EP4380398A1

EP4380398A1 - A consumable for use with an aerosol provision device

Info

Publication number: EP4380398A1
Application number: EP22761168.8A
Authority: EP
Inventors: Paul Gibson; Sam WHIFFEN
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: BR112024002317A2; CN118102936A; KR20240040083A; GB202111270D0; WO2023012298A1

Abstract

A method of manufacturing an article in which the article comprises aerosol generating material and a support (30), is provided. The method comprises the steps of (a1) modifying at least a part of a surface (28) of the support to provide at least one modification area (42), or (a2) providing a support in which at least a part of a surface of the support has been modified to form at least one modification area; and (b) applying aerosol generating material to at least one application area (40) on the surface of the support, in which at least one application area is associated with at least one modification area.

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 an article in which the article comprises aerosol generating material and a support, in which the method comprises the steps of (a1) modifying at least a part of a surface of the support to provide at least one modification area,

(b) applying aerosol generating material to at least one application area on the surface of the support, in which at least one application area is associated with at least one modification area.

According to a second aspect of the present disclosure there is provided a method of manufacturing an article in which the article comprises aerosol generating material and a support, in which the method comprises the steps of (a2) providing a support in which at least a part of a surface of the support has been modified to form at least one modification area,

According to a third aspect of the present disclosure there is provided an article, in which the article comprises a support and aerosol generating material, a first surface of the support comprises at least one application area and at least one modification area, the surface of the support in at least one modification area is modified, and aerosol generating material is applied to at least one application area.

According to a fourth aspect of the present disclosure there is provided an aerosol provision device for use with a consumable formed from an article of the third aspect of the present disclosure, in which the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable.

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

According to a sixth aspect of the present disclosure there is provided a method of generating aerosol from a consumable formed from an article according to the third 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 ;

Figures 3 and 4 show the support of Figure 2 in the process of being surface treated according to a first embodiment of the method of the present disclosure; Figure 5 shows a section of the support of Figure 4 once a slurry comprising a binder and an aerosol former has been applied to the support along the line A-A’; Figure 6 shows a representative part of a support in a second embodiment of the method of the present disclosure;

Figure 7 shows a primary mask for use in the second embodiment of the method of the present disclosure; Figure 8 shows a secondary mask for use in the second embodiment of the method of the present disclosure;

Figure 9 shows the representative part of the support of Figure 6 after being surface treated according to a first embodiment of the method of the present disclosure;

Figure 10 shows the representative part of the support of Figure 9 once a slurry comprising a binder and an aerosol former has been applied to the support;

Figures 11 and 12 show a support in a third embodiment of the method of the present disclosure;

Figure 13 shows an exploded schematic view of an embodiment of a support and a sheet of a modification material according to a fourth embodiment of the present disclosure;

Figures 14 and 15 shows first and second views of the support and sheet of modification material of Figure 13 adhered to each other;

Figures 16 and 17 show sectional views of the support and sheet of modification material of Figure 15 along the line B-B’; and

Figure 17 shows an article according to a fifth embodiment of the present disclosure.

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 aerosol generating 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 non- combustible aerosol provision device and a consumable for use with the non- combustible 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 method of manufacturing an article in which the article comprises aerosol generating material and a support, in which the method comprises the steps of

(a1) modifying at least a part of a surface of the support to provide at least one modification area,

(b) applying aerosol generating material to at least one application area on the surface of the support, in which at least one application area is associated with at least one modification area. According to a second aspect of the present disclosure there is provided a method of manufacturing an article in which the article comprises aerosol generating material and a support, in which the method comprises the steps of (a2) providing a support in which at least a part of a surface of the support has been modified to form at least one modification area,

(b) applying aerosol generating material to at least one application area on the surface of the support, in which at least one application area is associated with at least one modification area. In this aspect the modification of the surface of the support can be performed at a different location and / or by a different party to the party who performs the remainder of the method.

In an embodiment of any of the above embodiments the article is shaped and dimensioned for use as a consumable for use with a non-combustible aerosol provision system I. In this embodiment the article acts as a consumable without any dimensional change.

In an embodiment of any of the above embodiments the article is larger than is compatible for use with a non-combustible aerosol provision system, in which the method further comprises a step of

(c) separating the article into two or more article portions, in which each article portion is shaped and dimensioned for use as a consumable for use with an apparatus for heating an aerosol generating material to volatilise at least one component of the aerosol generating material. In this embodiment, the article may be a unit of material that is larger or considerably larger than the size of a consumable for use with the apparatus for heating an aerosolisable material. Manufacturing the article larger than required and then separating that article into consumable sized article portions may give rise to easier and more efficient manufacturing techniques than making consumable sized articles. In an embodiment of any of the above embodiments the application of aerosol generating material of step (b) comprises application of a slurry of aerosol generating material.

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

(d) allowing or causing the aerosol generating material slurry to set, in which the aerosol generating material sets as aerosol generating material.

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

The aerosol generating material may comprise or be in the form of an aerosol generating film. The aerosol generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, 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 is thus a precursor to 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 modification of the surface of the support in the modification area comprises changing one or more characteristics of the surface of the support in that area. In some embodiments of the above embodiment the characteristic changed is the attraction or otherwise of the surface to water, that is the hydrophilicity or hydrophobicity of the surface.

