IMPROVED EXTINGUISHMENT

The present invention relates to a consumable article comprising an aerosol-generating article of the type comprising an aerosol-generating substrate and a combustible heat source for heating the aerosol-generating substrate.

Aerosol-generating articles in which an aerosol-generating substrate, such as a tobacco- containing substrate, is heated rather than combusted, are known in the art. Typically in such heated aerosol-generating articles, an aerosol is generated by the transfer of heat from a heat source to a physically separate aerosol-generating substrate or material, which may be located in contact with, within, around, or downstream of the heat source. During use of the aerosol generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

For example, WO-A2-2009/022232 discloses an aerosol-generating article comprising a combustible heat source, an aerosol-forming substrate downstream of the combustible heat source, and a heat-conducting element around and in contact with a rear portion of the combustible heat source and an adjacent front portion of the aerosol-forming substrate. The combustible heat source and the aerosol-forming substrate are in abutting coaxial alignment and, along with the heat-conducting element, are overwrapped in an outer wrapper of cigarette paper of low air permeability to hold the various components of the aerosol-generating article together. In use, the front portion of the aerosol-forming substrate is heated primarily by conduction through the abutting rear portion of the combustible heat source and via the heat-conducting element.

Aerosol-generating articles including one such combustible heat source may have a combustion zone or zone of heating that is larger, more dense, and not as readily extinguished by crushing or "stubbing out" the heat source compared to a conventional cigarette, in which tobacco is burnt or combusted to heat and release volatile compounds from the tobacco. This is because such aerosol-generating articles may have a heat source that contains significantly more energy in the form of heat than found in the combustion zone of a conventional cigarette. Consequently, such aerosol-generating articles may require more effort to extinguish or to remove sufficient heat to facilitate disposal.

Thus, it would be desirable to provide a consumable article comprising an aerosol generating article of the type comprising a combustible heat source for heating the aerosol generating substrate such that it is easier to extinguish or cool down the combustible heat source after use. In particular, it would be desirable to provide one such aerosol-generating article in a form that facilitates extinguishment without requiring use of an ashtray or the like, so as to improve the ease of use for the consumer. It would be equally desirable to provide one such consumable article that can be manufactured efficiently and at high speed, as well as to provide a method of manufacturing such a consumable article that is reliable and easy to implement.

According to an aspect of the present invention, there is provided a consumable article comprising an aerosol-generating article for producing an inhalable aerosol when heated. The aerosol-generating article comprises a combustible heat source; a rod of aerosol-generating substrate downstream of the combustible heat source; and a wrapper circumscribing the rod of aerosol-generating substrate and at least a downstream portion of the combustible heat source. The consumable article further comprises an individual wrapper circumscribing the aerosol generating article. The individual wrapper comprises a first and a second line of weakness extending circumferentially about a longitudinal axis of the consumable article at two distinct locations along the length of the consumable article, such that an upstream end portion and a downstream end portion of the individual wrapper are separable along a respective one of the first and second lines of weakness from an intermediate portion of the individual wrapper extending between the first and the second lines of weakness. The intermediate portion of the individual wrapper is longitudinally slidable over an outer surface of the aerosol-generating article.

According to another aspect of the present invention, there is provided a method of manufacturing a consumable article, the method comprising providing an array of aerosol generating articles, wherein each aerosol-generating article comprises a combustible heat source, a rod of aerosol-generating substrate downstream of the combustible heat source, and a wrapper circumscribing the rod of aerosol-generating substrate and at least a downstream portion of the combustible heat source, the aerosol-generating articles in the array being spaced from one another by a first distance. Further, the method comprises wrapping the continuous array of aerosol-generating articles with a continuous sheet of a packaging material, the sheet of packaging material comprising a plurality of lines of weakness extending perpendicular to a longitudinal axis of the array and arranged such that a first and a second line of weakness extend at two distinct locations along the length of each aerosol-generating article. In addition, the method comprises cutting the wrapped article array at an intermediate position between two consecutive aerosol-generating articles to provide multiple wrapped array segments, and folding or twisting or sealing the packaging material at the ends of the wrapped array segments.

According to a further aspect of the present invention there is provided a method of using a consumable article, the method comprising: longitudinally sliding the intermediate portion of the individual wrapper along the aerosol-generating article such that an upstream end of the intermediate portion projects beyond an upstream end of the aerosol-generating article; and folding or twisting the upstream end of the intermediate portion of the individual wrapper such as to envelop the combustible heat source with the individual wrapper. It will be appreciated that any features described with reference to one aspect of the present invention are equally applicable to any other aspect of the invention.

The term“aerosol-generating article” is used herein to denote both articles wherein an aerosol-generating substrate is heated and articles wherein an aerosol-generating substrate is combusted, such as conventional cigarettes. As used herein, the term “aerosol-generating substrate” denotes a substrate capable of releasing volatile compounds upon heating to generate an aerosol.

A conventional cigarette is lit when a user applies a flame to one end of the cigarette and draws air through the other end. The localised heat provided by the flame and the oxygen in the air drawn through the cigarette causes the end of the cigarette to ignite, and the resulting combustion generates an inhalable smoke. By contrast, in heated aerosol-generating articles, an aerosol is generated by heating a flavour generating substrate, such as tobacco.

