JP7640665B2 - Articles for use in aerosol delivery systems - Google Patents

Description

The present invention relates to an article for use in a non-combustion aerosol delivery system and a non-combustion aerosol delivery system including the article.

Certain tobacco industry products generate an aerosol that is inhaled by the user when used. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, to form an aerosol by heating the substrate without burning it.

The aerosol generated when the aerosol-generating substrate is heated may condense on the surfaces of the tobacco heating device, leaving behind deposits. Such deposits may interfere with the insertion of an article into the tobacco heating device or may prevent the article from heating properly during use.

In some embodiments described herein, a consumable is provided for insertion into an aerosol delivery device, the aerosol delivery device including a heating apparatus having walls at least partially defining a chamber for containing the consumable for heating during use of the device, the consumable being heated to deposit condensate on the walls, the consumable including a first section of aerosol-generating material and a second section of absorbent material at least partially exposed along a length of the consumable such that the absorbent material is in direct contact with the walls of the chamber to absorb the deposit when the consumable is contained in the chamber.

The consumable of the present invention may include a mouth end and a distal end, the mouth end configured to protrude from the aerosol delivery device, the distal end configured to be inserted deepest into a chamber of the aerosol delivery device, and at least the distal end including a second section of absorbent material, the absorbent material extending from the distal end of the consumable toward the mouth end.

The consumable product of the present invention may further include a packaging material that at least partially encases the first section made of the aerosol-generating material and at least partially encases the second section made of the absorbent material.

The wrapper may extend partially over the second section of absorbent material to form an exposed section of absorbent material.

The wrapper may extend partially along the entire length of the second section of absorbent material.

The wrapper may extend partially along the second section of absorbent material from a proximal end thereof toward a distal end of the second section of absorbent material.

The packaging material may include a cut-out section on the second section of absorbent material.

The exposed section of absorbent material may be configured to abut against a wall of the aerosol delivery device in use.

The exposed section of absorbent material may include a wicking material configured to abut a wall of the aerosol delivery device in use, and a core portion formed of absorbent material.

The second section of absorbent material may include at least one absorbent particle.

The at least one absorbent particle may be embedded in the absorbent material.

The second section of absorbent material may include a packaging material carrying the at least one absorbent particle, and the second section of absorbent material is at least partially wrapped around the first section of aerosol-generating material.

The second section of absorbent material may include a wrapping material configured to be wrapped around the first section of aerosol-generating material.

The packaging material may include at least one absorbent particle embedded in the packaging material.

The absorbent particles may include at least one of putty, charcoal, clay and sepiolite.

The consumables of the present invention may further include a hydrophilic coating configured to absorb condensation from the walls of the chamber of the aerosol delivery device.

The hydrophilic coating may at least partially cover the second section of absorbent material.

The hydrophilic coating may at least partially cover the packaging material.

The consumables of the present invention may further include an impermeable coating.

A non-permeable coating may cover the distal end of the consumable and may be configured to prevent absorbed condensate from escaping from the consumable.

The non-permeable coating may be a hydrophobic coating.

In another aspect of the invention described herein, there is provided a system including an aerosol delivery device and a consumable according to any one of claims 1 to 21 for insertion into the aerosol delivery device.

In another aspect of the invention described herein, there is provided a pack comprising one or more consumable products according to any one of claims 1 to 21.

In another aspect of the invention described herein, there is provided a method of cleaning a chamber of a heating apparatus of an aerosol delivery device, the method comprising inserting a consumable according to any one of claims 1 to 21 into the chamber of the aerosol delivery device, consuming the consumable, waiting for an absorbent material in the consumable to absorb condensate on the walls of the chamber, and removing the consumable from the chamber.

In another aspect of the invention described herein, there is provided an article for cleaning an aerosol delivery device, the article comprising an absorbent portion arranged for insertion into a heating chamber of the aerosol delivery device in use, the absorbent portion comprising a carrier material having a plurality of absorbent particles applied or distributed thereon.

The carrier material may extend along the length of the article, and the plurality of absorbent particles may be applied along the length and circumference of the carrier material.

The absorbent particles may include at least one of putty, charcoal, clay and sepiolite.

In another aspect of the invention described herein, there is provided a system comprising an aerosol delivery device and an article according to any one of claims 25 to 27 for cleaning the aerosol delivery device.

In another aspect of the invention described herein, there is provided a pack comprising an article according to any one of claims 25 to 27 and one or more aerosol generating consumables for use in an aerosol delivery device.

In another aspect of the invention described herein, there is provided a method of cleaning a chamber of a heating apparatus of an aerosol delivery device, the method comprising inserting an article according to any one of claims 24 to 27 into the chamber of the aerosol delivery device, waiting for an absorbent material in the article to absorb condensation on the walls of the chamber, and removing the article from the chamber.

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
1 shows a schematic representation of an aerosol delivery device according to an embodiment of the present invention. 1 shows a schematic representation of a consumable item according to an embodiment of the present invention. 1 shows a schematic representation of a consumable item according to an embodiment of the present invention. 1 shows a schematic representation of a consumable item according to an embodiment of the present invention. 1 shows a schematic representation of a consumable item according to an embodiment of the present invention. 1 shows a schematic representation of a consumable item according to an embodiment of the present invention. 1 is a schematic cross-sectional view along a longitudinal axis of a consumable according to an embodiment of the present invention. 1 shows a schematic representation of a consumable item according to an embodiment of the present invention. 1 shows a schematic representation of a consumable item according to an embodiment of the present invention. 1 is a schematic cross-sectional view along a longitudinal axis of a consumable according to an embodiment of the present invention. 1 shows a schematic representation of a consumable item according to an embodiment of the present invention. 1 shows a schematic representation of an article according to an embodiment of the present invention.

