WO2022189551A1

WO2022189551A1 - Consumable for a vaporizer

Info

Publication number: WO2022189551A1
Application number: PCT/EP2022/056143
Authority: WO
Inventors: Thomas JOHAENTGES
Original assignee: Jt International Sa
Priority date: 2021-03-10
Filing date: 2022-03-10
Publication date: 2022-09-15
Also published as: CN117042636A; WO2022189551A9; JP2024508462A; TW202235014A; KR20230167353A; EP4304393A1; EP4304392A1; KR20230155485A; WO2022189452A1; JP2024509232A; US20240138471A1

Abstract

The present invention relates to as consumable for an aerosol generating device comprising particles of at least one electrically conductive material, at least one binding agent for binding the particles, at least one aerosol forming agent and optionally at least one flavorant material.

Description

CONSUMABLE FOR A VAPORIZER

The present invention relates to a consumable for an aerosol generating device. Furthermore, the invention relates to a method for manufacturing such a consumable and to an aerosol generating device comprising the consumable.

Many kinds of electric smoking devices are available on the market. The most popular ones are known as e-cigarettes and vaporize an e-liquid to an inhalable vapor. However, such devices are vulnerable to leakage of the e-liquid. This can be disadvantageous for users, for instance if they keep the electric smoking devices in their pockets or bags. Alternative devices with solid consumables that do not leak are available. Such devices consist in heating rather than burning a tobacco reconstituted substance wrapped in paper. However, such devices require a heater as part of the device and require a proper insulation to avoid high temperature at the surface of the device. Such devices are relatively complex to assemble and accordingly are relatively expensive.

Conventional solid consumables take a long time to heat up and it may be difficult to provide heat to the core or bulk of the material. Any heat applied to the solid consumable may char or burn the outside surface of the solid consumable, before heat arrives at the core thereof. For instance, a solid consumable can be placed as a compressed block in a vaporizer and brought to an aerosolization temperature. The aerosol will be mainly released at the surface of the block. By the time enough heat has been transported into the core of the tobacco serving to release aerosol, most of the surface will be charred.

It is an objective of the invention to provide a solid consumable for an aerosol generating device, wherein any flavorant material and/or aerosol forming agent contained in the consumable can be easily and uniformly released.

A consumable, an aerosol generating device comprising the consumable, a method for manufacturing the consumable and a method for generating an aerosol are defined in the independent claims. Preferred embodiments are defined in the dependent claims.

SHORT DESCRIPTION OF THE INVENTION A consumable for an aerosol generating device according to the invention comprises particles of at least one electrically conductive material, at least one binding agent for binding the particles, at least one aerosol forming agent and optionally at least one flavorant material.

If the consumable contains electrically conductive material, this can enable heat to be transported to the core of the consumable. Since heat can be readily transported throughout the consumable, any flavorant material and/or aerosol forming agent contained in the consumable can be easily and uniformly heated.

If the consumable is electrically conductive, it can enable operating an aerosol generating device with a rechargeable, e.g. lithium-ion, battery without requiring a heating system or lighter to be part of the device.

The particles of electrically conductive material are preferably present in an amount of 35 to 60 wt%, based on the total weight of the consumable. The binding agent and the aerosol forming agent and the optional flavorant material together are preferably present in an amount of 40 to 65 wt%, based on the total weight of the consumable.

The electrically conductive material is preferably an electrically conductive carbon- containing material, preferably selected from charcoal, activated carbon, black carbon and graphite. The particles of the electrically conductive material preferably have a particle size in the range of 1 pm to 10 mm, preferably from 10 pm to 1 mm, even more preferably from 100 pm to 500 pm.

The flavorant material preferably is derived from a plant, preferably selected from tobacco. The particles of the flavorant material are preferably tobacco particles obtained from ground tobacco leaves, pulverized tobacco leaves or flue cured tobacco (FCT). The tobacco particles preferably have a particle size in the range of 200 pm to 5 mm, preferably from 250 pm to 4.5 mm, even more preferably from 300 pm to 4 mm and even more preferably from 350 pm to 3.5 mm, an even more preferably lower than 1000 pm. The flavorant material is preferably present in an amount of 0.1 to 60 wt%, and if present without electrically conductive material is preferably present in an amount of 35 to 60 wt%, even more preferably about 45 wt% based on the total weight of the consumable. The at least one binding agent is preferably present in an amount of 0.1 to 7 wt% based on the total weight of the consumable. The at least one binding agent preferably comprises at least one of a cellulose derivative and a gum. Preferably, the cellulose derivative is selected from carboxymethyl cellulose and the gum is selected from gellan gum.

The at least one aerosol forming agent is preferably present in an amount of 5 to 70 wt% based on the total weight of the consumable. The at least one aerosol forming agent preferably is a humectant, preferably selected from glycerin, propylene glycol and an alcohol.

The consumable preferably comprises at least one of charcoal particles as electrically conductive material and tobacco particles as flavorant material, a binding agent comprising carboxymethyl cellulose and optionally gellan gum, and glycerin.

The consumable preferably is electrically conductive. The consumable preferably is configured to heat to a temperature at which at least the one of the flavorant material and the aerosol forming agent forms an aerosol. Preferably the electrical conductivity of the consumable is at least 3x10² S/m (at 20°C), preferably up to 3x10⁶ S/m (at 20°C).

The at least one binding agent and the least one aerosol forming agent preferably form a gel. Preferably, the weight ratio of gel to electrically conductive material lies between 0.01:1 to 100:1, preferably between 0.1:1 to 10:1, more preferably between 0.5:1 to 5:1, even more preferably between 0.5:1 to 1:1, and most preferably wherein the weight ratio of gel to electrically conductive material is 2:1, 1.75:1, 1.5:1, 1.25:1 or 1:1.

An aerosol generating device according to the disclosure comprises the consumable.

A method for manufacturing a consumable for a vaporizer, comprises the steps of: i) providing particles of at least one electrically conductive material and optionally a flavorant material, ii) mixing the particles and the optional flavorant material with at least one binding agent for binding the particles, at least one aerosol forming agent, and optionally water, and iii) solidifying the mixture such as by curing and/or drying. In a preferred embodiment, the particles, the binding agent, the aerosol forming agent and the optional water form a paste or dough. The paste or dough can then be pressed into a layer. This layer can then be solidified such as by curing and/or drying.

In a preferred embodiment, the binding agent, the aerosol forming agent and the optional water form a gel-forming agent. Preferably, the weight ratio of gel-forming agent to electrically conductive material lies between 0.01:1 to 100:1, preferably between 0.1:1 to 10:1, more preferably between 0.5:1 to 5:1, even more preferably between 0.5:1 to 1:1, and most preferably wherein the weight ratio of gel-forming agent to electrically conductive material is 2:1, 1.75:1, 1.5:1, 1.25:1 or 1:1.

A method of generating an aerosol, comprises the steps of: i) providing a consumable as defined herein, ii) arranging the consumable, preferably in layer form, between two electrodes of an aerosol generating device, iii) pressing the electrodes on the consumable, iv) supplying the electrodes with a current, wherein the consumable conducts the current between the electrodes, and v) heating the consumable, thereby creating an aerosol.

SHORT DESCRIPTION OF THE FIGURES

The figures show:

Fig. 1a schematic cross-sectional view of a consumable comprising electrically conductive material between two electrodes with one particle of the electrically conductive material;

Fig. 1b schematic cross-sectional view of a consumable comprising electrically conductive material between two electrodes with two touching particles of the electrically conductive material;

Fig. 1c schematic top view of a consumable comprising electrically conductive material between two electrodes;

Fig. 2 schematic view of a device for delivering aerosol with two electrodes and a consumable arranged between the electrodes;

Fig. 3 flow chart of a method for manufacturing a consumable comprising an electrically conductive material; Fig.4 flow chart of a method of aerosol production with a device comprising two electrodes and a consumable arranged between the electrodes;

Fig. 5a schematic view of a cartridge comprising a consumable arranged as a spiral;

Fig. 5b schematic view of a cartridge comprising a consumable arranged as a hyperbolic spiral;

Fig. 6 photograph of three consumables manufactured at different ratios of gel to particles,

Fig. 7 photograph of consumables including different contents of charcoal.

Unless defined otherwise, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

All values given in the present disclosure are to be understood to be complemented by the word “about”, unless it is clear to the contrary from the context.

