WO2023118185A1

WO2023118185A1 - A method of manufacturing a product comprising aerosol generating material

Info

Publication number: WO2023118185A1
Application number: PCT/EP2022/087054
Authority: WO
Inventors: Dorcas JONES; John Richardson; Robert Press; Richard Hepworth; Joanna SOFFE
Original assignee: Nicoventures Trading Limited
Priority date: 2021-12-20
Filing date: 2022-12-20
Publication date: 2023-06-29

Abstract

A method of manufacturing a product (2) is disclosed. The product comprises aerosol generating material (6), a support (4), and a mask (8). The method comprises providing a support (4), in which the support (4) has a first surface (10) and a second surface (11) which are of the same size and which are on opposing surfaces of the support (4); providing a mask (8), in which the mask (8) is so configured that if the mask (8) were to be applied to the first surface (10) of the support (4) in an application orientation relative to the support (4) there is at least one area on the first surface (10) of the support (4) which is not covered by the mask (8), each area not covered by the mask (8) is a support area; applying aerosol generating material to the first surface of the support (4), in which at least one of the support areas is at least partially covered by aerosol generating material (6) and applying the mask (8) to one of the first (10) and second surfaces of the support (4) in the application orientation.

Description

A METHOD OF MANUFACTURING A PRODUCT COMPRISING AEROSOL GENERATING MATERIAL

Technical Field

This disclosure relates to the field of non-combustible aerosol-provision systems, in particular to a method of manufacturing a product comprising aerosol generating material for use as a consumable for use with an aerosol provision device, a method for manufacturing consumables for use with an aerosol provision device, and an aerosol provision system including a consumable and an aerosol provision device.

Background

Aerosol-generating 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 articles, aerosol generating assemblies, or aerosol provision devices.

One example of such a product is a heating device which release compounds by heating an aerosolisable material, which may be referred to as a solid aerosolgenerating 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.

As another example, there are hybrid devices. These hybrid devices contain a liquid source (which may or may not contain an active) 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 botanical material) and components of this material are entrained in the inhalable vapour or aerosol to produce the inhaled medium.

Summary

According to a first aspect of the present disclosure there is provided a method of manufacturing a product in which the product comprises aerosol generating material, a support, and a mask in which the method comprises providing a support, in which the support has a first surface and a second surface which are of the same size and which are on opposing surfaces of the support, providing a mask, in which the mask is so configured that if the mask were applied to the first surface of the support in an application orientation relative to the support there is at least one area on the first surface of the support which is not covered by the mask, each area not covered by the mask is an active area, applying aerosol generating material to the first surface of the support, in which at least one of the active areas is at least partially covered by aerosol generating material, and applying the mask to one of the first and second surfaces of the support in the application orientation.

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 a non-combustible aerosol provision system in which the product comprises aerosol generating material, a support, and a mask. The support has a first surface and a second surface which are of the same size and which are on opposing surfaces of the support. Aerosol generating material is supported on the first surface of the support, and the mask is so configured that if the mask were applied to the first surface of the support in an application orientation relative to the support there would be at least one support area on the first surface of the support which is not covered by the mask. At least one of the support areas is at least partially covered by aerosol generating material, and the mask is applied to one of the first and second surfaces of the support in the application orientation.

According to a third aspect of the present disclosure there is provided a consumable for use with a non-combustible aerosol provision system in which the consumable is a portion of a product according to the second aspect of the present disclosure which has been shaped and dimensioned to a desired configuration.

According to a fourth aspect of the present disclosure there is provided an aerosol provision device for use with a consumable 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.

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

According to a sixth aspect of the present disclosure there is provided a method of generating aerosol from a consumable according to the second 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 perspective view of a first embodiment of a product according to the present disclosure;

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

Figure 3 shows a plan view of the support of the product of Figure 1 ;

Figure 4 shows a section along the line A - A’ of Figure 1 ;

Figure 5 shows a plan view of the support of a second embodiment of a product according to the present disclosure;

Figure 6 shows a section of the product of the second embodiment of Figure 5 along the equivalent line to line A - A’ of Figure 1 ;

Figure 7 shows a plan view of the support of a third embodiment of a product according to the present disclosure;

Figure 8 shows a section of the product of the third embodiment of Figure 7 along the equivalent line to line A - A’ of Figure 1 ; Figure 9 shows a section of the product of the third embodiment of Figure 7 along the equivalent line to line A - A’ of Figure 1 , the product having an alternative adhesive configuration;

Figure 10 shows a schematic view of an embodiment of a method of manufacture of a product of the present disclosure;

Figure 11 shows an enlarged view of a part of the embodiment of Figure 10;

Figure 12 shows an alternative storage roll of the schematic view of Figure 9;

Figure 13 shows a product manufactured according to the method of Figure 10; and Figure 14 shows a consumable made from the product of Figure 13.

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 at least one substance to a user. In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

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

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

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

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

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

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

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

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

According to a first aspect of the present disclosure there is provided a method of manufacturing a product in which the product comprises aerosol generating material, a support, and a mask. The method comprises providing a support, in which the support has a first surface and a second surface which are of the same size and which are opposing surfaces of the support. The method also comprises providing a mask, in which the mask is so configured that if the mask were to be applied to the first surface of the support in an application orientation relative to the support there is at least one area on the first surface of the support which is not covered by the mask, each area not covered by the mask is a support area.