The modification may be achieved by the addition of one or more layers or coatings of a modification material that will have the desired surface characteristics after application to the surface of the support in at least one modification area. The application may be achieved by known application techniques, for example but not limited to, by use of a brush, or spraying an aerosol of the substance.

In an embodiment of any of the above embodiments the application of a modification material to the surface of the support in step (a1) or (a2) comprises the application of a liquid, paste or gel of a material that will cause a desired modification to the surface of the support in at least one modification area.

In an embodiment of any of the above embodiments the method comprises a further step of (e) allowing or causing the liquid, paste or gel of the modification material to set or increase in viscosity.

In an embodiment of any of the above embodiments the application of a modification material to the surface of the support in step (a1) or (a2) comprises the application of a layer of a modification material.

In an embodiment of any of the above embodiments the layer of modification material is a sheet or film of modification material.

In an embodiment of any of the above embodiments the layer of modification material is adhered to the surface of the support.

In an embodiment of any of the above embodiments the layer of modification material comprises a substrate of adhesive on one surface of the layer and the layer of adhesive is placed against a surface of the support to form an attachment between the support and the layer of modification material.

In an embodiment of any of the above embodiments the layer of modification material is discontinuous. In an embodiment of any of the above embodiments the discontinuities in the layer of modification material correspond to the application areas. In some embodiments, the perimeters of the discontinuities are cut into a sheet of modification material, the whole sheet of modification material applied to the support, and the parts of the sheet within the perimeter of the discontinuities subsequently peeled off the surface of the support. In such an embodiment the adhesive adhering the sheet to the support is a releasable adhesive.

In an embodiment of any of the above embodiments the support comprises a susceptor.

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 and is a susceptor. 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 an 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 modification of at least one modification area in step (a1) or (a2) comprises application of a modification material to the surface of the support in at least one modification area. In some embodiments the application of the modification material may be via electrostatic coating techniques. In other embodiments the modification material may be applied as a thin film. In an embodiment of any of the above embodiments two or more layers of modification material may be applied to the surface of the support in at least one modification area.

In an embodiment of any of the above embodiments the modification of at least one modification area in step (a1) or (a2) comprises a process which results in modification of the surface of the support in at least one modification area. The process may activate the surface chemistry of the support or physically alter the surface of the support, such alterations may be at a microscopic scale.

In an embodiment of any of the above embodiments the process comprises plasma treatment of the surface of the support. The plasma treatment uses known techniques. An advantage of using plasma treatment techniques to modify the surface of the support is that such techniques are environmentally friendly and do not give rise to waste chemicals, can be fine tuned to provide the desired modification, do not require temperatures that may damage the support, and are economical.

In an embodiment of any of the above embodiments the modification of at least one modification area in step (a1) or (a2) causes the modified surface of the support to become hydrophobic.

In an embodiment of any of the above embodiments the hydrophobicity of the modification area after modification is greater than the hydrophobicity of the application area.

In an embodiment of any of the above embodiments at least one modification area with a hydrophobic surface is so positioned relative to an application area that it deters slurry applied to the application area from spreading away from that application area.

In an embodiment of any of the above embodiments at least one modification area of step (a1) or (a2) at least partially surrounds at least one application area. In an embodiment of any of the above embodiments at least one modification area of step (a1) or (a2) forms a band around an application area.

In some embodiments of the above embodiments a plurality of modification areas, each with a hydrophobic surface, are so positioned relative to an application area that they collectively deter slurry applied to the application area from spreading away from that application area.

These embodiments are advantageous because the hydrophobic nature of the surface of each modification area prevents the slurry from spreading onto that modification area. This can control the location of the slurry without any need to place other physical barriers to the flow of the slurry onto the surface of the support. A further advantage is that plasma treatment of the surface can be performed through a mask or template which allows accurate and I or complex shapes of modification areas to be formed on the surface of the support.

Once the slurry sets or at least partially dewaters (achieves a lower concentration of water) the viscosity of the remaining binder and other components will increase until an aerosol generating material in the form of an aerosol generating film which has more or less fixed dimensions is formed. The hydrophobic nature of the modification areas will then cease to have an effect on the shape of the aerosol generating film. The hydrophobic nature of the modification areas may, however, continue to be of use in the maintenance of the consumable because, when the consumable is in use and is being caused to generate aerosol in an aerosol generating device, it is possible that condensate will form within the aerosol generating device. If the condensate forms on the surface of the support it will not do so on the hydrophobic surface of the modification areas and will not readily flow across those areas. Thus the modification areas may prevent that condensate from reaching and soaking into not yet aerosolised aerosol generating film.

In an embodiment of any of the above embodiments at least one modification area with a hydrophobic surface is positioned on at least one part of the surface of the support where it is desired that there is no aerosol generating material. This will cause any aerosol generating material or precursor thereof not to flow into that area. It will also cause any aerosol generating material or precursor thereof that is accidentally deposited onto the area to be readily removable, for example by scraping because any bond formed between the aerosol generating material and surface of the modified area will be of low strength.

