阅读说明：本技术 可气溶胶化结构 (Aerosolisable structure ) 是由 瓦利德·阿比·奥恩 格伦·埃尔加 安德鲁·戴维斯 于 2018-12-06 设计创作，主要内容包括：公开了一种可气溶胶化结构(1),在与用于加热可气溶胶化材料以使可气溶胶化材料的至少一种成分挥发的设备一起使用的制品中使用。可气溶胶化结构包括：聚集分层结构(10、20、30、40、50),其具有：包括可气溶胶化材料的第一片材(11、21、31、41),以及包括加热材料的第二片材(12、22、32、42),该加热材料可通过用变化磁场穿透而加热,从而加热第一片材的可气溶胶化材料。第二片材不含可气溶胶化材料。(An aerosolizable structure (1) is disclosed for use in an article of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material. The aerosolizable structure comprises: an aggregate layered structure (10, 20, 30, 40, 50) having: a first sheet (11, 21, 31, 41) comprising an aerosolizable material, and a second sheet (12, 22, 32, 42) comprising a heating material which is heatable by penetration with a varying magnetic field, thereby heating the aerosolizable material of the first sheet. The second sheet is free of an aerosolizable material.)

1. An aerosolizable structure for use in an article of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the aerosolizable structure comprising:

an aggregated layered structure having:

a first sheet comprising an aerosolizable material; and

a second sheet comprising a heating material that is heatable by penetration with a varying magnetic field to heat the aerosolizable material of the first sheet,

wherein the second sheet is free of an aerosolizable material.

2. The aerosolizable structure according to claim 1, wherein the aerosolizable material is a reconstituted, cellulosic, or gel-form aerosolizable material.

3. The aerosolizable structure according to claim 2, wherein the aerosolizable structure is free of any aerosolizable material between the heating material and reconstituted or cellulosic aerosolizable material, or the aerosolizable material in gel form.

4. The aerosolizable structure according to claim 2 or 3, wherein the aerosolizable material reconstituted or cellulose, or in gel form, is in surface contact with the heating material.

5. An aerosolizable structure for use in an article of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the aerosolizable structure comprising:

an aggregated layered structure having:

a first sheet comprising an aerosolizable material;

a second sheet comprising a heating material; and

a third sheet comprising an aerosolizable material;

wherein the second sheet is positioned between the first sheet and the third sheet, and wherein the heating material is heatable by penetration with a varying magnetic field to heat the aerosolizable material of the first sheet and the third sheet.

6. The aerosolizable structure according to claim 5, wherein the second sheet is free of aerosolizable material.

7. The aerosolizable structure according to any one of claims 1-6, wherein the layered structure is coiled.

8. The aerosolizable structure according to any one of claims 1-7, wherein the heating material comprises one or more materials selected from the group consisting of: conductive materials, magnetic materials, and magnetically conductive materials.

9. The aerosolizable structure according to any one of claims 1-8, wherein the heating material comprises a metal or metal alloy.

10. The aerosolizable structure according to any one of claims 1-9, wherein the heating material comprises one or more materials selected from the group consisting of: aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, copper, and bronze.

11. The aerosolizable structure according to any one of claims 1-10, wherein the first sheet comprises reconstituted tobacco.

12. The aerosolizable structure according to any one of claims 1-11, wherein the second sheet comprises aluminum foil.

13. The aerosolizable structure according to any one of claims 1-12, comprising a wrap wrapped around the aggregated layered structure.

14. The aerosolizable structure according to any one of claims 1-13, wherein the aerosolizable structure is substantially cylindrical.

15. An article of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the article of manufacture comprising an aerosolizable structure according to any one of claims 1-14.

16. An article according to claim 15, comprising a filter for filtering aerosols released from the aerosolizable structure in use, and a connector to retain the filter relative to the aerosolizable structure.

17. A system for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the system comprising:

the article of claim 15 or 16; and

apparatus for heating the aerosolizable material of the article to volatilize at least one component of the aerosolizable material, the apparatus comprising:

a heating zone for receiving the article, an

A magnetic field generator for generating a varying magnetic field for penetrating the heating material of the article when the article is located in the heating region.

18. A method of manufacturing an aerosolizable structure for use in an article of manufacture for use with apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the method comprising:

providing a layered structure having a first sheet comprising an aerosolizable material and a second sheet comprising a heating material heatable by penetration with a varying magnetic field to heat the aerosolizable material; and

aggregating the hierarchical structures to form an aggregated hierarchical structure.

19. The method of claim 18, wherein the second sheet is free of an aerosolizable material.

20. The method of claim 18 or 19, wherein the layered structure has a third sheet comprising an aerosolizable material, wherein the second sheet is positioned between the first sheet and the third sheet, and wherein the heating material is heatable by penetration with a varying magnetic field to heat the aerosolizable material of the first sheet and the third sheet.

21. The method of any one of claims 18 to 20, wherein the step of aggregating comprises feeding the layered structure through a converging funnel.

22. The method of any one of claims 18 to 21, wherein the step of aggregating causes the layered structure to become substantially cylindrical.

23. The method of any one of claims 18 to 22, comprising crimping the layered structure prior to the step of aggregating.

24. The method of any of claims 18 to 23, wherein the step of providing the hierarchical structure comprises: causing the first sheet to contact the second sheet.

25. The method of any of claims 18 to 24, comprising: wrapping a wrapper around the aggregate layered structure to form a wrapped aggregate layered structure.

26. The method of claim 25, comprising: severing the wrapped aggregate layered structure to form a discontinuous wrapped aggregate layered structure.

27. A method of manufacturing an article for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the method comprising:

performing the method of any one of claims 18 to 26; and

connecting a filter to the gathering layered structure using a connector that holds the filter relative to the gathering layered structure.

Technical Field

The present invention relates to an aerosolizable structure for use in an article for use with an apparatus for heating an aerosolizable material, a method of manufacturing an aerosolizable structure, an article for use with an apparatus for heating an aerosolizable material, a method of manufacturing an article for use with an apparatus for heating an aerosolizable material, and a system comprising such an article and such an apparatus.

Background

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these articles by producing products that release compounds without burning. Examples of such products are so-called "heated but not burning" products or tobacco heating devices or products which release compounds by heating but not burning the material. The material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine.

Disclosure of Invention

A first aspect of the invention provides an aerosolizable structure for use in an article of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the aerosolizable structure comprising: an aggregate layered structure having: a first sheet comprising an aerosolizable material; and a second sheet comprising a heating material that is heatable by penetration with a varying magnetic field to heat the aerosolizable material of the first sheet, wherein the second sheet is free of aerosolizable material.

