U.S. patent application number 17/264054 was filed with the patent office on 2021-12-02 for consumable for use with apparatus for heating aerosolisable material.
The applicant listed for this patent is NICOVENTURES TRADING LIMITED. Invention is credited to Walid Abi AOUN, Andrew Jonathan BRAY, Gary FALLON, Richard HEPWORTH, Karl KALJURA, John RICHARDSON.
Application Number | 20210368851 17/264054 |
Document ID | / |
Family ID | 1000005838148 |
Filed Date | 2021-12-02 |
United States Patent
Application |
20210368851 |
Kind Code |
A1 |
KALJURA; Karl ; et
al. |
December 2, 2021 |
CONSUMABLE FOR USE WITH APPARATUS FOR HEATING AEROSOLISABLE
MATERIAL
Abstract
Described herein is a consumable for use with apparatus for
heating aerosolizable material to volatilize at least one component
of the aerosolizable material, the consumable comprising a hollow
tube comprising a wound structure comprising aerosolizable
material.
Inventors: |
KALJURA; Karl; (London,
GB) ; HEPWORTH; Richard; (London, GB) ; AOUN;
Walid Abi; (London, GB) ; FALLON; Gary;
(London, GB) ; BRAY; Andrew Jonathan; (London,
GB) ; RICHARDSON; John; (London, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NICOVENTURES TRADING LIMITED |
London |
|
GB |
|
|
Family ID: |
1000005838148 |
Appl. No.: |
17/264054 |
Filed: |
July 31, 2019 |
PCT Filed: |
July 31, 2019 |
PCT NO: |
PCT/EP2019/070735 |
371 Date: |
January 28, 2021 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24C 5/01 20200101; A24B
15/14 20130101; A24D 1/20 20200101; A24F 40/20 20200101; A24B 15/30
20130101; A24B 15/186 20130101; A24B 15/167 20161101 |
International
Class: |
A24B 15/167 20060101
A24B015/167; A24C 5/01 20060101 A24C005/01; A24B 15/14 20060101
A24B015/14; A24B 15/30 20060101 A24B015/30; A24F 40/20 20060101
A24F040/20; A24B 15/18 20060101 A24B015/18; A24D 1/20 20060101
A24D001/20 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 31, 2018 |
GB |
1812492.5 |
Claims
1. A consumable for use with apparatus for heating aerosolizable
material to volatilise at least one component of the aerosolizable
material, the consumable comprising a hollow tube comprising a
wound structure comprising aerosolizable material.
2. The consumable of claim 1, wherein the wound structure is a
helically wound structure.
3. The consumable of claim 1, wherein the wound structure defines
at least part of a surface of the consumable.
4. The consumable of claim 3, wherein the surface is an innermost
surface of the consumable.
5. The consumable of claim 1, wherein the wound structure comprises
corrugations, embossing or debossing.
6. The consumable of claim 1, wherein the wound structure forms a
layer of the hollow tube, and the hollow tube comprises one or more
further layers.
7. The consumable of claim 5, wherein the wound structure forms a
layer of the hollow tube, wherein the hollow tube comprises one or
more further layers, and wherein the hollow tube comprises one or
more aerosol flow paths defined by and between the corrugations,
embossing or debossing of the structure comprising aerosolizable
material and at least one of the one or more further layers.
8. The consumable of claim 1, wherein the hollow tube comprises a
barrier layer that defines at least part of a surface of the
consumable.
9. The consumable of claim 1, further comprising a heating material
that is heatable by penetration with a varying magnetic field.
10. The consumable of claim 9, wherein the hollow tube comprises a
layer comprising the heating material.
11. The consumable of claim 9 or claim 10, when dependent directly
or indirectly on claim 8, wherein the layer comprising the heating
material is located between the barrier layer and the wound
structure comprising aerosolizable material.
12. The consumable of claim 6, wherein at least one of the one or
more further layers comprises aerosolizable material.
13. The consumable of claim 12, wherein the hollow tube comprises a
layer comprising a heating material, wherein the layer comprising
the heating material is located between the wound structure
comprising aerosolizable material and the at least one further
layer comprising aerosolizable material.
14. The consumable of claim 6, wherein at least one of the one or
more further layers comprises a flavorant or a sensate.
15. The consumable of claim 1, wherein the aerosolizable material
of the wound structure comprises an amorphous solid.
16. A system for heating aerosolizable material to volatilize at
least one component of the aerosolizable material, the system
comprising: a consumable comprising a hollow tube comprising a
wound structure comprising aerosolizable material; and an apparatus
for heating the aerosolizable material of the consumable to
volatilize at least one component of the aerosolizable material,
the apparatus comprising a heating zone for receiving the
consumable, and a device for causing heating of the aerosolizable
material when the consumable is in the heating zone.
17. The system of claim 16, wherein the device comprises a magnetic
field generator for generating a varying magnetic field for
penetrating the heating zone when the consumable is in the heating
zone.
18. A method of manufacturing a hollow tube for use in or as a
consumable for use with an apparatus for heating aerosolizable
material to volatilize at least one component of the aerosolizable
material, the method comprising: winding a structure comprising
aerosolizable material.
19. The method of claim 18, wherein the winding comprises helically
winding the structure comprising aerosolizable material.
20. The method of claim 18, wherein the winding comprises winding
the structure comprising aerosolizable material around a
mandrel.
21. The method of claim 20, further comprising applying the
aerosolizable material to a material using the mandrel to form the
structure.
22. The method of claim 18, comprising winding a material while
drawing the material from a supply, and applying the aerosolizable
material to the material downstream of the supply.
23. The method of claim 18, wherein the wound structure forms a
layer of the hollow tube, and the method comprises winding one or
more further layers.
24. The method of claim 23, wherein at least one of the one or more
further layers comprises a heating material that is heatable by
penetration with a varying magnetic field.
25. The method of claim 18, wherein winding the structure
comprising aerosolizable material comprises winding the structure
comprising aerosolizable material to form an innermost surface of
the hollow tube.
26. The method of claim 18, wherein the structure comprising
aerosolizable material consists of the aerosolizable material, or
comprises a carrier with the aerosolizable material on a surface of
the carrier or impregnated in the carrier.
27. The method of claim 18, wherein the aerosolizable material of
the structure comprises an amorphous solid.
Description
PRIORITY CLAIM
[0001] The present application is a National Phase entry of PCT
Application No. PCT/EP2019/070735, filed Jul. 31, 2019 which claims
priority from GB Patent Application No. 1812492.5 filed Jul. 31,
2018, each of which is hereby fully incorporated herein by
reference.
TECHNICAL FIELD
[0002] The present disclosure relates to consumables for use with
apparatus for heating aerosolizable material, to systems comprising
such a consumable and an apparatus for heating aerosolizable
material of the consumable to volatilize at least one component of
the aerosolizable material, and to methods of manufacturing
consumables for use with apparatus for heating aerosolizable
material.
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 a
consumable for use with apparatus for heating aerosolizable
material to volatilize at least one component of the aerosolizable
material, the consumable comprising a hollow tube comprising a
wound structure comprising aerosolizable material.
[0005] In an exemplary embodiment, the consumable is
non-combustible.
[0006] In an exemplary embodiment, the wound structure is a
helically wound structure.
[0007] In an exemplary embodiment, the aerosolizable material
comprises tobacco. In an exemplary embodiment, the aerosolizable
material comprises reconstituted aerosolizable material. In an
exemplary embodiment, the aerosolizable material comprises an
amorphous solid.
[0008] In an exemplary embodiment, the structure comprising
aerosolizable material comprises a carrier, and the aerosolizable
material is on a surface of the carrier or impregnated in the
carrier. In an exemplary embodiment, the structure comprising
aerosolizable material consists of the aerosolizable material. For
example, the aerosolizable material may be cast or otherwise
shaped.
[0009] In an exemplary embodiment, the wound structure comprising
aerosolizable material defines at least part of a surface of the
consumable. In an exemplary embodiment, the wound structure
comprising aerosolizable material defines the surface of the
consumable. In an exemplary embodiment, the surface is an innermost
surface of the consumable.
[0010] In an exemplary embodiment, the wound structure comprising
aerosolizable material comprises corrugations, embossing or
debossing.
[0011] In an exemplary embodiment, the wound structure forms a
layer of the hollow tube, and the hollow tube comprises one or more
further layers. In an exemplary embodiment, at least one of the
further layer is a wound layer, such as a helically wound layer. In
an exemplary embodiment, the aerosolizable material adheres the
wound structure comprising aerosolizable material to at least one
of the one or more further layers.
[0012] In an exemplary embodiment, the wound structure comprising
aerosolizable material comprises corrugations, embossing or
debossing, and the hollow tube comprises one or more aerosol flow
paths defined by and between the corrugations, embossing or
debossing of the structure comprising aerosolizable material and at
least one of the one or more further layers.
[0013] In an exemplary embodiment, the hollow tube comprises a
barrier layer that defines at least part of a surface of the
consumable. In an exemplary embodiment, the barrier layer is
impermeable to aerosol released from the aerosolizable material
during heating of the aerosolizable material in use. In an
exemplary embodiment, the barrier layer is a wound layer, such as a
helically wound layer. In an exemplary embodiment, the barrier
layer defines the surface of the consumable. In an exemplary
embodiment, the surface is an outermost surface of the
consumable.
[0014] In an exemplary embodiment, the consumable is free from
heating material that is heatable by penetration with a varying
magnetic field. In an alternate exemplary embodiment, the
consumable comprises heating material that is heatable by
penetration with a varying magnetic field. In an exemplary
embodiment, the hollow tube comprises a layer comprising the
heating material.
[0015] 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. In an exemplary
embodiment, the heating material comprises a metal or a metal
alloy. 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, molybdenum, silicon carbide, copper, and
bronze.
[0016] In an exemplary embodiment, the layer comprising the heating
material comprises a metal foil or a metal alloy foil.
[0017] In an exemplary embodiment, the layer comprising the heating
material is a wound layer, such as a helically wound layer.
[0018] In an exemplary embodiment, the hollow tube comprises a
barrier layer that defines at least part of a surface of the
consumable, and the layer comprising the heating material is
located between the barrier layer and the wound structure
comprising aerosolizable material.
[0019] In an exemplary embodiment, the layer comprising the heating
material is located radially outwards of the wound structure
comprising aerosolizable material.
[0020] In an exemplary embodiment, the one or more further layers
comprise one or more further wound layers, such as helically wound
layers.
[0021] In an exemplary embodiment, the hollow tube comprises one or
more further layers, and at least one of the one or more further
layers comprises aerosolizable material. In an exemplary
embodiment, the hollow tube comprises a layer comprising heating
material, wherein the layer comprising heating material is located
between the wound structure comprising aerosolizable material and
the at least one further layer comprising aerosolizable
material.
[0022] In an exemplary embodiment, the hollow tube comprises one or
more further layers, and at least one of the one or more further
layers comprises a flavorant or a sensate.
[0023] In an exemplary embodiment, the aerosolizable material of
the wound structure comprises an amorphous solid.
[0024] A second 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: the
consumable of the first aspect of the present disclosure; and
apparatus for heating the aerosolizable material of the consumable
to volatilize at least one component of the aerosolizable material,
the apparatus comprising a heating zone for receiving the
consumable, and a device for causing heating of the aerosolizable
material when the consumable is in the heating zone.
[0025] In an exemplary embodiment, the device comprises a magnetic
field generator for generating a varying magnetic field for
penetrating the heating zone when the consumable is in the heating
zone.
[0026] In an exemplary embodiment, the device for causing heating
of the aerosolizable material when the consumable is in the heating
zone is configured for heating different sections of the heating
zone independently of each other.
[0027] A third aspect of the present disclosure provides a method
of manufacturing a hollow tube for use in or as a consumable for
use with apparatus for heating aerosolizable material to volatilize
at least one component of the aerosolizable material, the method
comprising: winding a structure comprising aerosolizable
material.