In an embodiment of any of the above embodiments the modification of at least one modification area in step (d) causes the modified surface of the support to become hydrophilic. An advantage of causing the surface of at least one modification area to be hydrophilic is that locating the slurry so that it is in at least partial contact with such a hydrophilic surface will cause water in the slurry to wick out of the slurry and onto the hydrophilic surface. The water may subsequently evaporate from the hydrophilic surface. This has the effect of assisting in the drying of the slurry during the manufacture of the consumable. It has been found that such wicking will continue until the water content of the slurry reaches a certain level, in some embodiments between around 10% and 40% by weight (wt%).

Causing the surface of at least one modification area to be hydrophilic also has the effect that after manufacture of the consumable but before the aerosol generating material is caused to generate aerosol, the wicking effect will occur if the water content of the aerosol generating material, which is a hygroscopic material and absorbs water from the atmosphere, increases. As a result, the hydrophilic surface of the at least one modification area helps prevent the aerosol generating material from reabsorbing and retaining too much water. If sufficient water is reabsorbed and retained, that water may damage the consumable and / or a user’s experience when using the consumable.

In an embodiment of any of the above embodiments, the method comprises a step of (f) embossing or debossing at least part of the support in at least one modification area, in which step (f) is performed after step (a1) or (a2) and before step (b). This has an advantage that the embossing or debossing can assist the prevention of the spread of aerosol generating material slurry when applied to the surface of the support. A further advantage is that the embossing or debossing can add structural rigidity to the support in at least one modification area.

In an embodiment of any of the above embodiments at least a part of at least one modification area of step (a1) or (a2) overlaps at least part of at least one application area. In some embodiments a part of at least one modification area overlaps a part of at least one application area. Such an overlap assists in the wicking of water out of the aerosol generating material slurry and onto a hydrophilic surface of at least one modification area.

In an embodiment of any of the above embodiments the method includes applying aerosol generating material to at least two application areas.

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

In an embodiment of any of the above embodiments the application areas of step (b) 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 the aerosol generating material applied to at least two application areas of step (b) have different compositions from each other. This has an 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 I 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 aerosol generating material applied to at least one application area of step (b) is of a shape and / or colour that is indicative of the composition of the aerosol generating material in that application area.

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.

According to a second aspect of the present invention there is provided an article, in which the article comprises a support and aerosol generating material, a first surface of the support comprises at least one application area and at least one modification area, the surface of the support in at least one modification area is modified, and aerosol generating material is applied to at least one application area.

In an embodiment of any of the above embodiments the article is shaped and dimensioned for use as a consumable for use with a non-combustible aerosol provision system.

In an embodiment of any of the above embodiments the article is larger than is compatible for use with a non-combustible aerosol provision system, in which each article portion is shaped and dimensioned for use as a consumable for use with an apparatus for heating an aerosol generating material to volatilise at least one component of the aerosol generating material.

In an embodiment of any of the above embodiments the support has a first surface and a second surface, and both of the first and second surfaces comprise at least one application area and at least one modification area, in which the surfaces of the support in at least one modification area on each of the first and second surfaces of the support are modified, and aerosol generating material is applied to at least one application area on each of the first and second surfaces of the support. In an embodiment of any of the above embodiments at least part of at least one modification area at least partially overlaps at least part of at least one application area.

In an embodiment of any of the above embodiments the at least one modification area has a modification material applied to the surface of the support in that at least one modification area.

In an embodiment of any of the above embodiments the modification material applied to the surface of the support is a liquid, paste or gel of a material that has set or increased in viscosity.

In an embodiment of any of the above embodiments the modification material applied to the surface of the support is a layer of modification material.

In an embodiment of any of the above embodiments layer of modification material applied to the surface of the support is a sheet or film of modification material.

In an embodiment of any of the above embodiments the layer of modification material is discontinuous.

In an embodiment of any of the above embodiments the discontinuities in the layer of modification material correspond to the application areas.

In an embodiment of any of the above embodiments the surface of at least one modification area is plasma coated. In an embodiment of any of the above embodiments the surface of at least one modification area is physically altered relative to the surface of the support on which that modification area is located and which is not in a modification area.

In an embodiment of any of the above embodiments the surface of at least one modification area is one or more of plasma cleaned, plasma surface activated, or plasma etched.

In an embodiment of any of the above embodiments at least one modification area has a surface that is hydrophilic.

In an embodiment of any of the above embodiments at least one modification area with a hydrophilic surface at least partially overlaps with at least one application area and the hydrophilic surface allows liquid such as water within the aerosol generating material applied to the application area to wick out of the aerosol generating material and onto the hydrophilic surface.

In an embodiment of any of the above embodiments the part of each modification area that does not overlap with an application area allows liquid such as water wicked from the aerosol generating material onto the hydrophilic surface to evaporate.

In an embodiment of any of the above embodiments at least one modification area has a surface that is hydrophobic.

In an embodiment of any of the above embodiments at least one modification area with a hydrophobic surface at least partially surrounds an application area.