In an exemplary embodiment, the aerosolizable material is reconstituted, cellulosic, or gel form.

In one exemplary embodiment, the aerosolizable structure is devoid of any aerosolizable material between the heating material and the reconstituted or cellulosic aerosolizable material or aerosolizable material in gel form.

In an exemplary embodiment, the reconstituted or cellulosic aerosolizable material or the aerosolizable material in gel form is contacted with a heating material surface.

In one exemplary embodiment, the second sheet is composed of only the heating material.

In one exemplary embodiment, the layered structure is crimped.

In one exemplary embodiment, the heating material comprises one or more materials selected from the group consisting of: conductive materials, magnetic materials, and magnetically conductive materials.

In one exemplary embodiment, the heating material comprises a metal or metal alloy.

In one exemplary embodiment, the heating material comprises one or more materials selected from the group consisting of: aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, copper, and bronze.

In one exemplary embodiment, the first sheet comprises reconstituted tobacco.

In one exemplary embodiment, the second sheet comprises aluminum foil.

In one exemplary embodiment, the aerosolizable structure comprises a wrap wrapped around the aggregation layered structure.

In one exemplary embodiment, the aerosolizable structure is substantially cylindrical.

A second aspect of the invention provides an aerosolizable structure for use in an article of manufacture for use with apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the aerosolizable structure comprising: an aggregate layered structure having: a first sheet comprising an aerosolizable material; a second sheet comprising a heating material; and a third sheet comprising an aerosolizable material; wherein the second sheet is positioned between the first sheet and the third sheet, and wherein the heating material is heatable by penetration with a varying magnetic field to heat the aerosolizable material of the first sheet and the third sheet.

In one exemplary embodiment, the second sheet is free of an aerosolizable material.

In one exemplary embodiment, the second sheet is composed of only the heating material.

In one exemplary embodiment, the layered structure is crimped.

In one exemplary embodiment, the heating material comprises one or more materials selected from the group consisting of: conductive materials, magnetic materials, and magnetically conductive materials.

In one exemplary embodiment, the heating material comprises a metal or metal alloy.

In one exemplary embodiment, the heating material comprises one or more materials selected from the group consisting of: aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, copper, and bronze.

In one exemplary embodiment, the aerosolizable material of the first sheet is reconstituted, cellulosic, or in gel form.

In one exemplary embodiment, the first sheet comprises reconstituted tobacco.

In one exemplary embodiment, the second sheet comprises aluminum foil.

In one exemplary embodiment, the aerosolizable material of the third sheet is reconstituted, cellulosic or in gel form.

In one exemplary embodiment, the third sheet comprises reconstituted tobacco.

In one exemplary embodiment, the aerosolizable structure comprises a wrap wrapped around the aggregation layered structure.

In one exemplary embodiment, the aerosolizable structure is substantially cylindrical.

A third aspect of the invention provides an article for use with apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the article comprising the aerosolizable structure of the first aspect of the invention or the aerosolizable structure of the second aspect of the invention.

In one exemplary embodiment, the article includes a filter for filtering aerosols released from the aerosolizable structure in use, and a connector for retaining the filter relative to the aerosolizable structure.

A fourth aspect of the invention provides a system for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the system comprising: an article according to the third aspect of the invention; and an apparatus for heating the aerosolizable material of the article to volatilize at least one component of the aerosolizable material, the apparatus comprising: a heating zone for receiving the article, and a magnetic field generator for generating a changing magnetic field for penetrating a heating material of the article when the article is located in the heating zone.

A fifth aspect of the invention provides a method of manufacturing an aerosolizable structure for use in an article of manufacture for use with apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, the method comprising: providing a layered structure having a first sheet comprising an aerosolizable material and a second sheet comprising a heating material which is heatable by penetration with a varying magnetic field to heat the aerosolizable material; and aggregating the hierarchy to form an aggregated hierarchy.

In one exemplary embodiment, the second sheet is free of an aerosolizable material.

In one exemplary embodiment, the second sheet is composed of only the heating material.

In one exemplary embodiment, the second sheet comprises aluminum foil.

In one exemplary embodiment, the aerosolizable material of the first sheet is reconstituted, cellulosic, or in gel form.

In one exemplary embodiment, the first sheet comprises reconstituted tobacco.

In one example embodiment, the layered structure has a third sheet comprising an aerosolizable material, the second sheet is positioned between the first sheet and the third sheet, and the heating material is heatable by penetration with a varying magnetic field to heat the aerosolizable material of the first sheet and the third sheet.

In one exemplary embodiment, the aerosolizable material of the third sheet is reconstituted, cellulosic or in gel form.

In one exemplary embodiment, the third sheet comprises reconstituted tobacco.

In an exemplary embodiment, the step of aggregating includes feeding the layered structure through a convergence funnel.

In one exemplary embodiment, this step of aggregating results in the layered structure becoming substantially cylindrical.

In one exemplary embodiment, the method includes curling the layered structure prior to the step of aggregating.

In one exemplary embodiment, the step of providing a hierarchical structure comprises: causing the first sheet to contact the second sheet.

In one exemplary embodiment, the step of providing a hierarchical structure comprises: causing the third sheet to contact the second sheet.

In one exemplary embodiment, the method comprises: wrapping a wrapper around the aggregate layered structure to form a wrapped aggregate layered structure.

In one exemplary embodiment, the method comprises: severing the wrapped gathered layered structure to form a discontinuous wrapped gathered layered structure.

A sixth aspect of the invention provides a method of manufacturing an article for use with an apparatus for heating an aerosolizable material to volatilise at least one component of the aerosolizable material, the method comprising:

performing the method of the fifth aspect of the invention; and

the filter is connected to the gathering laminate using a connector that holds the filter relative to the gathering laminate.

Drawings

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

fig. 1 shows a schematic side view of an example of an aerosolizable structure for use in an article of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material;

fig. 2 shows a schematic cross-sectional view of the aerosolizable structure of fig. 1;

fig. 3 shows a partial schematic cross-sectional view of an example of a layered structure of an aerosolizable structure for use in an article of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material;

fig. 4 shows a partial schematic cross-sectional view of an example of a layered structure of another aerosolizable structure for use in an article of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material;

fig. 5 shows a partial schematic cross-sectional view of an example of a layered structure of another aerosolizable structure for use in an article of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material;

fig. 6 shows a partial schematic cross-sectional view of an example of a layered structure of yet another aerosolizable structure for use in an article of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material;

fig. 7 shows a schematic cross-sectional side view of an example of another aerosolizable structure for use in an article of manufacture with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material;

figure 8 shows a schematic cross-sectional side view of an example of an article of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material;

figure 9 shows a schematic cross-sectional side view of an example of another article of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material;

fig. 10 shows a schematic cross-sectional side view of an example of a system including the article of fig. 9 and an apparatus for heating the aerosolizable material of the article to volatilize at least one component of the aerosolizable material;

figure 11 shows a flow diagram illustrating an example of a method of manufacturing an aerosolizable structure for use in an article of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material;

figure 12 shows a flow diagram illustrating an example of another method of manufacturing an aerosolizable structure for use in an article of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material; and

figure 13 shows a flow diagram illustrating an example of a method of manufacturing an article for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material.