For purposes of this disclosure, a "non-combustion" aerosol delivery system is one that does not combust or burn the constituent aerosol-generating materials of the aerosol delivery system (or its components) to facilitate delivery of at least one substance to a user.

In some embodiments, the non-combustion aerosol delivery system includes an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustion aerosol delivery system may be a hybrid system that uses a combination of aerosol-generating materials, one or more of which are heated to generate the aerosol. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and consumables for use with the non-combustion aerosol delivery device.

In some embodiments, the present disclosure relates to consumables that include an aerosol generating material and are configured for use in non-combustion based aerosol delivery devices. These consumables are sometimes referred to as articles throughout this disclosure.

In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, a power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that is energized to deliver power in the form of heat to an aerosol generating material or a thermally conductive material proximate to the heat generating power source.

In some embodiments, the non-combustion aerosol delivery system may include an area for containing a consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and/or an aerosol modifier.

In some embodiments, consumables for use in non-combustion based aerosol delivery systems may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transport component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol modifier.

In some embodiments, the substance delivered comprises an active agent.

The active substance used in the present invention is a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, psychotropic drugs. The active substance may be naturally occurring or synthetically derived. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives or mixtures thereof. The active substance may include one or more components, derivatives or extracts of tobacco, cannabis or other plants.

In some embodiments, the active agent comprises nicotine. In some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

As described herein, the active agent may include or be derived from a plant or its components, derivatives, or extracts. As used herein, the term "plant" includes, but is not limited to, any material derived from a plant, such as extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, pods, etc. Alternatively, the material may include active compounds naturally occurring in the plant or synthetically derived. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, pieces, strips, sheets, etc. Examples of plants include tobacco, eucalyptus, cornstarch, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, Lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, sedge, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiene, oregano, olive, lemon balm, lemon basil, chives, fennel, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following mint species: mentha, moroccan mint, egyptian mint, peppermint, cologne mint, candy mint, curly mint, kentucky kernel mint, horse mint, pineapple mint, pennyroyal mint, english spearmint, and malva.

In some embodiments, the active agent may include or be derived from a plant or one or more of its components, derivatives, or extracts, and the plant is tobacco.

In some embodiments, the active agent may include or be derived from one or more of a plant or its components, derivatives or extracts, the plant being selected from eucalyptus, tallow tree, cocoa and hemp.

In some embodiments, the composition may comprise or be derived from one or more plants or components, derivatives or extracts thereof, the plants being selected from rooibos and fennel.

In some embodiments, the substance includes a flavoring agent.

As used herein, the terms "flavoring agent" and "flavoring agent" are used as permitted by local ordinance to produce a taste, odor or other somatosensory stimulus desired by the adult consumer. They include naturally occurring flavoring materials, plants, plant extracts, synthetically derived materials or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, and the like). Roots, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey extract, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang ylang, Sage, fennel, wasabi, pimento, ginger, coriander, coffee, hemp, peppermint oil from any species of the genus Mentha, eucalyptus, burdock, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, scutellaria, curcuma, cilantro, myrtle, black currant, valerian, pimento, melon. , damien, origanum, olive, lemon balm, lemon basil, chives, fennel, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, mannitol, etc.), and other additives such as charcoal, chlorophyll, minerals, botanicals or breath fresheners. They may be mimics, synthetic or natural ingredients or blends thereof. They may be in any suitable form, e.g. liquids such as oils, solids such as powders or gases.

In some embodiments, the flavoring agent comprises menthol, spearmint, and/or peppermint. In some embodiments, the flavoring agent comprises cucumber, blueberry, citrus, and/or red berry flavor components. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring agent comprises flavor components extracted from tobacco. In some embodiments, the flavoring agent comprises flavor components extracted from cannabis.

In some embodiments, the flavoring agent may include a sensory agent, which is chemically induced and recognized by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the aroma or taste nerves, and which may include agents that impart heating, cooling, tingling, or numbing sensations. A suitable heating agent is, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent is, but is not limited to, eucalyptol, WS-3.

An aerosol-generating material is a material that can generate an aerosol when excited, for example, by heating, irradiation, or in some other way. The aerosol-generating material may be in the form of a solid, liquid, or gel, for example, which may or may not contain active substances and/or flavorants. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," alternatively referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that holds a fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material comprises about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

The aerosol-generating material may include one or more active substances and/or flavourings, one or more aerosol-forming materials and, if desired, one or more other functional materials.

The aerosol forming material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

The one or more functional ingredients may include one or more of a pH regulator, a colorant, a preservative, a binder, a filler, a stabilizer, and/or an antioxidant.

The generating material may be on or in a support to form a substrate. The support may be or include, for example, paper, cardboard, paperboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support includes a susceptor. In some embodiments, the susceptor is embedded in the material. In some other embodiments, the susceptor is on one or both sides of the material.