In an embodiment of any of the above embodiments at least one application area has an outer perimeter, one or more modification areas with a hydrophobic surface collectively partially surround the application area perimeter, and the rest of the application area perimeter is surrounded by at least one modification area with a hydrophilic surface. Such an arrangement benefits from the advantages of the hydrophobic and hydrophilic areas as discussed above.

In an embodiment of any of the above embodiments at least one modification area has a hydrophobic surface and is located at a position on the support surface which is to be kept free of aerosol generating material.

In an embodiment of any of the above embodiments at least one application area is at least partially surrounded by at least one modification area.

In an embodiment of any of the above embodiments one or more application areas are surrounded by a modification area.

In an embodiment of any of the above embodiments one or more application areas are each surrounded by a modification area.

In an embodiment of any of the above embodiments each modification area forms a band around the application area it surrounds.

In an embodiment of any of the above embodiments at least one modification area of the support is embossed or debossed. The embossment or debossment may be over all or part f the modification area.

In an embodiment of any of the above embodiments the article comprises at least two application areas and aerosol generating material is applied to at least two application areas.

In an embodiment of any of the above embodiments the consumable comprises at least three application areas and aerosol generating material is applied to at least three application areas, and those application areas are in a grid pattern on the first surface of the support. In an embodiment of any of the above embodiments one or more of the application areas 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 the aerosol generating material applied to at least two application areas have different compositions from each other.

In an embodiment of any of the above embodiments the aerosol generating material applied to at least one application area is of a shape and I or colour that is indicative of the composition of the aerosol generating material.

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

In an embodiment of any of the above embodiments the susceptor forms the first surface of the support.

In an embodiment of any of the above embodiments the the susceptor is one of a metal, a metal alloy, a metal or metal alloy film, or a metal or metal alloy foil

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 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 gel which may or may not contain an active substance and/or flavourants.

The aerosol generating material comprises an aerosol former. 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 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.

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.

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 or 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 or 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 aerosol generating material comprising the aerosol generating material is formed and incorporated into an aerosol generating consumable as a sheet.

The aerosol generating material comprising 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 and 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 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 an article that is dimensionally of the desired size of a consumable 24 is formed. The consumable 24 comprises a support 30. The support 30 comprises a longitudinally extending sheet of a 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 36 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 first layer 36 may act as a susceptor when the consumable 24 is used in connection with an aerosol generator 10 in the form of a magnetic field generator.

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 may be handled and used without being damaged.

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.

It is identified that on the first surface 28 six application areas 40 and six modification areas 42 are to be formed. Each application area 40 is surrounded by a modification area 42.

In Figure 2 the application areas 40 and modification areas 42 are shown as being rectangular. The actual shape of the outer perimeters of the application areas 40 and modification areas 42 may be different without departing from the scope of the present disclosure. For example, the application areas 40 may be, 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.

To create the application areas 40 and modification areas 42, and with reference to Figure 3, first masks 50 are applied to and removably fixed to each of the application areas 40. A second mask 52 includes six apertures 54. The second mask 52 is so dimensioned and configured that may be removably fixed to and cover most or all of the first surface 28 of the support 30 with the edges of the second mask 52 that define apertures 54 overlying the outer perimeters of the modification areas 42. A surface coating 56 (shown in Figure 4) is then sprayed over the combined first and second masks 50, 52 and support 30. The coating 56 coats the surface of modification areas 42.

As shown in Figure 4, once the coating 56 has stabilized, for example by drying, first and second masks 50, 52 are removed from surface 28 to leave coatings 56 overlying (and thus modifying) modification areas 42. The reminder of the first surface 28 is unmodified. The coating 56 is selected to provide a hydrophobic surface. As a result, the surface of modified areas 42 is now hydrophobic.

With reference to Figure 5 which shows a cross section of the support 30 of Figure 4, a nozzle 60 is connected to a reservoir (not shown) of a slurry comprising a binder and an aerosol former.

The nozzle 60 applied a predetermined quantity of slurry 58 to each application area 40. The slurry 58 spreads across each application area 40 but, because of the hydrophobic nature of the coating 56, the slurry 58 does not flow onto the surface coating 56. The slurry is now left to set or is caused to set by known slurry seting means.

In alternative, non-illustrated examples of the method of the present disclosure, the application areas 40 may be of different shapes. In those examples the slurry 58 will flow to occupy those shapes assuming that the shapes do not include such small dimensions that the surface tension or viscosity of the slurry 58 prevents the flow of the slurry 58 into the full shape.

Once the slurry 58 is dry, the support 30 may be used as a consumable 24 in an aerosol generating device 2. Alternatively, the support 30 can now be separated into a plurality of smaller units that can be used as consumables 24.

In an alternative embodiment of Figure 5, there may be two or more nozzles 60 each of which is connected to a different slurry reservoir (not shown). In each reservoir is a slurry of a different composition, for example containing different flavourants and or of different colours. Portions of different composition slurry may be applied to different application areas 40 on the support 30. In such embodiments, the different application areas 40 can be of different shapes to indicate that different composition slurry are applied to the different application areas 40.

