SMOKING SUBSTITUTE CONSUMABLE

Abstract

The present disclosure provides an aerosol-forming article comprising an aerosol-forming substrate and an axially adjacent, downstream filter arrangement. In some implementations, the filter arrangement comprises an upstream filter element, an intermediate filter element and a terminal filter element. The upstream and terminal filter elements may be independently selected from a solid filter element and a hollow bore filter element. The intermediate filter element may be a hollow bore filter element having a greater bore diameter than any other hollow bore filter element in the filter arrangement.

Claims

1. An aerosol-forming article 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 the 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.

2. An article according to claim 1 wherein the article is a heat-not-burn (HNB) consumable.

3. An article according to claim 1 wherein the intermediate filter element comprises cellulose acetate or polypropylene tow.

4. An article according to claim 1 wherein the bore diameter in the intermediate filter element is greater than 3 mm.

5. An article according to claim 4 wherein the bore diameter in the intermediate filter element is greater than or equal to 5 mm.

6. An article according to claim 1 wherein the upstream filter element is a hollow bore filter element having a smaller bore diameter than the intermediate filter element.

7. An article according to claim 1 wherein the terminal filter element is a hollow bore filter element having a smaller bore diameter than the intermediate filter element.

8. An article according to claim 1 wherein both the upstream and terminal filter elements are hollow bore filter element and wherein the upstream filter element has a larger bore diameter than the terminal filter element.

9. An article according to claim 1 wherein the terminal filter element is a solid filter element.

10. A system comprising a smoking substitute article according to claim 1 and a device comprising a heating element.

11. A system according to claim 10 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.

12. A method of using the system according to claim 10, the method comprising: inserting the article into the device; and heating the article using the heating element.

13. A method according to claim 12 comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.

14. An aerosol-forming article comprising an aerosol-forming substrate and a hollow bore terminal filter element at a downstream axial end of an 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.

15. An article according to claim 14 wherein the article is a heat-not-burn (HNB) consumable.

16. An article according to claim 14 comprising a plurality of radial air flow paths circumferentially-arranged around the article.

17. An article according to claim 14 further comprising a spacer element or an aerosol-cooling element upstream and axially adjacent the terminal filter portion.

18. An article according to claim 17 wherein the or each radial air flow path is provided within the spacer/aerosol-cooling element proximal a join between the terminal filter element and the spacer/aerosol-cooling element.

19. An article according to claim 17 wherein the aerosol-forming substrate and the spacer/aerosol-cooling element are at least partly circumscribed by a wrapping layer and wherein the radial air flow path(s) are provided by one or more ventilation holes provided in the wrapping layer.

20. An article according to claim 19 wherein the terminal filter element is joined to the spacer/aerosol-cooling element by a circumscribing tipping layer that partly overlays the wrapping layer and wherein the radial air flow path(s) are provided by one or more ventilation holes provided in the tipping layer.

21. An article according to claim 20 wherein the ventilation hole(s) in the tipping layer are aligned or overlap with the ventilation hole(s) in the wrapping layer.

22. An article according to claim 17 comprising a spacer element having a tubular wall wherein the radial air flow path(s) are provided by one or more ventilation holes provided in the tubular wall of the spacer element.

23. An article according to claim 22 wherein the ventilation hole(s) in the tubular wall of the spacer element are aligned or overlap with the ventilation hole(s) in the wrapping layer and/or tipping layer.

24. A system comprising a smoking substitute article according to claim 1 and a device comprising a heating element.

25. A system according to claim 24 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.

26. A method of using the system according to claim 24, the method comprising: inserting the article into the device; and heating the article using the heating element.

27. A method according to claim 26 comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.

28. An aerosol-forming article 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.

29. An article according to claim 28 wherein the article is a heat not burn consumable.

30. An article according to claim 28 wherein the spacer element is provided axially adjacent and upstream of the terminal filter element.

31. An article according to claim 28 wherein further comprising an upstream filter element and wherein the spacer element may be provided between the terminal filter element and the upstream filter element.

32. An article according to claim 28 wherein the spacer element is a tubular spacer element.

33. An article according to claim 32 wherein the spacer element comprises a tube formed of cardboard or extruded plastic material.

34. An article according to claim 28 wherein the heat reflective material is a metallic foil.

35. A system comprising an article according to claim 28 and a device comprising a heating element.

36. A system according to claim 35, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.

37. A method of using the system according to claim 35, the method comprising: inserting the article into the device; and heating the article using the heating element.

38. A method according to claim 37 comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.

39. A heat-not-burn (HNB) consumable comprising: an aerosol-forming substrate; and a cooling element located downstream of the substrate, the cooling element comprising a sheet formed of a plastics material, and an additive applied to a surface of the sheet.