As used herein, wt.-% is to be understood as weight percent, based on the total weight of the consumable, unless explicitly otherwise specified. In the present disclosure, furthermore all amounts given in wt.-% in a particular consumable add up to 100 wt.-%. The weight percent are thereby calculated by dividing the mass of each component by the total mass of the consumable, unless indicated otherwise or clear from context.

Further advantages, objectives and features of the present invention will be described, by way of example only, in the following description with reference to the appended figures. In the figures, like components in different embodiments can exhibit the same reference symbols.

DETAILED DESCRIPTION OF THE INVENTION

A consumable 1 for an aerosol generating device according to the invention comprises particles of at least one electrically conductive material 7, at least one binding agent for binding the particles, at least one aerosol forming agent 6, and optionally at least one flavorant material 5.

In a preferred embodiment, the consumable 1 is formed of particles of at least one electrically conductive material 7, at least one binding agent for binding the particles, and at least one aerosol forming agent 6 and optionally at least one flavorant material 5. In such an embodiment, the consumable 1 does not comprise any other carrier material, but instead its solid structure is provided by the particles the electrically conductive material 7, at least one binding agent for binding the particles, and at least one aerosol forming agent 6. In another embodiment, the consumable 1 consists of particles of at least one electrically conductive material 7, at least one binding agent for binding the particles, at least one aerosol forming agent 6, and optionally at least one flavorant material 5.

As shown in Figures 1a and 1b, a consumable 1 can be in the form of a layer 3. The shown consumable 1 comprises particles of electrically conductive material 7, particles of a flavorant material 5, and an aerosol forming agent 6. The consumable further comprises a binding agent not specifically designated in the figures. In the embodiment shown, the consumable 1 in layer form 3 is placed between two electrodes 4a, 4b of an aerosol generating device. The remaining parts shown in the Figures will be described further below.

ELECTRICALLY CONDUCTIVE CONSUMABLE

In a particularly preferred embodiment, the consumable is electrically conductive. Preferbaly, the amount of electrically conductive particles is sufficient to generate an electrically conductive consumable.

ELECTRICALLY CONDUCTIVE MATERIAL

The electrically conductive material 7 is preferably selected from nontoxic approved additives used in the tobacco industry or food industry.

In a preferred embodiment, the electrically conductive material 7 is an electrically conductive carbon-containing material. The electrically conductive carbon-containing material is preferably selected from charcoal, activated carbon, black carbon and graphite. The use of charcoal may be particularly preferred, since it provides a good electrical conductivity and flavorant materials such as tobacco materials may be absorbed or stick thereto. The charcoal can be charged with liquid materials, such as nicotine or other flavors and aerosol forming agents described below. Preferably, the charcoal is not completely filled with liquid materials, since otherwise it may become too moist and will no longer bond with the gel.

The electrically conductive material 7 is preferably present in an amount that allows current to flow through the consumable. The amount of electrically conductive material 7 in the consumable can depend on the thickness of the consumable or layer thereof. The amount of electrically conductive material 7 in the consumable can also depend on pressure applied between the electrodes 4a, 4b of an aerosol generating device. The electrically conductive material 7 is preferably present in an amount of 35-60 wt% and preferably about 45 wt% based on the total weight of the consumable. In order to ensure electrical conductivity, it can be preferable to provide the electrically conductive material 7 in the amount of 35 to 60 wt%, or even 50 to 60 wt%.

The particles of electrically conductive material 7 used to form the consumable may be provided in the form of a powder, loose particles or agglomerated particles. The particles of the electrically conductive material 7 preferably have a particle size in the range of 1 pm to 10 mm, preferably from 10 pm to 1 mm, even more preferably from 250 pm to 1000 pm, for example about 250 microns, or 300 microns, or 350 microns, or 400 microns, or 450 microns, or 500 microns, or 550 microns, or 600 microns, or 650 microns, or 700 microns, or 750 microns, or 800 microns.

The electrically conductive material 7 comprised in the consumable or in the heating layer can have an electrical conductivity in the range of 3x10² S/m and 3x10⁶ S/m (at 20°C).

The electrically conductive material 7 can be configured to conduct applied current, and due to its electrical resistance, to provide a temperature sufficient to aerosolize the aerosol forming agent 6 and/or flavorant material 5 comprised in the consumable. While the temperature depends on the specific aerosol forming agent 6 and/or flavorant material 5, the temperature provided by the may lie electrically conductive material 7 between 90 to 230°C, which are typical aerosolization temperature of aerosol forming agents 6 such as glycerin and flavorant materials 5 such as tobacco.

The electrically conductive material 7 may have a hollow structure. The hollow structure can be formed by pores or tubes or another capillary or spongy structure. A hollow structure can provide a reserve for aerosol forming agent 6 without softening the consumable. A typical example of an electrically conductive material 7 having a hollow structure is charcoal, which has bulk density of 0.2 to 0.4 g/cm³ and an absolute density of 1.38 to 1.46 g/cm³.

FLAVORANT MATERIAL

The consumable can further comprise a flavorant material 5. The flavorant material 5 is preferably present in particulate form.

The flavorant material 5 is a material that can be aerosolized upon heating or burning. In the present invention, the flavorant material 5 is preferably heated, but not burned. The flavorant material 5 preferably provides an aerosol comprising the flavorant upon heating.

The flavorant material 5 can be present in an amount of 0.1 to 60 wt%, preferably 1 to 30 wt%, even more preferably 2.5 to 20 wt%, even more preferably 3 to 15 wt% or 5 to 10 wt% based on the total weight of the consumable.

In case both electrically conductive material 7 and flavorant material 5 are present, they may both together be present in an amount of 35 to 60 wt%, or 50.1 to 60 wt% and even more preferably about 45 wt%, based on the total weight of the consumable. The remainder of the consumable may then be formed by the binding agent and aerosol forming agent 6. For instance, the binding agent and the aerosol forming agent 6 may together be present in an amount of 40-65 wt%, more preferably about 55 wt% based on the total weight of the consumable. In this case, the binding agent may be present in an amount of 0.1 to 7 wt% and the aerosol forming agent 6 may be present in an amount of 33 to 64.9 wt%, based on the total weight of the consumable.

The flavorant material 5 can comprise natural and/or synthetic components, which enhance and modify the taste of a generated aerosol. Preferably, the flavorant material 5 is derived from plant leaves. The plant leaves are preferably selected from tobacco leaves.

Preferably, the particles of flavorant material 5 are tobacco particles. The tobacco particles may originate from any part of the tobacco plant, e.g. leaves, stems or roots. The tobacco particles can be obtained from ground tobacco leaves, pulverized tobacco leaves, shredded tobacco or flue cured tobacco (FCT). Flue cured tobacco may comprise a blend of tobacco strands and tobacco dust. For example, shredded tobacco may comprise tobacco strands (e.g. tobacco cut filler) of up to about 5-mm long. The flavorant material 5 can contain a combination of different types of tobacco material. Due to this, it is possible to enhance the consumable with different tobacco tastes using for instance fire-cured tobacco and/or flue cured tobacco and/or other plant additives.

In one example, the flavored material comprises flue cured tobacco (FCT) in an amount of 1 to 47.5 wt% or about 25 wt% based on the total weight of the consumable.

In a preferred embodiment, the flavorant material 5 is a tobacco material and even more preferably comprises particles of tobacco material. The flavorant material 5 may however be other particles enriched with or comprising tobacco flavor and/or nicotine. However, the invention is not limited to tobacco material. For instance, a non-tobacco-flavor present in the flavorant material 5 may be chocolate, vanilla or menthol.

The particles of flavorant material, in particular tobacco particles, preferably have a particle size in the range of 200 pm to 5 mm, preferably from 250 pm to 4.5 mm, even more preferably from 300 pm to 4 mm and even more preferably from 350 pm to 3.5 mm, an even more preferably lower than 1000 pm or lower than 600 pm.

The particle size of the flavorant material can enhance the delivered taste. For instance, it has been found that grinding of tobacco particles to a smaller particle size can affect the odor. It is believed that some of the odorizing molecules decompose due to the high shear energy during grinding.

Furthermore, some odorizing molecules may exit too small tobacco particles during a grinding process or during a later handling process. This can result in a depletion of odorizing molecules in the tobacco particles and an odorizing composition not having full tobacco odor. However, tobacco particles having a small average particle size provide a high surface area from which odorizing molecules can leave the particle. Due to this, small tobacco particles can provide a full tobacco flavor over a long period.

In a preferred embodiment, the consumable may comprise more than one type of flavorant agent. For instance, the consumable may comprise particles of tobacco in addition to a non-tobacco-flavor such as chocolate, vanilla or menthol.