A heated aerosol-generating article may comprise an on-board heating means forming part of the aerosol-generating article, as is the case with the consumable articles of the present invention, or may be configured to interact with an external heater forming part of a separate aerosol-generating device.

An aerosol-generating article may be one article that generates an aerosol that is directly inhalable into a user's lungs through the user's mouth. An aerosol-generating article may resemble a conventional smoking article, such as a cigarette. An aerosol-generating article may comprise tobacco. An aerosol-generating article may be disposable. An aerosol-generating article may be partially reusable and comprise a replenishable or replaceable aerosol-generating substrate.

The term“line of weakness” is typically used to describe a portion of a surface of a container or blank for forming a container wherein the structural strength of the material has been weakened by any suitable technique. For example, a line of weakness may be formed as a scoring line, a creasing line, an ablation line, or a perforated line.

The term“scoring line” is used to describe a line formed by partially cutting into the material of the blank. A scoring line may be formed by removing material from the blank, that is, by forming a groove or trough in the blank. As an alternative, a scoring line may be formed without removing any material from the blank. This would typically involve a partial sideways displacement and compression of material.

The term “creasing line” typically refers to a line formed by displacing a portion of the material substantially perpendicular to the plane of the blank, which results in the formation of a groove or trough in the blank. The displacement may involve compression and is typically achieved by means of a compression tool, such as a roller. Alternatively, or in addition, the material in the creasing line may be displaced so as to at least partially protrude from the opposite side of the blank. Generally, no material is removed when a creasing line is formed. The term“ablation line” is used instead to describe a line formed by removing material from a surface of the blank to a predetermined depth by way of ablation, such as by means of a laser beam or a blade.

The term“perforated line” describes a line or sequence of discrete holes or slots formed in the blank. The holes may be formed by pushing an object through the blank, which may result in material being removed from the blank, for example by punching. Alternatively, the holes may be created without effectively removing material, the object being used to push material outwardly from a centre of the hole

The term“length” denotes the dimension of a component of the aerosol-generating article in the longitudinal direction. For example, it may be used to denote the dimension of the rod of aerosol-generating substrate or of the heat source in the longitudinal direction.

As used herein, the term“longitudinal” refers to the direction corresponding to the main longitudinal axis of the aerosol-generating article, which extends between the upstream and downstream ends of the aerosol-generating article. During use, air is drawn through the aerosol generating article in the longitudinal direction. The term“transverse” refers to the direction that is perpendicular to the longitudinal axis. Any reference to the “cross-section” of the aerosol generating article or a component of the aerosol-generating article refers to the transverse cross- section unless stated otherwise.

As used herein, the terms“upstream” and“downstream” describe the relative positions of elements, or portions of elements, of the aerosol-generating article in relation to the direction in which the aerosol is transported through the aerosol-generating article during use.

As briefly described above, a consumable article in accordance with the present invention comprises an aerosol-generating article of the type comprising a combustible heat source, a rod of aerosol-generating substrate downstream of the combustible heat source, and a wrapper circumscribing the rod of aerosol-generating substrate and at least a downstream portion of the combustible heat source.

Aerosol-generating articles, including aerosol-generating articles comprising a combustible heat source, are typically packaged and sold in containers, such as rigid hinge-lid containers, housing a bundle of aerosol-generating articles. The bundle is commonly wrapped in an inner liner, or package, of metallised paper, metal foil or other flexible sheet material. A sealed condition of the inner package is appreciated by consumers as proof that the goods inside the package are preserved in their original form at least until the first opening of the container.

In contrast to such conventional arrangement, in a consumable article in accordance with the present invention the aerosol-generating article is circumscribed by an individual wrapper comprising two lines of weakness extending circumferentially about a longitudinal axis of the consumable article at two distinct locations along the length of the article. Thus, both an upstream end portion and a downstream end portion of the individual wrapper are separable along a respective line of weakness from an intermediate portion of the individual wrapper.

The intermediate portion of the individual wrapper can thus be slidably moved longitudinally such that a portion of the individual wrapper projects beyond the upstream end of the aerosol generating article. In other words, the intermediate portion of the individual wrapper forms a slidable sleeve that can be moved away from the downstream end, that is, the mouth end of the aerosol-generating article to overlie the combustible heat source in its entirety. The upstream end of the intermediate portion of the individual wrapper can be folded or twisted such that the combustible heat source is enveloped by the packaging material of the individual wrapper, which greatly facilitates extinguishment of the aerosol-generating article. In particular, it is easy for the consumer to extinguish the aerosol-generating article at any location, without needing an ash tray or any equivalent means.

Without wishing to be bound by theory, it is understood that the intermediate portion of the individual wrapper enveloping the combustible heat source may substantially cut off the oxygen supply to the combustible heat source. This advantageously results in the extinguishment of the aerosol-generating article.

In consumable articles in accordance with the present invention the combustible heat source is preferably a solid heat source, and may comprise any suitable combustible fuel including, but not limited to, carbon and carbon-based materials containing aluminium, magnesium, one or more carbides, one or more nitrides and combinations thereof. Solid combustible heat sources for heated aerosol-generating articles and methods for producing such heat sources are known in the art and described in, for example, US-A-5,040,552 and US-A- 5,595,577. Typically, known solid combustible heat sources for heated aerosol-generating articles are carbon-based, that is they comprise carbon as a primary combustible material. In consumable articles in accordance with the invention the combustible heat source is preferably a combustible carbonaceous heat source.