Applying aerosol generating material to the first surface of the support, in which at least one of the support areas is at least partially covered by aerosol generating material, and applying the mask to one of the first and second surfaces of the support in the application orientation.

The mask has a first surface and a second surface which are of the same size and which are opposing surfaces of the mask.

The mask and support are both sheet like materials and thus have two surfaces which are joined by one or more edges. The application orientation is a predetermined and constant orientation of the mask relative to the first surface of the support. Application of the mask in the application orientation to the second surface of the support causes the mask to have the same orientation as if it were applied to the first surface of the support and the only difference is that whereas the first surface of the mask would be in contact with the first surface of the support, the second surface of the mask is in contact with the second surface of the support.

The support areas are defined by the parts of the first support surface not covered by the mask when the mask is applied to the first surface. The support areas are areas where at least some of the area is covered by aerosol generating material.

In an embodiment of the above embodiment the mask is applied to the first surface of the support.

In an alternative embodiment of the above embodiment the mask is applied to the second surface of the support.

In an embodiment of any of the above embodiments, the application of aerosol generating material is application of an aerosol generating material slurry.

In an embodiment of any of the above embodiments, the method further comprises allowing or causing the aerosol generating material slurry applied to the support to at least partially set, in which the aerosol generating material slurry at least partially sets as an aerosol generating material film. Allowing or causing the aerosol generating material slurry to at least partially set occurs after applying aerosol generating material to the support.

In an embodiment of any of the above embodiments, the application of aerosol generating material to the first surface of the support is application of at least one discrete portion of aerosol generating material.

In an embodiment of any of the above embodiments, the application of aerosol generating material to the support is application of at least two discrete portions of aerosol generating material. In an embodiment of any of the above embodiments, at least two discrete portions of aerosol generating material each contain the same predetermined volume of aerosol generating material. In some embodiments this is measured at the time of application of the aerosol generating material slurry. In some embodiments this is measured when the aerosol generating material is set.

In an embodiment of any of the above embodiments, at least one discrete portion of aerosol generating material contains a first volume of aerosol generating material, at least one discrete portion of aerosol generating material contains a second volume of aerosol generating material, and the first and second volumes are different.

In an embodiment of any of the above embodiments, at least two discrete portions of aerosol generating material each have the same shape as each other.

In an embodiment of any of the above embodiments, at least one discrete portion of aerosol generating material has a first shape, at least one discrete portion of aerosol generating material has a second shape, and the first and second shapes are different.

In an embodiment of any of the above embodiments, at least one discrete portion of aerosol generating material is formed from an aerosol generating material with a first composition, at least one discrete portion of aerosol generating material is formed from an aerosol generating material with a second composition, and the first and second compositions are different.

In an embodiment of any of the above embodiments, there are at least two support areas, and at least two of the support areas are at least partially covered by the same quantities of aerosol generating material as each other, and the quantity of aerosol generating material is determined by one of the surface area in the plane of the first surface of the support, mass, or volume.

In an embodiment of any of the above embodiments, each support area is at least partially covered by the same quantity of aerosol generating material as each other. In an embodiment of any of the above embodiments, at least one support area is wholly covered by aerosol generating material.

In an embodiment of any of the above embodiments, each support area has a periphery and in at least one of the support areas the aerosol generating material is so configured and positioned that the aerosol generating material is spaced from the periphery of that support area.

In an embodiment of any of the above embodiments, in at least one of the support areas the aerosol generating material extends out of the support area. The aerosol generating material may extend out of all of the support areas or less than all but at least one surface area.

In an embodiment of any of the above embodiments, the aerosol generating material extends between at least two support areas.

In an embodiment of any of the above embodiments, the method further comprises use of an adhesive to adhere the mask to one or both of the support and the aerosol generating material applied to the first surface of the support.

In an embodiment of any of the above embodiments, aerosol generating material slurry is used as the adhesive. The aerosol generating material slurry is sticky and forms an adhesive when it sets. This is advantageous because the components of the aerosol generating material are known and acceptable for use in the manufacture of consumables.

In an embodiment of any of the above embodiments, the method further comprises ultrasound welding at least one part of the mask to at least one part of the first or second surface of the support. Other appropriate means of fixing may be used and fall within the scope of the present disclosure.

In an embodiment of any of the above embodiments, the adhesive is applied to the support or the mask in beads or strips. In some embodiments the beads or strips are so located on the support or the mask that the beads or strips extend between discrete portions of aerosol generating material on the support.

In an embodiment of any of the above embodiments, the adhesive is applied to the support, aerosol generating material and I or mask by a glue roller, spraying the adhesive, or any other known adhesive application means.

In an embodiment of any of the above embodiments, the aerosol generating material slurry is caused or allowed to partially set, and the mask is applied to the first surface of the support when the aerosol generating material slurry is partially set.

In an embodiment of any of the above embodiments, the mask is a flexible sheet material.

