Aerosol Provision Device

Abstract

There is provided an aerosol provision system comprising: a housing having a mouthpiece, the mouthpiece having an air outlet; and, a consumable unit contained within the housing, the consumable unit comprising: a source of aerosol generating medium; and, an airflow channel wall forming an airflow channel that passes the source of aerosol generating medium and terminates in the vicinity of the air outlet of the housing.

Description

PRIORITY CLAIM

[0001] The present application is a National Phase entry of PCT Application No. PCT/GB2020/050706, filed Mar. 18, 2020, which claims priority from Great Britain Application No. 1904846.1, filed Apr. 5, 2019, each of which is hereby fully incorporated herein by reference.

TECHNICAL FIELD

[0002] The present invention relates to an aerosol provision system, a method of providing an aerosol, a consumable unit for use in an aerosol provision system, a housing for an aerosol provision system and an aerosol provision device.

BACKGROUND

[0003] Aerosol generating devices are known. Electronic aerosol provision systems such as electronic cigarettes (e-cigarettes) generally contain a reservoir of a source liquid containing a formulation, typically including nicotine, from which an aerosol is generated, e.g. through heat vaporization. An aerosol source for an aerosol provision system may thus comprise a heater having a heating element arranged to receive source liquid from the reservoir, for example through wicking/capillary action. While a user inhales on the device, electrical power is supplied to the heating element to vaporize source liquid in the vicinity of the heating element to generate an aerosol for inhalation by the user. Such devices are usually provided with one or more air inlet holes located away from a mouthpiece end of the system. When a user sucks on a mouthpiece connected to the mouthpiece end of the system, air is drawn in through the inlet holes and past the aerosol source. There is a flow path connecting between the aerosol source and an opening in the mouthpiece so that air drawn past the aerosol source continues along the flow path to the mouthpiece opening, carrying some of the aerosol from the aerosol source with it. The aerosol-carrying air exits the aerosol provision system through the mouthpiece opening for inhalation by the user.

[0004] Various approaches are described which seek to help address some of these issues.

SUMMARY

[0005] Aspects of the invention are defined in the accompanying claims.

[0006] In accordance with some embodiments described herein, there is provided an aerosol provision system comprising: a housing having a mouthpiece, the mouthpiece having an air outlet; and, a consumable unit contained within the housing, the consumable unit comprising: a source of aerosol generating medium; and, an airflow channel wall forming an airflow channel that passes the source of aerosol generating medium and terminates in the vicinity of the air outlet of the housing.

[0007] In accordance with some embodiments described herein, there is provided a consumable unit for use in an aerosol provision system.

[0008] In accordance with some embodiments described herein, there is provided a housing for an aerosol provision system.

[0009] In accordance with some embodiments described herein, there is provided a consumable unit for use with an aerosol provision system, the unit comprising a projecting first portion and a recessed second portion, wherein the projecting first portion is of a conforming shape to the recessed second portion.

[0010] In accordance with some embodiments described herein, there is provided aerosol provision means comprising: a housing having a mouthpiece, the mouthpiece having air outlet means; and, a consumable unit contained within the housing, the consumable unit comprising: a source of aerosol generating means; and, an airflow channel means forming an airflow channel that passes the source of aerosol generating means and terminates in the vicinity of the air outlet means of the housing.

[0011] In accordance with some embodiments described herein, there is provided a method of providing an aerosol, comprising: providing a housing having a mouthpiece, the mouthpiece having an air outlet; and, providing a consumable unit contained within the housing, the consumable unit comprising: a source of aerosol generating medium; and, an airflow channel wall forming an airflow channel that passes the source of aerosol generating medium and terminates in the vicinity of the air outlet of the housing, passing air through the airflow channel within the airflow channel wall; passing air over the source of aerosol generating medium; and, passing air through the air outlet of the housing.

