CN118102894A

CN118102894A - Consumable for use with an aerosol supply device

Info

Publication number: CN118102894A
Application number: CN202280054361.7A
Authority: CN
Inventors: 保罗·吉布森; 安德鲁·乔纳森·布雷
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2021-08-04
Filing date: 2022-08-04
Publication date: 2024-05-28
Also published as: EP4380384A1; GB202111276D0; KR20240040075A; WO2023012297A1

Abstract

A method of manufacturing an article is provided, wherein the article comprises a support and an aerosol-generating material (56). The method comprises the following steps: step (a) of providing a mould body (40); a step (b) of forming one or more mould recesses (42) extending into the first surface (30) of the mould body; a step (c) of applying at least one discrete portion of aerosol-generating material to the first surface of the mould body, wherein each mould recess extends into the first surface of the mould body, the at least one discrete portion of aerosol-generating material at least partially covering the mould recess, or the at least one discrete portion of aerosol-generating material at least partially covering the location in step (b) where the mould recess was formed.

Description

Consumable for use with an aerosol supply device

Technical Field

The present disclosure relates to the field of non-combustible aerosol supply systems, and in particular to consumables for use with an aerosol supply device, methods for manufacturing consumables for use with an aerosol supply device, and aerosol supply systems including consumables and aerosol supply devices.

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 compounds by heating but not burning the substrate material, thereby releasing an inhalable aerosol or aerosol. 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 but not 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 volatilizes at least one component of the material that normally forms the inhalable aerosol. These products may be referred to as heated non-combustion devices, tobacco heating devices, or tobacco heating products. Various different means for volatilizing 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 is atomized by heating to produce an inhalable atomized gas or aerosol. The device additionally contains a solid aerosol-generating material (which may or may not contain tobacco material) and the components of the material are entrained in the inhalable aerosol 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 an article, wherein the article comprises a support and an aerosol-generating material, wherein the method comprises:

a step (a) of providing a mold body,

A step (b) of forming one or more mold recesses extending into the first surface of the mold body,

A step (c) of applying at least one discrete portion of an aerosol-generating material to a first surface of the mould body, wherein

Each mold recess extends into the first surface of the mold body,

At least one discrete portion of aerosol-generating material at least partially covers the mould recess, or at least one discrete portion of aerosol-generating material at least partially covers the location where the mould recess was formed in step (b).

According to a second aspect of the present disclosure there is provided 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 consumable is manufactured according to the method of the first aspect of the present disclosure.

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

According to a fourth 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 having at least one aerosol generator arranged to heat but not burn the consumable in use.

According to a fifth 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.

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

Drawings

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

FIG. 2 illustrates a view of an embodiment of a mold body used in accordance with a first embodiment of the method of the present disclosure;

FIG. 3 shows a schematic diagram of a debossing apparatus used in accordance with a first embodiment of the method of the present disclosure;

FIG. 4 shows a view of the mold body of FIG. 2 after staking;

Fig. 5 shows a cross-section along line A-A' in fig. 4 after application of the aerosol-generating material;

Fig. 6 shows a cross section along line A-A' in fig. 4 when excess aerosol-generating material is removed from the mould body;

FIG. 7 shows a cross section along line A-A' in FIG. 4 after the sheet material has been placed on the first surface of the mold body;

FIG. 8 shows a cross section of the sheet material of FIG. 7 after removal from the mold body;

FIG. 9 illustrates a cross-section along line B-B' of the consumable of FIG. 1 manufactured using a first embodiment of the method of the present disclosure;

FIG. 10 illustrates a cross-section along line B-B' of an alternative embodiment of the consumable of FIG. 1 manufactured using a first embodiment of the method of the present disclosure;

FIG. 11 shows a schematic diagram of a vacuum blister former used in accordance with a second embodiment of the method of the present disclosure;

FIG. 12 illustrates an embodiment of a cross-section equivalent to that along line A-A' in FIG. 4 after a mold body used in accordance with a second embodiment of the method of the present disclosure has been processed using the vacuum blister shaper of FIG. 11;

Fig. 13 shows a cross-section of the embodiment of the mould body in fig. 12 after application of an aerosol-generating material;

Fig. 14 shows a cross section of the embodiment of the mould body in fig. 12 when excess aerosol-generating material is removed from the mould body; and

Fig. 15 shows a cross-section along line B-B' of the consumable of fig. 1 manufactured using a second embodiment of the method 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 means for heating the aerosol-generating material for use with the consumable is part of a non-combustible aerosol supply system. Non-combustible aerosol provision systems such as electronic cigarettes, tobacco heating products and mixing systems release compounds from aerosol-generating materials to generate aerosols using a combination of aerosol-generating materials without igniting the aerosol-generating materials.

In accordance with 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 ignited or burned to facilitate delivery of at least one substance to a user.

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

In some embodiments, the non-combustible aerosol supply system is an electronic cigarette, also known as a vapor 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 aerosol supply system is an aerosol-generating material heating system, also referred to as a heated non-combustion system. One 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 aerosols using a combination of aerosol-generating materials, one or more of which may be heated. Each of these aerosol-generating materials may be, for example, in solid, liquid or gel form 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 for example comprise tobacco or a non-tobacco product.

In general, a non-combustible aerosol supply system may include a non-combustible aerosol supply device and a consumable for use with the non-combustible aerosol 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. Throughout this disclosure, these consumables are sometimes also referred to as articles of manufacture.

In some embodiments, a non-combustible aerosol supply system (such as a non-combustible aerosol supply device thereof) may include a power source and a controller. For example, the power source may be an electrical power source or a exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate that can be energized to distribute power in the form of heat to an aerosol-generating material or a heat transfer material in proximity to the exothermic power 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 packaging material, a filter, a mouthpiece, and/or an aerosol modifier.

a step (a) of providing a mold body,

Each mold recess extends into the first surface of the mold body,

In some of the above embodiments, the article is shaped and sized for use as a consumable for use with a device for heating an aerosol-generating material to volatilize at least one component of the aerosol-generating material.

In some alternative of the above embodiments, the article is larger than an article for use compatible with an apparatus for heating an aerosol-generating material to volatilize at least one component of the aerosol-generating material, wherein the method further comprises:

a step (d) of dividing the article into two or more consumable portions,

Wherein each consumable portion is shaped and sized for use as a consumable product with a device for heating an aerosol-generating material to volatilize at least one component of the aerosol-generating material. In such embodiments, the article may be large and may be divided into a large number of consumable parts. This may have the advantage of improving manufacturing efficiency.

In some of any of the above embodiments, the aerosol-generating material applied to the first surface of the mould body in step (c) is an aerosol-generating material slurry. An advantage of applying the aerosol-generating material as a slurry of aerosol-generating material is that the slurry will readily conform to any three-dimensional appearance of the surface to which it is applied.

In some of any of the above embodiments, the method further comprises:

A step (e) of allowing or allowing the aerosol-generating material slurry to set, wherein the aerosol-generating material slurry sets to form an aerosol-generating material, and step (e) occurs after step (c).

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

An aerosol-generating material is a material capable of generating an aerosol, for example, when heated, irradiated or otherwise stimulated. The aerosol-generating material may for example be in solid, liquid or semi-solid (e.g. gel) form, which may or may not contain active substances and/or flavourings.

