SMOKING SUBSTITUTE CONSUMABLE

FIELD OF THE DISCLOSURE

The present disclosure relates to a consumable for use in a smoking substitute system and particularly, although not exclusively, to a heat-not-burn (HNB) consumable.

BACKGROUND

The smoking of tobacco is generally considered to expose a smoker to potentially harmful substances. It is generally thought that a significant amount of the potentially harmful substances are generated through the heat caused by the burning and/or combustion of the tobacco and the constituents of the burnt tobacco in the tobacco smoke itself.

Conventional combustible smoking articles, such as cigarettes, typically comprise a cylindrical rod of tobacco comprising shreds of tobacco which is surrounded by a wrapper, and usually also a cylindrical filter axially aligned in an abutting relationship with the wrapped tobacco rod. The filter typically comprises a filtration material which is circumscribed by a plug wrap. The wrapped tobacco rod and the filter are joined together by a wrapped band of tipping paper that circumscribes the entire length of the filter and an adjacent portion of the wrapped tobacco rod. A conventional cigarette of this type is used by lighting the end opposite to the filter, and burning the tobacco rod. The smoker receives mainstream smoke into their mouth by drawing on the mouth end or filter end of the cigarette.

Combustion of organic material such as tobacco is known to produce tar and other potentially harmful by-products. There have been proposed various smoking substitute systems (or “substitute smoking systems”) in order to avoid the smoking of tobacco.

Such smoking substitute systems can form part of nicotine replacement therapies aimed at people who wish to stop smoking and overcome a dependence on nicotine.

Smoking substitute systems include electronic systems that permit a user to simulate the act of smoking by producing an aerosol (also referred to as a “vapour”) that is drawn into the lungs through the mouth (inhaled) and then exhaled. The inhaled aerosol typically bears nicotine and/or flavourings without, or with fewer of, the odour and health risks associated with traditional smoking.

In general, smoking substitute systems are intended to provide a substitute for the rituals of smoking, whilst providing the user with a similar experience and satisfaction to those experienced with traditional smoking and with combustible tobacco products. Some smoking substitute systems use smoking substitute articles that are designed to resemble a traditional cigarette and are cylindrical in form with a mouthpiece at one end.

The popularity and use of smoking substitute systems has grown rapidly in the past few years. Although originally marketed as an aid to assist habitual smokers wishing to quit tobacco smoking, consumers are increasingly viewing smoking substitute systems as desirable lifestyle accessories.

There are a number of different categories of smoking substitute systems, each utilising a different smoking substitute approach.

One approach for a smoking substitute system is the so-called “heat not burn” (“HNB”) approach in which tobacco (rather than an “e-liquid”) is heated or warmed to release vapour. The tobacco may be leaf tobacco or reconstituted tobacco. The vapour may contain nicotine and/or flavourings. In the HNB approach the intention is that the tobacco is heated but not burned, i.e., the tobacco does not undergo combustion.

A typical HNB smoking substitute system may include a device and a consumable. The consumable may include the tobacco material. The device and consumable may be configured to be physically coupled together. In use, heat may be imparted to the tobacco material by a heating element of the device, wherein airflow through the tobacco material causes moisture in the tobacco material to be released as vapour. A vapour may also be formed from a carrier in the tobacco material (this carrier may for example include propylene glycol and/or vegetable glycerine) and additionally volatile compounds released from the tobacco. The released vapour may be entrained in the airflow drawn through the tobacco.

As the vapour passes through the consumable (entrained in the airflow) from an inlet to a mouthpiece (outlet), the vapour cools and condenses to form an aerosol for inhalation by the user. The aerosol will normally contain the volatile compounds.

In HNB smoking substitute systems, heating as opposed to burning the tobacco material is believed to cause fewer, or smaller quantities, of the more harmful compounds ordinarily produced during smoking. Consequently, the HNB approach may reduce the odour and/or health risks that can arise through the burning, combustion and pyrolytic degradation of tobacco.

In some cases, the aerosol passing from the mouthpiece (i.e., being inhaled by a user) may not be in a desirable state. Thus, it may be desirable to alter one or more characteristics of the aerosol before it is inhaled by the user.

There is a need for an improved design of HNB consumables to enhance the user experience and improve the function of the HNB smoking substitute system.

The present disclosure has been devised in the light of the above considerations.

SUMMARY OF THE DISCLOSURE

First Mode of the Disclosure: Thin-Walled Hollow Bore Filter Element

At its most general, the first mode of the present disclosure relates to an aerosol-forming article e.g., a smoking substitute article such as an HNB consumable having a thin-walled hollow bore filter element interposed between two other filter elements.

According to a first aspect of the first mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising: an aerosol-forming substrate; and an axially adjacent, downstream filter arrangement wherein the filter arrangement comprises an upstream filter element, an intermediate filter element and a terminal filter element, wherein the upstream and terminal filter elements are independently selected from a solid filter element and a hollow bore filter element and wherein intermediate filter element is a hollow bore filter element having a greater bore diameter than any other hollow bore filter element in the filter arrangement.

The provision of an intermediate hollow bore filter element interposed between two other filter elements within a filter arrangement axially downstream of the substrate, the intermediate filter element can act as a cooling/mixing chamber by allowing cooling/mixing of the aerosol/vapour generated by heating the substrate within its axial bore. The intermediate filter element thus helps reduce thermal transfer to the user's lips whilst having little effect on the volume of visible vapour (unlike known polylactic acid cooling elements which reduce visible vapour).

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Amica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m²such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m²e.g., less than or equal to 250 g/m²or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt % e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm e.g., between 6 and 9 mm or 6 and 8 mm e.g., around 7 mm. It may have an axial length of between 10 and 15 mm e.g., between 11 and 14 mm such as around 12 or 13 mm.

The filter arrangement comprises an upstream filter element which is axially adjacent/immediately downstream of the aerosol-forming substrate, a terminal filter element which is at the downstream axial end of the article/consumable and an intermediate filter element which is interposed in abutment with the other two filter elements.

The upstream and intermediate filter elements may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element/intermediate filter element) may be comprised of cellulose acetate or polypropylene tow. The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element/intermediate filter element) may be comprised of activated charcoal. The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element/intermediate filter element) may be comprised of paper. The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element/intermediate filter element) may be comprised of plant material e.g., extruded plant material. The or each filter element may be circumscribed with a plug wrap e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the upstream and/or terminal filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm e.g., between 10 and 12 mm. The axial length of the intermediate filter element may be between 10 and 15 mm e.g., between 12 and 14 mm or 13 and 14 mm e.g., around 14 mm.

The intermediate filter element is a hollow bore filter element having a larger bore diameter than any other hollow bore filter element in the filter arrangement.

In some embodiments, the bore diameter in the intermediate filter element is greater than 3 mm, e.g., greater than or equal to 4 mm, such as greater than or equal to 5 or 6 mm. Given that the external diameter of the intermediate filter element preferably matches the diameter of the substrate (e.g., with a diameter around 7 mm), it can be seen that the intermediate hollow bore filter element is preferably a thin-walled hollow bore filter element. This maximises the volume of the axial bore to maximise mixing/cooling of the vapour.

The terminal filter element and/or upstream filter element may be a solid filter element.

The terminal filter element and/or upstream filter element may be a hollow bore filter element. In that case, the upstream and or terminal hollow bore filter element may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm. Where both the upstream and terminal filter elements are hollow bore filter elements, the upstream filter element may have a larger bore diameter than the terminal filter element (with the intermediate filter element having the largest bore diameter within the filter arrangement).

In preferred embodiments, the upstream filter element is a hollow bore filter element (with a bore diameter less than the bore diameter of the intermediate hollow bore filter element. In this way, the vapour passing through the axial bore of the upstream hollow bore filter element can expand into the larger axial bore in the intermediate hollow bore filter element, this expansion resulting in effective cooling/mixing.

Providing a terminal hollow bore filter element may help the components of the vapour/aerosol within the larger axial bore of the intermediate filter element co-locate prior to inhalation by the user.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

Where one of the upstream/terminal filter elements is a solid filter element, it may include a capsule e.g., a crushable capsule (crush-ball) containing a liquid flavourant e.g., any of the flavourants listed above. The capsule can be crushed by the user during smoking of the article/consumable to release the flavourant. The capsule may be located at the axial centre of the solid filter element.

In a second aspect of the first mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated, e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the first mode, there is provided a method of using a smoking substitute system according to the second aspect, the method comprising: inserting the article/consumable into the device; and heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects of the first mode may be applied to any other aspect of the first mode. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect of the first mode and/or combined with any other feature or parameter of the first mode described herein.

Second Mode of the Disclosure: Air Flow Path Upstream of Terminal Filter Element

At its most general, the second mode of the present disclosure relates to an aerosol-forming article e.g., a smoking substitute article such as an HNB consumable having an air flow path into the consumable upstream of a terminal filter element.

According to a first aspect of the second mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and a hollow bore terminal filter element at a downstream axial end of the article/consumable wherein the article comprises at least one radial air flow path into the article/consumable interposed between the aerosol-forming substrate and the terminal filter element.

By providing at least one radial air flow path into the article/consumable upstream of the terminal filter element and downstream of the aerosol-forming substrate, air can be drawn into the article/consumable as the user inhales and this air can help to cool and mix the vapour prior to inhalation. The cross-sectional area of the at least one air flow path and/or the number of radial air flow paths can be tailored to tailor the resistance to draw (RTD) of the article/consumable.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

In some embodiments, there is a plurality of radial air flow paths which may be circumferentially-arranged around the article/consumable.

In some embodiments, the article/consumable may further comprise a spacer element or an aerosol-cooling element upstream and axially adjacent the terminal filter portion.

