EP4620336A1

EP4620336A1 - Aerosol generating material product

Info

Publication number: EP4620336A1
Application number: EP24165700.6A
Authority: EP
Inventors: John Richardson; Dorcas JONES; Glynn SIMS; Martin DAW; Philip HYDE
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2024-03-22
Filing date: 2024-03-22
Publication date: 2025-09-24
Also published as: WO2025195988A1

Abstract

An apparatus (2) for use in the manufacture of a product in which the product comprises aerosol generating material gel supported on a first surface of a support (8) is disclosed. The apparatus is configured to provide a path along which the support may travel in a first direction (14) and which comprises in order in the first direction a converging position (26), an application position (28), and a diverging position (30). The apparatus comprises a support drive (40) which is configured to move the support along the path in the first direction, a stencil (18), and a fluid aerosol generating material application means (24). The apparatus is configured to cause at least a portion of the stencil to overlie the first surface (46) of the support and travel at the same speed as the support along the path from the converging position to the diverging position. The application means is configured to apply fluid aerosol generating material to the first surface of the support and stencil as the support and stencil pass through the application position on the path.

Description

Technical Field

The present invention relates to an aerosol generating material product, a method of manufacturing an aerosol generating material product, and apparatus for manufacturing an aerosol generating material product.

Background

Aerosol generating material products are used in aerosol provision systems which generate an aerosol for a user to inhale. Aerosol provision systems which generate an aerosol for a user to inhale are well known in the art. Such systems are generally battery powered and contain an aerosol provision device comprising the battery and an aerosol generator, and an article which includes aerosol generating material. Such an article is sometimes known as a consumable. The article may comprise an aerosol generating material product, or be formed from part of an aerosol generating material product.
The aerosol can be generated in a variety of ways. For example, the aerosol may be generated by heating a substrate that includes or is formed from an aerosol generating material to form a vapour which subsequently condenses in passing air so to form a condensation aerosol. Alternatively, the aerosol might be generated by mechanical means, vibration etc., so that the substrate becomes dispersed in passing air so as to form an aerosol.

Summary

According to a first aspect of the present disclosure there is provided an apparatus for use in the manufacture of a product in which the product comprises aerosol generating material supported on a first surface of a support, in which the apparatus is configured to provide a path along which the support may travel in a first direction and which comprises in order in the first direction a converging position, an application position, and a diverging position;

in which the apparatus comprises a support drive which is configured to move the support along the path in the first direction, a stencil, and a fluid aerosol generating material application means;
in which the apparatus is configured to cause at least a portion of the stencil to overlie the first surface of the support and travel at the same speed as the support along the path from the converging position to the diverging position, and the application means is configured to apply fluid aerosol generating material to the first face of the support and stencil as the support and stencil pass through the application position on the path.

According to a second aspect of the present disclosure there is provided a stencil for use in the manufacture of a product in which the product comprises aerosol generating material supported on a first surface of a support, in which the stencil comprises a sheet material and defines one or more apertures, in which one or more apertures are configured to produce a desired shape of aerosol generating material supported on a first surface of a support.
According to a third aspect of the present disclosure there is provided a method of manufacturing a product which comprises an aerosol generating material supported on a first surface of a support, in which the method comprises

providing a longitudinally extending support,
providing a stencil,
providing a path along which the support may travel, the path comprising in order in the first direction of travel a converging position, an application position, and a diverging position,
overlying a first surface of the support with the stencil at the converging position on the path,
moving the support and stencil from the converging position to the diverging position via the application position,
applying aerosol generating fluid to the stencil and first portions of the first surface of the support exposed by the stencil at the application position,
moving the support and stencil to the divergent position, and separating the stencil from the support.

According to a fourth aspect of the present disclosure there is provided a method of manufacture of an article which comprises aerosol generating material for use in an aerosol provision device, in which the method comprises providing a product manufactured according to the method of the third aspect of the present disclosure, and cutting the product into an appropriate size for use in an article.
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 a first embodiment of the apparatus of the present disclosure;
Figure 2 shows a schematic view of a first detail of the apparatus of Figure 1;
Figure 3 shows a schematic view of a second detail of the apparatus of Figure 1;
Figure 4 shows a schematic view of a third detail of the apparatus of Figure 1; and
Figure 5 shows a schematic view of a detail of a second embodiment of the apparatus of the present disclosure.

