WO2023012289A1

WO2023012289A1 - A consumable for use with an aerosol provision device

Info

Publication number: WO2023012289A1
Application number: PCT/EP2022/071987
Authority: WO
Inventors: John Richardson
Original assignee: Nicoventures Trading Limited
Priority date: 2021-08-04
Filing date: 2022-08-04
Publication date: 2023-02-09
Also published as: GB202111286D0; KR20240040076A

Abstract

A method of manufacture of a product (2) for use in the manufacture of an article for use in a non-combustible aerosol provision system is provided. The product (2) comprises aerosol generating material (20) and a carrier (4). The carrier (4) comprises a base layer (6) and a carrier layer (8), and the carrier layer (8) is releasably attached to the base layer (6). The method comprises the following steps: (a) the carrier (4) is provided; (b) an aerosol generating material (20) is applied to a support surface (10) of the carrier layer (8) of the carrier (4); and (c) the carrier (4) and aerosol generating material (20) is configured for storage.

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 and products for making such consumables, a method for manufacturing consumables for use with an aerosol provision device and products for manufacturing such consumables, and an aerosol provision system including a consumable and an aerosol provision device.

Background

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

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

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

Summary

According to a first aspect of the present disclosure there is provided a method of manufacture of a product for use in the manufacture of a consumable for use with an apparatus for heating an aerosol generating material to volatilise at least one component of the aerosol generating material, in which the product comprises aerosol generating material and a carrier, in which the carrier comprises a base layer and a carrier layer, and the carrier layer is releasably attached to the base layer, and the method comprises the following steps

(a) the carrier is provided,

(b) an aerosol generating material slurry is applied to a support surface of the carrier layer of the carrier, and

(c) the carrier and aerosol generating material is configured for storage.

According to a second aspect of the present disclosure there is provided a product for use in the manufacture of a consumable for use with an apparatus for heating an aerosol generating material to volatilise at least one component of the aerosol generating material, in which the product comprises aerosol generating material and a carrier, in which the carrier comprises a base layer and a carrier layer, the carrier layer is releasably attached to the base layer, at least one discrete portion of aerosol generating material is supported on a support surface of the carrier layer of the carrier.

According to a third aspect of the present disclosure there is provided a method of making a consumable for use with an apparatus for heating an aerosol generating material comprising a support and aerosol generating material, in which method comprises (i) providing at least one product according to the second aspect of the present disclosure, and

(ii) releasing at least one portion of the carrier layer from the base layer of at least one product.

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

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

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

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

Drawings

Figure 1 shows a schematic view of a representative part of a first embodiment of a product according to the present disclosure during manufacture;

Figure 2 shows an exploded view of the part of Figure 1 ;

Figure 3 shows further schematic view of the part of Figure 1 ; Figure 4 shows a schematic view of a first embodiment of a product according to the present disclosure;

Figure 5 shows a second schematic view of the product of Figure 4;

Figure 6 shows a schematic view of a consumable from the product of Figure 4; Figure 7 shows a schematic view of an aerosol provision device for use with the consumable of Figure 6;

Figure 8 shows a schematic view of a representative part of a first embodiment of a product according to the present disclosure during manufacture;

Figure 9 shows further schematic view of the part of Figure 8; and

Figure 10 shows a schematic side view of a second embodiment of a product 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 aerosolgenerating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

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

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

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

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

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

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

In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device 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.

According to a first aspect of the present disclosure there is provided a method of manufacture of a product for use in the manufacture of a consumable for use with an apparatus for heating an aerosol generating material to volatilise at least one component of aerosol generating material, in which the product comprises aerosol generating material and a carrier, in which the carrier comprises a base layer and a carrier layer, and the carrier layer is releasably attached to the base layer, and the method comprises the following steps

(a) the carrier is provided,

(b) an aerosol generating material is applied to a surface of the carrier layer of the carrier, and

(c) the carrier and aerosol generating material is configured for storage.

In an embodiment of the above embodiment the application of the aerosol generating material in step (b) is application of an aerosol generating material slurry.

In an embodiment of the above embodiment the method comprises a further step of allowing or causing the aerosol generating material slurry to set to an aerosol generating material, in which this step occurs between steps (b) and (c). In some embodiments the aerosol generating material slurry sets as an aerosol generating material in the form of an aerosol generating film.

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

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

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

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

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

The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film. The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.

The aerosol-generating material may comprise or be an “amorphous solid”. In some embodiments, the aerosol-generating material comprises an aerosolgenerating film that is an amorphous solid. The amorphous solid may be a “monolithic solid”. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.

