A consumable for use in an aerosol provision system

Abstract

The present disclosure relates to a consumable (1) for use in an aerosol provision system. The consumable (1) comprises one or more pouches comprising first and second aerosol generating materials (4, 5). The second aerosol generating material (4, 5) has a higher density than the first aerosol generating material (4). The present disclosure also relates to a method of manufacturing a consumable (1), a kit of parts comprising a consumable (1) and an aerosol provision device, and to a package of consumables (1).

1 . A consumable for use in an aerosol provision system, wherein the consumable comprises one or more pouches comprising first and second aerosol generating materials, wherein the second aerosol generating material has a higher density than the first aerosol generating material. 
     
     
         2 . A consumable according to  claim 1 , wherein the or each pouch comprises a sheet material. 
     
     
         3 . A consumable according to  claim 1 or claim 2 , wherein the sheet material comprises paper. 
     
     
         4 . A consumable according to  claim 2 or claim 3 , wherein the sheet material has a thickness in the range of 20 to 100 microns and, preferably, in the range of 30 to 80 microns, 35 to 55 microns or 40 to 50 microns. 
     
     
         5 . A consumable according to  any one of the preceding claims , wherein the sheet material is gas permeable. 
     
     
         6 . A consumable according to  claim 5 , wherein the sheet material has a permeability in the range of 10 TO 25000 Coresta Units and, optionally, has a permeability in the range of 25 to 100 Coresta Units. 
     
     
         7 . A consumable according to any one of  claims 2 to 6 , wherein the sheet material is folded and/or wrapped to form the or each pouch. 
     
     
         8 . A consumable according to any one of  claims 2 to 7 , wherein at least one edge of the sheet material is attached to another portion of the sheet material to retain the first and/or second aerosol generating materials within the or each pouch. 
     
     
         9 . A consumable according to any one of  claims 2 to 8 , wherein the or each pouch is formed from a single piece of sheet material. 
     
     
         10 . A consumable according to any one of  claims 2 to 9 , wherein the or each pouch is formed from two or more pieces of sheet material that are joined together. 
     
     
         11 . A consumable according to any one of  claims 2 to 10 , wherein the sheet material of the or each pouch completely envelopes the aerosol generating material contained in the pouch. 
     
     
         12 . A consumable according to  any one of the preceding claims , wherein the or each pouch forms an exterior surface of the consumable. 
     
     
         13 . A consumable according to  any one of the preceding claims , wherein the first and/or second aerosol generating material is a loose material. 
     
     
         14 . A consumable according to  any one of the preceding claims , wherein the second aerosol generating material comprises extruded and/or compressed aerosol generating material. 
     
     
         15 . A consumable according to  any one of the preceding claims , wherein the second aerosol generating material comprises beads. 
     
     
         16 . A consumable according to  claim 12 , wherein the beads have a diameter in the range of 0.5 to 3 mm and, preferably, in the range of 1 to 2 mm. 
     
     
         17 . A consumable according to  any one of the preceding claims , wherein the first aerosol generating material comprises, consists of, or essentially consists of tobacco material. 
     
     
         18 . A consumable according to  claim 17 , wherein the tobacco material of the first aerosol generating material is derived only from tobacco lamina and no other types of tobacco material. 
     
     
         19 . A consumable according to  claim 17 , wherein the first aerosol generating material comprises tobacco lamina and reconstituted tobacco. 
     
     
         20 . A consumable according to  any one of the preceding claims , wherein the second aerosol generating material comprises, consists of, or essentially consists of tobacco material. 
     
     
         21 . A consumable according to  claim 20 , when dependent on any one of  claims 17 to 19 , wherein the first and second aerosol generating material together have an average nicotine level in the range of 0.5% to 2.5% by weight of the first and second aerosol generating material and, preferably, in the range of 1% to 2.1%. 
     
     
         22 . A consumable according to  claim 20 or claim 21 , wherein the tobacco material of the second aerosol generating material is derived from only tobacco lamina and no other types of tobacco material. 
     
     
         23 . A consumable according to any one of  claims 20 to 22  wherein the second aerosol generating material comprises lamina tobacco and/or reconstituted tobacco. 
     
     
         24 . A consumable according to  any one of the preceding claims , wherein consumable comprises in the range of about 20 to about 330 mg of the first aerosol generating material and, preferably, in the range of about 50 to about 300 mg, or about 40 to about 125 mg of the first aerosol generating material. 
     
     
         25 . A consumable according to  any one of the preceding claims , wherein consumable comprises in the range of about 20 to about 330 mg of the second aerosol generating material and, preferably, in the range of about 50 to about 300 mg, or about 40 to about 125 mg of the second aerosol generating material. 
     