Detailed Description

In an embodiment of the above embodiment, the apparatus is configured to cause the stencil to move toward and into contact with the first surface of the support at the converging position.
In an embodiment of any of the above embodiments, the apparatus is configured to cause the stencil to move away from and out of contact with the first surface of the support at the diverging position.
In an embodiment of any of the above embodiments, the support is a longitudinally extending support.
In an embodiment of any of the above embodiments, the support is a flexible sheet material suitable for supporting aerosol generating material, and for use in an aerosol provision device as an article or as part of an article.
In an embodiment of any of the above embodiments, the support comprises a susceptor, for example, but without limitation, a metal foil such as aluminum foil.
In an embodiment of any of the above embodiments, the support is a laminate. In some embodiments the laminate includes a metal foil and paper.
In an embodiment of any of the above embodiments, the apparatus includes one or more surfaces, rollers and / or other suitable features that, in combination, guide the support along the path at least between the converging position, application position, and diverging position.
The apparatus is so configured that, when the apparatus is operating, a support is moved along the path in the first direction. References herein to upstream and downstream are relative to that first direction and a support or portion of support that travels along the path in the first direction moves from an upstream position to a downstream position.
In an embodiment of any of the above embodiments, the longitudinally extending support is of a sufficient longitudinal dimension that at any given time in the operation of the apparatus, only a portion of the support is moving between the converging and diverging positions.
In an embodiment of any of the above embodiments, the path followed by the support starts at a store of support, for example a roll of support, and terminates downstream of the diverging position.
In an embodiment of any of the above embodiments, the support drive is configured to pull the support along the path from a position downstream of the diverging position.
In an embodiment of any of the above embodiments, the support drive is configured to contact the support to move / drive the support along the path at one or more positions along the path followed by the support.
In an embodiment of any of the above embodiments, the stencil includes a stencil sheet. The stencil sheet defines one or more apertures that extend through the stencil sheet between the major surface of the stencil sheet. One or more or all of those apertures are each so configured that when the apparatus of present disclosure is in use, the stencil causes the deposition of fluid aerosol generating material trough the apertures and on to the first surface of the support in the desired shape and position or positions.
The major surfaces of the stencil sheet are the surfaces that have the largest surface area and which are separated from each other by the material that forms the stencil sheet.
An advantage of the use of the stencil is that the apertures in the stencil are the size of the desired aerosol generating material that is to be left on the support sheet. This is in contract to normal screen printing techniques in which the aerosol generating material would be forced through the mesh of the screen. This allows the aerosol generating material to include constituents, for example shreds or flakes of tobacco, that would not pass through the mesh used in screen printing techniques.
In an embodiment of any of the above embodiments, the stencil is formed from a flexible sheet material.
In an embodiment of any of the above embodiments, the stencil is longitudinally extending.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 2.0 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 1.0 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.9 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.8 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.7 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.6 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.5 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.4 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.3 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.2 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is selected to provide a desired thickness of the fluid aerosol generating material deposited on the first surface of the support. It is an advantage that the stencil allows accurate control of the thickness of the fluid aerosol generating material deposited on the first surface of the support.
In an embodiment of any of the above embodiments, the stencil includes a stainless steel.
In an embodiment of any of the above embodiments, the stencil is formed from a stainless steel. It is an advantage to use stainless steel because of its low reactivity with the fluid aerosol generating material. It is a further advantage that the stencil will have a desirable length of working life because of the resistance of stainless steel to damage.
In an embodiment of any of the above embodiments, the stencil is a continuous loop. That is the stencil is formed from a portion of flexible material that extends between a first and a second end, and the first and second ends are joined to each other to form a continuous loop of stencil.
In an embodiment of any of the above embodiments, the apparatus is so configured that when the stencil is a continuous loop, a portion of the loop follows the same path as the support between the converging and diverging positions. The rest of the loop follows a stencil path that takes a portion of the stencil from the diverging position to the converging position along a loop return path.
In an embodiment of the above embodiment, the apparatus includes a stencil cleaning means, and the stencil cleaning means cleans the stencil as it follows at least a portion of the loop return path. The cleaning includes removal of any aerosol generating material adhering to the stencil.
In an embodiment of any of the above embodiments, the stencil is longitudinally extending and the apparatus is configured to have the stencil follow a path which extends from an initial stencil store, for example a roll of stencil, along a path that includes following the same path as the support between the converging and diverging positions, and to a second stencil store.
In an embodiment of any of the above embodiments, the stencil includes one or more apertures. One or more or all of those apertures are so configured that when the apparatus of present disclosure is in use, the stencil causes the deposition of fluid aerosol generating material gel on the first surface of the support in the desired shape and position or positions.
In an embodiment of any of the above embodiments, the apparatus comprises a stencil drive, in which the stencil drive is configured to move at least a portion of the stencil along the path in the first direction from the converging position to the diverging position.
In an embodiment of any of the above embodiments, the stencil is moved along the path between the converging and diverging positions by the support drive.
In an embodiment of any of the above embodiments, the stencil has a first and a second surface, and the first and second surfaces are the major surfaces of the stencil.
In an embodiment of any of the above embodiments, the first surface of the stencil is in contact with the first surface of the support when the stencil overlies the support as the support travels along the path between the converging and diverging positions.
In an embodiment of any of the above embodiments, the fluid aerosol generating material application means includes a fluid aerosol generating material reservoir and an application means. The application means may be any suitable known application means.
In an embodiment of any of the above embodiments, the application means is configured to apply fluid aerosol generating material to the second surface of the stencil and, through one or more apertures in the stencil, the first surface of the support and as the support and stencil pass through the application position on the path.
In an embodiment of any of the above embodiments, the application means comprises a doctor blade. In this embodiment the doctor blade both scrapes fluid aerosol generating material off the second surface of the stencil, and helps to ensure that the volume defined by the first surface of the support and the edges of the stencil that define each aperture in the stencil are filled with the fluid aerosol generating material. That filling is up to and level with the second surface of the stencil.
In an embodiment of any of the above embodiments, the apparatus comprises a support bed, and the support bed is configured to at least partially provide support to the support and stencil as they travel along the path between the application position and the divergent position.
In an embodiment of any of the above embodiments, the support bed is configured to accelerate the gelification of the fluid aerosol generating material.
In an embodiment of the above embodiment, the support bed is configured to heat the support and stencil as the support and stencil travel across the support bed.
In an embodiment of any of the above embodiments, the apparatus comprises a means configured to maintain the relative positions of the support and the stencil as the support and stencil travel along the path from the converging position to the diverging position.
In an embodiment of any of the above embodiments, the apparatus comprises an indexing means configured to maintain the same speed for the support and the stencil as the support and stencil travel along the path from the converging position to the diverging position.
In an embodiment of any of the above embodiments, the indexing means comprises index apertures in the support and stencil which are physical linked whilst the the support and stencil travel along the path from the converging position to the diverging position.
In an embodiment of any of the above embodiments, the apparatus is configured to cause the period of time for the stencil and support to travel between the application position and the diverging position is sufficient for fluid aerosol generating material applied to the first surface of the support to cure sufficiently that when the stencil moves away from the support at the diverging position the fluid aerosol generating material is dimensionally stable.
In an embodiment of the above embodiment, the speed at which a given position on the support and stencil travel between the application position and the diverging position is selected to result in the time taken for that movement of the position to take a predetermined period of time.
In an embodiment of any of the above embodiments, the ambient conditions to which a given position on the support and stencil is exposed whilst travelling between the application position and the diverging position are selected to result in the fluid aerosol generating material achieving a predetermined amount of dimensional stability during the time taken for that position to move from the application position to the diverging position.
In an embodiment of the above embodiment, the ambient conditions surrounding the support and stencil may be one or more of the temperature, humidity, or exposure to electromagnetic radiation in one or more ranges in the electromagnetic spectrum, for example microwave or infrared radiation.
According to a second aspect of the present disclosure there is provided a stencil for use in the manufacture of a product in which the product comprises aerosol generating material gel supported on a first surface of a support, in which the stencil comprises a sheet material and defines one or more apertures, in which one or more apertures are each configured to produce a desired shape of fluid aerosol generating material gel supported on a first surface of a support.
In an embodiment of any of the above embodiments, the stencil is one or both of longitudinally extending, and formed from a flexible sheet material.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 2.0 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 1.0 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.9 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.8 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.7 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.6 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.5 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.4 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.3 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.2 mm.
In an embodiment of any of the above embodiments, the stencil includes a stainless steel.
In an embodiment of any of the above embodiments, the stencil is formed from a stainless steel.
In an embodiment of any of the above embodiments, the stencil is a continuous loop. That is the stencil is formed from a portion of flexible material that extends between a first and a second end, and the first and second ends are joined to each other to form a continuous loop of stencil.
According to a third aspect of the present disclosure there is provided a method of manufacturing a product which comprises an aerosol generating material gel supported on a first surface of a support, in which the method comprises