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

In an embodiment of any of the above embodiments the application of the aerosol generating material in step (b) is application of one or more discrete portions of aerosol generating material.

In an embodiment of any of the above embodiments at least two discrete portions of aerosol generating material, and at least two discrete portions of aerosol generating material have different compositions relative to each other. This has the advantage that a user of the consumable manufactured according to the present disclosure may have different experiences when different discrete portions of aerosol generating material on the consumable are aerosolised. This may make the use of the consumable more enjoyable and I or more interesting than use of a consumable that has aerosol generating material of only one composition.

In an embodiment of any of the above embodiments there are three or more distinct portions of aerosol generating material and the discrete portions are applied to a surface of the carrier layer in a grid pattern. In an embodiment of any of the above embodiments one or more of the discrete portions of the aerosol generating material applied in step (b) are, in the plane of the support surface of the carrier layer, substantially circular, longitudinally extending stripes, stripes including at least one curve or angle, or of a shape that will tessellate.

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

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

In an embodiment of any of the above embodiments releasable attachment of the carrier layer to the base layer comprises the use of an adhesive, that adhesive allowing the carrier layer to be released from the base layer. In some embodiments the adhesive is a pressure adhesive.

In an embodiment of any of the above embodiments the carrier layer comprises a sheet material, and the sheet material comprises at least one of paper, card, a plastics material, or a metallic material. In some embodiments the carrier is of a sheet material that is undamaged by flexing of the material.

In an embodiment of any of the above embodiments the support surface of the carrier layer is one of the major or largest surfaces of the carrier layer, and the other of the major surfaces of the carrier layer is the surface that is adhered to the base layer. In an embodiment of any of the above embodiments the method includes a further step of (d) introducing at least one line of separation into at least part of the carrier, in which each line of separation is a predetermined line along which at least part of the carrier will separate or tear.

The introduction of at least one line of separation has an advantage that the separation or tearing is more controlled than would be the case for the separation or tearing of a part of the carrier layer that does not include a line of separation. More controlled is to be understood to mean that when separating the carrier layer by tearing, the tearing of the carrier layer follows the line of separation. This is in contrast to tearing a part of the carrier layer where there is no line of separation where the line of tearing may be expected to follow lines of weakness in the carrier layer and or be reflective of the geometry and magnitudes of the forces being applied to the carrier layer to cause the tearing.

In an embodiment of any of the above embodiments at least one line of separation is a predetermined line along which the carrier layer will separate or tear.

In an embodiment of any of the above embodiments the one or more lines of separation are so located that the carrier layer can be separated along at least one line of separation into at least two portions of a predetermined size and shape. In some embodiments the at least two portions of a predetermined size and shape are all of the same size and shape. In some other embodiments the at least two portions of a predetermined size and shape are of different predetermined sizes and I or shapes.

In an embodiment of any of the above embodiments at least one line of separation of step (d) comprises a line of perforations. In some embodiments the perforations extend through the carrier layer only. In some embodiments the perforations extend through the carrier layer and base layer. In some embodiments the perforations extend into the carrier layer from the support surface, but not wholly through the carrier layer. In an embodiment of any of the above embodiments at least one line of separation of step (d) comprises a cut line. In some embodiments the cut line may be a cut that extends the full depth of the carrier layer. In some embodiments the cut line may be a cut that that extends into the carrier layer from the support surface, but not wholly through the carrier layer.

In an embodiment of any of the above embodiments the cut line is formed using a kiss cutting technique.

In an embodiment of any of the above embodiments at least one line of separation extends between at least two discrete portions of aerosol generating material or between at least two locations at which discrete portions of aerosol generating material will be applied in step (b).

In an embodiment of any of the above embodiments at least a part of at least one line of separation extends through aerosol generating material applied to the carrier layer, or a location at which aerosol generating material will be applied in step (b).

In an embodiment of any of the above embodiments the carrier is a sheet of material, and the configuration of step (c) comprises stacking two or more sheets of the carrier into pile.

In an embodiment of any of the above embodiments the carrier is a longitudinally extending sheet of material, and the configuration of step (c) comprises forming at least one fold line in the carrier, and subsequently folding the carrier about at least one of those fold lines.

In an embodiment of any of the above embodiments a fold line corresponds to a line of separation.

In an embodiment of any of the above embodiments the carrier is folded into a concertina. In an embodiment of any of the above embodiments the configuration of step (c) comprises forming the carrier into a roll.

