WO2022243434A2

WO2022243434A2 - A Consumable for use with an Aerosol Provision Device

Info

Publication number: WO2022243434A2
Application number: PCT/EP2022/063582
Authority: WO
Inventors: Muhammad Fahim Ashraf ASHRAF; Walid Abi Aoun
Original assignee: British American Tobacco (Investments) Limited
Priority date: 2021-05-20
Filing date: 2022-05-19
Publication date: 2022-11-24
Also published as: EP4340651A2; WO2022243434A3

Abstract

A consumable (24) for use with an aerosol provision device (2) is described. The consumable (24) comprises a support (28), an aerosol generating material (26), and a substance to be delivered (40) that may be caused to volatise, in which the support (28) supports the aerosol generating material (26), and the substance to be delivered (40) volatilises on heating of one or both of the support (28) or the aerosol generating material (26).

Description

A CONSUMABLE FOR USE WITH AN AEROSOL PROVISION DEVICE

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

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

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

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

According to a first aspect of the present disclosure there is provided a consumable for use with an aerosol provision device. The consumable comprises a support, an aerosol generating material, and substance to be delivered that may be caused to volatise, in which the support supports the aerosol generating material, and the substance to be delivered volatilises on 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 provision device, in which the consumable comprises a support, an aerosol generating material, and at least one substance that may be caused to volatise, in which the method comprises the steps of a) providing a support; b) applying a slurry of the aerosol generating material to a surface of the consumable, c) drying the applied aerosol generating material, d) applying the at least one substance to a surface of the consumable.

According to a third aspect of the present disclosure there is provided an aerosol provision system comprising an aerosol provision 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 aerosol from a consumable according to the first aspect of the present disclosure using an aerosol generating device with at least one heat source disposed to heat, but not burn, the consumable in use, wherein at least one heat source is a resistive heater element.

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

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

Figure 2 shows a first embodiment of the consumable of Figure 1 along section-line

AA’;

Figure 3 shows the second surface of the support of the first embodiment of the consumable of Figure 1 ;

Figure 4 shows a second embodiment of the consumable of Figure 1 along section line AA’;

Figure 5 shows a perspective view of the second consumable of Figure 4;

Figure 6 shows a third embodiment of the consumable of Figure 1 along section line AA’;

Figure 7 shows a fourth embodiment of the consumable of Figure 1 along section line AA’;

Figure 8 shows a fifth embodiment of the consumable of Figure 1 along section-line

AA’;

Figure 9 shows a schematic first example of a method of manufacture of a consumable according to the present disclosure;

Figure 10 shows a schematic second example of a method of manufacture of a consumable according to the present disclosure; and Figure 11 shows a schematic third example of a method of manufacture of a consumable according to the present disclosure.

Detailed Description

The consumable of the present description may be alternatively referred to as an article.

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

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

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

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

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

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

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

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

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

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

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

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

According to a first aspect of the present disclosure there is provided a consumable for use with an aerosol provision device. The consumable comprises a support, an aerosol generating material, and substance to be delivered that may be caused to volatilise. The support supports the aerosol generating material, and the substance to be delivered volatilises on heating of the support or the aerosol generating material. An advantage of the consumable of the present disclosure is that the aerosol generating material and the substance to be delivered are separate from each other in that although they may be, but are not necessarily, physically close to each other, they may be at different locations on or in the consumable, they may be treated or behave differently during the manufacture, storage and / or use of the consumable. The aerosol generating material and the substance to be delivered may be different from each other and possessed of different characteristics such as the optimal range of temperatures of vaporisation or aerosol formation, the chemical composition of vapour or aerosol deriving from the aerosol generating material and the substance to be delivered, storage characteristics, volatility, and speed and / or rate of volatilisation. This may be advantageous at the time of use of the consumable, during the storage of the consumable prior to the use of the consumable and / or at the time of manufacture of the consumable.

Reference to the substance to be delivered in this disclosure is to be understood to include reference to a single substance or a mixture of two or more substances.

In some embodiments of the above embodiment the support comprises a sorbent material and the sorbent comprises the substance to be delivered. It is to be understood that in this disclosure, discussion of a sorbent comprising the substance to be delivered refers to that substance to be delivered being absorbed into or adsorbed onto the sorbent material. This includes the situations where the substance to be delivered enters into pores or voids in the sorbent material but does not chemically interact with the sorbent material, - the substance to be delivered enters into the sorbent material and does chemically interact with the sorbent material, 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 substance to be delivered forms a film of the substance to be delivered on the sorbent material and chemically interacts with the sorbent material to form an adsorbate. In some embodiments of any of the above embodiments the substance to be delivered is located or absorbed / adsorbed in one or more discrete zones of the sorbent material, and not located outside of those discrete zones. In other embodiments, the substance to be delivered is located or absorbed / adsorbed in one or more discrete zones of the sorbent material at a higher concentration than the concentration of the substance to be delivered in the portions of the sorbent material not in those discrete zones.

In some embodiments, the substance to be delivered being absorbed into or adsorbed onto the sorbent material is achieved by the application of the substance to be delivered to a surface of the sorbent material and allowing the absorption or adsorption of the substance to be delivered into the sorbent material to take place. That application may be, but is not limited to, via spraying, brushing, application via a roller, or a known printing technique such as inkjet or valve jet printing. The use of a separate aerosol generating material and the substance to be delivered has one or more advantages. One such advantage is that the substance to be delivered may be selected so that it forms an aerosol faster and / or at lower temperatures than the formation of an aerosol from the aerosol generating material. This allows a user to experience a puff of aerosol quicker than would be experienced from a consumable that only included aerosol generating material.

A further advantage is that the aerosol generating material and the substance to be delivered may be selected to give a user a puff that has the same taste throughout the puff, or the aerosol generating material and the substance to be delivered may be chosen to give a puff with an initial first taste from the substance to be delivered followed by a second taste from the aerosol generating material.

A further advantage is that the substance to be delivered may have an aerosol formation temperature that is sufficiently low that that temperature is achieved using heat that dissipates from the aerosol generating material or that is not directed to / absorbed by that aerosol generating material whilst that aerosol generating material is being heated. This increases the overall amount or volume of aerosol (from the substance to be delivered and the aerosol generating material) that may be generated per unit of heat energy applied to the consumable compared to a consumable that only includes an aerosol generating material.

The support may be of a material suitable to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal 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 either side or surface of the material.

The sorbent material is a material which is either absorbent or adsorbent in connection with the substance to be delivered and which is suitable for use in a non-combustible aerosol provision system. Suitable materials for the sorbent material are, but are not limited to, porous materials, dried gels (aerogel, xerogel, cryogel), fibrous materials (natural or synthetic), paper, cardboard, ceramics, wood, aerogel, activated carbon, porous polymers, sponges. In the consumable of the disclosure, the sorbent material has a desired substance to be delivered absorbed or adsorbed into the structure of the sorbent material. The sorbent material may be heated to cause the substance to be delivered absorbed or adsorbed therein or thereon to aerosolise. The sorbent material may be chosen for its heat conductivity and the rate at which the substance to be delivered may aerosolise and the aerosol leave the sorbent material. In some embodiments of any of the above embodiments the at least one substance absorbed or adsorbed into / onto the sorbent material comprises one or more of a flavourant, an active substance, a mixture of flavourants, a mixture of active substances, a mixture of one or more flavourants and one or more active substances, one or more solvents, and / or one or more aerosol generators or aerosol former materials.

In some embodiments of any of the above embodiments the substance to be delivered may have a temperature at which it aerosolises of 60 degrees centigrade or above.

In some embodiments of any of the above embodiments the support may comprise a sorbent material. In some embodiments of any of the above embodiments the support may be formed from a sorbent material.

