The present invention relates to a consumable for an aerosol generating device.

Aerosol generating devices such as electronic cigarettes are relatively well known and are becoming increasingly popular with consumers. A common operating principle for such electronic cigarettes is to heat a consumable without burning it to provide an aerosol (also referred to as a vapour) to a user for inhalation. Examples of such consumables include charges of tobacco material or capsules of liquid containing flavourants and/or active ingredients such as nicotine.

Aerosol generating devices often comprise a heater, a power source for supplying electricity to the heater and a receptacle, such as a heating chamber, for receiving the consumable in the vicinity of the heater such that the consumable may be heated to produce the vapour for inhalation.

In recent years the popularity of multiple use aerosol generating devices has surpassed that of single use devices which are disposed of after use. Since, the consumable can only provide the required active ingredients or flavourants for a limited duration of heating before these components are depleted, in multiple use devices the consumable must be replaced. This is generally achieved by removing the depleted consumable from the heating chamber and replacing with a new consumable.

There are, however, several shortcomings with such consumables and aerosol generating devices. In particular, the replacement of the consumable is often an awkward process for the user, given the size of the components and the requirement to manoeuvre the aerosol generating device into the appropriate orientation while removing the spent consumable and replacing with a new consumable. This process has to be carried out regularly which exacerbates the problem. Moreover, consumable articles often comprise a bulky outer container to hold the aerosol generating material. The requirement for a container increases the size of the consumable article and increases the amount of material that ultimately enters landfill.

Therefore, there is need to provide a consumable article which addresses one or more of these shortcomings.

According to an aspect of the invention, there is provided a consumable article for an aerosol generating device comprising: an aerosol generating substrate comprising a cylindrical outer surface; and a strip removably attached to the cylindrical outer surface of the aerosol generating substrate, wherein the strip directly interfaces with the cylindrical outer surface, and wherein the strip comprises a tab which extends away from the cylindrical outer surface such that a user can grip the tab to pick up the consumable article.

In this way, a consumable article is provided which can be gripped and deposited within an aerosol generating device with ease. The tab allows for easy handling by a user whilst the removable strip prevents direct contact between the aerosol generating substrate and the user and increases the durability of the consumable article.

Preferably, the strip surrounds at least a portion of the cylindrical outer surface. Preferably, the strip surrounds the entire cylindrical outer surface of the aerosol generating substrate. In other words, a cylindrical pellet of aerosol generating substrate is provided with a strip of material extending around the cylindrical pellet in a circumferential direction. This arrangement allows for the efficient removal of the strip from the aerosol generating substrate and produces a compact consumable having only a small surface area of aerosol generating substrate not protected by the strip.

Preferably, the consumable article has a length and a width, wherein the length is greater than the width. The skilled person will appreciate that the length of the consumable article refers to the extent of the consumable article in a direction parallel to its cylindrical (i.e. longitudinal) axis, whereas the width of the consumable article refers to the diameter of the consumable article (i.e. the extent of the consumable article in a direction perpendicular to its cylindrical axis).

Preferably, a first portion of the strip overlaps with a second portion of the strip, wherein the first and second portions of the strip are bonded at the overlap. In this way, a mechanism for removably attaching the strip to the aerosol generating substrate is provided. The bonded portions of the strip secure the strip around the aerosol generating substrate until a force sufficient to break the bond is applied which results in removal of the strip from the aerosol generating substrate. In use, the consumable article may be placed within an aerosol generating device and the tab gripped and pulled by a user with sufficient force to break the bond and remove the strip whilst the aerosol generating substrate is retained with the aerosol generating device. Additionally or alternatively, the strip may be bonded directly to the aerosol generating substrate.

Preferably, the tab is located at an end portion of the strip in a circumferential direction with respect to the cylindrical outer surface of the aerosol generating substrate. In this way, a pulling force applied to the tab will be distributed evenly around the length of strip, thereby reducing the likelihood of the tab tearing and ensuring the strip is decoupled at the bonded overlap as intended. Moreover, as the tab extends in the same general direction as the strip, the bulkiness of the consumable article is reduced and the packing efficiency of multiple consumable articles is improved. In one example, the strip is substantially rigid such that the strip retains its shape under gravity, thus ensuring that the tab extends away from the aerosol generating substrate and can be gripped by a user.