[0028] In an exemplary embodiment, the aerosolizable material
comprises tobacco. In an exemplary embodiment, the aerosolizable
material is reconstituted aerosolizable material. In an exemplary
embodiment, the aerosolizable material comprises an amorphous
solid.
[0029] In an exemplary embodiment, the structure comprising
aerosolizable material comprises a carrier, and the aerosolizable
material is on a surface of the carrier or impregnated in the
carrier. In an exemplary embodiment, the structure comprising
aerosolizable material consists of the aerosolizable material. For
example, the aerosolizable material may be cast or otherwise
shaped.
[0030] In an exemplary embodiment, the winding comprises helically
winding the structure comprising aerosolizable material.
[0031] In an exemplary embodiment, the winding comprises winding
the structure comprising aerosolizable material around a
mandrel.
[0032] In an exemplary embodiment, the method comprises applying
the aerosolizable material to a material using the mandrel to form
the structure.
[0033] In an exemplary embodiment, the method comprises winding a
material while drawing the material from a supply, and applying the
aerosolizable material to the material downstream of the
supply.
[0034] In an exemplary embodiment, the material is porous to the
aerosolizable material.
[0035] In an exemplary embodiment, the method comprises drying the
aerosolizable material during or after the winding of the structure
comprising aerosolizable material.
[0036] In an exemplary embodiment, the wound structure forms a
layer of the hollow tube, and the method comprises winding one or
more further layers. In an exemplary embodiment, the method
comprises winding one or more further layers around the structure
comprising aerosolizable material. In an exemplary embodiment, the
method comprises winding the structure comprising aerosolizable
material around one or more layers.
[0037] In an exemplary embodiment, the method comprises helically
winding the one or more further layers.
[0038] In an exemplary embodiment, the method comprises winding the
structure comprising aerosolizable material around a mandrel, and
winding the one or more layers around the mandrel.
[0039] In an exemplary embodiment, at least one of the one or more
layers comprises heating material that is heatable by penetration
with a varying magnetic field.
[0040] In an exemplary embodiment, the winding the structure
comprising aerosolizable material comprises winding the structure
comprising aerosolizable material to form an innermost surface of
the hollow tube.
[0041] In an exemplary embodiment, the structure comprising
aerosolizable material consists of the aerosolizable material, or
comprises a carrier with the aerosolizable material on a surface of
the carrier or impregnated in the carrier.
[0042] In an exemplary embodiment, the aerosolizable material of
the structure comprises an amorphous solid.
[0043] A further aspect of the present disclosure may provide the
use of the consumable of the first aspect of the present disclosure
in the generation of an inhalable aerosol.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] Embodiments of the disclosure will now be described, by way
of example only, with reference to the accompanying drawings, in
which:
[0045] FIG. 1 shows a schematic cross-sectional side view of an
example of a consumable for use with apparatus for heating
aerosolizable material to volatilize at least one component of the
aerosolizable material;
[0046] FIG. 2 shows a schematic cross-sectional end view of the
consumable of FIG. 1 taken along the line II-II in FIG. 1;
[0047] FIG. 3 shows a schematic cross-sectional side view of an
example of another consumable for use with apparatus for heating
aerosolizable material to volatilize at least one component of the
aerosolizable material;
[0048] FIG. 4 shows a schematic cross-sectional end view of the
consumable of FIG. 3 taken along the line Iv-Iv in FIG. 3;
[0049] FIG. 5 shows a schematic cross-sectional side view of an
example of a system comprising a consumable and apparatus for
heating aerosolizable material of the consumable to volatilize at
least one component of the aerosolizable material;
[0050] FIG. 6 shows a flow diagram showing an example of a method
of manufacturing a hollow tube for use in or as a consumable for
use with apparatus for heating aerosolizable material to volatilize
at least one component of the aerosolizable material; and
[0051] FIG. 7 shows a flow diagram showing an example of another
method of manufacturing a hollow tube for use in or as a consumable
for use with apparatus for heating aerosolizable material to
volatilize at least one component of the aerosolizable
material.
DETAILED DESCRIPTION
[0052] 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.
[0053] In some embodiments, the aerosolizable material comprises an
"amorphous solid", which may alternatively be referred to as a
"monolithic solid" (i.e. non-fibrous), or as a "dried gel". The
amorphous solid is a solid material that may retain some fluid,
such as liquid, within it. In some cases, the aerosolizable
material comprises from about 50 wt %, 60 wt % or 70 wt % of
amorphous solid, to about 90 wt %, 95 wt % or 100 wt % of amorphous
solid. In some cases, the aerosolizable material consists of
amorphous solid.
[0054] The amorphous solid may be formed as a sheet. It may be
incorporated into the consumable in sheet form. In some cases, the
aerosolizable material may be included as a planar sheet, as a
bunched or gathered sheet, as a crimped sheet, or as a rolled sheet
(i.e. in the form of a tube). In some such cases, the amorphous
solid of these embodiments may be included in a consumable or
system as a sheet, such as a sheet circumscribing a rod of
aerosolizable material (e.g. tobacco). In some other cases, the
aerosolizable material may be formed as a sheet and then shredded
and incorporated into the consumable. In some cases, the shredded
sheet may be mixed with cut rag tobacco and incorporated into the
consumable.
[0055] In some embodiments, the amorphous solid takes the form of a
foam, such as an open celled foam.
[0056] "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.
[0057] In some cases, the amorphous solid may comprise 1-60 wt % of
a gelling agent wherein these weights are calculated on a dry
weight basis.
[0058] Suitably, the amorphous solid may comprise from about 1 wt
%, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 60 wt %,
50 wt %, 45 wt %, 40 wt %, 35 wt %, 30 wt % or 27 wt % of a gelling
agent (all calculated on a dry weight basis). For example, the
amorphous solid may comprise 1-50 wt %, 5-40 wt %, 10-30 wt % or
15-27 wt % of a gelling agent.
[0059] In some embodiments, the gelling agent comprises a
hydrocolloid. In some embodiments, the gelling agent comprises one
or more compounds selected from the group comprising alginates,
pectins, starches (and derivatives), celluloses (and derivatives),
gums, silica or silicones compounds, clays, polyvinyl alcohol and
combinations thereof. For example, in some embodiments, the gelling
agent comprises one or more of alginates, pectins, hydroxyethyl
cellulose, hydroxypropyl cellulose, carboxymethylcellulose,
pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum,
fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol.
In some cases, the gelling agent comprises alginate and/or pectin,
and may be combined with a setting agent (such as a calcium source)
during formation of the amorphous solid. In some cases, the
amorphous solid may comprise a calcium-crosslinked alginate and/or
a calcium-crosslinked pectin.
[0060] In some embodiments, the gelling agent comprises alginate,
and the alginate is present in the amorphous solid in an amount of
from 10-30 wt % of the amorphous solid (calculated on a dry weight
basis). In some embodiments, alginate is the only gelling agent
present in the amorphous solid. In other embodiments, the gelling
agent comprises alginate and at least one further gelling agent,
such as pectin.
[0061] In some embodiments the amorphous solid may include gelling
agent comprising carrageenan.
[0062] Suitably, the amorphous solid may comprise from about 5 wt
%, 10 wt %, 15 wt %, or 20 wt % to about 80 wt %, 70 wt %, 60 wt %,
55 wt %, 50 wt %, 45 wt % 40 wt %, or 35 wt % of an aerosol
generating agent (all calculated on a dry weight basis). The
aerosol generating agent may act as a plasticizer. For example, the
amorphous solid may comprise 10-60 wt %, 15-50 wt % or 20-40 wt %
of an aerosol generating agent. In some cases, the aerosol
generating agent comprises one or more compound selected from
erythritol, propylene glycol, glycerol, triacetin, sorbitol and
xylitol. In some cases, the aerosol generating agent comprises,
consists essentially of or consists of glycerol. The inventors have
established that if the content of the plasticizer is too high, the
amorphous solid may absorb water resulting in a material that does
not create an appropriate consumption experience in use. The
inventors have established that if the plasticizer content is too
low, the amorphous solid may be brittle and easily broken. The
plasticizer content specified herein provides an amorphous solid
flexibility which allows the amorphous solid sheet to be wound onto
a bobbin, which is useful in manufacture of aerosol generating
articles.
[0063] In some cases, the amorphous solid may comprise a flavor.
Suitably, the amorphous solid may comprise up to about 60 wt %, 50
wt %, 40 wt %, 30 wt %, 20 wt %, 10 wt % or 5 wt % of a flavor. In
some cases, the amorphous solid may comprise at least about 0.1 wt
%, 0.5 wt %, 1 wt %, 2 wt %, 5 wt % 10 wt %, 20 wt % or 30 wt % of
a flavor (all calculated on a dry weight basis). For example, the
amorphous solid may comprise 0.1-60 wt %, 1-60 wt %, 5-60 wt %,
10-60 wt %, 20-50 wt % or 30-40 wt % of a flavor. In some cases,
the flavor (if present) comprises, consists essentially of or
consists of menthol. In some cases, the amorphous solid does not
comprise a flavor.
[0064] In some cases, the amorphous solid comprises an active
substance. For example, in some cases, the amorphous solid
comprises a tobacco material and/or nicotine. For example, the
amorphous solid may comprise powdered tobacco and/or nicotine
and/or a tobacco extract. In some cases, the amorphous solid may
comprise from about 1 wt %, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25
wt % to about 70 wt %, 50 wt %, 45 wt % or 40 wt % (calculated on a
dry weight basis) of active substance. In some cases, the amorphous
solid may comprise from about 1 wt %, 5 wt %, 10 wt %, 15 wt %, 20
wt % or 25 wt % to about 70 wt %, 60 wt %, 50 wt %, 45 wt % or 40
wt % (calculated on a dry weight basis) of a tobacco material
and/or nicotine.
[0065] In some cases, the amorphous solid comprises an active
substance such as tobacco extract. In some cases, the amorphous
solid may comprise 5-60 wt % (calculated on a dry weight basis) of
tobacco extract. In some cases, the amorphous solid may comprise
from about 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 55
wt %, 50 wt %, 45 wt % or 40 wt % (calculated on a dry weight
basis) tobacco extract. For example, the amorphous solid may
comprise 5-60 wt %, 10-55 wt % or 25-55 wt % of tobacco extract.
The tobacco extract may contain nicotine at a concentration such
that the amorphous solid comprises 1 wt % 1.5 wt %, 2 wt % or 2.5
wt % to about 6 wt %, 5 wt %, 4.5 wt % or 4 wt % (calculated on a
dry weight basis) of nicotine. In some cases, there may be no
nicotine in the amorphous solid other than that which results from
the tobacco extract.
[0066] In some embodiments the amorphous solid comprises no tobacco
material but does comprise nicotine. In some such cases, the
amorphous solid may comprise from about 1 wt %, 2 wt %, 3 wt % or 4
wt % to about 20 wt %, 15 wt %, 10 wt % or 5 wt % (calculated on a
dry weight basis) of nicotine. For example, the amorphous solid may
comprise 1-20 wt % or 2-5 wt % of nicotine.
[0067] In some cases, the total content of active substance and/or
flavor may be at least about 0.1 wt %, 1 wt %, 5 wt %, 10 wt %, 20
wt %, 25 wt % or 30 wt %. In some cases, the total content of
active substance and/or flavor may be less than about 80 wt %, 70
wt %, 60 wt %, 50 wt % or 40 wt % (all calculated on a dry weight
basis).
[0068] In some cases, the total content of tobacco material,
nicotine and flavor may be at least about 1 wt %, 5 wt %, 10 wt %,
20 wt %, 25 wt % or 30 wt %. In some cases, the total content of
tobacco material, nicotine and flavor may be less than about 70 wt
%, 60 wt %, 50 wt % or 40 wt % (all calculated on a dry weight
basis).