Detailed Description

As used herein, the term "aerosolizable material" includes materials that provide a volatile component upon heating, typically in the form of a vapor or aerosol. The "aerosolizable material" can be a tobacco-free material or a tobacco-containing material. The "aerosolizable material" can, for example, comprise one or more of tobacco itself, a tobacco derivative, expanded tobacco, reconstituted tobacco, a tobacco extract, homogenized tobacco, or a tobacco substitute. The aerosolizable material can be in the form of ground tobacco, shredded tobacco, extruded tobacco, reconstituted aerosolizable material, a liquid, a gel, a gelled sheet, a powder, or an agglomerate, and the like. The "aerosolizable material" can also include other non-tobacco products, which may or may not contain nicotine, depending on the product. An "aerosolizable material" can include one or more humectants, such as glycerin or propylene glycol.

As used herein, the term "sheet" means an element having a width and length substantially greater than its thickness.

As used herein, when it is stated that the sheet is "free of aerosolizable material," this means that the sheet itself does not include or consist of aerosolizable material, and is not coated or impregnated with aerosolizable material. However, this does not mean that the sheet may not be adjacent (directly or indirectly) to or adhered to the sheet comprising the aerosolizable material.

As used herein, the term "gathered" includes shapes that are wrinkled, folded, wrinkled, or otherwise coiled, whether in a regular or irregular manner. Accordingly, as used herein, the term "gathered" includes shapes that are wrinkled, folded, pleated, or otherwise coiled, whether in a regular or irregular manner.

As used herein, the term "crimped" includes having a plurality of substantially parallel corrugations or ridges and grooves therein.

As used herein, the term "heating material" or "heater material" refers to a material that can be heated by penetration with a changing magnetic field.

Induction heating is a process of heating an electrically conductive object by penetrating the object with a varying magnetic field. The process is described by faraday's law of induction and ohm's law. The induction heater may comprise an electromagnet and means for passing a varying current (e.g. an alternating current) through the electromagnet. When the electromagnet and the object to be heated are appropriately positioned relative to each other such that the resultant varying magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are generated inside the object. The object has a resistance to the flow of current. Therefore, when such an eddy current is generated in the object, it flows opposite to the resistance of the object, causing the object to be heated. This process is known as joule, ohmic or resistive heating. An object that can be inductively heated is called a susceptor.

It has been found that when the susceptor is in the form of a closed circuit, the magnetic coupling between the susceptor and the electromagnet is enhanced in use, which results in greater or improved joule heating.

Hysteresis heating is the process of heating an object made of a magnetic material by penetrating the object with a varying magnetic field. Magnetic materials can be considered to include many atomic-scale magnets or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipole aligns with the magnetic field. Thus, when a changing magnetic field (e.g., an alternating magnetic field generated by an electromagnet) penetrates a magnetic material, the orientation of the magnetic dipoles changes with the changing applied magnetic field. This reorientation of the magnetic dipoles results in the generation of heat in the magnetic material.

When the object is both electrically conductive and magnetic, penetration of the object with a varying magnetic field can cause joule heating and hysteresis heating in the object. In addition, the use of magnetic materials may enhance the magnetic field, which may enhance joule heating and hysteresis heating.

In each of the above processes, since heat is generated within the object itself, rather than by an external heat source through heat conduction, rapid temperature rise and more uniform heat distribution in the object can be achieved, particularly through selection of appropriate object materials and geometries, as well as appropriate varying magnetic field sizes and orientations relative to the object. Furthermore, since induction heating and hysteresis heating do not require a physical connection to be provided between the source of the varying magnetic field and the object, design freedom and control over the heating profile can be greater and costs can be lower.

Referring to fig. 1 and 2, schematic side and cross-sectional views of an example of an aerosolizable structure according to an embodiment of the present invention are shown. The aerosolizable structure 1 is for use in an article of manufacture, such as article 100 shown in fig. 8 and described below, for use with an apparatus that heats an aerosolizable material to volatilize at least one component of the aerosolizable material.

The aerosolizable structure 1 is substantially cylindrical with a substantially circular cross-section (see fig. 2), but in other embodiments the aerosolizable structure 1 may have an oval or elliptical cross-section or be non-cylindrical. In some embodiments, the aerosolizable structure 1 can have, for example, a polygonal, quadrilateral, rectangular, square, triangular, star-shaped, or irregular cross-section. In this embodiment, the aerosolizable structure 1 is a rod. In some other embodiments, the aerosolizable structure can be tubular with a hollow interior region.

In this embodiment, the aerosolizable structure 1 is elongate and has a longitudinal axis a-a. The length of the aerosolisable structure 1 in the direction of the longitudinal axis a-a may fall in the range of 40 mm to 150 mm, for example 70 mm to 120 mm. In other embodiments, the aerosolizable structure 1 may not be elongated. In some such other embodiments, the aerosolizable structure 1 still has an axial direction a-a perpendicular to the cross-section of the aerosolizable structure 1 shown in fig. 2. The width of the aerosolisable structure 1 perpendicular to the axial direction a-a may fall in the range of 4 mm to 10 mm, for example 5 mm to 8 mm. The circumference of the aerosolisable structure 1 perpendicular to the axial direction a-a may fall in the range of 12 mm to 30 mm, for example 16 mm to 25 mm.

The aerosolizable structure 1 comprises a layered structure 10. Fig. 3 shows a partial schematic cross-sectional view of a layered structure 10 of an aerosolizable structure 1. The layered structure 10 includes a first sheet 11 and a second sheet 12, and in some embodiments, the layered structure 10 is a laminate. In some embodiments, the first sheet 11 is bonded to the second sheet 12, for example by an adhesive or by chemical bonding. Examples of binders are polyvinyl acetate (PVA) and Ethylene Vinyl Acetate (EVA). In other embodiments, the first sheet 11 may not be bonded to the second sheet 12.

