JP2024519551A - Consumables for use with aerosol delivery devices - Patent application - Google Patents

Abstract

A consumable (24) for use with an aerosol delivery device (2) is described. The consumable (24) includes a substrate (28), an aerosol-generating material (26), and a delivered substance (40) that can be volatilized, where the substrate (28) supports the aerosol-generating material (26), and the delivered substance (40) volatilizes upon heating of one or both of the substrate (28) or the aerosol-generating material (26). [Selected Figure]

Description

The present disclosure relates to a non-combustible aerosol delivery system, and in particular to consumables for use with an aerosol delivery device, methods of making consumables for use with an aerosol delivery device, and an aerosol delivery system including the consumables and the aerosol delivery device.

background

Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. Alternatives to these types of articles release inhalable aerosols or vapors by releasing compounds from a substrate material through heating rather than combustion. These can be referred to as non-combustible smoking articles, aerosol generating assemblies, or aerosol delivery devices.

One example of such a product is a heating device that releases compounds by heating, without combustion, an aerosolizable material, which may be referred to as a solid aerosol-generating material, which in some cases includes tobacco material. Upon heating, at least one component of the material is volatilized, typically forming an inhalable aerosol. These products may be referred to as non-combustion heating devices, tobacco heating devices, or tobacco heating products. A variety of different configurations for volatilizing at least one component of a solid aerosol-generating material are known.

As another example, there are hybrid devices. These hybrid devices include a liquid source (which may or may not contain nicotine) that is vaporized by heating to produce an inhalable vapor or aerosol. The device further includes a solid aerosol-generating material (which may or may not contain tobacco material), the components of which are entrained in the inhalable vapor or aerosol to produce the inhaled medium.

overview

According to a first aspect of the present disclosure, a consumable for use with an aerosol delivery device is provided. The consumable includes a support, an aerosol generating material, and a delivered substance that can be volatilized, where the support supports the aerosol generating material, and the delivered substance volatilizes upon heating of one or both of the support or the aerosol generating material.

According to a second aspect of the present disclosure, there is provided a method of manufacturing a consumable for use with an aerosol delivery device, the consumable including a support, an aerosol-generating material, and at least one substance capable of being volatilized. The method includes:
a) providing a support;
b) applying a slurry of aerosol-generating material to a surface of the consumable;
c) drying the applied aerosol-generating material; and
d) applying at least one substance to a surface of the consumable;
including.

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

According to a fourth aspect of the present disclosure, there is provided a method of generating an aerosol from a consumable according to the first aspect of the present disclosure using an aerosol generating device, the aerosol generating device having at least one heat source arranged to heat the consumable in use without burning it, the at least one heat source being a resistive heating element.

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

1A-1D show schematic diagrams of an embodiment of an aerosol delivery device and an embodiment of a consumable according to the present disclosure. 2 shows a first embodiment of the consumable of FIG. 1 along section line AA'. 2 shows a second surface of the support of the first embodiment of the consumable of FIG. 1 . 2 shows a second embodiment of the consumable of FIG. 1 taken along section line AA'. 5 shows a perspective view of the second consumable of FIG. 4 . 2 shows a third embodiment of the consumable of FIG. 1 taken along section line AA'. 2 shows a fourth embodiment of the consumable of FIG. 1 taken along section line AA'. 2 shows a fifth embodiment of the consumable of FIG. 1 taken along section line AA'. 1 shows a first schematic example of a method for manufacturing a consumable product according to the present disclosure. 4 shows a second schematic example of a method for manufacturing a consumable product according to the present disclosure. 13 shows a schematic third example of a method for manufacturing a consumable product according to the present disclosure.

Detailed Description

Consumables herein may alternatively be referred to as articles.

In some embodiments, the consumable includes an aerosol generating material. The consumable may include an aerosol generating material storage area, an aerosol generating material transport component, an aerosol generator, an aerosol generating area, a housing, a wrapper, an aerosol modifier, one or more active ingredients, one or more flavorings, one or more aerosol former materials, and/or one or more other functional materials.

The device for heating the aerosol-generating material used with the consumable is part of a non-combustion aerosol delivery system. A non-combustion aerosol delivery system releases compounds from the aerosol-generating material without burning the aerosol-generating material, such as e-cigarettes, tobacco heating products, and mixing systems for generating aerosols using combinations of aerosol-generating materials.

In accordance with the present disclosure, a "non-combustion" aerosol delivery system is one in which the aerosol-generating components of the aerosol delivery system (or components thereof) are not combusted or burned to facilitate delivery of at least one substance to a user.

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

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

In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustion aerosol delivery system is a mixing system for generating an aerosol using a combination of aerosol-generating materials, and one or more of the aerosol-generating materials may be heated. Each of the aerosol-generating materials may be in the form of, for example, a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the mixing system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, a tobacco or non-tobacco product.

Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

In some embodiments, the present disclosure relates to consumables that include aerosol generating materials and are configured for use with non-combustible aerosol delivery devices. These consumables are sometimes referred to as articles throughout this disclosure.

In some embodiments, the non-combustion aerosol delivery system, e.g., a non-combustion aerosol delivery device of the non-combustion aerosol delivery system, can include a power source and a controller. The power source can be, for example, a power source or a heat source. In some embodiments, the heat source includes a carbon substrate that can be excited to dissipate power in the form of heat to an aerosol-generating material or a heat transfer material in proximity to the heat source.

In some embodiments, the non-combustible aerosol delivery device may include an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and/or an aerosol modifier.

In some embodiments, consumables for use with the non-combustible aerosol delivery device may include aerosol generating materials, aerosol generating material storage areas, aerosol generating material transport components, aerosol generators, aerosol generating areas, housings, wrappers, filters, mouthpieces, and/or aerosol modifiers.

According to a first aspect of the present disclosure, a consumable for use with an aerosol delivery device is provided. The consumable includes a support, an aerosol generating material, and a delivered substance that can be volatilized. The support supports the aerosol generating material, and the delivered substance volatilizes upon heating of the support or the aerosol generating material.

An advantage of the consumables of the present disclosure is that the aerosol-generating material and the delivered substance are separate from one another in that they may be, but are not required to be, physically close to one another, but may be in different locations on or within the consumable and may be treated or behave differently during manufacture, storage, and/or use of the consumable. The aerosol-generating material and the delivered substance may differ from one another and possess different properties, such as optimal temperature ranges for vaporization or aerosol formation, chemical composition of the vapor or aerosol resulting from the aerosol-generating material and the delivered substance, storage characteristics, volatility, and rate and/or rate of volatilization. This may be advantageous during use of the consumable, during storage of the consumable prior to use of the consumable, and/or during manufacture of the consumable.

It is understood that any reference in this disclosure to a substance to be delivered includes a reference to a single substance or a mixture of two or more substances.

In some of the above embodiments, the support includes a sorbent material, and the sorbent includes the substance to be delivered.

In this disclosure, discussion of a sorbent containing a substance to be delivered refers to the substance to be delivered being absorbed or adsorbed onto the sorbent material.
A situation in which the substance to be delivered enters pores or voids in the sorbent material but does not chemically interact with the sorbent material;
the circumstances under which the substance to be delivered enters the sorbent material and chemically interacts with the sorbent material;
A situation in which the substance to be delivered forms a film of the substance to be delivered on the sorbent material but does not chemically interact with the sorbent material; or
the situation where the delivered substance forms a film of the delivered substance on the sorbent material and chemically interacts with the sorbent material to form an adsorbate;
including.

In some embodiments of any of the above embodiments, the delivered substance is located or absorbed/adsorbed within one or more distinct zones of the sorbent material and is not located outside of these distinct zones. In other embodiments, the delivered substance is located or absorbed/adsorbed within one or more distinct zones of the sorbent material at a concentration greater than the concentration of the delivered substance in portions of the sorbent material that are not within these distinct zones.

In some embodiments, absorption or adsorption of the substance to be delivered into the sorbent material is accomplished by applying the substance to be delivered to a surface of the sorbent material and allowing absorption or adsorption of the substance to be delivered into the sorbent material. This application may be by spraying, brushing, roller application, or by known printing techniques such as inkjet or valve jet printing, without limitation.

The use of separate aerosol generating material and delivered substance has one or more advantages. One such advantage is that the delivered substance can be selected to form an aerosol faster and/or at a lower temperature than the formation of the aerosol from the aerosol generating material. This allows a user to receive a puff of aerosol more quickly than would be received from a consumable that includes only the aerosol generating material.

A further advantage is that the aerosol generating material and delivered substance can be selected to provide the user with a puff having the same flavor throughout the puff, or the aerosol generating material and delivered substance can be selected to provide a puff having an initial first flavor from the delivered substance followed by a second flavor from the aerosol generating material.

A further advantage is that the delivered substance can have a sufficiently low aerosol formation temperature such that the temperature is achieved by heat emanating from the aerosol-generating material or heat not directed at/absorbed by the aerosol-generating material while it is being heated. This increases the overall amount or volume of aerosol (from the delivered substance and the aerosol-generating material) that can be generated per unit of thermal energy applied to the consumable, as compared to a consumable that includes only an aerosol-generating material.

The support may be of a material suitable for forming a substrate. The support may be or include, for example, paper, card, corrugated board, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material of the support. In some alternative embodiments, the susceptor is on or attached to one or both sides or surfaces of the material.