[0069] In some cases, the amorphous solid comprises from about 1 wt
% to about 15 wt % water, or from about 5 wt % to about 15 wt %
calculated on a wet weight basis. Suitably, the water content of
the amorphous solid may be from about 5 wt %, 7 wt % or 9 wt % to
about 15 wt %, 13 wt % or 11 wt % (WWB), most suitably about 10 wt
%.
[0070] In some embodiments, the amorphous solid is a hydrogel and
comprises less than about 20 wt % of water calculated on a wet
weight basis. In some cases, the hydrogel may comprise less than
about 15 wt %, 12 wt % or 10 wt % of water calculated on a wet
weight basis (WWB). In some cases, the hydrogel may comprise at
least about 2 wt % or at least about 5 wt % of water (WWB).
[0071] The amorphous solid may be made from a gel, and this gel may
additionally comprise a solvent, included at 0.1-50 wt %. However,
the inventors have established that the inclusion of a solvent in
which the flavor is soluble may reduce the gel stability and the
flavor may crystallize out of the gel. As such, in some cases, the
gel does not include a solvent in which the flavor is soluble.
[0072] In some embodiments, the amorphous solid comprises less than
60 wt % of a filler, such as from 1 wt % to 60 wt %, or 5 wt % to
50 wt %, or 5 wt % to 30 wt %, or 10 wt % to 20 wt %.
[0073] In other embodiments, the amorphous solid comprises less
than 20 wt %, suitably less than 10 wt % or less than 5 wt % of a
filler. In some cases, the amorphous solid comprises less than 1 wt
% of a filler, and in some cases, comprises no filler.
[0074] The filler, if present, may comprise one or more inorganic
filler materials, such as calcium carbonate, perlite, vermiculite,
diatomaceous earth, colloidal silica, magnesium oxide, magnesium
sulphate, magnesium carbonate, and suitable inorganic sorbents,
such as molecular sieves. The filler may comprise one or more
organic filler materials such as wood pulp, cellulose and cellulose
derivatives. In particular cases, the amorphous solid comprises no
calcium carbonate such as chalk.
[0075] In particular embodiments which include filler, the filler
is fibrous. For example, the filler may be a fibrous organic filler
material such as wood pulp, hemp fiber, cellulose or cellulose
derivatives. Without wishing to be bound by theory, it is believed
that including fibrous filler in an amorphous solid may increase
the tensile strength of the material. This may be particularly
advantageous in examples wherein the amorphous solid is provided as
a sheet, such as when an amorphous solid sheet circumscribes a rod
of aerosolizable material.
[0076] In some embodiments, the amorphous solid does not comprise
tobacco fibers.
[0077] In particular embodiments, the amorphous solid does not
comprise fibrous material.
[0078] In some embodiments, the aerosolizable material does not
comprise tobacco fibers. In particular embodiments, the
aerosolizable material does not comprise fibrous material.
[0079] In some embodiments, the aerosol generating substrate does
not comprise tobacco fibers. In particular embodiments, the aerosol
generating substrate does not comprise fibrous material.
[0080] In some embodiments, the consumable does not comprise
tobacco fibers. In particular embodiments, the consumable does not
comprise fibrous material.
[0081] In some cases, the amorphous solid may consist essentially
of, or consist of a gelling agent, an aerosol generating agent, a
tobacco material and/or a nicotine source, water, and optionally a
flavor.
[0082] A method of making an aerosolizable material may comprise
(a) forming a slurry comprising components of the amorphous solid
or precursors thereof, (b) forming a layer of the slurry, and (c)
setting the slurry to form a gel and (d) drying to form an
amorphous solid.
[0083] The step (b) of forming a layer of the slurry may comprise
spraying, casting or extruding the slurry, for example. In some
cases, the layer is formed by electro-spraying the slurry. In some
cases, the layer is formed by casting the slurry.
[0084] In some cases, the slurry is applied to a carrier.
[0085] In some cases, the steps (b) and/or (c) and/or (d) may, at
least partially, occur simultaneously (for example, during
electro-spraying). In some cases, these steps may occur
sequentially.
[0086] The step (c) of setting the gel may comprise the addition of
a setting agent to the slurry. For example, the slurry may comprise
sodium, potassium or ammonium alginate as a gel-precursor, and a
setting agent comprising a calcium source (such as calcium
chloride), may be added to the slurry to form a calcium alginate
gel.
[0087] The total amount of the setting agent, such as a calcium
source, may be 0.5-5 wt % (calculated on a dry weight basis). The
inventors have found that the addition of too little setting agent
may result in an amorphous solid which does not stabilize the
amorphous solid components and results in these components dropping
out of the amorphous solid. The inventors have found that the
addition of too much setting agent results in an amorphous solid
that is very tacky and consequently has poor handleability.
[0088] Alginate salts are derivatives of alginic acid and are
typically high molecular weight polymers (10-600 kDa). Alginic acid
is a copolymer of .beta.-D-mannuronic (M) and .alpha.-L-guluronic
acid (G) units (blocks) linked together with (1,4)-glycosidic bonds
to form a polysaccharide. On addition of calcium cations, the
alginate crosslinks to form a gel. The inventors have determined
that alginate salts with a high G monomer content more readily form
a gel on addition of the calcium source. In some cases therefore,
the gel-precursor pay comprise an alginate salt in which at least
about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the
alginate copolymer are .alpha.-L-guluronic acid (G) units.
[0089] The drying step may cause the cast material thickness to
reduce by at least 80%, suitably 85% or 87%. For instance, the
slurry may be cast at a thickness of 2 mm, and the resulting dried
amorphous solid material may have a thickness of 0.2 mm.
[0090] In some cases, the amorphous solid may have a thickness of
about 0.015 mm to about 1.0 mm. Suitably, the thickness may be in
the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or
0.3 mm. The inventors have found that a material having a thickness
of 0.2 mm is particularly suitable. The amorphous solid may
comprise more than one layer, and the thickness described herein
refers to the aggregate thickness of those layers.
[0091] In some cases, the slurry solvent may consist essentially of
or consist of water. In some cases, the slurry may comprise from
about 50 wt %, 60 wt %, 70 wt %, 80 wt % or 90 wt % of solvent
(WWB).
[0092] In cases where the solvent consists of water, the dry weight
content of the slurry may match the dry weight content of the
amorphous solid. Thus, the discussion herein relating to the solid
composition is explicitly disclosed in combination with the slurry
aspect of the invention.
[0093] In some examples, the slurry has a viscosity of from about
10 to about 20 Pas at 46.5.degree. C., such as from about 14 to
about 16 Pas at 46.5.degree. C.
[0094] The aerosolizable material comprising the amorphous solid
may have any suitable area density, such as from 30 g/m.sup.2 to
120 g/m.sup.2. In some embodiments, aerosolizable material may have
an area density of from about 30 to 70 g/m.sup.2, or about 40 to 60
g/m.sup.2. In some embodiments, the amorphous solid may have an
area density of from about 80 to 120 g/m.sup.2, or from about 70 to
110 g/m.sup.2, or particularly from about 90 to 110 g/m.sup.2. Such
area densities may be particularly suitable where the
aerosol-generating material is included in a consumable or system
in sheet form, or as a shredded sheet (described further
hereinbelow).
[0095] In some examples, the amorphous solid in sheet form may have
a tensile strength of from around 200 N/m to around 900 N/m. In
some examples, such as where the amorphous solid does not comprise
a filler, the amorphous solid may have a tensile strength of from
200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. Such
tensile strengths may be particularly suitable for embodiments
wherein the aerosolizable material is formed as a sheet and then
shredded and incorporated into a consumable. In some examples, such
as where the amorphous solid comprises a filler, the amorphous
solid may have a tensile strength of from 600 N/m to 900 N/m, or
from 700 N/m to 900 N/m, or around 800 N/m. Such tensile strengths
may be particularly suitable for embodiments wherein the
aerosolizable material is included in a consumable or system as a
rolled sheet, suitably in the form of a tube
[0096] In one particular case, the carrier may be a paper-backed
foil; the paper layer abuts the amorphous solid layer and the
properties discussed in the previous paragraphs are afforded by
this abutment. The foil backing is substantially impermeable,
providing control of the aerosol flow path. A metal foil backing
may also serve to conduct heat to the amorphous solid.
[0097] In another case, the foil layer of the paper-backed foil
abuts the amorphous solid. The foil is substantially impermeable,
thereby preventing water provided in the amorphous solid to be
absorbed into the paper which could weaken its structural
integrity.
[0098] In some cases, the carrier is formed from or comprises metal
foil, such as aluminum foil. A metallic carrier may allow for
better conduction of thermal energy to the amorphous solid.
Additionally, or alternatively, a metal foil may function as a
susceptor in an induction heating system. In particular
embodiments, the carrier comprises a metal foil layer and a support
layer, such as cardboard. In these embodiments, the metal foil
layer may have a thickness of less than 20 .mu.m, such as from
about 1 .mu.m to about 10 .mu.m, suitably about 5 .mu.m.
[0099] The active substance as used herein may be a physiologically
active material, which is a material intended to achieve or enhance
a physiological response. The active substance may for example be
selected from nutraceuticals, nootropics, and psychoactives. The
active substance may be naturally occurring or synthetically
obtained. The active substance may comprise for example nicotine,
caffeine, taurine, theine, vitamins such as B6 or B12 or C,
melatonin, cannabinoids, or constituents, derivatives, or
combinations thereof. The active substance may comprise one or more
constituents, derivatives or extracts of tobacco, cannabis or
another botanical.
[0100] In some embodiments, the active substance comprises
nicotine.
[0101] In some embodiments, the active substance comprises
caffeine, melatonin or vitamin B12.
[0102] As noted herein, the active substance may comprise one or
more constituents, derivatives or extracts of cannabis, such as one
or more cannabinoids or terpenes.
[0103] Cannabinoids are a class of natural or synthetic chemical
compounds which act on cannabinoid receptors (i.e., CB1 and CB2) in
cells that repress neurotransmitter release in the brain.
Cannabinoids may be naturally occurring (phytocannabinoids) from
plants such as cannabis, from animals (endocannabinoids), or
artificially manufactured (synthetic cannabinoids). Cannabis
species express at least 85 different phytocannabinoids, and are
divided into subclasses, including cannabigerols, cannabichromenes,
cannabidiols, tetrahydrocannabinols, cannabinols and
cannabinodiols, and other cannabinoids. Cannabinoids found in
cannabis include, without limitation: cannabigerol (CBG),
cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol
(THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL),
cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin
(CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV),
cannabigerol monomethyl ether (CBGM), cannabinerolic acid,
cannabidiolic acid (CBDA), Cannabinol propyl variant (CBNV),
cannabitriol (CBO), tetrahydrocannabmolic acid (THCA), and
tetrahydrocannabivarinic acid (THCV A).
[0104] As noted herein, the active substance may comprise or be
derived from one or more botanicals or constituents, derivatives or
extracts thereof. As used herein, the term "botanical" includes any
material derived from plants including, but not limited to,
extracts, leaves, bark, fibers, stems, roots, seeds, flowers,
fruits, pollen, husk, shells or the like. Alternatively, the
material may comprise an active compound naturally existing in a
botanical, obtained synthetically. The material may be in the form
of liquid, gas, solid, powder, dust, crushed particles, granules,
pellets, shreds, strips, sheets, or the like. Example botanicals
are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel,
lemongrass, peppermint, spearmint, rooibos, chamomile, flax,
ginger, Ginkgo biloba, hazel, hibiscus, laurel, licorice
(liquorice), matcha, mate, orange skin, papaya, rose, sage, tea
such as green tea or black tea, thyme, clove, cinnamon, coffee,
aniseed (anise), basil, bay leaves, cardamom, coriander, cumin,
nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel,
mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant,
curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom,
myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive,
lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium,
mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana,
guarana, chlorophyll, baobab or any combination thereof. The mint
may be chosen from the following mint varieties: Mentha arvensis,
Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita
citrata c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha
cordifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha
pulegium, Mentha spicata c.v. and Mentha suaveolens.