The or each radial air flow path may be provided within the spacer/aerosol-cooling element. For example, the radial air flow path(s) may be provided immediately upstream of the terminal filter element proximal a join between the terminal filter element and the spacer/aerosol-cooling element.

There may also be an upstream filter element provided upstream of the spacer/aerosol-cooling element and downstream of the aerosol-forming substrate.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol, i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end. The axial direction of the article/consumable is aligned with the flow direction of the vapour/aerosol i.e., extends between the upstream and downstream ends of the article/consumable. The radial air flow path extends substantially perpendicularly to the axial direction/flow direction of the vapour/aerosol.

The aerosol-forming substrate may be circumscribed by a wrapping layer e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The spacer/aerosol-cooling element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer. The upstream filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The radial air flow path(s) may be provided by one or more ventilation holes provided in the wrapping layer e.g., by a plurality of ventilation holes circumferentially arranged around the article/consumable. For example, there may be a plurality of ventilation holes arranged circumferentially around the wrapping layer immediately upstream of the terminal filter element.

The or each filter element is formed of a smoke-permeable material. The terminal and/or upstream filter element(s) may be comprised of cellulose acetate or polypropylene tow. The terminal and/or upstream filter element(s) may be comprised of activated charcoal. The terminal and/or upstream filter element(s) may be comprised of paper. The terminal and/or upstream filter element(s) may each be circumscribed with a respective plug wrap e.g., a paper plug wrap.

The porosity of the upstream filter element may be greater than the porosity of the terminal filter element.

The terminal and/or upstream filter element(s) may each have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm e.g., between 10 and 12 mm.

The upstream filter element may be a solid filter element or may be a hollow bore filter element comprising an axial bore.

The terminal filter element and optionally the upstream filter element may each have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm. The diameter of the axial bore in the (hollow bore) upstream filter element may be greater than the diameter of the bore in the terminal filter element.

The radial air flow path(s) may be provided by one or more ventilation holes provided in the tipping layer e.g., by a plurality of ventilation holes circumferentially arranged around the article/consumable. For example, there may be a plurality of ventilation holes arranged circumferentially around the tipping layer immediately upstream of the terminal filter element.

The ventilation hole(s) in the tipping layer may be aligned or overlapping with the ventilation hole(s) in the wrapping layer.

The aerosol-cooling element is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximise heat exchange and cooling of the aerosol.

The spacer element defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable e.g., between the upstream and terminal filter elements. The spacer element acts to allow both cooling and mixing of the aerosol. The spacer element may have a tubular wall e.g., formed of cardboard.

The radial air flow path(s) may be provided by one or more ventilation holes provided in the tubular wall of the spacer element e.g., by a plurality of ventilation holes circumferentially arranged around the tubular wall. For example, there may be a plurality of ventilation holes arranged circumferentially around the tubular wall proximal the downstream end of the spacer element.

The ventilation hole(s) in the tubular wall of the spacer element may be aligned or overlapping with the ventilation hole(s) in the wrapping layer and/or tipping layer.

The spacer element may have an external diameter of between 5 and 10 mm e.g., between 6 and 9 mm or 6 and 8 mm e.g., around 7 mm. It may have an axial length of between 10 and 15 mm e.g., between 12 and 14 mm or 13 and 14 mm e.g., around 14 mm.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

The sheet may have a grammage of less than or equal to 300 g/m²e.g., less than or equal to 250 g/m²or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 8 wt %.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 9 wt %.

In a second aspect of the second mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

In a third aspect of the second mode, there is provided a method of using a smoking substitute system according to the second aspect of the second mode, the method comprising: inserting the article/consumable into the device; and heating the article/consumable using the heating element.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects of the second mode may be applied to any other aspect of the second mode. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect of the second mode and/or combined with any other feature or parameter of the second mode described herein.

Third Mode of the Disclosure: Spacer Element

At its most general, the third mode of the present disclosure relates to an aerosol-forming article e.g., a smoking substitute article such as an HNB consumable comprising a spacer element adapted to retain heat within the vapour/aerosol.

According to a first aspect of the third mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and a terminal filter element at a downstream axial end of the article, wherein the article further comprises a spacer element interposed between the substrate and the terminal filter element, the spacer element being at least partly lined with a heat reflective material.

By providing a spacer element lined with a heat reflective material, it is possible to maintain heat within the aerosol/vapour generated by heating of the aerosol-forming substrate and prevent condensation of the aerosol on the inner surface of the spacer element thus ensuring that an increased volume of vapour is available to the user for inhalation at the terminal filter element.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

The sheet may have a grammage of less than or equal to 300 g/m²e.g., less than or equal to 250 g/m²or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m². The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 8 wt %.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent.

In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt % e.g., between 6-9 wt % such as between 7-9 wt %.

The article/consumable comprise a terminal filter element at the downstream/mouth end of the article/consumable. There may be an upstream filter element (upstream of the downstream axial end).

There may be a plurality of a terminal filter element and an upstream filter element which may be adjacent one another or which may be spaced apart. The upstream of the terminal filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be comprised of cellulose acetate or polypropylene tow. The at least one filter element (e.g., the terminal filter element/upstream filter element) may be comprised of activated charcoal. The at least one filter element (e.g., the terminal element/upstream filter element) may be comprised of paper. The at least one filter element (e.g., the terminal element/upstream filter element) may be comprised of plant material e.g., extruded plant material. The or each filter element may be circumscribed with a plug wrap e.g., a paper plug wrap.

The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be a solid filter element. The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be a hollow bore filter element. The or each hollow bore filter element may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

The or at least one of the filter elements e.g., the terminal filter element may include a capsule e.g., a crushable capsule (crush-ball) containing a liquid flavourant e.g., any of the flavourants listed above. The capsule can be crushed by the user during smoking of the article/consumable to release the flavourant. The capsule may be located at the axial centre of the filter element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The article/consumable comprises a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable, i.e., between the aerosol-forming substrate and the terminal filter element.

The spacer element may be provided axially adjacent and upstream of the terminal filter element. For example, the spacer element may be provided between the terminal filter element and the upstream filter element.

The spacer element may be a tubular spacer element e.g., it may comprise a cardboard tube or a tube formed of extruded plastics material. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element is at least partly lined (e.g., fully lined) with a heat reflective material i.e., lined on its inner surface such that the heat reflective material faces the cavity/chamber within the spacer element. In this way, the heat within the aerosol/vapour generated by heating the aerosol-forming substrate is retained such that condensation of the aerosol/vapour does not occur on the spacer element. In this way, more of the volatile compounds and visible vapour (humectants) reach the terminal filter element for inhalation by the user.

The heat reflective material may be a metallic foil e. g. an aluminium foil.

In a second aspect of the third mode of the present disclosure, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the third mode and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

In a third aspect of the third mode of the present disclosure, there is provided a method of using a smoking substitute system according to the second aspect of the third mode, the method comprising: inserting the article/consumable into the device; and heating the article/consumable using the heating element.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects of the third mode may be applied to any other aspect of the third mode. Furthermore, except where mutually exclusive, any feature or parameter of the third mode described herein may be applied to any aspect of the third mode and/or combined with any other feature or parameter of the third mode described herein.

Fourth Mode of the Disclosure: Cooling Element

At its most general, the present disclosure relates to a HNB consumable comprising a cooling element in the form of a sheet formed of a plastics material.

According to a first aspect of the fourth mode, there is provided a heat-not-burn (HNB) consumable comprising an aerosol-forming substrate and a cooling element located downstream of the substrate wherein the cooling element comprises a sheet formed of plastics material, and an additive applied to a surface of the sheet.

Vapour formed by the aerosol-forming substrate may flow through the cooling element before exiting at the downstream end of the consumable (i.e., for inhalation by a user). The additive may be such that it alters a characteristic of the vapour formed by heating the aerosol-forming substrate that flows across the cooling element. For example, the additive (or components of the additive) may become entrained in the aerosol as it flows through the cooling element. Alternatively or additionally, the additive (or components of the additive) may interact with the aerosol in another manner (e.g., without becoming entrained in the aerosol) so as to affect a characteristic of the aerosol.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol i.e., with the downstream end of the consumable being the mouth end or outlet where the aerosol exits the consumable for inhalation by the user. An upstream end of the consumable is the opposing end to the downstream end.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

The plastics material may comprise polylactic acid (PLA). In this respect, the plastics material (and consequently, the sheet) may be biodegradable. The sheet may solely be formed of PLA, or may be formed of PLA in combination with another material (e.g., another plastics material).

The sheet may alternatively or additionally be formed of a plastics material selected from the group consisting of polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), and polyethylene terephthalate (PET).

In some embodiments the additive comprises a flavourant. In this respect, the flavourant may be dispersed from the cooling element to a vapour flowing from the aerosol-forming substrate. The flavourant that is dispersed to the vapour may thus alter the flavour of the vapour prior to it being inhaled by a user. The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the cooling element or may be provided in isolated locations and/or varying concentrations throughout the cooling element.

In some embodiments the additive comprises a phase change material. This may facilitate cooling of the aerosol/vapour (generated by the aerosol-forming substrate), by heat exchange, before being inhaled by a user. The additive may comprise both a flavourant (as discussed above) and a phase change material.

The phase change material may be capable of storing and releasing energy during phase changes. The phase change material may be a solid-liquid phase change material, whereby when the phase change material is heated, it melts from a solid to a liquid and stores the thermal energy. The phase change material may have a melting point at a temperature that is close to room temperature (e.g., 25° C. to 35° C.) such that heat from vapour (that may be hotter than room temperature) passing across the cooling element is transferred to the phase change material (which stores the heat as latent heat during the phase change). This transfer of heat from the vapour to the phase change material may result in cooling of the vapour that may facilitate condensation of the vapour so as to form an aerosol. During phase change, the phase change material remains at a generally consistent temperature, allowing a large amount of heat to be transferred (due to a temperature differential between the vapour and the phase change material) from the vapour to the phase change material.