Aerosol generators or aerosol-former materials may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol- former material may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso- Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some embodiments of any of the above embodiments the support comprises the sorbent material. In some embodiments the support is a laminate, the laminate comprises at least a first and second substrate, and at least one of the substrates is formed from the sorbent material. In some embodiments another substrate of the laminate may be present for structural purposes, in particular to provide the consumable with desired handling characteristics, for example 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 comprised of a sorbent material and the other surface of the support is comprised of a material that is not a sorbent material.

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

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically- conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the susceptor by resistive heating as a result of electric eddy currents. The susceptor may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the susceptor. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator. The susceptor may comprise a ferromagnetic metal such as iron or an iron alloy such as steel or an iron nickel alloy. Some example ferromagnetic metals are a 400 series stainless steel such as grade 410 stainless steel, or grade 420 stainless steel, or grade 430 stainless steel, or stainless steel of similar grades. Alternatively, the susceptor may comprise a suitable non-magnetic, in particular paramagnetic, conductive material, such as aluminium. In a paramagnetic conductive material inductive heating occurs solely by resistive heating due to eddy currents. Alternatively, the susceptor may comprise a non-conductive ferrimagnetic material, such as a non-conductive ferrimagnetic ceramic. In that case, heat is only generated by hysteresis losses. The susceptor may comprise a commercial alloy like Phytherm 230 (with a composition (in % by weight = wt %) with 50 wt % Ni, 10 wt % Cr and the rest Fe) or Phytherm 260 (with a composition with 50 wt % Ni, 9 wt % Cr and the rest Fe). The susceptor may in some embodiments of any of the above embodiments be a metal foil, optionally an aluminium foil or a ferrous foil. Alternatively, the susceptor may in some embodiments of any of the above embodiments be any conductor that could be sprayed or vapour deposited on a material that forms the support.

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

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

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

In an embodiment of any of the above embodiments the support comprises a plastics material which can withstand the temperatures typically encountered in a non-combustible aerosol provision device. In some embodiments the support comprises polyether ether ketone (PEEK). Such embodiments have the advantage that the support may be reused, and that the consumable is less affected by any condensation in the non-combustible aerosol provision device than consumables that comprise a support which includes use of a sorbent material for structural purposes.

In some embodiments of any of the above embodiments the aerosol generating material is supported on a surface of the support that is not a sorbent material.

Such an arrangement has the effect that during the manufacture, subsequent storage and use of the consumable neither the aerosol generating material or any components of the aerosol generating material will be adsorbed / absorbed into the support or sorbent material. In some embodiments of any of the above embodiments the aerosol generating material is supported on a surface of the support that is 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 the support.

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

In some embodiments of any of the above embodiments the aerosol generating material is supported on the 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 rather supported on the surface of the support. Such an arrangement has the advantage that the sorbent material can be supported on the support only in the positions where it is desirable for the sorbent material to be located. In some embodiments of any of the above embodiments the aerosol generating material and sorbent material are both so located on the consumable that heating of the aerosol generating material to cause at least one component of the aerosol generating material to aerosolise also heats at least a portion of the sorbent material. That heating of at least a portion of the sorbent material may be by thermal conduction from the aerosol generating material and / or the portion of the support that supports the aerosol generating material. Such heating of the sorbent material may be considered to be indirect heating.

Such indirect heating may result in the sorbent material being heated to a temperature that is lower than the temperature to which the aerosol generating material is heated, but to a temperature sufficient to cause the substance to be delivered to volatise. The heating profile of the sorbent material may in some embodiments be influenced by the shape and proximity of the sorbent material to the aerosol generating material. In some embodiments of any of the above embodiments the support may comprise or support means for regulating or facilitating the conduction of heat from the aerosol generating material and / or the portion of the support that supports the aerosol generating material to the sorbent material.

In some embodiments of any of the above embodiments the sorbent material comprises at least one discrete zone. Each discrete zone is a volume of sorbent material which may be so located relative to the aerosol generating material that heating of the aerosol generating material to cause at least one component of the aerosol generating material to aerosolise results in the sorbent material in the discrete zone being heated to a temperature high enough to cause the at least one substance absorbed or adsorbed therein to volatise or aerosolise. The sorbent material may comprise one or more discrete zones.

In some embodiments of any of the above embodiments the substance to be delivered is volatised a period of time PS after commencement of heating the support or aerosol generating material, the aerosol generating material is configured to release aerosol a period of time PA after commencement of heating the support or aerosol generating material, and period PS is smaller than or equal to PA. In some embodiments period PS is smaller than PA.

In some embodiments of any of the above embodiments the sorbent material comprises one or more discrete zones, and the concentration of the substance to be delivered in the sorbent material in the discrete zones may be caused to be greater, in some embodiments significantly greater, than the concentration of the substance to be delivered in those parts of the sorbent material which are not in a discrete zone. The relative concentrations of the substance to be delivered in the discrete zone and outside the discrete zone may be determined by the position of absorption / adsorption of the substance to be delivered into the sorbent material.

In some embodiments of any of the above embodiments the discrete zone is identifiable only by the relative position on the consumable and / or by the concentration of the substance to be delivered in the sorbent material in the discrete zone.

In other, alternative, embodiments, the discrete zone has a shape and size which is at least partially defined by the sorbent material surrounding the discrete zone having a reduced capacity for sorption of the at least one the substance to be delivered into that sorbent material relative to the capacity for sorption of the at least one substance into the sorbent material in the discrete zones. The capacity for sorption of the substance to be delivered of the sorbent material at least partially surrounding the discrete zone may, in some embodiments, be influenced by adsorbing / absorbing a non-volatile substance into the sorbent material at least partially surrounding the discrete zone. In some other embodiments, the surface of the sorbent material at least partially surrounding the discrete zone may be treated to limit the permeability of the surface to the substance to be delivered to be less than the permeability of the surface in the discrete zone. In some embodiments at least 50%, at least 60 %, at least 70%, at least 80% or at least 90% less than the surface of the discrete zone. Preventing or limiting the degree of sorption of the substance to be delivered into the sorbent material in areas of sorbent material where it is not desired that the sorbent comprises the substance to be delivered is likely to result in a reduction of the substance to be delivered used in the manufacture of the consumable with attendant cost savings. Such prevention or limitation may also make the use of consumables of this disclosure more consistent than would be achieved if the location of the substance to be delivered in the sorbent material were not controlled.

In some embodiments of any of the above embodiments there are at least two discrete zones, and at least two of the discrete zones comprise different substances to be delivered or different mixtures of the 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 discrete portions and at least one discrete zone is associated with each discrete portion of aerosol generating material.

In some embodiments of any of the above embodiments the surface of the support on which a discrete portion of the aerosol generating material is supported comprises or supports a sorbent material, that sorbent material includes a discrete zone, and the discrete zone substantially surrounds the discrete portion of the aerosol generating material. This arrangement has the advantage that when the discrete portion of the aerosol generating material is heated, the sorbent material of the discrete zone is indirectly heated by the discrete portion of the aerosol generating material.

In some embodiments of any of the above embodiments the consumable includes a discrete portion of the aerosol generating material which is on a first surface of the support, and a discrete zone of sorbent material is on the second surface of the support, and the discrete portion of the aerosol generating material and the discrete zone are in corresponding positions on their respective surfaces. By corresponding positions it is to be understood that when one of the discrete portion of the aerosol generating material and the discrete zone are viewed from a position perpendicular to the surface on which it is located, the one of the discrete portion of the aerosol generating material and the discrete zone substantially overlies the other of the discrete portion of the aerosol generating material and the discrete zone.

In some embodiments of any of the above embodiments the shapes of the discrete portion of the aerosol generating material and the discrete zone in the plane of the first and second surfaces of the support are substantially the same.

In some embodiments of any of the above embodiments the discrete portion of the aerosol generating material covers a first area on the surface of the support on which it is supported, the discrete zone covers a second area on the surface of the support on which it is supported, and one of the first and second areas is larger than the other of the first and second areas. In some embodiments of any of the above embodiments the consumable includes one or more perforations which extend at least between a first and second surface of the support. This arrangement has the advantage that when the consumable is in use, aerosol generated on one side or from a first surface of the support may pass through the perforations to the other side or a second surface of the support. This is advantageous because in some embodiments it allows an aerosol generated from 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 may mix before the aerosol passes to a mouth piece prior to being inhaled by a user.