[0012] In accordance with some embodiments described herein, there is provided an aerosol provision device configured to receive a consumable unit contained within the housing, the consumable unit comprising a source of aerosol generating medium and an airflow channel wall forming an airflow channel that passes the source of aerosol generating medium, the aerosol provision device comprising: a housing having a mouthpiece, the mouthpiece having an air outlet, wherein, in use, the airflow channel terminates in the vicinity of the air outlet of the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present teachings will now be described by way of example only with reference to the following figures in which like parts are depicted by like reference numerals:

[0014] FIG. 1 is a schematic sectional view of a portion of an aerosol provision device according to an example;

[0015] FIG. 2 is a schematic sectional view of a portion of an aerosol provision device according to an example;

[0016] FIG. 3 is a schematic sectional view of a portion of an aerosol provision device according to an example;

[0017] FIG. 4(i) is a schematic sectional view of a consumable unit for use in an aerosol provision device according to an example;

[0018] FIG. 4(ii) is a schematic sectional view of three consumable units for use in an aerosol provision device according to an example;

[0019] FIG. 5 is a schematic sectional view of a portion of an aerosol provision device according to an example; and,

[0020] FIG. 6 is a schematic sectional view of a portion of an aerosol provision device according to an example.

[0021] While the invention is susceptible to various modifications and alternative forms, specific embodiments are shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the drawings and detailed description of the specific embodiments are not intended to limit the invention to the particular forms disclosed. On the contrary, the invention covers all modifications, equivalents and alternatives falling within the scope of the present invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE DRAWINGS

[0022] Aspects and features of certain examples and embodiments are discussed/described herein. Some aspects and features of certain examples and embodiments may be implemented conventionally and these are not discussed/described in detail in the interests of brevity. It will thus be appreciated that aspects and features of apparatus and methods discussed herein which are not described in detail may be implemented in accordance with any conventional techniques for implementing such aspects and features.

[0023] The present disclosure relates to aerosol provision systems, which may also be referred to as aerosol provision systems, such as e-cigarettes. Throughout the following description the term "e-cigarette" or "electronic cigarette" may sometimes be used, but it will be appreciated this term may be used interchangeably with aerosol provision system/device and electronic aerosol provision system/device. Furthermore, and as is common in the technical field, the terms "aerosol" and "vapor", and related terms such as "vaporize", "volatilize" and "aerosolize", may generally be used interchangeably.

[0024] FIG. 1 illustrates a schematic view of a portion of an aerosol provision system 100. The system 100 includes an aerosol provision device and a consumable unit 120 configured to be received in the device (however the system may herein occasionally be referred to as a device for brevity). The device 100 is designed to simulate a cigarette and therefore may have a substantially cylindrical shape and may be approximately the same size as a cigarette. The device 100 has a housing 110 having a mouthpiece 112. The mouthpiece 112 has an air outlet 113. The device 100 also has a consumable unit 120 contained within the housing 110. The consumable unit 120 has a source of aerosol generating medium 122 and an airflow channel wall 124 forming an airflow channel 125 that passes the source of aerosol generating medium 122 and terminates in the vicinity of the air outlet 113 of the housing 110. In an example of the present device, the mouthpiece 112 is an air outlet 113. The air outlet 113 may be located on a projection so that it is more easily received in the mouth of a user, or it may be an opening on a surface of the housing 110 providing fluid communication between the inside of the device 100 and the outside of the device 100.

[0025] In the example shown in FIG. 1, air flow entering the consumable unit 120 is constrained within the airflow channel wall 124 which enables the air to flow through the consumable unit 120 and pass the source of aerosol generating medium 122 and along to the air outlet 113 of the mouthpiece 112. As air flow passes over a source of aerosol generating medium 122, components of the source of aerosol generating medium 122 may be entrained in the air flow. This aerosol or aerosol is transported to the end of the airflow channel (near the air outlet 113 of the mouthpiece 112) and the aerosol may then exit the device 100 and be inhaled by a user. This device 100 therefore prevents significant levels of deposition of condensing aerosol on the inside of the housing 110 of the device 100. Such condensing aerosol can damage components on which it condenses, and as such the present arrangement extends the lifetime of the device 100. In a similar manner, the arrangement results in improved cleanliness of the device 100 as the consumable unit 120 may be removed after depletion of the source of aerosol generating medium 122: removal of the consumable unit 120 simultaneously removes the condensed aerosol on the airflow channel wall 124. The air channel wall 124 of the consumable unit 120 may be made of a material which is impermeable to aerosol.

