EP4380397A1

EP4380397A1 - A consumable for use with an aerosol provision device

Info

Publication number: EP4380397A1
Application number: EP22760978.1A
Authority: EP
Inventors: Paul Gibson
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2021-08-04
Filing date: 2022-08-04
Publication date: 2024-06-12
Also published as: CN117940034A; WO2023012292A1; GB202111256D0; JP2024530133A; KR20240040081A

Abstract

A method of manufacturing a consumable (24) for use with a non-combustible aerosol provision system, in which the consumable comprises a support (30) and aerosol generating material (32), is provided. The method comprises the steps of (a) providing a support; (b) surface treating at least a portion of a first surface (28) of the support; and (c) applying aerosol generating material to at least a portion of the first surface of the support. The surface treatment of step (b) comprises changing one or more chemical or physical characteristics of the surface where the physical characteristic changes to the surface are achieved by one or more processes that do not include perforating or embossing the support.

Description

A CONSUMABLE FOR USE WITH AN AEROSOL PROVISION DEVICE

Technical Field

This disclosure relates to the field of non-combustible aerosol provision systems, in particular to consumables for use with an aerosol provision device, a method for manufacturing consumables for use with an aerosol provision device, and an aerosol provision system including a consumable and an aerosol provision device.

Background

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Alternatives to these types of articles release an inhalable aerosol or vapour by releasing compounds from a substrate material by heating without burning. These may be referred to as non-combustible smoking articles, aerosol generating assemblies, or aerosol provision devices.

One example of such a product is a heating device which release compounds by heating, but not burning, an aerosolisable material which may be referred to as a solid aerosol-generating material. This solid aerosol-generating material may, in some cases, contain a tobacco material. The heating volatilises at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as heat-not-burn devices, tobacco heating devices or tobacco heating products. Various different arrangements for volatilising at least one component of the solid aerosol-generating material are known.

As another example, there are hybrid devices. These hybrid devices contain a liquid source (which may or may not contain nicotine) which is vaporised by heating to produce an inhalable vapour or aerosol. The device additionally contains a solid aerosol-generating material (which may or may not contain a tobacco material) and components of this material are entrained in the inhalable vapour or aerosol to produce the inhaled medium. Summary

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

(a) providing a support,

(b) surface treating at least a portion of a first surface of the support, and

(c) applying aerosol generating material to at least a portion of the first surface of the support, in which the surface treatment of step (b) comprises changing one or more chemical or physical characteristics of the surface where the physical characteristic changes to the surface are achieved by one or more processes that do not include perforating or embossing the support.

According to a second aspect of the present disclosure there is provided a consumable comprising a support and aerosol generating material which 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 provision device for use with a consumable manufactured by a method according to the first aspect of the present disclosure, in which the device comprises a heater assembly configured to heat at least a portion of the aerosol generating material supported on the consumable.

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

According to a fifth aspect of the present disclosure there is provided a method of generating aerosol from a consumable according to the first aspect of the present disclosure using an aerosol-generating device with at least one aerosol generator disposed to heat, but not burn, the consumable in use; wherein at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.

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

Drawings

Figure 1 shows a schematic view of an embodiment of an aerosol provision device and an embodiment of a consumable manufactured according to an embodiment of a method of the present disclosure;

Figure 2 shows a first embodiment of a support used in the manufacture of the consumable of Figure 1 ;

Figure 3 shows the support of Figure 2 once it has been surface treated according to a first embodiment of the method of the present disclosure;

Figure 4 shows the support of Figure 3 once aerosol generating material has been applied to the support;

Figure 5 shows the support of Figure 2 once it has been surface treated according to a second embodiment of the method of the present disclosure;

Figure 6 shows the support of Figure 5 once aerosol generating material has been applied to the support;

Figure 7 shows the support of Figure 6 separated into two consumables;

Figure 8 shows the support of Figure 2 in the process of being surface treated according to a third embodiment of the method of the present disclosure;

Figure 9 shows the support of Figure 5 once aerosol generating material has been applied to the support.

Detailed Description

The consumable of the present description may be alternatively referred to as an article. In some embodiments, the consumable comprises aerosol-generating material. The consumable may comprise an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, an aerosol-modifying agent, one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.

The apparatus for heating the aerosol-generating material with which the consumable is to be used is a part of a non-combustible aerosol provision system. Non-combustible aerosol provision systems release compounds from an aerosolgenerating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

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

In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosolgenerating material is not a requirement.

In some embodiments, the non-combustible aerosol provision system is an aerosolgenerating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise a noncombustible aerosol provision device and a consumable for use with the noncombustible aerosol provision device.

In some embodiments, the disclosure relates to consumables comprising aerosolgenerating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.

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

(a) providing a support,

(b) surface treating at least a portion of a first surface of the support, and

In an embodiment of any of the above embodiments the surface treatment of step (b) provides an increased strength of the bond created between the aerosol generating material and a treated portion of the first surface of the support relative to the strength of the bond created between the aerosol generating material and an untreated portion of the first surface of the support.

The strength of the bond between the aerosol generating material and the surface of the support to which it is applied may be measured by assessing the maximum tensile stress needed to detach or unstick the aerosol generating material from that surface when pulled in a direction perpendicular to the surface. It is often the case that the maximum tensile stress is the tensile stress required to cause the aerosol generating material to commence separating from the surface. Once that separation has commenced, the tensile stress needed to continue the separation of the aerosol generating material from the surface will be lower than that required to start the separation.