In this embodiment, the first sheet 11 comprises an aerosolizable material. The aerosolizable material of the first sheet 11 can be any aerosolizable material discussed herein, such as reconstituted aerosolizable material (e.g., reconstituted tobacco) or in gel form. The first sheet 11 may comprise a substrate, such as paper, impregnated or coated with an aerosolizable material, such as a gel. The aerosolizable material of the first sheet 11 may be a cellulose aerosolizable material.

In this embodiment, the second sheet 12 comprises a heating material that can be heated by penetration with a varying magnetic field. More specifically, the heating material may be heated by penetration with a varying magnetic field to heat the aerosolizable material of the first sheet 11. That is, the heating material is in thermal contact with the aerosolizable material. Since the first sheet 11 and the second sheet 12 are part of the same layered structure 10, the heat generated in the second sheet 12 by penetration with a varying magnetic field approaches the first sheet 11, so that a relatively efficient heating of the aerosolizable material of the first sheet 11 can be achieved. In some embodiments, the aerosolizable material of the first sheet 11 is in surface contact with the heating material of the second sheet 12. Thus, heat can be directly transferred from the heating material to the aerosolizable material. This may help to further increase the heating efficiency of the aerosolizable material of the first sheet 11. In other embodiments, the heating material may not be in contact with the aerosolizable material surface. For example, in some embodiments, a thermally conductive barrier that is free of the heating material and the aerosolizable material may separate the heating material from the aerosolizable material. In some embodiments, the thermal conductive barrier may be a coating on the first sheet 11 or the second sheet 12. Providing such a barrier may be advantageous to help dissipate heat to mitigate hot spots in the heating material.

In some embodiments, the aerosolizable material of the first sheet 11 is reconstituted, cellulosic, or gel-form, and the aerosolizable structure 1 may be devoid of any aerosolizable material between the reconstituted, cellulosic, or gel-form aerosolizable material of the first sheet 11 and the heating material of the second sheet 12. In some embodiments, this is advantageous in that a greater proportion of the heat generated in the second sheet 12 by penetrating the heating material with a varying magnetic field is available to heat the aerosolizable material of the first sheet 11.

In this embodiment, the heating material is aluminum and the second sheet 12 is a sheet of aluminum foil. However, in other embodiments, the heating material may be any one or more of those described herein, and/or the sheet 12 including the heating material may take any form described herein.

In this embodiment, the second sheet 12 is free of an aerosolizable material. In some embodiments, the second sheet 12 consists only of the heating material. In other embodiments, such as will be described below with reference to fig. 5 and 6, this may not be the case. In some embodiments, a benefit of removing the aerosolizable material from the second sheet 12 in this manner is that a greater proportion of the heat generated in the second sheet 12 by penetrating the heating material with a varying magnetic field is available to heat the aerosolizable material of the first sheet 11.

As best shown in fig. 2, the layered structure 10 of the aerosolizable structure 1 is an aggregate layered structure 10. In other words, the hierarchical structure 10 has been aggregated. An exemplary method for aggregating hierarchical structure 10 is described in more detail below. This gathering of the layered structure 10 enables a larger portion of the second sheet 12 comprising heating material to be brought close to the first sheet 11 comprising the aerosolizable material to be heated, than for example wrapping the second sheet 12 comprising heating material just around the outside of the plug or gathering of aerosolizable material, or positioning blades or rods of heating material in a relatively concentrated manner in the plug or gathering of aerosolizable material. Therefore, the heating efficiency of the aerosolizable material of the first sheet 11 can be improved. Further, the sheet comprising the aerosolizable material may have a relatively high surface area to volume ratio, and aggregating the sheet comprising the aerosolizable material may expose a majority of the surface area of the sheet to release the aerosol in use. Furthermore, the gathered sheet may define one or more flow paths along which aerosols generated in use can escape from the aerosolizable structure.

In a variation of the embodiment of fig. 1-3, the layered structure may be crimped. Fig. 4 shows a partial schematic cross-sectional view of an example of another aggregated layered structure of an aerosolizable structure according to an embodiment of the invention, in which the layered structure is coiled. The aggregate layered structure 20 of fig. 4 also includes a first sheet 21 comprising an aerosolizable material, and a second sheet 22 comprising a heating material that is heatable by penetration with a varying magnetic field to heat the aerosolizable material of the first sheet 21. Further, the second sheet 22 also does not contain an aerosolizable material. In some embodiments, the second sheet 22 is composed of only a heating material. In some variations of this embodiment, the first and second sheets 21, 22 may have any of the optional or alternative features described herein with respect to the first and second sheets 11, 12 shown in fig. 2 and 3.

Such curling may aid in the aggregation of layered structure 20 and/or indicate how layered structure 20 aggregates during the manufacture of the aerosolizable structure. For example, the distance that layered structure 20 curls may help determine the path that the windings of layered structure 20 will take when gathered, and may help determine the porosity of the resulting gathered layered structure 20. Additionally or alternatively, such curling may further increase the proportion of the second sheet 22 that is adjacent to the first sheet 21, which in turn helps to increase the heating efficiency of the aerosolizable material of the first sheet 21 in use. Some, most, or all of the plurality of substantially parallel corrugations or ridges and troughs present in the layered structure 20 due to curling may be parallel to the axial direction a-a of the aerosolizable structure in which the layered structure 20 is included.

In each of the embodiments shown in fig. 1-3 and 4 and described herein, the aggregate layered structure 10, 20 comprises two sheets 11, 12, 21, 22. However, in some embodiments, the aggregation layered structure may include more than two sheets. Fig. 5 shows a partial schematic cross-sectional view of an example of another aggregated layered structure 30 of an aerosolizable structure according to an embodiment of the present invention.

The aggregation layered structure 30 of fig. 5 has a first sheet 31, a second sheet 32, and a third sheet 33. The second sheet 32 is located between the first sheet 31 and the third sheet 33. Each of the first sheet 31 and the second sheet 33 comprises an aerosolizable material. The aerosolizable material of the first sheet 31 can be any aerosolizable material discussed herein, such as reconstituted tobacco or in gel form. Similarly, the aerosolizable material of the third sheet 33 can be any aerosolizable material discussed herein, such as reconstituted tobacco or in gel form. One or each of the first sheet 31 and the third sheet 33 may be a cellulose aerosolizable material.

The second sheet 32 comprises a heating material that can be heated by penetration with a varying magnetic field to heat the aerosolizable material of the first sheet 31 and the third sheet 33. Positioning the second sheet 32 between the first sheet 31 and the third sheet 33 enables a larger part of the total area of the surface of the second sheet 32 to access the sheets 31, 33 comprising the aerosolizable material. This in turn allows thermal energy emanating from both surfaces of the second sheet 32 in use to heat the aerosolizable material of the layered structure 30.