[0105] In some embodiments, the botanical is selected from
eucalyptus, star anise, cocoa and hemp.
[0106] In some embodiments, the botanical is selected from rooibos
and fennel.
[0107] As used herein, the terms "flavor" and "flavorant" refer to
materials which, where local regulations permit, may be used to
create a desired taste, aroma or other somatosensorial sensation in
a product for adult consumers.
[0108] They may include naturally occurring flavor materials,
botanicals, extracts of botanicals, synthetically obtained
materials, or combinations thereof (e.g., tobacco, cannabis,
licorice (liquorice), hydrangea, eugenol, Japanese white bark
magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol,
Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices,
Asian spices, herb, wintergreen, cherry, berry, red berry,
cranberry, peach, apple, orange, mango, clementine, lemon, lime,
tropical fruit, papaya, rhubarb, grape, durian, dragon fruit,
cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon,
scotch, whiskey, gin, tequila, rum, spearmint, peppermint,
lavender, aloe vera, cardamom, celery, cascarilla, nutmeg,
sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine,
honey essence, rose oil, vanilla, lemon oil, orange oil, orange
blossom, cherry blossom, cassia, caraway, cognac, jasmine,
ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander,
coffee, hemp, a mint oil from any species of the genus Mentha,
eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, Ginkgo
biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such
as green tea or black tea, thyme, juniper, elderflower, basil, bay
leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel,
mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian,
pimento, mace, damien, marjoram, olive, lemon balm, lemon basil,
chive, carvi, verbena, tarragon, limonene, thymol, camphene),
flavor enhancers, bitterness receptor site blockers, sensorial
receptor site activators or stimulators, sugars and/or sugar
substitutes (e.g., sucralose, acesulfame potassium, aspartame,
saccharine, cyclamates, lactose, sucrose, glucose, fructose,
sorbitol, or mannitol), and other additives such as charcoal,
chlorophyll, minerals, botanicals, or breath freshening agents.
They may be imitation, synthetic or natural ingredients or blends
thereof. They may be in any suitable form, for example, liquid such
as an oil, solid such as a powder, or gas.
[0109] The flavor may suitably comprise one or more mint-flavors
suitably a mint oil from any species of the genus Mentha. The
flavor may suitably comprise, consist essentially of or consist of
menthol.
[0110] In some embodiments, the flavor comprises menthol, spearmint
and/or peppermint.
[0111] In some embodiments, the flavor comprises flavor components
of cucumber, blueberry, citrus fruits and/or redberry.
[0112] In some embodiments, the flavor comprises eugenol.
[0113] In some embodiments, the flavor comprises flavor components
extracted from tobacco.
[0114] In some embodiments, the flavor comprises flavor components
extracted from cannabis.
[0115] In some embodiments, the flavor may comprise a sensate,
which is intended to achieve a somatosensorial sensation which are
usually chemically induced and perceived by the stimulation of the
fifth cranial nerve (trigeminal nerve), in addition to or in place
of aroma or taste nerves, and these may include agents providing
heating, cooling, tingling, numbing effect. A suitable heat effect
agent may be, but is not limited to, vanillyl ethyl ether and a
suitable cooling agent may be, but not limited to eucalyptol,
WS-3.
[0116] As used herein, the term "aerosol generating agent" refers
to an agent that promotes the generation of an aerosol. An aerosol
generating agent may promote the generation of an aerosol by
promoting an initial vaporization and/or the condensation of a gas
to an inhalable solid and/or liquid aerosol.
[0117] Suitable aerosol generating agents include, but are not
limited to: a polyol such as erythritol, sorbitol, glycerol, and
glycols like propylene glycol or triethylene glycol; a non-polyol
such as monohydric alcohols, high boiling point hydrocarbons, acids
such as lactic acid, glycerol derivatives, esters such as diacetin,
triacetin, triethylene glycol diacetate, triethyl citrate or
myristates including ethyl myristate and isopropyl myristate and
aliphatic carboxylic acid esters such as methyl stearate, dimethyl
dodecanedioate and dimethyl tetradecanedioate. The aerosol
generating agent may suitably have a composition that does not
dissolve menthol. The aerosol generating agent may suitably
comprise, consist essentially of or consist of glycerol.
[0118] As used herein, the term "tobacco material" refers to any
material comprising tobacco or derivatives therefore. The term
"tobacco material" may include one or more of tobacco, tobacco
derivatives, expanded tobacco, reconstituted tobacco or tobacco
substitutes. The tobacco material may comprise one or more of
ground tobacco, tobacco fiber, cut tobacco, extruded tobacco,
tobacco stem, reconstituted tobacco and/or tobacco extract.
[0119] The tobacco used to produce tobacco material may be any
suitable tobacco, such as single grades or blends, cut rag or whole
leaf, including Virginia and/or Burley and/or Oriental. It may also
be tobacco particle `fines` or dust, expanded tobacco, stems,
expanded stems, and other processed stem materials, such as cut
rolled stems. The tobacco material may be a ground tobacco or a
reconstituted tobacco material. The reconstituted tobacco material
may comprise tobacco fibers, and may be formed by casting, a
Fourdrinier-based paper making-type approach with back addition of
tobacco extract, or by extrusion.
[0120] In some embodiments, the amorphous solid comprises
menthol.
[0121] Particular embodiments comprising a menthol-containing
amorphous solid may be particularly suitable for including in a
consumable or system as a shredded sheet. In these embodiments, the
amorphous solid may have the following composition (DWB): gelling
agent (preferably comprising alginate, more preferably comprising a
combination of alginate and pectin) in an amount of from about 20
wt % to about 40 wt %, or about 25 wt % to 35 wt %; menthol in an
amount of from about 35 wt % to about 60 wt %, or from about 40 wt
% to 55 wt %; aerosol generating agent (preferably comprising
glycerol) in an amount of from about 10 wt % to about 30 wt %, or
from about 15 wt % to about 25 wt % (DWB).
[0122] In one embodiment, the amorphous solid comprises about 32-33
wt % of an alginate/pectin gelling agent blend; about 47-48 wt %
menthol flavorant; and about 19-20 wt % glycerol aerosol generating
agent (DWB).
[0123] As noted above, the amorphous solid of these embodiments may
be included in a consumable or system as a shredded sheet. The
shredded sheet may be provided in the consumable or system blended
with cut tobacco. Alternatively, the amorphous solid may be
provided as a non-shredded sheet. Suitably, the shredded or
non-shredded sheet has a thickness of from about 0.015 mm to about
1 mm, preferably from about 0.02 mm to about 0.07 mm.
[0124] Particular embodiments of the menthol-containing amorphous
solid may be particularly suitable for including in a consumable or
system as a sheet, such as a sheet circumscribing a rod of
aerosolizable material (e.g. tobacco). In these embodiments, the
amorphous solid may have the following composition (DWB): gelling
agent (preferably comprising alginate, more preferably comprising a
combination of alginate and pectin) in an amount of from about 5 wt
% to about 40 wt %, or about 10 wt % to 30 wt %; menthol in an
amount of from about 10 wt % to about 50 wt %, or from about 15 wt
% to 40 wt %; aerosol generating agent (preferably comprising
glycerol) in an amount of from about 5 wt % to about 40 wt %, or
from about 10 wt % to about 35 wt %; and optionally filler in an
amount of up to 60 wt %--for example, in an amount of from 5 wt %
to 20 wt %, or from about 40 wt % to 60 wt % (DWB).
[0125] In one of these embodiments, the amorphous solid comprises
about 11 wt % of an alginate/pectin gelling agent blend, about 56
wt % woodpulp filler, about 18% menthol flavorant and about 15 wt %
glycerol (DWB).
[0126] In another of these embodiments, the amorphous solid
comprises about 22 wt % of an alginate/pectin gelling agent blend,
about 12 wt % woodpulp filler, about 36% menthol flavorant and
about 30 wt % glycerol (DWB).
[0127] As noted above, the amorphous solid of these embodiments may
be included as a sheet. In one embodiment, the sheet is provided on
a carrier comprising paper. In one embodiment, the sheet is
provided on a carrier comprising metal foil, suitably aluminum
metal foil. In this embodiment, the amorphous solid may abut the
metal foil.
[0128] In one embodiment, the sheet forms part of a laminate
material with a layer (preferably comprising paper) attached to a
top and bottom surface of the sheet. Suitably, the sheet of
amorphous solid has a thickness of from about 0.015 mm to about 1
mm.
[0129] In some embodiments, the amorphous solid comprises a
flavorant which does not comprise menthol. In these embodiments,
the amorphous solid may have the following composition (DWB):
gelling agent (preferably comprising alginate) in an amount of from
about 5 to about 40 wt %, or from about 10 wt % to about 35 wt %,
or from about 20 wt % to about 35 wt %; flavorant in an amount of
from about 0.1 wt % to about 40 wt %, of from about 1 wt % to about
30 wt %, or from about 1 wt % to about 20 wt %, or from about 5 wt
% to about 20 wt %; aerosol generating agent (preferably comprising
glycerol) in an amount of from 15 wt % to 75 wt %, or from about 30
wt % to about 70 wt %, or from about 50 wt % to about 65 wt %; and
optionally filler (suitably woodpulp) in an amount of less than
about 60 wt %, or about 20 wt %, or about 10 wt %, or about 5 wt %
(preferably the amorphous solid does not comprise filler)
(DWB).
[0130] In one of these embodiments, the amorphous solid comprises
about 27 wt % alginate gelling agent, about 14 wt % flavorant and
about 57 wt % glycerol aerosol generating agent (DWB).
[0131] In another of these embodiments, the amorphous solid
comprises about 29 wt % alginate gelling agent, about 9 wt %
flavorant and about 60 wt % glycerol (DWB).
[0132] The amorphous solid of these embodiments may be included in
a consumable or system as a shredded sheet, optionally blended with
cut tobacco. Alternatively, the amorphous solid of these
embodiments may be included in a consumable or system as a sheet,
such as a sheet circumscribing a rod of aerosolizable material
(e.g. tobacco). Alternatively, the amorphous solid of these
embodiments may be included in a consumable or system as a layer
portion disposed on a carrier.
[0133] In some embodiments, the amorphous solid comprises tobacco
extract. In these embodiments, the amorphous solid may have the
following composition (DWB): gelling agent (preferably comprising
alginate) in an amount of from about 5 wt % to about 40 wt %, or
about 10 wt % to 30 wt %, or about 15 wt % to about 25 wt %;
tobacco extract in an amount of from about 30 wt % to about 60 wt
%, or from about 40 wt % to 55 wt %, or from about 45 wt % to about
50 wt %; aerosol generating agent (preferably comprising glycerol)
in an amount of from about 10 wt % to about 50 wt %, or from about
20 wt % to about 40 wt %, or from about 25 wt % to about 35 wt %
(DWB).
[0134] In one embodiment, the amorphous solid comprises about 20 wt
% alginate gelling agent, about 48 wt % Virginia tobacco extract
and about 32 wt % glycerol (DWB).
[0135] The amorphous solid of these embodiments may have any
suitable water content. For example, the amorphous solid may have a
water content of from about 5 wt % to about 15 wt %, or from about
7 wt % to about 13 wt %, or about 10 wt %.
[0136] The amorphous solid of these embodiments may be included in
a consumable or system as a shredded sheet, optionally blended with
cut tobacco. Alternatively, the amorphous solid of these
embodiments may be included in a consumable or system as a sheet,
such as a sheet circumscribing a rod of aerosolizable material
(e.g. tobacco). Alternatively, the amorphous solid of these
embodiments may be included in a consumable or system as a layer
portion disposed on a carrier. Suitably, in any of these
embodiments, the amorphous solid has a thickness of from about 50
.mu.m to about 200 .mu.m, or about 50 .mu.m to about 100 .mu.m, or
about 60 .mu.m to about 90 .mu.m, suitably about 77 .mu.m.