In an embodiment of any of the above embodiments the carrier is wound around a core. In some embodiments the core is a spool, bobbin or other structure that supports the carrier and around which the carrier can be wound.

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

(e) placing a sheet of barrier material over the support surface of the carrier layer and aerosol generating material, in which step (e) is performed before step (c).

In some embodiments the barrier material is a material to which aerosol generating material may only weakly adhere if it adheres to the barrier material at all. For the purposes of the present disclosure, adhesion to the barrier material may be considered to be weak adhesion if aerosol generating material which is adhered to both the barrier material and supported on the support surface of the carrier layer is attached more strongly to the support surface of the carrier layer than it adheres to the barrier material.

According to a second aspect of the present disclosure, there is provided a product for use in the manufacture of a consumable for use with an apparatus for heating an aerosol generating material to volatilise at least one component of the aerosol generating material, in which the product comprises aerosol generating material and a carrier, in which the carrier comprises a base layer and a carrier layer, the carrier layer is releasably attached to the base layer, and at least one discrete portion of aerosol generating material is supported on a support surface of the carrier layer.

In an embodiment of any of the above embodiments the aerosol generating material is an aerosol generating film. In an embodiment of any of the above embodiments there are at least two discrete portions of aerosol generating material, and at least two discrete portions of aerosol generating material have different compositions relative to each other.

In an embodiment of any of the above embodiments there are three or more distinct portions of aerosol generating material and the discrete portions are applied to the support surface of the carrier layer in a grid pattern.

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

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

In an embodiment of any of the above embodiments the carrier layer comprises an adhesive backed sheet material, and the sheet material comprises at least one of paper, card, a plastics material, or a metallic material.

In an embodiment of any of the above embodiments the carrier comprises at least one line of separation, in which each line of separation is a predetermined line along which at least part of the carrier will separate or tear.

In an embodiment of any of the above embodiments at least one line of separation is a predetermined line along which the carrier layer will separate or tear. In an embodiment of any of the above embodiments at least one line of separation comprises a line of perforations.

In an embodiment of any of the above embodiments at least one line of separation comprises a cut line.

In an embodiment of any of the above embodiments at least one cut line is the result of kiss cutting.

In an embodiment of any of the above embodiments at least one line of separation extends between at least two discrete portions of aerosol generating material.

In an embodiment of any of the above embodiments at least a part of at least one line of separation extends through aerosol generating material applied to the carrier layer.

In an embodiment of any of the above embodiments the carrier is a sheet material.

In an embodiment of any of the above embodiments the carrier is a longitudinally extending sheet of material, the carrier comprises at least one fold line, and the carrier is folded about at least one of those fold lines.

In an embodiment of any of the above embodiments a fold line corresponds to a separation line.

In an embodiment of any of the above embodiments the carrier is folded into a concertina.

In an embodiment of any of the above embodiments the carrier is rolled into a roll.

In an embodiment of any of the above embodiments the roll of carrier is wound around a core. In an embodiment of any of the above embodiments the product further comprises a sheet of barrier material placed over the carrier layer and aerosol generating material.

In an embodiment of any of the above embodiments the adhesive that adheres the carrier layer to the base layer may be a pressure adhesive.

In an embodiment of any of the above embodiments the surfaces of the base layer and carrier layer that are adhered to each other are such that when the carrier layer is released or removed from the base layer all, or at least 95% by weight, of the adhesive remains on the base.

According to a third aspect of the present disclosure there is provided a method of making a consumable for use with an apparatus for heating an aerosol generating material, in which the method comprises

(i) providing at least one product according to the second aspect of the present disclosure, and

(ii) releasing at least one portion of the carrier layer from the base layer of at least one product, in which the separated portion of the carrier layer supports aerosol generating material. In some embodiments the separated portion of the carrier supports two or more discrete portions of aerosol generating material. In some embodiments two or more dots of aerosol generating film.

The separated portion of the carrier layer may be used in conjunction with a suitably configured aerosol generation device and the separated portion of the carrier film may thus be understood to be a consumable.

According to a fourth aspect of the present disclosure there is provided an aerosol provision device for use with a consumable made according to the third aspect of the present disclosure in which the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable. In an embodiment of any of the above embodiments the aerosol generator comprises a heatable plate adapted to support a consumable made according to the third aspect of the present disclosure. In some embodiments the heatable plate is configured to receive and retain the separated portion of the carrier layer. In some embodiments the heatable plate is adapted to heat different parts of the separated portion of the carrier layer at different times. In some embodiments the disposition of aerosol generating material on the surface of the separated portion of the carrier layer matches the disposition of separately heatable parts of the heater plate.