It is to be understood that in this disclosure the term “a number” is intended to mean zero, one, or more than one. In some embodiments of any of the above embodiments one or more perforations extend at least between one of the first side or surface of the support and the face of the consumable that is adjacent the other side or surface of the support. In such embodiments the perforations extend through the support and, for example, a portion of the aerosol generating material supported on the surface of the support, or, in an alternative example, 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 that is adjacent the first side or surface of the support and the face of the consumable that is adjacent to the second side or surface of the support. In such embodiments the perforations may extend through the support, a portion of the aerosol generating material, and a portion of the sorbent material. In some embodiments of any of the above embodiments at least one of the perforations has a blind first end within the consumable, and the other end opens through a surface of one of the support, the substance to be delivered, the aerosol generating material or a surface of the consumable. A blind end is an end which is in a material and as such the end of the perforation is closed by that material. In some embodiments of any of the above embodiments the perforations 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.

In an embodiment of any of the above embodiments the aerosol generating material supported on the support is so located that there is a band of support on both surfaces of the support which extends a predetermined distance onto the support from an edge of the support that is free from aerosol generating material. That band may extend the same distance from the edge of the support for the whole length of the edge of the support. The band may assist in the handling of the consumable during use and or packaging. The band may be continuous along the whole length of the edge of the support or it may be discontinuous. The band may extend different distances onto the surfaces of the support at different positions 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 provision device, in which the consumable comprises a support, an aerosol generating material, and at least one substance, in which the method comprises the steps of a) providing a support; b) applying a slurry of the aerosol generating material to a surface of the consumable, c) drying the applied aerosol generating material, d) applying the at least one substance into the sorbent material to a surface of the consumable.

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 support my occur separately both in time and space. Such an ability overcomes a known issue with the manufacture of consumables for use with an aerosol provision device. It is known that in the manufacture of consumable for use with an aerosol provision device a slurry of aerosol generating material is formed, that slurry comprising a solvent which causes the aerosol generating material to be a slurry and one or more different substances or groups of substances (for example, one or more physiologically active materials and one or more flavours or flavourants) which will form part of the aerosol when the consumable is used and the aerosol generating material aerosolised. The solvent and those substances may, however, have different evaporation rates at any given temperature. In the manufacture of the consumable, the aerosol generating material slurry is applied to a surface of a support or a sheet of material which will subsequently be cut to form a plurality of supports. The slurry is then dried so as to form aerosol generating material of more or less fixed dimensions on the surface on which it is supported. In some embodiments the aerosol generating material dries to form an aerosol generating gel or an aerosol generating film. During that drying process, the solvent for the slurry evaporates as do some of the substances which are to form part of the aerosol on use of the consumable. It has been found that during the slurry drying process, that different evaporation rates of the solvent for the aerosol generating material and the various substances that will be aerosolised has the effect that it can be difficult to accurately control the quantities of the substances which are to form part of the aerosol in the dried aerosol material. This can result in it being difficult to achieve a consistent, predictable and repeatable commercial product. A further effect is that a significant amount of the active substances incorporated into the slurry is lost before the slurry has dried sufficiently to form an aerosol generating material of more or less fixed dimensions, an aerosol generating gel or an aerosol generating film.

The method of the disclosure allows the slurry to be formulated to include only those substances which will not evaporate in undesirable quantities during the drying of the slurry. Those substances may be those with an evaporation rate that is higher or significantly higher than that of the solvent in the conditions in which the slurry is dried. In some embodiments of any of the above embodiments, the substances that have hitherto evaporated in undesirable quantities during the drying of the slurry can comprise all or some of the substance to be delivered of the present disclosure.

This lowers the quantities of those substances lost to evaporation during the manufacturing process which increases the efficiency of use of those substances and lowers the environmental problems of evaporation of those substances during the consumable manufacturing process.

A further advantage of the method of the present disclosure may be that the slurry can be subject to a drying process involving higher temperatures than has been previously possible thus decreasing the manufacturing time for the consumables.

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 gaps 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 comprises a step (e) comprising providing a sorbent material.

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

In some embodiments of any of the above embodiments a sorbent material can be fixed to the consumable at any time in the manufacturing process. It will be understood that the sorbent material may be such that it will be unaffected by exposure to the drying process for the aerosol generating material slurry. In some embodiments the sorbent material is fixed to the support.

In some embodiments of any of the above embodiments, the support of step (a) comprises a sorbent material. In some embodiments of any of the above embodiments step (e) comprises application of a paste to the consumable and subsequently drying that paste, the paste drying to form a sorbent material. Such a method step can allow the sorbent material to be applied only to predetermined parts 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) comprises forming a desired shape of sorbent material, and fixing that shape of sorbent material to a desired position on the consumable. This approach to the shaping and then fixing of the sorbent to the support allows the sorbent material to be moulded, 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) comprise providing a sheet of sorbent material, applying an adhesive on a first surface and covering that adhesive with removable carrier sheet, applying the substance to be delivered to the other surface of the sorbent material and allowing the substance to be delivered to absorb or adsorb into or onto the sorbent material, and cutting the sorbent material into one or more desired shapes.

The adhesive may be a peel-able adhesive, a repositionable adhesive, a low tack adhesive or other appropriate adhesive.

The sorbent material can then be stored or transported to the consumable, the carrier sheet peeled off the sorbent material, and the sorbent material can then be adhered to the consumable in a desired position. The sorbent material may be adhered to the consumable during the manufacture of the consumable.

Alternatively, a user of the consumable may adhere the sorbent material to the consumable prior to the use of the consumable. This would allow a user to obtain one or more portions of sorbent material which comprise different substances to be delivered, for example flavours, choose which flavour they wish to use, and apply that flavour to the consumable. This embodiment has the advantage to the user of choice and control of their experience, and the advantage to the manufacturer that they can manufacture a limited range of consumables which can be used with a much wider range of substances to be delivered.

In some embodiments of any of the above embodiments step (d) occurs before the sorbent material is fixed to the consumable. This may have the advantage that the absorption / adsorption of the substance to be delivered into the sorbent material can occur at a location remote from the location of the 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 be built up in layers on the consumable. In some embodiments those layers may be formed of different compositions of aerosol generating material.

In some embodiments of any of the above embodiments the aerosol generating material may be applied to one or more discrete regions of the consumable. In some embodiments, at least two of the different discrete regions of consumable may be formed from aerosol generating material of different compositions from each other and step (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) comprises the use of one or more of time, conducted heat, radiant heat, or air movement across the exposed surfaces of the aerosol generating material.

In some embodiments of any of the above embodiments the method comprises a further step (f) comprising providing a susceptor and fixing the susceptor to the support. This step is included where the aerosol generating material is to be heated using magnetic induction techniques or a combination of magnetic induction and resistive heating techniques. Where the consumable is to heated using only resistive heating techniques no susceptor needs to be provided but may be present. In some embodiments of any of the above embodiments step (f) occurs after step (a) and the susceptor is fixed to the first surface of the support, step (b) occurs after step (f), and the slurry of aerosol generating material is at least partially applied to the susceptor. In some embodiments the susceptor is a sheet of metallic 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 comprises a step (h) comprising cutting the support into two or more consumables. Such an approach is advantageous in that it facilitates the handling of the support in the manufacturing process because it may be easier to handle a larger sheet of material than the size of material that is generally required to form a consumable for a hand aerosol provision device. 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 comprises a step (i) comprising perforating at least the support to form one or more perforations. One or more those perforations may extend at least between the first and second surfaces of the support, one or more those perforations may extend at least between one of the first or second surface of the support and the face of the consumable that is adjacent the other of the first or second surface of the support, one or more those perforations may extend between a face of the consumable that is adjacent the first surface of the support and the face of the consumable that is adjacent to the second face of the support, one or more those perforations may extend at least through the sorbent material, one or more those perforations may extend at least through the aerosol generating material, or one or more those perforations may extend between a blind first end within the consumable and the other end which opens through a surface of one of the support, the substance to be delivered, the aerosol generating material or a surface of the consumable.