40. A consumable according to claim 39, wherein the plastics material comprises polylactic acid (PLA).

41. A consumable according to claim 39, wherein the additive comprises a flavourant.

42. A consumable according to claim 39, wherein the additive comprises a phase change material.

43. A consumable according to claim 39, wherein the additive is sprayed onto the surface of the sheet.

44. A consumable according to claim 39, wherein the sheet is gathered and/or crimped so as to have a generally cylindrical shape.

45. A consumable according to claim 39, further comprising a terminal hollow bore filter element at a downstream end of the consumable.

46. A consumable according to claim 45, further comprising an upstream filter element located upstream of the terminal filter element.

47. A cooling element for a heat-not-burn (HNB) consumable, the cooling element comprising a sheet formed of a plastics material, and an additive applied to a surface of the sheet.

48. A cooling element according to claim 47, wherein the plastics material comprises polylactic acid (PLA).

49. A cooling element according to claim 47, wherein the additive comprises a flavourant.

50. A cooling element according to claim 47, wherein the additive comprises a phase change material.

51. A cooling element according to claim 47, wherein the additive is sprayed or coated onto the surface of the sheet.

52. A cooling element according to claim 47, wherein the sheet is gathered and/or crimped so as to have a generally cylindrical shape.

53. A method of forming a cooling element, the method comprising: providing a sheet formed of a plastics material; applying an additive to a surface of the sheet; and gathering and/or crimping the sheet to form a cooling element.

54. A method according to claim 53, wherein the step of applying an additive to the surface of the sheet is performed separately to the step of gathering and/or crimping the sheet.

55. A method according to claim 53, wherein the step of applying the additive comprises spraying the additive onto the surface of the sheet.

56. A system comprising a consumable according claim 39, and a device comprising a heating element.

57. A system according to claim 56, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.

58. A method of using the system according to claim 56, the method comprising: inserting the article into the device; and heating the article using the heating element.

59. An aerosol-forming article comprising a cooling element, the cooling element comprising a solid body, formed of a plastics material, defining one or more bores extending through the cooling element.

60. An aerosol-forming article according to claim 59, wherein the body is one of injection moulded, extruded or additive manufactured.

61. An aerosol-forming article according to claim 59, wherein the plastics material comprises polylactic acid (PLA).

62. An aerosol-forming article according to claim 59, wherein the body is substantially tubular.

63. An aerosol-forming article according to claim 59, wherein the body defines a plurality of bores arranged in a predetermined manner.

64. An aerosol-forming article according to claim 59, wherein the cooling element comprises an additive.

65. An aerosol-forming article according to claim 59, comprising an aerosol-forming substrate, the cooling element located downstream of the aerosol-forming substrate.

66. An aerosol-forming article according to claim 64, comprising a hollow bore terminal filter element at a downstream end of the article, the cooling element located between the aerosol-forming substrate and the terminal filter.

67. A method for forming a cooling element for an aerosol-forming article, the method comprising: providing an at least partially molten plastics material; and forming the plastics material into a solid body defining one or more bores.

68. A method according to claim 67, wherein the step of forming the plastics material comprises one of injection moulding, extrusion or additive manufacturing.

69. A method according to claim 68, wherein the bores are formed in the injection moulding, extrusion, or additive manufacturing process.

70. A system comprising an aerosol-forming article according to claim 67, and a device comprising a heating element.

71. A system according to claim 70, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.

72. A method of using the system according to claim 70, the method comprising: inserting the article into the device; and heating the article using the heating element.

73. A method according to claim 72, comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.

74. An aerosol-forming article comprising an aerosol-forming substrate and a filter element wherein the article comprises at least one radial air flow path into the filter element.

75. An article according to claim 74, wherein the article is a heat-not-burn (HNB) consumable.

76. An article according to claim 74, wherein the filter element is a solid filter element.

77. An article according to claim 76, comprising a plurality of radial air flow paths circumferentially-arranged around the filter element.

78. An article according to claim 77, comprising a plurality of axially spaced, circumferentially-extending rows of radial flow paths.

79. An article according to claim 74, wherein the radial air flow path(s) is/are 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 of the aerosol-forming substrate.

80. An article according to claim 79, wherein the radial air flow path(s) is/are provided in the terminal filter element and the article further comprises an upstream filter element.

81. An article according to claim 80, wherein the terminal filter element is at least partially circumscribed by a tipping layer and the radial air flow path(s) is/are provided by one or more ventilation holes provided in the tipping layer surrounding the terminal filter element.