In some embodiments, the second sheet 32 is free of an aerosolizable material. In some embodiments, the second sheet 32 is composed of only a heating material. However, in other embodiments, the second sheet 32 may itself comprise the aerosolizable material, for example by providing a coating of the aerosolizable material, or the second sheet 32 may be impregnated or interwoven with the aerosolizable material. In some variations of this embodiment, one or each of the first and third sheets 31, 33 may have any of the optional or alternative features described herein with respect to the first sheet 11 shown in fig. 2 and 3. In some variations of this embodiment, the second sheet 32 may have any of the optional or alternative features described herein with respect to the second sheet 12 shown in fig. 2 and 3.

In a variation of the embodiment of fig. 5, the layered structure may be crimped. Fig. 6 shows a partial schematic cross-sectional view of an example of an aggregated layered structure of yet another aerosolizable structure, in accordance with embodiments of the present invention. Aggregation layered structure 40 of fig. 6 is the same as aggregation layered structure 30 of fig. 5, except that aggregation layered structure 40 of fig. 6 is curled. The layered structure 40 of fig. 6 also includes a first sheet 41 and a third sheet 43 that include an aerosolizable material, and also includes a second sheet 42 therebetween that includes a heating material that can be heated by penetration with a varying magnetic field to heat the aerosolizable material of the first sheet 41 and the third sheet 43. Any possible variations to the embodiment of fig. 5 described herein may be made to the embodiment of fig. 6 to form other embodiments.

Fig. 7 shows a schematic cross-sectional side view of another example of an aerosolizable structure according to an embodiment of the present invention. The aerosolizable structure 5 of fig. 7 is also substantially cylindrical, having a substantially circular cross-section and a longitudinal axis a-a. For example, the length and/or width of aerosolizable structure 5 may be any of those discussed herein, e.g., with respect to aerosolizable structure 1 of fig. 1-3. In other embodiments, the aerosolizable structure 5 may have a different cross-section, such as any of those discussed herein, or may be other than cylindrical, or not elongated.

The aerosolizable structure 5 of fig. 7 comprises an aggregate layered structure 50. Aggregation hierarchy 50 may be the same as any of aggregation hierarchies 10, 20, 30, 40 discussed above or any variations thereof discussed herein.

Aerosolizable structure 5 further comprises a wrap 51 wrapped around aggregation laminate 50. Wrap 51 surrounds the aggregate layered structure 50 and may help to avoid or prevent separation or unraveling of layered structure 50 and help to protect the aggregate layered structure 50 from damage during shipping and use. During use, the wrapper 51 may also help direct the flow of air into and through the gathering layered structure 50, and may help direct the flow of vapor or aerosol through and out of the gathering layered structure 50.

In this embodiment, the wrap 51 is wrapped around the aggregation laminate 50 such that the free ends of the wrap 51 overlap one another. The wrapper 51 may form all or a majority of the circumferential outer surface of the aerosolizable structure 5. The wrapper 51 may be made of any suitable material, such as paper, card, reconstituted aerosolizable material (e.g., reconstituted tobacco), or heating material (e.g., metal or metal alloy foil, such as aluminum foil). The wrap 51 may also include an adhesive (not shown) that bonds the overlapping free ends of the wrap 51 to one another. The binder may include, for example, one or more of gum arabic, natural or synthetic resins, starches, and varnishes. The adhesive helps prevent separation of the overlapping free ends of the wrap 51. In other embodiments, the adhesive may be omitted, or the wrap 51 may take a form different from that described. Any of these types of wraps may be applied to the other aerosolizable structures described or illustrated herein to form other embodiments.

Any of the aerosolizable structures described or illustrated herein may themselves be used as an article of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, such as apparatus 500 shown in fig. 10 and described below. However, in other embodiments, the article may include an aerosolizable structure and one or more other components.

For example, fig. 8 shows a schematic cross-sectional side view of an example of an article according to an embodiment of the invention. The article 100 of fig. 8 includes the aerosolizable structure 1 of fig. 1-3. However, in other embodiments, the aerosolizable structure of the article can be, for example, any of the other aerosolizable structures described herein.

The article 100 is substantially cylindrical with a substantially circular cross-section, but in other embodiments, the article 100 may have an oval or elliptical cross-section or be non-cylindrical. In some embodiments, article 100 may have a polygonal, quadrilateral, rectangular, square, triangular, star-shaped, or irregular cross-section, for example. In this embodiment, the article 100 is a rod. In some other embodiments, the article may be tubular with a hollow interior region.

In this embodiment, article 100 is elongated and has a longitudinal axis B-B. The longitudinal axis B-B of the article 100 coincides with the longitudinal axis a-a of the aerosolizable structure 1. The length of the article 100 in the direction of the longitudinal axis B-B may fall within the range of 40 mm to 150 mm, such as 70 mm to 120 mm. In other embodiments, article 100 may not be elongated. In some such other embodiments, article 100 still has an axial direction B-B that is perpendicular to the cross-section of article 100. The width of the article 100 perpendicular to the axial direction B-B may fall in the range of 4 mm to 10 mm, for example 5 mm to 8 mm. The circumference of the aerosolisable structure 1 perpendicular to the axial direction B-B may fall in the range of 12 mm to 30 mm, for example 16 mm to 25 mm.

The article 100 of fig. 8 also includes a filter 1 b. The filter 1b is used to filter aerosols or vapours released from the aerosolizable structure 1 of the article 100 in use. The filter 1b may be of any type used in the tobacco industry. For example, the filter 1b may be made of cellulose acetate. In this embodiment, the filter plug 1b is substantially cylindrical, having a substantially circular cross-section and a longitudinal axis. In other embodiments, the filter 1b may have different cross-sections, such as any of those discussed herein with respect to the aerosolizable structure, either other than cylindrical or not elongated.

In this embodiment, the filter 1b is adjacent to a longitudinal end of the aerosolizable structure 1 and is axially aligned with the aerosolizable structure 1. In other embodiments, the filter 1b may be spaced from the aerosolizable structure, such as by a gap and/or by one or more other components of the article 100. Exemplary additional ingredients are additive or flavor sources (e.g., capsules or threads containing additives or flavors) that may be held, for example, by or between bodies of filter material.

