CN117835858A

CN117835858A - Consumable for use with an aerosol supply device

Info

Publication number: CN117835858A
Application number: CN202280054363.6A
Authority: CN
Inventors: 保罗·吉布森; 巴纳比·奥克利
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2021-08-04
Filing date: 2022-08-04
Publication date: 2024-04-05

Abstract

A method of manufacturing a consumable (124) for use with a non-combustible sol supply system is provided. The consumable comprises a support (30) and an aerosol-generating material (32A, 32B). The method comprises the following steps: providing a support; -forming at least one reinforcing area (40 a,40 b) on the support; the aerosol-generating material is applied to the support in at least one location corresponding to at least a portion of the at least one reinforcing region.

Description

Consumable for use with an aerosol supply device

Technical Field

The present disclosure relates to the field of non-combustible aerosol supply systems, in particular to consumables for use with an aerosol supply device, a method of manufacturing consumables for use with an aerosol supply device, and an aerosol supply system comprising consumables and an aerosol supply device.

Background

Smoking articles such as cigarettes, cigars, and the like burn tobacco during use to produce tobacco smoke. Alternatives to these types of articles release inhalable aerosols or atomizing gases by heating without burning compounds released from the matrix material. These may be referred to as non-combustible smoking articles, aerosol-generating components or aerosol-supplying devices.

One example of such a product is a heating device that releases a compound by heating without burning an aerosolizable material, which may be referred to as a solid aerosol-generating material. In some cases, the solid aerosol-generating material may comprise tobacco material. The heating causes at least one component of the material to aerosolize, typically forming an inhalable aerosol. These products may be referred to as heated non-combustion devices, tobacco heating devices, or tobacco heating products. Various arrangements for aerosolizing at least one component of a solid aerosol-generating material are known.

As another example, there is a mixing device. These mixing devices contain a liquid source (which may or may not contain nicotine) that evaporates by heating to produce an inhalable aerosol or aerosol. The device additionally comprises a solid aerosol-generating material (which may or may not comprise tobacco material) and components of the solid aerosol-generating material are entrained in the inhalable aerosol-generating gas or aerosol to produce an inhalation medium.

Disclosure of Invention

According to a first aspect of the present disclosure there is provided a method of manufacturing a consumable for use with a non-combustible aerosol provision system, wherein the consumable comprises a support and an aerosol generating material, wherein the method comprises:

A support member is provided which is configured to support the support member,

at least one reinforcing area is formed on the support,

the aerosol-generating material is applied to the support at least one location corresponding to at least a portion of the at least one reinforcing region.

According to a second aspect of the present disclosure there is provided a consumable for use with a non-combustible sol supply system, wherein the consumable comprises a support and at least one reinforcing region located on the support and comprising an aerosol generating material, and the aerosol generating material is supported on the support at least one location corresponding to at least a portion of the at least one reinforcing region.

According to a third aspect of the present disclosure there is provided an aerosol provision device for use with a consumable according to the second aspect of the present disclosure, wherein the device comprises an aerosol generator configured to heat at least a portion of an aerosol generating material supported on the consumable.

According to a fourth aspect of the present disclosure there is provided an aerosol provision system comprising an aerosol provision device and a consumable according to the second aspect of the present disclosure.

According to a fifth aspect of the present disclosure there is provided a method of generating an aerosol from a consumable according to the second aspect of the present disclosure using an aerosol-generating device, wherein at least one aerosol generator is arranged to heat without combusting the consumable in use; wherein the at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.

Other features and advantages of the present disclosure will become apparent from the following description of embodiments of the disclosure, given by way of example and with reference to the accompanying drawings.

Drawings

Fig. 1 shows a schematic view of an embodiment of an aerosol supply device and an embodiment of a consumable manufactured according to a first embodiment of the method of the present disclosure;

FIG. 2 illustrates a first embodiment of a support for manufacturing the consumable of FIG. 1;

FIG. 3 illustrates the support of FIG. 2 after formation of a first embodiment of the reinforced region;

fig. 4 shows the support of fig. 3 after aerosol-generating material has been applied to the support;

FIGS. 5 and 6 illustrate the support of FIG. 2 during formation of a second embodiment of the reinforced region;

fig. 7 shows the support of fig. 5 and 6 after aerosol-generating material has been applied to the support;

fig. 8 shows a second embodiment of the support of fig. 5 and 6 after aerosol-generating material has been applied to the support;

figures 9 and 10 show the support of figure 2 during formation of a third embodiment of the reinforced region;

figure 11 shows a portion of a susceptor that is ready for use in forming the third embodiment of the reinforcing region;

Fig. 12 shows the support of fig. 9 and 10 after aerosol-generating material has been applied to the support;

FIGS. 13 and 14 illustrate a second embodiment of a support for manufacturing the consumable of FIG. 1;

fig. 15-18 illustrate the support of fig. 13 and 14 during formation of a fourth embodiment of the reinforced region; and

fig. 19 and 20 show the support of fig. 13 to 18 after aerosol-generating material has been applied to the support.

Detailed Description

The consumable of the present specification may alternatively be referred to as an article.

In some embodiments, the consumable comprises an aerosol generating material. The consumable may include an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, an aerosol modifier, one or more active components, one or more flavourings, one or more aerosol-former materials, and/or one or more other functional materials.

The device for heating the aerosol-generating material to be used with the consumable is part of a non-combustible aerosol supply system. The non-combustible aerosol supply system releases compounds, such as electronic cigarettes, tobacco heating products, and mixing systems, from the aerosol-generating material without burning the aerosol-generating material to generate an aerosol using a combination of aerosol-generating materials.

According to the present disclosure, a "non-combustible" aerosol-supply system is a system in which the constituent aerosol-generating materials of the aerosol-supply system (or components thereof) are not combusted to deliver at least one substance to a user.

In some embodiments, the delivery system is a non-combustible sol supply system, such as a powered device non-combustible sol supply system.

In some embodiments, the non-combustible aerosol supply system is an electronic cigarette, also referred to as an electronic cigarette device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol generating material is not required.

In some embodiments, the non-combustible sol supply system is an aerosol-generating material heating system, also referred to as a heated but non-combustion system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, wherein one or more of the aerosol-generating materials may be heated. Each aerosol-generating material may be in the form of a solid, liquid or gel, for example, and may or may not contain nicotine. In some embodiments, the mixing system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, a tobacco or non-tobacco product.

In general, a non-combustible sol supply system may include a non-combustible sol supply device and a consumable for use with the non-combustible sol supply device.

In some embodiments, the present disclosure relates to a consumable comprising an aerosol-generating material and configured for use with a non-combustible aerosol supply device. These consumables are sometimes referred to in this disclosure as articles of manufacture.

In some embodiments, a non-combustible sol supply system (such as a non-combustible sol supply thereof) may include a power source and a controller. The power source may be, for example, an electrical power source or an exothermic source. In some embodiments, the heat-generating source comprises a carbon matrix that can be energized to distribute power in the form of heat to the aerosol-generating material or the heat-transfer material in proximity to the heat-generating source.

In some embodiments, the non-combustible aerosol supply system may include a region for receiving a consumable, an aerosol generator, an aerosol generating region, a housing, a mouthpiece, a filter, and/or an aerosol modifier.

In some embodiments, a consumable for use with a non-combustible aerosol supply device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material delivery component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol modifier.

a support member is provided which is configured to support the support member,

at least one reinforcing area is formed on the support,

In one of the above embodiments, the aerosol-generating material is applied to the surface of the support in the form of a slurry of aerosol-generating material.

An aerosol-generating material is a material that is capable of generating an aerosol, for example, when heated, irradiated or energized in any other way. The aerosol-generating material may for example be in the form of a solid, liquid or semi-solid (such as a gel), which may or may not contain an active substance and/or a fragrance.

The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional materials.

The aerosol-generating material may comprise a binder (such as a gelling agent) and an aerosol-former. Optionally, substances and/or fillers to be delivered may also be present. Optionally, a solvent (such as water) is also present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

The aerosol-generating material may comprise or be in the form of an aerosol-generating film. The aerosol-generating film may comprise a binder (such as a gelling agent) and an aerosol-former. Optionally, substances and/or fillers to be delivered may also be present. The aerosol-generating film may be substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

The aerosol-generating film may have a thickness of about 0.015mm to about 1 mm. For example, the thickness may be in the range of about 0.05mm, 0.1mm, or 0.15mm to about 0.5mm, or 0.3 mm.

The aerosol-generating film may be formed by: a binder (such as a gelling agent) is combined with a solvent (such as water), an aerosol former, and one or more other ingredients (such as one or more substances to be delivered) to form a slurry, and then the slurry is heated to aerosolize at least some of the solvent to form an aerosol-generating film.

The slurry may be heated to remove at least about 60wt%, 70wt%, 80wt%, 85wt%, or 90wt% of the solvent.

The aerosol-generating material may comprise or may be an "amorphous solid". In some embodiments, the aerosol-generating material comprises an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid". The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. Amorphous solids are solid materials that can retain some fluid (such as a liquid) within their interior. In some embodiments, the amorphous solids may include, for example, from about 50wt%, 60wt%, or 70wt% amorphous solids to about 90wt%, 95wt%, or 100wt% amorphous solids.

The amorphous solid may be substantially free of plant material. The amorphous solid may be substantially free of tobacco.

In one embodiment of any of the above embodiments, the method comprises the further step of allowing or allowing the slurry of aerosol-generating material to cure. The slurry of aerosol-generating material may be cured using known techniques for curing slurries of aerosol-generating material.

In one embodiment of any of the above embodiments, the slurry of aerosol-generating material is solidified into an aerosol-generating material in the form of an aerosol-generating film.

The support may be a material suitable for forming the matrix. The carrier may for example be or comprise paper, cardboard, paperboard, cardboard, recombinant material, plastic material, ceramic material, composite material, glass, metal or metal alloy.

In one embodiment of any of the above embodiments, the support comprises a plastic material capable of withstanding temperatures typically encountered in non-combustible sol supply devices. In some embodiments, the support comprises Polyetheretherketone (PEEK). Such an embodiment has the advantage that the support may be reusable and that the consumable is less affected by any condensation in the non-combustible sol supply means than a consumable comprising a support comprising the use of an adsorption material for structural purposes.

The reinforced region on the surface of the support is a region of the support that has properties that are more or different than (i) the equivalent properties of the non-reinforced region on the surface of the support and/or (ii) the equivalent properties of the region on the surface of the support prior to the region being reinforced.