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

The aerosol-generating material may comprise a binder (e.g. a gelling agent) and an aerosol-former. Optionally, substances and/or fillers to be delivered may also be present. Optionally, a solvent (e.g. 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 (e.g. 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 thickness of the aerosol-generating film may be about 0.015mm to about 1mm. 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.

Aerosol-generating films may be formed by combining a binder (e.g., a gelling agent) with a solvent (e.g., water, an aerosol-forming agent, and one or more other ingredients, such as one or more substances to be delivered) to form a slurry, and then heating the slurry to volatilize at least some of the solvent to form the 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 (e.g., 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 some of the above embodiments, the mold body may be a sheet material that can be deformed to form the mold recess. In some embodiments, the sheet material has a thickness of less than 1.0mm, less than 0.9mm, less than 0.8mm, less than 0.7mm, less than 0.6mm, less than 0.5mm, less than 0.4mm, less than 0.3mm, less than 0.2mm, or less than 0.1mm. In such an embodiment, the mold recess may have the form of a depression in one major surface of the sheet material. The depressions extend through the sheet material and form ridges or upstanding portions in the other major surface of the sheet material. The deformation of the material used to form the mold recess may be permanent. Alternatively, the deformation may be temporary in that the formation of the mold recess is an elastic deformation of the mold body, the mold recess remaining present for a time sufficient to complete the method of the present disclosure, but the final mold body returning to or near its original shape.

In some of the above embodiments, the mold recess is formed by using known staking or embossing techniques. In other embodiments, the mold recess may be formed using known vacuum forming techniques. In some of the above embodiments, other known techniques for forming the recess may be employed.

In some other of the above embodiments, the sheet material may have a thickness sufficient to form the mold recess within the mold body, i.e., without causing deformation of any outer surface of the mold body other than the surface forming the mold recess. In such embodiments, the thickness may be greater than 0.2mm, greater than 0.3mm, greater than 0.4mm, greater than 0.5mm, greater than 0.6mm, greater than 0.7mm, greater than 0.8mm, greater than 0.9mm, or greater than 1.0mm.

In such embodiments, the mold recess may be formed by pressing the material of the mold body, for example, using known imprint techniques, or by removing a portion of the mold body, for example, using known drilling or milling techniques.

In some other of the above embodiments, the mold body is formed with a mold recess, and thus steps (a) and (b) effectively occur simultaneously.

In some of any of the above embodiments, step (a) and step (b) are performed before step (c).

In some of any of the above embodiments, step (a) and step (b) are performed as a process separate from step (c), and the products of step (a) and step (b) are stored and/or transported between different locations prior to performing step (c). This approach may have the following advantages: the mold body and mold recess therein may be produced by a specialized manufacturer of such articles and then transported to a party who will perform the remainder of the method of the present disclosure. This may result in an improved efficiency of execution of the methods of the present disclosure.

In some of any of the above embodiments, step (c) is performed after step (a) and before step (b). This method is advantageous when forming the mould recess using a vacuum blister former or the like, in which case the aerosol generating material is sucked into the blister when it is formed.

In some of any of the above embodiments, the method further comprises:

Step (f) of passing a doctor blade over at least a portion of the first surface of the mold body after performing step (c). Step (f) may be performed before or after step (e) is performed.

Performing step (f) has the advantage of ensuring that the aerosol-generating material is confined to the mould recess. In other words, the doctor blade passing the first surface of the mould body ensures that the aerosol-generating material is distributed as one or more discrete areas of aerosol-generating material on the mould body. A further advantage is that in case the mould recess is not yet filled with aerosol generating material, the doctor blade may push any aerosol generating material deposited on the first surface of the mould body into the recess past the first surface of the mould body. This helps to ensure that each mould recess is filled to a certain volume (thus ensuring that the desired amount or volume of aerosol-generating material is deposited in each mould recess) whilst also minimising the amount of aerosol-generating material used.

In some of any of the above embodiments, the doctor blade may be a doctor blade.

In some of any of the above embodiments, step (c) comprises applying aerosol-generating material to at least a portion of the first surface of the mold body comprising the mold recess. In some alternative embodiments, step (c) comprises applying the aerosol-generating material to substantially all of the first surface of the mould body.

In some of any of the above embodiments, the method further comprises:

and (g) covering the first surface of the mold body with a layer of material.

In some of any of the above embodiments, in the case of performing step (f), step (g) is performed after step (c) and after step (f).

In some of any of the above embodiments, the method further comprises:

A step (h) of attaching an aerosol-generating material to the layer of material, wherein step (h) is performed after step (g).

In some of any of the above embodiments, the method further comprises:

step (i) of applying a release agent to the first surface of the mold body, and

A step (j) of removing the material layer to which the aerosol-generating material is attached from the mould body,

Wherein step (i) is performed before step (c) and step (j) is performed after step (h).

In some of any of the above embodiments, after step (j), attaching a layer of material to the support.

In some of any of the above embodiments, the material layer is attached to the support, wherein a surface of the material layer to which the aerosol-generating material is attached faces away from the support.

In some of any of the above embodiments, the material layer comprises a susceptor. In other embodiments, the material layer may be a material suitable for use in conjunction with a resistive heater.

In some of any of the above embodiments, the support comprises a layer of material.

In some of any of the above embodiments, the support comprises a mold body or a portion of a mold body.

In some of any of the above embodiments, the support comprises a susceptor.

In some of any of the above embodiments, the method further comprises:

a step (k) of applying a susceptor layer to the first surface of the mold,

Wherein step (k) is performed after step (b) and before step (d). In such an embodiment, the susceptor will be applied to the portion of the surface of the mold body defining the mold recess.

The support may be formed of a material suitable for forming the substrate. The support may be or comprise, for example, paper, cardboard, paperboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal or metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the support. In some alternative embodiments, the susceptor is on or attached to one or either side or surface of the material of the support.

In some of any of the above embodiments, the susceptor is a metal or metal alloy.

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

In some of any of the above embodiments, the method further comprises:

step (m) of perforating one or more of the mould body (when present), the aerosol-generating material, the support (when present), the susceptor (when present) and the layer of material (when present).

In some of the above embodiments, the perforations extend between two surfaces of the consumable. In some other of the above embodiments, the perforation has one end that is open to the atmosphere surrounding the consumable and one end that is blind. The blind end is closed by one of the mould body (when present), the aerosol generating material, the support (when present), the susceptor (when present) and the layer of material (when present).

In some of any of the above embodiments, the perforations have a cross-sectional area of at least 0.01mm ², at least 0.05mm ², at least 0.1mm ², at least 0.5mm ², at least 1mm ², at least 2mm ², or at least 3mm ².

In some of the above embodiments, the at least one mold recess intersects the first surface of the mold body, the at least one mold recess being one of longitudinally extending, rectangular, circular, or elliptical in shape.

In some of the above embodiments, step (c) comprises applying at least two discrete portions of the aerosol-generating material to the first surface of the mould body, wherein those discrete portions of the aerosol-generating material have different compositions from each other.