The article 100 further comprises a wrapper 1c wrapped around the aerosolizable structure 1 and the filter 1b to retain the filter 1b relative to the aerosolizable structure 1. The wrap 1c surrounds the aerosolizable structure 1 and filter 1b, can help to avoid or prevent separation or unraveling of the layered structure of the aerosolizable structure 1, and can help to protect the aggregated layered structure from damage during transport and use. During use, the wrapper 1c may also help to direct a flow of air into and through the aerosolizable structure 1, and may help to direct a flow of vapor or aerosol through and out of the aerosolizable structure 1.

In this embodiment, the wrapper 1c is wrapped around the aerosolizable structure 1 and the filter 1b such that the free ends of the wrapper 1c overlap one another. The wrap 1c may form all or a majority of the circumferential outer surface of the article 100. The wrapper 1c may be made of any suitable material, such as paper, card, or reconstituted aerosolizable material (e.g., reconstituted tobacco). The wrap 1c may also include an adhesive (not shown), such as one of those discussed elsewhere herein, that bonds the overlapping free ends of the wrap 1c to one another. The adhesive helps to prevent separation of the overlapping free ends of the wrapper 1 c. In other embodiments, the adhesive may be omitted or the wrap 1c may take a form different from that described. In other embodiments, the filter 1b may be retained relative to the aerosolizable structure 1 by a connector (e.g., an adhesive) other than the wrap 1 c.

Fig. 9 shows a schematic cross-sectional side view of an example of another article according to an embodiment of the invention. The article 200 of fig. 9 is the same as the article of fig. 8 except that the article 200 has the aerosolizable structure 5 of fig. 7 in place of the aerosolizable structure 1. Thus, the wrapper 1c of the article 200 of fig. 9 is wrapped around the wrapper 51 of the aerosolizable structure 5 and the filter 1b to retain the filter 1b relative to the aerosolizable structure 5. Any possible variations of the article 100 of fig. 8 discussed herein may be made to the article 200 of fig. 9 to form other embodiments.

In some embodiments, the article may be provided with an apparatus for heating the aerosolizable material of the article to volatilize at least one component of the aerosolizable material. The apparatus may include a heating zone for receiving the article, and a magnetic field generator for generating a varying magnetic field for penetrating a heating material of the article when the article is in the heating zone, thereby heating the aerosolizable material of the article.

For example, fig. 10 shows a schematic cross-sectional side view of an example of a system according to an embodiment of the invention. System 1000 includes article 200 of fig. 9 and apparatus 500 for heating the aerosolizable material of article 200 to volatilize at least one component of the aerosolizable material. In other embodiments, the article 200 may be replaced by any other article described herein. In this embodiment, the apparatus 500 is a tobacco heating product (also referred to in the art as a tobacco heating device or a heating but non-combustion device).

Broadly, the apparatus 500 includes a heating region 511 for receiving the article 200, and a magnetic field generator 512 for generating a changing magnetic field for penetrating a heating material of the article 200 when the article 200 is positioned in the heating region 511.

More specifically, the apparatus 500 of this embodiment includes a body 510 and a mouthpiece 520. The mouthpiece 520 may be made of any suitable material, such as a plastic material, cardboard, cellulose acetate, paper, metal, glass, ceramic, or rubber. The mouthpiece 520 defines a passage 522 therethrough. The mouthpiece 520 may be positioned relative to the body 510 to cover the opening to the heating zone 511. When the mouthpiece 520 is so positioned relative to the body 510, the channels 522 of the mouthpiece 520 are in fluid communication with the heating zone 511. In use, the channels 522 serve as pathways to allow volatile material to pass from the aerosolizable material of an article inserted into the heating zone 511 to the exterior of the apparatus 500. In this embodiment, the mouthpiece 520 is releasably engaged with the main body 510 to connect the mouthpiece 520 to the main body 510. In other embodiments, the mouthpiece 520 and the body 510 may be permanently connected, such as by a hinge or flexible member. In some embodiments, such as embodiments in which the article itself comprises a mouthpiece, the mouthpiece 520 of the apparatus 500 may be omitted.

The apparatus 500 may define an air inlet (not shown) fluidly connecting the heating zone 511 with an exterior of the apparatus 500. Such air inlets may be defined by the body 510 and/or the mouthpiece 520. A user may be able to inhale volatile components of the aerosolizable material by drawing the volatile components through the channels 522 of the mouthpiece 520. As volatile components are removed from the article 200, air may be drawn into the heating zone 511 via the air inlet of the apparatus 500.

In this embodiment, the body 510 includes a heating region 511. In this embodiment, the heating zone 511 includes a recess 511 for receiving at least a portion of the article 200. In other embodiments, the heating zone 511 may be a component other than a recess, such as a shelf, surface, or protrusion, and may need to mechanically cooperate with the article in order to cooperate with or receive the article. In this embodiment, the heating zone 511 is elongated and sized and shaped to accommodate the entire article 200. In other embodiments, the heating zone 511 may be sized to receive only a portion of the article 200.

In this embodiment, the magnetic field generator 512 comprises a power source 513, a coil 514, means 516 for passing a varying current (e.g., alternating current) through the coil 514, a controller 517, and a user interface 518 for user operation of the controller 517.

The power supply 513 of this embodiment is a rechargeable battery. In other embodiments, the power supply 513 may be a battery other than a rechargeable battery, such as a non-rechargeable battery, a capacitor, a battery-capacitor hybrid, or a connection to a mains power supply.

The coil 514 may take any suitable form. In this embodiment, the coil 514 is a helical coil of conductive material (e.g., copper). In some embodiments, the magnetic field generator 512 may include a magnetically permeable core around which the coil 514 is wound. Such a magnetically permeable core concentrates the magnetic flux generated by the coil 514 in use and generates a stronger magnetic field. The permeable core may be made of, for example, iron. In some embodiments, the magnetically permeable core may extend only partially along the length of the coil 514 to concentrate magnetic flux only in certain areas. In some embodiments, the coil may be a pancake coil. That is, the coil may be a two-dimensional spiral. In this embodiment, the coil 514 surrounds the heating region 511. The coil 514 extends along a longitudinal axis that is substantially aligned with the longitudinal axis of the heating zone 511. The axes of alignment are coincident. In a variation of this embodiment, the aligned axes may be parallel or oblique to each other.

