CN117940030A

CN117940030A - Consumable for use with an aerosol supply device

Info

Publication number: CN117940030A
Application number: CN202280054362.1A
Authority: CN
Inventors: 约翰·理查森
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2021-08-04
Filing date: 2022-08-04
Publication date: 2024-04-26
Also published as: WO2023012289A1; KR20240040076A; GB202111286D0

Abstract

A method of manufacturing a product (2) for use in manufacturing an article for use in a non-combustible sol supply system is provided. The product (2) comprises an aerosol-generating material (20) and a carrier (4). The carrier (4) comprises a base layer (6) and a carrier layer (8), and the carrier layer (8) is releasably attached to the base layer (6). The method comprises the following steps: step (a) providing a carrier (4); step (b) applying an aerosol-generating material (20) to a support surface (10) of a carrier layer (8) of a carrier (4); and (c) the carrier (4) and aerosol-generating material (20) are configured for storage.

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 aerosol supplies and products for manufacturing such consumables, a method for manufacturing consumables for use with aerosol supplies and products for manufacturing such consumables, and an aerosol supply system comprising a consumable and an aerosol supply.

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 product for use in manufacturing a consumable for use with an apparatus for heating an aerosol-generating material to aerosolize at least one component of the aerosol-generating material, wherein the product comprises the aerosol-generating material and a carrier, wherein the carrier comprises a base layer and a carrier layer, and the carrier layer is releasably attached to the base layer,

And the method comprises the steps of:

(a) A carrier is provided which is capable of being moved,

(B) Applying an aerosol-generating material slurry to a support surface of a carrier layer of a carrier, and

(C) The carrier and aerosol-generating material are configured for storage.

According to a second aspect of the present disclosure there is provided a product for use in the manufacture of a consumable for use with an apparatus for heating an aerosol-generating material to aerosolize at least one component of the aerosol-generating material, wherein the product comprises the aerosol-generating material and a carrier, wherein,

The carrier comprises a base layer and a carrier layer,

The carrier layer is releasably attached to the base layer,

At least one discrete portion of the aerosol-generating material is supported on a support surface of a carrier layer of the carrier.

According to a third aspect of the present disclosure there is provided a method of making a consumable for use with an apparatus for heating an aerosol-generating material, the consumable comprising a support and an aerosol-generating material, wherein the method comprises:

(i) Providing at least one product according to the second aspect of the present disclosure, and

(Ii) At least a portion of the carrier layer is released from the base layer of at least one product.

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

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

According to a sixth aspect of the present disclosure there is provided a method of generating an aerosol from a consumable manufactured according to the third aspect of the present disclosure using an aerosol-generating device, wherein at least one aerosol generator is arranged to heat but not burn 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 diagram of a representative portion of a first embodiment of a product according to the present disclosure during manufacture;

FIG. 2 shows an exploded view of a portion of FIG. 1;

FIG. 3 shows another schematic view of the portion of FIG. 1;

FIG. 4 shows a schematic view of a first embodiment of a product according to the present disclosure;

FIG. 5 shows a second schematic view of the product of FIG. 4;

FIG. 6 shows a schematic diagram of a consumable from the product of FIG. 4;

FIG. 7 shows a schematic view of an aerosol supply device for use with the consumable of FIG. 6;

FIG. 8 shows a schematic diagram of a representative portion of a first embodiment of a product according to the present disclosure during manufacture;

FIG. 9 shows another schematic view of the portion of FIG. 8; and

Fig. 10 shows a schematic side view of a second embodiment of a product according to the present disclosure.

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 or ignited in order to facilitate delivery of a substance to be delivered to a user.

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

According to a first aspect of the present disclosure there is provided a method of manufacturing a product for use in manufacturing a consumable for use with a device for heating an aerosol-generating material to aerosolize at least one component of the aerosol-generating material, wherein the product comprises the aerosol-generating material and a carrier, wherein the carrier comprises a base layer and a carrier layer, and the carrier layer is releasably attached to the base layer,

And the method comprises the steps of:

Step (a) provides a carrier,

Step (b) applying an aerosol-generating material to a surface of a carrier layer of a carrier, and

Step (c) the carrier and aerosol-generating material are configured for storage.