The consumable article may further comprise a hole extending through the aerosol generating substrate in a direction parallel to the cylindrical axis of the cylindrical outer surface of the aerosol generating substrate. Preferably, the hole and the cylindrical outer surface of the aerosol generating surface are concentric. In this way, the surface area of the aerosol generating substrate is increased resulting in improved aerosol generating properties. Moreover, the hole (columnar or otherwise) extending through the consumable article may be employed to allow the aerosol generating substrate to be easily located within an aerosol generating device or packaging for consumable articles. Furthermore, the hole may enable rotation of the consumable article whilst it is situated within an aerosol generating device. For example, the hole may enable the consumable article to be mounted on an axle or shaft provided within an aerosol generating device such that the aerosol generating substrate can be rotated about the axle. As a result, more uniform heating and improved aerosol generating properties may be achieved. Moreover, rotation of the consumable article may enable easier removal of the strip from the aerosol generating substrate by the application of a pulling force in the direction of rotation, i.e. in a circumferential direction with respect to the cylindrical outer surface of the aerosol generating substrate.

Preferably, the aerosol generating substrate has a solid or semi-solid form. The aerosol generating substrate may comprise a foam tobacco material, which may be known as a “tobacco mousse”.

Preferably, the consumable article is configured such that the strip may be removed from the aerosol generating substrate, and wherein the aerosol generating substrate is configured to be heated to generate an aerosol. That is the consumable article is configured to be heated to generate an aerosol after removal of the strip.

According to another aspect of the invention, there is provided an aerosol generating device comprising: a body portion; a chamber for receiving a consumable article as set out above, wherein the chamber is disposed within the body portion, wherein the chamber is configured such that the tab of the consumable article protrudes from the device when the consumable article is received within the chamber; and an outer shell, wherein the outer shell can be moved relative to the body portion to adjust an opening area of the chamber. In this way, consumable articles may be easily deposited and replaced within the device. Moreover, as the opening area of the chamber may be adjusted (i.e. the outer shell can be moved relative to the body portion to reveal or conceal the chamber) to it is possible to prevent objects from inadvertently entering the chamber thereby protecting the internal components of the aerosol generating device from damage.

Preferably, the aerosol generating device is further configured such that when the consumable article is received within the chamber and the outer shell is moved to conceal the chamber, the tab of the consumable article can be pulled by a user to remove the strip from the aerosol generating substrate whilst the aerosol generating substrate is retained within the device. In particular, the arrangement allows the tab to protrude from the chamber whilst the outer shell is positioned to close the chamber opening, thereby blocking the aerosol generating substrate from leaving the chamber whilst still allowing the tab to be pulled by a user.

According to another aspect of the invention, there is provided an aerosol generating system comprising: an aerosol generating device as set out above; and a consumable article as set out above received within the chamber of the aerosol generating device.

According to another aspect of the invention, there is provided a system comprising a packaging and a plurality of consumable articles as set out above, the packaging comprising an inner portion comprising a cavity in which the plurality of consumables articles as defined above are held and an outer portion, wherein the outer portion is movable relative to the inner portion to reveal or conceal the cavity. In one example, both portions may be tubular and the outer portion may be rotated around the inner portion to reveal the chamber, thereby providing a compact and efficient method of storing consumable articles. The packaging may be constructed from cardboard tubing or pressed paper-pulp. Preferably, the packaging is configured such that the tab of each of the plurality consumable articles held within the cavity protrudes from the packaging when the outer portion is moved to reveal the cavity, thereby allowing a user to grip the tab to pick up each consumable article.

Preferably, the cavity is a cylindrical cavity having substantially the same circumference as each of the plurality of consumable articles, thereby allowing the plurality of consumable articles to be arranged in a line along the length of the cavity, with the cylindrical axis of each of the plurality of consumable articles orientated parallel to the cylindrical axis of the cavity. In this way, a high packing density of consumable articles may be provided, allowing easy storage and transportation of a number of consumable articles.