The increased strength of the bond to the treated portions of the first surface of the support is advantageous because it will result in a decrease in the likelihood of the aerosol generating material delaminating or unintentionally separating from the surface of the support. Such a decrease in the likelihood of delamination results in an increase in the shelf life or the period for which a consumable can be stored without delamination of the consumable. In an embodiment of any of the above embodiments the surface treatment of step (b) provides a treated surface that is less reactive than the untreated surface. In some embodiments that reactivity results in a reduced likelihood of chemical corrosion of the treated portions of the surface. It is advantageous to reduce the reactivity of the treated surface because it is undesirable for that surface to react with aerosol generating material applied to the surface, aerosol generated when the aerosol generating material is heated, or condensate resultant from the generation of that aerosol. Such reactions may lead to chemical corrosion of the first surface of the support. Chemical corrosion of the first surface of the support can be unsightly, or impair the proper functioning of the consumable and I or the non-combustible aerosol provision system.

In an embodiment of any of the above embodiments the physical characteristic changes to the treated surface resulting from step (b) comprise changes at a microscopic scale.

In an embodiment of any of the above embodiments the support is a laminate, the laminate comprises at least two layers, and a first layer of the laminate forms the first surface of the support.

In an embodiment of any of the above embodiments the first surface of the support comprises a metal or metal alloy. In some embodiments, the first surface of the support comprises a foil or film of a metal or metal alloy.

In an embodiment of any of the above embodiments the first surface of the support comprises aluminium or aluminium alloy. In some embodiments, the first surface of the support comprises a foil or film of aluminium or aluminium alloy.

In an embodiment of any of the above embodiments, the support comprises a second layer, and the second layer is formed from a material suitable to form a substrate. The second layer may, for example, be or comprise card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In an embodiment of any of the above embodiments the support comprises a plastics material which can withstand the temperatures typically encountered in a non-combustible aerosol provision device. In some embodiments the support comprises polyether ether ketone (PEEK). Such embodiments have the advantage that the support may be reused, and that the consumable is less affected by any condensation in the non-combustible aerosol provision device than consumables that comprise a support which includes use of a sorbent material for structural purposes.

In an embodiment of any of the above embodiments the method further comprises a step of

(d) separating the support into two or more smaller portions of a desired shape and size. This step has the advantage that the support can be treated when it is of a size that renders the support easy to handle and allows treatment of the support in an efficient and economic fashion. The subsequent separation of the support into a plurality of smaller portions can be separation into portions of a size suitable for use as a consumable, or which can, at a later time, be further separated into a plurality of consumables.

In an embodiment of any of the above embodiments the surface treatment of step (b) comprises electrostatic coating of at least a portion of the first surface of the support. In some embodiments the electrostatic coating comprises electrostatic coating of at least a portion of the first surface of the support with a primer and the surface treatment of step (b) further comprises a step of (e) curing at least a portion of the primer, and in which step (e) is performed subsequent to step (b) and before step (c).

In some embodiments in which the electrostatic coating comprises electrostatic coating of at least a portion of the first surface of the support with a primer, and the primer is subsequently cured, the curing may take the form of baking the support.

The electrostatic coating of at least a portion of the support is a suitable method of treating the support because the support can be configured to be flat or substantially flat and without surface features that will promote disproportionately or undesirably high quantities of electrostatic deposition. For example, sharp edges promote disproportionally high quantities of electrostatic deposition. Further, the support can also be configured to be without surface features that will promote disproportionately or undesirably low quantities of electrostatic deposition. For example recesses promote disproportionally low quantities of electrostatic deposition.

In an embodiment of any of the above embodiments the surface treatment of step (b) comprises chemical treatment of at least a portion of the first surface of the support.

In an embodiment of any of the above embodiments the chemical treatment of step (b) comprises chemically etching at least a portion of the first surface of the support. Chemically etching at least a portion of the surface of the support has the advantage that, at a microscopic level, the surface area of the etched portion of the first surface of the support is increased. This enhances the bond between the aerosol generating material and the surface of the support.

In an embodiment of any of the above embodiments the surface treatment of step (b) comprises exposure of at least a portion of the first surface of the support or at least a portion of a coated first surface of the support to a source of ultraviolet radiation.

In an embodiment of any of the above embodiments the exposure of at least a portion of the first surface of the support or at least a portion of the coated first surface to a source of ultraviolet radiation of step (b) causes a modification to the structure or surface chemistry of the exposed first surface of the support. The coating of the first surface of the support may catalyse or otherwise alter the change of characteristics of the surface structure or surface chemistry of the treated portions of the first surface of the support. Such changes in the surface structure or surface chemistry can promote a stronger bond between the aerosol generating material and the first surface of the support. In an embodiment of any of the above embodiments the surface treatment of step (b) comprises a plasma surface treatment of at least a portion of the first surface of the support.

In an embodiment of any of the above embodiments the plasma surface treatment of step (b) comprises one or more of surface cleaning of the support, surface activation of the support, coating of the support, and etching of the support. Again such surface treatment promotes stronger bond between the aerosol generating material and the first surface of the support.

In an embodiment of any of the above embodiments, step (b) comprises applying the aerosol generating material to the first surface of the support as two or more discrete portions of aerosol generating material.