Sorbent materials are either absorbents or adsorbents related to the substance to be delivered and are suitable for use in non-combustible aerosol delivery systems. Suitable materials for sorbent materials include, but are not limited to, porous materials, dry gels (aerogels, xerogels, cryogels), fibrous materials (natural or synthetic), paper, cardboard, ceramics, wood, aerogels, activated carbon, porous polymers, sponges. In the consumables of the present disclosure, the sorbent material has the desired matter to be delivered absorbed or adsorbed into the structure of the sorbent material.

The sorbent material can be heated to cause the substance to be delivered to be absorbed or adsorbed into the sorbent material and aerosolized. The sorbent material can be selected for its calorific properties and the rate at which the substance to be delivered can be aerosolized and the aerosol leaves the sorbent material.

In some embodiments of any of the above embodiments, the at least one substance absorbed or adsorbed onto the sorbent material includes one or more of a flavorant, an active substance, a mixture of flavorants, a mixture of active substances, a mixture of one or more flavorants and one or more active substances, one or more solvents, and/or one or more aerosol generator agents or aerosol forming agent materials.

In some embodiments of any of the above embodiments, the substance being delivered can have an aerosolization temperature of 60 degrees Celsius or greater.

In some embodiments of any of the above embodiments, the support can include a sorbent material. In some embodiments of any of the above embodiments, the support can be formed from a sorbent material.

The aerosol generating agent or aerosol forming agent material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol forming agent material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

In some embodiments of any of the above embodiments, the support comprises a sorbent material. In some embodiments, the support is a laminate, the laminate comprising at least a first and a second substrate, at least one of the substrates being formed from a sorbent material. In some embodiments, another substrate of the laminate may be present for structural purposes, in particular to provide desired handling characteristics to the consumable, e.g., to provide a degree of elastic resilience to deformation of the consumable and/or to provide stiffness.

In some embodiments of any of the above embodiments, the sorbent material forms one or both of the first or second surfaces of the support. In some embodiments, one surface of the support is composed of a sorbent material and the other surface of the support is composed of a material that is not a sorbent material.

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

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

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

The susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that the penetration of the varying magnetic field causes inductive heating of the susceptor by resistive heating as a result of eddy currents. The susceptor may be a magnetic material, such that the penetration of the varying magnetic field causes magnetic hysteresis heating of the susceptor. The susceptor may be both conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. A device configured to generate a varying magnetic field is called a magnetic field generator.

The susceptor may comprise a ferromagnetic metal such as iron or an iron alloy such as steel or an iron-nickel alloy. Some exemplary ferromagnetic metals are 400 series stainless steel, such as grade 410 stainless steel, or grade 420 stainless steel, or grade 430 stainless steel, or similar grade stainless steel. Alternatively, the susceptor may comprise a suitable non-magnetic, particularly paramagnetic, conductive material, such as aluminum. In paramagnetic conductive materials, induction heating occurs only by resistive heating due to eddy currents. Alternatively, the susceptor may comprise a non-conductive ferrimagnetic material, such as a non-conductive ferrimagnetic ceramic. In that case, heat is generated only by hysteresis losses. The susceptor can include commercially available alloys such as Phytherm 230 (having a composition (in weight percent = wt%) of 50 wt% Ni, 10 wt% Cr, and the balance Fe) or Phytherm 260 (having a composition of 50 wt% Ni, 9 wt% Cr, and the balance Fe).

The susceptor may be a metal foil, optionally an aluminum foil or an iron foil, in some embodiments of any of the above embodiments. Alternatively, the susceptor may be any conductor that can be sprayed or vapor deposited onto the material forming the support in some embodiments of any of the above embodiments.

In some embodiments of any of the above embodiments, the sorbent material forms both the first and second surfaces of the support.

In some embodiments of any of the above embodiments, the support is formed entirely from a sorbent material.

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

In one embodiment of any of the above embodiments, the support comprises a plastic material capable of withstanding temperatures typically encountered in non-combustion aerosol delivery devices. In some embodiments, the support comprises polyetheretherketone (PEEK). Such an embodiment has the advantage that the support can be reused and the consumable is less susceptible to any condensation in non-combustion aerosol delivery devices than consumables that include supports that include the use of sorbent materials for structural purposes.

In some embodiments of any of the above embodiments, the aerosol-generating material is supported on a surface of a support that is not a sorbent material. Such a configuration has the advantage that the aerosol-generating material or any components of the aerosol-generating material are not adsorbed/absorbed onto the support or sorbent material during manufacture, subsequent storage, and use of the consumable.

In some embodiments of any of the above embodiments, the aerosol-generating material is supported on a surface of a support formed from a sorbent material.

In some embodiments of any of the above embodiments, the substance to be delivered is supported on a surface of a support.

In some embodiments of any of the above embodiments, the consumable further includes a sorbent material that is not part of the support, but is supported on the support and includes the substance to be delivered.

In some of any of the above embodiments, the aerosol-generating material is supported on a first surface of the support, and the sorbent material is supported on one or both of the first and second surfaces of the support. In these embodiments, the sorbent material is not part of the support, but is supported on a surface of the support. Such a configuration has the advantage that the sorbent material can be supported on the support only in locations where it is desired to be located.

In some embodiments of any of the above embodiments, the aerosol-generating material and the sorbent material are both located on the consumable such that heating of the aerosol-generating material to aerosolize at least one component of the aerosol-generating material also heats at least a portion of the sorbent material. This heating of at least a portion of the sorbent material may be by thermal conduction from a portion of the aerosol-generating material and/or a support supporting the aerosol-generating material. Such heating of the sorbent material may be considered indirect heating.

As a result of such indirect heating, the sorbent material may be heated to a temperature that is lower than the temperature to which the aerosol-generating material is heated, but sufficient to volatilize the substance being delivered. The heating profile of the sorbent material may, in some embodiments, be influenced by the shape of the sorbent material and its proximity to the aerosol-generating material.

In some embodiments of any of the above embodiments, the support may include or support means for regulating or enhancing the transfer of heat from the aerosol-forming material and/or the portion of the support supporting the aerosol-forming material to the sorbent material.

In some embodiments of any of the above embodiments, the sorbent material includes at least one distinct zone. Each distinct zone is a volume of the sorbent material that can be positioned relative to the aerosol-generating material such that, as a result of heating of the aerosol-generating material to aerosolize at least one component of the aerosol-generating material, the sorbent material in the distinct zone is heated to a temperature high enough to volatilize or aerosolize at least one substance absorbed or adsorbed therein. The sorbent material can include one or more distinct zones.

In some of any of the above embodiments, the substance to be delivered is volatilized a period of time PS after initiation of heating of the support or aerosol-generating material, and the aerosol-generating material is configured to emit an aerosol a period of time PA after initiation of heating of the support or aerosol-generating material, where the period of time PS is less than or equal to PA. In some embodiments, the period of time PS is less than PA.

In some embodiments of any of the above embodiments, the sorbent material includes one or more distinct zones, and the concentration of the delivered substance in the sorbent material within the distinct zones can be greater, and in some embodiments significantly greater, than the concentration of the delivered substance in portions of the sorbent material that are not within the distinct zones. The relative concentrations of the delivered substance in and outside the distinct zones can be determined by the location of absorption/adsorption of the delivered substance in the sorbent material.

In some embodiments of any of the above embodiments, the distinct zones are identifiable only by the relative positions of the consumables and/or by the concentration of the delivered substance in the sorbent material within the distinct zones.

In other alternative embodiments, the separate zones have a shape and size that are at least partially defined by a sorbent material surrounding the separate zones, the sorbent material having a reduced capacity for sorption of at least one delivered substance to the sorbent material relative to the capacity for sorption of at least one substance to the sorbent material in the separate zones.

The sorption capacity of the sorbent material at least partially surrounding the separate zone for the delivered substance can, in some embodiments, be affected by adsorption/absorption of non-volatile substances to the sorbent material at least partially surrounding the separate zone. In some other embodiments, the surface of the sorbent material at least partially surrounding the separate zone can be treated to limit the permeability of the surface for the delivered substance to be less than the permeability of the surface in the separate zone. In some embodiments, it is at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% lower than the separate surface.

Preventing or limiting the degree of adsorption of the delivered substance to the sorbent material in areas of the sorbent material where the sorbent is not desired to contain the delivered substance is likely to result in a reduction of the delivered substance used in the manufacture of the consumable, with attendant cost savings. Such prevention or limitation also allows for more consistent utilization of the consumables of the present disclosure than would be achieved if the location of the delivered substance in the sorbent material were not controlled.

In some embodiments of any of the above embodiments, there are at least two distinct zones, and at least two of the distinct zones include different substances to be delivered or different mixtures of substances to be delivered.

In some embodiments of any of the above embodiments, the aerosol-generating material is supported on the support in one or more separate portions, and at least one separate zone is associated with each separate portion of the aerosol-generating material.

In some of any of the above embodiments, the surface of the support on which the separate portions of the aerosol-generating material are supported includes or supports a sorbent material, the sorbent material including separate zones that substantially surround the separate portions of the aerosol-generating material. This configuration has the advantage that when the separate portions of the aerosol-generating material are heated, the sorbent material of the separate zones is indirectly heated by the separate portions of the aerosol-generating material.