Other combustible heat sources suitable for use in consumable articles according to the invention, and methods for producing such heat sources, are well known in the art and described in, for example, US-A-5,060,676, US-A-5, 146,934, US-A-5,188,130, US-A-5,240,014, US-A- 5,246,018, US-A-5, 247, 949, US-A-5, 443, 560, or US-A-5, 468, 266.

The combustible heat source is preferably a blind combustible heat source. As used herein, the term“blind” describes a heat source that does not comprise any air flow channels extending from the front end face to the rear end face of the combustible heat source. Further, the term blind is also used herein to describe a combustible heat source including one or more airflow channels extending from the front end face of the combustible heat source to the rear end face of the combustible heat source, wherein a combustible substantially air impermeable barrier between the rear end face of the combustible heat source and the aerosol-forming substrate barrier prevents air from being drawn along the length of the combustible heat source through the one or more airflow channels.

Aerosol-generating articles included in consumable articles according to the invention comprising blind combustible heat sources comprise one or more air inlets downstream of the rear end face of the combustible heat source for drawing air into the one or more airflow pathways. Aerosol-generating articles comprising non-blind combustible heat sources may also comprise one or more air inlets downstream of the rear end face of the combustible heat source for drawing air into the one or more airflow pathways. In certain preferred embodiments, aerosol-generating included in consumable articles according to the invention comprising blind combustible heat sources comprise one or more air inlets located proximate to the downstream end of the aerosol generating substrate.

In use, air drawn along the one or more airflow pathways of aerosol-generating articles included in consumable articles according to the invention comprising a blind combustible heat source for inhalation by a user does not pass through any airflow channels along the blind combustible heat source. The lack of any airflow channels through the blind combustible heat source advantageously substantially prevents or inhibits activation of combustion of the blind combustible heat source during puffing by a user. This substantially prevents or inhibits spikes in the temperature of the aerosol-generating substrate during puffing by a user. By preventing or inhibiting activation of combustion of the blind combustible heat source, and so preventing or inhibiting excess temperature increases in the aerosol-generating substrate, combustion or pyrolysis of the aerosol-forming substrate under intense puffing regimes may be advantageously avoided. In addition, the impact of a user’s puffing regime on the composition of the mainstream aerosol may be advantageously minimised or reduced.

The inclusion of a blind combustible heat source may also advantageously substantially prevent or inhibit combustion and decomposition products and other materials formed during ignition and combustion of the blind combustible heat source from entering air drawn through aerosol-generating articles included in consumable articles according to the invention during use thereof. This is particularly advantageous where the blind combustible heat source comprises one or more additives to aid ignition or combustion of the blind combustible heat source.

In aerosol-generating articles comprising a blind combustible heat source, heat transfer from the blind combustible heat source to the aerosol-generating substrate occurs primarily by conduction and heating of the aerosol-generating substrate by forced convection is minimised or reduced. This may advantageously help minimise or reduce the impact of a user’s puffing regime on the composition of the mainstream aerosol.

In other embodiments, the combustible heat source comprises at least one longitudinal airflow channel, which provides one or more airflow pathways through the heat source. The term “airflow channel” is used herein to describe a channel extending along the length of the heat source through which air may be drawn through the aerosol-generating article for inhalation by a user. Such heat sources including one or more longitudinal airflow channels are referred to herein as“non-blind” heat sources.

In consumable articles in accordance with the present invention the“aerosol-generating substrate” is a substrate capable of releasing upon heating volatile compounds, which can form an aerosol. The aerosols generated from aerosol-generating substrates of aerosol-generating articles according to the invention may be visible or invisible and may include vapours (for example, fine particles of substances, which are in a gaseous state, that are ordinarily liquid or solid at room temperature) as well as gases and liquid droplets of condensed vapours.

The aerosol-generating substrate may be a solid aerosol-generating substrate. Alternatively, the aerosol-generating substrate may comprise both solid and liquid components. The aerosol-generating substrate may comprise a tobacco-containing material containing volatile tobacco flavour compounds, which are released from the substrate upon heating. Alternatively, the aerosol-generating substrate may comprise a non-tobacco material. The aerosol-generating substrate may further comprise one or more aerosol formers. Examples of suitable aerosol formers include, but are not limited to, glycerine and propylene glycol.

In some embodiments, the aerosol-generating substrate is a rod comprising a tobacco- containing material. If the aerosol-generating substrate is a solid aerosol-generating substrate, the solid aerosol-generating substrate may comprise, for example, one or more of: powder, granules, pellets, shreds, spaghetti strands, strips or sheets containing one or more of: herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted tobacco, homogenised tobacco, extruded tobacco and expanded tobacco. The solid aerosol-generating substrate may be in loose form, or may be provided in a suitable container or cartridge. For example, the aerosol-generating material of the solid aerosol-generating substrate may be contained within a paper or other wrapper and have the form of a plug. Where an aerosol-generating substrate is in the form of a plug, the entire plug including any wrapper is considered to be the aerosol-generating substrate.