The phase change material may be an organic phase change material that may, for example, be paraffin (CnH2n+2) based e.g., paraffin with 14 to 34 carbons e.g., 20 carbons (icosane/eicosane).

In some embodiments, the additive may be sprayed or coated onto the surface of the sheet. Alternatively or additionally, the sheet may be impregnated with the additive. In this respect, the sheet may be a porous sheet (e.g., formed of a porous material).

In some embodiments the sheet is crimped. The sheet may be crimped and gathered (e.g., to form a structure having a high surface area). Where the cooling element comprises a flavourant, the high surface area may maximise dispersion of the flavourant to the aerosol. Similarly, where the cooling element comprises a phase change material, the high surface area may maximise heat exchange with the aerosol and may thus facilitate cooling of the aerosol. The gathered sheet may define a plurality of channels.

In some embodiments the sheet is gathered so as to form a substantially cylindrical shape. Where the gathered sheet defines channels, the channels may extend in the direction of a longitudinal axis of the gathered sheet.

The cooling element and the aerosol-forming substrate may be at least partly (e.g., completely) circumscribed by a wrapping layer (e.g., a paper wrapping layer). The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The diameter of the cooling element may substantially match the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the cooling element may be less than 20 mm, e.g., between 8 and 18 mm, for example between 13 and 15 mm.

The aerosol-forming substrate may be capable of being heated to release at least one volatile compound that can form an aerosol.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

The sheet may have a grammage of less than or equal to 300 g/m², e.g., less than or equal to 250 g/m²or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous and non-aqueous solvents and binders.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may comprise fibrous fillers such as cellulose fibres

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 9 wt %.

Like the flavourant of the cooling element (as described above), the flavourant of the substrate may be provided in solid or liquid form. It may include one or more of the flavourants listed above with respect to the cooling element. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm e.g., between 6 and 9 mm or 6 and 8 mm e.g., around 7 mm. It may have an axial length of between 10 and 15 mm e.g., between 11 and 14 mm such as around 12 or 13 mm.

The consumable may comprise at least one filter element. There may be a terminal filter element located at a downstream (i.e., mouth) end of the consumable (i.e., at an opposite end of the consumable to the substrate).

The consumable may further comprise an upstream filter element located between the aerosol-forming substrate and the cooling element. The upstream filter element may be located adjacent the aerosol-forming substrate.

The or each filter element may be comprised of cellulose acetate or polypropylene tow. The or each filter element may be comprised of activated charcoal. The or each filter element may be comprised of paper. The or each filter element may be comprised of extruded plant material. The or each filter element (e.g., terminal filter element or upstream filter element) may be circumscribed with a plug wrap, e.g., a paper plug wrap.

The or each filter element may be a solid filter element. The or each filter element may be a hollow bore filter element. The or each filter element may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

Any filter element(s) upstream of the terminal filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The terminal filter element (at the downstream end of the consumable) may be joined to upstream filter elements and/or the cooling element by a circumscribing tipping layer e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream filter element or the cooling element.

The or at least one of the filter elements, e.g., the terminal filter element may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavourant, e.g., any of the flavourants listed above. The capsule can be crushed by the user during smoking of the consumable to release the flavourant. The capsule may be located at the axial centre of the terminal filter element.

The consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the consumable. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may comprise a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer. The spacer may, for example, be located between the cooling element and one of the filter elements.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the fourth mode, there is provided a cooling element for a heat-not-burn (HNB) consumable (e.g., such as that described in the first aspect of the fourth mode) wherein the cooling element comprises a sheet formed of a plastics material, and an additive applied to a surface of the sheet.

The cooling element may be as described with respect to the first aspect of the fourth mode.

In a third aspect of the fourth mode, there is provided a method of forming a cooling element (e.g., such as that described above in the first and second aspects), the method comprising providing a sheet formed of a plastics material, applying an additive to a surface of the sheet, and gathering the sheet to form a cooling element.

In some embodiments the step of applying an additive to the surface of the sheet is performed separately to the step of gathering the sheet. In other embodiments, the step of applying an additive to the surface of the sheet may be performed concurrently with the step of gathering the sheet.

In some embodiments the step of applying the additive comprises spraying the additive onto the surface.

In some embodiments the method further comprises crimping the sheet. The sheet may be crimped prior to gathering it to form the cooling element. The method may additionally or alternatively comprise forming slits in the sheet. The slits may be formed prior to crimping the sheet (i.e., where the crimping step is performed).

The cooling element formed by the method of the third aspect of the fourth mode may be as described above with respect to the first and second aspects of the fourth mode. In that respect, the method may comprise applying a flavourant and/or a phase change material to the sheet.

In a fourth aspect of the fourth mode, there is provided a smoking substitute system comprising a HNB consumable according to the first aspect of the fourth mode and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate of the HNB consumable.

In a fifth aspect of the fourth mode, there is provided a method of using a smoking substitute system according to the fourth aspect, the method comprising inserting the consumable into the device, and heating the consumable using the heating element.

In some embodiments, the method comprises inserting the consumable into a cavity within the main body and penetrating the consumable with the heating element upon insertion of the consumable. For example, the heating element may penetrate the aerosol-forming substrate in the consumable.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects may be applied to any other aspect. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect and/or combined with any other feature or parameter described herein.

Fifth Mode of the Disclosure

At its most general, the present disclosure relates to an aerosol-forming article e.g., a smoking substitute article such as an HNB consumable.

According to a first aspect of the fifth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising a cooling element, the cooling element comprising a solid body, formed of a plastics material, defining one or more axial bores extending through the cooling element.

A solid body may be formed in a single-step process, which may facilitate manufacture of the article. Further, a cooling element formed of a solid body may provide structural support (e.g., rigidity) to the aerosol-forming article.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

In some embodiments the solid body may be one of injection moulded, extruded or additive manufactured. Each of these processes may involve forming the cooling element in a single-step process. That is, the bores may be formed concurrently with the body (rather than e.g., machined/cut-out out of the body in a separate process).

In some embodiments the plastics material comprises polylactic acid (PLA) e.g., biodegradable polylactic acid. In this respect, the plastics material (and consequently, the cooling element) may be biodegradable. The cooling element may solely be formed of PLA, or may be formed of PLA in combination with another material (e.g., another plastics material).

The cooling element may alternatively or additionally be formed of a plastics material selected from the group consisting of polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), and polyethylene terephthalate (PET).

In some embodiments the body is substantially tubular. That is, the cooling element may be substantially cylindrical with a bore extending therethrough. The bore may have a substantially circular transverse profile. Alternatively, the bore may have a transverse profile that is e.g., rectangular, triangular, elliptical, etc. The bore may extend along a central longitudinal axis of the body.

The cooling element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm. The bore of the cooling element may have a diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm. Alternatively, the bore may have a diameter of between 3 and 7 mm, e.g., between 4 and 6 mm.

In some embodiments, the body may define a plurality of bores (e.g., two, three, four etc. bores). The bores may be arranged in a predetermined manner. The term ‘predetermined’ means the bores are formed (and arranged) in a deliberate manner, rather than being formed simply as a consequence of the nature of the material of the cooling element (e.g., such as pathways being formed between fibres of a fibrous material).

The or each bore may extend so as to be substantially parallel to the longitudinal axis. Alternatively, the or each bore may extend at an angle relative to a longitudinal axis, or may e.g., have a curved (rather than linear) path. The use of injection moulding or additive manufacturing may be conducive to the inclusion of bores that extend non-longitudinally (e.g., in a curvilinear or at an angle to the longitudinal axis). The plurality of bores may be arranged so as to maximise the surface area of the bores in the cooling element (i.e., to maximise heat exchange between vapour flowing through the cooling element and the body of the cooling element).

In some embodiments the cooling element may comprise an additive. The additive may comprise a flavourant. In this respect, the flavourant may be dispersed from the cooling element to vapour flowing through the cooling element. The flavourant that is dispersed to the vapour may thus alter the flavour of the vapour prior to it being inhaled by a user. The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the cooling element or may be provided in isolated locations and/or varying concentrations throughout the cooling element.

In some embodiments the additive may be sprayed onto, or coated on, the cooling element. The additive may be added to the plastics material prior to e.g., injection moulding, extrusion or additive manufacturing of the body of the cooling element.

In some embodiments the additive may be in the form of a thread passed through the cooling element. The thread may be formed into the cooling element (e.g., during the injection moulding, extrusion or additive manufacturing process).

In some embodiments the aerosol-forming article may further comprise an aerosol-forming substrate. The cooling element may be located downstream of the aerosol-forming substrate.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol, i.e., with the downstream end of the article being the mouth end or outlet where the aerosol exits the article for inhalation by the user. The upstream end of the article is the opposing end to the downstream end.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

The sheet may have a grammage of less than or equal to 300 g/m2, e.g., less than or equal to 250 g/m²or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 8 wt %.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 9 wt %.

As discussed above, with respect to the cooling element, the flavourant of the substrate may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be at least partly circumscribed by a wrapping layer e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost). The cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The article/consumable may comprise at least one filter element. There may be a terminal filter element at the downstream/mouth end of the article/consumable. The cooling element may be located between the terminal filter element and the substrate. There may be an upstream filter element (upstream of the downstream axial end).