[0026] In examples the shape and size airflow channel wall 124 of the consumable unit 120 may vary. The likelihood of the phenomenon "hot puff", wherein the aerosol has not cooled sufficiently prior to inhalation by a user, arising can be reduced by the present device 100. The airflow channel wall 124 may be formed to be relatively long so as to increase the time between the air flow entering the consumable unit 120 and exiting the air outlet 113. This will allow greater dissipation of heat from the air flow prior to inhalation by the user, and so reduce the likelihood of hot puff.

[0027] In an example, a portion of the airflow channel wall 124 may be arranged alongside the housing 110. Heat loss through the airflow channel wall 124 and, subsequently, the housing 110 to the environment external to the device 100, is often more efficient than heat loss emanating from the center of the device 100. As such, this arrangement of the airflow channel wall 124 may also contribute to reduction of the likelihood of hot puff.

[0028] In an example, the airflow channel wall 124 may be contained centrally in the device 100 and not near the housing 110. Although heat loss to the outer environment of the device 100 is beneficial to reduce the likelihood of hot puff, if high levels of thermal energy are passed through the housing 110 of the device 100 a user may injure themselves holding the device 100. As such, this arrangement of the airflow channel wall 124 may reduce the likelihood of a user injuring themselves while holding the device 100 as a result of an overly hot housing 110.

[0029] The airflow channel wall 124 may be one wall or may be a number of walls in which an airflow channel may formed.

[0030] FIG. 2 illustrates a sectional view of a portion of an aerosol provision device 100. FIG. 2 shows an arrangement similar to that shown in FIG. 1. Reference numerals indicating the same features as shown in FIG. 1 are the same as those numerals used in FIG. 1. These same features will not all be discussed in detail here. The example of the device 100 shown in FIG. 2 differs to that of FIG. 1 in the position of the source of aerosol generating medium 122. The source of aerosol generating medium 122, in the example shown, terminates in the vicinity of the air outlet 113. Aerosol will form when incoming air flow passes over the source of aerosol generating medium 122. As such, the aerosol is formed substantially in the vicinity of the air outlet 113. This reduces the area inside the device 100 on which aerosol can condense. This arrangement therefore increases the lifetime and cleanliness of the device 100, as described above.

[0031] FIG. 3 illustrates a sectional view of a portion of an aerosol provision device 100. Reference numerals indicating the same features as shown in FIGS. 1 and 2 are the same as those numerals used in FIGS. 1 and 2. These same features will not be discussed in detail here. In the example shown in FIG. 3, the consumable unit 120 has a source of aerosol generating medium 122 and a filter material 126. The filter material 126 is arranged towards the air outlet 113. The filter material 126 is arranged downstream of the source of aerosol generating medium 122 so that aerosol produced from air flowing over the source of aerosol generating medium 122 is passed through the filter material 126 prior to passing through the air outlet 113 of the mouthpiece 112. In this way, particulates in the air flow may be removed prior to inhalation by the user.

[0032] FIG. 3 shows incoming air as arrow C. This air may pass through or over the source of aerosol generating medium 122. The air flow will entrain components from the source of aerosol generating medium 122 to form an aerosol. The device 100 may comprise a heater for heating the air flow and/or the source of aerosol generating medium 122 to encourage release of components from the source of aerosol generating medium 122.

[0033] The filter material 126, in the example of FIG. 3, is in the airflow channel 125. As such, air flow through the consumable unit 120 will pass through the filter material 126. The filter material 126 may fill a portion of the airflow channel 125 within the airflow channel wall 124. The filter material may alternatively form all, or a portion, of the airflow channel wall 124.

[0034] FIG. 3 shows two regions of the consumable unit 120, a first region A and a second region B. In the second region B, the filter material 126 is connected to the first region A and may form the airflow channel wall 124 within which the airflow channel 125 is formed. Air flowing through this section is filtered to remove particulates and the like prior to inhalation.