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

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

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

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

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

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

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

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel. In some embodiments, the aerosol-generating material comprises a flavour or flavourant.

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

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

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

The aerosol generating material comprises an aerosol former.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

In examples, the setting agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the setting agent comprises or consists of calcium formate and/or calcium lactate. In particular examples, the setting agent comprises or consists of calcium formate. The inventors have identified that, typically, employing calcium formate as a setting agent results in an aerosol generating material having a greater tensile strength and greater resistance to elongation. The total amount of the setting agent, such as a calcium source, may be 0.5-5wt% (calculated on a dry weight basis). Suitably, the total amount may be from about 1wt%, 2.5wt% or 4wt% to about 4.8wt% or 4.5wt%. The inventors have found that the addition of too little setting agent may result in an aerosol generating material which does not stabilise the aerosol generating material components and results in these components dropping out of the aerosol generating material. The inventors have found that the addition of too much setting agent results in an aerosol generating material that is very tacky and consequently has poor handleability.

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

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

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

In examples, the drying (d) removes from about 50wt%, 60wt%, 70wt%, 80wt% or 90wt% to about 80wt%, 90wt% or 95wt% (WWB) of water in the slurry. In examples, the drying (d) reduces the cast material thickness by at least 80%, suitably 85% or 87%. For instance, the slurry is cast at a thickness of 2mm, and the resulting dried aerosol generating material material has a thickness of 0.2mm.

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

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

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

The aerosol generating material may comprises a filler.

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

In other embodiments, the aerosol generating material comprises less than 20wt%, suitably less than 10wt% or less than 5wt% of a filler. In some cases, the aerosol generating material comprises less than 1wt% of a filler, and in some cases, comprises no filler. In some such cases the aerosol generating material comprises at least 1 wt% of the filler, for example, at least 5 wt%, at least 10wt%, at least 20wt% at least 30wt%, at least 40wt%, or at least 50wt% of the filler. In some embodiments, the aerosol generating material comprises 5-25wt% of the filler.

The filler, if present, may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)).

In particular cases, the aerosol generating material comprises no calcium carbonate such as chalk.

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

Without wishing to be bound by theory, it is believed that including fibrous filler in an aerosol generating material may increase the tensile strength of the material. This may be particularly advantageous in examples wherein the aerosol generating material is provided as a sheet, such as when an aerosol generating material sheet circumscribes a rod of aerosolisable material.

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

The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material. In some embodiments, the aerosol generating material additionally comprises an active substance. For example, in some cases, the aerosol generating material additionally comprises a tobacco material and/or nicotine. In some embodiments, the aerosol generating material comprises powdered tobacco and/or nicotine and/or a tobacco extract.

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

In some cases, the aerosol generating material comprises an active substance such as tobacco extract. In some cases, the aerosol generating material may comprise 5-60wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the aerosol generating material may comprise from about 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt%, 35wt%, or 30wt% (calculated on a dry weight basis) tobacco extract. For example, the aerosol generating material may comprise 10-50wt%, 15-40wt% or 20-35wt% of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the aerosol generating material comprises 1wt% 1.5wt%, 2wt% or 2.5wt% to about 6wt%, 5wt%, 4.5wt% or 4wt% (calculated on a dry weight basis) of nicotine. In some cases, there may be no nicotine in the aerosol generating material other than that which results from the tobacco extract. In some embodiments the aerosol generating material comprises no tobacco material but does comprise nicotine. In some such cases, the aerosol generating material may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) of nicotine. For example, the aerosol generating material may comprise 1-20wt%, 2-18wt% or 3- 12wt% of nicotine.

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

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

The aerosol-generating composition may comprise one or more active substances. In examples, the aerosol generating material comprises one or more active substances, e.g. up to about 20wt% of the aerosol generating material. In examples, the aerosol generating material comprises active substance in an amount of from about 1wt%, 5wt%, 10wt%, or 15wt% to about 20wt%, 15wt%, 15wt% or 5wt% of the aerosol generating material.

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

Tobacco material may be present in the aerosol-generating composition in an amount of from about 50 to 95wt%, or about 60 to 90wt%, or about 70 to 90wt%, or about 75 to 85wt%. The tobacco material may be present in any format, but is typically fine-cut (e.g. cut into narrow shreds). Fine-cut tobacco material may advantageously be blended with the aerosol generating material to provide an aerosol-generating composition which has an even dispersion of tobacco material and aerosol generating material throughout the aerosol-generating composition.