In some of any of the above embodiments, the consumable includes distinct portions of aerosol-generating material on a first surface of a support, and distinct zones of sorbent material on a second surface of the support, the distinct portions and distinct zones of aerosol-generating material being in corresponding positions on their respective surfaces. By corresponding positions, it should be understood that one of the distinct portions and distinct zones of aerosol-generating material substantially overlaps the other of the distinct portions and distinct zones of aerosol-generating material when the distinct portions and distinct zones of aerosol-generating material are viewed from a position perpendicular to the surface on which they are located.

In some embodiments of any of the above embodiments, the shapes of the distinct portions and distinct zones of aerosol-generating material in the plane of the first and second surfaces of the support are substantially the same.

In some of any of the above embodiments, the separate portions of the aerosol-generating material cover a first area on a surface of the support on which the separate portions are supported, and the separate zones cover a second area on a surface of the support on which the separate zones are supported, one of the first and second areas being larger than the other of the first and second areas.

In some of any of the above embodiments, the consumable includes one or more perforations extending between at least the first and second surfaces of the support. This configuration has the advantage that when the consumable is being used, aerosol generated at or from the first side of the support passes through the perforations to the other side or second surface of the support. This is advantageous in some embodiments because it allows aerosol generated from the aerosol-generating material on one side or surface of the support to mix with aerosol generated from the sorbent material on the other side or surface of the support. This has the result that the two aerosols can mix before being passed to the mouthpiece before the aerosol is inhaled by the user.

It should be understood that in this disclosure, the term "number" is intended to mean 0, 1, or 2 or more.

In some embodiments of any of the above embodiments, one or more perforations extend between one of the first sides or surfaces of the support and a face of the consumable adjacent the other side or surface of the support. In such embodiments, the perforations extend through the support, e.g., through a portion of the aerosol-generating material supported on the surface of the support, or in an alternative embodiment, through the support and through a portion of the sorbent material supported on the surface of the support.

In some embodiments of any of the above embodiments, one or more perforations extend between a face of the consumable adjacent a first side or surface of the support and a face of the consumable adjacent a second side or surface of the support. In such embodiments, the perforations can extend through the support, a portion of the aerosol generation, and a portion of the sorbent material.

In some of any of the above embodiments, at least one of the perforations has a first dead-end end within the consumable and the other end opens through one of the surfaces of the support, the substance to be delivered, the aerosol-generating material, or the surface of the consumable. The dead-end end is the end that is within the material such that the end of the perforation is closed by the material.

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

In one embodiment of any of the above embodiments, the aerosol-generating material supported on the support is positioned such that there is a band of support on both surfaces of the support that extends a predetermined distance on the support from the edge of the support that is free of aerosol-generating material. The band can extend the same distance from the edge of the support for the entire length of the edge of the support. The band can assist in handling the consumable during use or packaging. The band can be continuous along the entire length of the edge of the support or can be discontinuous. The band can extend different distances on the surface of the support at different locations around the edge of the support.

According to a second aspect of the present invention, there is provided a method of manufacturing a consumable for use with an aerosol delivery device, the consumable comprising a support, an aerosol-generating material, and at least one substance. The method comprises the steps of:
a) providing a support;
b) applying a slurry of aerosol-generating material to a surface of the consumable;
c) drying the applied aerosol-generating material; and
d) applying at least one substance into a sorbent material to a surface of the consumable;
including.

An advantage of the method of the second aspect of the present disclosure is that the application of the aerosol generating material and the substance to be delivered to the substrate can be performed separately in both time and space. Such a capability overcomes known challenges associated with the manufacture of consumables for use with aerosol delivery devices.

In the manufacture of consumables for use with aerosol delivery devices, it is known to form a slurry of aerosol-generating material, the slurry including a solvent that causes the aerosol-generating material to become a slurry, and one or more different substances or groups of substances (e.g., one or more physiologically active materials and one or more fragrances or flavorings) that will form part of the aerosol when the consumable is used and the aerosol-generating material is aerosolized. However, the solvent and these substances may have different evaporation rates at any given temperature.

In the manufacture of consumables, the aerosol-generating material slurry is applied to a surface of a support or a sheet of material, which are then cut to form a plurality of supports. The slurry is then dried to form an aerosol-generating material of approximately fixed dimensions on the surface on which the slurry is supported. In some embodiments, the aerosol-generating material is dried to form an aerosol-generating gel or an aerosol-generating film. During the drying process, the solvent for the slurry evaporates as well as some of the substances that will form part of the aerosol upon use of the consumable. During the slurry drying process, it has been found that different evaporation rates of the solvent of the aerosol-generating material, and the various substances that will be aerosolized, have the effect that it can be difficult to precisely control the amount of substances that will form part of the aerosol in the dried aerosol material. This can result in difficulties in achieving a consistent, predictable and repeatable commercial product. A further effect is that a large amount of the active material incorporated in the slurry is lost before the slurry is sufficiently dried to form an aerosol-generating material, aerosol-generating gel or aerosol-generating film of approximately fixed dimensions.

The disclosed method allows the slurry to be formulated to contain only materials that do not evaporate in undesirable amounts during drying of the slurry. These materials may be materials that have evaporation rates that are higher or significantly higher than the evaporation rate of the solvent at the conditions under which the slurry is dried.

In some embodiments of any of the above embodiments, materials that previously evaporated in undesirable amounts during drying of the slurry may include all or some of the delivered materials of the present disclosure. This reduces the amount of materials lost to evaporation during the manufacturing process, thereby increasing the efficiency of use of these materials and reducing the environmental concerns of evaporation of these materials during the consumable manufacturing process.

A further advantage of the disclosed method may be that the slurry can be subjected to a drying process involving higher temperatures than previously possible, thereby shortening the manufacturing time of the consumable.

In some embodiments of any of the above embodiments, step (b) occurs any time after step (a), step (b) is followed by step (c), and step (d) occurs any time after step (c). For example, there may be a gap of days, weeks, or months between steps (a) and (b) and/or between steps (c) and (d).

In some embodiments of any of the above embodiments, the method further includes a step (e) that includes providing a sorbent material.

In some embodiments of any of the above embodiments, step (e) occurs before step (d), which includes applying the substance to be delivered to a sorbent material to form a sorbent material containing the substance to be delivered, and, if the support does not include a sorbent material, applying the sorbent material containing the substance to be delivered to the consumable.

In some embodiments of any of the above embodiments, the sorbent material can be fixed to the consumable at any point in the manufacturing process. It will be appreciated that the sorbent material can be unaffected by exposure to a drying process for the aerosol-generating material slurry. In some embodiments, the sorbent material is fixed to a support.

In some embodiments of any of the above embodiments, the support in step (a) comprises a sorbent material.

In some embodiments of any of the above embodiments, step (e) includes applying a paste to the consumable and then drying the paste, where the paste dries to form a sorbent material. Such method steps can allow the sorbent material to be applied only to a predetermined portion of the support. In some embodiments, the drying of the paste is simultaneous with step (c).

In some embodiments of any of the above embodiments, step (e) includes forming a desired shape of the sorbent material and fixing the shape of the sorbent material in a desired location on the consumable. This technique of creating a sorbent shape and then fixing it to a support allows the sorbent material to be molded or cut from a larger unit of sorbent material, such as a sheet of sorbent material.

In some embodiments of any of the above embodiments, steps (e) and (d) include providing a sheet of sorbent material, applying an adhesive on a first surface and covering the adhesive with a removable carrier sheet, applying the substance to be delivered to the other surface of the sorbent material, allowing the substance to be delivered to be absorbed or adsorbed into the sorbent material, and cutting the sorbent material into one or more desired shapes.

The adhesive may be a releasable adhesive, a repositionable adhesive, a low tack adhesive or other suitable adhesive.

The sorbent material can then be stored or transferred to the consumable, the carrier sheet peeled off the sorbent material, and the sorbent material can then be adhered to the consumable at the desired location. The sorbent material can be adhered to the consumable during manufacture of the consumable. Alternatively, a user of the consumable can adhere the sorbent material to the consumable prior to use of the consumable. This allows the user to obtain one or more portions of sorbent material containing different delivered substances, e.g., fragrances, select the fragrance they wish to use, and apply the fragrance to the consumable. This embodiment has the advantage for the user of choice and control of the experience, and for the manufacturer of being able to manufacture a limited range of consumables that can be used with a much wider variety of delivered substances.

In some embodiments of any of the above embodiments, step (d) occurs before the sorbent material is secured to the consumable. This has the advantage that absorption/adsorption of the substance delivered to the sorbent material can occur at a location remote from the site of manufacture of the consumable of the present disclosure.

In some embodiments of any of the above embodiments, steps (b) and (c) are repeated one or more times before step (d). The repetition of steps (b) and (c) can, in some embodiments, allow the aerosol generating material to build up in layers on the consumable. In some embodiments, the layers may be formed from different compositions of the aerosol generating material.

In some embodiments of any of the above embodiments, the aerosol generating material may be applied to one or more distinct regions of the consumable. In some embodiments, at least two of the distinct distinct regions of the consumable may be formed from aerosol generating material of different compositions, and steps (b) and (c) may be repeated for each different composition of aerosol generating material.

In some embodiments of any of the above embodiments, step (c) includes the use of one or more of time, conductive heat, radiant heat, or movement of air across the exposed surface of the aerosol-generating material.

In some embodiments of any of the above embodiments, the method includes a further step (f) including providing a susceptor and fixing the susceptor to a support. This step is included when the aerosol-generating material is heated using magnetic induction techniques or a combination of magnetic induction and resistive heating techniques. When the consumable is heated using resistive heating techniques only, a susceptor need not be provided, but may be present.