[0035] Prior to use of the device 100, the consumable unit 120 may be inserted into the device 100. Inserting the consumable unit 120 into the mouthpiece 112 portion of the housing 110 may compress the consumable unit 120. In the example wherein the filter material 126 forms the airflow channel wall 124, the filter material 126 may be compressed by the housing 110 when the consumable unit 120 is inserted into the housing 110. The filter material 126 may be made of a resilient material such that damage to the inside of the mouthpiece 112 is less likely to occur as a result of clumsy user insertion of the consumable unit 120 into the mouthpiece 112. This increases the lifetime of the device 100 and the consumable unit 120.

[0036] In the example shown in FIG. 3, the outer portion of the consumable unit 120 is of a conforming shape to the housing 110 near the air outlet 113. In this way, the direction of insertion of the consumable unit 120 into the mouthpiece 112 is more obvious and may avoid an incorrect insertion of the consumable 120. "Conforming", as used here, may be taken to mean the consumable unit 120 is of a complementary shape to the housing 110. The consumable unit 120 may also be malleable to conform to the shape of the housing 110. The consumable unit 120 may be of a shape that matches to the shape of the housing 110. The consumable unit 120 may fit tightly within the housing 110.

[0037] The filter material 126 may be any of tobacco, cellulose acetate, tow fibers or a nicotine-containing material. In other implementations, the filter material 126 may comprise any suitable material capable of filtering airflow.

[0038] The consumable unit 120 may have a number of different sources of aerosol generating medium 122. To prevent the sources of aerosol generating medium 122 depleting at the same rate, air flow through the consumable unit 120 may be controlled to pass selected sources of aerosol generating medium 122. This may be controlled by the presence and arrangement of walls within the consumable unit 120 and air inlets to the consumable unit 120. The device 100 may have a movement mechanism to rotate the consumable unit 120 relative to the housing 110. This may enable a user to selectively activate sources of aerosol generating medium 122 within the device 100. In use, a user will contact the mouthpiece 112 of the device 100. As such, motion of the consumable unit 120 will not be detected by the user. This arrangement prevents an uncomfortable user experience.

[0039] FIG. 4 shows schematic sectional views of consumable units 120 according to an example. A portion of the consumable unit 120, shown in the example of FIG. 4(i), has a frustoconical shape. The consumable unit 120 may have a projecting first portion and a recessed second portion. The projecting first portion may be of a conforming shape to the recessed second portion.

[0040] In the example of FIG. 4(i), the consumable unit 120 shown has a projecting upper portion, indicated broadly by section P, and a recessed bottom portion, indicated broadly by section R. Air flow through the consumable unit 120 is indicated by arrow C'. Air flow entering the consumable unit passes a source of aerosol generating medium 122 to entrain components from it and exits the consumable unit 120 as an aerosol for inhalation by a user. When a recessed bottom section R is present, the volume within the consumable unit 120 for air to pass is reduced.

[0041] The shape of the consumable unit 120 may be selected to correspond or complement the shape of the mouthpiece 112 of the housing 110. In this way, as mentioned above, insertion into the mouthpiece 112 is facilitated. A frustoconical shape is a common mouthpiece shape and, as such, the consumable unit 120 of FIG. 4(i) may be advantageous. Other shapes may be used to have similar benefits. Similarly, after depletion of the source of aerosol generating medium 122 the consumable unit 120 may be removed from the device 100 and replaced. The device 100 may have a removable section (such as a door or cover as part of the housing) through which the consumable unit 120 may be inserted and removed. Alternatively, the device 100 may be discarded after depletion of the sources of the consumable unit 120.

[0042] FIG. 4(ii) shows an example of a plurality of consumable units of the shape shown in FIG. 4(i). The consumable units 120', 120'', 120''' shown in FIG. 4(ii) are able to stack or nest on top of one another. This may provide a space saving measure. In the example shown, there are three consumable units 120', 120'', 120''' stacked together. There are shown a lowermost consumable unit 120', arranged beneath a middle consumable unit 120'' which itself is beneath an uppermost consumable unit 120'''. In the stacked arrangement shown, the projecting upper portion of the lowermost consumable unit 120' projects into the recess formed by the recessed bottom portion of the middle consumable unit 120''. Similarly, the projecting upper portion of the middle consumable unit 120'' projects into the recess formed by the recessed bottom portion of the middle consumable unit 120'''.