BINDING AGENT

The particles of the electrically conductive material 7 and/or the flavorant material 5 can be bound by the binding agent or binder. The binding agent can enable the consumable to be present as a solid. Further, the binding agent can enable the consumable to harden during the manufacturing process.

The binding agent is present in an amount sufficient to bind the particles of electrically conductive material 7 and/or the flavorant material 5 together. The binding agent can be present in an amount of 0.1 to 7 wt%, 0.1 to 5 wt%, 0.5 to 5 wt%, 0.6 to 4.55 wt%, 2.8 to 3.25 wt% and preferably 0.5 to 2.5 wt%, such as 1.74 wt% based on the total weight of the consumable. With respect to a gel-forming agent that can be used during the manufacturing process described further below, which comprises the binding agent, aerosol forming agent 6 and optionally water, the amount of binding agent can be 0.1 to 10 wt%, preferably between 0.1 to 5 wt%, 0.2 to 5 wt%, 0.2 to 4 wt%, 0.5 to 4 wt%, even more preferably 0.5 to 2.5 wt%, even more preferably 1 to 2 wt%, based on the total weight of the gel-forming agent.

The binding agent is preferably selected from binding agents that are approved additives for use in the tobacco industry or food industry.

The binding agent is preferably selected from a cellulose derivative and gums.

The cellulose derivative can act as an adhesive, gel or glue between the particles. The cellulose derivative can be present in an amount of 0.1 to 7 wt%, 0.1 to 5 wt%, 0.2 to 4 wt%, 0.4 to 3.25 wt%, 0.65 to 2 wt%, 1 to 2 wt%, and preferably 0.5 to 2.5 wt%, such as 1.74 wt% based on the total weight of the consumable. In the gel-forming agent that can be used during the manufacturing process, cellulose derivative can be present in an amount of 1 to 5 wt%, such as 1 wt%, 2 wt%, 2.5 wt% or 5 wt%, based on the total weight of the gel-forming agent. A particularly preferred cellulose derivative is carboxymethyl cellulose, CMC.

Gums can provide flexibility to the consumable. Gum can be present in an amount of 0.1 to 7 wt%, 0.1 to 5 wt%, 0.2 to 1.3 wt%, 0.325 to 0.8 wt%, 0.5 to 2 wt%, such as 0.5 to 1 wt% or 1 to 2 wt%, and preferably 0.5 to 2.5 wt%, such as 1.74 wt% based on the total weight of the consumable. In the gel-forming agent that can be used during the manufacturing process, gum can be present in an amount of 0.5 to 2 wt%, such as 0.5 wt%, 1 wt% or 2 wt%, based on the total weight of the gel-forming agent. A particularly preferred gum is gellan gum. In a particularly preferred embodiment, the binding agent comprises a cellulose derivative and/or a gum. A particularly preferred binding agent comprises carboxymethyl cellulose, CMC and/or gellan gum.

AEROSOL FORMING AGENT

An aerosol forming agent 6 can be any compound, mixture and/or solution that is capable of forming an aerosol, e.g. when heated and/or in mixture with a flavorant agent. The aerosol forming agent 6 can further support the role of the binding agent.

The aerosol forming agent 6 is present in an amount sufficient to provide an aerosol upon heating. The aerosol forming agent 6 is preferably present an amount of between 5 to 75 wt%, more preferably 20 to 75 wt%, even more preferably 20 to 30 wt%, or 33 to 64.9 wt%, or 39.9 wt% and 58 wt%, based on the total weight of the consumable. In another preferred embodiment, the aerosol forming agent is present in an amount of at least 5 wt% and less than 25 wt%, based on the total weight of the consumable.

With respect to a gel-forming agent that can be used during the manufacturing process described further below, which comprises the aerosol forming agent 6, binding agent, and optionally water, the amount of aerosol forming agent 6 can be 25 to 75 wt%, preferably 45 to 57.5 wt%, such as 25 wt%, 45 wt%, 57.5 wt% or 75 wt%, based on the total weight of the gel-forming agent.

Examples of aerosol forming agents 6 include humectants such as glycerin and propylene glycol, other alcohols, such as ethanol, etc. In a preferred embodiment, the aerosol forming agent 6 comprises glycerin, propylene glycol, and/or an alcohol. Most preferred is the use of glycerin and/or propylene glycol. For example, the aerosol forming agent 6 can be glycerin, propylene glycol, or a mixture of glycerin and propylene glycol. Glycerin can be useful to provide sufficient aerosol or vapor at a temperature of for instance 220 °C. The glycerin primarily functions as an aerosol forming agent, but may add binding capacity to the binding agent.

Albeit the use of aerosol forming agent 6 may be preferable to provide an aerosol, it is possible not to add the aerosol forming agent 6 to the consumable, or only add it in a low amount. In this case the electrically conductive material may need to provide a higher temperature for aerosolization of any flavorant material, such as tobacco, comprised in the consumable. Especially when using a consumable, it is conceivable to use a low amount of aerosol forming agent 6 or no aerosol forming agent. This can help to avoid unnecessary moisture content in the consumable. However, the aerosol forming agent 6 can be particularly advantageous for providing an aerosol and further to provide elasticity to the consumable. The use of aerosol forming agent 6 in the consumable can further help in avoiding brittleness, which can allow better shaping of the consumable.

WATER

The consumable can further comprise water. Water can be used in the manufacturing method described further below to activate the binding agent, and may be present in a low amount in the final consumable. Generally, water is introduced in the manufacturing process, together with an additive agent and an aerosol forming agent 6, which together can form a gel-forming agent. The amount of water can vary according the binding agent selected.

In a gel-forming agent, water is added to fill up to 100 wt%. Water can be present in an amount of 0.1 to 75 wt%, preferably 20 to 75 wt%, more preferably 22 to 72 wt%, even more preferably 40 to 69.5 wt%, such as about 50 wt% based on the total weight of the gel-forming agent. Since heat is generally applied during the manufacturing process, water may be present to only a minor degree in the consumable, i.e. the consumable may be considered substantially water-free or water may be present in a low amount of 0.1 to 10 wt%, 0.1 to 5 wt%, 0.1 to 2 wt% based on the total weight of the consumable.

ADDITIONAL FLAVOR OR NICOTINE

In addition to the flavorant material, such as tobacco material, additional flavorant materials, such as nicotine, or non-tobacco flavors such as menthol, vanilla or chocolate may be added to the consumable. These additional flavorant materials will generally be present in low amounts in the consumable, such as 0.1 to 5 wt%, 0.1 to 2 wt% or 0.5 to 1 wt% based on the total weight of the consumable.

TOTAL AMOUNT OF INGREDIENTS IN CONSUMABLE

As indicated above, during the manufacturing process a gel-forming agent can be used, which preferably comprises the binding agent, the aerosol generating agent and optional water. Is has been found that preferably, the amount of particles of electrically conductive material 7 and/or flavorant material 5 lies between 35 to 60 wt%, or 50.1 to 60 wt% with an optimum at 45 wt%, based on the total weight of the consumable. Further, it has been found that the amount of gel-forming agent lies between 40 to 65 wt%, with an optimum at 55 wt%, based on the total weight of the consumable.

The weight ratio of gel-forming agent to particles in the consumable preferably lies between 0.01:1 to 100:1, preferably between 0.1:1 to 10:1, more preferably between 0.5:1 to 5:1, even more preferably between 0.5:1 to 1:1, and most preferably wherein the weight ratio of gel-forming agent to particles is 2:1, 1.75:1, 1.5:1, 1.25:1 or 1:1. By using these weight ratios, it can be ensured that the consumable has sufficient electrical conductivity .

The gel-forming agent preferably comprises at least one binding agent in an amount of 0.5 to 7 wt%, preferably 1.5 to 7 wt%, such as 1.5 wt%, 2 wt%, 2.5 wt% or 5.5 wt%, based on the total weight of the gel-forming agent. The gel-forming agent preferably comprises an aerosol forming agent 6 in an amount of 25 to 75 wt%, such as 25 wt%, 45 wt%, 57.5 wt% or 75 wt%, based on the total weight of the gel-forming agent. The gel-forming agent preferably comprises water in an amount to fill up the gel-forming agent to 100 wt%, i.e. generally between 20 to 75 wt%, such as 22 wt%, 52 wt%, 69.5 wt% or 72 wt%.