In some embodiments of any of the above embodiments, step (f) occurs after step (a), where a susceptor is secured to a first surface of a support, and step (b) occurs after step (f), where a slurry of aerosol-generating material is at least partially applied to the susceptor. In some embodiments, the susceptor is a sheet of metal foil, and all of the aerosol-generating material is applied to the susceptor.

In some embodiments of any of the above embodiments, the support is a sheet of material and the method includes a step (h) that includes cutting the support into two or more consumables. Such an approach is advantageous in that it facilitates handling of the support in the manufacturing process because it may be easier to handle sheets of material that are larger than the size of material typically required to form consumables for handheld aerosol delivery devices. The support can be cut to form consumables of any desired shape, such as square, rectangular, or circular.

In some embodiments of any of the above embodiments, the method includes step (i) including perforating at least the support to form one or more perforations. The one or more perforations may extend at least between the first and second surfaces of the support, the one or more perforations may extend at least between one of the first or second surfaces of the support and a face of the consumable adjacent the other of the first or second surfaces of the support, the one or more perforations may extend between a face of the consumable adjacent the first surface of the support and a face of the consumable adjacent the second surface of the support, the one or more perforations may extend at least through the sorbent material, the one or more perforations may extend at least through the aerosol generating material, or the one or more perforations may extend between a first dead-end end in the consumable and an other end that is open through one of the support, the substance to be delivered, the aerosol generating material, or the surface of the consumable.

In one embodiment of any of the above embodiments, the aerosol-generating material and/or the substance to be delivered includes an active agent.

As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, psychoactive substances. The active substance may be naturally derived or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, non-cannabinoid derived terpenes, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance.

The active substance may include one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

In some embodiments, the active agent includes nicotine. In some embodiments, the active agent includes caffeine, melatonin, or vitamin B12.

The active material may include or be derived from one or more botanical materials, or components, derivatives, or extracts thereof. As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, shells, and the like. Alternatively, the material may include synthetically derived active compounds naturally occurring in the botanical material. The material may be in the form of a liquid, gas, solid, powder, fine powder, ground particles, granules, pellets, pieces, strips, sheets, and the like. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, bell pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, kavi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be any of the following mint varieties: Mentha arvensis, grapefruit mint, Egyptian mint, peppermint, lime mint, chocolate mint, curly mint, wild mint, horse mint, pineapple mint, pennyroyal mint, and citrus mint. pulegium), English spearmint (Mentha spicata c.v.), and apple mint (Mentha suaveolens).

In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substance is tobacco.

In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from rooibos and fennel.

In some embodiments, the aerosol-generating material and/or the substance to be delivered includes a fragrance or flavoring.

As used herein, the terms "flavor" and "flavoring agent" refer to materials that may be used, where local regulations permit, to create a desired taste, aroma, or other somatosensory sensation in products intended for adult consumers. Such materials may be naturally derived flavor materials, botanical substances, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, and the like). citrus, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus, drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-yi Orchid, sage, fennel, wasabi, pimenta, ginger, coriander, coffee, hemp, oil of any species of mint from the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, carvey, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. The materials may be imitation, synthetic, or natural ingredients, or mixtures thereof. The materials may be in any suitable form, for example, liquids such as oils, solids such as powders, or gases.

In some embodiments, the flavor comprises menthol, spearmint, and/or peppermint. In some embodiments, the flavor comprises cucumber, blueberry, citrus, and/or red berry flavor components. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises a flavor component extracted from tobacco. In some embodiments, the flavor comprises a flavor component extracted from cannabis.

In some embodiments, the flavorings may include sensory elicitors intended to achieve somatosensory sensations that are typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and may include agents that provide heating, cooling, tingling, and anesthetic effects. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol WS-3.

The aerosol-generating material and/or the substance to be delivered is a material capable of generating an aerosol when activated, for example, by heating, irradiation, or in any other manner. The aerosol-generating material and/or the substance to be delivered can be, for example, in the form of a solid, liquid, or semi-solid (such as a gel), and may or may not contain an active substance and/or a flavoring.

The aerosol generating materials and/or substances to be delivered may include one or more active agents and/or flavorings, one or more aerosol former materials, and optionally one or more other functional materials.

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

The aerosol-generating material and/or the substance to be delivered may include or take the form of an aerosol-generating film. The aerosol-generating film may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, the substance to be delivered and/or a filler may also be present. The aerosol-generating film may be substantially free of plant material. In particular, in some embodiments, the aerosol-generating material and/or the substance to be delivered is substantially free of tobacco.

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

The slurry can 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 include or be an "amorphous solid." In some embodiments, the aerosol-generating material includes 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 dry gel. An amorphous solid is a solid material that can hold some fluid within it, such as a liquid. In some embodiments, the amorphous solid may include, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

The amorphous solid may be substantially free of plant material. The amorphous solid may be substantially free of tobacco.

In some embodiments, the aerosol generating agent can include one or more components capable of forming an aerosol. In some embodiments, the aerosol generating agent can include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In certain examples, the aerosol generating agent includes glycerol. In some embodiments, the aerosol generating agent includes one or more of polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butylene glycol, 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 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10% to about 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of the aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticizer. For example, the aerosol generating material may comprise from 0.5 to 40 wt%, from 3 to 35 wt%, or from 10 to 25 wt% of the aerosol generating agent.

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

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

The aerosol-generating material may also include a gelling agent.

In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohols, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, 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 alginates and/or pectins, which may be combined with a solidifying agent (such as a calcium source) during formation of the aerosol-generating material. In some cases, the aerosol-generating material may comprise calcium cross-linked alginic acid and/or calcium cross-linked 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 hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, 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 hydroxyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, 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, alginic acid, and combinations thereof. In preferred embodiments, the non-cellulose based gelling agent is alginic acid or agar.

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

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

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

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

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

In examples, the aerosol generating material includes a gelling agent in an amount of about 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, or 35 wt% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the aerosol generating material (i.e., not taking into account the amount of filler). In examples, the aerosol generating material includes a gelling agent in an amount of about 5-60 wt%, 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt% of the aerosol generating material (i.e., not taking into account the amount of filler).

In some examples, the alginic acid is included in the gelling agent in an amount of about 5-40 wt %, or 15-40 wt % of the aerosol-generating material. That is, the aerosol-generating material includes alginic acid in an amount of about 5-40 wt %, or 15-40 wt %, by dry weight of the aerosol-generating material. In some examples, the aerosol-generating material includes alginic acid in an amount of about 20-40 wt %, or about 15 wt % to 35 wt % of the aerosol-generating material.

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

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

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

The aerosol-generating material can be formed by (a) forming a slurry containing the components of the aerosol material or its precursor, (b) forming a layer of the slurry, (c) solidifying the slurry to form a gel, and (d) drying to form the aerosol-generating material.

(b) Forming the layer of the slurry typically involves spraying, casting, or extruding the slurry. In an example, the slurry layer is formed by electrostatically spraying the slurry. In an example, the slurry layer is formed by casting the slurry.

In some examples, (b) and/or (c) and/or (d) are performed at least partially simultaneously (e.g., during electrostatic spraying). In some examples, (b), (c) and (d) are performed sequentially.

In some instances, the slurry is applied to a substrate. A layer can be formed on the substrate.

In an example, the slurry includes a gelling agent, an aerosol former material, and an active agent. The slurry can include these components in any of the ratios provided herein for the composition of the aerosol-generating material. For example, the slurry can include (on a dry weight basis):
a gelling agent and optionally a filler, the gelling agent and the filler together amounting to about 10-60 wt % of the slurry;
comprising an aerosol former material in an amount of about 40-80 wt % of the slurry;
Optionally, the active material may be included in an amount of up to about 20 wt % of the slurry.

Solidifying the gel (c) can include providing a solidifying agent to the slurry. For example, the slurry can include sodium alginate, potassium alginate, ammonium alginate as gel precursors, and a solidifying agent including a calcium source (such as calcium chloride) can be added to the slurry to form a calcium alginate gel.
In examples, the solidifying agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or combinations thereof. In some examples, the solidifying agent comprises or consists of calcium formate and/or calcium lactate. In particular examples, the solidifying agent comprises or consists of calcium formate. The inventors have determined that using calcium formate as the solidifying agent typically results in aerosol-generating materials having higher tensile strength and higher resistance to elongation.

The total amount of solidifying agent, such as a calcium source, may be 0.5 to 5 wt % (calculated on a dry weight basis). Preferably, the total amount may be from about 1 wt %, 2.5 wt %, or 4 wt % to about 4.8 wt % or 4.5 wt %. The inventors have found that adding too little solidifying agent may result in an aerosol-generating material that does not stabilize the aerosol-generating material components, such that these components fall off the aerosol-generating material. The inventors have found that adding too much solidifying agent may result in an aerosol-generating material that is very sticky and therefore difficult to handle.

When the aerosol-generating material does not contain tobacco, a larger amount of solidifying agent may need to be applied. Thus, in some cases, the total amount of solidifying agent may be 0.5 to 12 wt%, such as 5 to 10 wt%, calculated on a dry weight basis. Suitably, the total amount may be from about 5 wt%, 6 wt%, or 7 wt% to about 12 wt% or 10 wt%. In this case, the aerosol-generating material will typically not contain tobacco.