A consumable is an article that contains or consists of an aerosol-generating material that is intended to be consumed in whole or in part by a user during use. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and/or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater that radiates heat so that the aerosol-generating material generates an aerosol upon use. The heater may include, for example, a combustion-based material, a material heatable by electrical conduction, or a susceptor.

The aerosol modifier is a substance that is typically located downstream of the aerosol-generation region and configured to modify the generated aerosol, for example by changing the taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided within an aerosol modifier-releasing component that is operable to selectively release the aerosol modifier.

The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavorant, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, liquid, or gel. The aerosol modifier may be a powder, string, or granules. The aerosol modifier may not include a filtration material.

The aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to expose the aerosol-generating material to thermal energy to release one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating it. For example, the aerosol generator may be configured to expose the aerosol-generating material to one or more of vibration, high pressure, or electrostatic energy.

The same reference numbers are used in the drawings throughout this specification to indicate equivalent features, items or components.

A non-combustion aerosol delivery device 1 (herein simply referred to as device 1) according to an embodiment of the present invention is shown diagrammatically in FIG. 1. Device 1 includes a receptacle 2. Receptacle 2 includes at least one wall 3 defining a chamber or rod-shaped consumable-receiving space (herein simply referred to as "receiving space 4") and a heater 5 configured to heat consumable-receiving space 4.

The device 1 further includes a power source 7 and a control unit 8 configured to power and control the heater 5. The power source 7 may be a battery 7, for example a rechargeable or non-rechargeable battery. Examples of suitable batteries include lithium batteries (such as lithium ion batteries), nickel batteries (such as nickel-cadmium batteries) and alkaline batteries.

The various parts of the device, such as the receiver 2, heater 5, battery 7 and control unit 8, are held within the housing 6.

The device 1 is sized and shaped to allow a user to hold the device 1 in one hand. In use, a consumable 11, shown in FIG. 3, containing an aerosol-generating material is inserted into the receiving space 4 and heated by the heater 5. The heat causes one or more volatile substances from the aerosol-generating material to form an aerosol. A mouth end 12 of the consumable protrudes from the device 1, as shown in FIG. 2. To inhale the aerosol emitted by the heated consumable 11, a user draws on the mouth end 12 of the consumable 11, as with a conventional cigarette. The consumable 11 includes a distal end 13, shown in FIG. 3, located at the end of the consumable 11 opposite the mouth end 12.

The device 1 further includes an inlet 9 as shown in FIG. 1. When a user inhales on the consumable 11, air is drawn in from the inlet 9 through the consumable 11.

In some embodiments, the device 1 includes a first activation button 14 that allows a user to turn the device 1 on and off, and a second activation button 15 for activating the heater 5. To use the device 1, a user inhales on the mouth end of the consumable 11 and simultaneously presses the second activation button 15 to heat the consumable 11 via the heater 5 and generate an aerosol.

In some embodiments, the inlet 9 may include a pressure sensor (not shown) that functions as a "puff sensor." The puff sensor is configured to detect a pressure drop at the air inlet 9 that indicates that a user is drawing on a consumable 11 disposed within the storage space 4. The device 1 is thereby configured to activate the heater in response to a pressure drop detected at the air inlet 9.

The control unit 8 is configured to direct electrical energy from the battery 7 to start the heater 5 in response to an input signal.

In some embodiments and as shown in FIG. 1, the heater 5 is an induction heating device 17 that includes various components for heating the consumable receiving space 4 by induction heating. The induction heating device 17 includes an inductor coil 18 and a susceptor 19. The inductor coil 18 is made of an electrically conductive material. In an exemplary embodiment, the inductor coil 18 is made of a Litz wire/cable that is wound in a spiral shape around the susceptor 19. The Litz wire/cable includes multiple individual wires that are individually insulated and twisted together to form a single wire. The Litz wire is designed to reduce skin effect losses in the conductor. In an exemplary embodiment, the inductor coil 18 is made of copper Litz wire with a rectangular cross section. In other examples, the Litz wire may have a cross section of other shapes, such as circular. The inductor coil 18 is configured to generate a varying magnetic field to heat the susceptor 19.

Induction heating is a process of heating an electrically conductive object (such as a susceptor) by electromagnetic induction. The induction heating apparatus 17 may include an induction element 18, e.g. one or more inductor coils, and a device for passing a fluctuating current, such as an alternating current, through the induction element 18. The fluctuating current in the induction element 18 generates a fluctuating magnetic field. The fluctuating magnetic field penetrates a susceptor, preferably positioned relative to the induction element 18, generating eddy currents, which thus cause the susceptor to heat by Joule heating due to the flow of eddy currents against this resistance. If the susceptor 19 comprises a ferromagnetic material, such as iron, nickel or cobalt, heat may be generated by magnetic hysteresis losses in the susceptor, i.e. by the change in orientation of the magnetic dipoles of the magnetic material as a result of matching with the fluctuating magnetic field. In induction heating, heat is generated inside the susceptor 19, allowing for faster heating, as compared to heating by conduction, for example. Furthermore, no physical contact is required between the dielectric heater and the susceptor 19, allowing for greater freedom of construction and application.

The susceptor 19 in the illustrated embodiment is cylindrical and hollow and defines a receiving portion 2 in which the consumable 11 is received. For example, the consumable 11 can be inserted into the susceptor 19. In the illustrated embodiment, the susceptor 19 is tubular and has a circular cross section.