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

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

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

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

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

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

In some embodiments, the aerosol generating material and / or the substance to be delivered comprises a flavour or flavourant.

As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice

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

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

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

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

The aerosol generating material and / or substance to be delivered may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

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

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

The aerosol generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. The aerosol generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol generating film. The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent. The aerosol generating material may comprise or be an “amorphous solid”. In some embodiments, the aerosol generating material comprises an aerosol generating film that is an amorphous solid. The amorphous solid may be a “monolithic solid”. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid. The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free

In some embodiments the aerosol generating agent may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol generating agent may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In particular examples, the aerosol generating agent comprises glycerol. In some embodiments, the aerosol generating agent comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and/or aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

In some embodiments, the aerosol generating material may comprise from about 0.1wt%, 0.5wt%, 1wt%, 3wt%, 5wt%, 7wt% or 10% to about 50wt%, 45wt%,

40wt%, 35wt%, 30wt% or 25wt% of an aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticiser. For example, the aerosol generating material may comprise 0.5-40wt%, 3-35wt% or 10- 25wt% of an aerosol generating agent.

In some embodiments, the aerosol generating material may comprise from about 5wt%, 10wt%, 20wt%, 25wt%, 27wt% or 30wt% to about 60wt%, 55wt%, 50wt%,

45wt%, 40wt%, or 35wt% of an aerosol generating agent (DWB). For example, the aerosol generating material may comprise 10-60wt%, 20-50wt%, 25-40wt% or 30- 35wt% of an aerosol generating agent. In some embodiments, the aerosol generating material may comprise up to about 80wt%, such as about 40 to 80wt%, 40 to 75wt%, 50 to 70wt%, or 55 to 65wt% of an aerosol generating agent (DWB).

The aerosol generating material may also comprise a gelling agent.

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

In some embodiments, the gelling agent comprises one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum and mixtures thereof.

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

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

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

In some embodiments, the gelling agent comprises alginate, and the alginate is present in the aerosol generating material in an amount of from 10-30wt% of the aerosol generating material (calculated on a dry weight basis). In some embodiments, alginate is the only gelling agent present in the aerosol generating material. In other embodiments, the gelling agent comprises alginate and at least one further gelling agent, such as pectin. In some embodiments, the aerosol generating material comprises from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt% or 35wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 1-50wt%, 5-45wt%, 10-40wt% or 20- 35wt% of a gelling agent.

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

In some cases, the aerosol generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt% or 20wt% to about 60wt%, 50wt%, 40wt%, 30wt% or 25wt% of a gelling agent (DWB). For example, the aerosol generating material may comprise 10-40wt%, 15-30wt% or 20-25wt% of a gelling agent (DWB). In examples, the aerosol generating material comprises gelling agent and filler, taken together, in an amount of from about 10wt%, 20wt%, 25wt%, 30wt%, or 35wt% to about 60wt%, 55wt%, 50wt%, or 45wt% of the aerosol generating material. In examples, the aerosol generating material comprises gelling agent and filler, taken together, in an amount of from about 20 to 60wt%, 25 to 55wt%, 30 to 50wt%, or 35 to 45wt% of the aerosol generating material.

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

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

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

In some examples, guar gum is comprised in the gelling agent in an amount of from about 3 to 40wt% of the aerosol generating material. That is, the aerosol generating material comprises guar gum in an amount of from about 3 to 40wt% by dry weight of the aerosol generating material. In some examples, the aerosol generating material comprises guar gum in an amount of from about 5 to 10wt% of the aerosol generating material. In some examples, the aerosol generating material comprises guar gum in an amount of from about 15 to 40wt% of the aerosol generating material, or from about 20 to 40wt%, or from about 15 to 35wt%. In examples, the alginate is present in an amount of at least about 50wt% of the gelling agent. In examples, the aerosol generating material comprises alginate and pectin, and the ratio of the alginate to the pectin is from 1:1 to 10:1. The ratio of the alginate to the pectin is typically >1:1, i.e. the alginate is present in an amount greater than the amount of pectin. In examples, the ratio of alginate to pectin is from about 2:1 to 8:1, or about 3:1 to 6:1, or is approximately 4:1.

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

The (b) forming a layer of the slurry typically comprises spraying, casting or extruding the slurry. In examples, the slurry layer is formed by electrospraying the slurry. In examples, the slurry layer is formed by casting the slurry. In some examples, (b) and/or (c) and/or (d), at least partially, occur simultaneously (for example, during electrospraying). In some examples, (b), (c) and (d) occur sequentially.

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

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

The setting the gel (c) may comprise supplying a setting agent to the slurry. For example, the slurry may comprise sodium, potassium or ammonium alginate as a gel-precursor, and a setting agent comprising a calcium source (such as calcium chloride), may be added to the slurry to form a calcium alginate gel. In examples, the setting agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the setting agent comprises or consists of calcium formate and/or calcium lactate. In particular examples, the setting agent comprises or consists of calcium formate. The inventors have identified that, typically, employing calcium formate as a setting agent results in an aerosol generating material having a greater tensile strength and greater resistance to elongation.

The total amount of the setting agent, such as a calcium source, may be 0.5-5wt% (calculated on a dry weight basis). Suitably, the total amount may be from about

1wt%, 2.5wt% or 4wt% to about 4.8wt% or 4.5wt%. The inventors have found that the addition of too little setting agent may result in an aerosol generating material which does not stabilise the aerosol generating material components and results in these components dropping out of the aerosol generating material. The inventors have found that the addition of too much setting agent results in an aerosol generating material that is very tacky and consequently has poor handleability.

When the aerosol generating material does not contain tobacco, a higher amount of setting agent may need to be applied. In some cases the total amount of setting agent may therefore be from 0.5-12wt% such as 5-10wt%, calculated on a dry weight basis. Suitably, the total amount may be from about 5wt%, 6wt% or 7wt% to about 12wt% or 10wt%. In this case the aerosol generating material will not generally contain any tobacco. In examples, supplying the setting agent to the slurry comprises spraying the setting agent on the slurry, such as a top surface of the slurry.

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

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

In examples, the drying (d) reduces the cast material thickness by at least 80%, suitably 85% or 87%. For instance, the slurry is cast at a thickness of 2mm, and the resulting dried aerosol generating material has a thickness of 0.2mm. In some examples, the slurry solvent consists essentially of or consists of water. In some examples, the slurry comprises from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% of solvent (WWB).

In examples where the solvent consists of water, the dry weight content of the slurry may match the dry weight content of the aerosol generating material. Thus, the discussion herein relating to the solid composition is explicitly disclosed in combination with the slurry aspect of the invention.

The aerosol generating material may comprises a flavour. Suitably, the aerosol generating material may comprise up to about 80wt%, 70wt%, 60wt%, 55wt%,

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

The aerosol generating material may comprises a filler.

In some embodiments, the aerosol generating material comprises less than 60wt% of a filler, such as from 1wt% to 60wt%, or 5wt% to 50wt%, or 5wt% to 30wt%, or 10wt% to 20wt%. In other embodiments, the aerosol generating material comprises less than 20wt%, suitably less than 10wt% or less than 5wt% of a filler. In some cases, the aerosol generating material comprises less than 1wt% of a filler, and in some cases, comprises no filler.

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

The filler, if present, may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)). In particular cases, the aerosol generating material comprises no calcium carbonate such as chalk.

In particular embodiments which include filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fibre, cellulose or cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)).