The aerosol generator material or aerosol former material may comprise one or more components capable of forming an aerosol. In some embodiments, the aerosol former material 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 some embodiments, the support is a laminate comprising at least a first substrate and a second substrate. In some embodiments, for structural purposes, there may be at least one substrate of the laminate, in particular for providing desired handling characteristics to the consumable, for example for providing a degree of elastic resilience to deformation of the consumable, and/or for providing rigidity.

In some of any of the above embodiments, the surface of the support is formed of an impermeable material.

In some of any of the above embodiments, one of the plurality of surfaces of the support is formed by a susceptor.

In some of any of the above embodiments, the support is a laminate comprising at least three substrates, and the substrate that does not form the first surface or the second surface of the support is a susceptor.

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material such that when penetrated by a varying magnetic field, induction heating of the susceptor by resistive heating is caused by eddy currents. The susceptor may be a magnetic material such that it is penetrated by a varying magnetic field to hysteresis heat the susceptor. The susceptor may be electrically conductive and magnetic such that the susceptor may be heated by two 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 410 grade stainless steel, or 420 grade stainless steel, or 430 grade stainless steel, or similar grade 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 due to eddy currents. Alternatively, the susceptor may comprise a non-conductive ferrimagnetic material, such as a non-conductive ferrimagnetic ceramic. In that case, heat is generated only by hysteresis losses. Susceptors may include commercial alloys like nickel-based alloys (Phytherm) 230 (with the following composition (in weight percent wt.%) 50 wt.% nickel, 10 wt.% chromium and the rest of Fe) or nickel-based alloys 260 (with the following composition: 50 wt.% nickel, 9 wt.% chromium and the rest of Fe).

In some of any of the above embodiments, the susceptor may be a metal foil or film, optionally an aluminum foil or film or an iron foil or film. Alternatively, in some of any of the above embodiments, the susceptor may be any conductor that is sprayable or vapor-deposited on the material forming the support, sprayable or vapor-deposited on the uncovered portions of the aerosol-generating material located in the mold recess, or sprayable or vapor-deposited on the surface of the mold recess.

In case the aerosol-generating material is to be heated using magnetic induction techniques or a combination of magnetic induction and resistive heating techniques, susceptors are required. In the case where only resistive heating techniques are used to heat the consumable, no susceptor need be provided, but a susceptor may be present.

In one of any of the above embodiments, the support comprises a substrate of a support material, and the support material comprises one or more of paper, card, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy.

In one of any of the above embodiments, the support comprises a plastic material that can withstand the temperatures typically encountered in a non-combustible aerosol supply device. In some embodiments, the support comprises Polyetheretherketone (PEEK). Such an embodiment has the advantage that the support can be reused and that such a consumable is less affected by any condensation in the non-combustible aerosol supply device than a consumable comprising a support with the use of an adsorptive material for structural purposes.

In some of any of the above embodiments, the aerosol-generating material is supported on a surface of the support that is not formed of an adsorptive material. This arrangement has the effect that the aerosol-generating material or any component of the aerosol-generating material will not be absorbed/absorbed into the support during manufacture, subsequent storage and use of the consumable.

According to a second aspect of the present disclosure there is provided a consumable for use with an aerosol-supply device, wherein the consumable comprises a support and an aerosol-generating material, wherein the consumable is formed using a method according to the first aspect of the present disclosure.

In some of any of the above embodiments, step (e) comprises one or more of time of use, conduction heat, radiant heat, or air movement over the exposed surface of the aerosol-generating material.

In one 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 substance, 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 other plants.

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, cocoa, fennel, lemon grass, peppermint, spearmint, black leaf tea, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay, licorice (licorice root), 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, sweet pepper, nutmeg, damine, carrageenan, olive, lemon balm, lemon basil, bergamot, horsetail, tarragon, pelargil, geranium, mulberry, ginseng, tea, tetramethyl, uric acid, guava, kudzuvine, or combinations thereof. The mint may be selected from the following mint varieties: spearmint, peppermint cultivar, egyptian mint, spearmint cultivar, peppermint cultivar, spearmint, peppermint, pineapple, spearmint cultivar, and apple mint.

In some embodiments, the active 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 and cocoa.

In some embodiments, the active 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 flavoring.

As used herein, the terms "flavoring" and "flavoring" 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. They may include naturally occurring flavour materials, plants, extracts of plants, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice (licorice root), hydrangea, eugenol, japanese white 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, bouillon, scotch whiskey, juniper, tequila, rum, spearmint, peppermint, lavender, aloe, cardamom, celery, bitter bean peel, nutmeg, sandalwood, bergamot, geranium, arabian tea leaf, sorghum, betel leaf, coriander, pine, honey essence, rose oil, vanilla, lemon oil, orange flower, cherry flower, cinnamon, caraway, cogongrass, jasmine, ylang-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, perilla, turmeric, coriander, myrtle, black currant, valerian, spanish sweet pepper, nutmeg dried skin, dami, myrtle, cuttlefish, olive, lemon balm, lemon basil, nori onion, celery, 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, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, plants, or breath fresheners. They may be imitation, synthetic or natural ingredients or mixtures thereof. They may be in any suitable form, for example, a liquid such as oil, a solid such as powder or a gas.

In some embodiments, the flavoring agent comprises menthol, spearmint, and/or peppermint. In some embodiments, the flavoring includes a flavoring component of cucumber, blueberry, citrus fruit, and/or raspberry. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring includes a flavoring component 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 former. In some embodiments, the aerosol former may comprise one or more components capable of forming an aerosol. In some embodiments, the aerosol former 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 former comprises glycerin.

In some embodiments, the aerosol former comprises one or more polyols, such as propylene glycol, triethylene glycol, 1, 3-butanediol, and glycerol; esters of polyols such as monoacetin, diacetin or triacetin; and/or aliphatic esters of mono-, di-or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

In some embodiments, the amorphous solid may include from about 0.1wt%, 0.5wt%, 1wt%, 3wt%, 5wt%, 7wt%, or 10% to about 50wt%, 45wt%, 40wt%, 35wt%, 30wt%, or 25wt% (all calculated on a dry basis) of an aerosol former. The aerosol former may act as a plasticizer. For example, the amorphous solid may include 0.5wt% to 40wt%, 3wt% to 35wt%, or 10wt% to 25wt% aerosol former.

In some embodiments, the amorphous solid may include from about 5wt%, 10wt%, 20wt%, 25wt%, 27wt%, or 30wt% to about 60wt%, 55wt%, 50wt%, 45wt%, 40wt%, or 35wt% aerosol former (DWB). For example, the amorphous solid may include 10wt% to 60wt%, 20wt% to 50wt%, 25wt% to 40wt%, or 30wt% to 35wt% aerosol former.

In some embodiments, the amorphous solid may include up to about 80wt%, such as about 40wt% to 80wt%, 40wt% to 75wt%, 50wt% to 70wt%, or 55wt% to 65wt% aerosol former (DWB).

The amorphous solid may also include a gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group consisting of alginate, pectin, starch (and derivatives thereof), cellulose (and derivatives thereof), gums, silica or organosilicon compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent includes one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agar, acacia, fumed silica, polydimethylsiloxane (PDMS), sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the gelling agent includes alginate and/or pectin, and may be combined with a coagulating agent (such as a calcium source) during the formation of the amorphous solid. In some cases, the amorphous solid may include 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-cellulose 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 hydroxyethylcellulose, hydroxypropylcellulose, hydroxypropylmethyl cellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia.