[0137] The slurry for forming this amorphous solid may also form
part of the invention. In some cases, the slurry may have an
elastic modulus of from about 5 to 1200 Pa (also referred to as
storage modulus); in some cases, the slurry may have a viscous
modulus of about 5 to 600 Pa (also referred to as loss
modulus).
[0138] All percentages by weight described herein (denoted wt %)
are calculated on a dry weight basis, unless explicitly stated
otherwise. All weight ratios are also calculated on a dry weight
basis. A weight quoted on a dry weight basis refers to the whole of
the extract or slurry or material, other than the water, and may
include components which by themselves are liquid at room
temperature and pressure, such as glycerol. Conversely, a weight
percentage quoted on a wet weight basis refers to all components,
including water.
[0139] As used herein, the term "sheet" denotes an element having a
width and length substantially greater than a thickness thereof.
The sheet may be a strip, for example.
[0140] As used herein, the term "heating material" or "heater
material" refers to material that is heatable by penetration with a
varying magnetic field.
[0141] 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.
[0142] 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.
[0143] 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.
[0144] 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.
[0145] 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.
[0146] Referring to FIGS. 1 and 2, there are shown schematic
cross-sectional side and end views of an example of a consumable
according to an embodiment of the disclosure. The consumable 1 is
for use with apparatus for heating aerosolizable material to
volatilize at least one component of the aerosolizable material,
such as the apparatus 100 shown in FIG. 5 and described below. The
apparatus may be a tobacco heating product (also known in the art
as a tobacco heating device or a heat-not-burn device).
[0147] The consumable 1 comprises a hollow tube 1a. The hollow tube
1a defines a passageway 20 therein. The hollow tube 1a comprises a
wound structure 10 comprising aerosolizable material. In this
embodiment, the wound structure 10 is a helically wound structure
comprising aerosolizable material. However, in other embodiments,
the wound structure may be non-helically wound. For example, the
structure comprising aerosolizable material may be non-helically
spirally wound.
[0148] In some embodiments, the aerosolizable material of the
structure 10 comprises tobacco. In some embodiments, the
aerosolizable material comprises reconstituted aerosolizable
material, such as reconstituted tobacco. In some embodiments, the
aerosolizable material comprises an amorphous solid, which may, for
example, be carried by a carrier such as paper or card. In other
embodiments, the aerosolizable material may be in any of the other
forms discussed herein. The structure comprising aerosolizable
material may comprise a carrier such as paper or card, and the
aerosolizable material may be on a surface of the carrier or
impregnated in the carrier. For example, the aerosolizable material
may comprise tobacco extract. In some embodiments, the structure
comprising aerosolizable material consists of the aerosolizable
material. For example, the aerosolizable material may be cast or
otherwise shaped.
[0149] In this embodiment, the wound structure 10 comprising
aerosolizable material defines both an innermost surface 1b of the
hollow tube 1a and an outermost surface 1c of the hollow tube 1a.
Indeed, in some embodiments, the hollow tube 1a consists of, or
substantially consists of, the wound structure 10 comprising
aerosolizable material. In other embodiments, as will be understood
from the discussion below, the innermost surface 1b of the hollow
tube 1a and/or the outermost surface 1c of the hollow tube 1a may
be defined by a part of the consumable other than the wound
structure 10 comprising aerosolizable material. The part may be
another layer of the hollow tube 1a or of the consumable. In some
embodiments, the wound structure 10 comprising aerosolizable
material defines only part of the innermost surface 1b of the
hollow tube 1a and/or only part of the outermost surface 1c of the
hollow tube 1a, as a result of another part of the hollow tube 1a
or consumable defining some or all of the rest of the innermost
and/or outermost surface, respectively.
[0150] In this embodiment, the structure 10 comprising
aerosolizable material is circular. In other embodiments, the wound
structure 10 comprising aerosolizable material comprises
corrugations, embossing or debossing. Such an arrangement may
increase the surface area over which an aerosol is able to form
from the aerosolizable material in use.
[0151] Referring to FIGS. 3 and 4, there are shown schematic
cross-sectional side and end views of an example of another
consumable according to an embodiment of the disclosure. The
consumable 2 of FIGS. 3 and 4 is for use with apparatus for heating
aerosolizable material to volatilize at least one component of the
aerosolizable material, such as the apparatus 100 shown in FIG. 5
and described below. The apparatus may be a tobacco heating product
(also known in the art as a tobacco heating device or a
heat-not-burn device).
[0152] The consumable 2 comprises a hollow tube 2a. The hollow tube
2a defines a passageway 20 therein. The hollow tube 2a comprises
plural layers 10, 11, 12, 13. In some embodiments, two or some or
all of the plural layers 10, 11, 12, 13 are bonded together such
that the plural layers form a laminate.
[0153] One of the layers is a wound structure 10 comprising
aerosolizable material. In this embodiment, the wound structure 10
is a helically wound structure comprising aerosolizable material.
However, in other embodiments, the wound structure may be
non-helically wound. For example, the structure comprising
aerosolizable material may be non-helically spirally wound.
[0154] In some embodiments, the aerosolizable material of the
structure 10 comprises tobacco. In some embodiments, the
aerosolizable material is reconstituted aerosolizable material,
such as reconstituted tobacco. In some embodiments, the
aerosolizable material comprises an amorphous solid, which may, for
example, be carried by a carrier such as paper or card. The
structure comprising aerosolizable material may comprise a carrier
such as paper or card, and the aerosolizable material may be on a
surface of the carrier or impregnated in the carrier. For example,
the aerosolizable material may comprise tobacco extract. In some
embodiments, the structure comprising aerosolizable material
consists of the aerosolizable material. For example, the
aerosolizable material may be cast or otherwise shaped.
[0155] In this embodiment, the wound structure 10 comprising
aerosolizable material defines a surface of the hollow tube 2a, and
more specifically an innermost surface 2b of the hollow tube 2a. In
other embodiments, the wound structure 10 comprising aerosolizable
material defines only part of the innermost surface 2b hollow tube
2a, as a result of another part of the hollow tube 2a or of the
consumable defining some or all of the rest of the innermost
surface 2b.
[0156] The wound structure 10 comprising aerosolizable material
comprises corrugations in this embodiment. In other embodiments,
the structure 10 additionally or alternatively comprises embossing
or debossing, so as to be embossed or debossed, respectively. As
mentioned elsewhere herein, such an arrangement may increase the
surface area over which an aerosol is able to form from the
aerosolizable material in use. In still other embodiments, the
wound structure 10 comprising aerosolizable material is free from
corrugations, embossings or debossings.
[0157] As noted above, the hollow tube 2a comprises further layers
11, 12, 13. It is to be noted that not all of these further layers
11, 12, 13 may be present in all embodiments. In this embodiment,
each of the further layers 11, 12, 13 is a wound layer, such as a
helically wound layer, but in other embodiments one or more of the
further layers 11, 12, 13 may be a non-wound layer, such as a cast
or extruded layer.
[0158] In this embodiment, the consumable 2 comprises heating
material that is heatable by penetration with a varying magnetic
field. The heating material may be any of those discussed herein.
The heating material is heatable to heat the aerosolizable material
of the wound structure 10. In this embodiment, the hollow tube 2a
comprises a layer 11 comprising the heating material. More
specifically, the layer 11 comprising heating material is radially
adjacent and abuts the wound structure 10 comprising aerosolizable
material, so that heat energy generated in the heating material in
use is able efficiently to pass to the aerosolizable material. In
this embodiment, the layer 11 comprising heating material is
located radially outwards of the wound structure 10 comprising
aerosolizable material, but in other embodiments the layer 11
comprising heating material may be located radially inwards of the
wound structure 10 comprising aerosolizable material.
[0159] In this embodiment, the layer 11 comprising heating material
is a wound layer, such as a helically wound layer, and the layer 11
comprising heating material has been wound around the structure 10
comprising aerosolizable material. In other embodiments, the layer
11 comprising heating material may be non-wound. In some
embodiments, the layer 11 comprising heating material comprises a
carrier, such as paper, carrying the heating material. In other
embodiments, the layer 11 comprising heating material comprises a
foil, such as a metal or metal alloy foil, such as aluminum foil.
In some embodiments, the layer 11 comprising heating material may
be omitted. Indeed, in some embodiments, the consumable 2 may be
free from heating material that is heatable by penetration with a
varying magnetic field.
[0160] In this embodiment, the aerosolizable material of the wound
structure 10 adheres the wound structure 10 to the layer 11
comprising heating material. In other embodiments, this may not be
the case and/or the aerosolizable material of the wound structure
10 may adhere the wound structure 10 to a different layer or part
of the hollow tube 2a. In some embodiments, a separate adhesive may
be used to adhere layers to each other.
[0161] As noted above, in this embodiment, the structure 10
comprising aerosolizable material comprises corrugations, and in
some other embodiments the structure 10 additionally or
alternatively comprises embossing or debossing. The hollow tube 2a
of this embodiment comprises one or more aerosol flow paths 17
defined by and between the corrugations, embossing or debossing of
the structure 10 comprising aerosolizable material and the layer 11
comprising heating material. The aerosol flow path(s) extend in the
axial direction of the hollow tube 2a and provide a route via which
aerosol generated in or from the aerosolizable material is able to
leave the hollow tube 2a. This may be particularly advantageous
when the passageway 20 of the consumable 2 is filled by a heating
element of an apparatus with which the consumable 2 is useable. In
other embodiments, such as those in which the hollow tube 2a is
free from heating material, the one or more aerosol flow paths may
be defined by and between the corrugations, embossing or debossing
of the structure 10 comprising aerosolizable material and another
layer or part of the hollow tube 2a, such as the other layer 12 or
the barrier layer 13 described below.
[0162] In this embodiment, the hollow tube 2a comprises a barrier
layer 13 that defines a surface of the hollow tube 2a. In this
embodiment, the surface is an outermost surface 2c of the hollow
tube 2a. Therefore, the barrier layer 13 is located radially
outwards of the wound structure 10 of aerosolizable material.
Moreover, the layer 11 comprising heating material is located
between the barrier layer 13 and the structure 10 comprising
aerosolizable material, and abuts the structure 10 comprising
aerosolizable material. In some embodiments, the barrier layer 13
defines only part of the outermost surface 2c of the hollow tube
2a, as a result of another part of the hollow tube 2a or consumable
defining some or all of the rest of the outermost surface 2c. In
some embodiments, the barrier layer 13 is a wound layer, such as a
helically wound layer, but in other embodiments the barrier layer
13 may be a non-wound layer.
[0163] The barrier layer 13 may, for example, comprise one or more
materials selected from the group consisting of: paper, card,
paperboard, cardboard, reconstituted tobacco, a plastics material,
and heating material. The barrier layer 13 may help to provide the
hollow tube 2a with rigidity. In some embodiments, such as those in
which the barrier layer 13 abuts or is adjacent to the structure 10
comprising aerosolizable material, the barrier layer 13 is
impermeable to aerosol generated in or from the structure 10 in
use. This may help to prevent or discourage the generated aerosol
from contacting the apparatus, or depositing in the apparatus, with
which the consumable 2 is usable. It may also help to channel the
aerosol generated in or from the aerosolizable material along and
out of the hollow tube 2a. In some embodiments, the barrier layer
13 is omitted.
[0164] The consumable 2 of this embodiment comprises another layer
12, which is radially adjacent and abuts the layer 11 comprising
heating material, so that heat energy generated in the heating
material in use is able efficiently to pass to the other layer 12.