82. An article according to claim 80, wherein the radial air flow path(s) is/are provided by one or more radial bores extending into the terminal filter element.

83. An article according to claim 79, wherein the radial air flow path(s) is/are provided in the upstream filter element and the article further comprises a terminal filter element.

84. An article according to claim 83, wherein the upstream filter element is at least partially circumscribed by a wrapping layer and the radial air flow path(s) is/are provided by one or more ventilation holes provided in the wrapping layer surrounding the upstream filter element.

85. An article according to claim 83, wherein the radial air flow path(s) is/are provided by one or more radial bores extending into the upstream filter element.

86. An article according to claim 80, further comprising a spacer element or an aerosol-cooling element interposed between the upstream filter element and the terminal filter element.

87. An aerosol-forming article 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.

88. An article according to claim 87, wherein the article is a heat-not-burn (HNB) consumable.

89. An article according to claim 88, comprising a plurality of radial air flow paths circumferentially-arranged around the hollow bore filter element.

90. An article according to claim 89, comprising a plurality of axially spaced, circumferentially-extending rows of radial flow paths.

91. An article according to claim 87, wherein the radial air flow path(s) is/are 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 of the aerosol-forming substrate.

92. An article according to claim 91, wherein the radial air flow path(s) is/are provided in the terminal hollow bore filter element and the article further comprises an upstream hollow bore filter element.

93. An article according to claim 92, wherein the terminal filter element is at least partially circumscribed by a tipping layer and the radial air flow path(s) is/are provided by one or more ventilation holes provided in the tipping layer surrounding the terminal hollow bore filter element.

94. An article according to claim 92, wherein the radial air flow path(s) is/are provided by one or more radial bores extending into the terminal hollow bore filter element.

95. An article according to claim 91, wherein the radial air flow path(s) is/are provided in the upstream hollow bore filter element and the article further comprises a terminal hollow bore filter element.

96. An article according to claim 95, wherein the upstream filter element is at least partially circumscribed by a wrapping layer and the radial air flow path(s) is/are provided by one or more ventilation holes provided in the wrapping layer surrounding the upstream hollow bore filter element.

97. An article according to claim 95, wherein the radial air flow path(s) is/are provided by one or more radial bores extending into the upstream hollow bore filter element.

98. An article according to claim 92, further comprising a spacer element or an aerosol-cooling element interposed between the upstream filter element and the terminal filter element.

99. A system comprising a smoking substitute article according to claim 87, and a device comprising a heating element.

100. A system according to claim 99, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.

101. A method of using the system according to claim 99, the method comprising: inserting the article into the device; and heating the article using the heating element.

102. A method according to claim 101, comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.

103. A filter element for an aerosol-forming article, the filter element comprising at least one radial bore.

104. A filter element for an aerosol-forming article, the filter element comprising an axial bore and at least one radial bore.

105. An aerosol-forming article comprising an aerosol-forming substrate and a downstream cooling element formed of a granular or foamed plastics material.

106. An article according to claim 105, wherein the article is a HNB consumable.

107. An article according to claim 105, wherein the plastics material comprises polylactic acid (PLA).

108. An article according to claim 105, wherein the granular plastics material is combined to form a unitary structure or contained within a containment sleeve.

109. An article according to claim 105, wherein the foamed plastic material is an open cell foam.

110. An article according to claim 105, wherein the cooling element further comprises a flavourant additive.

111. An article according to claim 105, wherein the cooling element comprises an axially-extending bore.

112. An article according to claim 105, further comprising a terminal hollow bore filter element at a downstream end of the article.

113. An article according to claim 105, further comprising an upstream filter element located upstream of cooling element.

114. An article according to claim 105, comprising a terminal filter element and an upstream filter element axially spaced by the cooling element.

115. A system comprising an article according to claim 105, and a device comprising a heating element.

116. A system according to claim 115, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.

117. A method of using the system according to claim 115, the method comprising: inserting the article into the device; and heating the article using the heating element.

118. A method according to claim 117, comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.

Description

SUMMARY OF THE FIGURES

[0455] 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:

[0456] FIG. 1 shows a first embodiment of a first mode of an HNB consumable;

[0457] FIG. 2 shows a second embodiment of the first mode of an HNB consumable

[0458] FIG. 3 shows a third embodiment of the first mode of an HNB consumable;

[0459] FIG. 4 shows the first embodiment of the first mode within a device forming an HNB system;

[0460] FIG. 5 shows a first embodiment of a second mode of an HNB consumable;

[0461] FIG. 6 shows a second embodiment of the second mode of an HNB consumable;

[0462] FIG. 7 shows a third embodiment of the second mode of an HNB consumable;

[0463] FIG. 8 shows the first embodiment of the second mode within a device forming an HNB system;

[0464] FIG. 9 shows a first embodiment of a third mode of an HNB consumable;

[0465] FIG. 10 shows a second embodiment of the third mode of an HNB consumable;

[0466] FIG. 11 shows a third embodiment of the third mode of an HNB consumable;

[0467] FIG. 12 shows the first embodiment of the third mode within a device forming an HNB system.