In one of the above embodiments, the applying aerosol-generating material in step (b) is applying an aerosol-generating material slurry.

In one of the above embodiments, the method comprises a further step of allowing or curing the aerosol-generating material slurry to an aerosol-generating material, wherein the step occurs between step (b) and step (c). In some embodiments, the aerosol-generating material slurry is cured to an aerosol-generating material in the form of an aerosol-generating film.

An aerosol-generating material is a material that is capable of generating an aerosol, for example, when heated, irradiated, or excited 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 an embodiment of any of the above embodiments, the applying of the aerosol-generating material in step (b) is applying one or more discrete portions of the aerosol-generating material.

In an embodiment of any of the above embodiments, there are at least two discrete portions of aerosol-generating material, and the at least two discrete portions of aerosol-generating material have different compositions relative to each other. This has the advantage that a user of a consumable manufactured according to the present disclosure may have a different experience when different discrete portions of the aerosol-generating material on the consumable are aerosolized. This may make the use of the consumable more pleasant and/or interesting than a consumable using an aerosol-generating material having only one component.

In one embodiment of any of the above embodiments, there are three or more distinct portions of aerosol-generating material, and the discrete portions are applied to the surface of the carrier layer in the form of a grid pattern.

In an embodiment of any of the above embodiments, the one or more discrete portions of aerosol-generating material applied in step (b) are substantially circular in the plane of the support surface of the carrier layer, are longitudinally extending strips, are strips comprising at least one curve or angle, or have a shape to be tessellated.

In an embodiment of any of the above embodiments, the shape and/or color of the at least one discrete portion of aerosol-generating material applied in step (b) is indicative of the composition of the aerosol-generating material forming the discrete portion.

In one embodiment of any of the above embodiments, step (b) is performed two or more times. This may have the effect of producing a thicker aerosol-generating material on the medium than a single application of the aerosol-generating material. The increased thickness may cause the aerosol-generating material to generate a greater amount of aerosol and/or supply aerosol for a longer period of time than if the aerosol-generating material was applied only once.

In one embodiment of any of the above embodiments, the releasable attachment of the carrier layer to the base layer includes the use of an adhesive that allows the carrier layer to be released from the base layer. In some embodiments, the adhesive is a pressure adhesive.

In one embodiment of any of the above embodiments, the carrier layer comprises a sheet material, and the sheet material comprises at least one of paper, cardboard, plastic material, and metal material. In some embodiments, the carrier is made of a sheet material that is not damaged by bending of the material.

In one embodiment of any of the above embodiments, the support surface of the carrier layer is one of a major surface and a maximum surface of the carrier layer, and the other of the major surfaces of the carrier layer is a surface that is adhered to the base layer.

In one of any of the above embodiments, the method includes the further step of: (d) At least one separation line is introduced into at least a portion of the carrier, wherein each separation line is a predetermined line along which at least a portion of the carrier will separate or tear.

The introduction of at least one separation line has the advantage that the separation or tearing is more controlled than in the case of a separation or tearing of a portion of the carrier layer that does not comprise a separation line. It is further understood that when the carrier layer is separated by tearing, the tearing of the carrier layer follows the separation line. This is in contrast to tearing a portion of the carrier layer that has no separation line, where the tear line may be expected to follow a line of weakness in the carrier layer and or reflect the geometry and magnitude of the force applied to the carrier layer to cause the tear.

In one embodiment of any of the above embodiments, the at least one separation line is a predetermined line along which the carrier layer is to be separated or torn.

In one embodiment of any of the above embodiments, the one or more separation lines are positioned such that the carrier layer can be separated into at least two portions of predetermined size and shape along at least one separation line. In some embodiments, at least two portions of the predetermined size and shape have the same size and shape. In some other embodiments, at least two portions of the predetermined size and shape have different predetermined sizes and/or shapes.