With reference to Figure 6 an article that is dimensionally of the desired size of a consumable is formed. Figure 6 shows a representative part of a support 130 in an alternative embodiment of the method of the present disclosure. On that representative part, an application area 40 and first and second modification areas 42A, 42B are identified on the first surface 128 of the support 130. The support 130 as a whole contains a plurality of other application and modification areas 40, 42A, 42B in the same arrangement as the illustrated arrangement.

With reference to Figure 7 a primary mask 150 is provided. The primary mask is comprised of a sheet of material 162 which is dimensioned and shaped so that the outer edge of the sheet 162 (the minor surface that extends between the major surfaces) is of the same dimensions and shape as the outer edge of the support 130. The primary mask 150 is in a use position when it is laid onto the surface 128 of the support 130 and the edges of the sheet 162 and of the support 130 are aligned.

The sheet 162 defines a plurality of apertures 154 (for clarity, not all of apertures 154 are labelled). The plurality of apertures 154 are so located on the sheet 162 that when the primary mask 150 is in the use position, the apertures 154 overlie the intended positions of a plurality of first modification areas 42A.

Once the primary mask 150 is in the use position, the support 130 and primary mask 150 are subject to a plasma coating treatment in which the coating being deposited on the first surface 128 by the plasma coating treatment is a hydrophobic coating. This forms a plurality of hydrophobic areas 142A some of which are shown in Figure 9. As shown in Figure 9, the application area 40 is partially surrounded by four hydrophobic areas 142A. The same arrangement is associated with each application area 40 on the first surface 128. With reference to Figure 8, a secondary mask 152 is next provided. The secondary mask is comprised of a sheet of material 164 which is dimensioned and shaped so that the outer edge of the sheet 164 (the minor surface that extends between the major surfaces) is of the same dimensions and shape as the outer edge of the support 130. The secondary mask 152 is in a use position when it is laid onto the surface 128 of the support 130 and the edges of the sheet 164 and of the support 130 are aligned.

The sheet 164 defines a plurality of apertures 166 (for clarity, not all of apertures 166 are labelled). The plurality of apertures 166 are so located on the sheet 164 that when the secondary mask 152 is in the use position, the apertures 166 overlie the intended positions of a plurality of second modification areas 42B.

Once the secondary mask 152 is in the use position the support 130 and secondary mask 152 are subject to a plasma coating treatment in which the coating being deposited on the first surface 128 by the plasma coating treatment is a hydrophilic coating. This forms a plurality of hydrophilic areas 142B as shown in Figure 9.

In other embodiments of Figure 8, the surface of the modification areas 42B is physically altered relative to the first surface 128 of the support in those areas of surface 128 which are not in a modification area 42A, 42B. That alteration may be the result of one or more of plasma cleaning, plasma surface activation, or plasma etching.

As shown in Figure 9, the application area 40 is partially surrounded by four hydrophilic areas 142B. The Hydrophilic areas 142B extend between adjacent hydrophobic areas 142A and collectively the hydrophobic and hydrophilic areas 142A, 142B fully surround the application area 40.

The hydrophilic areas 142B each have an end portion 168A (for clarity only one end portion 168A is labelled). Each end portion 168A overlaps a part of the application area 40. The arrangement shown in Figure 9 is associated with each application area 40 on the first surface 128.

With reference to Figure 10, a nozzle (not shown) is connected to a reservoir (not shown) of a slurry 58.

The nozzle applies a predetermined quantity of slurry 58 to the application area 40. The slurry 58 spreads across the application area 40 but, because of the hydrophobic nature of the coated areas 142A, the slurry 58 does not flow onto the hydrophobic areas 142A. The slurry 58 flows onto the end portions 168A of the hydrophilic area 142B because of the attractiveness of that hydrophilic surface to the water in the slurry 58. The slurry 58 does not, however flow over stem portions 168B or base portions 168C of the hydrophilic surfaces 142. This is because the gap between adjacent hydrophobic areas 142A (which is occupied by the stem portion 168B of the hydrophilic area 142B) is so dimensioned that the surface tension or viscosity of the slurry 58 will prevent the slurry 58 flowing into that gap and along the stem portion 168B.

The slurry 58 is now left to set or is caused to set by known slurry setting means. At least a part of that setting will be caused by water wicking out of the slurry 58 along stem portion 168B and onto base portion 168C of the hydrophilic area 142B. The water can evaporate off the stem portion 168B and base portion 168C of the hydrophilic area 142B. The wicking of water from the slurry 58 continues until the slurry 58 is no longer a slurry but is an aerosol generating film of more or less fixed dimensions. Typically this is when the aerosol generating material has a water content of between 10 and 40 wt%, for example around 10 wt%.

This wicking pathway of stem portion 168B and base portion 168C of the hydrophilic area 142B remains in place after the consumable 124 of this embodiment of the present disclosure has been manufactured. As a result, the wicking pathway may wick out of the aerosol generating film at least some of any water that the aerosol generating film absorbs between manufacture and use of the consumable to aerosolise that aerosol generating film.

In alternative, non-illustrated examples of the method of the present disclosure, the application areas 40 may be of different shapes. In those examples the slurry 58 will flow to occupy those shapes assuming that the shapes do not include such small dimensions that the surface tension or viscosity of the aerosol generating material slurry prevents the flow of the slurry into the full shape.