providing a longitudinally extending support,
providing a stencil,
providing a path along which the support may travel, the path comprising in order in the first direction of travel a converging position, an application position, and a diverging position,
overlying a first surface of the support with the stencil at the converging position on the path,
moving the support and stencil from the converging position to the diverging position via the application position,
applying fluid aerosol generating material to the stencil and first portions of the first surface of the support exposed by the stencil at the application position,
moving the support and stencil to the divergent position, and separating the stencil from the support.

In an embodiment of any of the above embodiments, the stencil is one or both of longitudinally extending, and formed from a flexible sheet material.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 2.0 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 1.0 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.9 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.8 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.7 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.6 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.5 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.4 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.3 mm.
In an embodiment of any of the above embodiments, the thickness of the stencil is less than or equal to 0.2 mm.
In an embodiment of any of the above embodiments, the stencil includes a stainless steel.
In an embodiment of any of the above embodiments, the stencil is formed from a stainless steel.
In an embodiment of any of the above embodiments, the stencil is a continuous loop. That is the stencil is formed from a portion of flexible material that extends between a first and a second end, and the first and second ends are joined to each other to form a continuous loop of stencil.
In an embodiment of any of the above embodiments, the stencil has a first surface that is in contact with the first surface of the support, and a release agent is applied to the first surface of the stencil before the stencil overlies the support at the converging position.
In an embodiment of any of the above embodiments, the method comprises providing a support bed, and the support bed is configured to at least partially provide support to the support as it travels between the application position and the divergent position.
In an embodiment of any of the above embodiments, the support bed is configured to accelerate the gelification of the fluid aerosol generating material.
In an embodiment of any of the above embodiments, the method comprises configuring the apparatus used for the performance of the method so that the period of time any individual aperture in the stencil takes to travel between the application position and the divergent position is sufficient to allow the fluid aerosol generating material deposited in the apertures in the stencil to cure sufficiently that the fluid aerosol generating material is self supporting when the stencil moves away from the support at the diverging position.
In an embodiment of any of the above embodiments, the distance of the divergent position from the application position is at least partially determined by one or more of the period of time required for the fluid aerosol generating material to reach a predetermined level of gelification, the speed of the support along the path, the thickness of the stencil, the material of the support, and the ambient conditions around the path between the application position and the diverging position.
According to a fourth aspect of the present disclosure there is provided a method of manufacture of an article which comprises aerosol generating material for use in an aerosol provision device, in which the method comprises providing a product manufactured according to the method of the third aspect of the present disclosure, and cutting the product into an appropriate size for use in an article.
In some embodiments, the article comprises aerosol generating material. The article 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 article 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 aerosol generating material is not a requirement.
In some embodiments, the non-combustible aerosol provision system is an aerosol generating 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 aerosol generating 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 article 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.
Aerosol generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants.
The aerosol generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.
The aerosol generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol generating material may or may not be soluble in the solvent. In some embodiments, the aerosol generating material is substantially free from botanical material. In particular, in some embodiments, the aerosol generating material is substantially tobacco free.
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 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.
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).
In an embodiment of any of the above embodiments the aerosol generating material comprises an active substance.
The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, terpenes of non-cannabinoid origin, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.
The active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.
In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.
The active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v.,Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v.,Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens
In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.
In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.
In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.
In some embodiments, the aerosol generating material comprises a flavour or flavourant.
As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.
In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.
In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.
The aerosol generating material comprises an aerosol generating agent. In some embodiments the aerosol generating agent may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol generating agent may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1 ,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In particular examples, the aerosol generating agent comprises glycerol.
In some embodiments, the aerosol generating agent comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1 ,3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and/or aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.
In some embodiments, the aerosol generating material may comprise from about 0.1wt%, 0.5wt%, 1wt%, 3wt%, 5wt%, 7wt% or 10% to about 50wt%, 45wt%, 40wt%, 35wt%, 30wt% or 25wt% of an aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticiser. For example, the aerosol generating material may comprise 0.5-40wt%, 3-35wt% or 10-25wt% of an aerosol generating agent.