In one embodiment of any of the preceding embodiments, the at least one separation line of step (d) comprises a perforation line. In some embodiments, the perforations extend only through the carrier layer. In some embodiments, the perforations extend through the carrier layer and the base layer. In some embodiments, the perforations extend from the support surface into the carrier layer, but not completely through the carrier layer.

In one embodiment of any of the preceding embodiments, at least one of the separation lines of step (d) comprises a cut line. In some embodiments, the cut lines may be incisions that extend the entire depth of the carrier layer. In some embodiments, the cut lines may be incisions that extend from the support surface into the carrier layer, but not completely through the carrier layer.

In one embodiment of any of the above embodiments, the cut lines are formed using kiss cutting techniques.

In an embodiment of any of the above embodiments, the at least one separation line extends between at least two discrete portions of the aerosol-generating material or between at least two locations where discrete portions of the aerosol-generating material are to be applied in step (b).

In an embodiment of any of the above embodiments, at least a portion of the at least one separation line extends through the aerosol-generating material applied to the carrier layer, or the location where the aerosol-generating material is to be applied in step (b).

In one embodiment of any of the above embodiments, the carrier is a sheet of material, and the construction of step (c) comprises: two or more sheet stacks of the carrier are stacked into a laminate.

In one of any of the above embodiments, the carrier is a longitudinally extending sheet of material, and the construction of step (c) comprises: at least one fold line is formed in the carrier and the carrier is then folded about at least one of those fold lines.

In one embodiment of any of the above embodiments, the fold line corresponds to a separation line.

In one embodiment of any of the above embodiments, the carrier is folded into the form of an accordion.

In one embodiment of any of the preceding embodiments, the construction of step (c) comprises: the carrier is formed into a roll.

In one embodiment of any of the above embodiments, the carrier is wound around the core. In some embodiments, the core is a spool, bobbin, or other structure that supports the carrier and around which the carrier may be wound.

In one of any of the above embodiments, the method further comprises the step of:

(e) Placing a sheet of barrier material over the support surface of the carrier layer and the aerosol-generating material, wherein step (e) is performed prior to step (c).

In some embodiments, the barrier material is a material to which the aerosol-generating material may only weakly adhere if the aerosol-generating material fully adheres to the barrier material. For the purposes of this disclosure, adhesion to a barrier material may be considered to be a weak adhesion if an aerosol-generating material adhered to the barrier material and supported on a support surface of the carrier layer is more firmly attached to the support surface of the carrier layer than it is adhered to the barrier material.

According to a second aspect of the present disclosure there is provided a product for manufacturing a consumable for use with an apparatus for heating an aerosol-generating material to aerosolize at least one component of the aerosol-generating material, wherein the product comprises the aerosol-generating material and a carrier, wherein,

The carrier comprises a base layer and a carrier layer,

The carrier layer is releasably attached to the base layer, and

At least one discrete portion of the aerosol-generating material is supported on the support surface of the carrier layer.

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

In an embodiment of any of the above embodiments, there are at least two discrete portions of aerosol-generating material, and the at least two discrete portions of aerosol-generating material have different compositions relative to each other.

In one embodiment of any of the above embodiments, there are three or more distinct portions of aerosol-generating material, and the discrete portions are applied to the support surface of the carrier layer in a grid pattern.

In an embodiment of any of the above embodiments, the one or more discrete portions of aerosol-generating material are substantially circular in the plane of the support surface of the carrier layer, are longitudinally extending strips, are strips comprising at least one curve or angle, or have a shape to be tessellated.

In an embodiment of any of the above embodiments, the shape and/or color of at least one discrete portion of the aerosol-generating material is indicative of the composition of the aerosol-generating material forming the discrete portion.