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

The tobacco used to produce tobacco material may be any suitable tobacco, such as single grades or blends, cut rag or whole leaf, including Virginia and/or Burley and/or Oriental.

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

In some cases, the aerosol generating material may additionally comprise an emulsifying agent, which emulsified molten flavour during manufacture. For example, the aerosol generating material may comprise from about 5wt% to about 15wt% of an emulsifying agent (calculated on a dry weight basis), suitably about 10wt%. The emulsifying agent may comprise acacia gum. In some embodiments, the aerosol generating material is a hydrogel and comprises less than about 20 wt% of water calculated on a wet weight basis. In some cases, the hydrogel may comprise less than about 15wt%, 12 wt% or 10 wt% of water calculated on a wet weight basis. In some cases, the hydrogel may comprise at least about 1wt%, 2wt% or at least about 5wt% of water (WWB).

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

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

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

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

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

In some embodiments the aerosol generating material comprises an aerosol generating material, the aerosol generating material comprising:

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

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

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

In some embodiments, the aerosol generating material comprising:

1-50 wt% of a gelling agent;

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

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

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

1-60 wt% of a gelling agent;

5-60 wt% of an aerosol generating agent; and 10-60 wt% of a tobacco extract; wherein these weights are calculated on a dry weight basis.

In some embodiments, the aerosol generating material comprises:

1-60 wt% of a gelling agent;

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

In some embodiments, the aerosol generating material comprises 20 - 35 wt % of the gelling agent; 10 - 25 wt % of the aerosol-former material; 5 - 25 wt % of the filler comprising fibres; and 35 - 50 wt % of the flavourant and/or active substance. In some cases, the aerosol generating material may consist essentially of, or consist of a gelling agent, an aerosol generating agent a tobacco extract, water, and optionally a flavour. In some cases, the aerosol generating material may consist essentially of, or consist of glycerol, alginates and/or pectins, a tobacco extract and water.

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

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

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

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

In some cases, the aerosol generating material may have a thickness of about 0.015mm to about 1.0mm. Suitably, the thickness may be in the range of about 0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3mm. A material having a thickness of 0.2mm is particularly suitable. The aerosol generating material may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.

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

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

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

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

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

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

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

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

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

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

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

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 Figures 1 and 2, to commence the production of a product 2 a carrier 4 is provided. The carrier 4 is longitudinally extending with a representative portion of the carrier 4 shown in Figures 1 to 3. The carrier 4 is comprised of a base layer 6 and a carrier layer 8. The base layer 6 comprises paper and carrier layer 8 comprises a thin card. In other non-illustrated examples the carrier layer may comprise paper, a plastics material, or a metallic material. The carrier layer 8 has a support surface 10 and a carrier adhesion surface 12. The base layer 6 has a base adhesion surface 14 and a base surface 15. The carrier layer 8 and base layer 6 are adhered to each other by an adhesive (not shown) which acts on the carrier and base adhesion surfaces 12, 14. The adhesive is a releasable adhesive and the characteristics of each of the carrier and base adhesion surfaces 12, 14 are such that when the carrier layer 8 and base layer 6 are pulled or peeled away from each other the adhesive remains on the base adhesion surface 14 and comes off the carrier adhesion surface 12.

The length and width of the carrier 4 as shown in Figures 1 to 6 is for illustrative purposes only. The carrier 4 may have different lengths and widths without departing from the scope of the present disclosure.

Before the carrier layer 8 is adhered to the base layer 6 a plurality of lines of separation 16, 18 are introduced into the carrier layer 8. The line of separation 16 is a line of perforations which extends in a longitudinal direction along the carrier layer 8. The lines of separation 18 are lines of perforations which extend in a direction about perpendicular to the longitudinal direction, and which are approximately evenly longitudinally spaced along the carrier layer 8. The perforations in each of the lines of perforations 16, 18 are such that the a tear started at an end of a line of perforations 16, 18 will tend to follow that line of perforations until the tearing has stopped or the end of that line of perforations is reached.

The lines of perforations 16, 18 divide the support surface 10 of the carrier layer 8 into a plurality of portion areas 22 (for clarity not all portion areas 22 are labelled in all Figures). In the illustrated example each of the portion areas 22 is the same size and shape. In other non-illustrated examples of the present disclosure the portion areas may not all be of the same size and I or shape.