[0043] FIG. 5 shows a schematic sectional view of a portion of an aerosol provision device 100 according to an example. Reference numerals indicating the same features as shown in FIGS. 1, 2 and 3 are the same as those numerals used in FIGS. 1, 2 and 3. These same features will not be discussed in detail here. The example shown has incoming air flow, shown by arrow C, which enters the consumable unit 100. The air flow passes over sources of aerosol generating medium 110 and entrains components to form an aerosol. The flow of aerosol through the consumable unit 120 is shown by arrow C'. The aerosol passes along an air channel arranged near the housing 102 and exits the device 100 at the air outlet 113 of the mouthpiece 112. The consumable unit 120 has a conforming shape to the portion of the housing 110 in which the consumable unit 120 is arranged. This portion includes the mouthpiece 112 and the air outlet 113. In the example shown, the consumable unit 120 has air inlets for allowing air flow to enter the consumable unit 120. The consumable unit has an air outlet for allowing aerosol to flow out of the consumable unit 120.

[0044] FIG. 6 shows a schematic sectional view of a portion of an aerosol provision device 100 according to an example. Reference numerals indicating the same features as shown in FIGS. 1, 2, 3 and 5 are the same as those numerals used in FIGS. 1, 2, 3 and 5. These same features will not be discussed in detail here. The consumable unit 120 shown in FIG. 6 differs from the consumable unit shown in FIG. 5 by the lack of a recessed bottom portion. The consumable unit 120 shown in FIG. 6 has a slightly different array of air inlets and outlets. The air flow path through the consumable unit 120, shown by arrows C and C', also differs.

[0045] The air flow path enters the consumable unit 120 in the vicinity of the sources of aerosol generating medium 122 and flows over the sources of aerosol generating medium 122 to form an aerosol. The aerosol continues along a base portion Q of the consumable unit 120. The aerosol then passes into an upper portion S of the consumable unit 120. The aerosol then passes through the upper portion S and out of the air outlet 113 of the device 100.

[0046] The base portion Q may be flat disc-like element, which may be multi-layered. The layers of base portion Q may carry a plurality of sources of aerosol generating medium 122. The base portion Q may be rotated by a movement mechanism within the device 100 to control which specific source of aerosol generating medium 122 is used during a use session.

[0047] The upper portion S may be attached to the base portion Q. The upper portion S may be a hollow structure to enable air flow to pass through and out the air outlet 113 of the device 100. The upper portion S may be a substantially cone-shape element 128 and may be filled with a filter material or the like. The upper portion S may be formed of paper or card or the like. The upper portion S may be made of filter material to reduce condensation of aerosol on the inside of the device 100. The upper portion S may be of conforming size and shape to the inner surface of the mouthpiece 112.

[0048] The source of aerosol generating medium 122 in the consumable unit 120 may have a number of doses of aerosol generating medium. In other examples, the base portion Q of the consumable unit 120 may have a number of sources of aerosol generating medium 122. In some examples, the consumable unit 120 may have the doses of aerosol generating medium arranged in discrete doses. In other examples, the doses may be in the form of a disc, which may be continuous or discontinuous, disposed on one or more surfaces of a multi-layered consumable unit 120. In still other examples, the doses may be in the form of an annulus, a ring or any other shape. The consumable unit 120 may or may not have a rotationally symmetrical distribution of doses or sources of aerosol generating medium 122 on any of the surfaces of the consumable unit 120. A symmetrical distribution of sources of aerosol generating medium 122 could enable equivalently positioned sources of aerosol generating medium 122 (within a rotationally symmetrical distribution) to receive an equivalent heating profile from a heater within the device 100 upon rotation about the central axis, if arranged accordingly.