In one embodiment of any of the above embodiments, the enhancement region is a region having such enhancement: reinforcing the stiffness of the support in the reinforced region of the support to be greater than the stiffness of the support in the unreinforced region of the support, and forming the at least one reinforced region includes increasing the stiffness of the support in at least a portion of the at least one reinforced region. In some embodiments, the stiffness of the support is increased in substantially all of the at least one reinforcing region.

An advantage of increasing the stiffness of at least a portion of at least one reinforced region is that such region is less likely to bend or twist over a period of time than a non-reinforced portion of lower stiffness of the support. Thus, aerosol-generating material applied to such reinforced areas is less likely to delaminate (separate) from the support than is applied to a non-reinforced portion of the support where the stiffness is lower. This increases the useful life of consumables made in accordance with the present disclosure.

In one embodiment of any of the above embodiments, the enhancement region is a region having such enhancement: the contour of at least a portion of the surface of the reinforcing region, and forming the at least one reinforcing region includes embossing or coining a support in at least a portion of the at least one reinforcing region. In some embodiments, the embossing or imprinting of the support covers substantially all of the at least one reinforcing region.

An advantage of embossing or imprinting the support is that for contoured surfaces (such as those produced by embossing or imprinting), the aerosol-generating material adheres better, i.e. more strongly, to the support than to smooth, non-contoured surfaces. Another advantage is the increased stiffness of the reinforced area. This gives rise to the advantages described above.

Another possible advantage of embossing or gravure-printing the support in at least a portion of the at least one reinforcing region is that it can help to position the aerosol-generating material applied to the embossed or embossed region relative to one or more devices for heating the aerosol-generating material when the consumable is in use. For example, embossing/imprinting may cause the aerosol-generating material to be closer to the heating means than other parts of the support. This will have the advantage that the heating of the aerosol-generating material is more efficient than if the aerosol-generating material were remote from the heater. Furthermore, the space surrounding the aerosol-generating material is larger than the space between the aerosol-generating material and the heater, allowing the generated aerosol to move away from the aerosol-generating material and towards the desired destination of the aerosol.

In one embodiment of any of the above embodiments, the enhancement region is a region having such enhancement: enhancing the thermal transmissivity of the support in the enhanced regions of the support to be greater than the thermal transmissivity of the support in the unreinforced regions of the support, and forming the at least one enhanced region includes increasing the thermal transmissivity of at least a portion of the at least one enhanced region. In some embodiments, the thermal transmittance of the support is increased in substantially all of the at least one enhanced region.

An advantage of increasing the thermal transmissivity in the enhancement region is that it will increase the efficiency of heating the aerosol-generating material applied to the enhancement region when it is desired to generate an aerosol from the aerosol-generating material.

In one embodiment of any of the above embodiments, the thermal transmissivity increases for at least a portion of the surface of the support within at least a portion of the at least one enhanced region.

In one embodiment of any of the above embodiments, the enhancement region is a region having such enhancement: the thickness of the support in the reinforced region of the reinforced support is made greater than the thickness of the support in the unreinforced region of the support, and forming the at least one reinforced region includes increasing the thickness of the support in at least a portion of the at least one reinforced region. In some embodiments, the thickness of the support is increased in substantially all of the at least one reinforcing region.

An advantage of thickening the support in at least a portion of the at least one reinforcing region is that it may facilitate positioning of the aerosol-generating material applied to the thickened region relative to one or more devices for heating the aerosol-generating material when the consumable is in use. For example, the thickening may cause the aerosol-generating material to be closer to the heating means than other parts of the support. This has the advantage that heating of the aerosol-generating material is more efficient than if the aerosol-generating material were farther from the heater. Furthermore, the space surrounding the aerosol-generating material is larger than the space between the aerosol-generating material and the heater, allowing the generated aerosol to move away from the aerosol-generating material and towards the desired destination of the aerosol.

For the reasons described above, another advantage of the thickening of the support is that the stiffness of the support is increased.

In one embodiment of any of the above embodiments, the enhancement region is a region having such enhancement: the reinforcing region comprises a susceptor, and forming the at least one reinforcing region comprises applying the susceptor to at least a portion of the at least one reinforcing region.

In one embodiment of any of the preceding embodiments, forming the at least one enhancement region includes: the susceptor is applied to a surface of the support in at least a portion of the at least one reinforcing region. In this embodiment, the susceptor is not applied to those portions of the support that do not belong to the reinforcing region.

In one embodiment of any of the above embodiments, the susceptor is applied to substantially all of the at least one reinforcing region.

When the susceptor is heated during use of the consumable, the application of the susceptor to part or all of the one or more reinforcing areas has the advantage that the heating by the susceptor is limited to only those parts of the support to be heated, i.e. to only those parts of the reinforcing areas to which the susceptor is applied. This increases the heating efficiency of the consumable, since the parts of the support not intended to be heated are not heated.

In one embodiment of any of the preceding embodiments, applying the susceptor to the support comprises: one or more preformed portions of the susceptor are applied. The preformed portion of susceptor is cut or otherwise preformed into one or more predetermined shapes prior to application to the support. In some embodiments, all preformed portions of the susceptor are the same shape. In other embodiments, each of the preformed portions of the susceptor is one of a plurality (wherein the number is greater than one) of different shapes.

In one embodiment of any of the above embodiments, the preformed portion of susceptor is applied to the support in a predetermined pattern. In some embodiments, the predetermined pattern is a pattern of two or more preformed portions of susceptor that are applied to the same reinforcing region of the support.

The arrangement of the one or more preformed portions of susceptor on the surface of the support may be optimised to minimise the energy requirements to achieve a predetermined level of heating of the aerosol-generating material applied to the support.

In one embodiment of any of the preceding embodiments, applying the susceptor to the support comprises: applying a sheet of susceptor to a support, kissing the susceptor to form at least one predetermined closed cut line in the susceptor, and removing a portion of the susceptor not within the closed cut line, and the cut line coinciding with or falling within the perimeter of the at least one reinforcing region. When the cut line has no end or start point, the cut line is closed. For example, a line describing a circle is closed because the line has no starting or ending point. In some embodiments, the kissing of the susceptor may comprise one or more other cutting lines located within the area defined by the closed cutting line.

In one embodiment of any of the above embodiments, the susceptor comprises a metal or metal alloy. In some embodiments, the susceptor is a metal or metal alloy foil or film. Such as aluminum foil or film.

In one of any of the above embodiments, the method of applying the susceptor to at least a portion of the at least one reinforcing region comprises using a hot foil stamping technique. The use of such a technique is advantageous because the hot foil stamping technique allows for accurate placement of the foil, with the result that any inaccurate need for the susceptor to be oversized to allow the susceptor to be applied is reduced. This in turn leads to a reduction in the susceptors used and corresponding economic and environmental savings.

Another advantage of using hot foil stamping techniques is that in embodiments where the reinforced areas are created by embossing or stamping, embossing/stamping may be performed simultaneously with hot foil stamping by having the embossing or stamping tool also perform hot foil stamping. Another benefit of such an arrangement is that there is no need to register the susceptors separately to the embossing or imprinting area, as embossing or imprinting and applying the susceptors are performed simultaneously.

Susceptors are materials that can be heated by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material such that its penetration with a varying magnetic field causes induction heating of the susceptor by resistive heating as a result of eddy currents. The susceptor may be a magnetic material such that its penetration with a varying magnetic field causes hysteresis heating of the susceptor. The susceptor may be electrically conductive and magnetic such that the susceptor can be heated by both heating mechanisms. The device configured to generate a varying magnetic field is referred to as a magnetic field generator.

The susceptor may comprise a ferromagnetic metal, such as iron or an iron alloy, such as steel or an iron-nickel alloy. Some exemplary ferromagnetic metals are 400 series stainless steel, such as grade 410 stainless steel, or grade 420 stainless steel, or grade 430 stainless steel, or similar grades of stainless steel. Alternatively, the susceptor may comprise a suitable non-magnetic, in particular paramagnetic, conductive material, such as aluminium. In paramagnetic conductive materials, induction heating occurs only by resistive heating caused by eddy currents. Alternatively, the susceptor may comprise a non-conductive ferrimagnetic material, such as a non-conductive ferrimagnetic ceramic. In this case, heat is generated only by hysteresis loss. Susceptors may include commercial alloys such as Phytherm 230 (having a composition with 50wt% Ni, 10wt% Cr and the balance Fe (weight percent = wt%)) or Phytherm 260 (having a composition with 50wt% Ni, 9wt% Cr and the balance Fe).

In some of any of the above embodiments, the susceptor may be a metal foil, optionally an aluminum or iron foil. Alternatively, in some of any of the above embodiments, the susceptor may be any conductor that may be sprayed or vapor deposited on the material forming the support.

In one embodiment of any of the above embodiments, the at least one enhancement region comprises two or more enhancements.

In one embodiment of any of the above embodiments, forming at least one enhancement region includes forming at least two separate enhancement regions.

In one embodiment of any of the above embodiments, at least two separate enhancement regions of the at least two separate enhancement regions are distinguishable from each other by a human or automated observer. In this context, a human is understood to mean a human with average vision, which does not suffer from achromatopsia or similar diseases. In some embodiments, the enhancement regions have different shapes or colors.

In an embodiment of any of the above embodiments, applying the aerosol-generating material is applied to at least a portion of each reinforcing region of the support, and not to a portion of the support where the reinforcing region is not formed.

In one embodiment of any of the above embodiments, the aerosol-generating material is applied to the entire reinforcing region of each reinforcing region of the support member, without applying the aerosol-generating material to the portion of the support member where the reinforcing region is not formed.

In one embodiment of any of the above embodiments, the aerosol-generating material is applied to the entire reinforcing region of each reinforcing region of the support and at least a portion of the support surrounding each reinforcing region, without applying the aerosol-generating material to the remainder of the support where the reinforcing region is not formed. An advantage of this arrangement is that the aerosol-generating material on the support surrounding each reinforcing region will utilise any heat applied to the reinforcing region and that this heat is propagated out of the reinforcing region by conduction. This maximizes aerosol generation per joule (J) of thermal energy applied to the enhanced region.

In one embodiment of any of the above embodiments, at least a portion of the support surrounding each reinforcing region is a zone extending less than 1mm, less than 2mm, less than 3mm, less than 4mm, less than 5mm, less than 6mm, less than 8mm, or less than 10mm from the periphery of the reinforcing region.