Without wishing to be bound by theory, it is believed that including fibrous filler in an aerosol generating material may increase the tensile strength of the material. This may be particularly advantageous in examples wherein the aerosol generating material is provided as a sheet, such as when an aerosol generating material sheet circumscribes a rod of aerosolisable material. In some embodiments, the aerosol generating material does not comprise tobacco fibres. In particular embodiments, the aerosol generating material does not comprise fibrous material.

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

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

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

In some cases, the aerosol generating material may comprise 5-60wt% (calculated on a dry weight basis) of a tobacco material and/or nicotine. In some cases, the aerosol generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or

30wt% (calculated on a dry weight basis) of an active substance. In some cases, the aerosol generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 70wt%, 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) of a tobacco material. For example, the aerosol generating material may comprise 10-50wt%, 15-40wt% or 20-35wt% of a tobacco material. In some cases, the aerosol generating material may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) of nicotine. For example, the aerosol generating material may comprise 1-20wt%, 2-18wt% or 3-12wt% of nicotine. In some cases, the aerosol generating material comprises an active substance such as tobacco extract. In some cases, the aerosol generating material may comprise 5-60wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the aerosol generating material may comprise from about 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) tobacco extract. For example, the aerosol generating material may comprise 10-50wt%, 15-40wt% or 20-35wt% of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the aerosol generating material comprises 1wt% 1 5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%, 4.5wt% or 4wt% (calculated on a dry weight basis) of nicotine. In some cases, there may be no nicotine in the aerosol generating material other than that which results from the tobacco extract. In some embodiments the aerosol generating material comprises no tobacco material but does comprise nicotine. In some such cases, the aerosol generating material may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) of nicotine. For example, the aerosol generating material may comprise 1-20wt%, 2-18wt% or 3- 12wt% of nicotine.

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

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

The aerosol-generating composition may comprise one or more active substances. In examples, the aerosol generating material comprises one or more active substances, e.g. up to about 20wt% of the aerosol generating material. In examples, the aerosol generating material comprises active substance in an amount of from about 1wt%, 5wt%, 10wt%, or 15wt% to about 20wt%, 15wt%, 15wt% or 5wt% of the aerosol generating material. The active substance may comprise a physiologically and/or olfactory active substance which is included in the aerosol-generating composition in order to achieve a physiological and/or olfactory response.

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

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

In examples, the tobacco material comprises one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and/or tobacco extract. Surprisingly, the inventors have identified that it is possible to use a relatively large amount of lamina tobacco in the aerosol-generating composition and still provide an acceptable aerosol when heated by a non combustible aerosol provision system. Lamina tobacco typically provides superior sensory characteristics. In examples, the tobacco material comprises lamina tobacco in an amount of at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt%, or 95wt% of the tobacco material. In particular examples, the tobacco material comprises cut tobacco in an amount of at least about 50wt%, 60wt%, 70wt%, 80wt%, 85wt%, 90wt%, or 95wt% of the tobacco material.

The tobacco used to produce tobacco material may be any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental. In some embodiments the one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants. In some cases, the aerosol generating material may additionally comprise an emulsifying agent, which emulsified molten flavour during manufacture. For example, the aerosol generating material may comprise from about 5wt% to about 15wt% of an emulsifying agent (calculated on a dry weight basis), suitably about 10wt%. The emulsifying agent may comprise acacia gum.

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

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

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

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

In examples, the aerosol generating material consists essentially of, or consists of a gelling agent, aerosol generating agent, active substance, and water. In examples, the aerosol generating material consists essentially of, or consists of a gelling agent, aerosol generating agent, and water.

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

In some embodiments the aerosol generating material comprises:

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

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

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

In some embodiments, the aerosol generating material comprising:

1-50 wt% of a gelling agent;

0.1-50 wt% of an aerosol generating agent; and 30-60 wt% of a flavour; wherein these weights are calculated on a dry weight basis.

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

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

10-60 wt% of a tobacco extract; wherein these weights are calculated on a dry weight basis. In some embodiments, the aerosol generating material comprises:

1-60 wt% of a gelling agent;

20-60 wt% of an aerosol generating agent; and 10-60 wt% of a tobacco extract; wherein these weights are calculated on a dry weight basis. In some embodiments, the aerosol generating material comprises 20 - 35 wt % of the gelling agent; 10 - 25 wt % of the aerosol-former material; 5 - 25 wt % of the filler comprising fibres; and 35 - 50 wt % of the flavourant and/or active substance.

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

In some embodiments, the aerosol generating material may have the following composition (DWB): gelling agent (preferably comprising alginate) in an amount of from about 5wt% to about 40wt%, or about 10wt% to 30wt%, or about 15wt% to about 25wt%; tobacco extract in an amount of from about 30wt% to about 70wt%, or from about 40wt% to 55wt%, or from about 45wt% to about 50wt%; aerosol generating agent (preferably comprising glycerol) in an amount of from about 10wt% to about 50wt%, or from about 20wt% to about 40wt%, or from about 25wt% to about 35wt% (DWB). In one embodiment, the aerosol generating material comprises about 20wt% alginate gelling agent, about 48wt% Virginia tobacco extract and about 32wt% glycerol (DWB).

The “thickness” of the aerosol generating material describes the shortest distance between a first surface and a second surface. In embodiments where the aerosol generating material is in the form of a sheet, the thickness of the aerosol generating material is the shortest distance between a first planar surface of the sheet and a second planar surface of the sheet which opposes the first planar surface of the sheet.

In some cases, the aerosol-forming aerosol generating material layer has a thickness of about 0.015mm to about 1.5mm, suitably about 0.05mm to about 1 5mm or 0.05mm to about 1.0mm. Suitably, the thickness may be in the range of from about 0.1mm or 0.15mm to about 1.0mm, 0.5mm or 0.3mm. In some cases, the aerosol generating material may have a thickness of about 0.015mm to about 1.0mm. Suitably, the thickness may be in the range of about 0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3mm.

A material having a thickness of 0.2mm is particularly suitable. The aerosol generating material may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers. It has been observed that if the aerosol-generating material is too thick, then heating efficiency is compromised. This adversely affects the power consumption in use. Conversely, if the aerosol-generating material is too thin, it is difficult to manufacture and handle; a very thin material is harder to cast and may be fragile, compromising aerosol formation in use.

The thickness stipulated herein is a mean thickness for the material. In some cases, the aerosol generating material thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%. In some examples, the aerosol generating material in sheet form may have a tensile strength of from around 200 N/m to around 900 N/m. In some examples, such as where the aerosol generating material does not comprise a filler, the aerosol generating material may have a tensile strength of from 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m.

Such tensile strengths may be particularly suitable for embodiments wherein the aerosol generating material is formed as a sheet and then shredded and incorporated into an aerosol generating article. In some examples, such as where the aerosol generating material comprises a filler, the aerosol generating material may have a tensile strength of from 600 N/m to 900 N/m, or from 700 N/m to 900 N/m, or around 800 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosol generating material is included in an aerosol generating article/assembly as a rolled sheet, suitably in the form of a tube. In some examples, the aerosol generating material in sheet form may have a tensile strength of from around 200 N/m to around 2600 N/m. In some examples, the aerosol generating material may have a tensile strength of from 600 N/m to 2000 N/m, or from 700 N/m to 1500 N/m, or around 1000 N/m. Such tensile strengths may be particularly suitable for embodiments wherein the aerosol generating material is formed and incorporated into an aerosol-generating consumable as a sheet.

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

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

The aerosol generating material may comprise a colourant. The addition of a colourant may alter the visual appearance of the aerosol generating material. The presence of colourant in the aerosol generating material may enhance the visual appearance of the aerosol generating material. By adding a colourant to the aerosol generating material, the aerosol generating material may be colour- matched to other components of an article comprising the aerosol generating material. A variety of colourants may be used depending on the desired colour of the aerosol generating material. The colour of aerosol generating material may be, for example, white, green, red, purple, blue, brown or black. Other colours are also envisaged. Natural or synthetic colourants, such as natural or synthetic dyes, food- grade colourants and pharmaceutical-grade colourants may be used. In certain embodiments, the colourant is caramel, which may confer the aerosol generating material with a brown appearance. In such embodiments, the colour of the aerosol generating material may be similar to the colour of other components (such as tobacco material) in an aerosol generating material.