[0468] FIG. 13 shows a first embodiment of a fourth mode of an HNB consumable;

[0469] FIG. 14 shows a second embodiment of the fourth mode an HNB consumable

[0470] FIG. 15 shows a third embodiment of the fourth mode an HNB consumable;

[0471] FIG. 16 shows the first embodiment of the fourth mode of FIG. 13 within a device forming an HNB system.

[0472] FIG. 17 shows a first embodiment of the fifth mode of an HNB consumable;

[0473] FIG. 18 shows a second embodiment of the fifth mode of an HNB consumable

[0474] FIG. 19 shows a third embodiment of the fifth mode of an HNB consumable;

[0475] FIG. 20 shows the first embodiment of the fifth mode of FIG. 17 within a device forming an HNB system.

[0476] FIG. 21 shows a first embodiment of a sixth mode of an HNB consumable;

[0477] FIG. 22 shows a second embodiment of the sixth mode of an HNB consumable;

[0478] FIG. 23 shows a third embodiment of the sixth mode of an HNB consumable;

[0479] FIG. 24 shows the first embodiment of the sixth mode of FIG. 21 within a device forming an HNB system;

[0480] FIG. 25 shows a fourth embodiment of the sixth mode of an HNB consumable;

[0481] FIG. 26 shows a fifth embodiment of the sixth mode of an HNB consumable;

[0482] FIG. 27 shows a sixth embodiment of the sixth mode of an HNB consumable;

[0483] FIG. 28 shows the fourth embodiment of the sixth mode of FIG. 25 within a device forming an HNB system.

[0484] FIG. 29 shows a first embodiment of a seventh mode of an HNB consumable;

[0485] FIG. 30 shows a second embodiment of the seventh mode of an HNB consumable

[0486] FIG. 31 shows a third embodiment of the seventh mode of an HNB consumable;

[0487] FIG. 32 shows the first embodiment of the seventh mode within a device forming an HNB system.

DETAILED DESCRIPTION OF THE FIGURES

[0488] First Mode of the Disclosure:

[0489] As shown in FIG. 1, the HNB consumable 1 comprises an aerosol-forming substrate 2 at the upstream end of the consumable 1.

[0490] The aerosol-forming substrate comprises reconstituted tobacco which includes nicotine as a volatile compound.

[0491] 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.

[0492] 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.

[0493] The aerosol-forming substrate 2 is circumscribed by a paper wrapping layer 3.

[0494] 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).

[0495] 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.

[0496] 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.

[0497] 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.

[0498] The intermediate hollow bore filter element 6 has the largest bore diameter at around 5 or 6 mm.

[0499] The upstream filter element 4 and intermediate filter element 6 are circumscribed by the wrapping layer 3.

[0500] 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.

[0501] 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.

[0502] 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.

[0503] 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.

[0504] 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.

[0505] 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.

[0506] Second Mode of the Disclosure

[0507] As shown in FIG. 5, the HNB consumable 1a comprises an aerosol-forming substrate 2a at the upstream end of the consumable 1a.

[0508] The aerosol-forming substrate comprises reconstituted tobacco which includes nicotine as a volatile compound.

[0509] 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.

[0510] 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.

[0511] The aerosol-forming substrate 2a is circumscribed by a paper wrapping layer 3a.

[0512] 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).

[0513] 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.

[0514] The cardboard tube spacer is longer than each of the two filter elements having an axial length of around 14 mm.

[0515] 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.

[0516] The cardboard tube spacer 6a and the upstream filter element 4a are circumscribed by the wrapping layer 3a.

[0517] 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.

[0518] 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.

[0519] 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.

[0520] 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.

[0521] 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.

[0522] 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.

[0523] 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.

[0524] 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.

[0525] Third Mode of the Disclosure:

[0526] As shown in FIG. 9, the HNB consumable 1b comprises an aerosol-forming substrate 2b at the upstream end of the consumable 1b.

[0527] The aerosol-forming substrate comprises reconstituted tobacco which includes nicotine as a volatile compound.

[0528] 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.

[0529] 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.

[0530] The aerosol-forming substrate 2b is circumscribed by a paper wrapping layer 3b.

[0531] The consumable 1b comprises an upstream filter element 4b and a downstream (terminal) filter element 5b.