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

In some embodiments, the gelling agent comprises an alginate, and the alginate is present in the amorphous solid in an amount of 10wt% to 30wt% (based on dry weight) of the amorphous solid. In some embodiments, the alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises an alginate and at least one additional gelling agent, such as pectin.

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

In some embodiments, the amorphous solid comprises from about 20wt%, 22wt%, 24wt%, or 25wt% to about 30wt%, 32wt%, or 35wt% (all calculated on a dry weight basis) of the gelling agent. For example, the amorphous solid may include 20wt% to 35wt% or 25wt% to 30wt% of the gellant.

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

In examples, the amorphous solids include a gellant and a filler in a total amount of about 10wt%, 20wt%, 25wt%, 30wt%, or 35wt% to about 60wt%, 55wt%, 50wt%, or 45wt% of the amorphous solids. In examples, the amorphous solids include a gellant and a filler in a total amount of about 20wt% to 60wt%, 25wt% to 55wt%, 30wt% to 50wt%, or 35wt% to 45wt% of the amorphous solids.

In examples, the amorphous solid includes a gellant (i.e., regardless of the amount of filler) in an amount of about 5wt%, 10wt%, 15wt%, 20wt%, 25wt%, 30wt%, or 35wt% to about 60wt%, 55wt%, 50wt%, or 45wt% of the amorphous solid. In examples, the amorphous solid includes a gellant (i.e., regardless of the amount of filler) in an amount of about 5wt% to 60wt%, 20wt% to 60wt%, 25wt% to 55wt%, 30wt% to 50wt%, or 35wt% to 45wt% of the amorphous solid.

In some examples, alginate is included in the gellant in an amount of about 5wt% to 40wt%, or 15wt% to 40wt% of the amorphous solids. That is, the amorphous solids include alginate in an amount of about 5wt% to 40wt%, or 15wt% to 40wt%, based on the dry weight of the amorphous solids. In some embodiments, the amorphous solid comprises alginate in an amount of about 20wt% to 40wt% or about 15wt% to 35wt% of the amorphous solid.

In some examples, pectin is included in the gellant in an amount of from about 3wt% to 15wt% of the amorphous solids. That is, the amorphous solids include pectin in an amount of about 3wt% to 15wt% of the amorphous solids. In some examples, the amorphous solids include pectin in an amount of about 5wt% to 10wt% of the amorphous solids.

In some examples, the gelling agent comprises guar gum in an amount of about 3wt% to 40wt% of the amorphous solids. That is, the amorphous solids include guar gum in an amount of about 3wt% to 40wt% based on the dry weight of the amorphous solids. In some examples, the amorphous solids include guar in an amount of about 5wt% to 10wt% of the amorphous solids. In some examples, the amorphous solids include guar in an amount of about 15wt% to 40wt%, or about 20wt% to 40wt%, or about 15wt% to 35wt% of the amorphous solids.

In an example, the alginate is present in an amount of at least about 50wt% of the gelling agent. In an example, the amorphous solid comprises alginate and pectin, and the ratio of alginate to pectin is 1:1 to 10:1. the ratio of alginate to pectin is typically greater than 1:1, i.e. the amount of alginate present is greater than the amount of pectin. In an example, the ratio of alginate to pectin is about 2:1 to 8: 1. or about 3:1 to 6: 1. or about 4:1.

The amorphous solid may be formed by the steps of: step (a) forming a slurry comprising components of an amorphous solid or precursor thereof; step (b) forming a slurry layer; step (c) setting the slurry to form a gel; and (d) drying to form an amorphous solid. Step (b) of forming the slurry layer typically comprises spraying, casting or extruding the slurry. In some examples, the slurry layer is formed by electrospraying a slurry. In an example, the slurry layer is formed by casting a slurry.

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

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

In an example, the slurry includes a gelling agent, an aerosol former material, and an active substance. The slurry may include these ingredients in any of the ratios given herein in relation to the components of the amorphous solids. For example, the slurry may include (on a dry weight basis):

-a gelling agent, and optionally a filler, wherein the total amount of gelling agent and filler is about 10wt% 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.

The step (c) of setting the gel may comprise providing a setting agent to the slurry. For example, the slurry may include sodium alginate, potassium alginate, or ammonium alginate as gel precursors, 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 setting agent includes or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, and combinations thereof. In some examples, the setting agent comprises or consists of calcium formate and/or calcium lactate. In specific examples, the coagulant comprises or consists of calcium formate. The inventors have determined that calcium formate is generally used as a coagulant, resulting in an amorphous solid with greater tensile strength and greater elongation resistance.

The total amount of coagulants (such as calcium sources) may be 0.5wt% to 5wt% (calculated on 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 coagulant may result in amorphous solids that fail to stabilize the amorphous solid components and cause these components to fall out of the amorphous solids. The inventors have found that adding too much coagulant results in a very viscous amorphous solid and thus has poor operability.

When the amorphous solid does not contain tobacco, it may be desirable to apply a greater amount of coagulant. In some cases, the total amount of coagulant may thus be from 0.5 to 12wt%, such as 5 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 amorphous solid generally does not contain any tobacco.

In an example, supplying the coagulant to the slurry includes spraying the coagulant onto the slurry, such as a top surface of the slurry.

Alginate is a derivative of alginic acid and is typically a high molecular weight polymer (10 kDa to 600 kDa). Alginic acid is a copolymer of β -D-mannuronic acid (M) and α -L-guluronic acid (G) units (blocks) that are crosslinked together using (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 alginate having a high G monomer content forms 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 α -L-guluronic acid (G) units.

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

In an example, the drying step (d) reduces the thickness of the casting material by at least 80%, suitably by 85% or 87%. For example, the slurry is cast at a thickness of 2mm, and the resulting dried amorphous solid 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 the example where the solvent consists of water, the dry weight content of the slurry may match the dry weight content of the amorphous solid. Thus, discussion herein regarding solid components is explicitly disclosed in connection with the slurry aspects of the present invention.

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

The amorphous solid may include a filler.

In some embodiments, the amorphous solid includes 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 amorphous solid comprises less than 20wt%, suitably less than 10wt% or less than 5wt% filler. In some cases, the amorphous solid includes less than 1wt% filler, and in some cases no filler.

In some such cases, the amorphous solid includes at least 1wt% filler, such as at least 5wt%, at least 10wt%, at least 20wt%, at least 30wt%, at least 40wt%, or at least 50wt% filler. In some embodiments, the amorphous solid comprises 5wt% to 25wt% filler.

The filler (if present) may include 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 methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC). In specific cases, the amorphous solid does not include 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 such as wood pulp, cellulose or cellulose derivatives such as methylcellulose, hydroxypropyl cellulose and carboxymethyl cellulose (CMC).

Without wishing to be bound by theory, it is believed that including fibrous fillers in the amorphous solids may increase the tensile strength of the material. This may be particularly advantageous in instances where the amorphous solid is provided as a sheet, such as when the sheet of amorphous solid surrounds a rod of aerosolizable material.