In one embodiment of any of the above embodiments, the carrier layer comprises an adhesive-backed sheet material, and the sheet material comprises at least one of paper, cardboard, plastic material, or metal material.

In one embodiment of any of the above embodiments, the carrier comprises at least one separation line, wherein each separation line is a predetermined line along which at least a portion of the carrier will separate or tear.

In one embodiment of any of the above embodiments, the at least one separation line comprises a perforation line.

In one embodiment of any of the above embodiments, the at least one separation line comprises a cut line.

In one embodiment of any of the preceding embodiments, the at least one cut line is the result of kissing.

In an embodiment of any of the above embodiments, the at least one separation line extends between at least two discrete portions of the aerosol-generating material.

In one embodiment of any of the above embodiments, at least a portion of the at least one separation line extends through the aerosol-generating material applied to the carrier layer.

In one embodiment of any of the above embodiments, the carrier is a sheet material.

In one embodiment of any of the above embodiments, the carrier is a longitudinally extending sheet of material, the carrier includes at least one fold line, and the carrier is folded about at least one of those fold lines.

In one embodiment of any of the above embodiments, the carrier is rolled into a roll.

In one embodiment of any of the above embodiments, the web of carrier is wound around the core.

In one of any of the above embodiments, the product further comprises

A sheet of barrier material is placed over the carrier layer and the aerosol-generating material.

In one embodiment of any of the above embodiments, the adhesive adhering the carrier layer to the base layer may be a pressure adhesive.

In one embodiment of any of the above embodiments, the surfaces of the base layer and the carrier layer that adhere to each other are such that when the carrier layer is released or removed from the base layer, at least 95% of the adhesive, either all or by weight, remains on the base.

According to a third aspect of the present disclosure there is provided a method of manufacturing a consumable for use with an apparatus for heating an aerosol-generating material, wherein the method comprises

(Ii) Releasing at least a portion of the carrier layer from the base layer of the at least one product,

Wherein the separated portions of the carrier layer support the aerosol-generating material. In some embodiments, the separated portions of the carrier support two or more discrete portions of the aerosol-generating material. In some embodiments, the aerosol-generating film has two or more points.

The separated portion of the carrier layer may be used in combination with a suitably configured aerosol-generating device and the separated portion of the carrier film may thus be understood as a consumable.

According to a fourth aspect of the present disclosure there is provided an aerosol provision device for use with a consumable manufactured according to the third 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.

In an embodiment of any of the above embodiments, the aerosol generator comprises a heatable plate adapted to support a consumable manufactured according to the third aspect of the disclosure. In some embodiments, the heatable plate is configured to receive and retain a discrete portion of the carrier layer. In some embodiments, the heatable plate is adapted to heat different portions of the separated portion of the carrier layer at different times. In some embodiments, the arrangement of aerosol-generating material on the surface of the separated portion of the carrier layer matches the arrangement of the individually heatable portions of the heating plate.

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: spearmint, peppermint c.v., egypt, peppermint, basil c.v., peppermint c.v., spearmint, peppermint, pineapple, lip mint, spearmint c.v., 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.

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 gel, which may or may not contain an active substance and/or a fragrance.

The aerosol generating material comprises an aerosol former.

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% (WWB) of water 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:

-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.

If the aerosol-generating material or 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 or 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 areal density, such as from 30g/m ² to 120g/m ². In some cases, the sheet may have a mass per unit area 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 (so that it has a density similar to shredded tobacco and a mixture of these materials will not readily separate). In some cases, the sheet may have a mass per unit area of about 30g/m ² to 70g/m ²、40g/m² to 60g/m ² or 25g/m ² to 60g/m ² and may be used to encase 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 components (such as tobacco material) in the aerosol-generating material comprising the aerosol-generating 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 and 2, in order to begin producing the product 2, a carrier 4 is provided. The carrier 4 extends longitudinally with the representative portion of the carrier 4 shown in fig. 1-3. The carrier 4 comprises a base layer 6 and a carrier layer 8. The base layer 6 comprises paper and the carrier layer 8 comprises a sheet of paperboard. In other examples not shown, the carrier layer may comprise paper, a plastic material, or a metallic material.