In an alternative to any of the above embodiments, applying the aerosol-generating material is applying the aerosol-generating material to substantially all of the support. This arrangement has the advantage that there is no need to accurately locate the aerosol-generating material on the surface of the support, thereby matching the position of each reinforcing region.

In one embodiment of any of the above embodiments, applying the aerosol-generating material comprises applying the aerosol-generating material using a transfer wheel.

In one embodiment of any of the above embodiments, the aerosol-generating material is applied to the surface of the support in the form of a slurry of aerosol-generating material.

In one of any of the above embodiments, the method further comprises: allowing or curing the aerosol-generating material slurry, wherein the aerosol-generating material slurry cures to an aerosol-generating material. The aerosol-generating material may be cured using known aerosol-generating material curing techniques.

In one embodiment of any of the above embodiments, the aerosol-generating material is applied in the form of a cured aerosol-generating material.

In one embodiment of any of the preceding embodiments, applying the aerosol-generating material comprises: the aerosol-generating material is hot stamped onto the support. The hot stamping is performed using known hot stamping techniques. In some embodiments, the hot stamping temperature is below the temperature at which the aerosol-generating material begins to aerosolize.

In one embodiment of any of the above embodiments, the aerosol-generating material is an aerosol-generating film.

In one embodiment of any of the above embodiments, forming the at least one reinforcing region on the support and applying the aerosol-generating material are caused to occur substantially simultaneously. In some embodiments, the aerosol-generating material is hot stamped onto the support, and the hot stamping also forms one or more reinforcing regions on the support.

In one embodiment of any of the above embodiments, the support comprises a sheet having a first surface and a second surface, the forming the at least one reinforcing region comprises: at least one reinforcing region is formed on one or both of the first and second surfaces of the support, and applying the aerosol-generating material is one or both of (i) at least a portion of the at least one reinforcing region, and (ii) at least a portion of the surface that corresponds in location to the location of the at least one reinforcing region on the other surface. This arrangement has the advantage that aerosol-generating material may be applied to one or both surfaces of the support. When aerosol-generating material is applied to both the first and second surfaces of the support, a greater amount of aerosol-generating material may be associated with the reinforcing region than when aerosol-generating material is applied to only one surface of the support.

In one embodiment of any of the above embodiments, the support comprises a sheet having a first surface and a second surface, and forming the at least one reinforcing region comprises: at least one reinforcing region is formed on the first surface and the second surface of the support.

According to a second aspect of the present disclosure there is provided a consumable for use with an apparatus for heating a non-combustible sol supply system, wherein the consumable comprises a support, at least one reinforcing region located on the support and comprising an aerosol generating material, and the aerosol generating material is supported on the support in at least one position corresponding to at least a portion of the at least one reinforcing region.

In one embodiment of any of the above embodiments, the aerosol-generating material is in the form of an aerosol-generating film.

In an embodiment of any of the above embodiments, the reinforcement in the at least one reinforcement region of the support is that at least a portion of the at least one reinforcement region of the support has increased stiffness relative to a portion of the support not belonging to the reinforcement region.

In an embodiment of any of the above embodiments, the reinforcement in the at least one reinforcement region of the support is such that at least a portion of the at least one reinforcement region has increased thermal transmissivity relative to a portion of the support not belonging to the reinforcement region.

In one embodiment of any of the above embodiments, the reinforcement in the at least one reinforcement region of the support is embossed or stamped in at least a portion of the at least one reinforcement region.

In an embodiment of any of the above embodiments, the reinforcement in the at least one reinforcement region of the support is such that at least a portion of the at least one reinforcement region has an increased thickness relative to a portion of the support not belonging to the reinforcement region.

In one embodiment of any of the above embodiments, the reinforcement in the at least one reinforcement region of the support is that the at least one reinforcement region comprises a susceptor.

In one embodiment of any of the above embodiments, the susceptor is a metal or metal alloy. In some embodiments, the susceptor is a metal or metal alloy foil or film. Such as aluminum foil or film.

In one embodiment of any of the above embodiments, the susceptor has an outer perimeter that matches the shape and size of the perimeter of the reinforcing area to which the susceptor is applied.

In one embodiment of any of the above embodiments, the susceptor covers at least a portion of the reinforcing region, and an outer periphery of the reinforcing region surrounds the susceptor.

In one embodiment of any of the above embodiments, the at least one enhancement region comprises two or more enhancement modes.

In one embodiment of any of the above embodiments, there are at least two separate enhancement regions.

In one embodiment of any of the above embodiments, at least two separate enhancement regions of the at least two separate enhancement regions are distinguishable from each other by a human or automated observer.

In one embodiment of any of the above embodiments, the aerosol-generating material is supported on at least a portion of each reinforcing region, and no aerosol-generating material is supported on a portion of the support member where the reinforcing region is not formed.

In one embodiment of any of the above embodiments, the entire reinforcing region of each reinforcing region supports the aerosol-generating material, and no aerosol-generating material is supported on the portion of the support where the reinforcing region is not formed.

In one embodiment of any of the above embodiments, the entire reinforcing region and the surrounding region of each reinforcing region or at least a portion of the support surrounding each reinforcing region supports the aerosol-generating material, and no aerosol-generating material is supported on portions of the support where no reinforcing region or surrounding region is formed.

In one embodiment of any of the above embodiments, substantially all of the support supports the aerosol-generating material. In this context, substantially all supports should be understood as referring to the entire surface in case the support has only one surface on which one or more reinforcing areas are formed, or to all those surfaces in case the support has two or more surfaces on which one or more reinforcing areas are formed.

In an embodiment of any of the above embodiments, the aerosol-generating material comprises an aerosol-generating gel.

In one embodiment of any of the above embodiments, the support comprises a sheet having a first surface and a second surface, the at least one reinforcing region is located on one or both of the first surface and the second surface of the support, and the aerosol-generating material is supported on one or both of: (i) At least a portion of at least one enhancement region, and (ii) at least a portion of a surface that corresponds in location to a location of an enhancement region on another surface.

In one embodiment of any of the above embodiments, the support comprises a sheet having a first surface and a second surface, and the at least one reinforcing region is located on each of the first surface and the second surface of the support.

In one embodiment of any of the above embodiments, the aerosol-generating material comprises an active substance.

An active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropic agents, psychoactive substances. The active substance may be naturally occurring or synthetically obtained. The active may include, for example, nicotine, caffeine, taurine, caffeine, vitamins (such as B6 or B12 or C), melatonin, or components, derivatives, or combinations thereof. The active substance may comprise one or more components, derivatives or extracts of tobacco or another plant.

In some embodiments, the active comprises nicotine. In some embodiments, the active comprises caffeine, melatonin, or vitamin B12.

The active substance may comprise or be derived from one or more plants or components, derivatives or extracts thereof. As used herein, the term "plant" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, hulls, husks, and the like. Alternatively, the material may comprise an active compound naturally occurring in plants, which is obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, flakes, or the like. Exemplary plants are tobacco, eucalyptus, star anise, hemp, cocoa, fennel, lemon grass, peppermint, spearmint, black leaf tea, chamomile, flax, ginger, gingko, hazelnut, hibiscus, bay, licorice, green tea, mate, orange peel, papaya, rose, sage, tea (such as green tea or black tea), thyme, clove, cinnamon, coffee, star anise (fennel), basil, bay leaf, cardamon, coriander, cumin, nutmeg, oregano, red pepper, rosemary, saffron, lavender, lemon peel, peppermint, juniper, elder, vanilla, wintergreen, perilla, turmeric root powder, sandalwood, coriander leaf, bergamot, orange flower, myrtle, blackcurrant, valerian, spanish sweet pepper, nutmeg, damascene, carrageenan, olive, lemon basil, vanilla, bergamot, pelargan, geranium, tarragon, geranium, tea, tetramic acid, uric acid, marmora, ku, kudzuvine, any combination thereof, or any of the like. The mint may be selected from the following mint varieties: peppermint, artificially cultivated peppermint, egypt peppermint, artificially cultivated basil, artificially cultivated peppermint, spearmint, peppermint, pineapple, spearmint, and apple mint.

In some embodiments, the active substance comprises or is derived from one or more plants or components, derivatives or extracts thereof, and the plant is tobacco.

In some embodiments, the active substance comprises or is derived from one or more plants or components, derivatives or extracts thereof, and the plants are selected from eucalyptus, star anise, cocoa.

In some embodiments, the active substance comprises or is derived from one or more plants or components, derivatives or extracts thereof, and the plants are selected from the group consisting of camellia sinensis and fennel.

In some embodiments, the aerosol-generating material comprises a flavoring or a fragrance.

As used herein, the terms "flavoring" and "fragrance" refer to materials that can be used to create a desired taste, aroma, or other somatosensory in a product for an adult consumer, as permitted by local regulations. Which may include naturally occurring flavor materials, plants, extracts of plants, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice, hydrangea, eugenol, japanese magnolia leaf, chamomile, fenugreek, clove, maple, green tea, menthol, japanese mint, star anise (fennel), cinnamon, turmeric, indian spice, asian spice, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, citrus, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruit, du Linbiao wine, paraguay whiskey, scotch whiskey, juniper, tequila, rum, spearmint, peppermint, lavender, aloe, cardamom, celery, bitter orange peel, nutmeg, sandalwood, bergamot, geranium, arabian tea, sorghum, nutmeg, papaya, and the like) betel leaf, coriander, pine, honey essence, rose oil, vanilla, lemon oil, orange flower, cherry blossom, cinnamon, coriander, cognac, jasmine, ylang, sage, fennel, mustard, green pepper, ginger, coriander, coffee, peppermint oil from any variety of mentha plants, eucalyptus, star anise, cocoa, lemon grass, red bean, flax, ginkgo leaf, hazelnut, hibiscus, bay, mate, orange peel, rose, tea (e.g., green tea or black tea), thyme, juniper, elder, basil, bay leaf, cumin, oregano, capsicum, rosemary, saffron, lemon peel, peppermint, steak plant, turmeric, coriander, myrtle, black currant, valerian, spanish pepper, nutmeg dried skin, damianne, marjoram, olive, orange peel, rose, tea (e.g., green tea or black tea) Lemon balm, lemon basil, northleontopod, carvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulators, sugar and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, plants, or breath fresheners. It may be a imitation, synthetic or natural ingredient or a mixture thereof. It may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

In some embodiments, the flavoring agent comprises menthol, spearmint, and/or peppermint. In some embodiments, the flavoring includes flavoring ingredients of cucumber, blueberry, citrus fruit, and/or raspberry. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring includes a flavoring ingredient extracted from tobacco.