In some embodiments, the amorphous solid does not include tobacco fibers. In particular embodiments, the amorphous solid does not include fibrous 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.

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.

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

In some cases, the amorphous solid may include 5wt% to 60wt% (calculated on a dry weight basis) of tobacco material and/or nicotine. In some cases, the amorphous solid may include 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 the active material. In some cases, the amorphous solid may include 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 amorphous solids may include 10wt% to 50wt%, 15wt% to 40wt%, or 20wt% to 35wt% tobacco material. In some cases, the amorphous solid may include from about 1wt%, 2wt%, 3wt%, or 4wt% to about 20wt%, 18wt%, 15wt%, or 12wt% (calculated on a dry weight basis) nicotine. For example, the amorphous solid may comprise 1wt% to 20wt%, 2wt% to 18wt%, or 3wt% to 12wt% nicotine.

In some cases, the amorphous solid includes an active substance, such as a tobacco extract. In some cases, the amorphous solids may include from 5wt% to 60wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid may include from about 5wt%, 10wt%, 15wt%, 20wt%, or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of the tobacco extract. For example, the amorphous solids may include 10wt% to 50wt%, 15wt% to 40wt%, or 20wt% to 35wt% of tobacco extract. The tobacco extract may comprise nicotine in a concentration such that the amorphous solids comprise from 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, nicotine may not be present in the amorphous solid other than the nicotine produced by the tobacco extract.

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

In some cases, the total content of active and/or flavoring agents 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 examples, the amorphous solids include, for example, up to about 20wt% of the amorphous solids of one or more active materials. In examples, the amorphous solid includes an active in an amount of about 1wt%, 5wt%, 10wt%, or 15wt% to about 20wt%, 15wt%, or 5wt% of the amorphous solid.

The active substance may comprise a physiologically and/or olfactory active substance that 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 85wt%.

The tobacco material may be present in any form, but is typically shredded (e.g. cut into narrow strips). The shredded tobacco material may advantageously be blended with amorphous solids to provide an aerosol-generating composition, the tobacco material and amorphous solids being homogeneously dispersed throughout the aerosol-generating composition.

In examples, the tobacco material includes one or more of ground tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and/or tobacco extracts. Surprisingly, the inventors have determined that relatively large amounts of laminated tobacco can be used in aerosol-generating compositions and still provide acceptable aerosols when heated by a non-combustible aerosol supply system. Laminated tobacco generally provides excellent sensory characteristics. In examples, the tobacco material comprises laminated 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 comprises cut tobacco 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 blend, cut tobacco or whole tobacco, including virginia tobacco, and/or burley tobacco, and/or Oriental tobacco.

In some embodiments, the one or more other functional materials may include one or more of pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and/or antioxidants.

In some cases, the amorphous solid may additionally include an emulsifier that emulsifies the molten flavoring during manufacture. For example, the amorphous solid may include from about 5wt% to about 15wt% (calculated on a dry weight basis) of an emulsifier, suitably about 10wt% of an emulsifier. The emulsifying agent may include acacia.

In some embodiments, the amorphous solid is a hydrogel and includes less than about 20wt% water based on wet weight. 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 amorphous solid may have any suitable water content, such as from 1wt% to 15wt%. Suitably, the amorphous solids have a water content of from about 5wt%, 7wt%, or 9wt% to about 15wt%, 13wt%, or 11wt% (WWB), most suitably about 10wt%. The water content of the amorphous solid can be determined, for example, by karl fischer titration or gas chromatography with a thermal conductivity detector (GC-TCD).

In some cases, the amorphous solid may consist essentially of, or consist of, a gelling agent, water, an aerosol former, a flavoring agent, and optionally an active substance.

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

In embodiments, the amorphous solid consists essentially of, or consists of, a gelling agent, an aerosol former, an active substance, and water. In examples, the amorphous solid consists essentially of, or consists of, a gelling agent, an aerosol former, and water.

In examples, the amorphous solid does not include a flavoring; in a specific example, the amorphous solid does not include an active substance.

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

-1 to 60wt% of a gelling agent;

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

-0.1 To 80wt% of a flavouring agent;

wherein these weights are calculated on a dry weight basis.

In some embodiments, the amorphous solid comprises 1wt% to 80wt% flavoring agent (on a dry weight basis).

In some embodiments, the amorphous solid comprises:

-1 to 50wt% of a gelling agent;

-0.1 to 50wt% of an aerosol former; 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 amorphous solid comprising:

-1 to 60wt% of a gelling agent;

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

-10 To 60wt% of a tobacco extract;

wherein these weights are calculated on a dry weight basis.

In some embodiments, the amorphous solid comprises:

-1 to 60wt% of a gelling agent;

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

-10 To 60wt% of a tobacco extract;

wherein these weights are calculated on a dry weight basis.

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

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

In some embodiments, the amorphous solid may have the following composition (DWB): a gelling agent (preferably comprising alginate) in an amount of about 5wt% to about 40wt%, or about 10wt% to 30wt%, or about 15wt% to about 25wt%; a tobacco extract in an amount of about 30wt% to about 60wt%, or about 40wt% to 55wt%, or about 45wt% to about 50wt%; an aerosol former (preferably comprising glycerin) in an amount of about 10wt% to about 50wt%, or about 20wt% to about 40wt%, or about 25wt% to about 35wt% (DWB). In one embodiment, the amorphous solid comprises about 20wt% alginate gelling agent, about 48wt% tobacco virginia extract, and about 32wt% glycerin (DWB).

The "thickness" of an amorphous solid describes the shortest distance between a first surface and a second surface. In embodiments in which the amorphous solid is in the form of a sheet, the thickness of the amorphous solid is the shortest distance between a first plane of the sheet and a second plane of the sheet, the second plane being opposite the first plane of the sheet.

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

Materials having a thickness of 0.2mm are particularly suitable. The amorphous solid may include 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 or amorphous solid is too thick, heating efficiency may be affected. This adversely affects the power consumption in use. Conversely, if the aerosol-generating material or amorphous solid is too thin, it is difficult to manufacture and handle; very thin materials are more difficult to cast and can be brittle, thereby compromising aerosol formation in use.

The thickness specified herein is the average thickness of the material. In some cases, the amorphous solid may vary in thickness by no more than 25%, 20%, 15%, 10%, 5%, or 1%.

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

These tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is formed into a sheet and then chopped and incorporated into an aerosol-generating article. In some examples, such as when the amorphous solid includes a filler, the amorphous solid may have a tensile strength of from 600N/m to 900N/m, or from 700N/m to 900N/m, or about 800N/m. These tensile strengths 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 tubular form.

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

The aerosol-generating material comprising amorphous solids 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 similar density to cut tobacco and a mixture of these substances does 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 dry weight-based references to weight refer 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, weight percentages based on wet weight refer to all ingredients, including water.

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

Depending on the desired color of the amorphous solid, a variety of colorants can be used. The amorphous solid may be white, green, red, violet, blue, brown or black in color, for example. 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 particular embodiments, the colorant is caramel, which can impart a brown appearance to the amorphous solid. In such embodiments, the color of the amorphous solid may be similar to the color of other components in the aerosol-generating material (such as the tobacco material) comprising the amorphous solid. In some embodiments, a colorant is added to the amorphous solid such that it is visually indistinguishable from other components in the aerosol-generating material.