As indicated above, water will mostly or completely be evaporated during the manufacturing process. The resulting amounts of binding agent and aerosol forming agent 6 in the consumable can be readily calculated based on the amounts indicated above.

LAYER OF CONSUMABLE

The material can be formed as a layer, sheet, plate or film. The layer 3 can be configured to be positioned between two electrodes of an aerosol generating device. The consumable can comprise the particles of electrically conductive material 7 and/or flavorant material 5 embedded in the layer 3, as for instance shown in Figures 1a and 1b.

The thickness 8 of the layer 3 of material can be between 0.5 and 3 mm, preferably between 0.5 and 2 mm and most preferably be 0.75 mm. The thickness 8 of the layer 3 can correspond to the thickness of the entire consumable 1.

In this case, the layer 3 is preferably not formed as a separate layer, but is distributed throughout the entire consumable 1. Due to this, the entire consumable forms the layer.

The maximum thickness 8 of the consumable 1 can be determined by a design of the aerosol generating device. There may be little space available in the relatively small aerosol generating devices, so the thickness 8 of the consumable may be adjusted. Due to this, the preferred thickness of the consumable is particularly advantageous for storage in the cartridge. The minimum thickness of the consumable may be determined by the layer.

A narrow or thin layer thickness enables a greater capacity of a cartridge storing the consumable. At the same time, less electrical voltage and less heating time may be needed to heat a narrow layer. This allows a user to use a single cartridge with the consumable for a longer period of time. A further advantage for a preferred thickness of the consumable or layer would be a compact winding in the cartridge. This can help in avoiding wasteful voids in the cartridge comprising the consumable.

FORMS OF CONSUMABLE

The consumable 1 , in particular in form of a layer 3, can be formed as a paste or dough.

The consumable provided as a dough can be provided or stored as a layer which is rolled up on itself similar to a spiral or a hyperbolic spiral. It is also possible to provide the consumable rolled on a bobbin. Preferably, the entire consumable, in particular in layer form, can be stored in a cartridge, which can be intended for keeping the consumable fresh. The cartridge can be provided with a mechanism to open and close the cartridge. Various closures are available for this purpose. Due to this, it is conceivable that the cartridge is refillable with the consumable, in particular in layer form.

The consumable provided as a paste can have a viscosity of up to 10² mPas (at 20°C). The - preferably dynamic - viscosity of the consumable preferably decreases with increasing temperature. The consumable may be regarded as a non-Newtonian fluid that comprises solid particles. Depending on the composition of the materials of the consumable, an amount of the solid particles can vary. The viscosity, in particular the dynamic viscosity, of the consumable can depend on the selected ingredients and the amount of the solid particles in the consumable. DISTRIBUTION OF PARTICLES IN CONSUMABLE

The particles of electrically conductive material 7 and optionally flavorant material 5 can be distributed in and on the consumable 1, in particular in the form of a layer 3.

The particles 5, 7 can be distributed substantially homogeneously inside and/or on a surface the consumable 1. When particles of electrically conductive material 7 are present, the homogenous distribution allows current to flow from one electrode through the thickness of the consumable to the other electrode. In this case, the entire consumable may form a layer. However, it is also conceivable to use additional layers comprising electrically conductive material.

The electrically conductive material 7 is preferably dispersed to the extent that a current flow is ensured. The distribution of the conductive material inside a more liquid or viscous consumable, for instance in form of a paste, may be compared to the distribution inside of a consumable. Preferably, the conductive material is evenly dispersed inside the liquid or viscous consumable. This can be achieved through the use of liquid electrically conductive materials, or by using solid electrically conductive particles dispersed in a carrier liquid.

When particles of flavorant material 5 are present, the homogenous distribution provides for a homogeneous release of aerosol including the flavorant.

The particles 5, 7 can also be randomly distributed inside and/or on a surface of the consumable. The distribution of the conductive material in the consumable can be described with a Fick^'s law of diffusion. The particles can be anisotropically distributed inside the consumable. This can lead to the formation of areas with a higher and a lower concentration of particles inside the consumable.

CONSUMABLE COMPRISING PARTICLES OF ELECTRICALLY CONDUCTIVE MATERIAL

The consumable 1 comprises particles of electrically conductive material. The consumable thus comprises particles of an electrically conductive material 7, at least one binding agent for binding the particles, and at least one aerosol forming agent 6. The flavorant material 5 does not need to be present. The consumable without flavorant material 5 may provide an aerosol due to the presence of the aerosol forming agent 6. However, in a particularly preferred embodiment further described in detail below, the flavorant material 5 is present in addition to the electrically conductive material 7.

The particles of electrically conductive material 7 can provide electrical conductivity to the consumable. When an electrical current is applied, the consumable can heat up, thus aerosolizing the aerosol forming agent 6 and/or any present flavorant material 5.

The consumable 1, in particular in layer 3 form, can be arranged between two electrodes 4a, 4b of an aerosol generating device, and more preferably pressed between the electrodes. The two electrodes may be common electrodes commonly used in aerosol generating devices. It can be advantageous to provide the consumable in layer shape, at least because of the various storage possibilities, but also for ease of arrangement between two electrodoes.

The two electrodes of the aerosol generating device can be connected to a voltage source. The voltage source can provide a voltage in range of 1 V and 5 V and supply the whole aerosol generating device with electrical energy. In a preferred embodiment the voltage source is a lithium-ion battery delivering a voltage of 3.7 V. Such a voltage source is particularly advantageous for a modern aerosol generating device in view of rechargeability. When an electrical current is applied to the electrodes, the consumable can heat up, thus aerosolizing the aerosol forming agent 6 and/or any present flavorant material 5.

The consumable comprising the electrically conductive material 7 is thus electrically conductive and is configured to heat to a temperature at which at least the one of the flavorant material 5 and the aerosol forming agent 6 forms an aerosol. The consumable 1, in particular in layer 3 form, can appear as a conductor between the electrodes and can provide a direct aerosolization of the aerosol forming agent 6 and/or flavorant material 5 in the consumable. Preferably, the two electrodes and the heating layer reach a temperature in a range of 90 to 230°C to ensure a sufficient aerosolization of the aerosol forming agent 6 and/or flavorant material 5 comprised in the consumable.

The electrically conductive material 7 is preferably present to allow current to flow through the consumable. The consumable 1 or layer 3 can additionally be coated with electrically conductive material. The electrically conductive material 7 can allow the electric current to flow from the first electrode 4a to the second electrode 4b. The current can flow in a transverse direction perpendicular to a thickness 8 of the consumable. In this context, the thickness 8 of the consumable can correspond to the thickness of the layer, which is arranged between the first and second electrode. The amount of electrically conductive material 7 in the consumable can depend on the thickness of the consumable. The amount of electrically conductive material 7 in the consumable can also depend on pressure applied between the electrodes. Preferred amounts are indicated above.

The electrically conductive material 7 can have an electrical conductivity of at least 3*10² S/m (at 20°C) and up to 100*10⁶ S/m (at 20°C). A value of electrical conductivity of the consumable 1 can be varied, depending on the amount and type of electrically conductive material 7 in the consumable.

The consumable 1 can comprise two or more layers comprising the electrically conductive material. The layers can be arranged as an upper and lower layer, thereby creating a layered consumable comprising at least two layers. In this case, the upper and lower layers can be in contact to the electrodes. An intermediate layer can also be present, wherein the intermediate layer comprises the electrically conductive material, thereby ensuring a current flow from one electrode to the other electrode.

The electrical resistance of the consumable may be proportional to the thickness of the layer 3. Accordingly, a thinner layer may have a lower electrical resistance. The thickness 8 of the layer of material can be between 0.5 and 3 mm, preferably between 0.5 and 2 mm and most preferably be 0.75 mm.

Additionally or alternatively, the required electrical conductivity can be effected by a modulation of the contact surfaces of the electrodes 4a, 4b. It is conceivable that electrodes with a small electrode contact surface effect a greater resistance. Small electrode contact surfaces can comprise a contact surface area in range of 150 mm² and 200 mm². In this case, it is possible to increase the quantity of the electrically conductive material 7 in the consumable. Electrodes with a large electrode contact surface may be used with a consumable comprising a lower quantity of the electrically conductive material. Large electrode contact surfaces can comprise a contact surface area in range of 250 mm² and 320 mm². In the preferred embodiment the electrode contact surfaces area lies in range of 200 mm² to 250 mm², and more preferably is 215 mm². Due to the electrical conductivity, heat can be easily transported throughout the consumable 1 and the flavorant material 5 and/or aerosol forming agent 6 contained in the consumable 1 can be heated fast. Further, heat provided by the electrically conductive material 7 can be delivered readily to the core of the material.