In some embodiments, the flavoring agent may include a sensate intended to achieve a somatosensory that is generally chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in lieu of an aromatic or gustatory nerve, and these may include agents that provide heating, cooling, tingling, numbing effects. Suitable thermal agents may be, but are not limited to, vanillyl ether, and suitable coolants may be, but are not limited to, eucalyptol, WS-3.

The aerosol-generating material comprises an aerosol-generating agent. In some embodiments, the aerosol-generating agent may comprise one or more components capable of forming an aerosol. In some embodiments, the aerosol generating agent may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, meso-erythritol, ethyl vanillic acid, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetin, benzyl benzoate, benzyl phenyl acetate, glycerol tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In a specific example, the aerosol-generating agent comprises glycerin.

In some embodiments, the aerosol-generating agent comprises one or more polyols, such as propylene glycol, triethylene glycol, 1, 3-butanediol, and glycerol; esters of polyols such as monoacetate, diacetate, or triacetate of glycerol; and/or aliphatic esters of mono-, di-or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

In some embodiments, the aerosol-generating material may comprise from about 0.1wt%, 0.5wt%, 1wt%, 3wt%, 5wt%, 7wt% or 10wt% to about 50wt%, 45wt%, 40wt%, 35wt%, 30wt% or 25wt% of the aerosol-generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticizer. For example, the aerosol-generating material may comprise from 0.5wt% to 40wt%, from 3wt% to 35wt% or from 10wt% to 25wt% of the aerosol-generating agent.

In some embodiments, the aerosol-generating material may comprise from about 5wt%, 10wt%, 20wt%, 25wt%, 27wt%, or 30wt% to about 60wt%, 55wt%, 50wt%, 45wt%, 40wt%, or 35wt% aerosol-generating agent (DWB). For example, the aerosol-generating material may comprise from 10wt% to 60wt%, from 20wt% to 50wt%, from 25wt% to 40wt% or from 30wt% to 35wt% of the aerosol-generating agent.

In some embodiments, the aerosol-generating material may comprise up to about 80wt%, such as about 40wt% to 80wt%, 40wt% to 75wt%, 50wt% to 70wt%, or 55wt% to 65wt% aerosol-generating agent (DWB).

The aerosol-generating material may further comprise a gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds comprising a compound selected from the group consisting of alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the gelling agent includes alginate and/or pectin, and may be combined with a curing agent (such as a calcium source) during formation of the aerosol-generating material. In some cases, the aerosol-generating material may comprise calcium-crosslinked alginate and/or calcium-crosslinked pectin.

In some embodiments, the gelling agent comprises one or more compounds selected from the group consisting of cellulose gelling agents, non-fibrous gelling agents, guar gum, gum arabic, and mixtures thereof.

In some embodiments, the cellulose gelling agent is selected from the group consisting of: hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose Acetate (CA), cellulose Acetate Butyrate (CAB), cellulose Acetate Propionate (CAP), and combinations thereof.

In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or gum arabic.

In some embodiments, the gelling agent includes (or is) one or more non-cellulosic gelling agents including, but not limited to, agar, xanthan, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In a preferred embodiment, the non-cellulose based gelling agent is alginate or agar.

In some embodiments, the gelling agent comprises an alginate, and the alginate is present in the aerosol-generating material in an amount of from 10wt% to 30wt% of the aerosol-generating material (calculated on a dry weight basis). In some embodiments, the alginate is the only gelling agent present in the aerosol-generating material. In other embodiments, the gelling agent comprises an alginate and at least one additional gelling agent, such as pectin.

In some embodiments, the aerosol-generating material comprises from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt% or 35wt% of the gelling agent (all calculated on a dry weight basis). For example, the aerosol-generating material may comprise from 1wt% to 50wt%, from 5wt% to 45wt%, from 10wt% to 40wt% or from 20wt% to 35wt% of the gelling agent.

In some embodiments, the aerosol-generating material comprises from about 20wt%, 22wt%, 24wt%, or 25wt% to about 30wt%, 32wt%, or 35wt% of the gelling agent (all calculated on a dry weight basis). For example, the aerosol-generating material may comprise from 20wt% to 35wt% or from 25wt% to 30wt% of the gelling agent.

In some cases, the aerosol-generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, or 20wt% to about 60wt%, 50wt%, 40wt%, 30wt%, or 25wt% of a gelling agent (DWB). For example, the aerosol-generating material may comprise from 10wt% to 40wt%, from 15wt% to 30wt%, or from 20wt% to 25wt% of a gelling agent (DWB).

In examples, the aerosol-generating material comprises a gelling agent and a filler added together in an amount of from about 10wt%, 20wt%, 25wt%, 30wt% or 35wt% to about 60wt%, 55wt%, 50wt% or 45wt% of the aerosol-generating material. In examples, the aerosol-generating material comprises a gelling agent and a filler added together in an amount of from about 20wt% to 60wt%, 25wt% to 55wt%, 30wt% to 50wt%, or 35wt% to 45wt% of the aerosol-generating material.

In examples, the aerosol-generating material includes a gelling agent (i.e., regardless of the amount of filler) in an amount from about 5wt%, 10wt%, 15wt%, 20wt%, 25wt%, 30wt%, or 35wt% to about 60wt%, 55wt%, 50wt%, or 45wt% of the aerosol-generating material. In examples, the aerosol-generating material includes a gelling agent (i.e., regardless of the amount of filler) in an amount of from about 5wt% to 60wt%, 20wt% to 60wt%,25wt% to 55wt%, 30wt% to 50wt%, or 35wt% to 45wt% of the aerosol-generating material.

In some examples, the alginate is included in the gelling agent in an amount from about 5wt% to 40wt%, or 15wt% to 40wt% of the aerosol-generating material. That is, the aerosol-generating material comprises alginate in an amount of about 5wt% to 40wt%, or 15wt% to 40wt% based on the dry weight of the aerosol-generating material. In some examples, the aerosol-generating material comprises alginate in an amount of from about 20wt% to 40wt%, or about 15wt% to 35wt% of the aerosol-generating material.

In some examples, pectin is included in the gelling agent in an amount from about 3wt% to 15wt% of the aerosol-generating material. That is, the aerosol-generating material comprises pectin in an amount of from about 3wt% to 15wt% based on the dry weight of the aerosol-generating material. In some examples, the aerosol-generating material comprises pectin in an amount of from about 5wt% to 10wt% of the aerosol-generating material.

In some examples, guar gum is included in the gelling agent in an amount from about 3wt% to 40wt% of the aerosol-generating material. That is, the aerosol-generating material comprises guar gum in an amount of from about 3wt% to 40wt% based on the dry weight of the aerosol-generating material. In some examples, the aerosol-generating material comprises guar gum in an amount of from about 5wt% to 10wt% of the aerosol-generating material. In some examples, the aerosol-generating material comprises guar gum in an amount of from about 15wt% to 40wt%, or from about 20wt% to 40wt%, or from about 15wt% to 35wt% of the aerosol-generating material.

In an example, the alginate is present in an amount of at least about 50wt% of the gelling agent. In an example, the aerosol-generating material comprises alginate and pectin, and the ratio of alginate to pectin is from 1:1 to 10:1. The ratio of alginate to pectin is typically > 1:1, i.e. the alginate is present in a greater amount than the amount of pectin. In examples, the ratio of alginate to pectin is from about 2:1 to 8:1, or about 3:1 to 6:1, or about 4:1.

The aerosol-generating material may be formed by: (a) forming a slurry comprising components of the aerosol-generating material or a precursor thereof, (b) forming a slurry layer, (c) curing the slurry to form a gel, and (d) drying to form the aerosol-generating material.

(b) Forming the slurry layer typically includes spraying, casting, or extruding the slurry. In an example, the slurry layer is formed by electrospraying a slurry. In an example, the slurry layer is formed by casting a slurry.

In some examples, (b) and/or (c) and/or (d) occur at least partially simultaneously (e.g., during electrospraying). In some examples, (b), (c), and (d) occur sequentially.

In some examples, the slurry is applied to the support. The layer may be formed on the support.

In an example, the slurry includes a gelling agent, an aerosol former material, and an active substance. The slurry may include these components in any of the proportions given herein with respect to the composition of the aerosol-generating material. For example, the slurry may include (on a dry weight basis):

-a gelling agent and optionally a filler, wherein the amount of gelling agent and filler taken together is about 10 to 60wt% of the slurry;

-an aerosol former material in an amount of about 40 to 80wt% of the slurry; and

-optionally, an active substance in an amount of up to about 20wt% of the slurry;

curing the gel (c) may include supplying a curing agent to the slurry. For example, the slurry may include sodium, potassium or ammonium alginate as a gel precursor, and a setting agent including a calcium source (such as calcium chloride) may be added to the slurry to form a calcium alginate gel.

In examples, the curing agent includes or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the curing agent includes or consists of calcium formate and/or calcium lactate. In specific examples, the curing agent comprises or consists of calcium formate. The inventors have identified that typically the use of calcium formate as a curing agent results in an aerosol-generating material having greater tensile strength and greater elongation resistance.

The total amount of curing agent (such as a calcium source) may be 0.5wt% to 5wt% (calculated on a dry weight basis). Suitably, the total amount may be from about 1wt%, 2.5wt% or 4wt% to about 4.8wt% or 4.5wt%. The inventors have found that adding too little curing agent may result in the aerosol-generating material not being able to stabilize the aerosol-generating material components and in these components falling out of the aerosol-generating material. The inventors have found that adding too much curing agent results in the aerosol-generating material being very viscous and thus having poor operability.

When the aerosol-generating material does not comprise tobacco, it may be desirable to apply a higher amount of curing agent. Thus, in some cases, the total amount of curing agent may be 0.5wt% to 12wt%, such as 5wt% to 10wt%, calculated on a dry weight basis. Suitably, the total amount may be from about 5wt%, 6wt% or 7wt% to about 12wt% or 10wt%. In this case, the aerosol-generating material will generally not comprise any tobacco.

In an example, supplying the curing agent to the slurry includes: the curing agent is sprayed onto the slurry, such as the top surface of the slurry.