Optionally, the solid aerosol-generating substrate may contain additional tobacco or non tobacco volatile flavour compounds, to be released upon heating of the solid aerosol-generating substrate. The solid aerosol-generating substrate may also contain capsules that, for example, include the additional tobacco or non-tobacco volatile flavour compounds and such capsules may melt during heating of the solid aerosol-generating substrate.

Optionally, the solid aerosol-generating substrate may be provided on or embedded in a thermally stable carrier. The carrier may take the form of powder, granules, pellets, shreds, spaghetti strands, strips or sheets. The solid aerosol-generating substrate may be deposited on the surface of the carrier in the form of, for example, a sheet, foam, gel or slurry. The solid aerosol-generating substrate may be deposited on the entire surface of the carrier, or alternatively, may be deposited in a pattern in order to provide a non-uniform flavour delivery during use.

The aerosol-generating substrate may be in the form of a plug or segment comprising a material capable of emitting volatile compounds in response to heating circumscribed by a paper or other wrapper. As stated above, where an aerosol-generating substrate is in the form of such a plug or segment, the entire plug or segment including any wrapper is considered to be the aerosol-generating substrate.

The aerosol-generating substrate preferably has a length of between about 5 mm and about 20 mm. In certain embodiments, the aerosol-generating substrate may have a length of between about 6 mm and about 15 mm or a length of between about 7 mm and about 12 mm.

In preferred embodiments, the aerosol-generating substrate comprises a plug of tobacco- based material wrapped in a plug wrap. In particularly preferred embodiments, the aerosol generating substrate comprises a plug of homogenised tobacco-based material wrapped in a plug wrap.

Aerosol-generating articles included in consumable articles according to the invention may comprise a heat-conducting element around and in direct contact with both at least a rear portion of the combustible heat source and at least a front portion of the aerosol-generating substrate. In such embodiments, the heat-conducting element provides a thermal link between the combustible heat source and the aerosol-generating substrate of such aerosol-generating articles and thus advantageously helps to facilitate adequate heat transfer from the combustible heat source to the aerosol-generating substrate to provide an acceptable aerosol.

Alternatively or in addition, the aerosol-generating articles may comprise a heat-conducting element spaced apart from one or both of the combustible heat source and the aerosol-generating substrate, such that there is no direct contact between the heat-conducting element and one or both of the combustible heat source and the aerosol-generating substrate.

Where the aerosol-generating article comprises a heat-conducting element around at least a rear portion of the combustible heat source and at least a front portion of the aerosol-generating substrate, the heat-conducting element may be formed by at least one sheet of the gripping means. Alternatively, or in addition, the at least one sheet of the gripping means may be provided on an inner surface of the heat-conducting element so that the at least one sheet is fixed to the wrapper via the heat-conducting element.

The one or more heat-conducting elements are preferably non-combustible. In certain embodiments, the one or more heat conducting elements may be oxygen restricting. In other words, the one or more heat-conducting elements may inhibit or resist the passage of oxygen through the heat-conducting element.

Suitable heat-conducting elements for use in aerosol-generating articles included in consumable articles according to the invention include, but are not limited to: metal foil wrappers such as, for example, aluminium foil wrappers, steel wrappers, iron foil wrappers and copper foil wrappers; and metal alloy foil wrappers.

The aerosol-generating articles may further comprise a cap configured to at least partially cover the front end face of the combustible heat source, wherein the cap is removable to expose the front end face of the combustible heat source prior to use of the aerosol-generating article.

As used herein, the term“cap” refers to a protective cover that substantially surrounds the distal end of the aerosol-generating article, including the front end face. Providing a cap that is removed prior to ignition of the aerosol-generating article advantageously protects the combustible heat source prior to use.

For example, the aerosol-generating articles may comprise a removable cap attached at a line of weakness to the distal end of the aerosol-generating article, wherein the cap comprises a cylindrical plug of material circumscribed by a wrapper as described in WO-A1 -2014/086998. The aerosol-generating articles preferably comprise a mouthpiece located at the proximal end thereof.

Preferably, the mouthpiece is of low filtration efficiency, more preferably of very low filtration efficiency. The mouthpiece may be a single segment or component mouthpiece. Alternatively, the mouthpiece may be a multi-segment or multi-component mouthpiece.

The mouthpiece may comprise a filter comprising one or more segments comprising suitable known filtration materials. Suitable filtration materials are known in the art and include, but are not limited to, cellulose acetate and paper. Alternatively or in addition, the mouthpiece may comprise one or more segments comprising absorbents, adsorbents, flavourants, and other aerosol modifiers and additives or combinations thereof.

The aerosol-generating article may comprise a transfer element, or spacer element, between the aerosol-generating substrate and the mouthpiece. Such an element may take the form of a hollow tube that is located downstream of an aerosol-generating substrate.

The transfer element may abut one or both of the aerosol-generating substrate and the mouthpiece. Alternatively, the transfer element may be spaced apart from one or both of the aerosol-generating substrate and the mouthpiece.

The inclusion of a transfer element advantageously allows cooling of the aerosol generated by heat transfer from the combustible carbonaceous heat source to the aerosol-generating substrate. The inclusion of a transfer element also advantageously allows the overall length of the aerosol-generating article to be adjusted to a desired value, for example to a length similar to that of a conventional cigarette, through an appropriate choice of the length of the transfer element.