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

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

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

With reference to Figure 1, an aerosol provision device 2 comprises a casing 4 within which is located a heater assembly 6. The heater assembly 6 is comprised of a heating chamber 8 and 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 the opposite end of the heating chamber 8 is an aperture 14. The aperture 14 is in fluid communication with a mouth piece 16 via a conduit 18. Also located within the casing 4 is a controller 20 which is in electronic communication with and controls the functioning of the heater 10. The controller 20 may include a memory (not shown) within which one or more tables relating to the operation of the heater 10 may be stored. The heater 10 and controller 20 are powered by a power source 22. The power source 22 is a rechargeable battery. In other embodiments the power source may be other appropriate sources of electrical power.

The aerosol provision device 2 is suitable for use with a consumable 24. The consumable 24 is comprised of one or more discrete portions of aerosol generating material 26 supported on first surface 30 of a support 28. The discrete portions of 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 discrete portions of aerosol generating material 26 than shown in Figure 1, including a single portion of aerosol generating material 26, and those portions may be distributed on the surface of the support 28 in any pattern. The discrete portions of aerosol generating material 26 are shown to have an approximately circular shape in Figure 1, they may, in other embodiments, be of other shapes.

With reference to Figure 2, the support 28 is a laminate with three substrates or layers 34, 36, 38. Layer 34 forms the first surface 30 and is comprised of a layer of aluminium foil. When the consumable 24 is being used, the layer 34 can act as a susceptor and heat the discrete portions of aerosol generating material 26. In other non-illustrated embodiments, the susceptor layer 34 can be formed from other susceptor materials. In this embodiment the susceptor layer 34 is impermeable.

Layer 36 of the support 28 is a support layer and is present to give the consumable 24 sufficient strength that the consumable 24 does not deform or bend during normal use. Layer 28 may be formed from card or a plastics material such as polyether ether ketone (PEEK). It will be understood that layer 36 may comprise other materials. Layer 38 of the support 28 is comprised of material that is sorbent, that is absorbent or adsorbent, for at least one substance to be delivered 40. The substance to be delivered 40 is a substance that it is desired to include in the aerosol generated when the aerosol generating material 26 is heated and a user takes a puff from the aerosol provision device 2. The sorbent layer 38 forms the second surface 32 of the support 48.

In some embodiments, the substance to be delivered 40 is applied to the sorbent layer 38 in locations on the second surface 32 that correspond to the locations of the discrete portions of aerosol generating material 26 on the first surface 30 of the support and the substance to be delivered simply allowed to diffuse within the sorbent layer 38. In other embodiments, and with reference to Figure 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 lines 44). The boundaries 44 assist in retaining the substance to be delivered 40 within the discrete zone 42.

The boundaries 44 are at the interface of sorbent material within the discrete zone 42 which has a first level of absorbency / adsorbency (X) and the sorbent material outside of the discrete zone 42 that have a second level of absorbency / adsorbency (Y), and X is larger than Y. The level of absorbency / adsorbency Y of the sorbent material outside the discrete zone 42 is a result of treatment of that sorbent material to decrease its level of absorbency / adsorbency.

In some non-illustrated embodiments, the boundaries 44 of the discrete zones 42 may be of the same shape as the discrete portions of aerosol generating material 26. In some embodiments they may enclose a different area of the second surface of the support than the area of the first surface of the support covered by a discrete portion of aerosol generating material 26. The substance to be delivered 40 comprises one of a flavourant, an active substance, a mixture of flavourants, a mixture of active substances, or a mixture of one or more flavourants and one or more active substances. In one embodiment of the consumable 24 illustrated in Figure 3, the substance to be delivered 40 in each discrete zone 42 is of the same composition as in the each other discrete zone 42. In an alternative embodiment, the substance to be delivered 40 in at least two of the discrete zones 42 are of different compositions relative to each other.

One or more perforations 46 extend through the support 28 and discrete portions of aerosol generating material 26. Those perforations 46 are dimensioned so that aerosol generated from one surface of the support may travel along the perforations to the other side of the support This may assist in achieving a mixture of the aerosols prior to their exiting the mouthpiece 16 when a user takes a puff from the aerosol provision 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 provision device 2 for use with the consumable 24 of Figure 2 has a heater 10 which is comprised of one or more magnetic field generators (not shown). The magnetic field generators are so distributed in the heater 10 that each magnetic field generator will independently heat a portion of susceptor which supports a discrete portion of aerosol generating material 26. This allows one or more discrete portions of aerosol generating material to be heated at a time. When a consumable 24 is placed in the heating chamber 8 via the heating chamber mouth 12 each discrete portion of aerosol generating material 26 overlies a magnetic field generator. The controller 20 determines which discrete portion or portions of aerosol generating material 26 is / are to be heated and causes the appropriate magnetic field generator or generators to generate varying magnetic fields. This causes the portion or portions of the susceptor layer 34 which intersects those varying magnetic fields to heat up, which in turn heats the discrete portion or portions of aerosol generating material 26.

As the or each discrete portion of aerosol generating material 26 is heated some of the heat generated in the susceptor layer 34 is conducted away from the susceptor layer 34 by the support layer 36 and into the sorbent layer 38. That heat causes the volatile material 40 that is absorbed or adsorbed into the or each portion of the sorbent layer 38 corresponding to the or each heated discrete portion of aerosol generating material 26 to aerosolise. In some non-illustrated embodiments the portions of the support layer 36 that correspond with the discrete portions of aerosol generating material 26 may be modified to increase or decrease the thermal conductivity of those portions. This will increase or decrease the rate of heating of the sorbent layer 38 and the temperature to which the sorbent layer 38 is heated.

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

Layer 36 of the support 128 is a support layer and is present to give the consumable 124 sufficient strength that the consumable 124 does not deform or bend during normal use. Layer 36 may be formed from card or a plastics material such as polyether ether ketone (PEEK). It will be understood that layer 36 may comprise other materials.

Supported on the impermeable surface of the susceptor layer 34 are one or more discrete portions of aerosol generating material 26, and an equal number of portions of sorbent material 50. Each portion of the sorbent material 50 has the form of an annulus, and each portion of sorbent material 50 is supported on the first surface 30 of the support 128 in a position such that it surrounds a discrete portion of aerosol generating material 26 in the plane of the first surface of the support 128. Each portion of sorbent material 50 includes at least one substance absorbed / adsorbed into the sorbent material. The substance to be delivered absorbed / adsorbed into the sorbent material may be different for one or more of the portions of sorbent material 50. The consumable 124 is used in a similar fashion to the consumable 24 of Figures 2 and 3 with the exception that heating of the portion of sorbent material 50 is by direct conduction from the susceptor 34 and / or the discrete portions of aerosol generating material 26. With reference to Figure 6, a consumable 224 is comprised of a support 228 on which one or more discrete portions of aerosol generating material 26 are supported. The support 228 is a laminate with first and second substrates / layers 34, 36. First layer 34 is a susceptor in the form of a layer of aluminium foil.

Layer 36 of the support 128 is a support layer and is present to give the consumable 224 sufficient strength that the consumable 224 does not deform or bend during normal use. Layer 36 may be formed from card or a plastics material such as polyether ether ketone (PEEK). It will be understood that layer 36 may comprise other materials.

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

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

The consumable 224 is used in a similar fashion to the consumable 24 of Figures 2 and 3.

With reference to Figure 7, a consumable 324 is comprised of a support 328 on which one or more discrete portions of aerosol generating material 26 are supported. The support 328 is a laminate with first and second substrates / layers 36, 38. First layer 36 of the support 328 is a support layer and is present to give the consumable 324 sufficient strength that the consumable 324 does not deform or bend during normal use. Layer 36 may be formed from card or a plastics material such as polyether ether ketone (PEEK). It will be understood that layer 36 may comprise other materials.