In some embodiments, the aerosol generating material may comprise from about 5wt%, 10wt%, 20wt%, 25wt%, 27wt% or 30wt% to about 60wt%, 55wt%, 50wt%, 45wt%, 40wt%, or 35wt% of an aerosol generating agent (DWB). For example, the aerosol generating material may comprise 10-60wt%, 20-50wt%, 25-40wt% or 30-35wt% of an aerosol generating agent.
In some embodiments, the aerosol generating material may comprise up to about 80wt%, such as about 40 to 80wt%, 40 to 75wt%, 50 to 70wt%, or 55 to 65wt% of an aerosol generating agent (DWB).
The aerosol generating material may also comprise a gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group comprising alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In some cases, the gelling agent comprises alginate and/or pectin, and may be combined with a setting agent (such as a calcium source) during formation of the aerosol generating material. In some cases, the aerosol generating material may comprise a calcium-crosslinked alginate and/or a calcium-crosslinked pectin.
In some embodiments, the gelling agent comprises one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum and mixtures thereof.
In some embodiments, the cellulosic gelling agent is selected from the group consisting of: hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP) and combinations thereof.
In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose, guar gum, or acacia gum.
In some embodiments, the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum Arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In preferred embodiments, the non-cellulose based gelling agent is alginate or agar.
In some embodiments, the gelling agent comprises alginate, and the alginate is present in the aerosol generating material in an amount of from 10-30wt% of the aerosol generating material (calculated on a dry weight basis). In some embodiments, alginate is the only gelling agent present in the aerosol generating material. In other embodiments, the gelling agent comprises alginate and at least one further gelling agent, such as pectin.
In some embodiments, the aerosol generating material comprises from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt% or 35wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 1-50wt%, 5-45wt%, 10-40wt% or 20-35wt% of a gelling agent.
In some embodiments, the aerosol generating material comprises from about 20wt% 22wt%, 24wt% or 25wt% to about 30wt%, 32wt% or 35wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 20-35wt% or 25-30wt% of a gelling agent.
In some cases, the aerosol generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt% or 20wt% to about 60wt%, 50wt%, 40wt%, 30wt% or 25wt% of a gelling agent (DWB). For example, the aerosol generating material may comprise 10-40wt%, 15-30wt% or 20-25wt% of a gelling agent (DWB).
In examples, the aerosol generating material comprises gelling agent and filler, taken together, in an amount of from about 10wt%, 20wt%, 25wt%, 30wt%, or 35wt% to about 60wt%, 55wt%, 50wt%, or 45wt% of the aerosol generating material. In examples, the aerosol generating material comprises gelling agent and filler, taken together, in an amount of from about 20 to 60wt%, 25 to 55wt%, 30 to 50wt%, or 35 to 45wt% of the aerosol generating material.
In examples, the aerosol generating material comprises gelling agent (i.e. without taking into account the amount of filler) in an amount of from about 5wt%, 10wt%, 15wt%, 20wt%, 25wt%, 30wt%, or 35wt% to about 60wt%, 55wt%, 50wt%, or 45wt% of the aerosol generating material. In examples, the aerosol generating material comprises gelling agent (i.e. without taking into account the amount of filler) in an amount of from about 5 to 60wt%, 20 to 60wt%, 25 to 55wt%, 30 to 50wt%, or 35 to 45wt% of the aerosol generating material.
In some examples, alginate is comprised in the gelling agent in an amount of from about 5 to 40wt% of the aerosol generating material, or 15 to 40wt%. That is, the aerosol generating material comprises alginate in an amount of about 5 to 40wt% by dry weight of the aerosol generating material, or 15 to 40wt%. In some examples, the aerosol generating material comprises alginate in an amount of from about 20 to 40wt%, or about 15wt% to 35wt% of the aerosol generating material.
In some examples, pectin is comprised in the gelling agent in an amount of from about 3 to 15wt% of the aerosol generating material. That is, the aerosol generating material comprises pectin in an amount of from about 3 to 15wt% by dry weight of the aerosol generating material. In some examples, the aerosol generating material comprises pectin in an amount of from about 5 to 10wt% of the aerosol generating material.
In some examples, guar gum is comprised in the gelling agent in an amount of from about 3 to 40wt% of the aerosol generating material. That is, the aerosol generating material comprises guar gum in an amount of from about 3 to 40wt% by dry weight of the aerosol generating material. In some examples, the aerosol generating material comprises guar gum in an amount of from about 5 to 10wt% of the aerosol generating material. In some examples, the aerosol generating material comprises guar gum in an amount of from about 15 to 40wt% of the aerosol generating material, or from about 20 to 40wt%, or from about 15 to 35wt%.
In examples, the alginate is present in an amount of at least about 50wt% of the gelling agent. In examples, the aerosol generating material comprises alginate and pectin, and the ratio of the alginate to the pectin is from 1:1 to 10:1. The ratio of the alginate to the pectin is typically >1:1, i.e. the alginate is present in an amount greater than the amount of pectin. In examples, the ratio of alginate to pectin is from about 2:1 to 8:1, or about 3:1 to 6:1, or is approximately 4:1.
The aerosol generating material may be formed by (a) forming a slurry comprising components of the aerosol generating material or precursors thereof, (b) forming a layer of the slurry, (c) setting the slurry to form a gel, and (d) drying to form an aerosol generating material.
The (b) forming a layer of the slurry typically comprises spraying, casting or extruding the slurry. In examples, the slurry layer is formed by electrospraying the slurry. In examples, the slurry layer is formed by casting the slurry.
In some examples, (b) and/or (c) and/or (d), at least partially, occur simultaneously (for example, during electrospraying). In some examples, (b), (c) and (d) occur sequentially.
In some examples, the slurry is applied to a support. The layer may be formed on a support.
In examples, the slurry comprises gelling agent, aerosol-former material and active substance. The slurry may comprise these components in any of the proportions given herein in relation to the composition of the aerosol generating material. For example, the slurry may comprise (on a dry weight basis):