The transfer element may have a length of between about 7 mm and about 50 mm, for example a length of between about 10 mm and about 45 mm or of between about 15 mm and about 30 mm. The transfer element may have other lengths depending upon the desired overall length of the aerosol-generating article, and the presence and length of other components within the aerosol-generating article.

Preferably, the transfer element comprises at least one open-ended tubular hollow body. In such embodiments, in use, air drawn into the aerosol-generating article passes through the at least one open-ended tubular hollow body as it passes downstream through the aerosol generating article from the aerosol-forming substrate to the mouthpiece.

The transfer element may comprise at least one open-ended tubular hollow body formed from one or more suitable materials that are substantially thermally stable at the temperature of the aerosol generated by the transfer of heat from the combustible carbonaceous heat source to the aerosol-generating substrate. Suitable materials are known in the art and include, but are not limited to, paper, cardboard, plastics, such a cellulose acetate, ceramics and combinations thereof.

Alternatively or in addition, aerosol-generating articles according to the invention may comprise an aerosol-cooling element or heat exchanger between the aerosol-generating substrate and the mouthpiece. The aerosol-cooling element may comprise a plurality of longitudinally extending channels.

The aerosol-cooling element may comprise a gathered sheet of material selected from the group consisting of metallic foil, polymeric material, and substantially non-porous paper or cardboard. In certain embodiments, the aerosol-cooling element may comprise a gathered sheet of material selected from the group consisting of polyethylene (PE), polypropylene (PP), polyvinylchloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), cellulose acetate (CA), and aluminium foil.

In certain preferred embodiments, the aerosol-cooling element may comprise a gathered sheet of biodegradable polymeric material, such as polylactic acid (PLA) or a grade of Mater- Bi® (a commercially available family of starch based copolyesters).

Aerosol-generating articles according to the invention comprise a wrapper that circumscribes the aerosol-forming substrate and at least a rear portion of the combustible heat source. In preferred embodiments, the aerosol-generating articles included in the consumable articles of the present invention comprise an outer wrapper that circumscribes the aerosol generating substrate, at least a rear portion of the combustible carbonaceous heat source and any other components of the aerosol-generating article downstream of the aerosol-generating substrate.

The aerosol-generating may comprise outer wrappers formed from any suitable material or combination of materials. Suitable materials are well known in the art and include, but are not limited to, cigarette paper. Alternatively or in addition, the mouthpiece may be circumscribed by tipping paper. The aerosol-generating article may be substantially cylindrical in shape. The aerosol generating article may be substantially elongate. The aerosol-generating article has a length and a circumference substantially perpendicular to the length.

The aerosol-forming substrate may be substantially cylindrical in shape. The aerosol generating substrate may be substantially elongate. The aerosol-generating substrate also has a length and a circumference substantially perpendicular to the length. The aerosol-generating substrate may be located in the aerosol-generating article such that the length of the aerosol generating substrate is substantially parallel to the airflow direction in the aerosol-generating article.

The rod of aerosol-generating substrate may be formed from randomly oriented shreds, strands, or strips of tobacco material. Preferably, the rod of aerosol-generating substrate is formed from a gathered sheet of homogenised tobacco material. One such rod of aerosol generating substrate is known from WO-A-2012/164009 and has a longitudinal porosity that allows air to be drawn through the rod. Effectively, folds in the gathered sheets of tobacco material define longitudinal channels through the rod. International patent application WO-A-201 1/101 164 discloses alternative rods for heated aerosol-generating articles formed from strands of homogenised tobacco material, which may be formed by casting, rolling, calendering or extruding a mixture comprising particulate tobacco and at least one aerosol former to form a sheet of homogenised tobacco material. In an alternative embodiment, the rods of WO-A-201 1/101 164 may be formed from strands of homogenised tobacco material obtained by extruding a mixture comprising particulate tobacco and at least one aerosol former to form continuous lengths of homogenised tobacco material.

Aerosol-generating articles included in the consumable articles according to the invention may have any desired length. For example, aerosol-generating articles according to the invention may have a total length of between approximately 65 mm and approximately 100 mm.

Aerosol-generating articles included in the consumable articles according to the invention may have any desired external diameter. For example, aerosol-generating articles according to the invention may have an external diameter of between approximately 5 mm and approximately 12 mm. Aerosol-generating articles included in the consumable articles according to the invention may be assembled using known methods and machinery.

The consumable articles according to the present invention comprise individually wrapped aerosol-generating articles. Each individual wrapper circumscribing a single aerosol-generating article comprises a first and a second line of weakness extending circumferentially about a longitudinal axis of the consumable article at two distinct locations along the length of the consumable article. Thus, an upstream end portion and a downstream end portion of the individual wrapper are separable along a respective one of the first and second lines of weakness from an intermediate portion of the individual wrapper extending between the first and the second lines of weakness. Upon separation of the upstream end portion and downstream end portion, the intermediate portion of the individual wrapper becomes longitudinally slidable over an outer surface of the aerosol-generating article.