Once the carrier layer 8 has been adhered to the base layer 6, and as shown in Figure 3, a plurality of dots of aerosol generating material slurry 20 (for clarity not all the dots of slurry 20 are labelled) are applied to the support surface 10 of the carrier layer 8. The dots of slurry 20 are disposed on the support surface 10 in a square grid pattern with six dots of slurry being supported on the support surface 10 in each portion area 22. The relationship between the disposition of the dots of slurry 20 and the lines of perforations 16, 18 is such that for each of the portion areas 22, the dots of slurry 20 in that portion area are in the same place relative to the edges of that portion area as in the other portion areas.

Once the dots of slurry 20 have been applied to the carrier layer 8 time is allowed to allow the dots of slurry to set and form dots of aerosol generating film 20A. Alternatively and I or additionally the carrier 4 is subject to conditions such as heat and / or a low humidity atmosphere that decreases the time required for the dots of slurry 20 to set.

With reference to Figure 4, once the dots of slurry 20 have set and become aerosol generating film dots 20A the carrier 4 and aerosol generating film dots 20A form the product 2. The carrier 4 is rolled around a core 22 to form a roll to configure the product 2 for storage. The product 2 may now be stored until it is required.

With reference to Figure 5, when it is desired to use the product 2 to make one or more consumables the roll of carrier 4 is partially unrolled so that one or more portion areas 22 are accessible to a user. The user can then peel at least one portion area 22 off the base layer 6. Whilst the portion area is being peeled off, the perforations of the perforation lines 16, 18 bounding the portion area 22 being peeled off will tear and leave the portion areas that are not being peeled off adhered to the base layer 6.

Once the portion area 22 has been peeled off the user has a portion 24 of the carrier layer 8 as shown in Figure 6. Portion 24 of the carrier layer 8 may be used as a consumable 26 for use with an aerosol provision device 30.

With reference to Figure 7, an aerosol provision device 30 comprises a casing 32 within which is located a heater assembly 34. The heater assembly 34 is comprised of a heating chamber 36 and a heater 38. The heater 38 can be an electrical resistance heater or a magnetic field generator and a susceptor. The heating chamber 36 defines an opening or mouth 40 at a first end of the heating chamber 36. At the opposite end of the heating chamber 36 is an aperture 42. The aperture 42 is in fluid communication with a mouth piece 46 via a conduit 44.

Also located within the casing 32 is a controller 48 which is in electronic communication with and controls the functioning of the heater 38. The controller 48 may include a memory (not shown) within which one or more tables relating to the operation of the heater 38 may be stored. The heater 38 and controller 48 are powered by a power source 50. The power source 50 is a rechargeable battery. In other embodiments the power source may be other appropriate sources of electrical power.

In an alternative embodiment of the present disclosure, and with reference to Figure 8 a carrier layer 108 is provided. The carrier layer 108 comprises a metallic foil, for example aluminium foil. The carrier layer 108 has a support surface 110 and a carrier adhesion surface 112. A plurality of dots of aerosol generating material slurry 20 (for clarity not all the dots of slurry 20 are labelled) are applied to the support surface 110 of the carrier layer 108. The dots of slurry 20 are disposed on the support surface 110 in a square grid pattern.

Once the dots of slurry 20 have been applied to the carrier layer 108 time is allowed to allow the dots of slurry to set and form dots of aerosol generating film 20A. Alternatively and I or additionally the carrier layer 108 is subject to conditions such as heat and / or a low humidity atmosphere that decreases the time required for the dots of slurry 20 to set.

With reference to Figure 9, once the dots of slurry 20 have set and become aerosol generating film dots 20A the carrier layer 108 is adhered to a base layer 106 to form a carrier 104. The base layer 106 has a base adhesion surface 114 and a base surface 115. A plurality of fold lines 152 have been formed in the base layer 106 prior to the attachment of the carrier layer 108. The fold lines 152 extend approximately perpendicularly to what will be the longitudinal direction of the carrier layer 108 once it is adhered to the base layer 106. The carrier layer 108 and base layer 106 are adhered to each other by an adhesive (not shown) which acts on the carrier and base adhesion surfaces 112, 114. The adhesive is a releasable adhesive and the characteristics of each of the carrier and base adhesion surfaces 112, 14 are such that when the carrier layer 108 and base layer 106 are pulled or peeled away from each other the adhesive remains on the base adhesion surface 114 and comes off the carrier adhesion surface 112.