The carrier layer 8 has a support surface 10 and a carrier adhesion surface 12. The base layer 6 has a base adhesion surface 14 and a base surface 15. The carrier layer 8 and the base layer 6 are adhered to each other by an adhesive (not shown) acting on the carrier and base adhesion surfaces 12, 14. The adhesive is a releasable adhesive and the nature of each of the carrier and base adhesive surfaces 12, 14 is such that when the carrier layer 8 and the base layer 6 are pulled or peeled away from each other, the adhesive remains on the base adhesive surface 14 and detaches from the carrier adhesive surface 12.

The length and width of the carrier 4 as shown in fig. 1 to 6 are for illustration purposes only. The carrier 4 may have different lengths and widths without departing from the scope of the present disclosure.

A plurality of separation lines 16, 18 are introduced into the carrier layer 8 before the carrier layer 8 is adhered to the base layer 6. The separation line 16 is a perforation line extending along the carrier layer 8 in the longitudinal direction. The separation lines 18 are perforation lines extending in a direction substantially perpendicular to the longitudinal direction and are substantially evenly longitudinally spaced apart along the carrier layer 8. The perforations in each of the perforation lines 16, 18 are such that a tear initiated at the end of the perforation line 16, 18 will tend to follow the perforation line until the tear has stopped or reached the end of the perforation line.

The perforation lines 16, 18 divide the support surface 10 of the carrier layer 8 into a plurality of partial areas 22 (not all partial areas 22 are labeled in all figures for clarity). In the example shown, each of the partial areas 22 is the same size and shape. In other not shown examples of the present disclosure, the partial regions may not all have the same size and/or shape.

After the carrier layer 8 has been adhered to the base layer 6, and as shown in fig. 3, a plurality of dots of aerosol-generating material slurry 20 (not all dots of slurry 20 are labeled for clarity) are applied to the support surface 10 of the carrier layer 8. The dots of slurry 20 are arranged on the support surface 10 in a square grid pattern, with six dots of slurry in each partial region 22 supported on the support surface 10. The arrangement of the dots of slurry 20 in relation to the perforation lines 16, 18 is such that for each partial region 22 the dots of slurry 20 in that partial region are in the same position relative to the edges of that partial region as in the other partial regions.

After the dots of slurry 20 have been applied to the carrier layer 8, it is allowed to take a period of time to allow the dots of slurry to cure and form the dots of aerosol-generating film 20A. Alternatively and/or additionally, the carrier 4 is subjected to conditions such as heat and/or low humidity atmosphere, which reduces the time required for spot curing of the slurry 20.

Referring to fig. 4, after the dots of slurry 20 have cured and become aerosol-generating film dots 20A, the carrier 4 and aerosol-generating film dots 20A form the product 2. The carrier 4 is wound around the core 22 to form a roll to configure the product 2 for storage. The product 2 can now be stored until needed.

Referring to fig. 5, when it is desired to use product 2 to manufacture one or more consumables, the web of carrier 4 is partially opened so that one or more partial areas 22 are accessible to the user. The user may then peel at least one partial region 22 away from the base layer 6. At the same time as the partial region is peeled off, the perforations of the perforation lines 16, 18 defining the peeled off partial region 22 will be torn off and leave the non-peeled off partial region adhered to the base layer 6.

After the partial region 22 has been peeled off, the user has a portion 24 of the carrier layer 8, as shown in fig. 6. The portion 24 of the carrier layer 8 may be used as a consumable 26 for use with an aerosol supply device 30.

Referring to fig. 7, the aerosol provision device 30 includes a housing 32 within which is located a heater assembly 34. The heater assembly 34 includes a heating chamber 36 and a heater 38. The heater 38 may be a resistive heater or a magnetic field generator and susceptor.