Preferably an inner diameter of the intermediate portion of the individual wrapper is less than about 1 10 percent of an outer diameter of the aerosol-generating article. This is advantageous in that it is less likely that the intermediate portion of the individual wrapper can slip off the aerosol-generating article during use. In general, a tightly wrapped individual wrapper is preferable because it can more effectively cut off the supply of oxygen to the combustible heat source when extinguishing the aerosol-generating article. Even more preferably, an inner diameter of the intermediate portion of the individual wrapper is less than about 105 percent of an outer diameter of the aerosol-generating article.

In addition, or as an alternative, an inner diameter of the intermediate portion of the individual wrapper is at least about 101 percent of an outer diameter of the aerosol-generating article. Even more preferably, an inner diameter of the intermediate portion of the individual wrapper is at least about 103 percent of the intermediate portion of the aerosol-generating article. This advantageously ensures that the user can easily slide the intermediate portion along the aerosol-generating article when the time comes to extinguish the combustible heat source.

Preferably the individual wrapper is formed from a packaging material having dead-fold properties. As used herein, the term“dead-fold” denotes the property of a packaging material that is capable of being folded upon itself or wrapped about an item and to retain the fold, without spontaneously unfolding or unwrapping. By contrast, a packaging material that does not have dead-fold properties is one that, once folded or wrapped about an item, tends to quickly spring back and to revert towards its original, unfolded state. Conventional plastic food wraps, for example, display poor dead-fold characteristics in that, after being shaped about an item, they tend to rapidly unfold or unwrap.

Even more preferably, the individual wrapper is formed from a packaging material further displaying twist retention properties. As used herein, the term “twist retention” denotes the property of a packaging material that is capable of being twisted upon itself or when wrapped about an item, and to retain the twisted shape. By contrast, a packaging material that does not have good twist retention properties is one that, once twisted, has a tendency to untwist once released. Typical plastic food wraps are examples of poor twist retention.

Preferably, the individual wrapper is formed from a sufficiently heat resistant packaging material capable of withstanding the temperatures generally reached in operation by the combustible heat source.

In preferred embodiments, the individual wrapper is formed from a laminate packaging material comprising a layer of a metallic foil. More preferably, the layer of metallic foil is a layer of aluminium foil. The laminate packaging material preferably further comprises a printable outer layer. In preferred embodiments, the printable outer layer comprises polypropylene (PP) or polyethylene (PE). In some particularly preferred embodiments, the laminate packaging material further comprises an inner layer comprising a fire-retardant material. Multi-layer laminate packaging materials as described above advantageously combine very good dead-fold and twist retention properties with highly desirable heat resistance. This makes them particularly suitable for manufacturing the individual wrapper for use in consumable articles in accordance with the invention.

Preferably, a distance between the first and the second lines of weakness is at least about 30 percent of a length of the aerosol-generating article. More preferably, a distance between the first and the second lines of weakness is at least about 40 percent of a length of the aerosol generating article. Even more preferably, a distance between the first and the second lines of weakness is at least about 50 percent of a length of the aerosol-generating article.

In addition, or as an alternative, a distance between the first and the second line of weakness is less than about 80 percent of a length of the aerosol-generating article. More preferably, distance between the first and the second line of weakness is less than about 70 percent of a length of the aerosol-generating article. Even more preferably, distance between the first and the second line of weakness is less than about 60 percent of a length of the aerosol generating article.

In preferred embodiments, a distance between the first and the second line of weakness is at least about 3 times a length of the combustible heat source. More preferably, a distance between the first and the second line of weakness is at least about 4 times a length of the combustible heat source. Even more preferably, a distance between the first and the second line of weakness is at least about 5 times a length of the combustible heat source.

In addition, or as an alternative, a distance between the first and the second line of weakness is less than about 10 times a length of the combustible heat source.

Preferably, a distance between the downstream end of the aerosol-generating article and the most downstream of the first and the second lines of weakness is at least about 15 millimetres. More preferably, a distance between the downstream end of the aerosol-generating article and the most downstream of the first and the second lines of weakness is at least about 17 millimetres. Even more preferably, a distance between the downstream end of the aerosol-generating article and the most downstream of the first and the second lines of weakness is at least about 20 millimetres. This advantageously reduces the risk that the intermediate portion of the individual wrapper may obstruct any optionally present ventilation apertures in the aerosol-generating article. Further, it is less likely that, during use, the lips of the consumer may contact the intermediate portion of the individual wrapper.

In addition, or as an alternative, a distance between the downstream end of the aerosol generating article and the most downstream of the first and the second lines of weakness is preferably less than about 35 millimetres. More preferably, a distance between the downstream end of the aerosol-generating article and the most downstream of the first and the second lines of weakness is preferably less than about 30 millimetres.

Preferably, the individual wrapper comprises an upstream seal and a downstream seal. A sealed condition of the individual wrapper is appreciated by consumers as proof that the aerosol-generating article inside the wrapper is preserved in its original form until the consumer removes the ends of the individual wrapper to use the aerosol-generating article.