In an example, providing the solidifying agent to the slurry includes spraying the solidifying agent onto the slurry, such as onto a top surface of the slurry.

Alginates are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) linked by (1,4)-glycosidic bonds to form a polysaccharide. In addition to calcium cations, alginic acid crosslinks to form a gel. Alginates with high G monomer content have been found to form gels more readily upon addition of a calcium source. Thus, in some cases, the gel precursor may include alginate, where at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginic acid copolymer are α-L-guluronic acid (G) units.

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

In an example, drying (d) reduces the thickness of the cast material by at least 80%, preferably 85% to 87%. For example, the slurry is cast at a thickness of 2 mm and the resulting dried aerosol-generating material has a thickness of 0.2 mm.

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

In examples where the solvent comprises water, the dry weight content of the slurry can match the dry weight content of the aerosol-forming material. Thus, the discussion herein of solid compositions is expressly disclosed in conjunction with the slurry aspects of the invention.

The aerosol-generating material may include a flavoring. Preferably, the aerosol-generating material may include up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% flavoring. In some cases, the aerosol-generating material may include at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% flavoring (all calculated on a dry weight basis). For example, the aerosol-generating material may include 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% flavoring. In some cases, the flavoring consists essentially of or consists of menthol.

The aerosol generating material may include a filler.

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

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

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

When present, the filler may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler may include one or more organic filler materials, such as wood pulp, cellulose and cellulose derivatives, such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC). In certain cases, the aerosol generating material does not include calcium carbonate, such as chalk.

In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fiber, cellulose or a cellulose derivative (such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)).

Without wishing to be bound by theory, it is believed that the inclusion of fibrous fillers within the aerosol-generating material can increase the tensile strength of the material. This can be particularly advantageous in instances where the aerosol-generating material is provided as a sheet, such as when the aerosol-generating material sheet surrounds a rod of aerosolizable material.

In some embodiments, the aerosol-forming material does not include tobacco fibers. In certain embodiments, the aerosol-forming material does not include fibrous materials.

In some embodiments, the aerosol-forming material does not include tobacco fibers. In certain embodiments, the aerosol-forming material does not include fibrous materials.

The aerosol-generating materials may include one or more active agents and/or flavorings, one or more aerosol former materials, and optionally one or more other functional materials.

In some embodiments, the aerosol-generating material further comprises an active agent. For example, in some cases, the aerosol-generating material further comprises tobacco material and/or nicotine. In some embodiments, the aerosol-generating material comprises powdered tobacco and/or nicotine and/or tobacco extract.

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

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

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

In some cases, the total content of actives and/or fragrances may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and/or fragrances may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

In some cases, the total content of tobacco material, nicotine and flavorings may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and/or flavorings may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

The aerosol generating composition may include one or more active substances. In examples, the aerosol generating material includes one or more active substances, for example, up to about 20 wt% of the aerosol generating material. In examples, the aerosol generating material includes active substances in an amount of about 1 wt%, 5 wt%, 10 wt%, or 15 wt% to about 20 wt%, 15 wt%, 15 wt%, or 5 wt% of the aerosol generating material.

Active substances can include physiologically and/or olfactory active substances that are included in the aerosol generating composition to achieve a physiological and/or olfactory response.

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

The tobacco material may be present in any form, but is typically shredded (e.g., shredded). The shredded tobacco material can advantageously be mixed with the aerosol-forming material to provide an aerosol-forming composition having a uniform distribution of the tobacco material and the aerosol-forming material throughout the aerosol-forming composition.

In examples, the tobacco material comprises one or more of ground tobacco, tobacco fiber, shredded tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and/or tobacco extract. Surprisingly, the inventors have determined that it is possible to use relatively large amounts of laminar tobacco in an aerosol-generating composition and still provide an acceptable aerosol when heated by a non-combustion aerosol delivery system. Laminar tobacco typically provides superior organoleptic properties. In examples, the tobacco material comprises laminar tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material. In certain examples, the tobacco material comprises shredded tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material.

The tobacco used to make the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia and/or Burley and/or Orient.

In some embodiments, the one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and/or an antioxidant.

In some cases, the aerosol-forming material may further include an emulsifier that emulsifies the molten flavoring during manufacture. For example, the aerosol-forming material may include about 5 wt % to about 15 wt %, preferably about 10 wt %, of an emulsifier (calculated on a dry weight basis). The emulsifier may include gum acacia.

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

The aerosol-generating material can have any suitable water content, such as from 1 wt % to 15 wt %. Preferably, the water content of the aerosol-generating material is from about 5 wt %, 7 wt %, or 9 wt % to about 15 wt %, 13 wt %, or 11 wt % (WWB), most preferably about 10 wt %. The water content of the aerosol-generating material can be determined, for example, by Karl-Fischer titration or gas chromatography with a thermal conductivity detector (GC-TCD).

In some cases, the aerosol-forming materials may consist essentially of or consist of a gelling agent, water, an aerosol-forming agent, a flavoring agent, and optionally an active agent.

In some cases, the aerosol-forming materials may consist essentially of or consist of a gelling agent, water, an aerosol-forming agent, flavorings, and optionally tobacco materials and/or a nicotine source.

In examples, the aerosol-generating material may consist essentially of or consist of a gelling agent, an aerosol-generating agent, an active agent, and water. In examples, the aerosol-generating material consists essentially of or consists of a gelling agent, an aerosol-generating agent, and water.

In examples, the aerosol-generating material does not include a flavoring, and in certain examples, the aerosol-generating material does not include an active agent.

In some embodiments, the aerosol-forming material comprises:
1 to 60 wt % of a gelling agent;
0.1 to 50 wt % of an aerosol generating agent; and 0.1 to 80 wt % of a flavoring agent.
and these weights are calculated on a dry weight basis.

In some embodiments, the aerosol-forming material comprises 1-80 wt % flavoring (on a dry weight basis).

In some embodiments, the aerosol-forming material comprises:
1 to 50 wt % of a gelling agent;
0.1 to 50 wt % of an aerosol generating agent; and 30 to 60 wt % of a flavoring agent.
and these weights are calculated on a dry weight basis.

In an alternative embodiment of the aerosol-forming material, the aerosol-forming material comprises:
1 to 60 wt % of a gelling agent;
5-60 wt % of an aerosol generating agent; and 10-60 wt % of a tobacco extract.
and these weights are calculated on a dry weight basis.

In some embodiments, the aerosol-forming material comprises:
1 to 60 wt % of a gelling agent;
20-60 wt % of an aerosol generating agent; and 10-60 wt % of a tobacco extract.
and these weights are calculated on a dry weight basis.

In some embodiments, the aerosol generating material comprises 20-35 wt% gelling agent, 10-25 wt% aerosol former material, 5-25 wt% filler including fiber, and 35-50 wt% flavoring and/or active agent.

In some cases, the aerosol-forming materials may consist essentially of or consist of a gelling agent, an aerosol-forming agent, tobacco extract, water, and optionally flavorings. In some cases, the aerosol-forming materials may consist essentially of or consist of glycerol, alginic acid and/or pectin, tobacco extract, and water.

In some embodiments, the aerosol generating material may have the following composition (DWB): gelling agent (preferably including alginic acid) in an amount of about 5 wt% to about 40 wt%, or about 10 wt% to 30 wt%, or about 15 wt% to about 25 wt%; tobacco extract in an amount of about 30 wt% to about 70 wt%, or about 40 wt% to 55 wt%, or about 45 wt% to about 50 wt%, aerosol generating agent (preferably including glycerol) in an amount of about 10 wt% to about 50 wt%, or about 20 wt% to about 40 wt%, or about 25 wt% to about 35 wt% (DWB).

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

The "thickness" of an aerosol-generating material describes the shortest distance between a first surface and a second surface. In embodiments in which the aerosol-generating material is in the form of a sheet, the thickness of the aerosol-generating material is the shortest distance between a first flat surface of the sheet and a second flat surface of the sheet that is opposite the first flat surface of the sheet.

In some cases, the layer of aerosol-generating material that forms the aerosol has a thickness of about 0.015 mm to about 1.5 mm, preferably about 0.05 mm to about 1.5 mm or 0.05 mm to about 1.0 mm. Preferably, the thickness may be in the range of about 0.1 mm or 0.15 mm to about 1.0 mm, 0.5 mm or 0.3 mm.

In some cases, the aerosol-generating material can have a thickness of about 0.015 mm to about 1.0 mm. Preferably, the thickness can range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

Materials having a thickness of 0.2 mm are particularly suitable. The aerosol-generating material may have two or more layers, and the thicknesses mentioned herein refer to the aggregate thicknesses of these layers.

If the aerosol generating material is too thick, it has been observed that heating efficiency is compromised, which has a negative impact on power consumption during use. Conversely, if the aerosol generating material is too thin, it may be difficult to manufacture and handle, very thin materials may be more difficult to cast, and may be prone to breaking, impairing aerosol formation during use.

The thicknesses specified herein are the average thickness of the material. In some cases, the thickness of the aerosol-generating material may vary by 25%, 20%, 15%, 10%, 5%, or 1% or less.

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

Such tensile strength may be particularly suitable for embodiments in which the aerosol generating material is formed as a sheet, which is then torn and incorporated into the aerosol generating article. In some instances, such as when the aerosol generating material includes a filler, the aerosol generating material may have a tensile strength of 600 N/m to 900 N/m, or 700 N/m to 900 N/m, or about 800 N/m. Such tensile strength may be particularly suitable for embodiments in which the aerosol generating material is included in the aerosol generating article/assembly as a rolled sheet, preferably in the form of a tube.