Alginate is a derivative of alginic acid and is typically a high molecular weight polymer (10 to 600 kDa). Alginic acid is a copolymer of β -D-mannuronic acid (M) and α -L-guluronic acid (G) units (blocks) linked together by (1, 4) -glycosidic linkages to form a polysaccharide. Upon addition of the calcium cations, the alginate crosslinks to form a gel. It has been found that alginates with a high G monomer content form a gel more readily upon addition of a calcium source. Thus, in some cases, the gel precursor may include an alginate, wherein at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginate copolymer are alpha-L-guluronic acid (G) units.

In examples, drying (d) removes from about 50wt%, 60wt%, 70wt%, 80wt%, or 90wt% to about 80wt%, 90wt%, or 95wt% water (WWB) in the slurry.

In an example, drying (d) reduces the casting material thickness by at least 80%, suitably 85% or 87%. For example, the slurry is cast at a thickness of 2mm, and the resulting dried aerosol-generating material has a thickness of 0.2 mm.

In some examples, the slurry solvent consists essentially of or consists of water. In some examples, the slurry includes from about 50wt%, 60wt%, 70wt%, 80wt%, or 90wt% solvent (WWB).

In examples where the solvent consists of water, the dry weight content of the slurry may be matched to the dry weight content of the aerosol-generating material. Thus, the discussion herein regarding the composition of solids is explicitly disclosed in connection with the slurry aspects of the present invention.

The aerosol-generating material may comprise a flavour. Suitably, the aerosol-generating material may comprise up to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt% or 45wt% flavouring agent. In some cases, the aerosol-generating material may comprise at least about 0.1wt%, 1wt%, 10wt%, 20wt%, 30wt%, 35wt% or 40wt% of the flavouring agent (all on a dry weight basis). For example, the aerosol-generating material may comprise from 1wt% to 80wt%, from 10wt% to 80wt%, from 20wt% to 70wt%, from 30wt% to 60wt%, from 35wt% to 55wt% or from 30wt% to 45wt% of the flavouring agent. In some cases, the flavoring agent comprises, consists essentially of, or consists of menthol.

The aerosol-generating material may comprise a filler.

In some embodiments, the aerosol-generating material comprises less than 60wt% filler, such as from 1wt% to 60wt%, or 5wt% to 50wt%, or 5wt% to 30wt%, or 10wt% to 20wt%.

In other embodiments, the aerosol-generating material comprises less than 20wt%, suitably less than 10wt% or less than 5wt% filler. In some cases, the aerosol-generating material comprises less than 1wt% filler, and in some cases, no filler.

In some such cases, the aerosol-generating material comprises at least 1wt% filler, for example, at least 5wt%, at least 10wt%, at least 20wt%, at least 30wt%, at least 40wt%, or at least 50wt% filler. In some embodiments, the aerosol-generating material comprises from 5wt% to 25wt% filler.

The filler, if present, may comprise one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may include one or more organic filler materials such as wood pulp, cellulose, and cellulose derivatives such as methyl cellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC). In particular cases, the aerosol-generating material does not comprise calcium carbonate, such as chalk.

In embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, cellulose or cellulose derivatives such as methyl cellulose, hydroxypropyl cellulose and carboxymethyl cellulose (CMC).

Without wishing to be bound by theory, it is believed that including fibrous fillers in the aerosol-generating material may increase the tensile strength of the material. This may be particularly advantageous in examples where the aerosol-generating material is provided as a sheet, such as when the sheet of aerosol-generating material surrounds a strip of aerosolizable material.

In some embodiments, the aerosol-generating material does not comprise tobacco fibers. In a specific embodiment, the aerosol-generating material does not comprise a fibrous material.

In some embodiments, the aerosol-generating material further comprises an active substance. For example, in some cases, the aerosol-generating material additionally comprises tobacco material and/or nicotine. In some embodiments, the aerosol-generating material comprises powdered tobacco and/or nicotine and/or tobacco extract.

In some cases, the aerosol-generating material may comprise from 5wt% to 60wt% (calculated on a dry weight basis) of tobacco material and/or nicotine. In some cases, the aerosol-generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt% or 30wt% (calculated on a dry weight basis) of active substance. In some cases, the aerosol-generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt%, or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry basis) of tobacco material. For example, the aerosol-generating material may comprise from 10wt% to 50wt%, from 15wt% to 40wt% or from 20wt% to 35wt% of tobacco material. In some cases, the aerosol-generating material may comprise from about 1wt%, 2wt%, 3wt%, or 4wt% to about 20wt%, 18wt%, 15wt%, or 12wt% (calculated on a dry weight basis) nicotine. For example, the aerosol-generating material may comprise from 1wt% to 20wt%, from 2wt% to 18wt% or from 3wt% to 12wt% nicotine.

In some cases, the aerosol-generating material comprises an active substance, such as a tobacco extract. In some cases, the aerosol-generating material may comprise from 5wt% to 60wt% (calculated on a dry weight basis) of the tobacco extract. In some cases, the aerosol-generating material may comprise from about 5wt%, 10wt%, 15wt%, 20wt%, or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of tobacco extract. For example, the aerosol-generating material may comprise from 10wt% to 50wt%, from 15wt% to 40wt%, or from 20wt% to 35wt% of the tobacco extract. The tobacco extract may comprise a concentration of nicotine such that the aerosol-generating material comprises 1wt%, 1.5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%, 4.5wt% or 4wt% (calculated on a dry weight basis) nicotine. In some cases, the aerosol-generating material may be free of nicotine other than the material produced by the tobacco extract.

In some embodiments, the aerosol-generating material does not comprise tobacco material, but does comprise nicotine. In some such cases, the aerosol-generating material may comprise from about 1wt%, 2wt%, 3wt%, or 4wt% to about 20wt%, 18wt%, 15wt%, or 12wt% (calculated on a dry weight basis) nicotine. For example, the aerosol-generating material may comprise from 1wt% to 20wt%, from 2wt% to 18wt% or from 3wt% to 12wt% nicotine.

In some cases, the total content of active and/or flavoring agent may be at least about 0.1wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt%, or 30wt%. In some cases, the total content of active and/or flavoring agent may be less than about 90wt%, 80wt%, 70wt%, 60wt%, 50wt%, or 40wt% (all calculated on a dry weight basis).

In some cases, the total content of tobacco material, nicotine, and flavoring may be at least about 0.1wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt%, or 30wt%. In some cases, the total content of active and/or flavoring agent may be less than about 90wt%, 80wt%, 70wt%, 60wt%, 50wt%, or 40wt% (all calculated on a dry weight basis).

The aerosol-generating composition may comprise one or more active substances. In an example, the aerosol-generating material comprises one or more active substances, for example up to about 20wt% of the aerosol-generating material. In examples, the aerosol-generating material comprises the active in an amount of from about 1wt%, 5wt%, 10wt% or 15wt% to about 20wt%, 15wt% or 5wt% of the aerosol-generating material.

The active substance may comprise a physiologically and/or olfactory active substance which is included in the aerosol-generating composition to effect a physiological and/or olfactory reaction.

The tobacco material may be present in the aerosol-generating composition in an amount from about 50wt% to 95wt%, or about 60wt% to 90wt%, or about 70wt% to 90wt%, or about 75wt% to 85 wt%.

The tobacco material may be present in any form, but is typically fine cut (e.g., cut into filaments). The fine cut tobacco material may advantageously be mixed with an aerosol-generating material to provide an aerosol-generating composition having a uniform dispersion of tobacco material and aerosol-generating material throughout the aerosol-generating composition.

In examples, the tobacco material includes one or more of ground tobacco, tobacco fibers, cut filler, extruded tobacco, tobacco stems, reconstituted tobacco, and/or tobacco extracts. Surprisingly, the present inventors have found that a relatively large amount of sheet tobacco can be used in an aerosol-generating composition and still provide an acceptable aerosol when heated by a non-combustible aerosol delivery system. Sheet tobacco generally provides excellent organoleptic properties. In examples, the tobacco material includes lamina tobacco in an amount of at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt%, or 95wt% of the tobacco material. In specific examples, the tobacco material includes cut filler in an amount of at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt%, or 95wt% of the tobacco material.

The tobacco used to produce the tobacco material may be any suitable tobacco, such as single grade or mixed, chopped rags or whole leaf, including virginia and/or burley and/or oriental tobacco.

In some embodiments, the one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and/or an antioxidant.

In some cases, the aerosol-generating material may additionally include an emulsifier that emulsifies the melted flavoring during manufacture. For example, the aerosol-generating material may comprise from about 5wt% to about 15wt% of an emulsifier (calculated on a dry weight basis), suitably about 10wt%. The emulsifier may comprise gum arabic.

In some embodiments, the aerosol-generating material is a hydrogel and comprises less than about 20wt% water, calculated on a wet weight basis. In some cases, the hydrogel may include less than about 15wt%, 12wt%, or 10wt% water, calculated on a wet weight basis. In some cases, the hydrogel may include at least about 1wt%, 2wt%, or at least about 5Wt% Water (WWB).

The aerosol-generating material may have any suitable water content, such as from 1wt% to 15wt%. Suitably, the water content of the aerosol-generating material is from about 5wt%, 7wt% or 9wt% to about 15wt%, 13wt% or 11wt% (WWB), most suitably about 10wt%. The water content of the aerosol-generating material may be determined, for example, by karl fischer titration or gas chromatography with a thermal conductivity detector (GC-TCD).

In some cases, the aerosol-generating material may consist essentially of, or consist of, a gelling agent, water, an aerosol-generating agent, a flavoring agent, and optionally an active substance.

In some cases, the aerosol-generating material may consist essentially of, or consist of, a gelling agent, water, an aerosol-generating agent, a flavoring agent, and optionally a tobacco material and/or a nicotine source.

In an example, the aerosol-generating material consists essentially of, or consists of, a gelling agent, an aerosol-generating agent, an active substance and water. In an example, the aerosol-generating material consists essentially of, or consists of, a gelling agent, an aerosol-generating agent, and water.

In an example, the aerosol-generating material does not include a fragrance; in a specific example, the aerosol-generating material does not comprise an active substance.

In some embodiments, the aerosol-generating material comprises an aerosol-generating material comprising:

-1 to 60wt% of a gelling agent;

-0.1 to 50wt% of an aerosol generator; and

-0.1 to 80wt% of a flavouring agent;

wherein these weights are calculated on a dry weight basis.