CONSUMABLE COMPRISING PARTICLES OF ELECTRICALLY CONDUCTIVE MATERIAL AND FLAVORANT MATERIAL

In a particularly preferred embodiment, the consumable comprises particles of electrically conductive material 7 in addition to particles of a flavorant material 5.

The consumable of this embodiment is electrically conductive and does not require any external heating means. Since the particles or electrically conductive material 7 are present in the consumable, they provide heat throughout the entire consumable. Accordingly, heat can be substantially uniformly or homogenously provided throughout the bulk of the consumable, thereby allowing a controlled aerosol ization of flavorant material 5 and/or aerosol generating agents present in the consumable.

In a particularly preferred embodiment, the consumable comprises charcoal particles and tobacco particles, a binding agent comprising carboxymethyl cellulose and optionally gellan gum, and glycerin.

The charcoal provides for electrical conductivity and the binding agent enables the particles to be stably held together. Upon applying electrical current to the consumable, heat is provided to the tobacco particles and the glycerin, which are then both aerosolized. The tobacco particles provide an enhanced tobacco taste to the generated aerosol, the glycerin can give the aerosol a more vapor-like appearance.

DEVICE COMPRISING A CONSUMABLE

An aerosol generating device can comprise the consumable. The device can be configured to provide an aerosol from the consumable, for instance by applying current to the consumable and/or heating the consumable.

The device can comprise a pair of electrodes 4a, 4b and a source of electrical energy 19 configured to be applied to the electrodes. The electrodes can comprise a contact surface and can be configured to press the consumable 1 or a layer 3 thereof in sandwich along at least a portion of a surface area of the consumable or layer.

The portion in contact with the layer 3 can be 10 and 80 %, preferably 20-50% of the surface area between the electrodes 4a, 4b.

The electrodes 4a, 4b can be pressed on the consumable 1 or layer 3 thereof with a pressure comprised between 0.5 and 10 bar, preferably 5 bar. In a preferred embodiment the device comprises means for pressure generation. Preferably, the means comprise springs for generating a pressure between 0.5 and 10 bar. In the preferred embodiment, the means for pressure generation generate a pressure of 5 bar between two electrodes.

Preferably, the pressure acts on electrodes with a surface area of 150-300 mm², for example 215 mm². It is also possible to generate pressure of at least 5 bar on a larger surface area of the electrodes. However, the surface area of the electrodes depends on the size of the entire device. The electrodes may comprise holes or channels to facilitate the aerosol to flow out of the consumable. For example, each electrode can comprise a corrugated and/or apertured contact surface.

The device can in alternative, or addition comprise heating means (not shown in the figures), such as a resistive or inductive heating element at least partially surrounding the consumable or a heating chamber in which the consumable is embedded. Other means of heating a consumable may be conceivable, as known to the skilled person in the area of aerosol generating devices. However, as indicated, such heating means are not required for the functioning of the device, in view of the electrically conductive material in the consumable.

The device can further comprise mechanical, electrical and/or electronical parts known from common electrical aerosol delivering devices. The device can further comprise a cartridge for storage of the consumable. Preferably, the cartridge is refillable or replenishable with the consumable.

Turning back to the Figures, in Figures 1a and 1b schematic cross-sectional views of a consumable 1 comprising electrically conductive material 7 between two electrodes 4a, b are shown. In the embodiment shown in both figures, the consumable 1 comprises electrically conductive material 7, flavorant material 5, and an aerosol forming agent 6. The consumable further comprises a binding agent not specifically designated in the figures. It is conceivable that the consumable 1 further comprises ingredients which form an aerosol substrate (not shown).

The flavorant material 5 can be a material as described above. The flavorant material 5 can thus be a tobacco material for enhancing the aerosol substrate with an individual tobacco taste and/or may be another flavoring substance which is added additionally or alternatively to the tobacco material.

The electrically conductive material may be provided as a solid powder comprising the particles. Such particulate ingredients are preferably embedded in the consumable 1. The consumable 1 is preferably formed as a layer 3, in particular being or comprising a heating layer 3. The consumable 1 or layer 3 can be arranged between two electrodes 4a, b in an aerosol generating device 2 (shown in fig. 2).

As shown in Fig. 2, the two electrodes 4a, b are spaced apart from each other and are connected with the consumable 1 or the layer 3. Preferably, a distance between the electrodes 4a, b is considered as a thickness 8 of the consumable 1. The thickness 8 of the consumable 1 or the layer 3 can preferably be in range of 0.5 mm and 5 mm, preferably in the range of 0.5 and 2 mm. The thickness 8 can be dependent on the size of the aerosol generating device 2 (shown in Fig. 2) and a size of the electrodes 4a, b. Handy devices 2 preferably comprise electrodes 4a, b with small average contact surfaces 11. In an example, the contact surfaces 11 comprise an area of 215 mm². It is also conceivable that the contact surfaces 11 comprise an area in the range of 150 mm² and 300 mm². As shown in the Fig. 1a, the contact surfaces 11 of the electrodes 4a, b are in direct contact with the consumable 1 or the layer 3. In an example, 70 % to 95 % of the contact surfaces 11 touch the consumable 1 or the layer 3. Preferably the electrodes 4a, b apply pressure to the consumable 1 or the layer 3 to reduce the contact resistance between the electrodes and the electrically conductive particles.

The first 4a and the second 4b electrode can be connected to a voltage source 19. In a state of use of the aerosol generating device 2, the electrical current flows from the one electrode 4b through the consumable 1 to the other electrode 4a. In an example, the voltage source 19 is supplied by a rechargeable battery, such as lithium-ion, with a voltage value of 3.7 V. It is also conceivable to use other electrical energy sources 10 (shown in Fig. 2) for supplying the electrodes 4a, b with energy. The consumable 1 as shown in fig. 1a preferably comprises a thickness 8, after compression, equal to or lower than the largest dimensions of conductive particles. It is conceivable that the consumable 1 comprises more than one type of particles of the conductive material 7. Preferably, the consumable comprises a plurality of particles randomly dispersed in the consumable. For example, the electrically conductive material 7 can comprise particles having a particle size of about 780 microns. In one example, the electrically conductive material 7 was activated carbon particles under reference Jacobi EcoSorb MB3-10H.

The resistance between the electrodes may depend on the size of the particles of the conductive material 7. The electrically conductive material 7 may comprise two contact points 7a with the electrodes 4a, b, which are preferably arranged parallel to each other. Preferably the current flows from the one contact point 7a to the other, thereby electrically connecting the electrodes 4a, b. In another embodiment (see Fig. 1b), the electrical conductive material 7 comprising at least two particles preferably has at least three contact points 7a. Preferably two contact points 7a touch the electrodes 4a, b and the third contact point 7a is a contact point between the particles of the conductive material 7.

Of course, an electrically conductive material 7 with both arrangements of Figures 1a, 1b in the consumable is also possible. Preferably, the thickness 8 of the consumable is substantially equal to the particle size to ensure contacts points 7a with the electrodes for a plurality of particles. The thickness of the consumable may be 0 to 20% larger than the particle size to ensure contact points after compression of the consumable between the electrodes.

The thickness 8 of the consumable or distance 8 between the electrodes may be respectively between 200 and 1000 microns, for example between 200 and 250 microns, or between 300 and 360 microns, or between 350 and 420 microns, or between 400 and 480 microns, or between 450 and 540 microns, or between 500 and 600 microns, or between 55 and 660 microns, or between 600 and 720 microns, or between 650 and 780 microns, or between 700 and 840 microns, or between 750 and 900 microns, or between 800 and 960 microns.

Figs. 1a and b show particularly preferred embodiments, wherein the resistance at the thickness 8 of the consumable 1 decreases. The current flows better with a thickness 8 of the consumable which allows as few as possible contact points 7a to the electrodes 4a, b. Due to this, the transition resistance is preferably proportional to the thickness 8 and/or to a number of contact points 7a.

Fig. 1c shows a schematic top view of a consumable 1 comprising conductive material 7 between two electrodes 4a, b. As can be seen in Fig. 1b, the consumable 1 is arranged between the electrodes 4a, b (4b not shown). Preferably the consumable 1 or the heating layer 3 comprises at least one surface area 3a which touches the contact surfaces 11 (not shown) of the electrodes 4a, b. Due to the fact that the consumable 1 is pressed between the electrodes 4a, b, it is conceivable that only a portion of the surface 3b of the consumable 1 is heatable..