The heating chamber 36 defines an opening or mouth 40 at a first end of the heating chamber 36. At the other end of the heating chamber 36 is an orifice 42. The orifice 42 is in fluid communication with a mouthpiece 46 via a conduit 44.

Also located within the housing 32 is a controller 48 that is in electronic communication with and controls the function of the heater 38. The controller 48 may include a memory (not shown) in which one or more tables relating to the operation of the heater 38 may be stored. The heater 38 and controller 48 are powered by a power source 50. The power source 50 is a rechargeable battery. In other embodiments, the power source may be other suitable power sources.

In an alternative embodiment of the present disclosure and referring to fig. 8, a carrier layer 108 is provided. The carrier layer 108 comprises a metal foil, such as aluminum foil. Carrier layer 108 has a support surface 110 and a carrier attachment surface 112. A plurality of dots of aerosol-generating material slurry 20 (not all dots of slurry 20 are labeled for clarity) are applied to the support surface 110 of the carrier layer 108. The dots of slurry 20 are disposed on the support surface 110 in a square grid pattern.

After the dots of slurry 20 have been applied to the carrier layer 108, it is allowed to take a period of time to allow the dots of slurry to cure and form the dots of aerosol-generating film 20A. Alternatively and/or additionally, the carrier layer 108 is subjected to conditions such as heat and/or low humidity atmosphere, which reduces the time required for spot curing of the slurry 20.

Referring to fig. 9, after the dots of slurry 20 have cured and become aerosol-generating film dots 20A, the carrier layer 108 adheres to the base layer 106 to form the carrier 104.

The base layer 106 has a base adhesion surface 114 and a base surface 115. A plurality of fold lines 152 have been formed in the base layer 106 prior to attaching the carrier layer 108. After the carrier layer 108 is adhered to the base layer 106, the fold line 152 extends substantially perpendicular to the longitudinal direction of the carrier layer. The carrier layer 108 and the base layer 106 are adhered to each other by an adhesive (not shown) acting on the carrier and base adhesion surfaces 112, 114. The adhesive is a releasable adhesive and the characteristics of each of the carrier and base adhesive surfaces 112, 14 are such that when the carrier layer 108 and the base layer 106 are pulled or peeled away from each other, the adhesive remains on the base adhesive surface 114 and detaches from the carrier adhesive surface 112.

After adhering the carrier layer 108 to the base layer 106, a plurality of separation lines 116, 118 are introduced into the carrier layer 118. The separation line 116 is a cut line extending along the carrier layer 108 in the longitudinal direction. The separation line 118 is a cut line extending in a longitudinal direction substantially perpendicular to the carrier layer 108. The cut lines 118 are substantially uniformly longitudinally spaced apart along the carrier layer 108 and coincide with the fold lines 152 of the base layer 106 at longitudinal locations. The cut lines 116, 118 are cut by kiss cutting techniques and the cuts extend from the support surface 110 to the carrier attachment surface 112.

The cut lines 116, 118 divide the carrier layer 108 into a plurality of carrier portions 122 (not all carrier portions 122 are labeled in all figures for clarity). Each carrier portion 122 has eight aerosol-generating film points 20A supported on the support surface 110 of that portion. The relationship between the arrangement of aerosol-generating film dots 20A and the cut lines 116, 118 is such that for each carrier part 122 the aerosol-generating film dots will 20A be in the same position relative to the edges of the carrier parts as in the other carrier parts. In the example shown, each carrier portion 122 has the same size and shape. In other not shown examples of the present disclosure, the carrier portions may not all have the same size and/or shape.

Referring to fig. 10, the carrier 104 is now accordion folded about the fold line 152 in the base layer 106 to configure the product 102 for storage. The product 102 can now be stored until needed.

When it is desired to use the product 102 to provide one or more consumables, the accordion-like carrier 104 is partially deployed so that the one or more carrier portions 122 are accessible to the user. The user may then peel the at least one carrier portion 122 from the base layer 106. The cut lines 116, 118 defining the peeled carrier portions 122 will ensure that adjacent carrier portions 122 will not peel from the base layer 106.