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

Supported on the sorbent surface of the sorbent layer 38 are one or more discrete portions of aerosol generating material 26. The sorbent layer 38 includes one or more discrete zones 342 which have boundaries represented by lines 344. The discrete zones 342 are equal in number to the number of discrete portions of aerosol generating material 26, and each discrete zone 342 surrounds a discrete portion of aerosol generating material 26 in the plane of the first surface of the support 328. The boundaries 344 are at the interface of sorbent material within the discrete zone 342 which has a first level of absorbency / adsorbency (X) and the sorbent material outside of the discrete zone 342 that have a second level of absorbency / adsorbency (Y), and X is larger than Y. The level of absorbency / adsorbency Y of the sorbent material outside the discrete zone 342 is a result of treatment to decrease its level of absorbency / adsorbency.

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

The consumable 324 is used in a similar fashion to the consumable 24 of Figures 2 and 3 with the exception that heating of the consumable 324 is by a resistance heater. The resistance heater may include one or more separate heating zones which may be heated one at a time to allow individual discrete portions of aerosol generating material 26 to be heated. In a non-illustrated further embodiment of the consumable 324 of Figure 7, the support may be a single sheet of a sorbent material 38. The rest of the detail of this embodiment are as for the embodiment of Figure 7. With reference to Figure 8, a consumable 424 is comprised of a support 428. On the first face 30 of the support 428 one or more discrete portions of aerosol generating material 26 are supported. The support 428 is formed from a sorbent material. The consumable 424 is adapted to be heated with an external heating source (not shown), for example a resistive heater that emits radiant heat.

Absorbed or adsorbed into the second face 32 of the support 428 in the regions of the second face 32 corresponding to the discrete portions of aerosol generating material 26 is substance to be delivered 40. Extending through the discrete portions of aerosol generating material 26, the support 428, and the substance to be delivered 40 are one or more perforations 446.

With reference to Figure 9, a schematic method of manufacture of a consumable is shown in which the method includes the following steps: A support 28 comprising a susceptor layer 34, a support layer 36 and a sorbent layer 38 is provided in step 60.

In step 62 a slurry of an aerosol generating material is provided which includes a solvent for the aerosol generating material and one or more desired active substances.

In step 64 the slurry of an aerosol generating material 26 is applied to one or more areas on a surface 30, 32 of the support 28. In step 66 the applied slurry is dried so as to form a solid or gel of aerosol generating material on the surface of the support. The drying process may be to allow the solvent for the aerosol generating material to evaporate in ambient conditions. Alternatively, the drying process can be accelerated by heating the slurry to a temperature below the temperature at which the aerosol generating material starts to aerosolise so as to promote evaporation of the solvent. The heating can be by conductive or radiant heating methods. Alternatively or additionally step 66 can include exposing the aerosol generating material to a high airflow across the aerosol generating material so as to promote evaporation of the solvent from the aerosol generating material.

Step 66 can include drying techniques that would, if some desirable active ingredients were present in the slurry of aerosol generating material, cause those active ingredients to evaporate from the aerosol generating material at rates sufficient that once the drying was complete the remaining aerosol generating material would not include the desired quantities of those active ingredients.

Once step 66 is completed it can be decided at step 68 whether a further application of a slurry of an aerosol generating material is required. If is the answer to the question in step 68 is “yes”, then steps 64 to 68 are repeated. The second or subsequent applications of the slurry may be applications of the same slurry as the first application or the application of a slurry of a different composition to at least the first application. Once the answer to the question in step 68 is “no”, one or more substances to be delivered 40 are applied to the sorbent material 38 in step 70. These substances to be delivered may be of high volatility. They will not, however be subject to the conditions of the drying step 66 and thus the quantity of substances that need to be applied to the sorbent areas may be considerably less than if they were subject to the drying step 66. The substances to be delivered are applied to the surface of the sorbent material 38 and absorption or adsorption into the sorbent material 38 then follows.

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

In the step 74 the support is cut into two or more individual consumables ready for use or packaging and distribution for sale to users. With reference to Figure 10, a second schematic method of manufacture of a consumable is shown in which the method includes the steps described below. Those steps that are the same as in the method of Figure 7 have the same reference numerals and are not described again below.

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

Steps 62 to 68 are as the method of manufacture of Figure 9. Once the answer to the question in step 68 is “no”, one or more portions of sorbent material 50, 150 are fixed to the support 28 in step 78. The sorbent material can be applied to the support preformed and with one or more the substances to be delivered 40 already absorbed / adsorbed into the portion of sorbent material 50, 150. Alternatively, the portions of sorbent material 50, 150 can have the substances to be delivered applied to the portions of sorbent material 50, 150 after they have been fixed to the support. In this alternative, the substances to be delivered are then allowed to be absorbed or adsorbed.

Steps 72 and 74 follow step 78.

With reference to Figure 11 , a third schematic method of manufacture of a consumable is shown in which the method includes the steps described below. Those steps that are the same as in the methods of Figure 9 or 10 have the same reference numerals and are not described again below.

Step 76 is followed by steps 62 and 64.

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

If the answer to step 80 is “yes”, then that paste is provided and applied to the support in step 82. The process then moves to drying step 66.

If the answer to step 80 is “no”, the process moves to drying step 66. Steps 68, 70, 72 and 74 then follow.

It has been found that the consumables that are the result of the present disclosure have advantageous storage characteristics in that the substance to be delivered has been found to maintain a substantially consistent flavour amplitude for at least a 90 day period after the manufacture of the consumable.

A review of the long term flavour amplitude of the substance to be delivered in the form of a citrus flavour composition was performed. In a test a consumable was manufactured that comprised a card support overlaid with a layer of aluminium foil. On the face of the support formed by the layer of aluminium a layer of aerosol generating material (comprised of a binder and aerosol former (glycerol)) was applied and the aerosol generating material allowed to set. Once the aerosol generating material had set, a pipette was used to apply 0.34mg of citrus flavour composition to the face of the consumable formed from card at positions corresponding to predetermined heating zones. The consumable will be heated in the predetermined heating zones. A subjective assessment of the sample was made at a five time periods (T) after the application of the citrus flavour composition to the consumable.

To make the assessments at time periods T, the following procedure was followed: Two days before time period T a control sample was made using the same techniques and support as was used to make the test sample.

At time period T an aerosol provision device comprising a heater, a chamber (in which the aerosol forms when heated) and a mouthpiece was used to heat one of the predetermined heating zones on the test consumable. The tester then made a sensory assessment of the aerosol that was received out of the mouthpiece. This was repeated with the control sample after the aerosol provision device had been cleaned. The results of the assessment are shown in table 1 below:

As may be seen from Table 1, there is minimal flavour loss over the 90-day study.

A study of consumer reaction to various flavours as indicated in Table 2 below was performed.

The samples were then heated as above and the aerosol generated sampled by testers. The flavours were found to be cleaner in flavour than cigarettes and not to include any ashy or burnt off notes.

The testers also found that on exhalation of the inhaled aerosol lower levels of visible aerosol / particulates were present than experienced with cigarettes, and that little aroma was left in the testing room after the testing.

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

Claims

1. A consumable for use with an aerosol provision device, in which the consumable comprises a support, an aerosol generating material, and a substance to be delivered that may be caused to volatise, in which the support supports the aerosol generating material, and the substance to be delivered volatilises on heating of one or both of the support or the aerosol generating material.

2 A consumable according to claim 1 in which the support comprises a sorbent material, and the sorbent material comprises the substance to be delivered.

3 A consumable according to claim 2 in which the substance to be delivered is located in one or more discrete zones of the sorbent material and not located outside of those discrete zones.

4 A consumable according to claim 2 or 3 in which the support is a laminate, the laminate comprises at least a first and second substrate, and at least one of the substrates is formed from a sorbent material.

5 A consumable according to any of claims 2 to 4 in which the sorbent material forms one or both of a first or second surface of the support.