Once the slurry 58 is set, the article may be used as a consumable in an aerosol generating device 2. Alternatively, the article can now be separated into a plurality of smaller units or article portions that can be used as consumables.

With reference to Figures 11 and 12, these Figures show an article that is dimensionally of the desired size of a consumable in an alternative embodiment of the method of the present disclosure. The support 230 has a first surface 228A which is shown in Figure 11 , and a second surface 228B which is shown in Figure 12.

The first surface 228A includes two ring shaped application areas 240A, a first modification area 242A, and two second modification areas 242B. The first modification area 242A covers all of the surface 228A that is outside of the radially outer perimeter of the application areas 240A. The second modification areas 242B are defined by the radially inner perimeters of the application areas 240A.

The whole of the support 230 is embossed or debossed with parallel ridges 270, 272. The parallel ridges 270 are approximately perpendicular to parallel ridges 272. The ridges 270, 272, add rigidity to the support 230. This has an advantage that the support may be thinner than a support that is not embossed I debossed of the same rigidity. For clarity only one ridge 270 and 272 are labelled. The second surface 228B includes two circular application areas 240C, and a third modification area 242C. The third modification area 242C covers all of the surface 228B that is outside of the perimeter of the application areas 240C.

The first, second and third modification areas 242A, 242B, 242C have been modified to have a hydrophobic surface by use of a plasma coating technique. The surface of the application areas 240A, 240B is not treated and is thus physically different from the surface of first, second and third modification areas 242A, 242B, 242C.

A slurry 58 has been applied to the application areas 240A, 240B. For application areas 240A the second modification areas 242B keep the slurry 58 from spreading into the middle of the ring of the application areas 240A.

Once the slurry 58 is dry, the article may be used as a consumable in an aerosol generating device 2.

With reference to Figure 13, to commence the production of a consumable 324 an article that is dimensionally of the desired size of a consumable is formed. The article comprises a support 330 and a sheet of modification material 374. The support 330 comprises a longitudinally extending sheet of a laminate material which includes first and second layers 336, 338. The first layer 336 has a surface that is first surface 328, and is comprised of a sheet of aluminium foil. The first layer 336 is less than 0.025 mm thick. In other non-illustrated embodiments the material of first layer 336 may be an aluminium alloy or a different suitable material such as a different metal or metal alloy. The first layer 336 may act as a susceptor when the consumable 324 is used in connection with an aerosol generator 10 in the form of a magnetic field generator.

The second layer 338 is formed of card. The second layer 338 is sufficiently rigid that it supports the first layer and provides a support that may be handled and used without being damaged. The length and width of the support 330 as shown in Figures 13 to 15 is for illustrative purposes only. The support 330 may have different lengths and widths without departing from the scope of the present disclosure.

The sheet 374 is a longitudinally extending sheet of a material that has at least one hydrophobic surface. The sheet has two major surfaces 376, 378. The first major surface 376 is coated with an adhesive (not shown) and dimensionally of approximately the same dimensions as surface 328 of the support 330. Major surface 376 is adapted to be adhered to surface 328 of the support 330. The adhesive is a releasable adhesive.

Extending between or substantially between the major surfaces 376, 378 of the sheet 374 are cut lines 380. The cut lines 380 are so located that the cut lines 380 coincide with the perimeters of intended application areas 340 when, as is shown in Figure 14, the sheet 374 is adhered to the support 330.

With reference to Figure 15, once the sheet 374 has been adhered to the support 330, the portions of the sheet 374 that are within the cut lines 280 are peeled off the surface 328 of the support 330 to expose application areas 340 on the surface 328 of the support 330. In alternative non-illustrated embodiments, the portions of the sheet 374 within the cut lines 380 are removed before the sheet 374 is adhered to the support 30. The desirability or otherwise of that alternative embodiment will depend on the layout and spacing of the cut lines 380 and how handleable the sheet 34 is once those portions have been removed,

With reference to Figures 16 and 17, once the application areas 340 have been exposed, an aerosol generating material slurry 58 is applied to each application area 340. As illustrated in Figure 15, the slurry 58 does not flow onto the surface 378 of the sheet 374 but forms a meniscus above each application area 340. This is because of the hydrophobic nature of the surface of the sheet 374. The slurry 58 is thus retained in the position it is desired for the slurry to remain. As the slurry 58 dries, the volume of the slurry reduces and the slurry is thereafter referred to as aerosol generating material 58. As illustrated in Figure 17, the meniscus of the slurry 58 reduces as the slurry dries to become aerosol generating material 58.

The article is now a consumable 324 and is ready to be used.

In other, non-illustrated embodiments of the present disclosure the combined support 330 and sheet 374 may be manufactured from a third party. The performer of the method of the present disclosure may then purchase the combined support 330 and sheet 374 and perform the rest of the method. In some examples the sheet 374 may not include any cut lines when it is applied to the support 330. Cut lines may be subsequently introduced, for example by use of kiss cutting techniques.