After the carrier portion 122 has been peeled away, the carrier portion 122 may be used as a consumable for use with the aerosol provision device 30 in the same manner as described above in connection with the consumable 26.

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 product for use in manufacturing an article for use in a non-combustible aerosol provision system, wherein the product comprises an aerosol generating material and a carrier, wherein the carrier comprises a base layer and a carrier layer, and the carrier layer is releasably attached to the base layer,

And the method comprises the steps of:

step (a) provides the carrier,

Step (b) applying an aerosol-generating material to a support surface of the carrier layer of the carrier, and

The carrier and aerosol-generating material of step (c) are configured for storage.

2. A method according to claim 1, wherein the application of the aerosol-generating material in step (b) is the application of a slurry of aerosol-generating material.

3. A method according to claim 1 or 2, wherein the application of the aerosol-generating material in step (b) is the application of one or more discrete portions of aerosol-generating material.

4. A method according to claim 3, wherein the aerosol-generating material has at least two discrete portions and the at least two discrete portions of aerosol-generating material have different compositions relative to each other.

5. A method according to claim 3 or 4, wherein aerosol-generating material has three or more distinct portions and the discrete portions are applied to the support surface of the carrier layer in a grid pattern.

6. A method according to any one of claims 3 to 5, wherein one or more of the plurality of discrete portions of the aerosol-generating material applied in step (b) is substantially circular, longitudinally extending strip-shaped, strip-shaped comprising at least one curve or angle, or has a shape to be tessellated in the plane of the support surface of the carrier layer.

7. A method according to any one of claims 3 to 6, wherein the shape and/or colour of at least one discrete portion of the aerosol-generating material applied in step (b) is indicative of the composition of the aerosol-generating material forming the discrete portion.

8. The method of any of claims 1-7, wherein the carrier layer comprises a sheet material and the sheet material comprises at least one of paper, cardboard, plastic material, and metal material.

9. The method according to any one of claims 1 to 8, wherein the method comprises the further step of:

step (d) introduces at least one separation line into at least a portion of the carrier, wherein each separation line is a predetermined line along which at least a portion of the carrier is to be separated or torn.

10. The method of claim 9, wherein at least one separation line is a predetermined line along which the carrier layer is to be separated or torn.

11. The method of claim 9 or 10, wherein the at least one separation line in step (d) comprises a perforation line.

12. The method of claim 9 or 10, wherein at least one separation line in step (d) comprises a cut line.

13. The method of claim 12, wherein the cut line is formed using kissing techniques.

14. A method according to any one of claims 9 to 13 when dependent on claim 3 or any one of claims 3, wherein at least one separation line extends between at least two discrete portions of aerosol-generating material or between at least two locations where discrete portions of aerosol-generating material are to be applied in step (b).

15. A method according to any one of claims 9 to 14, wherein at least a portion of at least one separation line extends through the aerosol-generating material applied to the carrier layer, or through the location where aerosol-generating material is to be applied in step (b).

16. The method of any one of claims 1 to 15, wherein the carrier is a sheet of material and the configuring in step (c) comprises stacking two or more sheets of the carrier into a laminate.

17. The method of any one of claims 1 to 15, wherein the carrier is a longitudinally extending sheet of material and the configuring in step (c) comprises forming at least one fold line in the carrier and subsequently folding the carrier about at least one of those fold lines.

18. A method according to claim 17 when dependent on any of claims 9 to 15, wherein the fold line corresponds to a separation line.

19. A method according to claim 17 or 18, wherein the carrier is folded into the form of an accordion.

20. The method of any one of claims 1 to 15, wherein the structuring in step (c) comprises forming the carrier into a web.

21. The method of claim 20, wherein the carrier is wound around a core.

22. The method according to any one of claims 1 to 21, wherein the method further comprises the steps of:

step (e) placing a sheet of barrier material on the support surface of the carrier layer and aerosol-generating material, wherein the step (e) is performed before the step (c).