In an embodiment of any of the above embodiments the application of the aerosol generating material to at least a portion of the support is application of an aerosol generating material slurry.

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

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 material.

The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In particular, in some embodiments, the aerosolgenerating material is substantially tobacco free. The aerosol-generating material may comprise or be in the form of an aerosolgenerating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

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

The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film.

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

The aerosol-generating material may comprise or 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. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.

The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free.

In an embodiment of any of the above embodiments the method comprises a further method step of (g) allowing or causing the aerosol generating material slurry to set, in which the aerosol generating slurry sets to form an aerosol generating material.

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

In an embodiment of any of the above embodiments the surface treatment of step (b) comprises surface treating one or more discrete portions of the first surface of the support, and the application of aerosol generating material of step (c) comprises application of aerosol generating material to one or more discrete portions of the first surface of the support that have been surface treated.

In an embodiment of any of the above embodiments the surface treatment of step (b) comprises surface treating substantially all of the first surface of the support, and the application of aerosol generating material of step (c) comprises application of aerosol generating material to one or more discrete portions of the first surface of the support.

In an embodiment of any of the above embodiments the application of aerosol generating material of step (c) comprises application of aerosol generating material to three or more discrete portions on the first surface of the support, and the discrete portions are disposed on the first surface of the support in a grid pattern.

In an embodiment of any of the above embodiments one or more of the discrete portions of the aerosol generating material applied in step (c) are, in the plane of the first surface of the support, substantially circular, longitudinally extending stripes, stripes including at least one curve or angle, or of a shape that will tessellate.

In an embodiment of any of the above embodiments at least two discrete portions of the aerosol generating material applied in step (c) have different compositions from each other. This has the advantage that a user of the consumable may have different experiences from different discrete portions of aerosol generating material on the consumable. This may make the use of the consumable more enjoyable and / or more interesting than use of a consumable that has aerosol generating material of only one composition.

In an embodiment of any of the above embodiments, the application of aerosol generating material is performed two or more times. This may have the effect of producing thicker aerosol generating material on the support than a single application of aerosol generating material. An increased thickness may result in a greater amount of aerosol being generated by the aerosol generating material and I or provision of aerosol for a longer period of time than if only one application of aerosol generating material had occurred.

In an embodiment of any of the above embodiments at least one discrete portion of the aerosol generating material applied in step (c) is of a shape and I or colour that is indicative of the composition of the aerosol generating material forming the discrete portion.

In an embodiment of any of the above embodiments the method comprises a further method step of (f) treating the support with a further treatment, in which the further treatment comprises perforating or embossing at least part of the support.

In an embodiment of any of the above embodiments, the support comprises a susceptor. In some embodiments the support is a laminate, at least one layer of the laminate is a susceptor, and the treated first 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, so that penetration thereof with a varying magnetic field causes induction heating of the susceptor by resistive heating as a result of electric eddy currents. The susceptor may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the susceptor. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the 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 example ferromagnetic metals are a 400 series stainless steel such as grade 410 stainless steel, or grade 420 stainless steel, or grade 430 stainless steel, or stainless steel of similar grades. Alternatively, the susceptor may comprise a suitable non-magnetic, in particular paramagnetic, conductive material, such as aluminium. In a paramagnetic conductive material inductive heating occurs solely 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 only generated by hysteresis losses. The susceptor may comprise a commercial alloy like Phytherm 230 (with a composition (in % by weight = wt %) with 50 wt % Ni, 10 wt % Cr and the rest Fe) or Phytherm 260 (with a composition with 50 wt % Ni, 9 wt % Cr and the rest Fe).

The susceptor may in some embodiments of any of the above embodiments be a metal or a metal alloy. The susceptor may in some embodiments of any of the above embodiments be a metal foil, optionally an aluminium foil or a ferrous foil. Alternatively, the susceptor may in some embodiments of any of the above embodiments be any conductor that could be sprayed or vapour deposited on a material that forms the support.

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

The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, terpenes of non-cannabinoid origin, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical. The active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

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

The active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, Wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens

In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco. In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.

In some embodiments, the aerosol-generating material comprises a flavour or flavourant.

As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, Wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.

In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

The aerosol generating material comprises an aerosol generating agent. In some embodiments the aerosol generating agent may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol generating agent may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso- Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In particular examples, the aerosol generating agent comprises glycerol.

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

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

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

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

The aerosol generating material may also comprise 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 comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the gelling agent comprises alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during formation of the aerosol generating material. In some cases, the aerosol generating material may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin. In some embodiments, the gelling agent comprises one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum and mixtures thereof.

In some embodiments, the cellulosic gelling agent is selected from the group consisting of: hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP) and combinations thereof.

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

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

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

In some embodiments, the aerosol generating material comprises from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt% or 35wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 1-50wt%, 5-45wt%, 10-40wt% or 20- 35wt% of a gelling agent. In some embodiments, the aerosol generating material comprises from about 20wt% 22wt%, 24wt% or 25wt% to about 30wt%, 32wt% or 35wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 20-35wt% or 25-30wt% of a gelling agent.

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

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

In examples, the aerosol generating material comprises gelling agent (i.e. without taking into account the amount of filler) in an amount of from about 5wt%, 10wt%, 15wt%, 20wt%, 25wt%, 30wt%, or 35wt% to about 60wt%, 55wt%, 50wt%, or 45wt% of the aerosol generating material. In examples, the aerosol generating material comprises gelling agent (i.e. without taking into account the amount of filler) in an amount of from about 5 to 60wt%, 20 to 60wt%, 25 to 55wt%, 30 to 50wt%, or 35 to 45wt% of the aerosol generating material.