Once the carrier layer 108 is adhered to the base layer 106 a plurality of lines of separation 116, 118 are introduced into the carrier layer 118. The line of separation 116 is a cut line which extends in a longitudinal direction along the carrier layer 108. The lines of separation 118 are cut lines which extend in a direction approximately perpendicular to the longitudinal direction of the carrier layer 108. The cut lines 118 are approximately evenly longitudinally spaced along the carrier layer 108 and coincide in longitudinal position with the fold lines 152 of the base layer 106. The cut lines 116, 118 are cut by a kiss cutting technique and the cuts extend from the support surface 110 to the carrier adhesion surface 112.

The cut lines 116, 118 divide the carrier layer 108 into a plurality of carrier portions 122 (for clarity not all carrier portions 122 are labelled in all Figures). Each of the carrier portions 122 has eight aerosol generating film dots 20A supported on the support surface 110 of that portion. The relationship between the disposition of the aerosol generating film dots 20A and the cut lines 116, 118 is such that for each of the carrier portions 122, the aerosol generating film dots 20A are in the same place relative to the edges of that carrier portion as in the other carrier portions. In the illustrated example each of the carrier portions 122 is the same size and shape. In other non-illustrated examples of the present disclosure the carrier portions may not all be of the same size and / or shape. With reference to Figure 10, the carrier 104 is now folded about the fold lines 152 in the base layer 106 in a concertina fashion to configure the product 102 for storage. The product 102 may now be stored until it is required.

When it is desired to use the product 102 to make one or more consumables the concertina of carrier 104 is partially unfolded so that one or more carrier portions 122 are accessible to a user. The user can then peel at least one carrier portion 122 off the base layer 106. The cut lines 116, 118 bounding the carrier portions 122 being peeled off will ensure that the adjacent carrier portions 122 are not peeled off the base layer 106.

Once a carrier portion 122 has been peeled off, the carrier portion 122 may be used as a consumable for use with the aerosol provision device 30 in the same fashion as described in connection with consumable 26 above.

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

- 42 - Claims

1 A method of manufacture of a product for use in the manufacture of an article for use in a non-combustible aerosol provision system, in which the product comprises aerosol generating material and a carrier, in which the carrier comprises a base layer and a carrier layer, and the carrier layer is releasably attached to the base layer, and the method comprises the following steps

(a) the carrier is provided,

(b) an aerosol generating material is applied to a support surface of the carrier layer of the carrier, and

(c) the carrier and aerosol generating material is configured for storage.

2 A method according to claim 1 in which the application of the aerosol generating material in step (b) is application of an aerosol generating material slurry.

3 A method according to claim 1 or 2 in which the application of the aerosol generating material in step (b) is application of one or more discrete portions of aerosol generating material.

4 A method according to claim 3 in which there are at least two discrete portions of aerosol generating material, and at least two discrete portions of aerosol generating material have different compositions relative to each other.

5 A method according to claim 3 or 4 in which there are three or more distinct portions of aerosol generating material and the discrete portions are applied to the support surface of the carrier layer in a grid pattern.

6 A method according to any of claims 3 to 5 in which one or more of the discrete portions of the aerosol generating material applied in step (b) are, in the plane of the support surface of the carrier layer, substantially circular, longitudinally - 43 - extending stripes, stripes including at least one curve or angle, or of a shape that will tessellate.

7 A method according to any of claims 3 to 6 in which at least one discrete portion of the aerosol generating material applied in step (b) is of a shape and I or colour that is indicative of the composition of the aerosol generating material forming the discrete portion.

8 A method according to any of claims 1 to 7 in which the carrier layer comprises a sheet material, and the sheet material comprises at least one of paper, card, a plastics material, or a metallic material.

9 A method according to any of claims 1 to 8 in which the method includes a further step of

(d) introducing at least one line of separation into at least part of the carrier, in which each line of separation is a predetermined line along which at least part of the carrier will separate or tear.

10 A method according to claim 9 in which at least one line of separation is a predetermined line along which the carrier layer will separate or tear.

11 A method according to claim 9 or 10 in which at least one line of separation of step (d) comprises a line of perforations.

12 A method according to claim 9 or 10 in which at least one line of separation of step (d) comprises a cut line.

13 A method according to claim 12 in which the cut line is formed using a kiss cutting technique.

14 A method according to any of claims 9 to 13 when dependent on claim 3 or any claim dependent on claim 3 in which at least one line of separation extends between at least two discrete portions of aerosol generating material or between at - 44 - least two locations at which discrete portions of aerosol generating material will be applied in step (b).