In this embodiment, the means 516 for passing a varying current through the coil 514 is electrically connected between the power source 513 and the coil 514. In this embodiment, controller 517 is also electrically connected to power source 513 and communicatively connected to device 516 to control device 516. More specifically, in this embodiment, the controller 517 is used to control the device 516 to control the supply of power from the power source 513 to the coil 514. In this embodiment, controller 517 comprises an Integrated Circuit (IC), such as an integrated circuit on a Printed Circuit Board (PCB). In other embodiments, the controller 517 may take different forms. In some embodiments, the apparatus may have a single electrical or electronic component that includes the device 516 and the controller 517. In this embodiment, the controller 517 is operated by a user operation of the user interface 518. In this embodiment, the user interface 518 is located external to the body 510. The user interface 518 may include buttons, toggle switches, dials, touch screens, and the like. In other embodiments, the user interface 518 may be remote and wirelessly connected to the rest of the device, for example via a bluetooth connection.

In this embodiment, user operation of the user interface 518 causes the controller 517 to enable the device 516 to cause an alternating current to pass through the coil 514. This causes the coil 514 to generate an alternating magnetic field. The coil 514 and the heating zone 511 of the apparatus 500 are suitably positioned relative to each other such that the changing magnetic field generated by the coil 514 penetrates the heating material of the article 200 when the article 200 is in the heating zone 511. In this embodiment, the heating material is an electrically conductive material, and thus the penetration results in the generation of one or more eddy currents in the heating material. The flow of eddy currents in the heating material against the resistance of the heating material causes the heating material to be heated by joule heating. When the heating material is made of a magnetic material, the orientation of the magnetic dipoles in the heating material changes with a change in the applied magnetic field, which results in the generation of heat in the heating material.

The apparatus 500 of this embodiment includes a temperature sensor 519 for sensing the temperature of the heating zone 511. The temperature sensor 519 is communicatively connected to the controller 517 such that the controller 517 is able to monitor the temperature of the heating zone 511. Based on one or more signals received from the temperature sensor 519, the controller 517 may cause the device 516 to adjust the characteristics of the varying or alternating current through the coil 514 as needed to ensure that the temperature of the heating zone 511 is maintained within a predetermined temperature range. The characteristic may be, for example, amplitude or frequency or duty cycle. In use, the aerosolizable material within the article located in heating zone 511 is heated sufficiently within a predetermined temperature range to volatilize at least one component of the aerosolizable material without combusting the aerosolizable material. Thus, the controller 517 and the apparatus 500 as a whole are arranged to heat the aerosolizable material to volatilize at least one component of the aerosolizable material without burning the aerosolizable material. In some embodiments, the temperature range is between about 50 ℃ and about 300 ℃, e.g., between about 50 ℃ and about 250 ℃, between about 50 ℃ and about 150 ℃, between about 50 ℃ and about 120 ℃, between about 50 ℃ and about 100 ℃, between about 50 ℃ and about 80 ℃, or between about 60 ℃ and about 70 ℃. In some embodiments, the temperature range is between about 170 ℃ and about 220 ℃. In other embodiments, the temperature range may be a range other than this range. In some embodiments, the upper limit of the temperature range may be greater than 300 ℃. In some embodiments, temperature sensor 519 may be omitted. In some embodiments, the heating material may have a curie point temperature selected based on the maximum temperature to which it is desired to heat the heating material, such that further heating above that temperature by induction heating the heating material is impeded or prevented.

Fig. 11 and 12 show flow diagrams of examples of methods of fabricating an aerosolizable structure.

The method of fig. 11 may be used to make any of the aerosolizable structures described herein. The method comprises providing 11a layered structure having a first sheet 11, 21, 31, 41 comprising an aerosolizable material, and a second sheet 12, 22, 32, 42 comprising a heating material which is heatable by penetration with a varying magnetic field to heat the aerosolizable material; and aggregating 11b the layered structures to form an aggregated layered structure 10, 20, 30, 40.

The second sheet 12, 22, 32, 42 may be free of an aerosolizable material. The second sheet 12, 22, 32, 42 may be composed of only a heating material. In some embodiments, the second sheet comprises an aerosolizable material.

Step 11b of aggregating may comprise feeding the layered structure through a convergence funnel. Step 11b of aggregating may result in the layered structure becoming substantially cylindrical. The method may include crimping the layered structure prior to step 11b of aggregating. The step 11a of providing a layered structure may comprise causing the first sheet 11, 21, 31, 41 to contact the second sheet 12, 22, 32, 42. The method may include wrapping a wrapper around the aggregate layered structure to form a wrapped aggregate layered structure. In some embodiments, the method includes severing the wrapped aggregated layered structure to form a discontinuous wrapped aggregated layered structure.

The method of fig. 12 may be used to make an aerosolizable structure having an aggregated layered structure comprising three sheets, such as the sheets shown in fig. 5 and 6.

The method comprises providing a layered structure having a first sheet 31, 41 comprising an aerosolizable material, a second sheet 32, 42 comprising a heating material heatable by penetration with a varying magnetic field, and a third sheet comprising an aerosolizable material, wherein the second sheet 32, 42 is located between the first sheet 31, 41 and the third sheet 33, 43, and wherein the heating material is heatable by penetration with a varying magnetic field to heat the aerosolizable material of the first sheet 31, 41 and the third sheet 33, 43.

In some embodiments, the second sheet 32, 42 is free of an aerosolizable material. In some embodiments, the second sheet 32, 42 is composed of only a heating material. In some embodiments, the second sheet comprises an aerosolizable material.

In this embodiment, the providing includes causing the first sheet 31, 41 to contact the second sheet 32, 42 by 12 a. The first and second sheets 31, 41, 32, 42 may be drawn from respective supplies, such as respective spools (not shown), before contacting each other. In other embodiments, the first sheet and the second sheet may already be in contact with each other, and therefore the method does not include this reason. Instead, the combination of the first and second sheets 31, 41, 32, 42 (e.g., the laminate) may be drawn from a supply such as a spool (not shown).

In this embodiment, the providing includes causing the third sheet 33, 43 to contact the second sheet 32, 42 by 12 b. The third sheet 33, 43 may be drawn from a supply such as a spool (not shown) prior to contact with the second sheet 32, 42. In other embodiments, the second sheet and the third sheet may already be in contact with each other, and therefore the method does not include this reason. Instead, the combination of the second 32, 42 and third 33, 43 sheets (e.g., laminate) may be drawn from a supply such as a spool (not shown). Alternatively, a combination (e.g., a laminate) of the first sheet 31, 41, the second sheet 32, 42, and the third sheet 33, 43 may be drawn from a supply source such as a spool (not shown).

In embodiments where the manufactured aerosolizable structure has a rolled layered structure, such as the embodiment shown in fig. 6, the method includes rolling 12c to provide the layered structure. The crimping may be performed by transporting the layered structure between a pair of matable crimping rollers that engage and crimp the layered structure as it passes. In other embodiments where the manufactured aerosolizable structure has a non-curled layered structure, such as the embodiment shown in fig. 5, the curling may be omitted.