In this embodiment, the layer 11 comprising heating material is
located radially inwards of the other layer 12, but in other
embodiments the layer 11 comprising heating material may be located
radially outwards of the other layer 12. The other layer 12 is thus
located between the barrier layer 13 and the layer 11 comprising
heating material. The other layer 12 also abuts the barrier layer
13, in this embodiment.
[0165] In some embodiments, the other layer 12 comprises
aerosolizable material. In some such embodiments, the hollow tube
2a thus comprises a layer 11 comprising heating material that is
located between the wound structure 10 comprising aerosolizable
material and the other layer 12 comprising aerosolizable material.
The aerosolizable material of the other layer 12 may adhere the
other layer 12 to the barrier layer 13 and/or to the layer 11
comprising heating material. In some embodiments, the aerosolizable
material of the other layer 12 comprises tobacco. In some
embodiments, the aerosolizable material is reconstituted
aerosolizable material, such as reconstituted tobacco. In some
embodiments, the aerosolizable material comprises an amorphous
solid, which may, for example, be carried by a carrier such as
paper or card. In some embodiments, additionally or alternatively
to aerosolizable material, the other layer 12 may comprise a
flavorant or a sensate, for example. In some embodiments, the other
layer 12 is omitted.
[0166] In some embodiments, the other layer 12 is a wound layer,
such as a helically wound layer, but in other embodiments the other
layer 12 may be a non-wound layer. In some embodiments, the other
layer 12 has been wound around the layer 11 comprising heating
material or whatever other layer is radially inwards of the other
layer 12. Similarly, in some embodiments, the barrier layer 13 has
been wound around the other layer 12.
[0167] In some embodiments, the aerosolizable material of the other
layer 12 has a different form or chemical composition to the
aerosolizable material of the structure 10. For example, in some
embodiments, the difference in form may comprise a difference in
mean particle size of the aerosolizable material. Typically,
particles of aerosolizable material having a smaller mean particle
size are heatable more quickly, for example to volatilize at least
one component of the aerosolizable material, by a given heat source
than are particles of the aerosolizable material having a greater
mean particle size.
[0168] In some embodiments, the difference in form may comprise the
aerosolizable material of one of the structure 10 and layer 12
being in the form of reconstituted aerosolizable material (such as
reconstituted tobacco) and the aerosolizable material of the other
of the structure 10 and layer 12 comprising an amorphous solid.
[0169] In some embodiments, the difference in chemical composition
may comprise a difference in the ingredient or ingredients of the
aerosolizable material, such as a difference in chemical
compositions of respective amorphous solids. In some embodiments,
the difference in chemical composition may comprise a difference in
the type or density of aerosol forming agent, such as glycerol, in
the aerosolizable material. In some embodiments, the difference in
chemical composition may comprise a difference in quantities by
weight of a smoke modifying agent, such as a flavorant as a
percentage of a total weight of aerosolizable material.
[0170] In some embodiments, the layer 12 (when provided) and/or the
wound structure 10 comprising aerosolizable material may comprise
plural, spaced apart discrete regions of aerosolizable material. In
use, such discrete regions of aerosolizable material may be
heatable independently by respective heaters of an apparatus with
which the consumable 2 is usable.
[0171] Accordingly, as noted above, in some embodiments the
plurality of layers 10, 11, 12, 13 of the hollow consumable 2a may
be wound layers, wherein outward ones of the layers 11, 12, 13 have
been wound around inward ones of the layers 10, 11, 12. Example
methods for manufacturing such hollow tubes 2a are discussed
below.
[0172] In some embodiments, an order of the layers 10, 11, 12, 13
of the hollow consumable 2a may be other than that shown in FIGS. 3
and 4. For example, in some embodiments, the consumable may have a
wound structure comprising aerosolizable material that forms at
least part of an outermost surface of the hollow tube, and a layer
comprising heating material that is located radially inwards of the
structure comprising aerosolizable material.
[0173] In some embodiments, the hollow tube 2a may comprise at
least one additional layer, which may or may not be a wound layer,
such as a helically wound layer.
[0174] In each of the embodiments of FIGS. 1 to 4, the hollow tube
1a, 2a has circular inner and outer cross-sectional shapes. In
other embodiments, one or each of the inner and outer
cross-sectional shapes of the hollow tube may be non-circular, such
as elliptical, polygonal, rectangular, square, triangular, or
star-shaped.
[0175] In each of the embodiments discussed above, the hollow tube
1a, 2a extends along an axis A-A. The axis A-A is a central axis
that extends along the passageway 20, but in other embodiments the
configuration of the consumable 1, 2 may be such that the axis A-A
is offset from the passageway 20. In the illustrated embodiments,
the consumable 1, 2 is elongate in the direction of the axis A-A,
but in other embodiments a width or diameter of the consumable 1, 2
may be greater than or equal to a dimension of the consumable 1, 2
in the direction of the axis A-A, so that the consumable 1, 2 is
not elongate. Moreover, in the illustrated embodiments, the hollow
tube 1a, 2a of the consumable 1, 2 is elongate in the direction of
the axis A-A, but in other embodiments a width or diameter of the
hollow tube 1a, 2a may be greater than or equal to a dimension of
the hollow tube 1a, 2a in the direction of the axis A-A, so that
the hollow tube 1a, 2a is not itself elongate.
[0176] In each of the embodiments of FIGS. 1 to 4, the passageway
20 opens at an axial end 15 of the hollow tube 1a, 2a, and indeed
the consumable 1, 2. In some embodiments, such as some of those in
which the consumable is free from heating material, a heating
element of the apparatus may be insertable into the passageway 20
in use, as will be discussed in more detail below. In each of the
embodiments of FIGS. 1 to 4, the passageway 20 extends fully
through the hollow tube 1a, 2a from one axial end 15 of the hollow
tube 1a, 2a to an opposite axial end 16 of the hollow tube 1a, 2a.
Moreover, in each of these embodiments, the passageway 20 extends
fully through the consumable 1, 2 from a first axial end 15 of the
consumable 1, 2 to an opposite second axial end 16 of the
consumable 1, 2. However, in some embodiments, the passageway 20
may extend only partially along a length or axial dimension of the
consumable 1, 2, such as for a majority of the length or axial
dimension of the consumable 1, 2 or for a minority of a length or
axial dimension of the consumable 1, 2.
[0177] In some embodiments, the hollow tube 1a, 2a extends for a
full length or axial dimension of the consumable 1, 2. In other
embodiments, the consumable 1, 2 may comprise one or more elements
(not shown) at one or each axial end of the hollow tube 1a, 2a, so
that the hollow tube 1a, 2a extends for only part of the length or
axial dimension of the consumable 1, 2.
[0178] In some embodiments, the consumable 1, 2 comprises a porous
body (not shown). The porous body may be for filtering aerosol or
vapor released from the aerosolizable material in use.
Alternatively, or additionally, the porous body may be for
controlling the pressure drop over a length or axial dimension of
the consumable 1, 2. The porous body could be of any type used in
the tobacco industry. For example, the porous body may be made of
cellulose acetate. In some embodiments, the porous body is
substantially cylindrical with a substantially circular cross
section and a longitudinal axis. In other embodiments, the filter
may have a different cross section or not be elongate.
[0179] In some embodiments, the porous body abuts an axial end 15,
16 of the hollow tube 1a, 2a and is axially aligned with the hollow
tube 1a, 2a. In other embodiments, the porous body may be spaced
from the hollow tube 1a, 2a, such as by a gap and/or by one or more
further components of the consumable 1, 2. 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.
[0180] The consumable 1, 2 may also comprise a wrap that is wrapped
around the hollow tube 1a, 2a and the porous body to retain the
porous body relative to the hollow tube 1a, 2a. The wrap may
encircle the hollow tube 1a, 2a and the porous body. The wrap may
be wrapped around the hollow tube 1a, 2a and the porous body so
that free ends of the wrap overlap each other. The wrap may form
part of, or all of, a circumferential outer surface of the
consumable 1, 2. The wrap could be made of any suitable material,
such as paper, card, or reconstituted aerosolizable material (e.g.
reconstituted tobacco). The wrap may also comprise an adhesive that
adheres the overlapped free ends of the wrap to each other. The
adhesive helps prevent the overlapped free ends of the wrap from
separating. In other embodiments, the adhesive may be omitted or
the wrap may take a different from to that described. In other
embodiments, the porous body may be retained relative to the hollow
tube 1a, 2a by a connector other than a wrap, such as an
adhesive.
[0181] In some embodiments, the consumable 1, 2 has a length or an
axial dimension of between 30 millimeters and 150 millimeters, such
as between 70 millimeters and 120 millimeters.
[0182] In some embodiments, the consumable 1, 2 has an inner
dimension (e.g. an inner diameter) in a direction perpendicular to
the axial direction of between 2 millimeters and 10 millimeters,
such as between 4 millimeters and 8 millimeters.
[0183] In some embodiments, the consumable 1, 2 has an outer
dimension (e.g. an outer diameter) in a direction perpendicular to
the axial direction of between 4 millimeters and 10 millimeters,
such as between 4.5 millimeters and 8 millimeters.
[0184] In some embodiments, the aerosolizable material, wherever
provided in the consumable 1, 2, has a thickness of between 0.05
millimeters and 2 millimeters, such as between 0.05 millimeters and
1 millimeter, or such as between 0.1 millimeters and 1 millimeter,
or such as between 0.15 millimeters and 0.5 millimeters. The
thickness may be less than or equal to 1 millimeter, such as less
than or equal to 0.5 millimeters, or less than or equal to 0.25
millimeters, or less than or equal to 0.2 millimeters, or less than
or equal to 0.1 millimeters, or less than or equal to 0.05
millimeters.
[0185] As noted herein, the wound structure may comprising
aerosolizable material may comprise corrugations, embossing or
debossing. In some such embodiments, the corrugations, embossing or
debossing define a plurality of troughs or depressions, and
aerosolizable material (such as an amorphous solid described
herein) is disposed in at least one of the troughs or depressions,
such as a plurality of the troughs or depressions.
[0186] Example methods of manufacturing a hollow tube for use in or
as a consumable for use with apparatus for heating aerosolizable
material to volatilize at least one component of the aerosolizable
material will now be described. Any of the following methods may be
used in the manufacture of any of the hollow tubes described
herein, for example.
[0187] FIG. 6 shows a flow diagram showing an example of a method
of manufacturing such a hollow tube. The method 600 comprises
winding 601 a structure comprising aerosolizable material.
[0188] The aerosolizable material may, for example, be any of those
discussed herein. In some embodiments, the aerosolizable material
comprises tobacco. In some embodiments, the aerosolizable material
is reconstituted aerosolizable material, such as reconstituted
tobacco. In some embodiments, the aerosolizable material comprises
an amorphous solid, which may, for example, be carried by a carrier
such as paper or card. The structure comprising aerosolizable
material may comprises a carrier such as paper or card, and the
aerosolizable material may be on a surface of the carrier or
impregnated in the carrier. For example, the aerosolizable material
may comprise tobacco extract. In some embodiments, the structure
comprising aerosolizable material consists of the aerosolizable
material. For example, the aerosolizable material may be cast or
otherwise shaped.
[0189] In some embodiments, the winding 601 comprises helically
winding the structure comprising aerosolizable material. In some
embodiments, the winding 601 comprises spirally winding the
structure comprising aerosolizable material. In some embodiments,
the winding 601 comprises helically-spirally winding the structure
comprising aerosolizable material so that the structure adopts a
helical spiral form.
[0190] The winding 601 may comprise winding the structure
comprising aerosolizable material around a mandrel. The mandrel may
be made of any suitable material, such as a metal, metal alloy, or
a plastics material such as polyether ether ketone (PEEK).
Alternatively, a mandrel may not be used. For instance, the
structure comprising aerosolizable material may be wound using a
garniture. In embodiments in which the structure comprising
aerosolizable material comprises corrugations or embossings or
debossings, a surface of the mandrel may be correspondingly shaped
so as to engage with the corrugations, embossings or
debossings.