Embodiments of the invention are now described, by way of example, with reference to the drawings, in which:

Figure 1 is a perspective view of a consumable article for an aerosol generating device in an embodiment of the invention;

Figure 2 is a perspective view of the consumable article depicted in Figure 1 and an aerosol generating device in an embodiment of the invention;

Figure 3 is a series of perspective views of the aerosol generating device and consumable article depicted in Figure 2, illustrating the consumable article being deposited within the aerosol generating device and the strip being removed from the aerosol generating substrate;

Figure 4 is a series of perspective views of a packaging for consumables articles, illustrating the process of removing a consumable article from the packaging;

Figure 1 shows a consumable article 10 in an embodiment of the invention comprising an aerosol generating substrate 12 and a strip 14 which encircles a peripheral surface of the aerosol generating substrate 12. The aerosol generating substrate 12 is formed as a cylindrical pellet of aerosol generating material with a cylindrical hole 20 extending through the central portion of the cylindrical pellet (i.e. along its cylindrical axis). Thus, the aerosol generating substrate 12 can be described as a hollow cylinder, pipe or tubular section.

In alternative examples, the hole 20 may not be cylindrical but instead may comprise a triangular, square, hexagonal or other cross-sectional shape. In other examples, the hole 20 may be absent entirely.

The aerosol generating substrate 12 is formed of a solid or highly viscous aerosol generating material. For example, the aerosol generating substrate 12 may comprise a foam tobacco material, known as a “tobacco mousse”.

The strip 14 comprises a length of sheet material. The term “sheet” refers to a shape with a thickness many times smaller than its length or breadth. The strip 14 is arranged around the cylindrical outer surface of the aerosol generating substrate 12 such that the bottom major side of the strip 14 interfaces with the cylindrical outer surface and the strip 14 extends around the circumferential direction of the cylindrical outer surface. In one example, the strip 14 may cover the entire area of the cylindrical outer surface of the aerosol generating substrate 12. In another example, the strip 14 may only cover a central portion of the cylindrical outer surface, such that two bands of aerosol generating substrate 12 are exposed on the cylindrical outer surface either side of the strip 14.

The strip may be made of paper and/or other textile materials, and may also comprise various organic materials and/or inorganic materials.

The strip 14 is coupled to the aerosol generating substrate 12 in a removable manner. In the example shown, this is achieved by bonding (using adhesive or otherwise) a section of the bottom major side of the strip 14 to a section of the top major side of the strip 14 at an overlap 18. Thus, a coherent loop of strip 14 encircles the aerosol generating substrate 12, thereby attaching the strip 14 to the aerosol generating substrate 12 by virtue of the constraint imposed by the loop of strip 14. However, when a sufficient force is applied to the bonded overlap 18, the bond can be broken and the strip 14 decoupled from the aerosol generating substrate 12.

In other examples, the bottom major side of the strip 14 may be bonded or directly attached to the cylindrical outer surface of the aerosol generating substrate 12. This may be in addition to or as an alternative to the bonded overlap 18 described above. On application of a sufficient force to the strip 14, the bond between the strip 14 and the aerosol generating substrate 12 can be broken and the strip 14 removed from the aerosol generating substrate 12. The skilled person will appreciate that the strip 14 may be bonded to the aerosol generating substrate 12 over the entire area of the bottom major side of the strip 14, or only a portion of the area.

The strip 14 comprises a tab 16 located at one end of the length of strip 14, allowing a user to grasp the tab 16 to pick up the consumable article 10. The tab 16 is designed to stand away from the surface of strip 14 under gravity, e.g. in a radial direction. This increases the ease with which a user can grip the tab 16 to pick up the consumable article 10. Moreover, the tab 14 is able to lie flush with the rest of the strip 14 (i.e. following the direction of the cylindrical outer surface of the aerosol generating substrate 12) when external constraint is imposed, such as the constraint imposed by a packaging for consumable articles. However, when the constraint is removed, the tab 14 will spring back into its original positon and extend away from the aerosol generating substrate 12.

In addition to increasing the ease with which the consumable article 10 can be gripped and handled by a user, the strip 14 also provides a physical barrier which protects the underlying aerosol generating substrate 12. This increases the durability of the consumable article 10 and prevents contact of the aerosol generating substrate 12 with external surfaces such as the hands of a user. Figure 2 shows an aerosol generating device 30 in an embodiment of the invention which is configured to receive and heat consumable article 10. The aerosol generating device 30 comprises a chamber 32, a body portion 34, an outer shell 36, a mouthpiece 38 and an LED indicator 40.

The aerosol generating device 30 further comprises a heating element powered by a battery (not shown) such that, in use, a consumable article 10 may be inserted within the device 30 and heated using the heating element. This produces an aerosol (or vapour) which a user can inhale through the mouthpiece 38.