The method includes aggregating 12d the hierarchical structures to form an aggregated hierarchical structure 30, 40. In embodiments where the layered structure is to be crimped, the step 12c of crimping may occur before the step 12d of gathering. Step 12d of aggregating may include transporting the layered structures 30, 40 through a converging funnel. In other embodiments, the aggregation 12d may include alternative processes, such as squeezing the layered structures 30, 40 between bodies or plates that are movable relative to each other, or such as twisting (e.g., into a spiral form). In embodiments where the layered structure is curled, the aggregation may occur in a direction substantially perpendicular to the corrugations or ridges and troughs present in the layered structure as a result of the curling.

Step 12d of aggregating may result in the layered structure 30, 40 becoming substantially cylindrical. This may be caused by the shape of the converging funnel (if used). In other embodiments, step 12d of aggregating may result in layered structures 30, 40 taking on shapes other than cylindrical.

In this embodiment, the method includes wrapping 12e a wrap 51 around the aggregate layered structure 30, 40 to form a wrapped aggregate layered structure. The wrap 51 may be drawn from a supply (e.g., a spool) and enclosed about the gathering laminations 30, 40 by an appendage or endless belt conveyor. The wrap 51 may include an adhesive that may be applied to the wrap prior to or during step 12e of wrapping such that when the opposing free ends of the wrap 51 overlap one another, the adhesive bonds the opposing free ends to one another. The method may include passing the wrapped aggregate layered structure through or past a dryer to dry the adhesive. As discussed herein, in some embodiments, such a wrap may be omitted. That is, the aggregate layered structure may be free of a wrapper. As such, the method may not include step 12e of wrapping the package.

In this embodiment, the method includes severing the 12e wrapped aggregate layered structure to form a discrete wrapped aggregate layered structure for use in an article for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material. In embodiments where the wrapping is omitted step 12e, the method may include severing 12e the aggregate layered structure to form a discontinuous aggregate layered structure for use in an article. The step of severing may include cutting, for example, by a rotary cutter. In some still other embodiments, the severing step 12e may be omitted. For example, in some embodiments, the aggregated or wrapped aggregated layered structure produced according to the method may already be sized for use in an article without the need for cutting.

Fig. 13 illustrates a flow chart showing an example of a method of manufacturing an article of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material. The method of figure 13 comprises performing 13a the method of figure 11 or figure 12 (or any variation thereof described herein) and connecting 13b the filter to the gathering laminate using a connector that holds the filter relative to the gathering laminate. The filter may be, for example, the filter 1b discussed above. The connector may be, for example, any connector discussed herein, such as one of the wraps 1c described.

In some embodiments, the heating material is aluminum. However, in other embodiments, the heating material may comprise one or more materials selected from the group consisting of: conductive materials, magnetic materials, and magnetically conductive materials. In some embodiments, the heating material may comprise a metal or metal alloy. In some embodiments, the heating material may comprise one or more materials selected from the group consisting of: aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, copper, and bronze. Other heating materials may be used in other embodiments.

In some embodiments, the sheet comprising the heating material is free of holes or discontinuities. In some embodiments, the sheet comprising the heating material comprises a foil, such as a metal or metal alloy foil, such as aluminum foil. However, in some embodiments, the sheet comprising the heating material may have holes or discontinuous portions. For example, in some embodiments, the sheet comprising the heating material may comprise a mesh, a perforated sheet, or a perforated foil, such as a metal or metal alloy perforated foil, such as a perforated aluminum foil.

In some embodiments, such as those in which the heating material comprises iron, such as steel (e.g., mild steel or stainless steel) or aluminum, a sheet comprising the heating material may be coated to help avoid corrosion or oxidation of the heating material in use. Such coatings may include, for example, nickel plating, gold plating, or coatings of ceramic or inert polymers. In some embodiments, the sheet comprising the heating material comprises or consists of a nickel-plated aluminum foil.

The heating material may have a skin depth that is the outer region within which induced currents and/or induced reorientation of magnetic dipoles occur for a large portion. By providing a heating material with a relatively small thickness, a greater proportion of the heating material may be heated by a given varying magnetic field than a heating material with a relatively large depth or thickness compared to other dimensions of the heating material. Thus, a more efficient use of material is achieved and, in turn, costs are reduced.

In some embodiments, the aerosolizable material comprises tobacco. However, in other embodiments, the aerosolizable material can consist of, can consist essentially entirely of, can include tobacco and aerosolizable materials other than tobacco, can include aerosolizable materials other than tobacco, or can be free of tobacco. In some embodiments, the aerosolizable material can include a vapor or aerosol former or humectant, such as glycerin, propylene glycol, triacetin, or diethylene glycol. In some embodiments, the aerosolizable material is a non-liquid aerosolizable material, and the apparatus is for heating the non-liquid aerosolizable material to volatilize at least one component of the aerosolizable material.

In some embodiments, the article 100, 200 is a consumable article. Once all or substantially all of the volatizable material in article 100, 200 has been depleted, a user may remove article 100, 200 from heating zone 511 of apparatus 500 and dispose of article 100, 200. The user may then reuse the device 500 with the other of the articles 100, 200. However, in other respective embodiments, the article may be non-consumable and the device and article may be disposed of together once the volatizable components of the aerosolizable material have been depleted.

In some embodiments, the article 100, 200 is sold, supplied, or otherwise provided separately from the device 500 with which the article 100, 200 may be used. However, in some embodiments, the apparatus 500 and one or more of the articles 100, 200 may be provided together as a system, such as a kit or assembly, possibly with additional components, such as a cleaning appliance.

To solve the problems and advance the art, the entire disclosure shows by way of illustration and example various embodiments, the claimed invention may be practiced therein, and these embodiments provide superior aerosolizable structures for use in articles of manufacture for use with an apparatus for heating an aerosolizable material, articles of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of the aerosolizable material, methods of making aerosolizable structures for use in articles of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of an aerosolizable material, methods of making articles of manufacture for use with an apparatus for heating an aerosolizable material to volatilize at least one component of an aerosolizable material, and systems comprising such articles of manufacture and such apparatuses. The advantages and features of the present disclosure are merely representative of embodiments and are not exhaustive and/or exclusive. It is used only to assist in understanding and teaching the claimed and otherwise disclosed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the present disclosure are not to be considered limitations on the present disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope and/or spirit of the present disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of various combinations of the disclosed elements, components, features, parts, steps, means, and the like. The present disclosure may include other inventions not presently claimed, but which may be claimed in the future.