[0191] In some embodiments, the winding 601 comprises winding the
structure comprising aerosolizable material to form an innermost
surface of the hollow tube. In other embodiments, the structure
comprising aerosolizable material may be wound around one or more
other elements of the hollow tube being manufactured, such as one
or more helically-wound layers, so that the structure comprising
aerosolizable material does not form an innermost surface of the
hollow tube.
[0192] In some embodiments, the structure comprising aerosolizable
material comprises aerosolizable material on a surface of a
carrier, such as paper. In some such embodiments, the method
comprises winding the carrier and the aerosolizable material around
a mandrel with the carrier in contact with the mandrel and the
aerosolizable material outermost, and then winding a layer, such as
of paper, onto the aerosolizable material. This forms an
arrangement in which the aerosolizable material is sandwiched
between the carrier and the layer.
[0193] FIG. 7 shows a flow diagram showing an example of another
method of manufacturing a hollow tube for use in or as a
consumable. The method 700 comprises drawing 701 material from a
supply, such as a bobbin or spool. The material may, for example,
be paper or card. The method also comprises winding 702 the
material while drawing it from the supply. The winding 702 may be
helical winding, for example. The winding 702 may comprise winding
the material around a mandrel. The mandrel may be made of any of
the mandrel materials discussed herein, for example.
[0194] In some embodiments, the material drawn from the supply
already has aerosolizable material thereon or therein. However, in
some alternative embodiments, the method comprises applying 703
aerosolizable material to the material downstream of the supply.
The aerosolizable material may be any of those discussed herein.
The applying 703 may be performed upstream of the point at which
the winding 702 of the material is performed. Alternatively, in
embodiments in which the winding 702 comprises winding the material
around a mandrel, the applying 703 may be performed using the
mandrel. For example, the aerosolizable material may be passed,
such as pumped, in fluid form through the mandrel and into contact
with the material while the material is on the mandrel. The mandrel
may include a first portion around which the material is wound or
wrapped, and a second portion downstream of the first portion and
including aerosolizable material supply holes thorough which the
aerosolizable material passes into contact with the material. The
first portion of the mandrel may be free from aerosolizable
material supply holes. The material may be porous, or non-porous,
to the aerosolizable material. Following the application 703 of the
aerosolizable material to the material, the material carrying the
aerosolizable material continues to be wrapped around the
mandrel.
[0195] In some embodiments, the aerosolizable material may be
applied to an external surface of the mandrel, or to the material
on the mandrel or upstream of the mandrel, without first passing
through the mandrel. The aerosolizable material may take the form
of a slurry, when so applied.
[0196] The method may further comprise drying 704 the aerosolizable
material during, or after, the winding 702 of the structure.
[0197] In some embodiments, the structure comprising aerosolizable
material consists of the aerosolizable material. The aerosolizable
material may be cast or otherwise shaped. For example, the
aerosolizable material may be cast as a block, and then rolled or
otherwise pressed into a thinner form, such as a layer or
sheet.
[0198] The structure comprising aerosolizable material may, for
example, include corrugations or embossings or debossings when in
the supply, or the structure may be passed through a station at
which the corrugations or embossings or debossings are made in the
structure after it has been drawn from the supply.
[0199] The method may also comprise winding 705 one or more layers,
for example helically. The one or more layers may be wound around
the mandrel, when used. The one or more layers may be wound around
the structure comprising aerosolizable material. Alternatively, the
structure comprising aerosolizable material may be wound around the
one or more layers. In some embodiments, the structure comprising
aerosolizable material may be wound around one or more layers, and
then one or more further layers may be wound around the structure
comprising aerosolizable material.
[0200] At least one of the layers may comprise heating material
that is heatable by penetration with a varying magnetic field. The
heating material may be any one of those discussed herein, for
example. At least one of the layers may comprise a flavorant or
sensate. At least one of the layers may comprise aerosolizable
material. The aerosolizable material may be any one of those
discussed herein, for example.
[0201] Accordingly, when a mandrel is used, in some embodiments the
mandrel may be considered to have different zones: one in which
aerosolizable material is applied to the material to form the
structure comprising aerosolizable material, one in which the
structure is wound, one in which the aerosolizable material is
dried or allowed to dry, and optionally one or more zones in which
the one or more layers may be wound around the structure comprising
aerosolizable material.
[0202] In some embodiments, different materials or layers may be
wrapped around the mandrel from diametrically opposite sides of the
mandrel. These different materials may be wrapped around the
mandrel at a certain common region in the length direction of the
mandrel. Each of the materials or layers may be of any type
discussed herein, for example.
[0203] In some embodiments, in order to reduce sticking of the
aerosolizable material to the mandrel, the aerosolizable material
may be coated with, or comprise, a release agent. Alternatively, or
additionally, the mandrel may be coated with a release agent, or
may be heated or tapered or include a gas blower or ultrasonic
vibrator to discourage sticking of the aerosolizable material to
the mandrel, or to encourage release of the aerosolizable material
from the mandrel if sticking were to occur. The gas blower may
comprise one or more apertures in the surface of the mandrel on
which the aerosolizable material or material is wound in use, and a
source of gas, such as air, for supplying gas to the one or more
apertures in the surface of the mandrel. In some embodiments, the
mandrel could be made of porous material, and the gas could be
supplied from the gas source to a surface of the mandrel via pores
in the mandrel.
[0204] The method may result in the formation of a continuous
hollow tube. The continuous hollow tube may be drawn from the
mandrel while or after the winding takes place. The method may then
comprise separating 706, such as by cutting, the continuous hollow
tube to form discrete hollow tubes that can be incorporated into,
or form, a consumable for use with apparatus for heating
aerosolizable material to volatilize at least one component of the
aerosolizable material.
[0205] In manufacturing the hollow tube 2a shown in FIGS. 3 and 4,
the winding 702 may comprise winding the material to form an
innermost surface of the hollow tube, and the winding 705 of layers
may comprise winding a layer comprising heating material around the
structure comprising aerosolizable material, winding another layer
comprising aerosolizable material around the layer comprising
heating material, and winding a barrier layer around the other
layer comprising aerosolizable material.
[0206] In another embodiment, the method may comprise providing
aerosolizable material, such as comprising an amorphous solid, on a
carrier, such as paper so as to provide the structure comprising
aerosolizable material. The aerosolizable material may be coated,
such as cast, band-cast, sprayed or electro-sprayed, on the
carrier. The structure may be stored as a supply, on a bobbin for
example. The structure may be drawn, from the supply for example,
and wound, either around a mandrel or not, so that free ends of the
structure are circumferentially adjacent or abutting, but not
overlapping, thereby to create a tube or a near-tubular form with a
substantially uniform diameter. The tube may thus have a seamless
join between the free ends. The aerosolizable material may face an
inner hollow space of the tube or near-tubular form. A layer, such
as of paper, may be wound around the outside of the tube or
near-tubular form, and optionally adhered thereto, so as to help
maintain the shape of the tube or near-tubular form. This layer
similarly may have free ends that are adjacent or abut, but do not
overlap. The adhesive, when used, may be band casted onto the
structure. As the free ends of the structure do not overlap, such a
method is usable to form a hollow tube that is purely, or at least
closer to, circular or regular in cross-section, than a comparative
hollow tube that includes overlapping free ends of material. This
means that more uniform heating of the aerosolizable material may
be possible in use, as all regions of the aerosolizable material
may be more easily equally spaced from a heating element that heats
the aerosolizable material in use. However, in other embodiments,
the free ends of the combination may overlap.
[0207] In some of the embodiments in which the aerosolizable
material is carried by a carrier, a surface of the carrier that
abuts the aerosolizable material may be porous. For example, in
some cases, the carrier comprises paper. In some embodiments, the
carrier comprises or consists of a tobacco material, such as a
sheet of reconstituted tobacco, which may be porous. The inventors
have found that a porous carrier such as paper is particularly
suitable for some embodiments of the present disclosure; the porous
layer abuts the aerosolizable material and forms a strong bond. The
amorphous solid of the aerosolizable material of some embodiments
is formed by drying a gel and, without being limited by theory, it
is thought that the slurry from which the gel is formed partially
impregnates the porous carrier (e.g. paper) so that when the gel
sets and forms cross-links, the carrier is partially bound into the
gel. This provides a strong binding between the gel and the carrier
(and between the dried gel and the carrier). The porous layer (e.g.
paper) may also be used to carry flavors. In some cases, the porous
layer may comprise paper, suitably having a porosity of 0-300
Coresta Units (CU), suitably 5-100 CU or 25-75 CU.
[0208] Additionally, surface roughness may contribute to the
strength of bond between the aerosolizable material and the
carrier. The inventors have found that the paper roughness (for the
surface abutting the aerosolizable material) may suitably be in the
range of 50-1000 Bekk seconds, suitably 50-150 Bekk seconds,
suitably 100 Bekk seconds (measured over an air pressure interval
of 50.66-48.00 kPa). (A Bekk smoothness tester is an instrument
used to determine the smoothness of a paper surface, in which air
at a specified pressure is leaked between a smooth glass surface
and a paper sample, and the time (in seconds) for a fixed volume of
air to seep between these surfaces is the "Bekk smoothness".)
[0209] In some embodiments, the consumable 1, 2 is suitable for
insertion into a heating zone of an apparatus, such as the heating
zone 110 of the apparatus 100 shown in FIG. 5, wherein the
apparatus has a device for causing heating of the aerosolizable
material of the consumable 1, 2 when the consumable 1, 2 is in the
heating zone. Once in the heating zone 110, the device of the
apparatus causes heating of the aerosolizable material to
volatilize at least one component of the aerosolizable
material.
[0210] In some embodiments, the device is configured to apply heat
energy to the consumable 1, 2, and specifically to the
aerosolizable material thereof. In some such embodiments, the
device comprises a resistive heater that is heated by electrically
connecting the resistive heater to a supply of electricity, and
heat energy passes from the resistive heater to the consumable 1,
2.
[0211] In some other embodiments, the device may comprise a
magnetic field generator for generating a varying magnetic field
for penetrating the heating zone when the consumable 1, 2 is in the
heating zone 110, and the consumable 1, 2 comprises heating
material that is heatable by penetration with the varying magnetic
field to thereby heat the aerosolizable material. Accordingly, in
such embodiments, the device is configured to cause electromagnetic
energy to be applied to the heating material of the consumable 1, 2
to create heat in the heating material, and then heat energy is
applied from the heating material to the aerosolizable material. In
some embodiments, the consumable 1, 2 may comprise heating material
that is partially or fully embedded in the aerosolizable
material.
[0212] In still further embodiments, the apparatus 100 has a
heatable element comprising heating material, wherein the heatable
element is in thermal contact with the heating zone, and wherein
the magnetic field generator is for generating a varying magnetic
field for penetrating the heatable element of the apparatus, so as
to cause heating of the heatable element and thus the heating zone.
Heat energy is thus applied to any consumable present in the
heating zone.
[0213] In any event, the volatilized component(s) of the
aerosolizable material pass from the aerosolizable material and out
of the consumable 1, 2, such as by a user drawing on the consumable
1, 2 or a mouthpiece (when provided) of the apparatus.
[0214] Referring to FIG. 5, there is shown a schematic
cross-sectional side view of an example of a system comprising a
consumable and apparatus for heating aerosolizable material of the
consumable to volatilize at least one component of the
aerosolizable material, according to an embodiment of the
disclosure.
[0215] The system 1000 comprises the consumable 1 of FIGS. 1 and 2
and apparatus 100 for heating the aerosolizable material of the
consumable 1 to volatilize at least one component of the
aerosolizable material. In other embodiments, the consumable may be
replaced by any of the other consumables described herein, such as
the consumable 2 shown in FIGS. 3 and 4. In this embodiment, the
apparatus 100 is a tobacco heating product (also known in the art
as a tobacco heating device or a heat-not-burn device).