Fig. 2 shows a schematic view of a device 2 for delivering aerosol with two electrodes 4a, b and consumable 1 arranged between the electrodes 4a, b. The device 2 further comprises an electrical energy supply 10, a mouthpiece 12, an aerosol channel 13 and a cartridge 14. It is conceivable that the device 2 comprises further mechanical, electrical and/or electric components. Preferably the electrodes 4a, b are supplied with energy comprised in the electrical energy 10 supply. Due to this, electrodes 4a, b preferably do not need an external voltage source 19 (not shown). However, it is also possible that another embodiment of the device 2 comprises a voltage source 19 which supplies only the electrodes with energy (not shown).

Preferably the consumable 1 is comprised in a cartridge 14. The cartridge 14 can be used for storage of the consumable 1. The consumable 1 stored in the cartridge 14 is advantageously placed in a space saving way. The cartridge 14 is preferably connected to the electrodes 4a, b for supplying the electrodes 4a, b with fresh, in particular not burned consumable 1. It is conceivable that the cartridge comprises means for pushing the stored consumable 1 forwards to the electrodes 4a, b (not shown). This means could be a manual or electrical propulsion.

The heated consumable 1 which is arranged between two electrodes 4a, b preferably segregates inhalable aerosol 9. Preferably, the aerosol 9 is guided through the aerosol channel 13 to the mouthpiece 12 of the device 2. Due to this, it is conceivable that the aerosol channel 13 is connected to the electrodes 4a, b. It is also possible that the electrodes 4a, b are arranged in the aerosol channel 13. In such a case, the aerosol channel 14 might be connected to the cartridge 13.

METHOD FOR MANUFACTURING A CONSUMABLE A method for manufacturing a consumable comprises the steps of: i) providing particles of at least one electrically conductive material and optionally a flavorant material, ii) mixing the particles and the optional flavorant material with at least one binding agent for binding the particles, at least one aerosol forming agent, and optionally water,

, and iii) solidifying the mixture such as by curing and/or drying.

In a preferred embodiment, the mixture of the particles and the optional flavorant material, the binding agent, the aerosol forming agent and the optional water form a paste or dough. This paste or dough can be pressed into a layer. The layer can then be cured and/or dried.

The particles of electrically conductive material and optionally a flavorant material can be mixed with the binding agent, the aerosol forming agent and optionally water. Mixing means in this context that the ingredients are diffusionable or distributionable. It is conceivable that some ingredients are provided in solid form and others in liquid form. It is also conceivable to soak the solid ingredients with the liquid ingredients to manufacture the consumable. The paste or the dough can be kneaded for even distribution of the ingredients. Preferably, the electrically conductive material and/or the flavorant material are provided as solid ingredients. Also preferably, the aerosol forming agent, water and the binding agent are provided as liquid ingredients. Preferably an optimal proportion of the ingredients comprises at least 52 wt% of solid ingredients and at least 48 wt% of liquid ingredients.

Preferably, the ratio of solid-to-liquid ingredients content during the manufacturing and in the final consumable is comprised between 70:30 and 30:70, preferably 60:40 to 40:60, more preferably between 55:45 and 50:50, most preferably 52:48. Due to this, the consumable contains enough aerosol forming agent, may be formed into a layer without being too brittle while having enough electrically conductive material for electrical conductivity.

Preferably the dough or the paste are pressed into a layer, sheet or film with a thickness of at least 0.5 mm. It is also possible to press a layer with a thickness of 2 mm or less. However, the electrical resistance of the consumable raises with greater thickness. In an embodiment with the consumable provided as a paste or dough, it is possible to press the paste or dough to a layer and let this layer dry. Additionally or alternatively the paste or the dough can be pressed on a supporting layer, such as a paper layer or a silicon layer, and/or rolled between two wrapping layers. Such wrapping layers can be advantageous for forming and keeping the layered form of the pressed ingredients. The supporting layer and/or the wrapping layers preferably comprise paper or silicon. Thus, a particularly stable form of the consumable can be achieved.

The binding agent, the aerosol forming agent, and the optional water can form gel-forming agent. The weight ratio of gel-forming agent to particles preferably lies between 0.01:1 to 100:1, preferably between 0.1:1 to 10:1, more preferably between 0.5:1 to 5:1, even more preferably between 0.5:1 to 1:1. Most preferably, the weight ratio of gel-forming agent to particles is 2:1, 1.75:1, 1.5:1, 1.25:1 or 1:1.

Water is added to activate the binder. The amount of water may be selected such that a kneadable dough is created.

The gel-forming agent preferably comprises at least one binding agent in an amount of 0.5 to 7 wt%, preferably 1.5 to 7 wt%, such as 1.5 wt%, 2 wt%, 2.5 wt% or 5.5 wt%, based on the total weight of the gel-forming agent. The binding agent preferably is made up of 1-5 wt% of a cellulose derivative and 0.5 to 2 wt% of a gum. The gel-forming agent preferably comprises an aerosol forming agent in an amount of 25 to 75 wt%, such as 25 wt%, 45 wt%, 57.5 wt% or 75 wt%, based on the total weight of the gel-forming agent. The gel forming agent preferably comprises water in an amount to fill up the gel-forming agent to 100 wt%, i.e. generally between 20 to 75 wt%, such as 22 wt%, 52 wt%, 69.5 wt% or 72 wt%. In a preferred embodiment, the gel-forming agent comprises 2.5 wt.-% CMC, 1.0 wt% gum, 15-45 wt% glycerin and water.

Preferably, a temperature of 100 to 200°C, such as about 150°C is applied in the heating step, such that water in the gel-forming agent evaporates, and a pressure is applied such that a layer (3) of the consumable (1) is formed. The layer (3) preferably has a thickness (8) of 0.5 and 3 mm, preferably between 0.5 and 2 mm.

Fig. 3 shows a flow chart of a method for manufacturing a consumable 1 comprising an electrically conductive material 7 and/or a flavorant material 5. In a pre-step not shown, particles of at least one of an electrically conductive material 7 and a flavorant material 5 are provided. Further provided are a gel-forming agent comprising at least one binding agent for binding the particles, at least one aerosol forming agent and optionally water. The provided ingredients can be solid or liquid. The flavorant material 5 and the electrically conductive material 7 are preferably provided in particulate form, for instance as powder. It is also conceivable to soak conductive particles such as charcoal in a liquid forming agent before mixing with the other ingredients. The aerosol forming agent 6 and water are preferably provided as liquid ingredients. The gel-forming agent can be either solid or liquid, depending on the binding agent selected.

In an addition step 100, the ingredients are added together and preferably mixed. It can be advantageous to first mix the solid materials before adding any liquid ingredients to the solid ingredients. The binding agent in the gel-forming agent can provide a smoother aerosol substrate mixture. After mixing 100 the ingredients, an aerosol substrate can be obtained in form of a dough or paste.

In a pressing step 101, mechanical compression is applied to press the dough or paste into a form, such as a layer, sheet or film. It is noted that the invention is not limited to the use of a layer form any other form may also be used. The pressed consumable 1 can be arranged between two wrappings after pressing step 101. Such wrappings are preferably useful for rolling or layering the consumable 1. In some embodiments the consumable 1 can be rolled or layered without using the wrappings. The wrapping layers can be paper or silicon layers. It can be advantageous to bring the consumable 1 in a rolled shape for further storage in a cartridge 14.

In a solidifying step 102, the pressed and/or rolled consumable 1 is dried and/or cured. It is conceivable to arrange the consumable 1 in the cartridge 14 for further use in the device 2. The consumable 1 may preferably comprise a certain amount of moisture to provide it with sufficient elasticity for further use. Preferably, the consumable 1 is gradually rolled out in the further use in the device 2.

GENERATION OF AEROSOL

An aerosol can be generated with the steps of: providing a consumable comprising particles of electrically conductive material, in addition to a flavorant agent and/or an aerosol forming agent, arranging the consumable, preferably in layer form, between two electrodes of an aerosol generating device, pressing the electrodes on the consumable, supplying the electrodes with a current, wherein the consumable conducts the current between the electrodes, heating the consumable, thereby creating an aerosol.

Preferably, the heating of the consumable 1 is provided through the electrical current, which flows from electrode 4a to another electrode 4b of the aerosol generating device. The electrically conductive material preferably allows the current flow. Due to this, the flavorant agent and/or an aerosol forming agent present in the consumable are heated, thereby creating an inhalable aerosol.