The susceptor 19 may be made from one or more materials. Preferably, the susceptor 19 comprises carbon steel with a nickel or cobalt coating.

In some embodiments, the device 1 further includes an insulating member (not shown). The insulating member may be generally tubular and disposed between the susceptor 19 and the inductor coil 18. The insulating member may be constructed of an insulating material, such as, for example, a plastic. In this particular example, the insulating member is constructed of polyetheretherketone (PEEK). The insulating material helps to insulate the various components of the device 1 from heat generated within the susceptor 19.

In some embodiments, the outer surface of the susceptor 19 is separated from the inner surface of the inductor coil 18 by a distance measured in a direction perpendicular to the longitudinal axis of the susceptor 19. In one particular example, the distance is about 3 mm to 4 mm, about 3 to 3.5 mm, or about 3.25 mm.

In some embodiments, the outer surface of the insulating member is spaced from the inner surface of the inductor coil 18 by a distance measured in a direction perpendicular to the longitudinal axis of the susceptor 19. In one particular example, the distance is about 0.05 mm. In another example, the distance is substantially 0 mm such that the inductor coil 18 abuts and touches the insulating member.

In some embodiments, the susceptor 19 has a wall thickness of about 0.025 mm to 1 mm, or about 0.05 mm.

In some embodiments, the susceptor 19 has a length of about 40 mm to 60 mm, about 40 to 45 mm, or about 44.5 mm.

In some embodiments, the insulating member has a wall thickness of about 0.25 mm to 2 mm, 0.25 mm to 1 mm, or about 0.5 mm.

Figure 3 shows a consumable 11 according to an embodiment of the present invention. As described above, the consumable 11 includes a mouth end 12 and a distal end 13 opposite the mouth end 12. The distal end 13 is therefore closest to the base 2a of the receiver 2 shown in Figure 1 when received in the consumable receiving space 4.

During use of the device 1, a portion of the aerosol generated when the aerosol-generating material is heated condenses as it travels through the consumable 11. Condensate formed on the consumable 11 tends to condense on the walls 3 defining the chamber 4 or receiving space 4 and/or to leak from the distal end 13 of the consumable 11 and accumulate in the receiving space 4. An embodiment of the invention is configured to remove condensate accumulated over time from the walls 3 defining the receiving space 4 and to repeatedly heat the consumable 11.

In the embodiment shown in FIG. 3, the consumable 11 includes a first section 21 that comprises an aerosol-generating material 22.

In some embodiments, the aerosol-generating material 22 comprises tobacco material 23. The tobacco material 23 may comprise conventionally cured tobacco that has been cut or shredded in a conventional manner. Such tobacco is similar to tobacco found in cigarettes.

In another embodiment, the tobacco material 23 may be regenerated to produce tobacco paper that is then cut or shredded into strips. The tobacco paper may be further impregnated with an aerosol-forming material, such as glycerin, glycerol, or propylene glycol. Thus, as the aerosol passes through the rod of aerosol-generating material 22 upon inhalation by the user, heat from the aerosol vaporizes the aerosol-forming material. Advantageously, the aerosol-generating material is flavored by the tobacco paper to provide a tobacco flavor to the aerosol.

In some embodiments, the tobacco paper comprises longitudinal strips of tobacco paper, each longitudinal strip being oriented substantially parallel to the longitudinal axis of the article. Thus, the resistance to draw of the rod of aerosol-generating material 22 is reduced.

In another embodiment, the tobacco material 23 is regenerated to produce tobacco beads. The tobacco beads may have an average diameter of 0.5 mm to 3 mm. Naturally, the smaller the average diameter for a given volume occupied by the tobacco beads, the greater the overall surface area provided by the tobacco beads. Advantageously, the flavor imparted to the aerosol is proportional to the surface area provided by the tobacco beads.

The consumable 11 further includes a second section 25 of absorbent material 26. The absorbent material 26 may be, for example, but not limited to, paper, cellulose acetate, wood pulp and SAF™ airlaid fabric, or paper with additives such as flax or superabsorbent fibers such as abaca. The absorbent material 26 is at least partially exposed along the longitudinal axis of the consumable 11 as shown in FIG. 4. Additionally, the absorbent material 26 is exposed for direct contact with the walls of the chamber 4 to absorb condensate that accumulates when the consumable 11 is housed in the chamber 4 of the device 1.

The distal end 13 of the consumable 11 includes a second section of absorbent material 26. The absorbent material 26 extends from the distal end 13 of the consumable 11 to the mouth end 12. That is, the second section 25 of absorbent material 26 may be formed by a plug 30 of absorbent material 26.

In some embodiments, the consumable 11 further includes a first packaging material 31. The first packaging material 31 is at least partially wrapped around the first section of the aerosol-generating material 22. The packaging material 31 is further at least partially wrapped around the second section of the absorbent material 26. The first packaging material 31 may be electrically conductive, such as aluminum foil, metallized paper, or woven iron. Thus, the first packaging material 31 may function as an additional susceptor 19 for the induction heating device 17. The first packaging material 31 surrounds the first section 21 of the rod of aerosol-generating material 22 such that the edges of the first packaging material overlap. The overlapping edges of the first packaging material are glued along a seam.