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

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 level of tackiness or adhesion of the aerosol-generating material.

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

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 aperture 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. The power source 22 is a rechargeable battery. In other embodiments, the power source may be other suitable electrical power sources.

The aerosol provision device 2 is adapted for use with a consumable 24. The consumable 24 includes one or more discrete portions of the aerosol-generating material 26 supported on the first surface 30 of the support 28. Discrete portions of aerosol-generating material 26 are supported on the support 28 in a square checkered pattern. Other not shown embodiments of the consumable 24 may include more or fewer discrete portions of the aerosol-generating material 26 (including individual portions of the aerosol-generating material 26) than that shown in fig. 1, and those portions may be distributed in any pattern over the surface of the support 28. In fig. 1, the discrete portions of aerosol-generating material 26 are shown as having a generally circular shape, which may have other shapes in other embodiments.

Referring to fig. 2 to 8, a first embodiment of the method of manufacturing the consumable 24 is as follows:

Referring to fig. 2 and 4, a mold body 40 is provided. The mold body 40 is a sheet material having a uniform thickness t formed of a material that can be embossed or stamped. One example of such a material is cardboard. The mold body 40 has a first surface 30 in which one or more mold recesses 42 are to be formed. In fig. 1-8, nine mold recesses 42 are shown (but not numbered in their entirety for clarity). It should be appreciated that fewer or more mold recesses 42 may be formed in the surface 30 of the mold body 40, if desired. It should also be appreciated that the mold body 40 may be larger than a single consumable 24, and that when this is the case, a single mold body 40 may be used to manufacture more than one consumable 24.

Referring to fig. 3, a first embodiment of a method of manufacturing the consumable 24 uses a staking apparatus 44 as schematically illustrated in fig. 3 to form a mold recess 42 in the surface 30 of the mold body 40. The staking apparatus 44 includes a staking cylinder 46 and a planar surface 48. The staking cylinder 46 has a plurality of raised portions 50 (not numbered in their entirety) distributed about the cylindrical surface 52 of the staking cylinder 46.

In the illustrated embodiment, the raised portions 50 are square or rectangular and all have the same shape and size. In other embodiments not shown, the raised portions may have different shapes, such as longitudinally extending, circular or oval, and/or not all raised portions may have the same shape as each other.

The cylindrical surface 52 of the staking cylinder 46 is spaced from the flat surface 48 a distance approximately equal to the thickness t. The raised portion 50 of the staking cylinder 46 projects a distance from the cylindrical surface 52 less than the thickness t. The staking cylinder 46 is rotated about the central axis 54 by a rotational motion source (not shown). As the gravure cylinder 46 rotates, the die body 40 is fed into the gap between the gravure cylinder 46 and the platen 48. Rotation of the staking cylinder 46 pulls the mold body through the gap and causes the raised portions 50 to form a plurality of mold recesses 42 in the surface 30 of the mold body 40.

A release agent (not shown) is then applied to at least the surface of the mold recess 42. The application may be by spraying a release agent. In some examples, the release agent may be sprayed over the entire surface 30 and the surface of the mold recess 42. The stripper is selected such that when the aerosol-generating material 56 is subsequently applied to the mould recess 42, the aerosol-generating material 56 is stripped from the surface of the mould recess with a pull-off stress that is less than the stress that would cause damage to the aerosol-generating material 56, for example a stress of X pascals (Pa).

Referring to fig. 5, a source (not shown) of aerosol-generating material 56 supplies the aerosol-generating material 56 to one or more nozzles 58 (only one shown in fig. 5 for clarity). The nozzle 58 applies a portion of the aerosol-generating material 46 to the surface 30 of the mold body 40 in and around each mold recess 42. The number of nozzles 58 may be equal to the number of mold recesses 42 or may be a multiple thereof. In some not shown embodiments, there may be more than one source of aerosol-generating material 56, wherein at least two of those sources comprise aerosol-generating material 56 comprising different compositions from each other. The different components may include different actives and/or flavoring agents.

Referring to fig. 6, after the aerosol-generating material 56 is applied to each mould recess 42, a doctor blade in the form of a doctor blade 60 is pulled across the surface 30. The wiper 60 clears any aerosol-generating material 56 beyond that required to fill the mold recess 42 away from the surface 30 of the mold body 40 and forms an exposed surface 66 of the aerosol-generating material 56. The excess aerosol-generating material 56 may be returned to the source of aerosol-generating material 56 or discarded.

The mold body 40 and the aerosol-generating material 56 are now exposed to at least one condition suitable to allow, facilitate or promote a change in the properties of the aerosol-generating material 56. Such conditions may be, but are not limited to, a stationary period, a predetermined curing temperature, exposure to electromagnetic radiation, or a mixture thereof. In a first embodiment of the method of the present disclosure, the property of the aerosol-generating material 56 to be changed is the weight of the aerosol-generating material 56. This change is a result of applying the aerosol-generating material 56 as a slurry to the mold body 40, and subsequently drying after the excess aerosol-generating material 56 is removed from the surface 30 of the mold body 40. In other embodiments, the aerosol-generating material 56 is dried or partially dried prior to scraping any excess aerosol-generating material 56 from the surface 30.

Referring to fig. 7, after a desired level of change in the properties of the aerosol-generating material 56 has occurred, a sheet material 62 having a first surface 64 and a second surface 68 is placed on the mold body 40 such that the surface 64 of the sheet material 62 is in contact with the exposed surface 66 of the aerosol-generating material 56 and the portion of the surface 30 of the mold body 40 that does not form a portion of the mold recess 42. The surface 64 of the sheet material 62 is then allowed or caused to adhere to the exposed surface 66 of the aerosol-generating material 56. The exposed surface 66 of the aerosol-generating material will typically adhere to the surface 64 of the sheet material 62 due to inherent tackiness on that portion of the aerosol-generating material 56 or because the surface 66 of the aerosol-generating material 56 is caused to become tacky.

In the presently described embodiment, the sheet material 62 is a sheet of susceptor material, such as aluminum foil or film. In other embodiments, the sheet material 62 may be a sheet of a substitute susceptor, a sheet of a heat transfer material, or a sheet of a substitute material. The choice of material used to form sheet material 62 will depend, at least in part, on the intended mode of heating consumable 24 formed by the methods described herein.

Referring to fig. 8, after the adhesion of the surface 64 of the sheet material 62 to the exposed surface 66 of the aerosol-generating material 56 has reached a level where the pull-off stress pulling the surface 64 away from the exposed surface 66 has reached a value of Y Pa, the sheet material 62 is removed from the mold body 40 while the aerosol-generating material 56 is removed from the mold recess 42. The pull-off stress Y Pa is greater than the pull-off stress X Pa (pull-off stress X Pa is the pull-off stress for interaction between the aerosol-generating material 56 and the stripper-treated surface of the mold recess 42). The portion of the aerosol-generating material 56 that adheres to the surface 64 of the sheet material 62 will be the discrete portion 26 of the aerosol-generating material 56 in the consumable 24.