gelling agent and, optionally, filler, wherein the amount of gelling agent and filler taken together is about 10 to 60wt% of the slurry;
aerosol-former material in an amount of about 40 to 80wt% of the slurry; and
optionally, active substance in an amount of up to about 20wt% of the slurry.

The setting the gel (c) may comprise supplying a setting agent to the slurry. For example, the slurry may comprise sodium, potassium or ammonium alginate as a gel-precursor, and a setting agent comprising a calcium source (such as calcium chloride), may be added to the slurry to form a calcium alginate gel.
In examples, the setting agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the setting agent comprises or consists of calcium formate and/or calcium lactate. In particular examples, the setting agent comprises or consists of calcium formate. It has been 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%. It has been 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. It has been 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 β-D-mannuronic (M) and α-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 α-L-guluronic acid (G) units.
In examples, the drying (d) removes from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% to about 80wt%, 90wt% or 95wt% (WWB) of water in the slurry.
In examples, the drying (d) reduces the cast material thickness by at least 80%, suitably 85% or 87%. For instance, the slurry is cast at a thickness of 2mm, and the resulting dried aerosol generating material has a thickness of 0.2mm.
In some examples, the slurry solvent consists essentially of or consists of water. In some examples, the slurry comprises from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% of solvent (WWB).
In examples where the solvent consists of water, the dry weight content of the slurry may match the dry weight content of the aerosol generating material. Thus, the discussion herein relating to the solid composition is explicitly disclosed in combination with the slurry aspect of the invention.
The aerosol generating material may comprises a flavour. Suitably, the aerosol generating material may comprise up to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt% or 45wt% of a flavour. In some cases, the aerosol generating material may comprise at least about 0.1wt%, 1wt%, 10wt%, 20wt%, 30wt%, 35wt% or 40wt% of a flavour (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 1-80wt%, 10-80wt%, 20-70wt%, 30-60wt%, 35-55wt% or 30-45wt% of a flavour. In some cases, the flavour comprises, consists essentially of or consists of menthol.
The aerosol generating material may comprise 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%, 10vnt%, 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%, 10vnt%, 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 it has been 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 non-combustible 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 an aerosol generating material, the aerosol generating material comprising:

1-60 wt% of a gelling agent;
0.1-50 wt% of an aerosol generating agent; and
0.1-80 wt% of a flavour;

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;

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

1-60 wt% of a gelling agent;
5-60 wt% of an aerosol generating agent; and
10-60 wt% of a tobacco extract;

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;