23. A product for use in the manufacture of a consumable for use as an article for use in a non-combustible sol supply system, wherein the product comprises an aerosol generating material and a carrier, wherein:

the carrier comprises a base layer and a carrier layer,

The carrier layer is releasably attached to the base layer, and

At least one discrete portion of aerosol-generating material is supported on the support surface of the carrier layer.

24. A product according to claim 23, wherein the aerosol-generating material is an aerosol-generating film.

25. A product according to claim 23 or 24, wherein the aerosol-generating material has at least two discrete portions and the at least two discrete portions of aerosol-generating material have different compositions relative to each other.

26. A product according to any one of claims 23 to 25, wherein aerosol-generating material has three or more distinct portions and the discrete portions are applied to the support surface of the carrier layer in a grid pattern.

27. A product according to any one of claims 23 to 26, wherein one or more of the discrete portions of the aerosol-generating material are substantially circular in the plane of the support surface of the carrier layer, are longitudinally extending strips, are strips comprising at least one curve or angle, or have a shape to be tessellated.

28. A product according to any one of claims 23 to 27, wherein at least one discrete portion of the aerosol-generating material is shaped and/or coloured to indicate the composition of the aerosol-generating material forming the discrete portion.

29. The product of any of claims 23 to 28, wherein the carrier layer comprises an adhesive-backed sheet material, and the sheet material comprises at least one of paper, cardboard, plastic material, and metal material.

30. The product of any of claims 23 to 29, wherein the carrier comprises at least one line of separation, wherein each line of separation is a predetermined line along which at least a portion of the carrier is to be separated or torn.

31. The product of claim 30, wherein at least one separation line is a predetermined line along which the carrier layer is to be separated or torn.

32. The product of claim 30 or 31, wherein at least one separation line comprises a perforation line.

33. The product of claim 30 or 31, wherein at least one separation line comprises a cut line.

34. The product of claim 32, wherein at least one cut line is a result of kissing.

35. A product according to any one of claims 29 to 34, wherein at least one separation line extends between at least two discrete portions of aerosol-generating material.

36. A product according to any one of claims 29 to 35, wherein at least a portion of at least one separation line extends through aerosol-generating material applied to the carrier layer.

37. A product according to any one of claims 23 to 36, wherein the carrier is a sheet material.

38. The product of any of claims 23 to 37, wherein the carrier is a longitudinally extending sheet of material, the carrier comprises at least one fold line, and the carrier is folded about at least one of those fold lines.

39. The product of claim 38, wherein the fold line corresponds to a separation line.

40. A product according to claim 38 or 39, wherein the carrier is folded into the form of an accordion.

41. The product of any of claims 23 to 37, wherein the carrier is wound into a roll.

42. The product of claim 41 wherein the web of carrier is wound around a core.

43. The product of any one of claims 23 to 42, wherein the product further comprises:

A sheet of barrier material disposed on the carrier layer and the aerosol-generating material.

44. A method of manufacturing a consumable for use with an apparatus for heating an aerosol-generating material, wherein the method comprises:

(i) Providing at least one product according to any one of claims 23 to 43, and

(Ii) Releasing at least a portion of the carrier layer from the base layer of at least one product.

45. An aerosol provision device for use with a consumable made according to the method of claim 44, wherein the device comprises an aerosol generator configured to heat at least a portion of the aerosol-generating material supported on the consumable.

46. The aerosol provision device of claim 45, wherein the aerosol generator comprises a heatable plate adapted to support a consumable made according to the method of claim 44.

47. An aerosol provision system comprising an aerosol provision device according to claim 45 or 46 and a consumable made according to the method of claim 44.

48. A method of generating an aerosol from a consumable made according to the method of claim 44 using an aerosol-generating device, wherein at least one aerosol generator is arranged to heat but not burn the consumable in use; wherein the at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.