Also in this embodiment, the first wrapper 31 at least partially surrounds the second section 25 of the absorbent 26 such that the edges of the first wrapper 31 overlap near the distal end 13 of the consumable 11. The overlapping edges of the first wrapper 31 are glued along a seam.

The rod of aerosol-generating material 22 is attached to the filter section 32 by tipping material 33. The tipping material 33 surrounds the rod of aerosol-generating material 22 and the filter section 32 such that the edges of the tipping material 33 overlap. The overlapping edges of the tipping material 33 are glued along a seam.

The filter section 32 includes a cylindrical body of filter material wrapped in a plug wrapper 34. The plug wrapper 34 is disposed between the filter material and the tipping material 33.

As discussed above and with reference to FIG. 3, the first wrapper 31 is at least partially wrapped around the second section 25 of absorbent material 26. However, in this embodiment, the first wrapper 31 extends only partially over the second section 25 of absorbent material 26 to form an exposed section 27 of absorbent material 26.

The exposed section 27 of absorbent material 26 may be formed by forming the first wrapper 31 such that it does not extend the entire longitudinal length of the second section 25 of absorbent material 26.

Thus, as shown in FIG. 4, the distal end 13 of the second section 25 of absorbent material 26 may not be covered by the first wrapper 31. That is, the first wrapper 31 does not extend along the entire length of the second section 25 of absorbent material 26. The arcuate dashed line in FIG. 4 indicates where the second section 25 of absorbent material 26 begins, and the solid line indicates the amount of overlap of the first wrapper 31 of the second section 25 of absorbent material 26.

More specifically, the first wrapper 31 does not extend to the distal end 13 of the second section 25 of the absorbent 26. That is, the first wrapper 31 extends partially along the second section 25 of the absorbent 26 from its proximal end toward the distal end of the second section 25 of the absorbent 26. The exposed section 27 of the absorbent 26 is thus disc-shaped, i.e., the circumferential surface 28 of the distal end 13 of the absorbent 26 is exposed. The circular end 29 of the absorbent 26 may also be exposed.

In another embodiment shown in FIG. 5, the exposed section 27 of the absorbent 26 may be spaced longitudinally from the distal end 13 of the consumable 11. Thus, the exposed section 27 of the absorbent 26 may be ring-shaped, and the section of the first wrapper 31 may extend over the distal-most end of the second section 25 of the absorbent 26. Additionally, the circular end 29 of the absorbent 26 may be covered by the wrapper 31 so that it is not exposed.

In yet another embodiment shown in FIG. 6, the first wrapper 31 includes a cut-out section 36. The cut-out section 36 extends across the second section 25 of the absorbent 26 such that an exposed section of the absorbent 26 is formed. The cut-out section 36 may be circular as shown in FIG. 6. In other embodiments, the cut-out section 36 may be other shapes, such as triangular, square, etc. Only one cut-out section 36 of the wrapper 31 is shown. However, it will be appreciated that the consumable 11 may include multiple cut-out sections 36.

In the above-described embodiments, the exposed section 27 of the absorbent 26 may be configured to abut the wall 3 of the aerosol delivery device 1 in use. That is, in another embodiment, the exposed section 27 of the absorbent 26 may protrude radially through the cut-out section 36 slightly beyond the first wrapper 31 such that it abuts the wall 3 of the device 1. In some embodiments, the absorbent 26 expands upon absorbing condensate or in response to heating such that the absorbent 26 does not initially abut the wall 3 upon insertion, but at least comes into contact with the wall 3 when the consumable 11 is consumed.

7, in some embodiments, the exposed section 27 of the absorbent material 26 may include a wicking material 38. The wicking material may be configured to abut a wall of the aerosol delivery device 1 as described above. Thus, the second section 25 may include an outer section formed by the wicking material 38 and a core portion 39 formed from the plug 30 of the absorbent material 26. The wicking material 38 may be, for example, but is not limited to, sodium polyacrylate, wood pulp, silica gel, fluff pulp, cotton and modal fibers, or cellulosic fibers such as rayon.

Furthermore, in some embodiments, such as the embodiment shown in FIG. 8, the second section 25 of absorbent material 26 includes at least one absorbent particle 41. The at least one absorbent particle 41 may be embedded in the absorbent material 26, i.e., at and/or on the surface of the plug 30 of absorbent material. Preferably, the absorbent material includes a plurality of absorbent particles 41 dispersed throughout the second section 25 of absorbent material 26, i.e., throughout the plug 30 of absorbent material 26. In FIG. 8, the solid circles 41 represent absorbent particles 41 visible on the surface of the absorbent material 26, while the dashed circles represent absorbent particles 41 embedded within the absorbent material 26 or on the surface of the second section 25 not visible in this view, or under the first packaging material 31. The at least one absorbent particle 41 may include, for example, but is not limited to, at least one of putty, charcoal, clay, and sepiolite.

9, an embodiment is shown in which the consumable 11 includes an exposed section 27 of absorbent material 26 at the distal end 13 of the consumable 11. In addition, in this embodiment, the second section 25 of absorbent material 26 further includes a packaging material 31. That is, the packaging material 31 is configured to absorb condensate from the wall 3 of the device 1. The packaging material 31 may carry at least one absorbent particle 41. That is, the packaging material 31 is embedded with at least one absorbent particle 41, preferably a plurality of absorbent particles 41. As shown in FIG. 9, in some embodiments, the plug 30 of the second section 25 of absorbent material 26 and the first packaging material 31 may both include a plurality of absorbent particles 41.