In some embodiments, the aerosol-generating material comprises from 1wt% to 80wt% of the flavoring agent (on a dry weight basis).

In some embodiments, the aerosol-generating material comprises:

-1 to 50wt% of a gelling agent;

-0.1 to 50wt% of an aerosol generator; and

-30 to 60wt% of a flavouring agent;

wherein these weights are calculated on a dry weight basis.

In an alternative embodiment of the aerosol-generating material, the aerosol-generating material comprises an aerosol-generating material comprising:

-1 to 60wt% of a gelling agent;

-5 to 60wt% of an aerosol generator; and

-10 to 60wt% of a tobacco extract;

wherein these weights are calculated on a dry weight basis.

In some embodiments, the aerosol-generating material comprises:

-1 to 60wt% of a gelling agent;

-20 to 60wt% of an aerosol generator; and

-10 to 60wt% of a tobacco extract;

wherein these weights are calculated on a dry weight basis.

In some embodiments, the aerosol-generating material comprises from 20wt% to 35wt% of the gelling agent; 10 to 25wt% of an aerosol former material; 5 to 25wt% of a filler comprising fibers; and 35 to 50wt% of a perfume and/or active.

In some cases, the aerosol-generating material may consist essentially of, or consist of, a gelling agent, an aerosol-generating agent, a tobacco extract, water, and optionally a flavoring agent. In some cases, the aerosol-generating material may consist essentially of, or consist of, glycerin, alginate and/or pectin, tobacco extract and water.

In some embodiments, the aerosol-generating material may have the following composition (DWB): a gelling agent (preferably comprising alginate) in an amount from about 5wt% to about 40wt%, or about 10wt% to 30wt%, or about 15wt% to about 25wt%; a tobacco extract in an amount from about 30wt% to about 60wt%, or about 40wt% to 55wt%, or from about 45wt% to about 50wt%; the aerosol generating agent, preferably comprising glycerin, is present in an amount from about 10wt% to about 50wt%, or from about 20wt% to about 40wt%, or from about 25wt% to about 35wt% (DWB).

In one embodiment, the aerosol-generating material comprises about 20wt% alginate gelling agent, about 48wt% tobacco virginia extract, and about 32wt% glycerin (DWB).

The "thickness" of the aerosol-generating material describes the shortest distance between the first surface and the second surface. In embodiments in which the aerosol-generating material is in the form of a sheet, the thickness of the aerosol-generating material is the shortest distance between a first planar surface of the sheet and a second planar surface of the sheet opposite the first planar surface of the sheet.

In some cases, the aerosol-generating material layer forming the aerosol has a thickness of about 0.015mm to about 1.5mm, suitably about 0.05mm to about 1.5mm or 0.05mm to about 1.0 mm. Suitably, the thickness may be in the range from about 0.1mm or 0.15mm to about 1.0mm, 0.5mm or 0.3 mm.

In some cases, the aerosol-generating material may have a thickness of about 0.015mm to about 1.0 mm. Suitably, the thickness may be in the range of about 0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3 mm.

A material having a thickness of 0.2mm may be particularly suitable. The aerosol-generating material may comprise more than one layer and the thicknesses described herein refer to the total thickness of those layers.

It has been found that if the aerosol-generating material is too thick, the heating efficiency may be affected. This can adversely affect power consumption in use. Conversely, if the aerosol-generating material is too thin, it is difficult to manufacture and handle; very thin materials are more difficult to cast and can be fragile, affecting aerosol formation in use.

The thickness specified here is the average thickness of the material. In some cases, the thickness of the aerosol-generating material may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1%.

In some examples, the aerosol-generating material in sheet form may have a tensile strength of from about 200N/m to about 900N/m. In some examples, such as where the aerosol-generating material does not include a filler, the aerosol-generating material may have a tensile strength of from 200N/m to 400N/m, or 200N/m to 300N/m, or about 250N/m.

Such tensile strength may be particularly suitable for embodiments in which the aerosol-generating material is formed into a sheet and then shredded and incorporated into an aerosol-generating article. In some examples, such as where the aerosol-generating material includes a filler, the aerosol-generating material may have a tensile strength of from 600N/m to 900N/m, or from 700N/m to 900N/m, or about 800N/m. Such tensile strength may be particularly suitable for embodiments in which the aerosol-generating material is included in the aerosol-generating article/component as a rolled sheet (suitably in the form of a tube).

In some examples, the aerosol-generating material in sheet form may have a tensile strength of from about 200N/m to about 2600N/m. In some examples, the aerosol-generating material may have a tensile strength from 600N/m to 2000N/m, or from 700N/m to 1500N/m, or about 1000N/m. Such tensile strength may be particularly suitable for embodiments in which an aerosol-generating material comprising an aerosol-generating material is formed and incorporated as a sheet into an aerosol-generating consumable.

The aerosol-generating material comprising the aerosol-generating material may have any suitable area density, such as from 30g/m ² To 120g/m ² . In some cases, the sheet may have a weight of 80g/m ² To 120g/m ² Or from about 70g/m ² To 110g/m ² Or in particular from about 90g/m ² To 110g/m ² Or suitably about 100g/m ² (such that it has a density similar to shredded tobacco and a mixture of these will not readily separate) per unit area mass. In some cases, the sheet may have about 30g/m ² To 70g/m ² 、40g/m ² To 60g/m ² Or 25g/m ² To 60g/m ² And may be used to encapsulate an aerosolizable material, such as tobacco.

All weight percentages (expressed as wt%) described herein are calculated on a dry weight basis unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis. The weight quoted on a dry weight basis refers to the entire extract or slurry or material other than water and may include ingredients that are themselves liquid at room temperature and pressure, such as glycerin. Conversely, the weight percentages quoted on a wet weight basis refer to all ingredients, including water.

The aerosol-generating material may comprise a colourant. The addition of a colorant may alter the visual appearance of the aerosol-generating material. The presence of a colorant in the aerosol-generating material may enhance the visual appearance of the aerosol-generating material and the aerosol-generating material. By adding a colorant to the aerosol-generating material, the aerosol-generating material may be color matched with other components of the aerosol-generating material or with other components of an article comprising the aerosol-generating material.

Depending on the desired color of the aerosol-generating material, a variety of colorants may be used. The colour of the aerosol-generating material may be, for example, white, green, red, violet, blue, brown or black. Other colors are also contemplated. Natural or synthetic colorants such as natural or synthetic dyes, food grade colorants, and pharmaceutical grade colorants may be used. In certain embodiments, the colorant is caramel, which may impart a brown appearance to the aerosol-generating material. In such embodiments, the color of the aerosol-generating material may be similar to the color of other ingredients (such as tobacco material). In some embodiments, the addition of a colorant to the aerosol-generating material renders it visually indistinguishable from other components in the aerosol-generating material.

The colorant may be incorporated during formation of the aerosol-generating material (e.g., when forming a slurry comprising the material forming the aerosol-generating material), or it may be applied to the aerosol-generating material after formation of the aerosol-generating material (e.g., by spraying it onto the aerosol-generating material).

In some of any of the above embodiments, talc, calcium carbonate powder or other powder is applied to the exposed surface of at least one discrete portion of the aerosol-generating material. This may reduce the tack or adhesion level of the aerosol-generating material.

In the following discussion of the figures, like reference numerals are used throughout for more than one embodiment when like elements are present, and like reference numerals are used (like numerals plus multiples of 100) when like elements are present.

Referring to fig. 1, the aerosol provision device 2 comprises a housing 4 within which is located a heater assembly 6. The heater assembly 6 includes a heating chamber 8 and a heater 10. The heater 10 may be a resistive heater or a magnetic field generator for use with a susceptor.

The heating chamber 8 defines an opening or mouth 12 at a first end of the heating chamber 8. At the other end of the heating chamber 8 is an orifice 14. The orifice 14 is in fluid communication with the mouthpiece 16 via a conduit 18.

Also located within the housing 4 is a controller 20 which is in electronic communication with and controls the function of the heater 10. The controller 20 may include a memory (not shown) in which one or more tables relating to the operation of the heater 10 may be stored. The heater 10 and controller 20 are powered by a power source 22. Power source 22 is a rechargeable battery. In other embodiments, the power source may be other suitable power sources.

The aerosol provision device 2 is suitable for use with a consumable 24. The consumable 24 includes one or more discrete portions of aerosol-generating material 32 supported on the first surface 28 of the consumable 24. Discrete portions of aerosol-generating material 32 are supported on the surface 28 in a square grid pattern. Other not shown embodiments of the consumable 24 may include more or fewer discrete portions of the aerosol-generating material 32 than shown in fig. 1, including individual portions 32 of the aerosol-generating material, and those portions may be distributed on the surface 28 in any pattern. The discrete portions of aerosol-generating material 32 are shown in fig. 1 as being approximately circular in shape, in other embodiments they may be other shapes. An example of how the consumable 24 is produced or manufactured is described below.

Referring to fig. 2, a support 30 is provided for initiating the manufacture of the consumable 24. The support 30 comprises a longitudinally extending sheet of material, in the embodiment shown the support 30 is a sheet of paperboard 34. In other not shown embodiments, the material may be another suitable material, such as paper, cardboard, paperboard, cardboard, recombinant material, plastic material, ceramic material, composite material, or glass. The length and width of the support 30 as shown in fig. 2 are for illustration purposes only. The support 30 may have different lengths and widths without departing from the scope of the present disclosure.

The card paper 34 has two major surfaces, a first surface 36 and a second surface 38. The distance between the first surface 36 and the second surface 38 is the thickness t.

The first surface 36 of the support 30 is designated as having a first reinforced region 40A and a second reinforced region 40B.

Referring to fig. 3, the support 30 is embossed using a male and female die (not shown) to form a plurality of parallel ridges 42 (only two of which are labeled for clarity) that extend through the reinforcing regions 40A, 40B. The male and female dies are positioned adjacent the second face 38 and the first face 36, respectively, of the support 30. The dies are oriented such that the male and female die contours in the dies are aligned with one another and then the dies are urged toward one another to form the embossments/ridges 42 of the support 30.

The creation of ridges 42 in support 30 causes the stiffness or bending resistance of reinforced regions 40A, 40B to increase at least about the Y-axis (shown in fig. 2) relative to those portions of support 30 that are not embossed.