6 A consumable according to any of claims 1 to 5 in which a surface of the support is formed from an impermeable material.

7 A consumable according to any of claims 1 to 6 in which a surface of the support is formed from a susceptor.

8 A consumable according to claim 7 in which the susceptor is a metal foil.

9 A consumable according to any of claims 2 to 8 in which the aerosol generating material is supported on a surface of the support that is a sorbent material. 10 A consumable according to any of claims 1 to 8 in which the aerosol generating material is supported on a surface of the support that is not a sorbent material. 11 A consumable according to any of claims 1 to 9 in which the support is formed from a sorbent material.

12 A consumable according to any of claims 1 to 11 in which the substance to be delivered is supported on a surface of the support.

13 A consumable according to claim 12 further comprising a sorbent material, in which the sorbent material comprises the substance to be delivered, and the sorbent material is supported on a surface of the support. 14 A consumable according to any of claims 1 to 13 in which the substance to be delivered is volatised a period of time PS after commencement of heating the support or aerosol generating material, the aerosol generating material is configured to release aerosol a period of time PA after commencement of heating the support or aerosol generating material, and period PS is smaller than or equal to PA.

15 A consumable according to claim 14 in which period PS is smaller than PA.

16 A consumable according to any of claims 1 to 15 in which the temperature to which the substance to be delivered needs to be heated to cause the substance to be delivered to volatise is lower than the temperature to which the aerosol generating material needs to be heated to generate an aerosol.

17 A consumable according to claim 3 or any of claims 4 to 16 when dependent on claim 3 in which at least one discrete zone has a shape and size, and the shape and size of the discrete zone is at least partially defined by sorbent material surrounding the discrete zone having a reduced capacity for sorption of the at least one substance into that sorbent material relative to the capacity for sorption of the at least one substance into the sorbent material in the discrete zone. 18 A consumable according to claim 17 in which the consumable comprises two or more discrete zones. 19 A consumable according to claim 18 in which at least two of the discrete zones comprise different substances to be delivered.

20 A consumable according to claim 3 or any of claims 4 to 19 when dependent on claim 3 in which the aerosol generating material is supported on the support in one or more discrete portions and at least one discrete zone is associated with each discrete portion of aerosol generating material.

21 A consumable according to claim 3 or any of claims 4 to 20 when dependent on claim 3 in which a discrete zone is on the same surface of the support as a discrete portion of the aerosol generating material and substantially surrounds that discrete portion of the aerosol generating material.

22 A consumable according to claim 3 or any of claims 4 to 21 when dependent on claim 3 in which a discrete portion of the aerosol generating material is on a first surface of the support, and a discrete zone is on a second surface of the support, and the discrete portion of the aerosol generating material and the discrete zone are in corresponding positions on their respective surfaces.

23 A consumable according to claim 22 in which the shapes of the discrete portion of the aerosol generating material and the discrete zone in the plane of the first and second surfaces of the support are substantially the same.

24 A consumable according to claim 22 in which the discrete portion of the aerosol generating material covers a first area on the surface of the support on which it is supported, the discrete zone covers a second area on the surface of the support on which it is supported, and one of the first and second areas is larger than the other of the first and second areas. 25 A consumable according to any of claims 1 to 24 in which the consumable further comprises one or more perforations extending at least between a first and second surface of the support. 26 A consumable according to claim 25 in which at least one perforation extends at least between one of the first or second surface of the support and a face of the consumable that is adjacent the other of the first or second surface of the support. 27 A consumable according to claim 25 or 26 in which at least one perforation extends between a face of the consumable that is adjacent the first surface of the support and a face of the consumable that is adjacent to the second face of the support. 28 A consumable according to any of claims 25 to 27 in which at least one of the perforations extends through the substance to be delivered.

29 A consumable according to any of claims 25 to 28 in which at least one of the perforations extends through the aerosol generating material.

30 A consumable according to any of claims 25 to 29 in which at least one of the perforations has a blind first end within the consumable, and the other end opens through a surface of one of the support, the substance to be delivered, the aerosol generating material or a surface of the consumable.

31 A consumable according to any of claims 25 to 30 in which the perforations are 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. 32 A consumable according to any of claims 1 to 31 in which the at least one substance comprises a flavourant, an active substance, a mixture of flavourants, a mixture of active substances, a mixture of one or more flavourants and one or more active substances, one or more solvents, and / or one or more aerosol-generators or aerosol-former materials. 33 A consumable according to any of claims 1 to 32 in which the support is planar.

34 A method of manufacturing a consumable for use with an aerosol provision device, in which the consumable comprises a support, an aerosol generating material, and a substance to be delivered that may be caused to volatise, in which the method comprises the steps of a) providing a support; b) applying a slurry of the aerosol generating material to a surface of the consumable, c) drying the applied aerosol generating material, d) applying the substance to be delivered to a surface of the consumable.

35 A method according to claim 34 in which step (b) occurs any time after step (a), step (b) is followed by step (c), and step (d) occurs any time after step (c).

36 A method according to claim 34 or 35 including a step (e) comprising providing a sorbent material, step (e) occurs before step (d), and step (d) comprises applying the substance to be delivered to the sorbent material to form a sorbent material comprising the substance to be delivered and, if the support does not comprise the sorbent material, applying the sorbent material comprising the substance to be delivered to the consumable.

37 A method according to claim 36 in which step (e) comprises application of a paste to the consumable and subsequently drying that paste, the paste drying to form a sorbent material. 38 A method according to claim 36 in which step (e) comprises forming a desired shape of sorbent material, and fixing that shape of sorbent material to a desired position on the consumable. 39 A method according to claim 38 in which step (d) occurs before the sorbent material is fixed to the consumable.

40 A method according to any of claims 34 to 39 in which steps (b) and (c) are repeated one or more times before step (d).

41 A method according to any of claims 34 to 40 in which step (c) comprises the use of one or more of time, conducted heat, or radiant heat. 42 A method according to any of claims 34 to 41 in which the method comprises a further step (f) comprising providing a susceptor and fixing the susceptor to the support.

43 A method according to claim 42 in which step (f) occurs after step (a) and the susceptor is fixed to a first surface of the support, step (b) occurs after step (f), and the slurry of aerosol generating material is at least partially applied to a surface of the susceptor.

44 A method according to any of claims 34 to 43 in which the support is a sheet of material and the method further comprises a step (h) comprising cutting the support into two or more consumables.

45 A method according to any of claims 36 to 44 in which the method comprises a step (i) comprising perforating at least part of the consumable to form one or more perforations, and one or more of one or more those perforations extend at least between a first and second surface of the support, one or more those perforations extend at least between one of the first or second surface of the support and the face of the consumable that is adjacent the other of the first or second surface of the support, one or more those perforations extend between a face of the consumable that is adjacent the first surface of the support and the face of the consumable that is adjacent to the second face of the support, one or more those perforations extend at least through the sorbent material, one or more those perforations extend at least through the aerosol generating material, and one or more those perforations extend have a blind first end within the consumable, and the other end opens through a surface of one of the support, the substance to be delivered, the aerosol generating material or a surface of the consumable.

46 A method according to any of claims 34 to 45 to form a consumable according to any of claims 1 to 33.

47 An aerosol provision system comprising an aerosol provision device and a consumable according to any of claims 1 to 33.

48 A method of generating aerosol from a consumable according to any of claims 1 to 33 using an aerosol generating device with at least one heat source disposed to heat, but not burn, the consumable in use; wherein at least one heat source is a resistive heater element.

49 A method of generating aerosol from a consumable according to any of claims 1 to 33 using an aerosol generating device with at least one heat source disposed to heat, but not burn, the consumable in use; wherein at least one heat source is a magnetic field generator suitable for causing electrical eddy-currents in a susceptor. 50 A method of generating aerosol according to claim 48 or 49 in which the consumable comprises one or more discrete portions of aerosol generating material, and the or each heat source is configured to be able to heat one or more those discrete portions at a time.