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 0.1mm 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 found that if the aerosol generating material is too thick, then heating efficiency is compromised. This adversely affects the power consumption in use. Conversely, if the aerosol generating material is too thin, it is difficult to manufacture and handle; a very thin material is harder to cast and may be fragile, compromising aerosol formation in use.
The thickness stipulated herein is a mean thickness for the material. In some cases, the aerosol generating material thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%.
In some examples, the aerosol generating material in sheet form, and absent 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.
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 350 g/m². In some cases, the sheet may have a mass per unit area of 50-250 g/m², or from about 70 to 210 g/m², or from about 90 to 190 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.
As used herein, the term "sheet" denotes an element having a width and length substantially greater than a thickness thereof. A major surface of the sheet is a surface which extends in both width and length dimensions when the sheet is flat. The sheet may be a strip, for example.
The aerosol generating material may comprise a colourant. The addition of a colourant may alter the visual appearance of the aerosol generating material. The presence of colourant in the aerosol generating material may enhance the visual appearance of the aerosol generating material 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, food-grade 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 some embodiments, the addition of a colourant to the aerosol generating material renders it visually indistinguishable from other components in the aerosol generating material.
The colourant may be incorporated during the formation of the aerosol generating material (e.g. when forming a slurry comprising the materials that form the aerosol generating material) or it may be applied to the aerosol generating material after its formation (e.g. by spraying it onto the aerosol generating material).
In some embodiments of any of the above embodiments, talcum powder, calcium carbonate powder or other powder is applied to the exposed surface of at least one discrete portion of aerosol generating material. This may reduce the level of tackiness or adhesion of the aerosol generating material.
With reference to Figures 1 and 2, an apparatus 2 for use in the manufacture of a product includes an bed 4 having a bed surface 12, and a roll support system. In the illustrated example the roll support system is a roll holder 6 which is mounted on the bed 4. In other non-illustrated examples of the apparatus of the present disclosure the roll support system is supported by one or more other support elements.
The roll holder 6 is configured to support an axle (not shown) upon which a roll 10 of support 8 is mounted above the bed surface 12 by a distance sufficient to allow the roll 10 to be able to rotate about the axle and the support 8 to unroll from the roll 10.
The support 8 is a flexible sheet material with a first surface 46, an opposite second surface 48, and lateral side edges 60, 62.
The bed surface 12 is configured to provide a path or surface along which the support 8 may travel in a first direction 14 (represented by arrows 14). The second surface 48 of the support 8 is in sliding contact with the bed surface 12 when the support travels along the path.
The support 8 is caused to unroll from roll 10 and travel in the direction 14 by a drive means 40 which includes a pair of driven rollers 42, 44. The driven rollers 42, 44 are each configured to rotate about their axis, and the axes of the rollers are parallel with each other. The rollers 42, 44 are driven (by means not shown) so that the roller 42 rotates in a clockwise direction as seen in Figure 1, and roller 44 rotates in an anti-clockwise direction as seen in Figure 1.
The support 8 may be considered to be comprised of a plurality of finite elements that extend between the lateral edges 60, 62 of the support 8 and extend a distance x in the direction 14 when the apparatus 2 is in use and the support is positioned on the bed surface 12..
The rollers 42, 44 are so positioned relative to each other that the support 8 can pass between the rollers 42, 44 with roller 42 in contact with at least a portion of the first surface 46 of the finite element of the support 8 that is between the rollers, and roller 44 in contact with at least a portion of the second surface 46 of that finite element.
In some examples, each of the rollers 42, 44 are so configured that each roller is respectively in contact with a portion of the first or second surface 46, 48 of the support 8 adjacent the lateral edges 60, 62 of support 8.
The apparatus 2 further includes a stencil system 16. The stencil system 16 includes a stencil 18, and a pair of stencil rollers 20, 22.
With reference to Figures 1 to 3, the stencil 18 is formed from an endless loop of a flexible stainless steel sheet material.
The flexible stainless steel sheet material is of uniform thickness. In the illustrated example the thickness is less than 1.0 mm. In other non-illustrated the thickness may be less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6 mm, or less than 0.5 mm.
The stencil 18 includes a plurality of groups 32 of apertures 34 (for clarity not all of apertures 34 are labelled). The apertures 34 extend through the stencil 18 between an outer surface 52 of the endless loop and an inner surface 54 of the endless loop. In the representative stencil 18 shown in Figure 3 there are two groups 32 of apertures 34, and the groups 32 are separated from each other in a direction along the stencil 18 by blank portions 50.
In other non-illustrated examples there may be more groups 32 in one or both of the longitudinal and lateral directions along the endless loop.
In each of the groups 32 of apertures 34 the apertures 34 are positioned relative to each other in a predetermined pattern. For example in the illustrated example of Figures 1 to 3 the apertures 34 are laid out in a square lattice pattern.
The apertures 34 of each group 32 are also positioned on the stencil 18 in the same position relative to the lateral edges of the stencil 18.
The volume of the or each aperture 34 is the volumes bounded by the edge or edges of the stencil that define the aperture and the planes of the inner and outer surfaces 52, 54 of the stencil. The volume is dependent on both the dimensions of the aperture in the plane of the inner and outer surfaces 52, 54 of the stencil and the thickness of the stencil and determines the quantity of fluid aerosol generating material that may be retained in an aperture 34.
The apertures 34, in the plane of the inner and outer surfaces 52, 54 of the stencil 18 are circular in the example shown in Figures 1 to 3.
In other, non-illustrated examples, the apertures may be of other shapes, for example, but without limitation, triangles, squares, rectangles, or other polygons, or other shapes as desired.
The stencil 18 may be considered to be comprised of a plurality of finite elements each of which extend between the lateral edges 56, 58 of the stencil 18 and extend a distance x in the direction 14 when the apparatus 2 is in use.
The stencil 18 is mounted on the pair of rollers 20, 22. The rollers 20, 22 are each configured to rotate about their respective axis, and the axes of the rollers 20, 22 are parallel with each other and perpendicular to the direction 14. At least one of the rollers is configured to be driven by a drive means (not shown). Driving of one or both of the rollers 20, 22 causes the stencil 18 to follow a closed loop path that passes from roller 20 to roller 22, around the portion of roller 22 not facing the roller 20, back to roller 20, and around the portion of roller 20 not facing the roller 22.
The rollers 20, 22 are each positioned relative to the bed surface 12 so that the minimum distance between the radially outer surface of the roller and the bed surface 12 is equal to or closely equal to the cumulative thickness of the stencil 18 (the distance between the inner and outer surfaces 52, 54 of the stencil 18) and the support 8 (the distance between the first and second surfaces 46, 48 of the support 8).
The position along the bed surface 12 at which the roller 22 is closest to the bed surface 30 may be termed the converging position 26, and the position along the bed surface 12 at which the roller 20 is closest to the bed surface 12 may be termed the diverging position 30.
The drive means (not shown) for one or both of the rollers 20, 22 is configured to drive the or each roller in a clockwise direction as seen in Figure 2 with the result that the finite elements of the stencil 18 in the portion 36 of the stencil 18 that is closest to the support 8 move in direction 14.
The rollers 20, 22 are positioned relative to each other at a distance that ensures that the stencil 18 extending between the rollers is taut, that is there is no slack in the stencil 18. This has the effect, that the portion 36 of the stencil 18 overlies and remains in contact with the first surface 46 of the support 8 as the finite elements of the stencil 18 in portion 36 of the stencil move from the converging position 26 to the diverging position 30.