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

The aerosol-forming material can have any suitable areal density (mass per unit area), such as 30-120 g/ ^m2 . In some cases, the sheet may have a mass per unit area of 80-120 g/ ^m2 , or about 70-110 g/ ^m2 , or especially about 90-110 g/ ^m2 , or preferably about 100 g/ ^m2 (having a density similar to cut rag tobacco, so that mixtures of these materials do not easily separate). In some cases, the sheet may have a mass per unit area of about 30-70 g/ ^m2 , 40-60 g/ ^m2 , or 25-60 g/ ^m2 , and may be used to wrap aerosolizable material such as tobacco.

All weight percentages (expressed by wt%) set forth herein are calculated on a dry weight basis unless expressly indicated otherwise. All weight ratios are also calculated on a dry weight basis. Weights quoted on a dry weight basis refer to the entire extract or slurry or material, other than water, and may include components that are themselves liquids at room temperature and pressure, such as glycerol. Conversely, weight percentages quoted on a wet weight basis refer to all components, including water.

The aerosol generating material may include a colorant. The addition of a colorant may change the visual appearance of the aerosol generating material. The presence of a colorant in the aerosol generating material may enhance the visual appearance of the aerosol generating material. By adding a colorant to the aerosol generating material, the aerosol generating material may match in color to other components of the article that includes the aerosol generating material.

A wide variety of colorants may be used depending on the desired color of the aerosol-generating material. The color of the aerosol-generating material may be, for example, white, green, red, purple, blue, brown, or black. Other colors are contemplated. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food grade colorants, and pharmaceutical grade colorants. In some embodiments, the colorant is caramel, which may impart a brown appearance to the aerosol-generating material. In such embodiments, the color of the aerosol-generating material may resemble the color of other components in the aerosol-generating material, such as the tobacco material.

The colorant can be incorporated into the aerosol-generating material during its formation (e.g., when forming a slurry with the materials that form the aerosol-generating material) or can 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 an exposed surface of at least one distinct portion of the aerosol-generating material. This can reduce the level of tackiness or adhesiveness of the aerosol-generating material.

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

Referring to FIG. 1, the aerosol delivery device 2 includes a casing 4 within which is located a heater assembly 6. The heater assembly 6 is comprised of a heating chamber 8 and a heater 10. The heater 10 can be an electrical resistance heater or a magnetic field generator for use with a susceptor.

The heating chamber 8 defines an opening or mouth 12 at a first end of the heating chamber 8. At an opposing end of the heating chamber 8 is an aperture 14. The aperture 14 is in fluid communication with a mouthpiece 16 via a conduit 18.

Also located within the casing 4 is a controller 20 in electronic communication with the heater 10 and controlling the function of the heater 10. The controller 20 may include a memory (not shown) capable of storing one or more tables relating to the operation of the heater 10. The heater 10 and the controller 20 are powered by a power source 22. The power source 22 is a rechargeable battery. In other embodiments, the power source may be any other suitable power source.

The aerosol delivery device 2 is suitable for use with a consumable 24. The consumable 24 is comprised of one or more separate portions of an aerosol-generating material 26 supported on a first surface 30 of a support 28. The separate portions of the aerosol-generating material 26 are supported on the support 28 in a square grid pattern. Other non-illustrated embodiments of the consumable 24 may include more or less separate portions of the aerosol-generating material 26 other than those shown in FIG. 1, including a single portion of the aerosol-generating material 26, and these portions may be distributed on the surface of the support 28 in any pattern. The separate portions of the aerosol-generating material 26 are suitably shown in FIG. 1 as having a generally circular shape, but may be other shapes in other embodiments.

Referring to FIG. 2, the support 28 is a laminate of three substrates or layers 34, 36, 38. Layer 34 forms the first surface 30 and is comprised of a layer of aluminum foil. When the consumable 24 is in use, layer 34 acts as a susceptor and can heat separate portions of the aerosol-generating material 26. In other, not shown, embodiments, the susceptor layer 34 can be formed from other susceptor materials. In this embodiment, the susceptor layer 34 is impermeable.

Layer 36 of support 28 is a support layer and is present to provide consumable 24 with sufficient strength so that consumable 24 does not deform or flex during normal use. Layer 28 may be formed from a card or plastic material such as polyetheretherketone (PEEK). It will be appreciated that layer 36 may include other materials.

The layer 38 of the support 28 is composed of a material that is a solvent, i.e., an absorbent or adsorbent, for at least one delivered substance 40. The delivered substance 40 is the substance desired to be included in the aerosol generated when the aerosol-generating material 26 is heated, and about which a user takes a puff from the aerosol delivery device 2. The sorbent layer 38 forms the second surface 32 of the support 48.

In some embodiments, the substance 40 to be delivered is applied to the sorbent layer 38 at locations on the second surface 32 corresponding to the location of the substance to be delivered, which is simply allowed to diffuse into the sorbent layer 38, and to discrete portions of the aerosol-generating material 26 on the first surface 30 of the support. In other embodiments, referring to FIG. 3, on the second surface 32 of the support 28, one or more discrete zones 42 are each defined by a boundary 44 (represented by a line 44). The boundary 44 helps to keep the substance 40 to be delivered within the discrete zone 42.

The boundary 44 is at the interface between the sorbent material within the separate zone 42 having a first level of absorbency/adsorption (X) and the sorbent material outside the separate zone 42 having a second level of absorbency/adsorption (Y), where X is greater than Y. The absorbency/adsorption level Y of the sorbent material outside the separate zone 42 is the result of treatment of the sorbent material to reduce its absorbency/adsorption level.

In some non-illustrated embodiments, the boundaries 44 of the distinct zones 42 may be the same shape as the distinct zones of aerosol-generating material 26. In some embodiments, they may encompass an area of the second surface of the support that is different from the area of the first surface of the support that is covered by the distinct portions of aerosol-generating material 26.

The substance 40 delivered includes one of a flavorant, an active, a mixture of flavorants, a mixture of actives, or a mixture of one or more flavorants and one or more actives. In one embodiment of the consumable 24 shown in FIG. 3, the substance 40 delivered in each distinct zone 42 is of the same composition as each other distinct zone 42. In an alternative embodiment, the substance 40 delivered in at least two of the distinct zones 42 is of a different composition from one another.

One or more perforations 46 extend through distinct portions of the support 28 and the aerosol-generating material 26. These perforations 46 are dimensioned such that aerosol generated from one surface of the support can travel along the perforations to the other side of the support. This can help achieve mixing of the aerosol before it exits the mouthpiece 16 when a user takes a puff from the aerosol delivery device 2. The perforations 46 may have a cross-sectional area of at least 0.01 ^mm2 , at least 0.05 mm2, at least 0.1 ^mm2 , at least 0.5 ^mm2 , at least ^{1 mm2} , at least ² mm2, or at least ³ mm2.

The aerosol delivery device 2 for use with the consumable 24 of FIG. 2 has a heater 10 comprised of one or more magnetic field generators (not shown). The magnetic field generators are distributed in the heater 10 such that each magnetic field generator will independently heat a portion of the susceptor supporting a separate portion of the aerosol-generating material 26. This allows one or more separate portions of the aerosol-generating material to be heated at one time. When the consumable 24 is placed in the heating chamber 8 through the heating chamber port 12, each separate portion of the aerosol-generating material 26 overlies a magnetic field generator. The controller 20 determines which separate portion or portions of the aerosol-generating material 26 are to be heated and causes the appropriate magnetic field generator or generators to generate a varying magnetic field. This causes the portion or portions of the susceptor layer 34 that intersect with these varying magnetic fields to heat, which in turn heats the separate portion or portions of the aerosol-generating material 26.

As the or each separate portion of the aerosol-forming material 26 is heated, some of the heat generated in the susceptor layer 34 is transferred by the support layer 36 away from the susceptor layer 34 and into the sorbent layer 38. That heat aerosolizes the volatile material 40 that is absorbed or adsorbed in the or each portion of the sorbent layer 38 that corresponds to the or each heated separate portion of the aerosol-forming material 26.

In some non-illustrated embodiments, portions of the support layer 36 that correspond to distinct portions of the aerosol-generating material 26 may be altered to increase or decrease the thermal conductivity of those portions. This increases or decreases the rate at which the sorbent layer 38 heats up and the temperature to which the sorbent layer 38 is heated.

With reference to Figures 4 and 5, the consumable 124 is comprised of a support 128 on which one or more separate portions of the aerosol-generating material 26 are supported. The support 128 is a laminate with the first and second substrates/layers 34, 36. The first layer 34 is a susceptor in the form of a layer of aluminum foil.

Layer 36 of support 128 is a support layer and is present to provide consumable 124 with sufficient strength so that consumable 124 does not deform or bend during normal use. Layer 36 may be formed from a card or plastic material such as polyetheretherketone (PEEK). It will be appreciated that layer 36 may include other materials.

Supported on the impermeable surface of the susceptor layer 34 are one or more distinct portions of the aerosol-generating material 26 and an equal number of portions of the sorbent material 50. Each portion of the sorbent material 50 has the form of a ring, and each portion of the sorbent material 50 is supported on the first surface 30 of the support 128 in a position that surrounds the distinct portion of the aerosol-generating material 26 in the plane of the first surface of the support 128.