[0216] The apparatus comprises a heating zone 110 for receiving the
consumable 1, 2, and a device 112 for causing heating of the
aerosolizable material when the consumable 1, 2 is in the heating
zone 110.
[0217] The apparatus 100 may define at least one air inlet (not
shown) that fluidly connects the heating zone 110 with the exterior
of the apparatus 100. A user may be able to inhale the volatilized
component(s) of the aerosolizable material by drawing the
volatilized component(s) from the heating zone 110. As the
volatilized component(s) are removed from the heating zone 110 and
the consumable 1, 2, air may be drawn into the heating zone 110 via
the air inlet(s) of the apparatus 100.
[0218] In this embodiment, the heating zone 110 comprises a recess
for receiving at least a portion of the consumable 1, 2. In other
embodiments, the heating zone 110 may be other than a recess, such
as a shelf, a surface, or a projection, and may require mechanical
mating with the consumable 1, 2 in order to co-operate with, or
receive, the consumable 1, 2. In this embodiment, the heating zone
110 is elongate, and is sized and shaped to accommodate the whole
consumable 1, 2. In other embodiments, the heating zone 110 may be
dimensioned to receive only a portion of the consumable 1, 2.
[0219] In some cases in use, substantially all of the amorphous
solid is less than about 4 mm, 3 mm, 2 mm or 1 mm from the heater
(i.e. the heatable element or the resistive heater). In some cases,
the solid is disposed between about 0.010 mm and 2.0 mm from the
heater, suitably between about 0.02 mm and 1.0 mm, suitably 0.1 mm
to 0.5 mm. These minimum distances may, in some cases, reflect the
thickness of a carrier that supports the amorphous solid. In some
cases, a surface of the amorphous solid may directly abut the
heater.
[0220] In some embodiments, the device 112 comprises an electrical
power source, a resistive heater that is heated by passing
electricity through the resistive heater, and a controller for
controlling the passage of electricity through the resistive
heater. The resistive heater is configured to apply heat energy to
the heating zone 110, and thus to the consumable 1, 2 when the
consumable is in the heating zone 110. The resistive heater may
cause the heat energy to be applied to the aerosolizable material
of the consumable 1, 2. In some embodiments, the resistive heater
may project into the heating zone 110 so as to be located in the
passageway 20 of the consumable 1, 2 when the consumable 1, 2 is in
the heating zone 110. In some other embodiments, the resistive
heater may be located radially outwards of the consumable 1, 2 when
the consumable is in the heating zone 110. For example, the
resistive heater may at least partially define the heating zone
110. In some embodiments, the device may comprise a first resistive
heater that is in the passageway 20 of the consumable 1, 2 when the
consumable 1, 2 is in the heating zone 110, and a second resistive
heater that is located radially outwards of the consumable 1, 2
when the consumable 1, 2 is in the heating zone 110.
[0221] In some embodiments, such as that shown in FIG. 5, the
device 112 comprises a magnetic field generator for generating a
varying magnetic field for penetrating the heating zone 110 when
the consumable 1, 2 is in the heating zone 110.
[0222] As discussed above, in some embodiments, the consumable
comprises heating material for use in heating the aerosolizable
material. In such embodiments, the magnetic field generator of the
apparatus may be configured to generate a varying magnetic field
that penetrates the heating material of the consumable 1, 2 when
the consumable 1, 2 is in the heating zone 110.
[0223] In other embodiments, such as that shown in FIG. 5, the
device 112 of the apparatus 100 comprises a heatable heating
element 111, and the magnetic field generator is configured to
generate a varying magnetic field that penetrates the heating
element 111. In some embodiments, the heating element is located
radially outwards of the consumable 1, 2 when the consumable 1, 2
is in the heating zone 110. For example, the heating element may at
least partially define the heating zone 110. In other embodiments,
such as that shown in FIG. 5, the heating element 111 projects into
the heating zone 110. The heating element 111 may be insertable
into the passageway 20 of the consumable 1, 2 in use. In some
embodiments, such as that shown in FIG. 5, the heating element 111
enters the passageway 20 while the consumable 1, 2 is inserted into
the heating zone 110. In other embodiments the apparatus may be
configured so that the heating element 111 is movable relative to
the heating zone 110 so as to project into the passageway 20 when
the consumable 1, 2 is already located in the heating zone 110.
[0224] In some embodiments, the heating element 111 of the
apparatus has an outer cross-sectional shape, and the innermost
surface 1b, 2b of the hollow tube 1a, 2a of the consumable 1, 2 has
an inner cross-sectional shape that matches the outer
cross-sectional shape of the heating element 111. For example, the
inner and outer cross-sectional shapes may be circular or may be
non-circular, such as elliptical, polygonal, rectangular, square,
triangular, corrugated, or star-shaped. In some embodiments, the
heating element 111 of the apparatus and the innermost surface 1b,
2b of the hollow tube 1a, 2a of the consumable 1, 2 are relatively
dimensioned so that the innermost surface abuts the heating element
111 in use, so as to increase the efficiency and effectiveness of
heat energy transfer from the heating element 111 to the innermost
surface. The innermost surface may be a close fit to, or a snug fit
on, the heating element 111.
[0225] In this embodiment, the magnetic field generator comprises
an electrical power source 113, a coil 114, a device 116 for
passing a varying electrical current, such as an alternating
current, through the coil 114, a controller 117, and a user
interface 118 for user-operation of the controller 117.
[0226] The electrical power source 113 of this embodiment is a
rechargeable battery. In other embodiments, the electrical power
source 113 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.
[0227] The coil 114 may take any suitable form. In some
embodiments, the coil 114 is a helical coil of
electrically-conductive material, such as copper. In some
embodiments, the coil is a flat coil. That is, the coil may be a
two-dimensional spiral of electrically-conductive material, such as
copper. In some embodiments, the coil 114 encircles the heating
zone 110. In some embodiments, the coil 114 extends along a
longitudinal axis that is substantially aligned with a longitudinal
axis of the heating zone 110. The aligned axes may be coincident.
Alternatively, the aligned axes may be parallel or oblique to each
other.
[0228] In this embodiment, the device 116 for passing a varying
current through the coil 114 is electrically connected between the
electrical power source 113 and the coil 114. In this embodiment,
the controller 117 also is electrically connected to the electrical
power source 113, and is communicatively connected to the device
116 to control the device 116. More specifically, in this
embodiment, the controller 117 is for controlling the device 116,
so as to control the supply of electrical power from the electrical
power source 113 to the coil 114. In this embodiment, the
controller 117 comprises an integrated circuit (IC), such as an IC
on a printed circuit board (PCB). In other embodiments, the
controller 117 may take a different form. In some embodiments, the
apparatus 100 may have a single electrical or electronic component
comprising the device 116 and the controller 117. The controller
117 is operated in this embodiment by user-operation of the user
interface 118. The user interface 118 may comprise a push-button, a
toggle switch, a dial, a touchscreen, or the like. In other
embodiments, the user interface 118 may be remote and connected to
the rest of the apparatus 100 wirelessly, such as via
Bluetooth.
[0229] In this embodiment, operation of the user interface 118 by a
user causes the controller 117 to cause the device 116 to cause an
alternating electrical current to pass through the coil 114. This
causes the coil 114 to generate an alternating magnetic field. The
coil 114 and the heating zone 110 of the apparatus 100 are suitably
relatively positioned so that, when the consumable 1, 2, 3 is
located in the heating zone 110, the varying magnetic field
produced by the coil 114 penetrates the heating element 111 of the
apparatus 100. When the heating material of the heating element 111
is electrically-conductive, 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 of the
heating element 111 is 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.
[0230] In some embodiments, the consumable 1, 2 comprises heating
material and the coil 114 and the heating zone 110 of the apparatus
100 are suitably relatively positioned so that, when the consumable
1, 2 is located in the heating zone 110, the varying magnetic field
produced by the coil 114 penetrates the heating material of the
consumable 1, 2. In some embodiments, the apparatus 100 comprises
the heating element 111, the heating element 111 comprises heating
material, and the consumable 1, 2 also comprises heating material.
In some such embodiments, the coil 114 and the heating zone 110 of
the apparatus 100 may be suitably relatively positioned so that,
when the consumable 1, 2 is located in the heating zone 110, the
varying magnetic field produced by the coil 114 penetrates the
heating material of the consumable 1, 2 and the heating material of
the heating element 111.
[0231] The apparatus 100 of this embodiment comprises a temperature
sensor 119 for sensing a temperature of the heating zone 110. The
temperature sensor 119 is communicatively connected to the
controller 117, so that the controller 117 is able to monitor the
temperature of the heating zone 110. On the basis of one or more
signals received from the temperature sensor 119, the controller
117 may cause the device 112 to adjust a characteristic of the
varying or alternating electrical current passed through the coil
114 as necessary, in order to ensure that the temperature of the
heating zone 110 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 a consumable located in the heating
zone 110 is heated sufficiently to volatilize at least one
component of the aerosolizable material 14 without combusting the
aerosolizable material 14. Accordingly, the controller, and the
apparatus 100 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 350.degree. C., such as between about
100.degree. C. and about 300.degree. C., or between about
120.degree. C. and about 350.degree. C., or between about
140.degree. C. and about 250.degree. C., or between about
200.degree. C. and about 270.degree. C. In other embodiments, the
temperature range may be other than one of these ranges. In some
embodiments, the upper limit of the temperature range could be
greater than 350.degree. C. In some embodiments, the consumable may
be non-combustible, for example in these ranges of temperatures. In
some embodiments, the temperature sensor 119 may be omitted.
[0232] In some embodiments, the device 112 for causing heating of
the aerosolizable material when the consumable is in the heating
zone 110 is configured for heating different sections of the
heating zone 110 independently of each other, such as by way of
comprising independently-controllable heatable elements 111.
[0233] In some embodiments, the heating material of the consumable
1, 2, or of the heatable heating element 111 of the apparatus 100,
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, molybdenum, silicon carbide, copper, and bronze. Other
heating material(s) may be used in other embodiments.
[0234] 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 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.
[0235] In some embodiments, the consumable 1, 2 may comprise
heating material that is partially or fully embedded in the
aerosolizable material of the consumable 1, 2. In some embodiments,
the aerosolizable material may comprise heating material. In some
embodiments, the aerosolizable material may be free from heating
material.
[0236] 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.
[0237] In some embodiments, the consumable is non-combustible. In
some embodiments, the consumable is configured so as not to be
combustible in use.
[0238] In some embodiments, once all, or substantially all, of the
volatilizable component(s) of the aerosolizable material in the
consumable 1, 2 has/have been spent, the user may remove the
consumable 1, 2 from the heating zone of the apparatus 100 and
dispose of the consumable 1, 2. The user may subsequently re-use
the apparatus 100 with another of the consumables 1, 2. However, in
other respective embodiments, the apparatus 100 and the consumable
1, 2 may be disposed of together once the volatilizable
component(s) of the aerosolizable material has/have been spent.
[0239] In some embodiments, the consumable 1, 2 is sold, supplied
or otherwise provided separately from the apparatus 100 with which
the consumable 1, 2 is usable. However, in some embodiments, the
apparatus 100 and one or more of the consumables 1, 2 may be
provided together as a system, such as a kit or an assembly,
possibly with additional components, such as cleaning utensils.
[0240] For the avoidance of doubt, where in this specification the
term "comprises" is used in defining the invention or features of
the invention, embodiments are also disclosed in which the
invention or feature can be defined using the terms "consists
essentially of" or "consists of" in place of "comprises". Reference
to a material "comprising" certain features means that those
features are included in, contained in, or held within the
material.
[0241] 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 consumables for use with
apparatus for heating aerosolizable material to volatilize at least
one component of the aerosolizable material, systems comprising
such a consumable and such apparatus, and methods of manufacturing
a hollow tube for use in or as such a consumable. 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.
* * * * *