[0049] The device 100 may have a plurality of chambers or regions that may or may not be separate from one another. The device 100 may have a power chamber (not shown) comprising energy stores for supplying power to a heater and/or a movement mechanism. The heater may be an electrically resistive heater. The heater may be a chemically activated heater which may or may not operate via exothermic reactions or the like. The heater provides thermal energy, heat, to the surrounding environment of the heater. The heater may heat the sources of aerosol generating medium 122 or may heat air flow prior to the air flow entering the consumable unit 120. The heater may be part of an inductive heating system, wherein the heater is an inductive heater and the consumable unit 120 may be or may contain a susceptor or the like. The susceptor may for example be a sheet of aluminum foil or the like.

[0050] The shape of the device 100 may be cigarette-shape (longer in one dimension than the other two) or may be other shapes. In an example, the device 100 may have a shape that is longer in two dimensions than the other one, for example like a compact-disc player or the like. Alternatively, the shape may be any shape that can suitably house the consumable unit 120.

[0051] The source of aerosol generating medium of the consumable unit 120 may comprise at least one of tobacco and glycol and may include extracts (e.g., licorice, hydrangea, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, menthol, Japanese mint, aniseed, cinnamon, herb, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, scotch, whiskey, spearmint, peppermint, lavender, cardamon, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, piment, ginger, anise, coriander, coffee, or a mint oil from any species of the genus Mentha), 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, oil, liquid, or powder. Sources of aerosol generating medium 110 may be separated, adjacent or overlapping.

[0052] The aerosol-forming layer described herein 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 aerosol-forming layer 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 aerosol-forming layer consists of amorphous solid.

[0053] In some cases, the amorphous solid may comprise 1-50 wt % of a gelling agent wherein these weights are calculated on a dry weight basis.

[0054] Suitably, the amorphous solid may comprise from about 1 wt %, 5 wt %, 10 wt %, 15 wt %, 20 wt % or 25 wt % to about 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 5-40 wt %, 10-30 wt % or 15-27 wt % of a gelling agent.

[0055] 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.

[0056] 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.

[0057] 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 0.5 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 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.

[0058] In some cases, the amorphous solid additionally comprises a tobacco material and/or nicotine. For example, the amorphous solid may additionally 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 %, 60 wt %, 50 wt %, 45 wt % or 40 wt % (calculated on a dry weight basis) of a tobacco material and/or nicotine.

[0059] In some cases, the amorphous solid comprises a 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.

[0060] 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.

[0061] 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).

[0062] 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).

[0063] 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 crystalize out of the gel. As such, in some cases, the gel does not include a solvent in which the flavor is soluble.

[0064] The amorphous solid comprises less than 20 wt %, suitably less than 10 wt % or less than 5 wt % of a filler. The filler 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 some cases, the amorphous solid comprises less than 1 wt % of a filler, and in some cases, comprises no filler. In particular, in some cases, the amorphous solid comprises no calcium carbonate such as chalk.

[0065] 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.

[0066] Thus there has been described an aerosol provision device comprising: a housing having a mouthpiece, the mouthpiece having an air outlet; and, a consumable unit contained within the housing, the consumable unit comprising: a source of aerosol generating medium; and, an airflow channel wall forming an airflow channel that passes the source of aerosol generating medium and terminates in the vicinity of the air outlet of the housing.

[0067] The aerosol provision system may be used in a tobacco industry product, for example a non-combustible aerosol provision system.

[0068] In one embodiment, the tobacco industry product comprises one or more components of a non-combustible aerosol provision system, such as a heater and an aerosolizable substrate.

[0069] In one embodiment, the aerosol provision system is an electronic cigarette also known as a vaping device.

[0070] In one embodiment the electronic cigarette comprises a heater, a power supply capable of supplying power to the heater, an aerosolizable substrate such as a liquid or gel, a housing and optionally a mouthpiece.

[0071] In one embodiment the aerosolizable substrate is contained in or on a substrate container. In one embodiment the substrate container is combined with or comprises the heater.

[0072] In one embodiment, the tobacco industry product is a heating product which releases one or more compounds by heating, but not burning, a substrate material. The substrate material is an aerosolizable material which may be for example tobacco or other non-tobacco products, which may or may not contain nicotine. In one embodiment, the heating device product is a tobacco heating product.