Referring to fig. 9, surface 68 of sheet material 62 is next affixed to surface 72 of support 70 to form consumable 24. The support 70 is formed from card, a plastic material such as Polyetheretherketone (PEEK), or other suitable material that forms a support for the consumable 24.

Referring to fig. 10, an alternative embodiment of a consumable 124 is shown. Other than those discussed below, alternative embodiments of methods of manufacturing consumables 124 are shown in fig. 2-7 and described above. The reference numerals used in connection with fig. 10 are the same as those in fig. 2 to 7, wherein the elements shown are the same elements.

When the expendable 124 is manufactured, the stripper is not applied after the mold recess 42 is formed. This is because the aerosol-generating material 56 located in the mould recess 42 is not subsequently peeled away from the mould recess 42, but is released as an aerosol when the consumable 124 is used.

Optionally, an adhesive (not shown) is applied to one or both of the portion of the surface 30 of the mold body 40 that does not form a portion of the mold recess 42 and the surface 64 of the sheet material 62 before or while the surface 64 of the sheet material 62 is placed on the exposed surface 66 of the aerosol-generating material 56 and the portion of the surface 30 of the mold body 40 that does not form a portion of the mold recess 42.

Alternatively, the sheet material 62 is held in place relative to the mold body 40 by the inherent tackiness of the aerosol-generating material 56 that adheres the surface 64 to the exposed surface 66 of the aerosol-generating material 56.

After the sheet material 62 is held in place relative to the die body 40, the sheet material 62, the aerosol-generating material 56 and the die body 40 are perforated by suitable perforation means (not shown) to form a plurality of perforations 74. Perforations 74 may have a cross-sectional area of at least 0.01mm ², at least 0.05mm ², at least 0.1mm ², at least 0.5mm ², at least 1mm ², at least 2mm ², or at least 3mm ².

In an alternative embodiment not shown in the present disclosure, the perforations 74 do not extend through the entire depth of the consumable 124, but rather at least partially through the aerosol-generating material 56 and to one of the plurality of outer surfaces of the consumable 124.

In the consumable 124, the support for the consumable is the mold body 40, and the mold body 40 provides structural strength to the consumable 124. The sheet material 62 is a sheet of susceptor material, such as aluminum foil. In other embodiments not shown, the sheet material 62 may be a sheet of susceptor-replacing material, a sheet of heat transfer material, or a sheet of replacement material. The choice of material used to form sheet material 62 will depend, at least in part, on the intended mode of heating consumable 124 formed by the methods described herein.

Referring to fig. 11 to 16, in a second embodiment of the present disclosure, a mold body 240 is provided. The mold body 240 is a sheet material having a uniform thickness t formed of a plastically deformable material. The appearance of the mold body 240 is the same as that of the mold body 40 in fig. 2.

One example of such a material is … …. The mold body 240 has a first surface 30 in which one or more mold recesses 242 are formed and a second surface from which the mold recesses extend. In fig. 11 to 16, three mold recesses 242 are shown. It should be appreciated that fewer or more mold recesses 242 may be formed in the mold body 240, if desired. It should also be appreciated that the mold body 240 may be larger than a single consumable 224, and that when this is the case, more than one consumable 224 may be manufactured using a single mold body 240.

Referring to fig. 11, a second embodiment of a method of manufacturing consumable 224 uses a vacuum blister forming apparatus 244 as schematically shown in fig. 11 to form a mold recess 242 in a mold body 240. The blister formation apparatus 244 includes a bed 246 having a bed surface 248. A plurality of blister molds 250 extend from the bed surface 248 into the bed 246. Each blister mold 250 is in fluid communication with a vacuum pump 252 via a conduit network 254.

Essentially, the mold body 240 is placed on the bed surface 248 and the vacuum pump 252 is turned on. The vacuum created by the vacuum pump 252 in the conduit network 254 and the blister mold 250 plastically deforms the mold body to match the surface contours of the bed surface 248 and the blister mold 250.

Referring to fig. 12, after plastic deformation of the mold body 240 is completed, the mold body 242 is removed from the blister forming device 244. The mold body 240 now includes a plurality of mold recesses 242.

Referring to fig. 13, a source (not shown) of aerosol-generating material 56 supplies the aerosol-generating material 56 to one or more nozzles (not shown). The nozzle applies the aerosol-generating material 56 to the surface 230 of the mold body 240 and/or each mold recess 242. In some not shown embodiments, there may be more than one source of aerosol-generating material 56, wherein at least two of those sources comprise aerosol-generating material 56 comprising different compositions from each other. The different components may include different actives and/or flavoring agents. Different components of the aerosol-generating material 56 may be applied to different portions of the die body 240.

Referring to fig. 14, after the aerosol-generating material 56 is applied to the mould body 240, a doctor blade in the form of a doctor blade 256 is pulled across the surface 230. The wiper 256 clears any aerosol-generating material 56 beyond that required to fill the mold recess 242 away from the surface 230 of the mold body 240 and forms an exposed surface 258 of the aerosol-generating material 56. The excess aerosol-generating material 56 may be returned to the source of aerosol-generating material 56 or discarded.

The mold body 240 and the aerosol-generating material 56 are now exposed to at least one condition suitable to allow, facilitate or promote a change in the properties of the aerosol-generating material 56. Such conditions may be, but are not limited to, a stationary period, a predetermined curing temperature, exposure to electromagnetic radiation, or a mixture thereof. In a first embodiment of the method of the present disclosure, the property of the aerosol-generating material 56 to be changed is the weight of the aerosol-generating material 56. This change is a result of applying the aerosol-generating material 56 as a slurry to the mold body 240, and subsequently drying after the excess aerosol-generating material 56 is removed from the surface 230 of the mold body 240.

Referring to fig. 15, after a desired level of change in the properties of the aerosol-generating material 56 has occurred, a sheet material 260 having a surface 262 is placed on the mold body 240 such that the surface 262 of the sheet material 260 is in contact with the exposed surface 258 of the aerosol-generating material 56 and the portion of the surface 230 of the mold body 240 that does not form a portion of the mold recess 242. The surface 262 of the sheet material 260 is then allowed or caused to adhere to the exposed surface 258 of the aerosol-generating material 56. The exposed surface 258 of the aerosol-generating material will typically adhere to the surface 262 of the sheet material 260 due to inherent tackiness on that portion of the aerosol-generating material 56 or because the surface 258 of the aerosol-generating material 56 is caused to become tacky.

Optionally, an adhesive (not shown) is applied to one or both of the portion of the surface 230 of the mold body 240 that does not form a portion of the mold recess 242 and the surface 262 of the sheet material 260 before or while the surface 262 of the sheet material 260 is placed on the exposed surface 258 of the aerosol-generating material 56 and the portion of the surface 230 of the mold body 240 that does not form a portion of the mold recess 242.

In the presently described embodiment, the sheet material 260 is a sheet of susceptor material, such as aluminum foil. In other embodiments, the sheet material 260 may be a sheet of a heat transfer material, a sheet of a substitute susceptor, or a sheet of a substitute material. The choice of materials used to form sheet material 260 will depend, at least in part, on the intended mode of heating consumables 224 formed by the methods described herein.