Preferably, the method further comprises guiding the aerosol through a conduit or an aerosol channel to a mouthpiece outlet. It is conceivable that the conduit or the aerosol channel is connected to the mouthpiece and a heating section of the device. Preferably the heating section of the device comprises the two electrodes and the consumable arrangement.

Fig. 4 shows a flow chart of a method for generating aerosol with a device 2 comprising two electrodes 4a, b and a consumable 1 or layer 3 arranged between the electrodes 4a, b. In the arrangement step 200, the consumable 1 or layer 3 is arranged between the electrodes 4a, b of the device 2. It is also conceivable that the consumable 1 is rolled out and guided to the electrodes 4a, b out of the cartridge 14 of the device 2 before the arranging step 200. In a pressing step 201, the electrodes 4a, b are pressed with a pressure. Preferably the electrodes 4a, b are arranged parallel to each other (as shown in fig. 1a) and surround the consumable 1 or layer 3 from two sides or directions. In a supplying step 202, the electrodes 4a, b are provided with electrical current. Preferably the consumable 1 or layer 3 conducts the current between the two electrodes 4a, b. In a heating step 203, a temperature of the consumable 1 and/or the electrodes 4a, b increases, thereby heating the consumable 1. The inhalable aerosol 9 is generated from the consumable 1 during the heating step 203.

CARTRIDGE COMPRISING CONSUMABLE

Fig. 5a shows a schematic view of a cartridge 14 comprising consumable 1 arranged as a spiral. Preferably the consumable 1 or the layer 3 runs around a curve which emanates from a point (not shown), moving farther away as the consumable 1 revolves around the point. The consumable 1 is preferably arranged or stored in the cartridge 14. It is conceivable that the cartridge 14 is a storage box or another container which keeps the consumable fresh. The cartridge further comprises a leading channel 17 which is connected to the electrodes 4a, b of the device 2. It is also conceivable that the leading channel 17 is connected to the aerosol channel 13 of the device 2, wherein the electrodes 4a, b are arranged at least in part inside the aerosol channel 13. However, the cartridge 14 is preferably detachably connected to the electrodes 4a, b via connecting means 18. This could be useful in case of refill of the cartridge 14 with fresh consumable 1. It is conceivable that the device 2 further comprises a container 15 for used consumable 16. In some embodiments the used consumable 16 is preferably heated at a temperature up to 350C°, wherein the used consumable 16 comprises a very small or no amount of liquids.

If the amount of liquid forming agent is too low, a higher temperature, e.g. 350 °C (close to the combustion of tobacco) may be required to generate aerosol. If a sufficient amount of forming agent is contained in the consumable, the temperature to vaporize enough aerosol can be lowered e.g. below 300°C. The used consumable 16 preferably falls into the container 15 after the fresh consumable 1 is forwarded from the cartridge 14 to the electrodes 4a, b. It is also conceivable to arrange other constructions for storage of used consumable 16 in the device 2.

Fig. 5b shows a schematic view of a cartridge 14 comprising consumable 1 arranged as a hyperbolic spiral. The consumable 1 is preferably arranged in the cartridge 14 as shown in Fig. 5a. Preferably the consumable 1 is wrapped on a wrapper or a fixture (not shown) for a better support of the consumable 1 inside the cartridge 14. However, there are many possibilities to arrange the consumable 1 or the layer 3 inside the cartridge 14. Preferably, the consumable 1 is arranged very compact inside the cartridge 14 to provide a long uptime of the cartridge 14 inside the device 2.

The consumable can be stored in alternative forms to the ones of figures 5a, 5b such as a stack of a continuous accordion consumable or separate layers arranged in stack.

EXPERIMENTAL SECTION

METHODS

In the present application, the particle size refers to the mean diameter D90 determined by laser diffraction with a particle size analyzer Malvern 3000 using a dry dispersion method and software v3.62. However, particle sizes can also be measured with other suitable methods, such as sieving or laser diffraction.

PREPARATION OF CONSUMABLES As electrically conductive material, activated carbon (EcoSorb MB3-10H, 30x60 mesh from Jacobi Carbons) or charcoal was used. Charcoal ensures electrical conductivity and can absorb the ingredients to be evaporated. As binding agent, cellulose gum (Cekol® 30000 from CP Kelco) was used, comprising a highly purified sodium carboxymethylcellulose (CMC). A further binding agent used was gellan gum (gellan gum from Roeper). As glycerin typical commercially available glycerin (99.5 %) was used. As water, normal tap water was used.

A gel-forming agent was formed from 1-5 wt% CMC, 0.5-2 wt% gellan gum, 25-75 wt% glycerin based on the total weight of the gel-forming agent, and filled up with water (about 25-75 wt%) to form the gel-forming agent. The specific amounts are indicated in the tables below.

Glycerin was first weighed out and warmed to decrease its viscosity. CMC powder and gellan gum were weighed and both mixed together. The mixture was dissolved in the warmed glycerin during stirring. The mixture was activated by adding water. A gel was immediately created. Charcoal was added in the appropriate portion and then mixed with the gel to form a dough.

The mixture was spread on a baking paper and pressed with a Vogt LaboPress P200s to the required thickness while applying heat. It is noted that an extruder could also be used for the pressing. Different ratios of gel to charcoal were mixed and pressed with the Vogt LaboPress P200s at a pressing temperature of 150°C, a press time of 5 minutes and to a press thickness of 3 mm. Since the material to be pressed was a dough, there was no significant pressing pressure. The press was only used to produce a foil with a thickness of between 0.6 mm and 10 mm and to bake the dough. The charcoal was sticking together through the CMC and by pressing the heating plates together at 150 ° C, the water was evaporated quickly.

The consumable in form of a sheet was carefully removed from the baking paper. Fig. 6 shows three consumables manufactured with different ratios of gel to charcoal of 1:1.25, 1:5 and 1:1.75.

In order to find the optimum ratio of electrically conductive material to gel-forming agents, exemplary consumables were formed with the optimal concentrations indicated in Table 1 below. Table 1 : Weight ratios of ingredients during manufacturing process

It is noted that the concentrations in Table 1 already are the result of an optimization of the concentrations, since outside these ranges, adverse effects may be obtained.

Accordingly, the optimal amount of charcoal in the consumable was determined to be 35 to 60 wt%, with an optimum at 45 wt%. Correspondingly, the optimal amount of gel- forming agent in the consumable was determined to be 40 to 65 wt%, with an optimum at 55 wt%. It was found that with an even higher amount of charcoal and a lower amount of gel-forming agent, the adhesion was reduced and the amount of aerosol formed was reduced. Further, it was found that with a lower amount of charcoal and a larger amount of gel-forming agent, i.e. if the proportion of gel was too large, it was no longer possible to glue the charcoal.

It was found that an optimal amount of gellan gum was between 0.5 and 2.0 wt% based on the total weight of the gel-forming agent. It was further found that with a higher amount of gellan, the consumable was more elastic, however no significant improvement was found above a concentration of 2.0 wt% gellan gum. With an amount below 0.5 wt%, the consumable was observed to become too brittle.

It was found that an optimal amount of CMC was between 1 and 5 wt% based on the total weight of the gel-forming agent. It was observed that with a higher amount of CMC, the consumable was more elastic. However, an amount of above 5.0 wt% CMC may no longer be dissolvable in water. With an amount below 0.5 wt%, the charcoal particles were observed to no longer suitably bond together. It was found that an optimal amount of glycerin was between 25.0 and 75.0 wt% based on the total weight of the gel-forming agent. By adding more glycerin, the consumable was observed to be softer. With a lower glycerin content, the amount of aerosol or vapor formed was lowered.

It was found that an optimal amount of water was between 25 and 74.5 wt% and preferably 22 to 69.5 wt% based on the total weight of the gel-forming agent. The water can be used to control the expansion of the consumable under a press heating plate. Toward the higher end, the expansion was improved, towards the lower end, the expansion was lowered. It is noted that most of the water evaporates during the process.

EXPERIMENTS WITH RATIO OF GEL TO CHARCOAL In a further set of experiments, the optimal ratio of gel-forming agent to charcoal was determined. The following table indicates the different ratios of gel to charcoal, as well the observations of the retrieved material.

Table 2: Ratio of gel to charcoal

The preferred ratio of gel to charcoal was determined for Examples 6, 7 and 8 with a ratio of 1:1, 1:25:1 and 1.5:1, where the consumable had an optimal behavior. Corresponding consumables are shown in Fig. 6.

