in understanding and teach the claimed and
otherwise disclosed features. It is to be understood that
advantages, embodiments, examples, functions, features, structures
and/or other aspects of the disclosure are not to be considered
limitations on the disclosure as defined by the claims or
limitations on equivalents to the claims, and that other
embodiments may be utilized and modifications may be made without
departing from the scope and/or spirit of the disclosure. Various
embodiments may suitably comprise, consist of, or consist in
essence of, various combinations of the disclosed elements,
components, features, parts, steps, means, etc. The disclosure may
include other inventions not presently claimed, but which may be
claimed in future.
* * * * *