[0532] 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).

[0533] 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.

[0534] 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.

[0535] 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.

[0536] The cardboard tube spacer 6b and the upstream filter element 4b are circumscribed by the wrapping layer 3b.

[0537] 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.

[0538] 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.

[0539] 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.

[0540] 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.

[0541] 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.

[0542] 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.

[0543] Fourth Mode of the Disclosure

[0544] As shown in FIG. 13, the HNB consumable 1c comprises an aerosol-forming substrate 2c at the upstream end of the consumable 1c.

[0545] The aerosol-forming substrate 2c comprises reconstituted tobacco which includes nicotine as a volatile compound.

[0546] 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.

[0547] 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.

[0548] The aerosol-forming substrate 2c is circumscribed by a paper wrapping layer 3c.

[0549] 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).

[0550] 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.

[0551] 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.

[0552] 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.

[0553] 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.

[0554] The additive (applied to the surface of the sheet) comprises a flavourant e.g., menthol or a phase change material e.g., eicosane.

[0555] 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.

[0556] 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.

[0557] 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.

[0558] 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.

[0559] 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.

[0560] 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.

[0561] 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.

[0562] 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.

[0563] Fifth Mode of the Disclosure

[0564] As shown in FIG. 17, the HNB consumable 1d comprises an aerosol-forming substrate 2d at the upstream end of the consumable 1d.

[0565] The aerosol-forming substrate 2d comprises reconstituted tobacco which includes nicotine as a volatile compound.

[0566] 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.

[0567] 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.

[0568] The aerosol-forming substrate 2d is circumscribed by a paper wrapping layer 3d.

[0569] 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).

[0570] 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.

[0571] 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.

[0572] 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.

[0573] The cooling element 6d and the upstream filter element 4d are circumscribed by the wrapping layer 3d.

[0574] 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.

[0575] 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.

[0576] 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.

[0577] 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.

[0578] 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.

[0579] 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.

[0580] 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.

[0581] 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.

[0582] 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.

[0583] Sixth Mode of the Disclosure

[0584] As shown in FIG. 21, the HNB consumable 1e comprises an aerosol-forming substrate 2e at the upstream end of the consumable 1e.

[0585] The aerosol-forming substrate 2e comprises reconstituted tobacco which includes nicotine as a volatile compound.

[0586] 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.

[0587] 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.

[0588] The aerosol-forming substrate 2e is circumscribed by a paper wrapping layer 3e.

[0589] 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).

[0590] 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.

[0591] The cardboard tube spacer 6e is longer than each of the two filter elements 4e, 5e having an axial length of around 14 mm.

[0592] 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.

[0593] The cardboard tube spacer 6e and the upstream filter element 4e are circumscribed by the wrapping layer 3e.

[0594] 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.

[0595] 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.

[0596] 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.

[0597] 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.

[0598] 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.

[0599] 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.

[0600] 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.

[0601] 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.

[0602] 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.

[0603] The aerosol-forming substrate 2e comprises reconstituted tobacco which includes nicotine as a volatile compound.

[0604] 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.

[0605] 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.

[0606] The aerosol-forming substrate 2e is circumscribed by a paper wrapping layer 3e.

[0607] 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).

[0608] 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.

[0609] The cardboard tube spacer is longer than each of the two filter elements 4e, 5e having an axial length of around 14 mm.

[0610] 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.

[0611] The cardboard tube spacer 6e and the upstream filter element 4e are circumscribed by the wrapping layer 3e.

[0612] 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.

[0613] 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.

[0614] 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.

[0615] 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.

[0616] 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.

[0617] 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.

[0618] 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.

[0619] 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.

[0620] Seventh Mode of the Present Disclosure

[0621] As shown in FIG. 29, the HNB consumable 1f comprises an aerosol-forming substrate 2f at the upstream end of the consumable 1f.

[0622] The aerosol-forming substrate 2f comprises reconstituted tobacco which includes nicotine as a volatile compound.

[0623] 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.

[0624] 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.

[0625] The aerosol-forming substrate 2f is circumscribed by a paper wrapping layer 3f.

[0626] 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).

[0627] 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.

[0628] 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.

[0629] 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.

[0630] The cooling element 6f and the upstream filter element 4f are circumscribed by the wrapping layer 3f.

[0631] 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.

[0632] 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′.

[0633] 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.

[0634] 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′

[0635] 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.

[0636] 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.

[0637] 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.

[0638] 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.

[0639] 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.

[0640] 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.

[0641] 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.

[0642] 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.

[0643] Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

[0644] 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.

[0645] 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%.

[0646] 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.