     
         26 . A consumable according to  any one of the preceding claims , wherein the consumable does not comprise plastic. 
     
     
         27 . A consumable according to  any one of the preceding claims , wherein the density of the second aerosol generating material is at least 25% higher than the density of the first aerosol generating material. 
     
     
         28 . A consumable according to  any one of the preceding claims , wherein the first aerosol generating material has a density of from about 0.1 g/cm 3  to about 1 g/cm 3 . 
     
     
         29 . A consumable according to  any one of the preceding claims , wherein the second aerosol generating material has a density of from about 0.4 g/cm 3  to about 2 g/cm 3 . 
     
     
         30 . A consumable according to  any one of the preceding claims , wherein one pouch contains the first and second aerosol generating materials. 
     
     
         31 . A consumable according to  claim 30 , wherein the first and second aerosol generating materials are mixed together in said one pouch. 
     
     
         32 . A consumable according to  claim 30 , wherein the first and second aerosol generating materials are provided in discrete regions within said one pouch. 
     
     
         33 . A consumable according to any one of  claims 1 to 29 , wherein the consumable comprises a first pouch that contains the first aerosol generating material and a second pouch that contains the second aerosol generating material. 
     
     
         34 . A consumable according to  any one of the preceding claims , wherein the first and second aerosol generating materials are manufactured from the same aerosol generating starter materials that are processed to have different forms. 
     
     
         35 . A consumable according to  any one of the preceding claims , wherein the first and/or second aerosol generating materials comprises an aerosol-former material. 
     
     
         36 . A consumable according to  any one of the preceding claims , wherein the first and/or second aerosol generating material comprises: from about 10 to about 50 wt % aerosol-former material; from about 15 to about 60 wt % gelling agent; and optionally filler; wherein the wt % values are calculated on a dry weight basis. 
     
     
         37 . A consumable according to  claim 36 , wherein the first and/or second aerosol generating material comprises a flavourant. 
     
     
         38 . A method of manufacturing a consumable for use in an aerosol provision system, the method comprising:
 forming one or more pouches comprising first and second aerosol generating materials wherein the second aerosol generating material has a higher density than the first aerosol generating material.   
     
     
         39 . A method according to  claim 38 , wherein the or each pouch comprises a sheet material. 
     
     
         40 . A method according to  claim 39 , comprising forming the sheet material of the or each pouch into a tube that contains the first and/or second aerosol generating material. 
     
     
         41 . A method according to  claim 39 or 40 , comprising forming the sheet material into an arrangement that is closed at one end and open at the other end, and wherein first and/or second aerosol generating material is provided within the arrangement of the sheet material. 
     
     
         42 . A method according to  claim 41 , comprising feeding the first and/or second aerosol generating material into the arrangement under gravity. 
     
     
         43 . A method according to  claim 42 , comprising feeding a continuous stream of the first and/or second aerosol generating material into the arrangement. 
     
     
         44 . A method according to any one of  claims 41 to 43 , comprising sealing and cutting the arrangement of the sheet material at a location spaced from the closed end of the arrangement to form a pouch. 
     
     
         45 . A method according to  claim 44 , wherein the arrangement of sheet material is repeatedly sealed and cut to form a plurality of pouches. 
     
     
         46 . A method according to  claim 44 or claim 45 , wherein the arrangement of sheet material is sealed and cut simultaneously. 
     
     
         47 . A method according to any one of  claims 44 to 46 , wherein sealing the arrangement comprises manipulating the arrangement such that aerosol generating material in the arrangement is moved axially downstream and/or upstream of the portion of the arrangement being sealed. 
     
     
         48 . A method according to  claim 39 or claim 40 , comprising depositing first and/or second aerosol generating material on the sheet material and, preferably, depositing a metered amount of first and/or second aerosol generating material on the sheet material. 
     
     
         49 . A method according to any one of  claims 39 to 48 , comprising wrapping the sheet material about the first and/or second aerosol generating material. 
     
     
         50 . A method according to any one of  claims 39 to 49 , comprising attaching first and second portions of sheet material together such that the first and/or second aerosol generating material is held between the first and second portions of sheet material. 
     
     
         51 . A consumable manufactured according to the method of any one of  claims 38 to 50 . 
     
     
         52 . A package comprising a plurality of consumables according to any one of  claims 1 to 37 or 51  and, preferably, wherein the package is hermetically sealed. 
     
     
         53 . A kit of parts comprising the consumable of any one of  claims 1 to 37 or 51  and an aerosol provision device. 
     
     
         54 . A kit of parts according to  claim 53 , wherein the aerosol provision device comprises a heating zone for receiving the consumable to heat the first and second aerosol generating materials.