The drive means (not shown) for one or both of the rollers 20, 22 is further configured so that the or each roller is driven to rotate at a rotational speed that causes the finite elements of the stencil 18 to travel from the roller 20 to the roller 22 at the same speed as the finite elements of the support 8 move along the bed surface 12 with the result that at the converging position 26 a finite element of the stencil 18 and support 8 are positioned next to and in contact with each other, and that pair of finite elements moves in the direction 14 without relative movement between the pair of finite elements until that pair of finite elements reach the diverging position 30.
The apparatus 2 further comprises an application system 24 which is adapted to apply a fluid aerosol generating material to the inner surface 54 of the stencil 18. The application system 24 includes an applicator 64 and a doctor blade 66.
The application system 24 is held at an application position 28 along the bed surface 12. The application position 28 is, in the direction 14, between the converging position 26 and the diverging position 30. In some examples the application position 28 is closer to the converging position 24 than the diverging position 30.
The application system 24 is spaced from the bed surface 12 by a distance that allows the stencil 18 and support 8 to pass between the application system 24 and the bed surface 12.
The applicator 64 includes a reservoir (not shown) suitable for the storage of the fluid aerosol generating material prior to application of that material to the surface 54 of the stencil 18.
The applicator 64 further includes an application means such as a slot (not shown) which is configured and positioned to apply a layer of the fluid aerosol generating material to the surface 54 of the stencil 18. The application means is configured to apply the fluid aerosol generating material sufficient to cover across the lateral extent of the stencil 18 between the edges 56 , 58 so that when the apertures 34 of each aperture group 32 passes between the application means and the bed surface 12 fluid aerosol generating material is applied to all of the apertures 34 and hence to the first surface 46 of the support 8.
The doctor blade 66 is further in the direction 14 from the converging position than the applicator 64.
The doctor blade 66 is so configured and positioned that it scrapes the fluid aerosol generating material off the surface 54 of the stencil and either pushes that fluid aerosol generating material into an aperture 34 or into an aerosol generating material collection system (not shown) which is located at a suitable position along the doctor blade or adjacent one or both lateral ends (relative to direction 14) of the doctor blade.
The fluid aerosol generating material that remains in an aperture 34 after that aperture 34 has passed the doctor blade 66 may be termed a discrete portion 74 of fluid aerosol generating material.
The fluid aerosol generating material deposited in the one or more apertures can undergo a gellification process (e.g. solidify) into an aerosol generating material gel. The fluid aerosol generating material in each aperture transitions to form discrete portions of aerosol generating material gel. The discrete portions of aerosol generating material gel having a shape dependent (at least in part) on the shape of the aperture.
The apparatus bed 4 includes a heater element 68 which is configured to extend at least between the application position 28 and the divergent position 30 in the direction 14 and to extend between the lateral edges 60, 62 of the support with the result that the whole of the portion of the stencil 18 that extends between the application position 28 and the divergent position 30 overlies the heater element 68.
The heater element 68 is configured to heat the portion of the bed surface 12 adjacent to the heater element. The heater element 68 is configured to heat the bed surface 12, and hence the support 8 and the discrete portions 74 of fluid aerosol generating material, to a temperature that accelerates the gelification of the fluid aerosol generating material. That is, the temperature is a temperature that enhances the rate at which the fluid aerosol generating material of the discrete portions 74 becomes a gel that is sufficiently viscous that the gel of the discrete portions 74 will not flow or change dimension or position when the stencil 18 moves away from the support 8 as the stencil 18 passes around the roller 30.
The heater element is configured to not heat to a temperature that causes the discrete portions 74 of fluid aerosol generating material to vaporise / generate aerosol.
In use, the apparatus 2 functions as follows once a portion of the support 8 has been unwound from the roll 10 and passed between the rollers 42, 44 of the drive means 40:
As a finite element of the support 8 leaves the roll 10 it travels along the bed surface 12. That finite element first reaches the convergent position 26 where a finite element of the stencil 18 passing around the roller 22 comes into contact with the first surface 46 of finite element of the support 8.
The finite elements of the support 8 and stencil 18 move in direction 14 under the power of the drive means 40 (for the support 8) and the drive means (not shown) for the stencil 18.
When the pair of finite elements reach the application position 28, they pass between the application system 24 and the bed surface 12. The applicator 64 applies fluid aerosol generating material to the surface 54 of the finite element of the stencil 18 and the first surface 46 of the finite element of the support 8 via any apertures or parts of apertures 34 that are included in the finite element of the stencil 18.
Thereafter, the pair of finite elements pass between the doctor blade 66 and the bed surface 12. The doctor blade 66 scrapes the fluid aerosol generating material off the surface 54 of the finite element of the stencil 18 and either directs the fluid aerosol generating material into a collection system for excess fluid aerosol generating material, or directs the fluid aerosol generating material into any aperture 34 or part of an aperture 34 that is between the doctor blade 66 and the first surface 46 of support 8.
The fluid aerosol generating material remaining in the apertures 34 after the pair of finite elements has passed the doctor blade 66 are discrete portions 74 of fluid aerosol generating material.
The pair of finite elements continue to move in the direction shown by arrows 14 and pass over the heater element 68. That heater element 68 accelerates the gelification of the fluid aerosol generating material in the discrete portions 74 relative to the rate of gelification at ambient conditions.
The speed that the drive means 40 (for the support 8) and the drive means (not shown) for the stencil 18 cause the support 8 and stencil 18 to progress in direction 14 is selected so that by the time that the pair of finite elements reach the diverging position 30 the fluid aerosol generating material of the discrete portions 74 is a gel which is self supporting. This has the result that, when the finite element of the stencil 18 moves away from the support 8 as the stencil 18 passes around the roller 20, any fluid aerosol generating material that was applied to the first surface 46 of the finite element of the support 8 is part of a discrete portion 74 of aerosol generating material gel that retains it's dimensions and position on the first surface 46 of the support 8.
The first surface 46 of the support 8 now has the general appearance shown in Figure 4. It is noted that, for clarity, not all of the discrete portions 74 of fluid aerosol generating material are labelled.
The finite element of the support 8 subsequently continues to travel in the direction 14, through the drive means 40 and to the cutting position 70 where the cutting system 70 cuts the support 8 into a plurality of products. Each product including at least one group 32 of discrete portions 74 of aerosol generating material.
With reference to Figure 5, in an alternative example of an apparatus 2, the features of the apparatus 2 are as described in connection with Figures 1 to 4 above with the exception as follows:
One or both of the rollers 20, 22 of the stencil system 16 are provided with a plurality of indexing teeth 76 (for clarity, not all of the indexing teeth 76 are labelled). The indexing teeth 76 are configured to engage with indexing holes 78 (again for clarity, not all of the indexing holes 78 are labelled) in the support 8. The engagement of the indexing teeth 76 and holes 78 assists in maintaining the relative positions of the support 8 and the stencil 18 (not shown in Figure 5) as the support 8 and stencil 18 travel along the bed surface 12 from the converging position 26 to the diverging position 30. The indexing teeth 76 and holes 78 ensure that the support 8 and the stencil 18 maintain the same speed in direction 14.
Various aspects of the aerosol provision devices and systems disclosed in the various embodiments may be used alone, in combination, or in a variety of arrangements not specifically discussed in the embodiments described above. This disclosure is therefore not limited in its application to the details and arrangement of components set forth in the foregoing description or illustrated in the drawings. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments. Although particular embodiments have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from this disclosure in its broader aspects. The scope of the following claims should not be limited by the embodiments set forth in the examples, but should be given the broadest reasonable interpretation consistent with the description as a whole.