With reference to Figure 17, the consumable 324 as discussed in connection with Figures 13 to 16 is the result of an article of the same dimensions as the desired dimensions for a consumable. The article 482 is larger than the desired dimensions for a consumable. In Figure 17 the article 482 is shown to be of a size that cutting the article with a known cutting means (not shown) along separation paths 484 creates eighteen article portions or consumables 324. It will be understood that the article 482 can be of different dimensions.

The article 482 is created in the same way as is described in connection with the consumable 324 as discussed in connection with Figures 13 to 16.

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

- 53 -

Claims

1 A method of manufacturing an article in which the article comprises aerosol generating material and a support, in which the method comprises the steps of (a1) modifying at least a part of a surface of the support to provide at least one modification area,

2 A method of manufacturing an article in which the article comprises aerosol generating material and a support, in which the method comprises the steps of (a2) providing a support in which at least a part of a surface of the support has been modified to form at least one modification area,

3 A method according to claim 1 or 2 in which the article is shaped and dimensioned for use as a consumable for use with an a non-combustible aerosol provision system.

4 A method according to claim 1 or 2 in which the article is larger than is compatible for use with a non-combustible aerosol provision system, in which the method further comprises a step of

(c) separating the article into two or more article portions, in which each article portion is shaped and dimensioned for use as a consumable for use with an apparatus for heating an aerosol generating material to volatilise at least one component of the aerosol generating material. - 54 -

5 A method according to any of claims 1 to 4 in which the application of aerosol generating material of step (b) comprises application of a slurry of aerosol generating material.

6 A method according to claim 5 in which the method further comprises a step

7 A method according to any of claims 1 to 6 in which the aerosol generating material is an aerosol generating film.

8 A method according to any of claims 1 to 7 in which the modification of at least one modification area in step (a1) or (a2) comprises application of a modification material to the surface of the support in at least one modification area.

9 A method according to claim 8 in which the application of a modification material to the surface of the support in step (a1) or (a2) comprises the application of a liquid, paste or gel of a material that will cause a desired modification to the surface of the support in at least one modification area.

10 A method according to claim 9 in which the method comprises a further step of

(e) allowing or causing the liquid, paste or gel to set or increase in viscosity.

11 A method according to claim 8 in which the application of a modification material to the surface of the support in step (a1) or (a2) comprises the application of a layer of a modification material.

12 A method according to claim 11 in which the layer of modification material is a sheet or film of modification material.

13 A method according to claim 11 or 12 in which the layer of modification material is adhered to the surface of the support. - 55 -

14 A method according to claim 13 in which the layer of modification material comprises a substrate of adhesive on one surface of the layer and the layer of adhesive is placed against a surface of the support to form an attachment between the support and the layer of modification material.

15 A method according to any of claims 11 to 14 in which the layer of modification material is discontinuous.

16 A method according to claim 15 in which the discontinuities in the layer of modification material correspond to the application areas.

17 A method according to any of claims 1 to 16 in which the modification of at least one modification area in step (a1) or (a2) comprises a process which results in modification of the surface of the support in at least one modification area.

19 A method according to claim 17 in which the process comprises plasma treatment of the surface of the support.

20 A method according to any of claims 1 to 19 in which the modification of at least one modification area in step (a1) or (a2) causes the modified surface of the support to become hydrophilic.

21 A method according to any of claims 1 to 20 in which the modification of at least one modification area in step (a1) or (a2) causes the modified surface of the support to become hydrophobic.

22 A method according to any of claims 1 to 21 in which the hydrophobicity of the modification area after modification is greater than the hydrophobicity of the application area.

23 A method according to claim 21 or 22 when dependent on claim 5 or any of claims 6 to 20 when dependent on claim 5 in which at least one modification area - 56 - with a hydrophobic surface is so positioned relative to an application area that it deters slurry applied to the application area from spreading away from that application area.

24 A method according to any of claims 21 to 23 in which at least one modification area with a hydrophobic surface is positioned on at least one part of the surface of the support where it is desired that there is no aerosol generating material.

25 A method according to any of claims 1 to 24 in which at least one modification area of step (a1) or (a2) at least partially surrounds at least one application area.

26 A method according to any of claims 1 to 25 in which at least one modification area of step (a1) or (a2) forms a band around an application.

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

(f) embossing or debossing at least part of the support in at least one modification area, in which step (f) is performed after step (a1) or (a2) and before step (b).

28 A method according to any of claims 1 to 27 in which at least a part of at least one modification area of step (a1) or (a2) overlaps at least part of at least one application area.

29 A method according to any of claims 1 to 28 in which step (b) comprises applying aerosol generating material to at least two application areas.

30 A method according to claim 29 in which the application of aerosol generating material of step (b) comprises application of aerosol generating material to three or more application areas, and those application areas are in a grid pattern on the first surface of the support. 31 A method according to any of claims 1 to 30 in which one or more of the application areas of step (b) 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.

32 A method according to any of claims 1 to 31 in which the aerosol generating material applied to at least two application areas of step (b) have different compositions from each other.

33 A method according to any of claims 1 to 32 in which the aerosol generating material applied to at least one application area of step (b) is of a shape and I or colour that is indicative of the composition of the aerosol generating material in that application area.

34 An article, in which the article comprises a support and aerosol generating material, a first surface of the support comprises at least one application area and at least one modification area, the surface of the support in at least one modification area is modified, and aerosol generating material is applied to at least one application area.