There may be a plurality of, e.g., two filter elements which may be adjacent one another or which may be spaced apart. Any filter element(s) upstream of the terminal filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The or at least one of the filter elements e.g., the terminal filter element may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavourant, e.g., any of the flavourants listed above. The capsule can be crushed by the user during smoking of the article/consumable to release the flavourant. The capsule may be located at the axial centre of the filter element.

The article/consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. For example, it may be provided between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may be a tubular spacer element, e.g., it may comprise a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the fifth mode, there is provided a method for forming a cooling element for an aerosol-forming article, the method comprising providing an at least partially molten plastics material, forming the plastics material into a solid body defining one or more bores.

In some embodiments, the method may comprise one of injection moulding, extrusion or additive manufacturing. In this respect, the forming of the solid body may be a single-step process.

The method may comprise melting, or at least partially melting, the plastics material.

In some embodiments the bores may be formed in the injection moulding, extrusion, or additive manufacturing process (i.e., concurrently as the body is formed).

Where the method comprises injection moulding, the method may comprise injecting the at least partially molten plastics material into a mould. The mould may comprise one or more portions (e.g., core plates or portions) defining the one or more bores. Where the method comprises extrusion, the method may comprise passing the at least partially molten material through a die. The one or more bores may be formed by e.g., a mandrel located in the die. Where the method comprises additive manufacturing, the additive manufacturing may be in the form of 3d printing. In this respect, the one or more bores may be formed in the process of printing the body (e.g., each printed layer may include a non-printed space that defines a portion of a bore).

In a third aspect of the fifth mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the fifth mode and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

In a fourth aspect of the fifth mode, there is provided a method of using a smoking substitute system according to the third aspect of the fifth mode, the method comprising inserting the article/consumable into the device, and heating the article/consumable using the heating element.

Sixth Mode of the Disclosure

At its most general, the present disclosure relates to an aerosol-forming article e.g., a smoking substitute article such as an HNB consumable having an air flow path into the consumable upstream of a terminal filter element.

According to a first aspect of the sixth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and a filter element wherein the article comprises at least one radial air flow path into the filter element.

By providing at least one radial air flow path into a filter element, air can be drawn into the aerosol-forming substrate as the user inhales and this air can help to cool and mix the vapour. The cross-sectional area of the at least one air flow path and/or the number of radial air flow paths can be tailored to tailor the resistance to draw (RTD) of the article/consumable.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

The aerosol-forming article of the first aspect is preferably a heat-not-burn (HNB) consumable.

The filter element is preferably a solid filter element i.e., with no axial bore.

In some embodiments, there is a plurality of radial air flow paths which may be circumferentially-arranged around the filter element. There may be a plurality of axially spaced, circumferentially-extending rows of radial flow paths.

The radial air flow path(s) may be provided in a terminal filter element at the downstream axial end of the article/consumable and/or in an upstream filter element provided upstream from the downstream axial end of the article/consumable and downstream (e.g., adjacent the downstream axial end) of the aerosol-forming substrate.

According to a second aspect of the sixth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and a hollow bore filter element wherein the article comprises at least one radial air flow path into the hollow bore filter element.

By providing at least one radial air flow path into a hollow bore filter element, air can be drawn into the aerosol-forming substrate as the user inhales and this air can help to cool and mix the vapour. The cross-sectional area of the at least one air flow path and/or the number of radial air flow paths can be tailored to tailor the resistance to draw (RTD) of the article/consumable.

Further optional features will now be set out. These are applicable singly or in any combination with any aspect.

The aerosol-forming article of the second aspect of the sixth mode is preferably a heat-not-burn (HNB) consumable.

In some embodiments, there is a plurality of radial air flow paths which may be circumferentially-arranged around the hollow bore filter element. There may be a plurality of axially spaced, circumferentially-extending rows of radial flow paths.

The radial air flow path(s) may be provided in a terminal hollow bore filter element at the downstream axial end of the article/consumable and/or in an upstream hollow bore filter element provided upstream from the downstream axial end of the article/consumable and downstream (e.g., adjacent the downstream axial end) of the aerosol-forming substrate.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol, i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end. The axial direction of the article/consumable is aligned with the flow direction of the vapour/aerosol i.e., extends between the upstream and downstream ends of the article/consumable. The radial air flow path(s) extend(s) substantially perpendicularly to the axial direction/flow direction of the vapour/aerosol.

Where the radial air flow path(s) is/are provided in a terminal filter element or a terminal hollow bore filter element, the article/consumable may further comprise an upstream filter element which may be a hollow bore filter element comprising a further at least one radial air flow path (as described above), a hollow bore filter element with no radial flow path or a solid filter element.

Where the radial air flow path(s) is/are provided in an upstream filter element (e.g., adjacent the downstream axial end of the aerosol-forming substrate), the article/consumable may further comprise a terminal filter element which may be a hollow bore filter element comprising a further at least one radial air flow path (as described above), a hollow bore filter element with no radial flow path or a solid filter element.

In some embodiments, the article/consumable may further comprise a spacer element or an aerosol-cooling element upstream and axially adjacent the terminal filter element. The spacer/aerosol-cooling element may be interposed between the upstream filter element and the terminal filter element, e.g., between the upstream hollow bore filter element and the terminal hollow bore filter element.

The aerosol-forming substrate may be circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The spacer/aerosol-cooling element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer. The upstream filter element (e.g., the upstream filter element) may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The radial air flow path(s) may be provided by one or more ventilation holes provided in the wrapping layer surrounding the upstream filter element. There may be a plurality of ventilation holes circumferentially arranged around the upstream filter element e.g., a plurality of axially spaced, circumferentially-extending rows of ventilation holes.

The terminal filter element may be joined to the upstream elements forming the article/consumable (e.g., the upstream filter element and/or the spacer/aerosol-cooling element) by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element (e.g., the adjacent spacer element or aerosol-cooling element).

The radial air flow path(s) may be provided by one or more ventilation holes provided in the tipping layer surrounding the terminal filter element. There may be a plurality of ventilation holes circumferentially arranged around the terminal filter element, e.g., a plurality of axially spaced, circumferentially-extending rows of ventilation holes.

The radial air flow path(s) may be provided by one or more radial bores provided in the upstream filter element and/or the terminal filter element. There may be a plurality of radial bores circumferentially arranged around the upstream filter element and/or the terminal filter element e.g., a plurality of axially spaced, circumferentially-extending rows of radial bores.

The radial air flow path(s) may be provided by one or more ventilation holes provided in the tipping layer surrounding the terminal hollow bore filter element. There may be a plurality of ventilation holes circumferentially arranged around the terminal hollow bore filter element, e.g., a plurality of axially spaced, circumferentially-extending rows of ventilation holes.

The radial air flow path(s) may be provided by one or more radial bores provided in the upstream hollow bore filter element and/or the terminal hollow bore filter element. There may be a plurality of radial bores circumferentially arranged around the upstream hollow bore filter element and/or the terminal hollow bore filter element, e.g., a plurality of axially spaced, circumferentially-extending rows of radial bores.

The radial bore(s) may extend through the terminal/upstream filter element and join the axial bore of the terminal/upstream filter element.

The radial bore(s) in the upstream filter element may be aligned or overlapping with the ventilation hole(s) in the wrapping layer.

The radial bore(s) in the terminal filter element may be aligned or overlapping with the ventilation hole(s) in the tipping layer.

The radial bore(s) in the terminal hollow filter element may be aligned or overlapping with the ventilation hole(s) in the tipping layer.

The radial air flow path(s) may be provided by one or more ventilation holes provided in the respective plug wrap circumscribing the upstream filter element and/or the terminal filter element. There may be a plurality of ventilation holes in the plug wrap(s) circumferentially arranged around the upstream filter element and/or the terminal filter element e.g., a plurality of axially spaced, circumferentially-extending rows of ventilation holes.

The radial bore(s) in the upstream hollow filter element may be aligned or overlapping with the ventilation hole(s) in the upstream filter element plug wrap.

The radial bore(s) in the terminal hollow filter element may be aligned or overlapping with the ventilation hole(s) in the downstream filter element plug wrap.

The radial air flow path(s) may be provided by one or more ventilation holes provided in the respective plug wrap circumscribing the upstream hollow bore filter element and/or the terminal hollow bore filter element. There may be a plurality of ventilation holes in the plug wrap(s) circumferentially arranged around the upstream hollow bore filter element and/or the terminal hollow bore filter element, e.g., a plurality of axially spaced, circumferentially-extending rows of ventilation holes.

The radial bore(s) in the upstream hollow filter element may be aligned or overlapping with the ventilation hole(s) in the upstream filter element plug wrap.

The radial bore(s) in the terminal hollow filter element may be aligned or overlapping with the ventilation hole(s) in the downstream filter element plug wrap.

The porosity of the upstream filter element may be greater than the porosity of the terminal filter element.

The aerosol-cooling element is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The hollow bore terminal filter element(s) may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm. The diameter of the axial bore in the upstream hollow bore filter element may be greater than the diameter of the axial bore in the terminal filter element.

The spacer element defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable, e.g., between the upstream and terminal filter elements. The spacer element acts to allow both cooling and mixing of the aerosol. The spacer element may have a tubular wall, e.g., formed of cardboard.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m², such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m², e.g., less than or equal to 250 g/m²or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

In a third aspect of the sixth mode, there is provided a solid filter element for an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable), the solid filter element comprising at least one radial bore.

The term “solid filter element” is used to describe a filter element hot having an axial bore.

There may be a plurality of radial bores circumferentially arranged around the filter element, e.g., a plurality of axially spaced, circumferentially-extending rows of radial bores.

In a fourth aspect of the sixth mode, there is provided a filter element for an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable), the filter element comprising an axial bore and at least one radial bore.