Claims

An apparatus for use in the manufacture of a product in which the product comprises aerosol generating material gel supported on a first surface of a support, in which
the apparatus is configured to provide a path along which the support may travel in a first direction and which comprises in order in the first direction a converging position, an application position, and a diverging position;

in which the apparatus comprises a support drive which is configured to move the support along the path in the first direction, a stencil, and a fluid aerosol generating material application means;

in which the apparatus is configured to cause at least a portion of the stencil to overlie the first surface of the support and travel at the same speed as the support along the path from the converging position to the diverging position, and the application means is configured to apply fluid aerosol generating material to the first surface of the support and stencil as the support and stencil pass through the application position on the path.
An apparatus according to claim 1 in which the stencil is one or more of formed from a flexible sheet material, longitudinally extending, and a continuous loop.
An apparatus according to claims 1 or 2 in which the apparatus comprises a support bed, and the support bed is configured to at least partially provide support to the support and stencil as they travel along the path between the application position and the divergent position.
An apparatus according to claim 3 in which the support bed is configured to accelerate the gelification of the fluid aerosol generating material.
An apparatus according to any of claims 1 to 4 in which the apparatus comprises a means configured to maintain the relative positions of the support and the stencil as the support and stencil travel along the path from the converging position to the diverging position.
A stencil for use in the manufacture of a product in which the product comprises aerosol generating material gel supported on a first surface of a support, in which the stencil comprises a sheet material and defines one or more apertures, in which one or more apertures are configured to produce a desired shape of fluid aerosol generating material gel supported on a first surface of a support.
A stencil according to claim 6 in which the stencil is one or more of longitudinally extending, formed from a flexible sheet material, and a continuous loop.
A stencil according to claim 6 or 7 in which the stencil comprises stainless steel.
A method of manufacturing a product which comprises an aerosol generating material gel supported on a first surface of a support, in which the method comprises
providing a longitudinally extending support,

providing a stencil,

providing a path along which the support may travel, the path comprising in order in the first direction of travel a converging position, an application position, and a diverging position,

overlying a first surface of the support with the stencil at the converging position on the path,

moving the support and stencil from the converging position to the diverging position via the application position,

applying fluid aerosol generating material to the stencil and first portions of the first surface of the support exposed by the stencil at the application position,

moving the support and stencil to the divergent position, and

separating the stencil from the support.
A method according to claim 9 in which the stencil is one or both of longitudinally extending, and formed from a flexible sheet material.
A method according to claim 9 or 10 in which the stencil is a continuous loop.
A method according to any of claims 9 to 11 in which the stencil has a first surface that is in contact with the first surface of the support, and a release agent is applied to the first surface of the stencil before the stencil overlies the support at the converging position.
A method according to any of claims 9 to 12 in which the method comprises providing a support bed, and the support bed is configured to at least partially provide support to the support as it travels between the application position and the divergent position.
A method according to claim 13 in which the support bed is configured to accelerate the gelification of the fluid aerosol generating material.
A method according to any of claims 9 to 14 in which the distance of the divergent position from the application position is at least partially determined by one or more of the period of time required for the fluid aerosol generating material to reach a predetermined level of gelification, the speed of the support along the path, the thickness of the stencil, the material of the support, and the ambient conditions around the path between the application position and the diverging position.