Referring to fig. 16, after the sheet material 260 is held in place relative to the die body 240, the sheet material 260, the aerosol-generating material 56, and the die body 240 are perforated by suitable perforation means (not shown) to form a plurality of perforations 264. Perforations 264 may have a cross-sectional area of at least 0.01mm ², at least 0.05mm ², at least 0.1mm ², at least 0.5mm ², at least 1mm ², at least 2mm ², or at least 3mm ².

In an alternative embodiment not shown in the present disclosure, the perforations 264 do not extend through the entire depth of the consumable 224, but at least partially through the aerosol-generating material 56, and extend to one of the plurality of outer surfaces of the consumable 224.

In the consumable 224, the support for the consumable is a mold body 240, and the mold body 240 provides structural strength to the consumable 224. The sheet material 262 is a sheet of susceptor material, such as aluminum foil. In other embodiments not shown, the sheet material 260 may be a sheet of a substitute susceptor, a sheet of a heat transfer material, or a sheet of a substitute material. The choice of materials used to form sheet material 260 will depend, at least in part, on the intended mode of heating consumables 224 formed by the methods described herein.

Referring to fig. 17, in an alternative embodiment according to a second embodiment of the method of the present disclosure, consumable 324 comprises a mold body 240 that is a laminate having a support layer 266 and a susceptor layer 268. The support layer 266 is comprised of a suitable support material. The susceptor layer forms the surface 230 of the mold body 240. The sheet material 260 is a material suitable for protecting the aerosol-generating material 56 prior to use of the consumable 324. The consumable also includes perforations 264 as described in connection with fig. 16.

In alternative embodiments of the consumable 324, not shown, the sheet material 264 is not present, or the sheet material is removed prior to use of the consumable.

The various embodiments described herein are only used to assist in understanding and teaching 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 should not be considered as limiting the scope of the invention as defined by the claims or the equivalents of the claims, and that other embodiments may be used and modifications may be made without departing from the scope of the claimed invention. In addition to the elements, components, features, portions, steps, means, etc. specifically described herein, various embodiments of the present invention may suitably comprise, consist of, or consist essentially of the appropriate combinations of the elements, components, features, portions, steps, means, etc. disclosed. Furthermore, the present disclosure may include other inventions not presently claimed but which may be claimed in the future.

Claims

1. A method of manufacturing an article, wherein the article comprises a support and an aerosol-generating material, wherein the method comprises:

a step (a) of providing a mold body,

A step (b) of forming one or more mould recesses extending into the first surface of the mould body,

A step (c) of applying at least one discrete portion of the aerosol-generating material to the first surface of the mould body, wherein

Each of the mold recesses extends into the first surface of the mold body,

At least one discrete portion of the aerosol-generating material at least partially covers a mould recess, or at least one discrete portion of the aerosol-generating material at least partially covers a location where the mould recess was formed in step (b).

2. The method of claim 1, wherein the article is shaped and sized for use as a consumable with a non-combustible aerosol supply system.

3. The method of claim 1, wherein the method further comprises:

a step (d) of dividing the article into two or more consumable parts,

Wherein each of the consumable portions is shaped and dimensioned for use as a consumable with a device for heating the aerosol-generating material to volatilize at least one component of the aerosol-generating material.

4. A method according to any one of claims 1 to 3, wherein the aerosol-generating material applied to the first surface of the mould body in step (c) is an aerosol-generating material slurry.

5. The method of claim 4, wherein the method further comprises:

a step (e) of allowing or allowing the aerosol-generating material slurry to set,

Wherein the aerosol-generating material slurry solidifies to form an aerosol-generating material, and step (e) occurs after step (c).

6. A method according to any one of claims 1 to 3 or 5, wherein the aerosol-generating material is an aerosol-generating film.

7. A method according to any one of claims 1 to 6, wherein the aerosol-generating material comprises a binder and an aerosol former.

8. A method according to claim 7, wherein the aerosol-generating material comprises an active substance.

9. The method of claim 7 or 8, wherein the binder is a gelling agent.

10. The method of any one of claims 1 to 9, wherein steps (a) and (b) are performed before step (c).

11. The method of claim 10, wherein step (a) and step (b) are performed as a process independent of step (c), and the products of step (a) and step (b) are stored and/or transported between different locations prior to performing step (c).

12. The method of any one of claims 1 to 9, wherein step (c) is performed after step (a) and before step (b).

13. The method of any one of claims 1 to 12, wherein the method further comprises:

Step (f) of passing a doctor blade over at least a portion of the first surface of the mold body after performing step (c) and before or after performing step (e).

14. A method according to any one of claims 1 to 13, wherein step (c) comprises applying the aerosol-generating material to at least a portion of the first surface of the mould body comprising the mould recess.

15. A method according to any one of claims 1 to 14, wherein step (c) comprises applying the aerosol-generating material to substantially all of the first surface of the mould body.

16. The method of any one of claims 1 to 15, wherein the method further comprises:

And (g) covering the first surface of the mold body with a layer of material.

17. The method of claim 16, wherein in the case of performing step (f), step (g) is performed after step (c) and after step (f).

18. The method according to claim 16 or 17, wherein the method further comprises:

A step (h) of attaching the aerosol-generating material to the layer of material, wherein step (h) is performed after step (g).

19. The method of claim 18, wherein the method further comprises:

Step (i) of applying a release agent to the first surface of the mold body, and

20. The method of claim 19, wherein the material layer is attached to the support after step (i).

21. A method according to claim 20, wherein the layer of material is attached to the support with a surface of the layer of material to which the aerosol-generating material is attached facing away from the support.

22. A method according to any one of claims 16 to 21, wherein the layer of material comprises a susceptor.

23. The method of any one of claims 16 to 19, wherein the support comprises the layer of material.

24. The method of any one of claims 1 to 22, wherein the support comprises the mold body.

25. A method according to claim 23 or 24, wherein the support comprises a susceptor.

26. The method of any one of claims 1 to 24, wherein the method further comprises:

a step (k) of applying a susceptor layer to the first surface of the mold body, wherein step (k) is performed after step (a) and before step (c).

27. A method according to claim 22, 25 or 26, wherein the susceptor is a metal foil or film.

28. The method of any one of claims 1 to 27, wherein the method further comprises:

29. The method of any one of claims 1 to 28, wherein at least one of the mold recesses intersects the first surface of the mold body, the at least one of the mold recesses being one of longitudinally extending, rectangular, circular, or elliptical in shape.

30. A method according to any one of claims 1 to 29, wherein step (c) comprises applying at least two discrete portions of the aerosol-generating material to the first surface of the mould body, wherein the discrete portions of the aerosol-generating material have different compositions to each other.

31. A consumable for use with a device for heating aerosol-generating material, the consumable comprising a support and aerosol-generating material, wherein the consumable is manufactured according to the method of any of claims 1to 30.

32. An aerosol provision device for use with a consumable of claim 31, wherein the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable.

33. An aerosol provision system comprising an aerosol provision device according to claim 32 and a consumable according to claim 31.

34. A method of generating an aerosol from a consumable as claimed in claim 31 using an aerosol generating device having at least one aerosol generator arranged to heat but not combust the consumable in use; wherein the at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.