Each portion of the sorbent material 50 includes at least one substance absorbed/adsorbed to the sorbent material. The substance absorbed/adsorbed to the sorbent material and delivered may be different for one or more of the portions of the sorbent material 50.

The consumable 124 is used in a manner similar to the consumable 24 of Figures 2 and 3, except that heating of the portion of the sorbent material 50 is by direct conduction from the susceptor 34 and/or a separate portion of the aerosol-generating material 26.

Referring to FIG. 6, the consumable 224 is comprised of a support 228 on which one or more separate portions of the aerosol-generating material 26 are supported. The support 228 is a laminate of first and second substrates/layers 34, 36. The first layer 34 is a susceptor in the form of a layer of aluminum foil.

Layer 36 of support 128 is a support layer and is present to provide consumable 224 with sufficient strength so that consumable 224 does not deform or bend during normal use. Layer 36 may be formed from a card or plastic material such as polyetheretherketone (PEEK). It will be appreciated that layer 36 may include other materials.

One or more distinct portions of the aerosol-generating material 26 are supported on the impermeable first surface 30 of the susceptor layer 34. One or more portions of the sorbent material 150 are supported on the second surface 32 at locations corresponding to the distinct locations of the aerosol-generating material 26 on the first surface 30. The number of portions of the sorbent material 150 is equal to the number of distinct portions of the aerosol-generating material 26. Each portion of the sorbent material 150 has the same shape as, and covers a larger area than, a distinct portion of the aerosol-generating material 26.

Each portion of the sorbent material 150 includes at least one substance absorbed/adsorbed to the sorbent material. The substance to be delivered absorbed/adsorbed to at least one portion of the sorbent material 110 may be different from other portions of the sorbent material 150.

Consumables 224 are used in a manner similar to consumables 24 of Figures 2 and 3.

7, the consumable 324 is comprised of a support 328 on which one or more separate portions of the aerosol generating material 26 are supported. The support 328 is a laminate of first and second substrates/layers 36, 38. The first layer 36 of the support 328 is a support layer and is present to provide the consumable 324 with sufficient strength so that the consumable 324 does not deform or flex during normal use. The layer 36 may be formed from a card or plastic material such as polyetheretherketone (PEEK). It will be appreciated that the layer 36 may include other materials.

The second layer 38 of the support 328 is a layer of sorbent material. The second layer 38 forms the first surface 30 of the support 328.

One or more distinct portions of the aerosol-generating material 26 are supported on the sorbent surface of the sorbent layer 38. The sorbent layer 38 includes one or more distinct zones 342 having boundaries represented by lines 344. The distinct zones 342 are equal in number to the number of distinct portions of the aerosol-generating material 26, with each distinct zone 342 surrounding a distinct portion of the aerosol-generating material 26 in the plane of the first surface of the support 328.

Boundary 344 is at the interface between the sorbent material within separate zone 342 having a first level of absorbency/adsorption (X) and the sorbent material outside separate zone 342 having a second level of absorbency/adsorption (Y), where X is greater than Y. The absorbency/adsorption level Y of the sorbent material outside separate zone 342 is the result of an action taken to reduce its absorbency/adsorption level.

Each distinct zone 342 includes at least one delivered substance that is absorbed/adsorbed to the sorbent material of the distinct zone. The delivered substance that is absorbed/adsorbed to the sorbent material may be different for one or more of the distinct zones 342 relative to the other distinct zones 342.

Consumable 324 is used in a manner similar to consumable 24 of FIGS. 2 and 3, with the exception that heating of consumable 324 is by a resistive heater. The resistive heater may include one or more separate zones that may be heated one at a time to allow individual, separate portions of aerosol-generating material 26 to be heated.

In a further embodiment, not shown, of the consumable 324 of FIG. 7, the support may be a single sheet of sorbent material 38. The remaining details of this embodiment are as for the embodiment of FIG. 7.

8, the consumable 424 is comprised of a support 428. One or more discrete portions of the aerosol-generating material 26 are supported on a first surface 30 of the support 428. The support 428 is formed from a sorbent material. The consumable 424 is adapted to be heated using an external heating source (not shown), e.g., a resistive heater that emits radiant heat.

The substance 40 to be delivered is absorbed or adsorbed onto the second surface 32 of the support 428 in an area of the second surface 32 that corresponds to the distinct portion of the aerosol-generating material 26. One or more perforations 446 extend through the distinct portion of the aerosol-generating material 26, the support 428, and the substance 40 to be delivered.

Referring to FIG. 9, a schematic of a method for manufacturing a consumable product is shown, which includes the following steps:

A support 28 including a susceptor layer 34, a support layer 36 and a sorbent layer 38 is provided in step 60.

In step 62, a slurry of aerosol-generating material is prepared, the slurry including a solvent for the aerosol-generating material and one or more desired active substances.

In step 64, the slurry of aerosol-generating material 26 is applied to one or more areas on the surfaces 30, 32 of the support 28.

In step 66, the applied slurry is dried to form a solid or gel of the aerosol-generating material on the surface of the support. The drying process may be allowing the solvent of the aerosol-generating material to evaporate at ambient conditions. Alternatively, the drying process may be accelerated by heating the slurry to a temperature below the temperature at which the aerosol-generating material begins to aerosolize to promote evaporation of the solvent. The heating may be by induction or radiative heating methods. Alternatively or additionally, step 66 may include exposing the aerosol-generating material to a high airflow rate over the aerosol-generating material to promote evaporation of the solvent from the aerosol-generating material.

Step 66 may include techniques where some desired active ingredients are present in the slurry of aerosol-generating material, to evaporate these active ingredients from the aerosol-generating material at a rate sufficient such that, once drying is complete, the remaining aerosol-generating material does not contain the desired amount of these active ingredients.

Once step 66 is completed, in step 68, it can be determined whether further applications of the aerosol-generating material slurry are required. If the answer to the question in step 68 is "yes," steps 64-68 are repeated. The second or subsequent application of the slurry may be an application of the same slurry as the first application, or at least an application of a slurry of a different composition than the first application.

If the answer to the question in step 68 is "no," then in step 70, one or more delivered substances 40 are applied to the sorbent material 38. These delivered substances may have high volatility. However, they are not subjected to the conditions of the drying step 66, and therefore the amount of substance that needs to be applied to the adsorption area can be significantly less than if they were subjected to the drying step 66. The delivered substances are applied to the surface of the sorbent material 38, followed by absorption or adsorption into the sorbent material 38.

In step 72, at least the support 28 is perforated by a perforation means.

In step 74, the support is cut into two or more individual consumables ready for packaging and distribution for use or sale to a user.

With reference to FIG. 10, a second schematic method for manufacturing a consumable product is shown, which method includes the steps described below. Those steps that are the same as those in the method of FIG. 7 have the same reference numbers and will not be described again below.

A support 28 including a support layer 36 is provided in step 76.

Steps 62 to 68 are the same as the manufacturing method shown in Figure 9.

If the question in step 68 is answered "no," then in step 78, one or more portions of the sorbent material 50, 150 are secured to the support 28. The sorbent material may be applied to a preformed support with one or more delivered substances 40 already absorbed/adsorbed to the portion of the sorbent material 50, 150. Alternatively, the portion of the sorbent material 50, 150 may have the delivered substance applied to the portion of the sorbent material 50, 150 after being secured to the support. In this alternative, the delivered substance is then allowed to be absorbed or adsorbed.

Steps 72 and 74 follow step 78.

With reference to FIG. 11, a third schematic method for manufacturing a consumable product is shown, which method includes the steps described below. Those steps that are the same as those in the method of FIG. 9 or FIG. 10 have the same reference numbers and will not be described again below.

Step 76 is followed by steps 62 and 64.

In step 80, it is determined whether a paste that dries to form the sorbent material 50, 150 is to be applied to the support 28.

If the answer to step 80 is yes, the paste is provided and applied to the substrate in step 82. The process then proceeds to drying step 66.

If the answer to step 80 is "no," the process proceeds to drying step 66.

Steps 68, 70, 72 and 74 follow next.

The consumable products resulting from the present disclosure have been found to have advantageous storage characteristics in that the delivered substances have been found to maintain a substantially consistent flavor amplitude for at least 90 days after manufacture of the consumable product.

A test was conducted on the long-term flavor magnitude of a substance delivered in the form of a citrus-based flavor composition. In the test, a consumable was manufactured that included a card support overlaid with a layer of aluminum foil. A layer of aerosol-generating material (composed of a binder and an aerosol former (glycerol)) was applied onto the surface of the support formed by the layer of aluminum, and the aerosol-setting material was allowed to solidify. Once the aerosol-generating material had solidified, a pipette was used to apply 0.34 mg of the citrus-based flavor composition to the surface of the consumable formed from the card at a location corresponding to a predetermined heating zone. The consumable was then heated in the predetermined heating zone.

After the citrus fragrance composition was applied to the consumable product, the samples were subjectively evaluated at five time periods (T).

To conduct the evaluation during time period T, the following steps were followed:

Two days before period T, a control sample was prepared using the same technique and substrate as used to prepare the test sample.

During time period T, one of the predefined heating zones on the test consumable was heated using an aerosol delivery device comprising a heater, a chamber (where an aerosol is formed upon heating), and a mouthpiece. A tester then performed a sensory evaluation of the aerosol received through the mouthpiece. This was repeated with a control sample after the aerosol delivery device was cleaned.