As shown in FIG. 9, the wrapper 31 of the second section 25 of absorbent material 26 is at least partially wrapped around the first section 21 of aerosol-generating material 22. Of course, in another embodiment, the second section 25 of absorbent material 26 may include a wrapper 31 configured solely for absorbing condensate, without a longitudinally extending plug 30 of absorbent material 26 upstream of the first section 21 of aerosol-generating material 22.

For example, FIG. 10 shows a consumable 11 including a packaging material 31 configured such that a second section 25 of absorbent material 26 is wrapped around a first section 21 of aerosol-generating material 22. In this embodiment, the packaging material 31 includes at least one absorbent particle 41 embedded therein. The packaging material 31 and the absorbent particle 41 therein may be configured to abut against a wall 3 of the device 1 during use.

In some embodiments, the consumable 11 may further include a hydrophilic coating. The hydrophilic coating may be configured to absorb condensation from the wall 3 of the chamber 4 of the aerosol delivery device 1. The hydrophilic coating may at least partially cover the second section 25 of the absorbent material 26.

Referring to FIG. 11, the consumable 11 may further include an impermeable coating 43. The impermeable coating 43 is configured to prevent condensate from passing through the coating 43. In this embodiment, the impermeable coating 43 covers the distal end 13 of the consumable 11. Thus, the impermeable coating 43 is configured to prevent absorbed condensate from escaping from the consumable 11.

The impermeable coating 43 may extend across the circular end 29 of the second section 25 of absorbent material 26. The impermeable coating 43 may also extend proximally from the distal end 13 of the consumable 11, i.e., from the circular end 29 along the circumferential surface 28 of the second section 25 of absorbent material 26. Thus, a bucket is formed that captures condensation of the absorbent material 26 and prevents the condensation from escaping the consumable 11. The impermeable coating 43 may be a hydrophobic coating 44.

In this example, the consumable 11 has a circumference of about 21 mm (i.e., the consumable is in a demi-slim format). Preferably, the consumable 11 has a rod of aerosol-generating material 22 having a circumference greater than 19 mm. When the consumable 11 is heated, heat is transferred through the rod of aerosol-generating material 22, volatilizing the components of the rod of aerosol-generating material, and it has been found that a circumference greater than 19 mm is particularly effective in generating an aerosol in this manner. Since the consumable 11 is heated to emit an aerosol, improved heating efficiency can be achieved by using a consumable 11 having a smaller circumference within this range, for example a circumference less than 23 mm. A circumference greater than 19 mm and less than 23 mm is preferred to obtain good aerosol upon heating while maintaining a suitable product length. In some examples the circumference may be 20 mm to 22 mm, which provides a good combination of efficient heating and effective aerosol delivery.

The circumference of the filter section 32 is substantially the same as the circumference of the rod of aerosol generating material 22 and the plug 30 of absorbent material 26, which allows for a smooth transition between these components. In this example, the circumference of the filter section 32 is approximately 20.8 mm.

The tipping material 33 may have a basis weight greater than that of the outer packaging material used for the consumable 11, for example 40 gsm to 80 gsm, more preferably 50 gsm to 70 gsm, in this example 58 gsm. Basis weights in these ranges have been found to result in a tipping paper that is flexible enough to encase the consumable 11 while having acceptable tensile strength, and that adheres to itself along the longitudinal hold-down seam of the paper.

In some examples, the tipping material 33 and/or the first wrapper 31 tipping paper includes a citrate such as sodium citrate or potassium citrate. In such examples, the citrate content of these materials 31, 33 may be 2% or less by weight, or 1% or less by weight. It is believed that reducing the citrate content helps to reduce the scorching effect that occurs during use.

In some embodiments, the wrappers 31, 33 of the rod of aerosol-generating material 22 and the filter section 32, respectively, have a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. Preferably, the wrappers 31, 33 have a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. Preferably, the wrappers 31, 33 are non-porous, for example having an air permeability of less than 100 Coresta units, for example less than 50 Coresta units. However, in other embodiments, the wrappers 31, 33 may be porous plug wrappers, for example having an air permeability of more than 200 Coresta units. Preferably, the length of the filter section 32 is less than 20 mm. In this example, the length of the filter section 32 is 16 mm.

In some embodiments, the filter section 32 includes a body formed from filamentary tow. In this example, the tow used in the body has a d.p.f. of 8.4 and a total fineness of 21,000. Alternatively, the tow may have, for example, a d.p.f. of 9.5 and a total fineness of 12,000. In this example, the tow includes plasticized cellulose acetate tow. The plasticizer used in the tow comprises about 7% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, different materials can be used to form the body. For example, rather than tow, the body of the filter section 32 can be formed from paper, as in conventional paper filters, for example, for use in cigarettes. Alternatively, the body can be formed from materials other than cellulose acetate, such as polylactic acid (PLA), other materials described herein for filamentary tow, or similar materials. Preferably, the tow is formed from cellulose acetate. The tow, whether formed from cellulose acetate or other material, preferably has a d.p.f. of at least 5, more preferably at least 6, and even more preferably at least 7. These values of single yarn fineness provide a relatively coarse, thick fibrous tow having a smaller surface area than tows with lower single yarn finenesses, and as a result the pressure drop through the filter section 6 is less than tows with lower d.p.f. values. Preferably, to obtain a sufficiently uniform body, the tow has a single yarn fineness of less than 12 d.p.f., preferably less than 11 d.p.f., and more preferably less than 10 d.p.f.