[0073] In one embodiment, the heating product is an electronic device.

[0074] In one embodiment, the tobacco heating product comprises a heater, a power supply capable of supplying power to the heater, an aerosolizable substrate such as a solid or gel material.

[0075] In one embodiment the heating product is a non-electronic article.

[0076] In one embodiment the heating product comprises an aerosolizable substrate such as a solid or gel material, and a heat source which is capable of supplying heat energy to the aerosolizable substrate without any electronic means, such as by burning a combustion material, such as charcoal.

[0077] In one embodiment the heating product also comprises a filter capable of filtering the aerosol generated by heating the aerosolizable substrate.

[0078] In some embodiments the aerosolizable substrate material may comprise an aerosol or aerosol generating agent or a humectant, such as glycerol, propylene glycol, triacetin or diethylene glycol.

[0079] In one embodiment, the tobacco industry product is a hybrid system to generate aerosol by heating, but not burning, a combination of substrate materials. The substrate materials may comprise for example solid, liquid or gel which may or may not contain nicotine. In one embodiment, the hybrid system comprises a liquid or gel substrate and a solid substrate. The solid substrate may be for example tobacco or other non-tobacco products, which may or may not contain nicotine. In one embodiment, the hybrid system comprises a liquid or gel substrate and tobacco.

[0080] In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced and provide for a superior electronic aerosol provision system. 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 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 essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which may be claimed in future.

Claims

1. An aerosol provision system comprising: a housing having a mouthpiece, the mouthpiece having an air outlet; and, a consumable unit contained within the housing, the consumable unit comprising: a source of aerosol generating medium; and, an airflow channel wall forming an airflow channel that passes the source of aerosol generating medium and terminates in the vicinity of the air outlet of the housing.

2. An aerosol provision system according to claim 1, wherein the consumable unit comprises a filter material.

3. An aerosol provision system according to claim 2, wherein the filter material is in the airflow channel.

4. An aerosol provision system according to claim 2, wherein the filter material forms the airflow channel wall.

5. An aerosol provision system according to claim 2, wherein the filter material is compressed by the housing when the consumable unit is inserted into the housing.

6. An aerosol provision system according to claim 2, wherein the filter material is one or more members selected from the group consisting of: tobacco; cellulose acetate; and porous paper.

7. An aerosol provision system according to claim 1, comprising a movement mechanism to rotate the consumable unit relative to the housing.

8. An aerosol provision system according to claim 1, wherein an outer portion of the consumable unit is of a conforming shape to the housing near the air outlet.

9. An aerosol provision system according to claim 1, wherein a portion of the consumable unit has a frustoconical shape.

10. An aerosol provision system according to claim 1, wherein the source of aerosol generating medium terminates in the vicinity of the air outlet.

11. A consumable unit for use in the aerosol provision system of claim 1.

12. A housing for the aerosol provision system of claim 1.

13. A consumable unit for use with an aerosol provision system, the unit comprising a projecting first portion and a recessed second portion, wherein the projecting first portion is of a conforming shape to the recessed second portion.

14. A consumable unit according to claim 13, wherein the unit comprises aerosol generating medium arranged in the recessed second portion.

15. A consumable unit according to claim 14, wherein the unit comprises at least two portions of aerosol generating medium arranged in the recessed second portion.

16. Aerosol provision means comprising: a housing having a mouthpiece, the mouthpiece having air outlet means; and, a consumable unit contained within the housing, the consumable unit comprising: a source of aerosol generating means; and, an airflow channel means forming an airflow channel that passes the source of aerosol generating means and terminates in the vicinity of the air outlet means of the housing.

17. A method of providing an aerosol, comprising: providing a housing having a mouthpiece, the mouthpiece having an air outlet; and, providing a consumable unit contained within the housing, the consumable unit comprising: a source of aerosol generating medium; and, an airflow channel wall forming an airflow channel that passes the source of aerosol generating medium and terminates in the vicinity of the air outlet of the housing, passing air through the airflow channel within the airflow channel wall; passing air over the source of aerosol generating medium; and, passing air through the air outlet of the housing.

18. (canceled)