There may be a plurality of radial bores circumferentially arranged around the hollow bore filter element, e.g., a plurality of axially spaced, circumferentially-extending rows of radial bores. The radial bore(s) may extend through the filter element and join the axial bore of the filter element.

The filter element is formed of a smoke-permeable material. The filter element may be comprised of cellulose acetate or polypropylene tow. The filter element may be comprised of activated charcoal. The filter element may be comprised of paper.

The filter element may be circumscribed with a plug wrap, e.g., a paper plug wrap.

The plug wrap may comprise one or more ventilation holes. There may be a plurality of ventilation holes in the plug wrap circumferentially arranged around the filter element, e.g., a plurality of axially spaced, circumferentially-extending rows of ventilation holes.

The radial bore(s) in the filter element may be aligned or overlapping with the ventilation hole(s) in the plug wrap.

The filter element may each have a substantially cylindrical shape. The axial length of the filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

In a fifth aspect of the sixth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising at least one filter element according to the third aspect of the sixth mode.

In a sixth aspect of the sixth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising at least one filter element according to the fourth aspect of the sixth mode.

In a seventh aspect of the sixth mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first, second, fifth or sixth aspects of the sixth mode and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

In an eighth aspect of the sixth mode, there is provided a method of using a smoking substitute system according to the seventh aspect of the sixth mode, the method comprising:

inserting the article/consumable into the device; and

heating the article/consumable using the heating element.

Seventh Mode of the Disclosure

At its most general, the present disclosure relates to an aerosol-forming article e.g., a smoking substitute article such as an HNB consumable comprising a cooling element formed of a plastics material.

According to a first aspect of the seventh mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as a HNB consumable) comprising an aerosol-forming substrate and a downstream cooling element formed of a granular or foamed plastics material.

The provision of a cooling element comprising a granular or foamed plastics material results in a large surface area for effecting cooling of a vapour/aerosol (by heat transfer between the granules/foam and vapour/aerosol).

Further optional features will now be set out. These are applicable singly or in any combination with any aspect.

In some embodiments, the granular plastics material may be combined so as to form a unitary structure. In this respect, the granules may be compressed together so as to form the cooling element. The granules may be compressed so as to be formed into a structure having a plurality of channels extending therethrough. Due to the nature of the granules, the channels may be formed in a random manner (i.e., the cooling element may comprise a network of channels arranged in a substantially random manner).

In other embodiments, the granular plastics material may be contained within a containment sleeve, e.g., a paper or cardboard or plastics material containment sleeve.

The plastic material foam may be formed of an expanded plastic material. It preferably has an open-cell structure. The open cell structure may be formed by incorporating insert gas into a resinous or molten plastics material under pressure and then releasing the gas/plastics material mixing to atmospheric pressure prior to curing.

In some embodiments the plastics material may comprise polylactic acid (PLA) e.g., biodegradable-PLA. In this respect, the plastics material (and consequently, the cooling element) may be biodegradable. The cooling element may solely be formed of PLA, or may be formed of PLA in combination with another material (e.g., another plastics material).

In some embodiments the cooling element may comprise an additive. The additive may comprise a flavourant. In this respect, the flavourant may be dispersed from the cooling element to vapour/aerosol flowing through the cooling element. The flavourant that is dispersed to the vapour may thus alter the flavour of the vapour prior to it being inhaled by a user. The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the cooling element or may be provided in isolated locations and/or varying concentrations throughout the cooling element.

In some embodiments the additive may be sprayed or coated onto the cooling element (e.g., granules or foam). Where the cooling element comprises a granular plastics material, the additive may be applied (e.g., sprayed or coated) onto the granules prior to the granules being combined to form the cooling element e.g., by compression or containment within a sleeve.

In some embodiments, the additive may be applied by injecting the additive into the cooling element. The additive may be applied by way of impregnation of the additive in the cooling element. For example, the porous nature of a cooling element formed of a foam may be suited to impregnation of the additive.

In some embodiments the additive may be in the form of a thread passed through the cooling element. The thread may be formed into the cooling element. For example, where the cooling element comprises a granular plastics material, the thread may be compressed together with the granules to form the cooling element.

In some embodiments the cooling element may have a generally cylindrical form. The cooling element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 5 and 15 mm, e.g., between 6 and 15 mm or between 7 and 14 mm, e.g., around 14 mm.

In some embodiments the cooling element may comprise a bore extending longitudinally therethrough. The bore may extend along a central longitudinal axis of the cooling element. The bore may have a circular transverse cross-section or may have a square, triangular, elliptical, etc. cross section. Where the bore is circular, the ratio of the diameter of the bore to the diameter of the cooling element may be between 0.5:1 and 0.9:1, e.g., between 0.6:1 and 0.8:1. The diameter of the bore may be between 2 and 6 mm, e.g., between 4 and 6 mm, e.g., 5 and 6 mm.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

The sheet may have a grammage of less than or equal to 300 g/m², e.g., less than or equal to 250 g/m²or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 8 wt %.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 9 wt %.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be at least partly circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The article/consumable may comprise at least one filter element. There may be a terminal filter element at the downstream/mouth end of the article/consumable. There may be an upstream filter element which may be axially adjacent to or axially spaced from the terminal filter element, e.g., axially spaced by the cooling element.

The cooling element and/or upstream filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be comprised of cellulose acetate or polypropylene tow. The at least one filter element (e.g., the terminal filter element/upstream filter element) may be comprised of activated charcoal. The at least one of the filter elements (e.g., the terminal element/upstream filter element) may be comprised of paper. The or at least one of the filter elements (e.g., the terminal element/upstream filter element) may be comprised of plant material e.g., extruded plant material. The or each filter element may be circumscribed with a plug wrap e.g., a paper plug wrap.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The or at least one of the filter elements, e.g., the terminal filter element may include a capsule e.g., a crushable capsule (crush-ball) containing a liquid flavourant e.g., any of the flavourants listed above. The capsule can be crushed by the user during smoking of the article/consumable to release the flavourant. The capsule may be located at the axial centre of the filter element.

Where the terminal filter element comprises a bore, the bore of the cooling element may have a larger diameter than the bore of the terminal filter element.

Where the article/consumable comprises a hollow bore upstream filter element, upstream of the cooling element, the bore of the cooling element may have a larger diameter than the bore of the upstream filter element.

The article/consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. For example, it may be provided between the aerosol-forming substrate and the upstream filter element and/or between the upstream filter element and the cooling element filter. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may be a tubular spacer element e.g., it may comprise a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 5 and 10 mm, e.g., between 5 and 8 mm or between 6 and 8 mm e.g., around 7 mm.

In a second aspect of the seventh mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the seventh mode and a device comprising a heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

In a third aspect of the seventh mode, there is provided a method of using a smoking substitute system according to the second aspect of the seventh mode, the method comprising:

inserting the article/consumable into the device; and

heating the article/consumable using the heating element.

SUMMARY OF THE FIGURES

So that the disclosure may be understood, and so that further aspects and features thereof may be appreciated, embodiments illustrating the principles of the disclosure will now be discussed in further detail with reference to the accompanying figures, in which:

FIG. 1 shows a first embodiment of a first mode of an HNB consumable;

FIG. 2 shows a second embodiment of the first mode of an HNB consumable

FIG. 3 shows a third embodiment of the first mode of an HNB consumable;

FIG. 4 shows the first embodiment of the first mode within a device forming an HNB system;

FIG. 5 shows a first embodiment of a second mode of an HNB consumable;

FIG. 6 shows a second embodiment of the second mode of an HNB consumable;

FIG. 7 shows a third embodiment of the second mode of an HNB consumable;

FIG. 8 shows the first embodiment of the second mode within a device forming an HNB system;

FIG. 9 shows a first embodiment of a third mode of an HNB consumable;

FIG. 10 shows a second embodiment of the third mode of an HNB consumable;

FIG. 11 shows a third embodiment of the third mode of an HNB consumable;

FIG. 12 shows the first embodiment of the third mode within a device forming an HNB system.

FIG. 13 shows a first embodiment of a fourth mode of an HNB consumable;

FIG. 14 shows a second embodiment of the fourth mode an HNB consumable

FIG. 15 shows a third embodiment of the fourth mode an HNB consumable;

FIG. 16 shows the first embodiment of the fourth mode of FIG. 13 within a device forming an HNB system.

FIG. 17 shows a first embodiment of the fifth mode of an HNB consumable;

FIG. 18 shows a second embodiment of the fifth mode of an HNB consumable

FIG. 19 shows a third embodiment of the fifth mode of an HNB consumable;

FIG. 20 shows the first embodiment of the fifth mode of FIG. 17 within a device forming an HNB system.

FIG. 21 shows a first embodiment of a sixth mode of an HNB consumable;

FIG. 22 shows a second embodiment of the sixth mode of an HNB consumable;

FIG. 23 shows a third embodiment of the sixth mode of an HNB consumable;

FIG. 24 shows the first embodiment of the sixth mode of FIG. 21 within a device forming an HNB system;

FIG. 25 shows a fourth embodiment of the sixth mode of an HNB consumable;

FIG. 26 shows a fifth embodiment of the sixth mode of an HNB consumable;

FIG. 27 shows a sixth embodiment of the sixth mode of an HNB consumable;

FIG. 28 shows the fourth embodiment of the sixth mode of FIG. 25 within a device forming an HNB system.

FIG. 29 shows a first embodiment of a seventh mode of an HNB consumable;

FIG. 30 shows a second embodiment of the seventh mode of an HNB consumable

FIG. 31 shows a third embodiment of the seventh mode of an HNB consumable;

FIG. 32 shows the first embodiment of the seventh mode within a device forming an HNB system.