Referring to fig. 4, after embossing of the support 30, different portions 32A, 32B of aerosol-generating material are applied to the reinforcing regions 40A, 40B. The aerosol-generating material 32A, 32B covers the entire reinforcing region 40A, 40B and the ridge 42. The ridge 42 assists in the attachment of the aerosol-generating material to the support 30. No aerosol-generating material is applied to the support 30 except for the reinforcing regions 40A, 40B.

In the embodiment of the present disclosure shown in fig. 2-4, the portions 32A, 32B of aerosol-generating material are applied to the reinforcing regions 40A, 40B in the form of a slurry. After application to the reinforcing areas 40A, 40B, the slurry needs to be dried or allowed to dry before the support 30 and the aerosol-generating material portions 32A, 32B can be used as the consumable 24. While the support 30 and aerosol-generating material portions 32A, 32B may simply allow drying over a period of time, such an approach may result in inefficient production of the media and portions of aerosol-generating material 32, 232, 332. Thus, the aerosol-generating material portions 32A, 32B may be dried using known methods of drying aerosol-generating material slurries.

After drying, the aerosol supply device 2 may be used to generate an aerosol from the consumable 24.

In an alternative not shown example of the present disclosure, embossing of the support 30 may be performed by a male die and a female die, wherein at least the female die is heated and the sheet of aerosol-generating material covers the surface 36 of the support 30 in at least the reinforcing regions 40A, 40B. The heating of the die causes the portions of the sheet of aerosol-generating material covering the reinforcing regions 40A, 40B to adhere to the surface 36 of the support 30, while forming ridges 42 due to the configuration of the die. Any sheet of aerosol-generating material that is not attached to the reinforcing regions 40A, 40B may then be detached from the surface 36 of the support 30.

Referring to fig. 5, in a second embodiment of the method of manufacturing consumable 124 of the present disclosure, support 30 of fig. 2 has a susceptor material layer 44 on first surface 36 of support 30. The susceptor layer 44 is a metal foil or film, such as aluminum foil or film. The susceptor layer is reversibly secured to the support 30 by a suitable securing material (not shown).

A kiss cutter, not shown, is caused to cut closed cut lines 46A, 46B in the susceptor layer 44. The closed cut lines 46A, 46B coincide with the outer perimeter of the reinforced areas 40A, 40B. In other embodiments, not shown, the closed cut lines 46A, 46B are within the outer perimeter of the reinforced areas 40A, 40B.

Referring to fig. 6, after the closed cut lines 46A, 46B have been formed, portions of the susceptor layer 44 that are not within the closed cut lines 46A, 46B are removed from the support 30, leaving first and second susceptor portions 44A, 44B on the support 30, wherein the first and second susceptor portions 44A, 44B cover the reinforcing areas 40A, 40B.

Referring to fig. 7, different portions 32A, 32B of aerosol-generating material are next applied to the susceptor portions 44A, 44B and surrounding areas or regions 48A, 48B. The peripheral regions 48A, 48B are regions of the first surface 36 that extend around the perimeter of the reinforced regions 40A, 40B. The aerosol-generating material 32A, 32B thus covers all of the surface of the susceptor portion 44A, 44B that does not face the reinforcing region 40A, 40B. In some examples of the present disclosure, the zones 48A, 48B each extend less than 1mm, less than 2mm, less than 3mm, less than 4mm, less than 5mm, less than 6mm, less than 8mm, or less than 10mm from the perimeter of the reinforcing region 40A, 40B.

Referring to fig. 8, an alternative example of the use of the support 30 and susceptor portions 44A, 44B is shown. In this example, the aerosol-generating material 32 is applied to the entire first surface 36 and the susceptor portions 44A, 44B. The aerosol-generating material 32 is applied to the first surface 36 and the susceptor portions 44A, 44B using a transfer wheel (not shown).

In fig. 7 and 8, portions 32A, 32B/32 of aerosol-generating material are applied to the susceptor portions 44A, 44B and the areas 48A, 48B/first surface 36 and the susceptor portions 44A, 44B in a slurry form in a manner similar to the manner in which the aerosol-generating material is applied as discussed in connection with fig. 2-4. After the slurry of aerosol-generating material portions 32A, 32B/32 has been dried, the aerosol-supplying device 2 may be used to cause the consumable 124 to generate an aerosol.

Since the consumable 124 depends on the nature of the aerosol provision device 2 with which the consumable is used, the susceptor portions 44A, 44B in the consumable 124 have different functions.

When the aerosol provision device 2 is a device that uses induction heating to heat the consumable 124, the aerosol generator 10 is a magnetic field generator and the susceptor portions 44A, 44B are susceptors that are heated by a magnetic field from the magnetic field generator. This heat then causes the aerosol-generating material portions 32A, 32B to generate an aerosol.

When the aerosol provision device 2 is a device that uses resistive heating to heat the consumable 124, the aerosol generator 10 is a resistive heater and the susceptor portions 44A, 44B increase the heat/heat transmittance of the enhanced regions 40A, 40B by conducting thermal energy over the enhanced regions 40A, 40B.

Referring to fig. 9, in a third embodiment of the method of manufacturing consumable 224 of the present disclosure, support 30 of fig. 2 has thickened elements 50A, 50B applied to reinforcing regions 40A, 40B. The thickening elements 50A, 50B are formed of an inert material and, in the example shown in fig. 9, the thickness is non-uniform across the reinforcing region 40A, 40B. In other examples not shown, thickened elements 50A, 50B have a uniform thickness over all or part of reinforcing regions 40A, 40B. The inert material of the thickening elements 50A, 50B is inert at the temperature at which the consumable 224 will be used and may be formed, for example, from a wood fiber matrix and a suitable binder.

Referring to fig. 9 and 10, thickened elements 50A, 50B have surfaces 52A, 52B facing away from support 30. The portions 54A, 54B of susceptor material are attached to the surfaces 52A, 52B of the thickening elements 50A, 50B using suitable fixing means. The susceptor portions 54A, 54B are formed from a metal foil or film (e.g., aluminum foil or film).

Referring to fig. 10 and 11, the susceptor portions 54A, 54B have different shapes (triangular and rectangular, respectively) and are cut into shape when mounted on the back plate 56. The susceptor portions 54A, 54B are separated from their back plate 56 and attached to the surfaces 52A, 52B, respectively.

Referring to fig. 12, a different portion 132A, 132B of aerosol-generating material is next applied to the susceptor portions 54A, 54B and a portion of the surface 52A, 52B of the thickening element 50A, 50B surrounding the susceptor portions 54A, 54B. The aerosol-generating material 132A, 132B thus covers the entire surface of the surface 52A, 52B of the susceptor portion 54A, 54B not facing the thickening element 50A, 50B.

The portions 132A, 132B of aerosol-generating material are applied to the susceptor portions 54A, 54B and portions of the surfaces 52A, 52B of the thickening elements 50A, 50B in the form of a slurry in a manner similar to that of the aerosol-generating material discussed above in connection with fig. 2 to 4. After the slurry of aerosol-generating material portions 132A, 132B has been dried, the aerosol-supplying device 2 may be used to cause the consumable 224 to generate an aerosol.

Referring to fig. 13 and 14, in a fourth embodiment of the method of manufacturing a consumable 324 of the present disclosure, a support 130 is provided. The support 130 comprises a longitudinally extending sheet of material, in the embodiment shown the support 130 is a cardboard sheet. In other not shown embodiments, the material may be another suitable material, such as paper, cardboard, paperboard, cardboard, recombinant material, plastic material, ceramic material, composite material, or glass. The length and width of the support 130 as shown in fig. 13 and 14 are for illustration purposes only. The support 130 may have different lengths and widths without departing from the scope of the present disclosure.

The support 130 has two major surfaces, a first surface 36 and a second surface 38.

The first surface 36 of the support 130 is designated as having a first reinforced region 140A and a second reinforced region 140B. The second surface 38 of the support 130 is designated as having a third reinforced region 140C and a fourth reinforced region 140D. The first and third reinforced areas 140A, 140C are located at the same position of the first and second faces 36, 38 of the support 130 and thus correspond to each other. In a similar manner, the second reinforcing region 140B and the fourth reinforcing region 140D are located at the same position of the first face 36 and the second face 38 of the support 130, and thus correspond to each other.

Referring to fig. 15 and 16, a first layer 44 of susceptor material is located on the first surface 36 of the support 130. The susceptor layer 44 is a metal foil or film, such as aluminum foil or film. The susceptor layer is reversibly secured to the support 130 by a suitable securing material (not shown).

A kiss cutter, not shown, is caused to cut closed cut lines 146A, 146B in the first susceptor layer 44. The closed cut lines 146A, 146B coincide with the outer perimeter of the reinforced areas 140A, 140B. Thereafter, or simultaneously, a second layer 44 of susceptor material is disposed on the second surface 38 of the support 130. Each susceptor layer 44 is a metal foil or film, such as aluminum foil or film. The susceptor layer is reversibly secured to the support 130 by a suitable securing material (not shown).

A kiss cutter, not shown, is caused to cut closed cut lines 146C, 146D in the second susceptor layer 44. The closed cut lines 146C, 146D coincide with the outer perimeter of the reinforced areas 140C, 140D.

Referring to fig. 17 and 18, after the closed cut lines 146A, 146B, 146C, 146D have been formed, portions of the first and second susceptor layers 44 that are not within the closed cut lines 146A, 146B, 146C, 146D are removed from the support 130, leaving the first, second, third, and fourth susceptor portions 144A, 144B, 144C, 144D on the support 130 to cover the reinforcing regions 140A, 140B, 140C, 140D.

Referring to fig. 19 and 20, different portions 232A, 232B, 232D of aerosol-generating material are next applied to the susceptor portions 144A, 144B, 144C, 144D and the surrounding areas or regions 148A, 148B, 148C, 148D. The surrounding areas 148A, 148B are areas of the first surface 36 that extend around the perimeter of the reinforced areas 140A, 140B. The peripheral regions 148C, 148D are regions of the second surface 38 that extend around the perimeter of the reinforced regions 140C, 140D.

The aerosol-generating material portions 232A, 232B, 232D thus cover the entire surface of the susceptor portion 144A, 144B, 144C, 144D that is not facing the reinforcing region 140A, 140B, 140C, 140D. In some examples of the present disclosure, the peripheral regions 148A, 148B, 148C, 148D each extend less than 1mm, less than 2mm, less than 3mm, less than 4mm, less than 5mm, less than 6mm, less than 8mm, or less than 10mm from the periphery of the reinforced regions 140A, 140B, 140C, 140D.