ELECTRICAL CONDUCITIVTY TEST An electrical conductivity test was performed with the pressed materials in a test vaporizer. A rectangular portion of the charcoal sheet was cut and placed in the vaporization chamber of a vaporizer. The sheet was pressed between two electrodes and electrical power applied to generate heat. The pressure was selected such that current could flow between the electrodes. By increasing the pressure, the contact resistance could be influenced. The voltage was pulsed to prevent the vaporizer from overheating. A typical heating power was between 16 and 60 watt. An aerosol or vapor was created during the application of voltage.

The test was performed with two different kinds of gel-forming agent, having a low and a higher amount of glycerin, as well as with five sets having a different ratio of gel to charcoal.

Table 3: Electrical conductivity tests with different ratios

It as observed that a ratio of gel to charcoal of 1:1, 1.25:1 and 1.5:1 was optimal regarding vapor behavior and conductivity. Further, it was observed that at a high charcoal content, i.e. at a gel to charcoal ratio of 2:1, the material is no longer electrically conductive. It was further observed that with a higher glycerin content, the material tends to be sticky, but has a high vapor behavior. With a lover glycerin content, the vapor behavior is still acceptable and the material is less sticky. In a test, tobacco material was added during the manufacturing process and the resulting consumable was put into a vaporizer. Upon application of current, a vapor containing nicotine was created.

In the following Tables, further experiments are summarized.

Examples 11.0 to 11.4 (Tables 4.1 to 4.3)

Table 4.1 shows the ingredients of Examples 11.0 to 11.4 which are samples including charcoal. These samples do not contain any flavorant material. A gel was prepared according to the recipe with the indicated amounts of glycerine, CMC, gelan gum and water and this gel was mixed with charcoal in the indicated mixing ratio. The resulting materials were pressed at the indicated temperature and drying time. A good mixing ratio between "solid" = charcoal / "gel" component has been determined to be 1/1.25 - 1/1.75. Table 4.2 shows the weight loss after drying, which can be contributed to the water from the gel evaporating at the indicated temperature. As can be seen in Fig. 7, showing from left to right the samples of lots 1.0, 1.1, 1.2, 1.3 and 1.4, the diameter increased, as expressed in Table 4.2. Table 4.2 also indicates the thickness of the samples after drying. Table 4.2 further shows the weight proportion of the solids and the gel in the samples, as well as the ingredients in the gel of the samples.

Table 4.3 shows the amount of glycerin in the samples.

able 4.1 : Consumables with charcoal (production)

able 4.2: Consumables with charcoal (samples)

Table 4.3: Consumables with charcoal (results)

The applicant reserves his right to claim all features disclosed in the application document as being an essential feature of the invention, as long as they are new, individually or in combination, in view of the prior art. Furthermore, it is noted that in the Figures, features are described, which can be advantageous individually. Someone skilled in the art will directly recognize that a specific feature being disclosed in a figure can be advantageous also without the adoption of further features from this figure. Furthermore, someone skilled in the art will recognize that advantages can evolve from a combination of diverse features being disclosed in one or various figures.

List of reference symbols

1 consumable

2 aerosol generating device

3 layer of consumable

3a surface area of the layer 3b a portion of the surface of the layer 4a first electrode

4b second electrode

5 flavorant material / tobacco material

6 aerosol forming agent

7 electrically conductive material

7a contact point of the electrically conductive material with the electrode

8 thickness of the layer of consumable

9 aerosol

10 electrical energy

11 contact surfaces of the electrodes

12 mouthpiece

13 aerosol channel

14 cartridge

15 container for used consumable

16 used consumable

17 leading channel

18 connecting means

19 voltage source

100 mixing the ingredients of the consumable

101 pressing the dough or the paste to a layer

102 solidifying the layer

200 arranging the layer / consumable between electrodes

201 pressing the electrodes on the layer / consumable

202 supplying the electrodes with electrical current

203 heating the layer

Claims

1. A consumable (1) for a vaporizer, wherein the consumable (1) comprises particles of at least one electrically conductive material (7) at least one binding agent for binding the particles, at least one aerosol forming agent (6), and optionally at least one flavorant material (5).

2. The consumable (1) according to claim 1, wherein the particles of electrically conductive material (7) are present in an amount of 35 to 60 wt%, based on the total weight of the consumable, and wherein the binding agent, the aerosol forming agent and the optional flavorant material (5) together are present in an amount of 40 to 65 wt%, based on the total weight of the consumable.

3. The consumable (1) according to any of the preceding claims, wherein the electrically conductive material (7) is an electrically conductive carbon- containing material, preferably selected from charcoal, activated carbon, black carbon and graphite.

4. The consumable (1) according to any of the preceding claims, wherein the particles of the electrically conductive material (7) have a particle size in the range of 1 pm to 10 mm, preferably from 10 pm to 1 mm, even more preferably from 100 pm to 500 pm.

5. The consumable (1) according to any of the preceding claims, wherein the flavorant material (5) is derived from a plant, preferably selected from tobacco, preferably wherein the particles of the flavorant material (5) are tobacco particles obtained from ground tobacco leaves, pulverized tobacco leaves or flue cured tobacco (FCT), preferably wherein the tobacco particles have a particle size in the range of 200 pm to 5 mm, preferably from 250 pm to 4.5 mm, even more preferably from 300 pm to 4 mm and even more preferably from 350 pm to 3.5 mm, and even more preferably lower than 1000 pm.

6. The consumable (1) according to any of the preceding claims, wherein the at least one binding agent is present in an amount of 0.1 to 7 wt% based on the total weight of the consumable, preferably wherein the at least one binding agent comprises at least one of a cellulose derivative and a gum, preferably wherein the cellulose derivative is selected from carboxymethyl cellulose and the gum is selected from gellan gum.

7. The consumable (1) according to any of the preceding claims, wherein the at least one aerosol forming agent (6) is present in an amount of 5 to 75 wt% based on the total weight of the consumable (1), preferably 25 to 75 wt%,R preferably wherein the at least one aerosol forming agent (6) is a humectant, preferably selected from glycerin, propylene glycol and an alcohol.

8. The consumable (1) according to any of the preceding claims, comprising at least one of charcoal particles as electrically conductive material (7) and tobacco particles as flavorant material (5), a binding agent comprising carboxymethyl cellulose and optionally gellan gum, and glycerin.

9. The consumable (1) according to any of the preceding claims, wherein the electrical conductivity of the consumable (1) is at least 3xl0² S/m (at 20°C), preferably up to 3x10^s S/m (at 20°C).

10. The consumable (1) according to any of the preceding claims, wherein the at least one binding agent and the least one aerosol forming agent (6) form a gel, preferably wherein the weight ratio of gel to electrically conductive material (7) lies between 0.01:1 to 100:1, preferably between 0.1:1 to 10:1, more preferably between 0.5:1 to 5:1, even more preferably between 0.5:1 to 1:1, and most preferably wherein the weight ratio of gel to electrically conductive material is 2:1, 1.75:1, 1.5:1, 1.25:1 or 1:1.

11. An aerosol generating device (2) comprising the consumable (1) of any of the preceding claims.

12. A method for manufacturing a consumable (1) for a vaporizer, comprising the steps of: i) providing particles of at least one electrically conductive material (7) and optionally a flavorant material (5), ii) mixing the particles and the optional flavorant material (5) with at least one binding agent for binding the particles, at least one aerosol forming agent (6), and optionally water, and iii) solidifying the mixture such as by curing and/or drying.

13. The method according to claim 14, wherein the binding agent, the aerosol forming agent (6) and the optional water form a gel-forming agent, preferably wherein the weight ratio of gel-forming agent to electrically conductive material (7) lies between 0.01:1 to 100:1, preferably between 0.1:1 to 10:1, more preferably between 0.5:1 to 5:1, even more preferably between 0.5:1 to 1:1, and most preferably wherein the weight ratio of gel-forming agent to electrically conductive material (7) is 2:1, 1.75:1, 1.5:1, 1.25:1 or 1:1.

14. A method of generating an aerosol, the method comprising the steps of: i) providing a consumable according to any of the preceding claims, ii) arranging the consumable, preferably in layer form, between two electrodes of an aerosol generating device, iii) pressing the electrodes on the consumable, iv) supplying the electrodes with a current, wherein the consumable conducts the current between the electrodes, and v) heating the consumable, thereby creating an aerosol.