DETAILED DESCRIPTION OF THE FIGURES

First Mode of the Disclosure:

As shown in FIG. 1, the HNB consumable 1 comprises an aerosol-forming substrate 2 at the upstream end of the consumable 1.

The aerosol-forming substrate comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2 is circumscribed by a paper wrapping layer 3.

The consumable 1 comprises an upstream filter element 4 and a downstream (terminal) filter element 5. The upstream and terminal filter elements 4, 5 are spaced by an intermediate hollow bore filter element 6. All filter elements 4, 5, 6 are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

All filter elements have a substantially cylindrical shape. The diameter of the upstream filter element 4 and intermediate hollow bore filter element 6 matches the diameter of the aerosol-forming substrate 2. The diameter of the terminal filter element 5 is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 and the wrapping layer 3.

The upstream filter element 4 is slightly shorter in axial length than the terminal filter element 5 at an axial length of 10 mm compared to 12 mm for the terminal filter element 5. The intermediate filter element 6 is longer than each of the two filter elements 4, 5 having an axial length of around 14 mm.

Each filter element 4, 5, 6 is a hollow bore filter element with a hollow, longitudinally-extending axial bore. The diameter of the bore in the upstream filter element 4 is slightly larger than the diameter of the bore in the terminal filter element 5 having a diameter of 3 mm compared to 2 mm for the terminal filter element 5.

The intermediate hollow bore filter element 6 has the largest bore diameter at around 5 or 6 mm.

The upstream filter element 4 and intermediate filter element 6 are circumscribed by the wrapping layer 3.

The terminal filter element 5 is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7. The tipping layer 7 encircles the terminal filter element 5 and has an axial length of around 20 mm such that it overlays a portion of the intermediate filter element 6.

FIG. 2 shows a second embodiment of the first mode of a consumable 1′ which is the same as that shown in FIG. 1 except that the terminal filter element 5 is a solid filter element and comprises a crushable capsule 8 (crush-ball) having a shell wall containing a liquid menthol or cherry or vanilla flavourant. The capsule 8 is spherical and has a diameter of 3.5 mm. It is positioned within the axial centre of the terminal filter element 5.

FIG. 3 shows a third embodiment of the first mode of a consumable 1″ which is the same as the first embodiment except that the wrapping layer 3 does not completely circumscribe the cardboard tube spacer 6 such that there is an annular gap 9 between the tipping layer 7 and the intermediate filter element 6 downstream of the end of the wrapping layer 3.

FIG. 4 shows the first embodiment inserted into an HNB device 10 comprising a rod-shaped heating element 20. The heating element 20 projects into a cavity 11 within the main body 12 of the device.

The consumable 1 is inserted into the cavity 11 of the main body 12 of the device 10 such that the heating rod 20 penetrates the aerosol-forming substrate 2. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5.

As the vapour cools within the upstream filter element 4 and the intermediate filter element 6, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Second Mode of the Disclosure

As shown in FIG. 5, the HNB consumable 1a comprises an aerosol-forming substrate 2a at the upstream end of the consumable 1a.

The aerosol-forming substrate comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2a comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate 2a further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2a is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2a is circumscribed by a paper wrapping layer 3a.

The consumable 1a comprises an upstream filter element 4a and a downstream (terminal) filter element 5a. The two filter elements 4a, 5a are spaced by a cardboard tube spacer 6a. Both filter elements 4a, 5a are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements have a substantially cylindrical shape. The diameter of the upstream filter 4a matches the diameter of the aerosol-forming substrate 2a. The diameter of the terminal filter element 5a is slightly larger and matches the combined diameter of the aerosol-forming substrate 2a and the wrapping layer 3a. The upstream filter element is slightly shorter in axial length than the terminal filter element at an axial length of 10 mm compared to 12 mm for the terminal filter element.

The cardboard tube spacer is longer than each of the two filter elements having an axial length of around 14 mm.

Both filter elements 4a, 5a are hollow bore filter elements with a hollow, longitudinally-extending axial bore. The diameter of the axial bore in the upstream filter 4a is slightly larger than the diameter of the axial bore in the terminal filter element 5a having a diameter of 3 mm compared to 2 mm for the terminal filter element.

The cardboard tube spacer 6a and the upstream filter element 4a are circumscribed by the wrapping layer 3a.

The terminal filter element 5a is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7a. The tipping layer 7a encircles the terminal filter element 5a and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6a.

A plurality of radial air flow paths are provided by ventilation holes 13aa, 13ba which are circumferentially arranged around the cardboard spacer element 6 proximal the join between the spacer element 6a and the terminal filter element 5a. The ventilation holes 13aa, 13ba are provided through and aligned in all of the tipping layer 7a, wrapping layer 3a and the tubular wall of the spacer element 6a.

FIG. 6 shows a second embodiment of a consumable 1a′ which is the same as the first embodiment except that the upstream filter element 4a′ is a solid filter element and incudes a crushball 8a which contains a flavourant.

FIG. 7 shows a third embodiment of a consumable 1a″ which is the same as the first embodiment except that the wrapping layer 3a does not completely circumscribe the cardboard tube spacer 6a such that there is an annular gap 9a between the tipping layer 7a and the cardboard tube spacer 6a downstream of the end of the wrapping layer 3a.

FIG. 8 shows the first embodiment inserted into an HNB device 10a comprising a rod-shaped heating element 20a. The heating element 20a projects into a cavity 11a within the main body 12a of the device.

The consumable 1a is inserted into the cavity 11a of the main body 12a of the device 10a such that the heating rod 20a penetrates the aerosol-forming substrate 2a. Heating of the reconstituted tobacco in the aerosol-forming substrate 2a is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5a.

As the vapour cools within the upstream filter element 4a and the cardboard tube spacer 6a, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Inhalation by the user also draws in air along the radial flow paths through the ventilation holes 13aa, 13ba. This air helps to cool and mix the vapour within the chamber defined by the spacer element 6a.

Third Mode of the Disclosure:

As shown in FIG. 9, the HNB consumable 1b comprises an aerosol-forming substrate 2b at the upstream end of the consumable 1b.

The aerosol-forming substrate comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2b comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gumbinder.

The aerosol-forming substrate 2b is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2b is circumscribed by a paper wrapping layer 3b.

The consumable 1b comprises an upstream filter element 4b and a downstream (terminal) filter element 5b.

The two filter elements 4b, 5b and spaced by a cardboard tube spacer 6b. Both filter elements 4b, 5b are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements have a substantially cylindrical shape. The diameter of the upstream filter element 4b matches the diameter of the aerosol-forming substrate 2b. The diameter of the terminal filter element 5b is slightly larger and matches the combined diameter of the aerosol-forming substrate 2b and the wrapping layer 3b. The upstream filter element 4b is slightly shorter in axial length than the terminal filter element 5b at an axial length of 10 mm compared to 12 mm for the terminal filter element 5b.

The cardboard tube spacer 6b is longer than each of the two filter elements 4b, 5b having an axial length of around 14 mm. It is lined with a layer of aluminium foil 13b.

Each filter element 4b, 5b is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter is slightly larger than the diameter of the bore in the terminal filter having a diameter of 3 mm compared to 2 mm for the terminal filter element 5b.

The cardboard tube spacer 6b and the upstream filter element 4b are circumscribed by the wrapping layer 3b.

The terminal filter element 5b is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7b. The tipping layer 7b encircles the terminal filter element 5b and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6b.

FIG. 10 shows a second embodiment of a consumable 1b′ which is the same as that shown in FIG. 9 except that the terminal filter element 5b is a solid filter element and comprises a crushable capsule 8b (crush-ball) having a shell wall containing a liquid menthol or cherry or vanilla flavourant. The capsule 8b is spherical and has a diameter of 3.5 mm. It is positioned within the axial centre of the terminal filter element 5b.

FIG. 11 shows a third embodiment of a consumable 1b″ which is the same as the first embodiment except that the wrapping layer 3b does not completely circumscribe the cardboard tube spacer 6b such that there is an annular gap 9b between the tipping layer 7b and the cardboard tube spacer 6b downstream of the end of the wrapping layer 3b.

FIG. 12 shows the first embodiment inserted into an HNB device 10b comprising a rod-shaped heating element 20b. The heating element 20b projects into a cavity 11b within the main body 12b of the device.

The consumable 1b is inserted into the cavity 11b of the main body 12b of the device 10b such that the heating rod 20b penetrates the aerosol-forming substrate 2b. Heating of the reconstituted tobacco in the aerosol-forming substrate 2b is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5b.

The aluminium foil lining 13b on the cardboard tube spacer 6b prevents condensation of the vapour on the inside of the spacer 6b such that more of the volatile compounds and visible vapour (humectants) reach the terminal filter element for inhalation by the user.

Fourth Mode of the Disclosure

As shown in FIG. 13, the HNB consumable 1c comprises an aerosol-forming substrate 2c at the upstream end of the consumable 1c.

The aerosol-forming substrate 2c comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2c comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate 2c further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2c is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2c is circumscribed by a paper wrapping layer 3c.

The consumable 1c comprises an upstream filter element 4c and a downstream (terminal) filter element 5c. Both filter elements 4c, 5c are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 4c, 5c have a substantially cylindrical shape. The diameter of the upstream filter 4c matches the diameter of the aerosol-forming substrate 2c. The diameter of the terminal filter element 5c is slightly larger and matches the combined diameter of the aerosol-forming substrate 2c and the wrapping layer 3c. The upstream filter element 4c is slightly shorter in axial length than the terminal filter element 5c at an axial length of 10 mm compared to 12 mm for the terminal filter element 5c.

Each filter element 4c, 5c is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter 4c is slightly larger than the diameter of the bore in the terminal filter 5c having a diameter of 3 mm compared to 2 mm for the terminal filter element 5c.