35 An article according to claim 34 in which the article is shaped and dimensioned for use as a consumable for use with a non-combustible aerosol provision system.

36 An article according to claim 35 in which the article is larger than is compatible for use with a non-combustible aerosol provision system, the article is separable into two or more article portions, in which each article portion is shaped and dimensioned for use as a consumable for use with an apparatus for heating an aerosol generating material to volatilise at least one component of the aerosol generating material. 37 An article according to any of claims 34 to 36 in which the support has a first surface and a second surface, and both of the first and second surfaces comprise at least one application area and at least one modification area, in which the surfaces of the support in at least one modification area on each of the first and second surfaces of the support are modified, and aerosol generating material is applied to at least one application area on each of the first and second surfaces of the support.

38 An article according to any of claims 34 to 37 in which at least part of at least one modification area at least partially overlaps at least part of at least one application area.

39 An article according to any of claims 34 to 38 in which at least one modification area has a modification material applied to the surface of the support in that at least one modification area.

40 An article according to claim 39 in which the modification material applied to the surface of the support is a liquid, paste or gel of a material that has set or increased in viscosity.

41 An article according to claim 39 in which the modification material applied to the surface of the support is a layer of modification material.

42 An article according to claim 41 in which the layer of modification material applied to the surface of the support is a sheet or film of modification material.

43 An article according to claim 41 or 42 in which the layer of modification material is adhered to the surface of the support.

44 An article according to any of claims 41 to 43 in which the layer of modification material is discontinuous. - 59 -

45 An article according to claim 44 in which the discontinuities in the layer of modification material correspond to the application areas.

46 An article according to any of claims 34 to 45 in which the surface of at least one modification area is plasma coated.

47 An article according to any of claims 34 to 46 in which the surface of at least one modification area is physically altered relative to the surface of the support on which that modification area is located and which is not in a modification area.

48 An article according to claim 47 in which the surface of at least one modification area is one or more of plasma cleaned, plasma surface activated, or plasma etched.

49 An article according to any of claims 34 to 48 in which at least one modification area has a surface that is hydrophilic.

50 An article according to claim 49 in which at least one modification area with a hydrophilic surface at least partially overlaps with at least one application area and the hydrophilic surface allows water within the aerosol generating material applied to the application area to wick out of the aerosol generating material and onto the hydrophilic surface.

51 An article according to claim 50 in which the part of each modification area that does not overlap with an application area allows water wicked from the aerosol generating material onto the hydrophilic surface to evaporate.

52 An article according to any of claims 34 to 51 in which at least one modification area has a surface that is hydrophobic.

53 An article according to claim 52 in which at least one modification area with a hydrophobic surface at least partially surrounds an application area. - 60 -

54 An article according to claim 52 or 53 when dependent on any of claims 49 to 51 in which at least one application area has an outer perimeter, one or more modification areas with a hydrophobic surface collectively partially surround the application area perimeter, and the rest of the application area perimeter is surrounded by at least one modification area with a hydrophilic surface.

55 An article according to any of claims 52 to 54 in which at least one modification area has a hydrophobic surface and is located at a positon on the support surface which is to be kept free of aerosol generating material.

56 An article according to any of claims 34 to 55 in which at least one application area is at least partially surrounded by at least one modification area.

57 An article according to any of claims 34 to 56 in which one or more application areas are surrounded by a modification area.

58 An article according to any of claims 34 to 57 in which one or more application areas are each surrounded by a modification area.

59 An article according to claim 58 in which each modification area forms a band around the application area it surrounds.

60 An article according to any of claims 34 to 59 in which in at least one modification area of the support is embossed or debossed.

61 An article according to any of claims 34 to 60 in which the article comprises at least two application areas and aerosol generating material is applied to at least two application areas.

62 An article according to any of claims 34 to 61 in which the article comprises at least three application areas and aerosol generating material is applied to at least three application areas, and those application areas are in a grid pattern on the first surface of the support. - 61 -

63 An article according to any of claims 34 to 62 in which one or more of the application areas 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.

64 An article according to any of claims 34 to 63 in which the aerosol generating material applied to at least two application areas have different compositions from each other.

65 An article according to any of claims 34 to 64 in which the aerosol generating material applied to at least one application area is of a shape and I or colour that is indicative of the composition of the aerosol generating material.

66 An article according to any of claims 34 to 65 in which the aerosol generating material is an aerosol generating film or an aerosolisable gel.

67 An article according to any of claims 34 to 66 in which the support comprises a susceptor.

68 An article according to claim 67 in which the susceptor forms the first surface of the support.

69 An article according to claim 67 or 68 in which the susceptor is one of a metal, a metal alloy, a metal or metal alloy film, or a metal or metal alloy foil.

70 An aerosol provision device for use with a consumable formed from an article according to any of claims 34 to 69, in which the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable. - 62 -

71 An aerosol provision system comprising an aerosol provision device according to claim 70 and a consumable formed from an article according to any of claims 34 to 69. 72 A method of generating aerosol from a consumable formed from an article according to any of claims 34 to 69 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.