The total fineness of the tow forming the filter section 32 is preferably at most 30,000, more preferably at most 28,000 and even more preferably at most 25,000. These values of total fineness provide a tow that occupies a smaller proportion of the cross-sectional area of the filter section 32, resulting in a smaller resistance to suction and therefore a smaller pressure drop in the filter section 32 than tows with higher total fineness values. For a suitable hardness of the filter section 32, the tow preferably has a total fineness of at least 8,000 and more preferably at least 10,000. Preferably, the single yarn fineness is 5 to 12 and the total fineness is 10,000 to 25,000. More preferably, the single yarn fineness is 6 to 10 and the total fineness is 11,000 to 22,000. Preferably, the cross-sectional shape of the filaments in the tow is "Y" shaped, although in other embodiments other shapes can be used, such as "X" shaped filaments with the same d.p.f. and total fineness values provided herein.

The isoperimetric ratio L2/A of the cross-section of the filaments of the tow is 25 or less, 20 or less, or 15 or less, where L is the circumference of the cross-section and A is the cross-sectional area. Such filaments of the tow have a relatively small surface area for a given value of the single yarn fineness, which allows for good aerosol delivery to the consumer. In some cases, the body may include an absorbent material (e.g., charcoal) dispersed within the tow.

In some examples, the body of the filter section 32 may include a capsule. The capsule may include a breakable capsule, for example a capsule having a hard breakable shell surrounding a liquid payload. In some examples, a single capsule is used. The capsule is fully embedded within the body of the filter section 32. In other words, the capsule is fully surrounded by the material forming the body. In other examples, multiple breakable capsules may be disposed within the body of the filter section 32, for example two, three or more breakable capsules. The length of the body of the filter section 32 may be increased to accommodate the required number of capsules. In examples where multiple capsules are used, the individual capsules may be identical to one another or may differ in size and/or capsule payload. In other examples, multiple bodies of material may be provided, each containing one or more capsules.

The capsule has a core-shell structure. In other words, the capsule may include a shell that encapsulates a liquid agent, such as a flavorant or other substance, which may be any of the flavorants or aerosol modifiers described herein. The capsule shell can be burst by a user to release the flavorant or other substance into the body, which consists of the filter section 32.

In some examples, the capsule is spherical and has a diameter of about 3 mm. In other examples, other shapes and sizes are available. The total weight of the capsule may range from about 10 mg to about 50 mg.

For a given tow specification (8.4Y21000), it is known to generate a tow capacity curve for each of a range of weights, which represents the pressure drop through the length of the rod formed using the tow. Parameters such as rod length and circumference, wrapper thickness and amount of plasticizer in the tow are specified and combined with the tow specification to obtain a tow capacity curve, which gives an indication of the pressure drop that would be provided by different tow weights between the maximum and minimum weights achieved using standard rod forming machines. Such a tow capacity curve can be calculated, for example, using software available from the tow supplier. It has been found to be particularly advantageous to use a body consisting of a filter section 32 containing filamentary tow having a weight per mm of the length of the body that is about 10% to about 30% of the range between the maximum and minimum weights of the tow capacity curve obtained for the filamentary tow. This can be provided in a balance that allows for an acceptable pressure drop while providing sufficient tow weight to avoid shrinkage after the body is formed, while facilitating placement of the capsule in the tow for capsules of the size described herein.

In some embodiments, the filter section 32 may further include a hollow tubular member extending from the mouth end 12 and attached to the filter section by a tipping material 33. The hollow tubular member advantageously has a length of more than about 10 mm, for example, from about 10 mm to about 30 mm or from about 12 mm to about 25 mm. In some cases, it has been found that a consumer's lips tend to extend up to about 12 mm from the mouth end 12 of the consumable 11 when drawing aerosol from the consumable 11, and thus a hollow tubular member having a length of at least 10 mm or at least 12 mm will encircle most of the consumer's lips.

In another aspect of the invention, there is provided a system including an aerosol delivery device 1 and a consumable as described above for insertion into the aerosol delivery device 1. In yet another aspect of the invention, there is provided a pack including one or more consumables 11 as described above.

A method for cleaning the chamber 4 of the heating device 17 of the aerosol delivery device 1 is provided. The method includes inserting the consumable 11 described above into the chamber 4 of the aerosol delivery device 1, consuming the consumable 11, waiting for the absorbent 26 in the consumable 11 to absorb condensate on the wall 3 of the chamber 4, and removing the consumable 11 from the chamber 4.

Referring now to FIG. 12, another aspect of the present invention is shown. FIG. 12 shows an article for cleaning an aerosol delivery device 1. The article 51 includes an absorbent portion 52 that is arranged for insertion into the heating chamber 4 of the aerosol delivery device 1 during use. The absorbent portion 52 may include a carrier material 53. The carrier material 53 includes a plurality of absorbent particles 41 that are applied or distributed on the carrier material 53.

The carrier material 53 extends along the length of the article 51. As shown in FIG. 10, the plurality of absorbent particles 41 are applied to the entire length of the carrier material 53. Additionally, the plurality of absorbent particles 41 are applied to the circumference of the carrier material 53. Preferably, the plurality of absorbent particles 41 are evenly spread across the entire carrier material 53.