15 A method according to any of claims 9 to 14 in which at least a part of at least one line of separation extends through aerosol generating material applied to the carrier layer, or a location at which aerosol generating material will be applied in step (b).

16 A method according to any of claims 1 to 15 in which the carrier is a sheet of material, and the configuration of step (c) comprises stacking two or more sheets of the carrier into pile.

17 A method according to any of claims 1 to 15 in which the carrier is a longitudinally extending sheet of material, and the configuration of step (c) comprises forming at least one fold line in the carrier, and subsequently folding the carrier about at least one of those fold lines.

18 A method according to claim 17 when dependent on any of claims 9 to 15 in which a fold line corresponds to a line of separation.

19 A method according to claim 17 or 18 in which the carrier is folded into a concertina.

20 A method according to any of claims 1 to 15 in which the configuration of step (c) comprises forming the carrier into a roll.

21 A method according to claim 20 in which the carrier is wound around a core.

22 A method according to any of claims 1 to 21 in which the method further comprises a step of

23 A product for use in the manufacture of a consumable for use with an article for use in a non-combustible aerosol provision system, in which the product comprises aerosol generating material and a carrier, in which the carrier comprises a base layer and a carrier layer, the carrier layer is releasably attached to the base layer, and at least one discrete portion of aerosol generating material is supported on a support surface of the carrier layer.

24 A product according to claim 23 in which the aerosol generating material is an aerosol generating film.

25 A product according to claim 23 or 24 in which there are at least two discrete portions of aerosol generating material, and at least two discrete portions of aerosol generating material have different compositions relative to each other.

26 A product according to any of claims 23 to 25 in which there are three or more distinct portions of aerosol generating material and the discrete portions are applied to the support surface of the carrier layer in a grid pattern.

27 A product according to any of claims 23 to 26 in which one or more of the discrete portions of the aerosol generating material are, in the plane of the support surface of the carrier layer, substantially circular, longitudinally extending stripes, stripes including at least one curve or angle, or of a shape that will tessellate.

28 A product according to any of claims 23 to 27 in which at least one discrete portion of the aerosol generating material is of a shape and I or colour that is indicative of the composition of the aerosol generating material forming the discrete portion.

29 A product according to any of claims 23 to 28 in which the carrier layer comprises an adhesive backed sheet material, and the sheet material comprises at least one of paper, card, a plastics material, or a metallic material.

30 A product according to any of claims 23 to 29 in which the carrier comprises at least one line of separation, in which each line of separation is a predetermined line along which at least part of the carrier will separate or tear.

31 A product according to claim 30 in which at least one line of separation is a predetermined line along which the carrier layer will separate or tear.

32 A product according to claim 30 or 31 in which at least one line of separation comprises a line of perforations.

33 A product according to claim 30 or 31 in which at least one line of separation comprises a cut line.

34 A product according to claim 32 in which at least one cut line is the result of kiss cutting.

35 A product according to any of claims 29 to 34 in which at least one line of separation extends between at least two discrete portions of aerosol generating material.

36 A product according to any of claims 29 to 35 in which at least a part of at least one line of separation extends through aerosol generating material applied to the carrier layer.

37 A product according to any of claims 23 to 36 in which the carrier is a sheet material.

38 A product according to any of claims 23 to 37 in which the carrier is a longitudinally extending sheet of material, the carrier comprises at least one fold line, and the carrier is folded about at least one of those fold lines.

39 A product according to claim 38 in which a fold line corresponds to a separation line. - 47 -

40 A product according to claim 38 or 39 in which the carrier is folded into a concertina.

41 A product according to any of claims 23 to 37 in which the carrier is rolled into a roll.

42 A product according to claim 41 in which the roll of carrier is wound around a core.

43 A product according to any of claims 23 to 42 in which the product further comprises a sheet of barrier material placed over the carrier layer and aerosol generating material.

44 A method of making a consumable for use with an apparatus for heating an aerosol generating material, in which the method comprises

(i) providing at least one product according to any of claims 23 to 43, and

45 An aerosol provision device for use with a consumable made according to the method of claim 44 in which the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable.

46 An aerosol provision device according to claim 45 in which the aerosol generator comprises a heatable plate adapted to support a consumable made according to the method of claim 44.

47 An aerosol provision system comprising an aerosol provision device according to claim 45 or 46 and a consumable made according to the method of claim 44. - 48 -

48. A method of generating aerosol from a consumable made according to the method of claim 44 using an aerosol generating device with at least one aerosol generator disposed to heat, but not burn, the consumable in use; wherein at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.