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

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

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

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

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

The (b) forming a layer of the slurry typically comprises spraying, casting or extruding the slurry. In examples, the slurry layer is formed by electrospraying the slurry. In examples, the slurry layer is formed by casting the slurry.

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

In some examples, the slurry is applied to a support. The layer may be formed on a support. In examples, the slurry comprises gelling agent, aerosol-former material and active substance. The slurry may comprise these components in any of the proportions given herein in relation to the composition of the aerosol generating material. For example, the slurry may comprise (on a dry weight basis): gelling agent and, optionally, filler, wherein the amount of gelling agent and filler taken together is about 10 to 60wt% of the slurry; aerosol-former material in an amount of about 40 to 80wt% of the slurry; and optionally, active substance in an amount of up to about 20wt% of the slurry.

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

In examples, the setting agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the setting agent comprises or consists of calcium formate and/or calcium lactate. In particular examples, the setting agent comprises or consists of calcium formate. The inventors have identified that, typically, employing calcium formate as a setting agent results in an aerosol generating material having a greater tensile strength and greater resistance to elongation.

The total amount of the setting agent, such as a calcium source, may be 0.5-5wt% (calculated on a dry weight basis). Suitably, the total amount may be from about 1wt%, 2.5wt% or 4wt% to about 4.8wt% or 4.5wt%. The inventors have found that the addition of too little setting agent may result in an aerosol generating material which does not stabilise the aerosol generating material components and results in these components dropping out of the aerosol generating material. The inventors have found that the addition of too much setting agent results in an aerosol generating material that is very tacky and consequently has poor handleability. When the aerosol generating material does not contain tobacco, a higher amount of setting agent may need to be applied. In some cases the total amount of setting agent may therefore be from 0.5-12wt% such as 5-10wt%, calculated on a dry weight basis. Suitably, the total amount may be from about 5wt%, 6wt% or 7wt% to about 12wt% or 10wt%. In this case the aerosol generating material will not generally contain any tobacco.

In examples, supplying the setting agent to the slurry comprises spraying the setting agent on the slurry, such as a top surface of the slurry.

Alginate salts are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of p-D-mannuronic (M) and a- L-guluronic acid (G) units (blocks) linked together with (1 ,4)-glycosidic bonds to form a polysaccharide. On addition of calcium cations, the alginate crosslinks to form a gel. It has been found that alginate salts with a high G monomer content more readily form a gel on addition of the calcium source. In some cases therefore, the gel-precursor may comprise an alginate salt in which at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginate copolymer are a-L- guluronic acid (G) units.

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

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

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

In examples where the solvent consists of water, the dry weight content of the slurry may match the dry weight content of the aerosol generating material. Thus, the discussion herein relating to the solid composition is explicitly disclosed in combination with the slurry aspect of the invention. The aerosol generating material may comprises a flavour. Suitably, the aerosol generating material may comprise up to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt% or 45wt% of a flavour. In some cases, the aerosol generating material may comprise at least about 0.1wt%, 1wt%, 10wt%, 20wt%, 30wt%, 35wt% or 40wt% of a flavour (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 1-80wt%, 10-80wt%, 20-70wt%, 30-60wt%, 35- 55wt% or 30-45wt% of a flavour. In some cases, the flavour comprises, consists essentially of or consists of menthol.

The aerosol generating material may comprises a filler.

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

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

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

The filler, if present, may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)). In particular cases, the aerosol generating material comprises no calcium carbonate such as chalk. In particular embodiments which include filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, 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 filler in an aerosol generating material may increase the tensile strength of the material. This may be particularly advantageous in examples wherein the aerosol generating material is provided as a sheet, such as when an aerosol generating material sheet circumscribes a rod of aerosolisable material.

In some embodiments, the aerosol generating material does not comprise tobacco fibres. In particular embodiments, the aerosol generating material does not comprise fibrous material.

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

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

In some cases, the aerosol generating material comprises an active substance such as tobacco extract. In some cases, the aerosol generating material may comprise 5-60wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the aerosol generating material may comprise from about 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) tobacco extract. For example, the aerosol generating material may comprise 10-50wt%, 15-40wt% or 20-35wt% of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the aerosol generating material comprises 1wt% 1.5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%, 4.5wt% or 4wt% (calculated on a dry weight basis) of nicotine. In some cases, there may be no nicotine in the aerosol generating material other than that which results from the tobacco extract.

In some embodiments the aerosol generating material comprises no tobacco material but does comprise nicotine. In some such cases, the aerosol generating material may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) of nicotine. For example, the aerosol generating material may comprise 1-20wt%, 2-18wt% or 3- 12wt% of nicotine.

In some cases, the total content of active substance and/or flavour may be at least about 0.1wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of active substance and/or flavour 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 flavour may be at least about 0.1wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of active substance and/or flavour 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 aerosol generating material comprises one or more active substances, e.g. up to about 20wt% of the aerosol generating material. In examples, the aerosol generating material comprises active substance in an amount of from about 1wt%, 5wt%, 10wt%, or 15wt% to about 20wt%, 15wt%, 15wt% or 5wt% of the aerosol generating material.