As described above, the absorbent particles 41 may include at least one of putty, charcoal, clay, and sepiolite.

Of course, the article 51 may have substantially the same features as the consumable 11, apart from those relating to the first section 21 of the aerosol-generating material 22 and the filter section 32. That is, the article 51 may include an absorbent wrapper 31 having embedded therein absorbent particles 41, and/or a cut-out section 36 in the wrapper 31 to expose an exposed section 27 of the plug 30 of absorbent material 26 in some embodiments. In other embodiments, the article 51 may include only a rod of absorbent material 26 having absorbent particles 41 therein.

In another aspect of the present invention, a system is provided that includes an aerosol delivery device 1 and an article 51 as described above for cleaning the aerosol delivery device 1.

In another aspect of the present invention, a pack is provided that includes the above-described article 51 and one or more aerosol generating consumables for use with the aerosol delivery device 1.

In another aspect of the present invention, a method for cleaning the chamber 4 of the heating apparatus 17 of the aerosol delivery device 1 is provided. The method includes inserting the above-described article 51 into the chamber 4 of the aerosol delivery device 1, waiting for the absorbent material 26 in the article 51 to absorb condensate on the walls 3 of the chamber 4, and removing the article 51 from the chamber 4.

The various embodiments described herein are provided merely to aid in the understanding and teaching of the claimed features. These embodiments are merely representative examples and are not intended to be comprehensive or exclusive. It is to be understood that the advantages, embodiments, examples, features, features, structures, and/or other aspects of the present disclosure should not be construed as limiting the present disclosure to the scope of the claims or to the equivalents of the claims, but that other embodiments may be utilized or modified without departing from the scope and/or spirit of the present disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of the disclosed components, ingredients, features, parts, steps, means, or other combinations. The present disclosure also includes other inventions not currently claimed but which may be claimed in the future.

Claims (20)

1. A consumable for insertion into an aerosol delivery device, comprising:
The aerosol delivery device includes a heating apparatus having a wall at least partially defining a chamber for containing the consumable for heating during use of the aerosol delivery device;
Heating the consumable causes condensation to deposit on the walls;
the consumable product includes a first section made of an aerosol-generating material and a second section made of an absorbent material;
The consumable product further includes a packaging material at least partially enclosing a first section of the aerosol-generating material and at least partially enclosing a second section of the absorbent material;
The absorbent material is at least partially exposed along a length of the consumable such that when the consumable is contained in the chamber, the absorbent material is in direct contact with the walls of the chamber to absorb the condensate. The consumable of claim 1, wherein the consumable includes a mouth end and a distal end, the mouth end configured to protrude from the aerosol delivery device, the distal end configured to be inserted deepest into a chamber of the aerosol delivery device, and at least the distal end includes a second section of the absorbent material, the absorbent material extending from the distal end of the consumable toward the mouth end. The consumable product of claim 1 or 2, wherein the wrapper extends partially over the second section of absorbent material to form an exposed section of absorbent material. The consumable product of claim 3, wherein the wrapper extends partially along the entire length of the second section of absorbent material. The consumable product of claim 4, characterized in that the wrapper extends partially along the second section of absorbent material from a proximal end of the two sections toward a distal end of the second section of absorbent material. The consumable product of claim 3, wherein the packaging material includes a cut-out section on the second section of absorbent material. The consumable product of any one of claims 3 to 6, characterized in that the exposed section of absorbent material is configured to abut the wall of the aerosol delivery device in use. 8. The consumable of claim 7, wherein the exposed section of absorbent material includes a wick portion formed of the absorbent material and configured to abut the wall of the aerosol delivery device in use. The consumable product according to any one of claims 1 to 8, characterized in that the second section of absorbent material includes at least one absorbent particle. The consumable product of claim 9, wherein the at least one absorbent particle is embedded in the absorbent material. The consumable product according to claim 9 or 10, characterized in that the second section of absorbent material may include a packaging material carrying the at least one absorbent particle, and the second section of absorbent material is at least partially wrapped around the first section of aerosol-generating material. The consumable of any one of claims 1 to 11, further comprising a hydrophilic coating configured to absorb the condensate from a wall of a chamber of the aerosol delivery device. The consumable product of claim 12, wherein the hydrophilic coating at least partially covers the second section of absorbent material. The consumable product according to claim 12 or 13, characterized in that the hydrophilic coating at least partially covers the packaging material. The consumable product of any one of claims 1 to 14, further comprising an impermeable coating. 16. The consumable of claim 15, wherein the non-permeable coating covers a distal end of the consumable and is configured to prevent the absorbed condensate from escaping from the consumable. The consumable product according to claim 15 or 16, characterized in that the non-permeable coating is a hydrophobic coating. A system comprising an aerosol delivery device and a consumable according to any one of claims 1 to 17 for insertion into the aerosol delivery device. A pack comprising one or more consumables according to any one of claims 1 to 17. A method for cleaning a chamber of a heating device of an aerosol delivery device, the method comprising: inserting a consumable described in any one of claims 1 to 17 into the chamber of the aerosol delivery device; consuming the consumable; waiting for the absorbent material in the consumable to absorb condensation on the walls of the chamber; and removing the consumable from the chamber.

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