In some embodiments, the intermediate portion of the individual wrapper comprises a third and a fourth line of weakness substantially parallel to the first and the second lines of weakness and extending circumferentially about a longitudinal axis of the consumable article at two distinct locations along the length of the intermediate portion of the individual wrapper. Thus, the first and third lines of weakness and the second and fourth lines of weakness, respectively, define integral tear tapes in the individual wrapper for separating the upstream end portion and the downstream end portion from a core section of the intermediate portion of the individual wrapper. Thus, it is particularly easy for the consumer to separate the ends of the individual wrapper from the core section of the intermediate portion, the core section being thus slidable longitudinally towards the combustible heat source for extinguishment purposes, as described above in connection with the intermediate portion of the individual wrapper.

In some preferred embodiments, in a consumable article according to the invention the intermediate portion of the individual wrapper is affixed to the aerosol-generating article by a non permanent adhesive provided on the inner surface of the individual wrapper or on the outer surface of the aerosol-generating article or both at a location along the length of the intermediate portion of the individual wrapper.

In more detail, the consumable article may comprise a single dot of non-permanent adhesive at a location along the length of the intermediate portion of the individual wrapper. As an alternative, the consumable article may comprise a plurality of dots of non-permanent adhesive. In some embodiments, the dots of non-permanent adhesive are arranged about the circumference of the wrapper and the aerosol-generating article, preferably equally spaced about the circumference of the aerosol-generating article. In other embodiments, the consumable article may comprise a plurality of dots of non-permanent adhesive arranged longitudinally along the length of the intermediate portion of the individual wrapper. According to a further alternative, the non-permanent adhesive is provided over an annular portion of the surface of the aerosol generating article or of the wrapper or both.

Preferably, the non-permanent adhesive is provided at a distance of at least 5 millimetres from the most downstream one of the first and second lines of weakness. More preferably, the non-permanent adhesive is provided at a distance of at least 10 millimetres from the most downstream one of the first and second lines of weakness. Even more preferably, non-permanent adhesive is provided at a distance of at least 15 millimetres from the most downstream one of the first and second lines of weakness. In addition, or as an alternative, the non-permanent adhesive is provided at a distance of at least 5 millimetres from the most upstream one of the first and second lines of weakness.

The non-permanent adhesive may be a resealable adhesive. The term “resealable adhesive” is used herein to describe a generally low tack, removable adhesive capable of forming connection between two substrates - for example, between the individual wrapper and the aerosol-generating article - such that the two substrates can be repeatedly separated and re attached to one another. This means that, while the wrapper is secured to the aerosol-generating article prior to use, the intermediate portion of the individual wrapper may during use be detached from the underlying surface of the aerosol-generating article and moved longitudinally along the length of the aerosol-generating article to be temporarily reaffixed to the aerosol-generating article at a different location prior to being slid over the combustible heat source. This may be advantageous in that it lets the consumer decided how great a length of the downstream portion of the aerosol-generating to uncover during use. Further, when the user wishes to extinguish the aerosol-generating article, the intermediate portion of the individual wrapper can easily be detached from the aerosol-generating article and slid to envelop the combustible heat source.

In some particularly preferred embodiments, the non-permanent adhesive is a thermally deactivatable adhesive. As used herein, the term“deactivatable” is used to describe an adhesive which loses at least a significant portion of its tack or adhesion force (that is,“is deactivated”) under predetermined conditions. A“thermally deactivatable adhesive” exhibits a decrease in its adhesion force after being heated to a temperature at or above a“deactivation temperature” of the adhesive.

The "deactivation temperature" of a thermally deactivatable adhesive is the temperature at which the adhesive is deactivated, that is, the temperature at which the adhesion of the adhesive decreases significantly. In embodiments wherein deactivation is achieved over a range of temperatures, the deactivation temperature is the temperature at which the decrease in adhesion begins. In some embodiments, the deactivation temperature corresponds to the melting point of the adhesive, that is, the temperature at which the adhesive changes state from solid to liquid. Such state of matter change is accompanied by a significant decrease in the adhesion strength of the adhesive and may be optionally associated with an increase in the viscosity of the adhesive. This is typically the case with adhesives comprising crystalline polymers, for which melting is accompanied by discontinuous changes in volume and enthalpy.

In other embodiments, the deactivation temperature corresponds to a glass transition temperature of the adhesive, that is, the temperature at which the adhesive changes from a hard and relatively brittle, glassy state into a viscous, rubbery state. Glass transition is accompanied by a significant decrease in the adhesion strength of the adhesive. This is typically the case with adhesives comprising amorphous polymers, for which the glass transition is accompanied by discontinuous changes in heat capacity and in the thermal expansion coefficient. Without wishing to be bound by theory, this is understood to be related to an alteration of the rigidity of the polymer backbone.

In further embodiments, the deactivation temperature corresponds to a decomposition temperature of the adhesive, that is, the temperature at which the adhesive undergoes a degradation process typically accompanied by weight loss due to loss of moisture or of other groups loosely bonded to the main polymeric backbone, pyrolysis or other reactions.

The term“adhesion force” as used herein refers to the ability of an adhesive to stick to a surface and bond two surfaces together. It is measured by assessing the minimum tensile stress needed to detach or unstick two strips of paper adhered to one another by adhesive provided along a transverse line running across the width of both strips. An increasing traction (dynamic load) is applied on the strips of paper at room temperature and the tensile stress under which the two strips of paper are separated without fibre tear is taken as the“adhesion force”.