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

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

The tobacco material may be present in any format, but is typically fine-cut (e.g. cut into narrow shreds). Fine-cut tobacco material may advantageously be blended with the aerosol generating material to provide an aerosol-generating composition which has an even dispersion of tobacco material and aerosol generating material throughout the aerosol-generating composition.

In examples, the tobacco material comprises one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract. Surprisingly, the inventors have identified that it is possible to use a relatively large amount of lamina tobacco in the aerosol-generating composition and still provide an acceptable aerosol when heated by a noncombustible aerosol provision system. Lamina tobacco typically provides superior sensory characteristics. In examples, the tobacco material comprises lamina tobacco in an amount of at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt%, or 95wt% of the tobacco material. In particular 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 tobacco material may be any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental.

In some embodiments the one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

In some cases, the aerosol generating material may additionally comprise an emulsifying agent, which emulsified molten flavour during manufacture. For example, the aerosol generating material may comprise from about 5wt% to about 15wt% of an emulsifying agent (calculated on a dry weight basis), suitably about 10wt%. The emulsifying agent may comprise acacia gum.

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

The aerosol generating material may have any suitable water content, such as from 1wt % to 15wt%. Suitably, the water content of the aerosol generating material is from about 5wt%, 7wt% or 9wt% to about 15wt%, 13wt% or 11wt% (WWB), most suitably about 10wt%.. The water content of the aerosol generating material may, for example, be determined by Karl-Fischer-titration or Gas Chromatography with Thermal Conductivity Detector (GC-TCD).

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

In some cases, the aerosol generating material may consist essentially of, or consist of a gelling agent, water, an aerosol generating agent, a flavour, and optionally a tobacco material and/or a nicotine source. In examples, the aerosol generating material consists essentially of, or consists of a gelling agent, aerosol generating agent, active substance, and water. In examples, the aerosol generating material consists essentially of, or consists of a gelling agent, aerosol generating agent, and water.

In examples, the aerosol generating material does not comprise a flavourant; in particular examples, the aerosol generating material does not comprise an active substance.

In some embodiments the aerosol generating material comprises:

1-60 wt% of a gelling agent;

0.1-50 wt% of an aerosol generating agent; and

0.1 -80 wt% of a flavour; wherein these weights are calculated on a dry weight basis

In some embodiments, the aerosol generating material comprises 1-80 wt% of a flavour (dry weight basis).

In some embodiments, the aerosol generating material comprising:

1-50 wt% of a gelling agent;

0.1-50 wt% of an aerosol generating agent; and

30-60 wt% of a flavour; wherein these weights are calculated on a dry weight basis.

In alternative embodiments of the aerosol generating material, the aerosol generating material comprises:

1-60 wt% of a gelling agent;

5-60 wt% of an aerosol generating agent; and

10-60 wt% of a tobacco extract; wherein these weights are calculated on a dry weight basis.

In some embodiments, the aerosol generating material comprises:

1-60 wt% of a gelling agent;

20-60 wt% of an aerosol generating agent; and 10-60 wt% of a tobacco extract; wherein these weights are calculated on a dry weight basis.

In some embodiments, the aerosol generating material comprises 20 - 35 wt % of the gelling agent; 10 - 25 wt % of the aerosol-former material; 5 - 25 wt % of the filler comprising fibres; and 35 - 50 wt % of the flavourant and/or active substance.

In some cases, the aerosol generating material may consist essentially of, or consist of a gelling agent, an aerosol generating agent a tobacco extract, water, and optionally a flavour. In some cases, the aerosol generating material may consist essentially of, or consist of glycerol, alginates and/or pectins, a tobacco extract and water.

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

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

The “thickness” of the aerosol generating material describes the shortest distance between a first surface and a second surface. In embodiments where the aerosol generating material is in the form of a sheet, the thickness of the aerosol generating material is the shortest distance between a first planar surface of the sheet and a second planar surface of the sheet which opposes the first planar surface of the sheet. In some cases, the aerosol-forming aerosol generating material 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 of from about 0.1mm or 0.15mm to about 1.0mm, 0.5mm or 0.3mm.

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

A material having a thickness of 0.2mm is particularly suitable. The aerosol generating material may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.

It has been that if the aerosol-generating material is too thick, then heating efficiency is compromised. This adversely affects the power consumption in use. Conversely, if the aerosol-generating material is too thin, it is difficult to manufacture and handle; a very thin material is harder to cast and may be fragile, compromising aerosol formation in use.

The thickness stipulated herein is a mean thickness for the material. In some cases, the aerosol generating material thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%.

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

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

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

The aerosol generating material may have any suitable area density, such as from 30 g/m² to 120 g/m². In some cases, the sheet may have a mass per unit area of 80-120 g/m², or from about 70 to 110 g/m², or particularly from about 90 to 110 g/m², or suitably about 100 g/m² (so that it has a similar density to cut rag tobacco and a mixture of these substances will not readily separate). In some cases, the sheet may have a mass per unit area of about 30 to 70 g/m², 40 to 60 g/m², or 25- 60 g/m² and may be used to wrap an aerosolisable material such as tobacco.

All percentages by weight described herein (denoted wt%) are calculated on a dry weight basis, unless explicitly stated otherwise. All weight ratios are also calculated on a dry weight basis. A weight quoted on a dry weight basis refers to the whole of the extract or slurry or material, other than the water, and may include components which by themselves are liquid at room temperature and pressure, such as glycerol. Conversely, a weight percentage quoted on a wet weight basis refers to all components, including water.