The evaluation results are shown in Table 1 below.

As can be seen from Table 1, there is minimal fragrance loss over the 90 day study.

Studies have been conducted on consumer reactions to various fragrances, as shown in Table 2.

The samples were then heated as above and the aerosol produced was sampled by a tester. The flavouring was found to be cleaner in flavour than the cigarette and free of ashy or burnt off-notes.

Additionally, testers found that when they exhaled the inhaled aerosol, there were lower levels of visible aerosol/particles than with cigarettes, and very little scent remained in the test room after the test.

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

Claims (50)

A consumable for use with an aerosol delivery device, the consumable comprising a support, an aerosol generating material, and a delivered substance that can be volatilized, the support supporting the aerosol generating material, and the delivered substance volatilizing upon heating of one or both of the support or the aerosol generating material. The consumable of claim 1, wherein the support comprises a sorbent material, the sorbent material comprising the substance to be delivered. The consumable of claim 2, wherein the delivered substance is located within one or more distinct zones of the sorbent material and is not located outside of these distinct zones. The consumable of claim 2 or 3, wherein the support is a laminate, the laminate including at least first and second substrates, at least one of the substrates being formed from a sorbent material. The consumable product of any one of claims 2 to 4, wherein the sorbent material forms one or both of the first or second surfaces of the support. The consumable product according to any one of claims 1 to 5, wherein the surface of the support is formed from an impermeable material. The consumable according to any one of claims 1 to 6, wherein the surface of the support is formed from a susceptor. The consumable product according to claim 7, wherein the susceptor is a metal foil. The consumable product according to any one of claims 2 to 8, wherein the aerosol-generating material is supported on a surface of the support that is a sorbent material. The consumable of any one of claims 1 to 8, wherein the aerosol-generating material is supported on a surface of the support that is not a sorbent material. The consumable product according to any one of claims 1 to 9, wherein the support is formed from a sorbent material. The consumable product according to any one of claims 1 to 11, wherein the substance to be delivered is supported on the surface of the support. The consumable of claim 12, further comprising a sorbent material, the sorbent material comprising the substance to be delivered, the sorbent material being supported on a surface of the support. The consumable according to any one of claims 1 to 13, wherein the substance to be delivered is volatilized a certain period PS after the start of heating the support or aerosol-generating material, and the aerosol-generating material is configured to release an aerosol a certain period PA after the start of heating the support or aerosol-generating material, the period PS being equal to or less than PA. The consumable product according to claim 14, wherein the period PS is less than PA. The consumable product according to any one of claims 1 to 15, wherein the temperature to which the substance to be delivered needs to be heated to volatilize the substance to be delivered is lower than the temperature to which the aerosol-generating material needs to be heated to generate the aerosol. The consumable according to claim 3 or any one of claims 4 to 16 when dependent on claim 3, wherein at least one distinct zone has a shape and size, the shape and size of the distinct zone being at least partially defined by a sorbent material surrounding the distinct zone, the sorbent material having a reduced capacity for sorption of the at least one substance to the sorbent material relative to a capacity for sorption of the at least one substance to the sorbent material in the distinct zone. The consumable of claim 17, wherein the consumable includes two or more distinct zones. The consumable product of claim 18, wherein at least two of the distinct zones contain different substances to be delivered. A consumable according to claim 3 or any one of claims 4 to 19 when dependent on claim 3, wherein the aerosol-generating material is supported on the support in one or more separate portions, and at least one separate zone is associated with each separate portion of the aerosol-generating material. A consumable according to claim 3 or any one of claims 4 to 20 when dependent on claim 3, wherein the distinct zones are on the same surface of the support as the distinct portions of the aerosol-generating material and substantially surround the distinct portions of the aerosol-generating material. A consumable according to claim 3 or any one of claims 4 to 21 when dependent on claim 3, wherein the separate portions of the aerosol-generating material are on a first surface of the support and the separate zones are on a second surface of the support, the separate portions of the aerosol material and the separate zones being in corresponding positions on their respective surfaces. 23. The consumable of claim 22, wherein the shapes of the distinct portions and the distinct zones of the aerosol-generating material in the plane of the first and second surfaces of the support are substantially the same. 23. The consumable of claim 22, wherein the separate portions of the aerosol-generating material cover a first area on the surface of the support on which the separate portions are supported, and the separate zones cover a second area on the surface of the support on which the separate zones are supported, and one of the first and second areas is larger than the other of the first and second areas. The consumable according to any one of claims 1 to 24, further comprising one or more perforations extending between at least the first and second surfaces of the support. 26. The consumable of claim 25, wherein at least one perforation extends between one of the first or second surfaces of the support and a face of the consumable adjacent the other of the first or second surfaces of the support. The consumable of claim 25 or 26, wherein at least one perforation extends between a surface of the consumable adjacent the first surface of the support and a surface of the consumable adjacent the second surface of the support. The consumable product of any one of claims 25 to 27, wherein at least one of the perforations extends through the substance to be delivered. The consumable product of any one of claims 25 to 28, wherein at least one of the perforations extends through the aerosol-generating material. The consumable of any one of claims 25 to 29, wherein at least one of the perforations has a first dead-end end within the consumable and an other end that opens through a surface of one of the support, the substance to be delivered, the aerosol-generating material, or a surface of the consumable. The consumable product of any one of claims 25 to 30, wherein the perforations have a cross-sectional area of ^at least 0.01 mm ² , at least 0.05 mm ² , at least 0.1 mm ² , at least 0.5 mm ² , at least 1 mm ² , at least 2 mm 2 , or at least 3 mm ² . The consumable product of any one of claims 1 to 31, wherein the at least one substance comprises a flavorant, an active substance, a mixture of flavorants, a mixture of active substances, a mixture of one or more flavorants and one or more active substances, one or more solvents, and/or one or more aerosol generating or forming agent materials. The consumable product according to any one of claims 1 to 32, wherein the support is flat. 1. A method of manufacturing a consumable for use with an aerosol delivery device, the consumable including a support, an aerosol-generating material, and a substance to be delivered that can be volatilized, the method comprising:
a) providing a support;
b) applying a slurry of the aerosol-generating material to a surface of the consumable;
c) drying the applied aerosol-forming material; and
d) applying the substance to be delivered to a surface of the consumable;
A method comprising: 35. The method of claim 34, wherein step (b) occurs any time after step (a), step (b) is followed by step (c), and step (d) occurs any time after step (c). The method of claim 34 or 35, wherein the method includes a step (e) including providing a sorbent material, the step (e) being performed before the step (d), the step (d) including applying the substance to be delivered to the sorbent material to form a sorbent material including the substance to be delivered, and, if the support does not include the sorbent material, applying the sorbent material including the substance to be delivered to the consumable. 37. The method of claim 36, wherein step (e) includes applying a paste to the consumable and then drying the paste, the paste drying to form a sorbent material. 37. The method of claim 36, wherein step (e) includes forming a desired shape of a sorbent material and fixing the shape of the sorbent material in a desired location on the consumable. The method of claim 38, wherein step (d) occurs before the sorbent material is secured to the consumable. The method of any one of claims 34 to 39, wherein steps (b) and (c) are repeated one or more times before step (d). The method of any one of claims 34 to 40, wherein step (c) includes the use of one or more of time, conductive heat, or radiant heat. The method of any one of claims 34 to 41, wherein the method includes a further step (f) comprising providing a susceptor and fixing the susceptor to the support. 43. The method of claim 42, wherein step (f) occurs after step (a), the susceptor is secured to a first surface of the support, and step (b) occurs after step (f), the slurry of the aerosol-generating material is at least partially applied to a surface of the susceptor. The method of any one of claims 34 to 43, wherein the support is a sheet of material, and the method further comprises step (h) comprising cutting the support into two or more consumables. The method includes a step (i) comprising perforating at least a portion of the consumable to form one or more perforations;
one or more perforations extend between at least the first and second surfaces of the support;
one or more perforations extend between one of the first or second surfaces of the support and a face of the consumable adjacent the other of the first or second surfaces of the support;
one or more perforations extend between a surface of the consumable adjacent the first surface of the support and a surface of the consumable adjacent the second surface of the support;
one or more perforations extend at least through the sorbent material;
one or more perforations extend at least through the aerosol-forming material; and
one or more perforations have a first dead end within the consumable and an other end opening through a surface of one of the support, the substance to be delivered, the aerosol-forming material, or a surface of the consumable;
The method according to any one of claims 36 to 44, wherein the method is one or more of: The method according to any one of claims 34 to 45, which forms a consumable according to any one of claims 1 to 33. An aerosol delivery system comprising an aerosol delivery device and a consumable product according to any one of claims 1 to 33. A method of generating an aerosol from a consumable according to any one of claims 1 to 33 using an aerosol generating device, the aerosol generating device having at least one heat source arranged to heat the consumable in use without burning it, the at least one heat source being a resistive heating element. A method for generating an aerosol from a consumable according to any one of claims 1 to 33 using an aerosol generating device, the aerosol generating device having at least one heat source arranged to heat the consumable in use without burning it, the at least one heat source being a magnetic field generator suitable for generating eddy currents in a susceptor. A method of generating an aerosol according to claim 48 or 49, wherein the consumable comprises one or more separate portions of an aerosol generating material, and the or each heat source is configured to be capable of heating one or more of the separate portions at a time.

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