The same set-up may be used for determining the deactivation temperature. A predetermined load lower than the adhesion force at room temperature is applied to the strips of paper and temperature is increased until the predetermined load becomes sufficient for separated the strips of paper. The temperature at which the strips of paper are separated is taken as the “deactivation temperature”.

Providing the non-permanent adhesive as a thermally deactivatable adhesive has the advantage that the structural connection between the intermediate portion of the individual wrapper, which is ensured by the adhesive prior to use, is effectively eliminated during use due to the generation of heat that is associated with the use of the aerosol-generating article. Thus, when the user wishes to extinguish the aerosol-generating article, the intermediate portion of the individual wrapper is free to slide along the aerosol-generating article to envelop the combustible heat source.

A consumable article as described above may be manufactured by a method according to another aspect of the invention, as set out above. In a first step of the method according to the invention, there is provided an array of aerosol generating articles. Each aerosol generating article in the array comprises a combustible heat source, a rod of aerosol-generating substrate downstream of the combustible heat source, and a wrapper circumscribing the rod of aerosol generating substrate and at least a downstream portion of the combustible heat source. The aerosol generating articles in the array are spaced from one another by a first distance.

In a second step, the continuous array of aerosol generating articles is wrapped with a continuous sheet of a packaging material. The sheet of packaging material comprises a plurality of lines of weakness extending perpendicular to a longitudinal axis of the array and arranged such that a first and a second line of weakness extend at two distinct locations along the length of each aerosol generating article.

In a third step, the wrapped article array is cut at an intermediate position between two consecutive aerosol generating articles to provide multiple wrapped array segments.

In a fourth step, the packaging material at the ends of each wrapped array segment is folded or twisted to provide the consumable article.

Preferably, the twisted or folded ends of the wrapped array segment are sealed to provide a sealed consumable article.

A consumable article as described above may be used by a method according to a further aspect of the invention, as set out above. In a first step the intermediate portion of the individual wrapper is slided along the aerosol-generating article, such that an upstream end of the intermediate portion projects beyond an upstream end of the aerosol-generating article. In a second step, the upstream end of the intermediate portion of the individual wrapper is twisted or folded such as to envelop the combustible heat source with the intermediate portion of the individual wrapper.

The invention will now be further described with reference to the figures in which:

Figure 1 shows a schematic perspective view of a consumable article in accordance with the present invention;

Figure 2 shows a schematic perspective view of the consumable article of Figure 1 with the upstream and downstream ends of the individual wrapper removed and ready for use;

Figure 3 shows a schematic perspective view of the consumable article of Figure 2 with the intermediate portion of the individual wrapper being used to extinguish the aerosol-generating article in accordance with the method of use of the invention.

The consumable article 10 shown in Figure 1 comprises an aerosol-generating article 20 for producing an inhalable aerosol when heated. The aerosol-generating article 20 comprises a combustible heat source 22 and a rod 24 of aerosol-generating substrate downstream of the combustible heat source. Further, the aerosol-generating article 20 comprises a wrapper circumscribing the rod 24 of aerosol-generating substrate and a downstream portion of the combustible heat source 22.

The consumable article 10 further comprises an individual wrapper 30 circumscribing the aerosol-generating article 20. The individual wrapper 30 is formed from a packaging material having dead-fold properties, such as a laminate multi-layer packaging material comprising a metallic layer (for example, a layer formed from aluminium foil).

The individual wrapper 30 comprises an upstream seal 32 and a downstream seal 34.

Further, the individual wrapper 30 comprises a first and a second line of weakness 36, 38 extending circumferentially about a longitudinal axis of the consumable article 10 at two distinct locations along the length of the consumable article 20. In the embodiment of Figure 1 , a distance between the first and the second line of weakness 36, 38 is about 70 percent of a length of the aerosol-generating article 20.

An upstream end portion 40 and a downstream end portion 42 of the individual wrapper 30 are, therefore, separable along a respective one of the first and second lines of weakness 36, 38 from an intermediate portion 44 of the individual wrapper extending between the first and the second lines of weakness 36, 38. An inner diameter of the intermediate portion 44 of the individual wrapper 30 is about 105 percent of an outer diameter of the aerosol-generating article 20.

In Figure 2, the consumable article 10 is shown after removal of the upstream end portion 40 and downstream end portion 42 of the individual wrapper 30. Thus, the intermediate portion 44 of the individual wrapper 30 defines a sleeve element that is longitudinally slidable over an outer surface of the aerosol-generating article 20. Because of its size and because of the dead fold properties of the packaging material from which the individual wrapper 30 is formed, the intermediate portion 44 is adapted to slide longitudinally along the aerosol-generating article 20, yet at the same time it advantageously displays a tendency not to slip off the aerosol-generating article 20 during use.

As shown in Figure 3, after use, the consumer can conveniently and rapidly extinguish the aerosol-generating article 20 without needing an ash-tray or the like. In order to extinguish the aerosol-generating article 20, the consumer slides the intermediate portion 44 of the individual wrapper 30 towards the upstream end of the aerosol-generating article 20, such that the intermediate portion 44 partially projects beyond the combustible heat source 22, and then folds or twists (as shown in Figure 3), the intermediate portion 44 of the individual wrapper 30 such that it envelops the combustible heat source 22.