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

A variety of colourants may be used depending on the desired colour of the aerosol generating material. The colour of aerosol generating material may be, for example, white, green, red, purple, blue, brown or black. Other colours are also envisaged. Natural or synthetic colourants, such as natural or synthetic dyes, foodgrade colourants and pharmaceutical-grade colourants may be used. In certain embodiments, the colourant is caramel, which may confer the aerosol generating material with a brown appearance. In such embodiments, the colour of the aerosol generating material may be similar to the colour of other components (such as tobacco material) in an aerosol-generating. In some embodiments, the addition of a colourant to the aerosol generating material renders it visually indistinguishable from other components in the aerosol-generating material.

The colourant may be incorporated during the formation of the aerosol generating material (e.g. when forming a slurry comprising the materials that form the aerosol generating material) or it may be applied to the aerosol generating material after its formation (e.g. by spraying it onto the aerosol generating material).

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

In the following discussions of the accompanying drawings, where the same element is present in a more than one embodiment the same reference numeral is used for that element throughout, where there are similar elements similar reference numerals (the same numeral plus a multiple of 100) are used.

With reference to Figure 1, an aerosol provision device 2 comprises a casing 4 within which is located a heater assembly 6. The heater assembly 6 is comprised of a heating chamber 8 and an aerosol generator 10. The aerosol generator 10 can be an electrical resistance 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 opposite end of the heating chamber 8 is an aperture 14. The aperture 14 is in fluid communication with a mouth piece 16 via a conduit 18.

Also located within the casing 4 is a controller 20 which is in electronic communication with and controls the functioning of the aerosol generator 10. The controller 20 may include a memory (not shown) within which one or more tables relating to the operation of the heater 10 may be stored. The aerosol generator 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 appropriate sources of electrical power.

The aerosol provision device 2 is suitable for use with a consumable 24. The consumable 24 comprises of one or more discrete portions of aerosol-generating material 32 supported on first surface 28 of the consumable 24. The discrete portions of aerosol-generating material 32 are supported on the first surface 28 in a square grid pattern. Other, non-illustrated embodiments of the consumable 24 may include more or less discrete portions of aerosol-generating material 32 than shown in Figure 1 , including a single portion of aerosol-generating material 32, and those portions may be distributed on the first surface 28 in any pattern. The discrete portions of aerosol-generating material 32 are shown to have an approximately circular shape in Figure 1 , they may, in other embodiments, be of other shapes. Examples of how to produce or manufacture the consumable 24 are described below.

With reference to Figure 2, to commence the production of a consumable 24 a support 30 is provided. The support 30 comprises a longitudinally extending sheet of a flexible laminate material which includes first and second layers 36, 38. The first layer 36 has a surface that is first surface 28, and is comprised of a sheet of aluminium foil. The first layer is less than 0.025 mm thick. In other non-illustrated embodiments the material of first layer 36 may be an aluminium alloy or a different suitable material such as a different metal or metal alloy.

The second layer 38 is formed of card. The second layer 38 is sufficiently rigid that it supports the first layer and provides a support that has a fixed configuration.

The length and width of the support 30 as shown in Figures 1 and 2 is for illustrative purposes only. The support 30 may have different lengths and widths without departing from the scope of the present disclosure.

With reference to Figure 3, substantially all of the first surface 28 (area 40) is electrostatically coated with a primer using a known electrostatic coating technique. In this technique, the primer is caused to have a negative electrostatic charge and the first layer 36 is grounded and caused to have a positive electrostatic charge. The primer is sprayed toward the first surface 28 and the primer is attracted to the first surface 28. The support 30 is then baked at a suitable temperature for a suitable time to cause the primer applied to area 40 to cure.

The primer changes one or more of the chemical and I or physical characteristics of at least the area 40 of the first surface 28. For example, the primer may increase the strength with which aerosol generating material will bond to the surface of area 40 compared to the strength with which it would have bonded to the surface 28 before it was treated by the application of the primer.

Additionally or alternatively, the primer of at least area 40 will render the aluminium foil of the first layer 36 less likely to corrode (as a result of reaction between the aerosol generating material and the foil, the foil and the aerosol that will be generated within the heating chamber 8 of aerosol provision device 2, or the foil and any condensate within heating chamber 8) than foil of the first layer 36 which has not been treated with the primer.

With reference to Figure 4, once the primer in at least area 40 has cured, discrete portions of aerosol generating material 32 in the form of a slurry of aerosol generating material are applied to the surface of area 40 in a grid pattern. The slurry is applied to the surface 40 using a known aerosol generating material slurry application technique, for example from a reservoir (not shown) of aerosol generating material slurry via one or more nozzles (not shown).

The discrete portions of the aerosol generating material 32 are, in the plane of the first surface of the support, all substantially circular. In other non-illustrated examples of the method of the present disclosure one or more of the discrete portions of the aerosol generating material 32 may be in the shape of longitudinally extending stripes, stripes including at least one curve or angle, and / or of a shape that will tessellate.

The discrete portions of aerosol generating material 32 are then allowed to dry so that the slurry of aerosol generating material becomes aerosol generating material of more or less fixed dimensions and shape. The consumable 24 is then ready for use in an aerosol provision device 2. If the aerosol provision device 2 is one in which the aerosol generator 10 is a magnetic field generator, the foil of the first layer 36 acts as a susceptor to heat the aerosol generating material portions 32.