The portions 232A, 232B, 232D of aerosol-generating material are applied to the susceptor portions 144A, 144B, 144C, 144D and the regions 148A, 148B, 148C, 148D in a slurry form in a manner similar to that of the aerosol-generating material discussed above in connection with fig. 2-4. After the slurry of aerosol-generating material portions 232A, 232B, 232D has been dried, the aerosol-supplying device 2 may be used to cause the consumable 324 to generate an aerosol.

The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided as representative examples of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that the advantages, embodiments, examples, functions, features, structures and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be used and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist essentially of, or consist of the appropriate combination of the disclosed elements, components, features, parts, steps, means, etc. in addition to those specifically described herein. In addition, the present disclosure may include other inventions not presently claimed but which may be claimed in the future.

Claims

1. A method of manufacturing a consumable for use with a non-combustible sol supply system, wherein the consumable comprises a support and an aerosol generating material, wherein the method comprises:

a support member is provided which is configured to support the support member,

forming at least one reinforcing area on the support,

the aerosol-generating material is applied to the support in at least one location corresponding to at least a portion of at least one reinforcing region.

2. The method of claim 1, wherein the enhancement region is a region having such enhancement: reinforcing the stiffness of the support in the reinforced region of the support to be greater than the stiffness of the support in the unreinforced region of the support, and forming at least one reinforced region includes increasing the stiffness of the support in at least a portion of at least one reinforced region.

3. The method according to claim 1 or 2, wherein the enhancement region is a region having such an enhancement mode: the contour of at least a portion of the surface of the reinforcing region, and forming the at least one reinforcing region includes embossing or coining the support in at least a portion of the at least one reinforcing region.

4. A method according to any one of claims 1 to 3, wherein the enhancement region is a region having such an enhancement mode: enhancing the thermal transmissivity of the support in the enhanced regions of the support to be greater than the thermal transmissivity of the support in the un-enhanced regions of the support, and forming at least one enhanced region includes increasing the thermal transmissivity of at least a portion of the at least one enhanced region.

5. The method of any of claims 1 to 4, wherein the enhancement region is a region having such enhancement: reinforcing the thickness of the support in the reinforced region of the support to be greater than the thickness of the support in the unreinforced region of the support, and forming at least one reinforced region includes increasing the thickness of the support in at least a portion of at least one reinforced region.

6. The method of any of claims 1 to 5, wherein the enhancement region is a region having such enhancement: adding a region comprising the susceptor, and forming at least one reinforcing region comprises applying the susceptor to at least a portion of the at least one reinforcing region.

7. The method of claim 6, wherein applying the susceptor to at least a portion of the at least one reinforcing region comprises applying one or more preformed portions of the susceptor.

8. The method of claim 6, wherein applying susceptors to at least a portion of at least one reinforcing region comprises: applying a susceptor in sheet form to the support, kiss-cutting the susceptor to form at least one predetermined closed cut line in the susceptor, and then removing portions of the susceptor not within the closed cut line, and the cut line coincides with or falls within the perimeter of at least one reinforcing region.

9. The method of any one of claims 6 to 8, wherein the susceptor comprises a metal or metal alloy.

10. A method according to any one of claims 6 to 9, wherein the method of applying the susceptor to at least a portion of at least one reinforcing region comprises using a hot foil stamping technique.

11. The method of any of claims 2 to 10, wherein at least one enhancement region comprises two or more enhancements.

12. The method of any of claims 1-11, wherein forming at least one enhancement region comprises forming at least two separate enhancement regions.

13. The method of claim 12, wherein at least two separate enhancement regions of the at least two separate enhancement regions are distinguishable from each other by a human or automated observer.

14. A method according to any one of claims 1 to 13, wherein applying aerosol-generating material is applying aerosol-generating material to at least a portion of each reinforcing region of the support and not applying the aerosol-generating material to a portion of the support where reinforcing regions are not formed.

15. A method according to any one of claims 1 to 13, wherein applying aerosol-generating material is applying aerosol-generating material to the entire reinforcing region of each reinforcing region of the support and not to a portion of the support where no reinforcing region is formed.

16. A method according to any one of claims 1 to 13, wherein applying aerosol-generating material is applying aerosol-generating material to the entire reinforcing region of each reinforcing region of the support and to at least a portion of the support surrounding each reinforcing region, and not applying the aerosol-generating material to the remainder of the support where no reinforcing region is formed.

17. The method of claim 16, wherein at least a portion of the support surrounding each reinforcing region is a zone extending less than 1mm, 2mm, 3mm, 4mm, 5mm, 6mm, 8mm, or 10mm from the perimeter of the respective reinforcing region.

18. A method according to any one of claims 1 to 13, wherein applying aerosol-generating material is applying aerosol-generating material to substantially all of the support.

19. A method according to any one of claims 1 to 18, wherein applying the aerosol-generating material comprises applying the aerosol-generating material using a transfer wheel.

20. A method according to any one of claims 1 to 19, wherein the aerosol-generating material is applied to the surface of the support in the form of a slurry of aerosol-generating material.

21. A method according to claim 20, wherein the method further comprises allowing or curing the aerosol-generating material slurry, wherein the aerosol-generating material slurry is cured to an aerosol-generating material.

22. A method according to any one of claims 1 to 19, wherein the aerosol-generating material is applied in the form of a cured aerosol-generating material.

23. A method according to claim 22, wherein applying the aerosol-generating material comprises hot stamping the aerosol-generating material onto the support.

24. A method according to any one of claims 21 to 23, wherein the aerosol-generating material is an aerosol-generating film.

25. A method according to any one of claims 1 to 24, wherein forming at least one reinforcing region on the support and applying the aerosol-generating material are caused to occur substantially simultaneously.

26. The method of any one of claims 1 to 25, wherein the support comprises a sheet having a first surface and a second surface,

forming at least one reinforcing region includes forming at least one reinforcing region on one or both of the first surface and the second surface of the support, and

applying the aerosol-generating material is applying the aerosol-generating material to one or both of:

(i) At least a portion of the at least one enhancement region; and

(ii) At least a portion of one surface that corresponds in location to a location of at least one enhancement region on the other surface.

27. The method of any one of claims 1 to 25, wherein the support comprises a sheet having a first surface and a second surface, and forming at least one reinforcing region comprises forming at least one reinforcing region on the first surface and the second surface of the support.

28. A consumable for use with a non-combustible aerosol provision system, wherein the consumable comprises a support, at least one reinforcing region on the support and comprising an aerosol-generating material, and the aerosol-generating material is supported on the support in at least one position corresponding to at least a portion of the at least one reinforcing region.

29. The consumable of claim 28, wherein the reinforcement in the at least one reinforcement region of the support is an increased stiffness of at least a portion of the at least one reinforcement region relative to a portion of the support not belonging to the reinforcement region.

30. The consumable of claim 28 or 29, wherein the reinforcement in the at least one reinforcement region of the support is such that at least a portion of the at least one reinforcement region has an increased thermal transmissivity with respect to a portion of the support not belonging to the reinforcement region.

31. The consumable of any one of claims 28 to 30, wherein the reinforcement in the at least one reinforcement region of the support is at least a portion of the at least one reinforcement region embossed or stamped.

32. The consumable of any one of claims 28 to 31, wherein the reinforcement in the at least one reinforcement region of the support is that at least a portion of the at least one reinforcement region has an increased thickness relative to a portion of the support not belonging to the reinforcement region.

33. The consumable of any one of claims 28 to 32, wherein the reinforcement in at least one reinforcement region of the support is that the at least one reinforcement region comprises a susceptor.

34. The consumable of claim 33, wherein the susceptor is metallic or a metal alloy.

35. A consumable as claimed in claim 33 or claim 34 and wherein the outer periphery of the susceptor matches the shape and size of the periphery of the reinforcing region to which the susceptor is applied.

36. A consumable as claimed in any one of claims 33 to 35 and wherein the susceptor covers at least a part of the reinforcing region and an outer periphery of the reinforcing region surrounds the susceptor.

37. The consumable of any one of claims 28 to 36, wherein at least one enhancement zone comprises two or more enhancements.

38. A consumable as claimed in any one of claims 28 to 37 and wherein there are at least two separate enhancement regions.

39. The consumable of claim 38, wherein at least two of the at least two separate enhancement regions are distinguishable from each other by a human or automated observer.

40. A consumable as claimed in any one of claims 28 to 39 and wherein aerosol-generating material is supported on at least a portion of each reinforcing region and is not supported on a portion of the support where the reinforcing region is not formed.

41. A consumable according to any one of claims 28 to 39, wherein the entire reinforcing region of each reinforcing region supports aerosol-generating material and no aerosol-generating material is supported on the portion of the support where the reinforcing region is not formed.

42. A consumable as claimed in any one of claims 28 to 39 and wherein the entire reinforcing region and surrounding region of each reinforcing region supports aerosol-generating material and no aerosol-generating material is supported on the portion of the support where the reinforcing region or surrounding region is not formed.

43. The consumable of claim 42, wherein the peripheral region is a region extending less than 1mm, less than 2mm, less than 3mm, less than 4mm, less than 5mm, less than 6mm, less than 8mm, or less than 10mm from the periphery of the reinforcing region.

44. A consumable as claimed in any one of claims 28 to 39 and wherein substantially all of the support supports the aerosol generating material.

45. A consumable as claimed in any one of claims 28 to 44 and wherein the aerosol generating material comprises an aerosol generating film or gel.

46. A consumable as claimed in any one of claims 28 to 45 and wherein the support comprises a sheet having a first surface and a second surface, at least one reinforcing region being located on one or both of the first and second surfaces of the support and an aerosol generating material supported on one or both of: (i) At least a portion of at least one enhancement region, and (ii) at least a portion of one surface that corresponds in location to the location of at least one enhancement region on the other surface.

47. The consumable of any one of claims 28 to 45, wherein the support comprises a sheet having a first surface and a second surface, and at least one reinforcing region is located on each of the first surface and the second surface of the support.

48. An aerosol provision device for use with a consumable of any one of claims 28 to 47, wherein the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable.

49. An aerosol provision system comprising an aerosol provision device according to claim 48 and a consumable according to any one of claims 28 to 47.

50. A method of generating an aerosol from a consumable as claimed in any one of claims 28 to 47 using an aerosol generating device, in which at least one aerosol generator is arranged to heat without combusting the consumable in use; wherein the at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.