The consumable further comprises a cooling element 7c located between the upstream filter element 4c and the downstream (i.e., terminal) filter element 5c. The cooling element 7c comprises a sheet formed of a plastics material, comprising polylactic acid (PLA), and an additive applied to (e.g., sprayed/coated onto) a surface of the sheet. The use of PLA to form the sheet may mean the cooling element 7c is biodegradable.

Although not apparent from the figure, the sheet of the cooling element 7c may be crimped and gathered to form a substantially cylindrical structure having a high surface area.

The additive (applied to the surface of the sheet) comprises a flavourant e.g., menthol or a phase change material e.g., eicosane.

The cooling element 7c and the upstream filter element 4c are circumscribed by the wrapping layer 3c. The filter element is longer than each of the two filter portions having an axial length of around 14 mm.

The terminal filter element 5c is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 6c. The tipping layer 6c encircles the terminal filter portion and has an axial length of around 20 mm such that it overlays a portion of the filter element 7c.

FIG. 14 shows a second embodiment of a consumable 1c′ which is the same as that shown in FIG. 13 except that the consumable 1c′ comprises a cardboard spacer tube 8c, and the terminal filter element 5c is a solid filter element and comprises a crushable capsule 9c (crush-ball). The crushable capsule 9c has a shell wall which may contain a liquid menthol or cherry or vanilla flavourant. The capsule 8 is spherical and has a diameter of 3.5 mm. It is positioned within the axial centre of the terminal filter portion 5c.

The cardboard spacer tube 8c is disposed between the cooling element 7c and the upstream filter 4c, and acts to allow both cooling and mixing of the aerosol. The cardboard tube spacer 8c is approximately the same length as the cooling element 7c and has an axial length of around 7 mm. The cardboard spacer tube 8c, upstream filter element 4c, and cooling element 7c are circumscribed by the wrapping layer 3c.

FIG. 15 shows a third embodiment of a consumable 1c″ which is the same as the first embodiment except that it comprises (like the embodiment of FIG. 14) a cardboard spacer tube 8c. Further, the wrapping layer 3c does not completely circumscribe the cardboard spacer tube 8c such that there is an annular gap 10c′ between the tipping layer 6c and the cardboard spacer tube 8c downstream of the end of the wrapping layer 3c. In the third embodiment of the consumable 1c″ the cooling element 7c is located between the cardboard spacer tube 8c and the upstream filter 4c.

FIG. 16 shows the first embodiment inserted into an HNB device 10c comprising a rod-shaped heating element 20c (shown in dashed lines). The heating element 20c projects into a cavity 11c within the main body 12c of the device 10c.

The consumable 1c is inserted into the cavity 11c of the main body 12c of the device 10c such that the heating rod 20c penetrates the aerosol-forming substrate 2c. Heating of the reconstituted tobacco in the aerosol-forming substrate 2c is effected by powering the heating element 20c (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter portion 5c.

As the vapour cools within the upstream filter element 4c and the cooling element 7c, it condenses to form an aerosol containing the volatile compounds as well as the menthol flavourant for inhalation by the user.

Fifth Mode of the Disclosure

As shown in FIG. 17, the HNB consumable 1d comprises an aerosol-forming substrate 2d at the upstream end of the consumable 1d.

The aerosol-forming substrate 2d comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2d comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate 2d further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2d is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2d is circumscribed by a paper wrapping layer 3d.

The consumable 1d comprises an upstream filter element 4d and a downstream (terminal) filter element 5d. The two filter elements 4d, 5d and spaced by a cooling element 6d. Both filter elements 4d, 5d are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements have a substantially cylindrical shape. The diameter of the upstream filter element 4d matches the diameter of the aerosol-forming substrate 2d. The diameter of the terminal filter element 5d is slightly larger and matches the combined diameter of the aerosol-forming substrate 2d and the wrapping layer 3d. The upstream filter element 4d is slightly shorter in axial length than the terminal filter element 5d at an axial length of 10 mm compared to 12 mm for the terminal filter element 5d.

The cooling element 6d is longer than each of the two filter elements 4d, 5d having an axial length of around 14 mm. The cooling element 6d is formed of injection moulded polylactic acid (PLA) and comprises a tubular body defining a bore 8d having a circular transverse profile and extending longitudinally through the cooling element 6d. In use, the vapour formed by the aerosol-forming substrate 2d may cool and condense by way of heat exchange with the body of the cooling element 6d. The diameter of the bore 8d of the cooling element 6d is around 4 mm.

Each filter element 4d, 5d is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter element 4d is slightly larger than the diameter of the bore in the terminal filter element 5d having a diameter of 3 mm compared to 2 mm for the terminal filter element 5d.

The cooling element 6d and the upstream filter element 4d are circumscribed by the wrapping layer 3d.

The terminal filter element 5d is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7d. The tipping layer 7d encircles the terminal filter element 5d and has an axial length of around 20 mm such that it overlays a portion of the cooling element 6d.

FIG. 18 shows a second embodiment of a consumable 1d′ which is the same as that shown in FIG. 17 except for the cooling element 6d and the terminal filter element 5d.

The terminal filter element 5d is a solid filter element and comprises a crushable capsule 9d (crush-ball) having a shell wall containing a liquid menthol or cherry or vanilla flavourant. The capsule 9d is spherical and has a diameter of 3.5 mm. It is positioned within the axial centre of the terminal filter element 5d.

The cooling element 6d is formed by additive manufacturing (i.e., 3D printing) and comprises four bores 8d (only two are apparent from the cross-section). Each bore 8d has a circular transverse profile with a diameter of 1 mm, and extends longitudinally through the cooling element 6d.

FIG. 19 shows a third embodiment of a consumable 1d″ which is the same as the first embodiment except for the cooling element 6d and the further inclusion of a cardboard spacer tube 10d.

The cardboard spacer tube 10d is located between the cooling element 6d and the upstream filter 4d. The spacer element 10d defines a space in which vapour (formed by the substrate 2d) may mix and condense. The spacer tube 10d has a length of 6 mm. Due to the presence of the spacer tube 10d, the cooling element 6d is shorter than in previously described embodiments, and has a length of 8 mm. The cooling element 6d is similar to that shown in FIG. 17, except it is formed of extruded PLA.

FIG. 20 shows the first embodiment inserted into an HNB device 11d comprising a rod-shaped heating element 20d. The heating element 20d projects into a cavity 12d within the main body 13d of the device.

The consumable 1d is inserted into the cavity 12d of the main body 13d of the device 11d such that the heating rod 20d penetrates the aerosol-forming substrate 2d. Heating of the reconstituted tobacco in the aerosol-forming substrate 2d is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5d.

As the vapour cools within the upstream filter element 4d and the cardboard tube spacer 6d, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Sixth Mode of the Disclosure

As shown in FIG. 21, the HNB consumable 1e comprises an aerosol-forming substrate 2e at the upstream end of the consumable 1e.

The aerosol-forming substrate 2e comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2e comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2e is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2e is circumscribed by a paper wrapping layer 3e.

The consumable 1e comprises an upstream filter element 4e and a downstream (terminal) filter element 5. The two filter elements 4e, 5e and spaced by a cardboard tube spacer 6e. Both filter elements 4e, 5e are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements have a substantially cylindrical shape. The diameter of the upstream filter 4e matches the diameter of the aerosol-forming substrate 2e. The diameter of the terminal filter element 5e is slightly larger and matches the combined diameter of the aerosol-forming substrate 2e and the wrapping layer 3e. The upstream filter element 4e is slightly shorter in axial length than the terminal filter element 5e at an axial length of 10 mm compared to 12 mm for the terminal filter element 5e.

The cardboard tube spacer 6e is longer than each of the two filter elements 4e, 5e having an axial length of around 14 mm.

The upstream filter element 4e is hollow bore filter element with a hollow, longitudinally-extending axial bore. The diameter of the axial bore in the upstream filter 4e is 3 mm.

The cardboard tube spacer 6e and the upstream filter element 4e are circumscribed by the wrapping layer 3e.

The terminal filter element 5e is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7e. The tipping layer 7e encircles the terminal filter element 5e and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6e.

A plurality of radial air flow paths are provided by a first circumferentially-extending row of ventilation holes 13ae, 13be and an axially spaced second circumferentially-extending row of ventilation holes 14ae, 14be in the tipping layer 7e which are circumferentially arranged around the terminal filter element 5e.

FIG. 22 shows a second embodiment of the sixth mode of a consumable 1e which is the same as the first embodiment except that the upstream filter element 4e is a solid filter element and incudes a crushball 8e which contains a flavourant. Furthermore, the ventilation holes 13ae, 13be, 14ae, 14be extend through the tipping layer 7e and are aligned with radial bores 15ae, 15be, 16ae, 16be extending into the terminal filter element 5e. Of course, the upstream filter element could be replaced with a hollow bore filter element as shown in FIG. 21.

FIG. 23 shows a third embodiment of the sixth mode of a consumable 1e which is the same as the first embodiment except that the wrapping layer 3e does not completely circumscribe the cardboard tube spacer 6e such that there is an annular gap 9e between the tipping layer 7e and the cardboard tube spacer 6e downstream of the end of the wrapping layer 3e. Furthermore, the ventilation holes are provided in the upstream filter element 4e with a first row of ventilation holes 13ae, 13be extend through the wrapping layer 3 and through the upstream filter element 4e into the hollow bore of the terminal filter element 4e whilst the second row of ventilation holes 14ae, 14be extending only through the wrapping layer 3e.

FIG. 24 shows the first embodiment of the sixth mode inserted into an HNB device 10e comprising a rod-shaped heating element 20e. The heating element 20e projects into a cavity 11e within the main body 12e of the device.