With reference to Figure 5, a support 130 is a laminate having a first and a second layer 136, 138. The first layer 136 has a surface that is first surface 128, and is comprised of a sheet of aluminium foil. The first layer is less than 0.015 mm thick.

The second layer 138 is formed of polyether ether ketone (PEEK). The second layer 138 is sufficiently rigid that it supports the first layer 136 and provides a support that has a fixed configuration.

The length and width of the support 130 as shown in Figure 5 is for illustrative purposes only. The support 130 may have different lengths and widths without departing from the scope of the present disclosure.

Three areas 142, 144, 146 of the first surface 128 of the support 130 are chemically treated using a chemical that chemically etches the surface of the first surface 128. The etching of the areas 142, 144, 146 is at a microscopic scale but it does have the effect of, at a microscopic scale, making the first surface 128 rougher in areas 142, 144, 146 than the rest of the first surface 128 (the parts of first surface 128 that are not in areas 142, 144, 146). The etching increases the strength of the bond between the aerosol generating material and the surface 128 in areas 142, 144, 146 relative to the bond between the aerosol generating material and the rest of first surface 128.

With reference to Figure 6, discrete portions of first aerosol generating material 132A, and second aerosol generating material 132B, both in the form of an aerosol generating material slurry are applied to the surface of areas 142, 144, 146 in a grid pattern as shown in Figure 6. The slurry is applied to the surface of areas 142, 144, 146 using a known aerosol generating material slurry application technique, for example from first and second reservoirs (not shown) of aerosol generating material slurry 132A, 132B via at least two nozzles (not shown). The first and second aerosol generating materials 132A, 132B have different compositions. For example they contain different flavourants with the result that they generate different flavoured aerosols when heated.

The discrete portions of the first aerosol generating material 132A are, in the plane of the first surface 128 of the support 130, all substantially circular, and the discrete portions of the second aerosol generating material 132B are, in the plane of the first surface 128 of the support 130, all substantially square. Thus the shapes of portions of the first and second portions of aerosol generating material 132A, 132B are representative of the different compositions of the aerosol generating materials that comprise those portions. Optionally, the first aerosol generating material 132A is of a different colour to the second aerosol generating material 132B.

The discrete portions of the first and second aerosol generating materials 132A, 132B are then allowed to dry so that the slurries of aerosol generating materials 132A, 132B become aerosol generating materials of more or less fixed dimensions and shapes.

The support 130 is next separated along separation line 148 so as to form a pair of consumables 124 as shown in Figure 7. The consumables 124 are ready for use in an aerosol provision device 2. If the aerosol provision device 2 is one in which the aerosol generator 10 is a magnetic field generator, the foil of the first layer 136 acts as a susceptor to heat the first and second aerosol generating material portions 132A, 132B.

With reference to Figure 8, a support 230 is a laminate having a first and a second layer 236, 238. The first layer 236 has a surface that is first surface 228, and is comprised of a sheet of aluminium alloy foil. The first layer is less than 0.020 mm thick.

The length and width of the support 230 as shown in Figure 8 is for illustrative purposes only. The support 230 may have different lengths and widths without departing from the scope of the present disclosure.

The second layer 238 is formed of polyether ether ketone (PEEK). The second layer 238 is around 1.0 mm thick and sufficiently rigid that it supports the first layer 236 and provides a support 230 that has a fixed configuration.

Overlying first surface 228 is a mask 250. Mask 250 includes four apertures 252 which leave four areas 254 on the first surface 228 uncovered. The mask 250 is formed from a material that is undamaged by exposure to intensive ultraviolet (UV) light (electromagnetic radiation with a wave length of between 10 nm and 400 nm).

The masks and areas 254 on the first surface 228 are exposed to intensive UV light form a UV light source (not shown). This cleans the areas 254 of the first surface 228 so as to enhance the bonding of aerosol generating material to the areas 254 of the first surface 228 when applied to that surface, and as a result the strength of the bond of the aerosol generating material to the first surface 228 in areas 254.

In some embodiments the first layer 236 is coated with a layer of material that is activated by UV light, this again enhances the bonding of aerosol generating material to the areas 254 of the first surface 228.

With reference to Figure 9, once the areas 254 have been exposed to the UV light for a sufficient period of time, the mask 250 is removed from the first surface 250 and an aerosol generating material slurry is then applied to the areas 254 of the first surface 228 to form aerosol generating material portions 232.

The discrete portions of the aerosol generating materials 232 are then allowed to dry so that the slurry of aerosol generating material 232 becomes aerosol generating material of more or less fixed dimensions and shapes. The consumable 224 is then ready for use in an aerosol provision device 2. If the aerosol provision device 2 is one in which the aerosol generator 10 is a magnetic field generator, the foil of the first layer 236 acts as a susceptor to heat the aerosol generating material portions 232.

In an alternative embodiment of Figures 8 and 9, the mask 250 is an etching mask for use in a plasma etching process. The exposed surfaces 254 of the first surface 228 are etched using a known plasma etching technique until the required depth of etching is achieved. This produces a roughened surface of the foil in the areas 254 which produce an enhanced strength of bonding between the aerosol generating material and the surface 228 in areas 254. The support 230 is then further processed as described above to produce a consumable 224.