The chamber 32 is located on a side of the body portion 34 and arranged such that the consumable article 10 may be deposited within the chamber 32. The outer shell 36 is attached to the body portion 34 such that the relative position of the outer shell 36 and body portion 34 can be adjusted, e.g. using a sliding mechanism.

As depicted in Figure 3, movement of the outer shell 36 relative to the body portion 34 results in the opening and closing of the chamber 32. In use, a user can grip the tab 16 of consumable article 10 to place the consumable article 10 within the chamber 32, with the tab 16 protruding from the chamber 32. The outer shell 36 is then moved relative to the body portion 34 to close the chamber 32 and encase the consumable article 10. However, a small gap remains in the opening of the chamber 32 whereby the tab 16 remains protruding from the chamber 32. Thus, the tab 16 can be pulled by the user to remove the strip 14 from the aerosol generating substrate 12 whilst the aerosol generating substrate 12 is blocked from leaving the chamber 12 by the outer shell 36. In one example, the aerosol generating substrate 12 is then free to fall into an internal oven wherein it is heated by the heating element to produce an aerosol. Alternatively, the aerosol generating substrate 12 may be retained and heating within the chamber 32. In a further example, when the consumable article 10 is placed within the chamber 32, it may be retained by a shaft, axle or other protrusion arranged to extend through at least a portion of the hole 20 in the aerosol generating substrate 12. In this way, it is possible for the aerosol generating substrate 12 to rotate on its axis whilst positioned within the chamber 32. Thus, when a pulling force is applied to the tab 16, the aerosol generating substrate 12 is able to rotate such that the strip 14 is fed out of the small gap in the chamber 32, thereby improving the ease with which a user can remove the strip 14 from the aerosol generating substrate 12. When the strip 14 has been removed from the aerosol generating substrate 12, the aerosol generating substrate 12 may drop into an oven. Alternatively, the aerosol generating substrate 12 may be retained on the protrusion and heated within the chamber 32.

As will be appreciated by the skilled person, the chamber 32 may be revealed and concealed using alternative mechanisms without necessarily requiring a separate outer shell 36. For example, a sliding aperture or other closing mechanism may be disposed adjacent to the chamber 32 opening.

Figure 4 shows a packaging 50 suitable for holding a number of consumable articles 10. The packaging 50 comprises a tubular inner portion 52 held within a tubular outer portion 54, wherein the radius of the inner portion 52 is slightly smaller than the outer portion 54. In this way, the inner portion 52 and outer portion 54 are prevented from accidentally separating but can still be rotated relative to one another.

The inner portion 52 is hollow and defines a cylindrical cavity 56 which is accessible through a cut-away section 58 along the length of the inner portion 54. The outer portion 54 also comprises a cut-away section 60 extending along its length, such that access to the cavity 56 is provided when the inner portion 52 and outer portion 54 are rotated so that their respective cut-away sections 58, 60 are aligned. When the cut-away sections 58, 60 of the inner portion 52 and outer portion 54 are not aligned, access to the chamber 56 is prevented. The cylindrical cavity 56 is configured such that a plurality of consumable articles 10 may be arranged in a line along the length of cavity 56. Each consumable article 10 should be orientated within the cavity 56 so that its cylindrical axis points along the length (cylindrical axis) of the packaging 50. The cut-away sections 58, 60 have a width approximately equal to the diameter of a consumable article 10 allowing each consumable article 10 to be removed from the cavity 56.

The consumable articles 10 are arranged within the cavity 56 so that the tab 16 of each consumable article 10 lies adjacent to the cut-away section 58 of the inner portion 52. Thus, when the cavity 56 is exposed by rotating the outer portion 54 relative to the inner portion 52, the tab 16 of each consumable article 10 protrudes from the cavity 56 and can easily be gripped by a user to extract the consumable article 10 from the packaging 50.

On the other hand, when the outer portion 54 is rotated (in the direction of the extension direction of the tab 16) to hide the cut-away section 58 of the inner portion 54, the constraint imposed by the outer portion 54 flattens the tab 16 against the cylinder outer surface of the consumable article 10. In this way, an efficient packing design is provided which also allows easy access to consumable articles 10 contained within the packaging 50.

In one example, the packaging 50 may be formed of cardboard tubing. In another example, the packaging 50 may be formed of pressed paper-pulp.