The consumable 1e is inserted into the cavity 11e of the main body 12e of the device 10e such that the heating rod 20e penetrates the aerosol-forming substrate 2e. Heating of the reconstituted tobacco in the aerosol-forming substrate 2e is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5e.

As the vapour cools within the upstream filter element 4e and the cardboard tube spacer 6e, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Inhalation by the user also draws in air along the radial flow paths through the ventilation holes 13ae, 13be, 14ae, 14be. This air helps to mix and cool the vapour.

Turning now to consider FIG. 25, there is shown a fourth embodiment of an HNB consumable 1e comprising an aerosol-forming substrate 2e at the upstream end of the consumable 1e.

The aerosol-forming substrate 2e comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2e comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate 2e further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2e is circumscribed by a paper wrapping layer 3e.

Both filter elements 4e, 5e have a substantially cylindrical shape. The diameter of the upstream filter 4e matches the diameter of the aerosol-forming substrate 2e. The diameter of the terminal filter element 5e is slightly larger and matches the combined diameter of the aerosol-forming substrate 2e and the wrapping layer 3e. The upstream filter element 4e is slightly shorter in axial length than the terminal filter element 5e at an axial length of 10 mm compared to 12 mm for the terminal filter element 5e.

The cardboard tube spacer is longer than each of the two filter elements 4e, 5e having an axial length of around 14 mm.

In this embodiment, both filter elements 4e, 5e are hollow bore filter elements with a hollow, longitudinally-extending axial bore. The diameter of the axial bore in the upstream filter 4e is slightly larger than the diameter of the axial bore in the terminal filter element 5e having a diameter of 3 mm compared to 2 mm for the terminal filter element 5e.

The cardboard tube spacer 6e and the upstream filter element 4e are circumscribed by the wrapping layer 3e.

FIG. 26 shows a fifth embodiment of the sixth mode of a consumable 1e which is the same as the fourth embodiment except that the upstream filter element 4e is a solid filter element and incudes a crushball 8e which contains a flavourant. Furthermore, the ventilation holes 13ae, 13be, 14ae, 14be extend through the tipping layer 7e and are aligned with radial bores 15ae, 15be, 16ae, 16be extending through the terminal filter element 5e into the hollow axial bore of the terminal filter element 5e. Of course, the upstream filter element 4e could be replaced with a hollow bore filter element as shown in FIG. 25.

FIG. 27 shows a sixth embodiment of the sixth mode of a consumable 1e which is the same as the fourth embodiment except that the wrapping layer 3e does not completely circumscribe the cardboard tube spacer 6e such that there is an annular gap 9e between the tipping layer 7e and the cardboard tube spacer 6e downstream of the end of the wrapping layer 3e. Furthermore, the first row of ventilation holes 13ae, 13be extend through the wrapping layer 3e and through the upstream filter element 4e into the hollow bore of the terminal filter element 4e whilst the second row of ventilation holes 14ae, 14be extending only through the wrapping layer 3e.

FIG. 28 shows the fourth embodiment of the sixth mode inserted into an HNB device 10e comprising a rod-shaped heating element 20e. The heating element 20e projects into a cavity 11e within the main body 12e of the device 10e.

The consumable 1e is inserted into the cavity 11e of the main body 12e of the device 10e such that the heating rod 20 penetrates the aerosol-forming substrate 2e. Heating of the reconstituted tobacco in the aerosol-forming substrate 2e is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5e.

As the vapour cools within the upstream filter element 4e and the cardboard tube spacer 6e, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Inhalation by the user also draws in air along the radial flow paths through the ventilation holes 13ae, 13be, 14ae, 14be. This air helps to mix and cool the vapour.

Seventh Mode of the Present Disclosure

As shown in FIG. 29, the HNB consumable 1f comprises an aerosol-forming substrate 2f at the upstream end of the consumable 1f.

The aerosol-forming substrate 2f comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2f comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate 2f further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2f is formed in a substantially cylindrical shape such that the consumable 1f resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2f is circumscribed by a paper wrapping layer 3f.

The consumable 1f comprises an upstream filter element 4f and a downstream (terminal) filter element 5f. Both filter elements 4f, 5f are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 4f, 5f have a substantially cylindrical shape. The diameter of the upstream filter 4f matches the diameter of the aerosol-forming substrate 2f. The diameter of the terminal filter element 5f is slightly larger and matches the combined diameter of the aerosol-forming substrate 2f and the wrapping layer 3f. The upstream filter element 4f is slightly shorter in axial length than the terminal filter element 5f at an axial length of 10 mm compared to 12 mm for the terminal filter element 5f.

The two filter elements 4f, 5f are spaced by a cooling element 6f comprising a polylactic acid (PLA) based foam having a cylindrical form. The cooling element 6f is longer than each of the two filter elements 4f, 5f having an axial length of around 14 mm. Although not apparent from the figure, the cooling element 6f comprises an open cell foam comprising a plurality of channels that permit the passage of vapour (i.e., from the substrate 2f) through the cooling element 6f. Heat exchange between the vapour and the cooling element 6f may cool the vapour so as to cause it to condense.

Each filter element 4f, 5f is a hollow bore filter element with a hollow, longitudinally extending bore 8f, 9f. The diameter of the bore 8f in the upstream filter 4f is slightly larger than the diameter of the bore 9f in the terminal filter 5f having a diameter of 3 mm compared to 2 mm for the terminal filter element 5f.

The cooling element 6f and the upstream filter element 4f are circumscribed by the wrapping layer 3f.

The terminal filter element 5f is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7f. The tipping layer 7f encircles the terminal filter element 5f and has an axial length of around 20 mm such that it overlays a portion of the cooling element 6f.

FIG. 30 shows a second embodiment of the seventh mode of a consumable 1f which is generally same as that shown in FIG. 29 except that the consumable 1f′ comprises a spacer tube 19f between the terminal filter element 5f and the cooling element 6f′.

The spacer tube 19f acts to allow both mixing and cooling of the aerosol (or vapour). As a result of the presence of the spacer tube 19f, the cooling element 6f′ is shorter than in the previously described embodiment. The cardboard spacer tube 19f and the cooling element 6f′ are approximately the same length, and each have an axial length of around 7 mm. The cardboard spacer tube 19f and the cooling element 6f′ are circumscribed by the wrapping layer 3f.

In this embodiment, the cooling element 6f′ is formed of PLA granules that are compressed into a cylindrical form. The granules define a plurality of channels that extend through the cooling element 6f′ so as to permit the passage of vapour through the cooling element 6f′

The terminal filter element 5f is a solid filter element and comprises a crushable capsule 10f (crush-ball) having a shell wall containing a liquid menthol or cherry or vanilla flavourant. The capsule 10f is spherical and has a diameter of 3.5 mm. It is positioned within the axial centre of the terminal filter element 5f.

FIG. 31 shows a third embodiment of the seventh mode of a consumable 1f″ which is the same as the first embodiment except that a cooling element 6f″ comprises a bore 11f, and the wrapping layer 3f does not completely circumscribe the cooling element 6f″. In the present embodiment, the cooling element 6f″ is formed of PLA granules compressed into a tubular form (i.e., a cylindrical form with a centrally extending bore 11f). The bore 11f has a circular transverse profile with a larger diameter than the bores 8f, 9f of the upstream 4f and terminal 5f filters. The diameter of the bore 11f of the cooling element 6f″ is 5 mm.

FIG. 32 shows the first embodiment inserted into an HNB device 12f comprising a rod-shaped heating element 20f. The heating element 20f projects into a cavity 13f within the main body 14f of the device.

The consumable 1f is inserted into the cavity 13f of the main body 14f of the device 12f such that the heating rod 20f penetrates the aerosol-forming substrate 2f. Heating of the reconstituted tobacco in the aerosol-forming substrate 2f is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5f.

As the vapour cools within the upstream filter element 4f and the cooling element 6f, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the scope of the invention.

For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

Throughout this specification, including the claims which follow, unless the context requires otherwise, the words “have”, “comprise”, and “include”, and variations such as “having”, “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means, for example, +/−10%.

The words “preferred” and “preferably” are used herein refer to embodiments of the invention that may provide certain benefits under some circumstances. It is to be appreciated, however, that other embodiments may also be preferred under the same or different circumstances. The recitation of one or more preferred embodiments therefore does not mean or imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure, or from the scope of the claims.

Number	Date	Country	Kind
1817545.5	Oct 2018	GB	national
1817548.9	Oct 2018	GB	national
1817563.8	Oct 2018	GB	national
1817565.3	Oct 2018	GB	national
1817567.9	Oct 2018	GB	national
1817574.5	Oct 2018	GB	national
1817579.4	Oct 2018	GB	national
1817580.2	Oct 2018	GB	national

	Number	Date	Country
Parent	PCT/EP19/79212	Oct 2019	US
Child	17243074		US
Parent	PCT/EP19/79279	Oct 2019	US
Child	PCT/EP19/79212		US
Parent	PCT/EP19/79230	Oct 2019	US
Child	PCT/EP19/79279		US
Parent	PCT/EP19/79219	Oct 2019	US
Child	PCT/EP19/79230		US
Parent	PCT/EP19/79273	Oct 2019	US
Child	PCT/EP19/79219		US
Parent	PCT/EP19/79209	Oct 2019	US
Child	PCT/EP19/79273		US
Parent	PCT/EP19/79191	Oct 2019	US
Child	PCT/EP19/79209		US

SMOKING SUBSTITUTE CONSUMABLE

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Abstract

Description

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Priority Claims (8)

CROSS-REFERENCE TO RELATED APPLICATIONS

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