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

Claims

1 A method of manufacturing a consumable for use with a non-combustible aerosol provision system, in which the consumable comprises a support and aerosol generating material, and the method comprises the steps of

(a) providing a support,

(b) surface treating at least a portion of a first surface of the support, and

2 A method according to claim 1 in which the surface treatment of step (b) provides an increased strength of the bond created between the aerosol generating material and a treated portion of the first surface of the support relative to the adhesive strength of the bond created between the aerosol generating material and an untreated portion of the first surface of the support.

3 A method according to claim 1 or 2 in which the surface treatment of step (b) provides a treated surface, and the treated surface has a reduced reactivity relative to an untreated surface.

4 A method according to claim 4 in which the reactivity results in chemical corrosion of the surface.

5 A method according to any of claims 1 to 4 in which the physical characteristic changes to the treated surface resulting from step (b) comprise changes at a microscopic scale.

6 A method according to any of claims 1 to 5 in which the support is a laminate, the laminate comprises at least two layers, and a first layer of the laminate forms the first surface of the support. 7 A method according to any of claims 1 to 6 in which the first surface of the support comprises a metal or metal alloy.

8 A method according to claim 7 in which the first surface of the support comprises a foil or film of a metal or metal alloy.

9 A method according to claim 7 or 8 in which the metal or metal alloy is aluminium or an aluminium alloy.

10 A method according to any of claims 1 to 9 in which the method further comprises a step of

(d) separating the support into two or more smaller units of a desired shape and size.

11 A method according to any of claims 1 to 10 in which the surface treatment of step (b) comprises electrostatic coating of at least a portion of the first surface of the support.

12 A method according to claim 11 in which the electrostatic coating comprises electrostatic coating of at least a portion of the first surface of the support with a primer and the surface treatment of step (b) further comprises a step of

(e) curing at least a portion of the primer, in which step (e) is performed subsequent to step (b) and before step (c).

13 A method according to claim 12 in which step (e) comprises baking of the support to cure the primer.

14 A method according to any of claims 1 to 13 in which the surface treatment of step (b) comprises chemical treatment of at least a portion of the first surface of the support.

15 A method according to claim 14 in which the chemical treatment of step (b) comprises chemically etching at least a portion of the first surface of the support. 16 A method according to any of claims 1 to 15 in which the surface treatment of step (b) comprises exposure of at least a portion of the first surface of the support or at least a portion of a coated first surface to a source of ultraviolet radiation.

17 A method according to claim 16 in which the exposure of at least a portion of the first surface or at least a portion of the coated first surface to a source of ultraviolet radiation of step (b) causes a modification to the structure or surface chemistry of the exposed first surface of the support.

18 A method according to any of claims 1 to 17 in which the surface treatment of step (b) comprises a plasma surface treatment of at least a portion of the first surface of the support.

19 A method according to claim 18 in which the plasma surface treatment of step (b) comprises one or more of surface cleaning of the support, surface activation of the support, coating of the support, and etching of the support.

20 A method according to any of claims 1 to 19 in which the aerosol generating material is a slurry comprising a binder and an aerosol former.

21 A method according to any of claims 1 to 20 in which the surface treatment of step (b) comprises surface treating one or more discrete portions of the first surface of the support, and the application of aerosol generating material of step (c) comprises application of aerosol generating material to one or more discrete portions of the first surface of the support that have been surface treated.

22 A method according to any of claims 1 to 20 in which the surface treatment of step (b) comprises surface treating substantially all of the first surface of the support, and the application of aerosol generating material of step (c) comprises application of aerosol generating material to one or more discrete portions of the first surface of the support. 23 A method according to claim 21 or 22 in which the application of aerosol generating material of step (c) comprises application of aerosol generating material to three or more discrete portions on the first surface of the support, and the discrete portions are disposed on the first surface of the support in a grid pattern.

24 A method according to any of claims 21 to 23 in which one or more of the discrete portions of the aerosol generating material applied in step (c) are, in the plane of the first surface of the support, substantially circular, longitudinally extending stripes, stripes including at least one curve or angle, or of a shape that will tessellate.

25 A method according to any of claims 21 to 24 in which at least two discrete portions of the aerosol generating material applied in step (c) have different compositions from each other.

26 A method according to any of claims 21 to 25 in which at least one discrete portion of the aerosol generating material applied in step (c) is of a shape and I or colour that is indicative of the composition of the aerosol generating material forming the discrete portion.

27 A method according to any of claims 1 to 26 in which the method comprises a further method step of

(f) treating the support with a further treatment, in which the further treatment comprises perforating or embossing at least part of the support.

28 A method according to any of claims 1 to 27 in which the application of aerosol generating material to at least a portion of the first surface of the support in step (c) is application of an aerosol generating material slurry.

29 A method according to claim 28 in which the method comprises a further method step of

(g) allowing or causing the aerosol generating material slurry to set, in which the aerosol generating slurry sets to form an aerosol generating material. 30 A method according to any of claims 1 to 29 in which the aerosol generating material is an aerosol generating film.

31 A consumable for use with a non-combustible aerosol provision system, in which the consumable comprises a support and aerosol generating material and the consumable is manufactured according to the method of any of claims 1 to 30.

32 An aerosol provision device for use with a consumable according to claim 31 , in which the device comprises a 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 aerosol from a consumable manufactured according to any of claims 1 to 30 using an aerosol-generating device with at least one aerosol generator disposed to heat, but not burn, the consumable in use; wherein at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.