In an embodiment of any of the above embodiments, the mask comprises paper, card, a metal foil, aluminium foil, felt, a non-woven material, a spun material, or a woven material. In other embodiments the mask may comprise other sheet materials or be a laminate material comprising two or more layers of material.

In an embodiment of any of the above embodiments, the mask comprises a material that is a relatively flexible material in comparison to stiff card, plastically deformable or elastically deformable.

In an embodiment of any of the above embodiments, the mask comprises a material that is heat resistant, or heat resistant to at least the temperatures typically experienced in an aerosol provision device.

In an embodiment of any of the above embodiments, the mask comprises a material that is porous or non-porous, water repellent, or that absorbs or adsorbs water.

In an embodiment of any of the above embodiments, the mask comprises a surface that can be printed on. In some embodiments the mask may have print applied to a surface of the mask before the mask is applied to a surface of the support. In an embodiment of any of the above embodiments, the thickness of the mask, in a direction perpendicular to the first surface of the support when the mask is applied to the support, is equal to or greater than the thickness of the aerosol generating material applied to the first surface of the support. In some embodiments the thickness of the aerosol generating material is measured when the aerosol generating material is set, or at least partially set. In some embodiments the thickness of the set aerosol generating material is in the range of 0.1 mm to 2.0 mm, 0.05 mm to 1.5 mm, 0.05 mm to 1.0 mm, 0.1 mm to 0.8 mm, or 0.05 mm to 0.5 mm.

An advantage of the mask being of the same or greater thickness than the set aerosol generating material is that the mask protects the aerosol generating material at least partially covering the at least one support areas because the material of the mask stops or at least lessens any physical damage to the aerosol generating material such as that caused by rubbing or abrasion of the aerosol generating material. Such damage to the aerosol generating material may occur during manufacture, storage or transportation of the product or of any consumable made using the product.

A further advantage of the mask being of the same or greater thickness than the set aerosol generating material is that the mask protects the aerosol generating material from contamination by contact with other substances, or at least lessens the risk of that occurring. This is important from a hygienic perspective.

A further advantage of the mask being of the same or greater thickness than the set aerosol generating material is that because the aerosol generating material does not extend higher than the surface of the mask remote from the support the combined support / aerosol generating material I mask can, when the mask is applied to the first surface of the support, be rolled, folded, or otherwise configured into a stack of multiple layers of support I aerosol generating material I mask without any danger of any stickiness of the aerosol generating material causing adjacent layers of support I aerosol generating material I mask to adhere to each other. In an embodiment of any of the above embodiments, the mask defines one or more apertures which extend through the mask in a direction perpendicular to the first surface of the support when the mask is applied to the support, and each aperture defines a support area.

In an embodiment of any of the above embodiments, the support is a flexible sheet material.

In an embodiment of any of the above embodiments, the support is aluminium foil. In some other embodiments the support comprises one or more of a flexible sheet material, a metallic foil, a metallic film, a plastics film, or aluminium foil. In some embodiments the support is a laminate material. In some embodiments the laminate material comprises at least two layers, and one of the layers is a metallic foil, a metallic film, a plastics film, or aluminium foil.

In an embodiment of any of the above embodiments, the support is a laminate flexible sheet material comprising at least two layers, one of the layers is paper, and one of the layers is one of a metallic foil, a metallic film, a plastics film, or aluminium foil.

In an embodiment of any of the above embodiments, the mask is thinner than the support in the direction perpendicular to the first surface of the support. Such a configuration may result in a product that is readily folded or rolled.

In an embodiment of any of the above embodiments, the mask is of equal thickness to the support.

In an embodiment of any of the above embodiments, the mask is thicker than the support in the direction perpendicular to the first surface of the support.

In an embodiment of any of the above embodiments, the mask is sufficiently thick in the direction perpendicular to the first surface of the support that the mask alone is sufficiently rigid to be handled without bending, folding or being damaged, for example a material of between 0.5 mm and 2.5 mm. In such embodiments the support does not need to contribute any rigidity to a consumable made from a product of the method of the present disclosure. The support may have a thickness of between 0.005 mm and 0.040 mm, for example an aluminium foil with a thickness of 0.007 mm.

In an embodiment of any of the above embodiments, causing the aerosol generating material slurry applied to at least one of the support areas to at least partially set comprises exposure of the aerosol generating material slurry to infrared radiation.

In an embodiment of any of the above embodiments, causing the aerosol generating material slurry applied to at least one of the support areas to at least partially set comprises exposure of the aerosol generating material slurry to electromagnetic energy sources, and I or environmental conditions that cause the aerosol generating material to set. This is advantageous because it decreases the time taken for the aerosol generating material to set or partially set.

In an embodiment of any of the above embodiments, causing the aerosol generating material slurry applied to the support to at least partially set comprises controlling the rate and I or conditions in which the aerosol generating material slurry sets. The ability to control the rate and I or conditions of setting of the aerosol generating material slurry has the result that the quality and characteristics of the set or partially set aerosol generating material can be controlled. For example, the setting rate may be kept at a rate which does not induce the formation of cracks or other discontinuities in the aerosol generating material.

In an embodiment of any of the above embodiments, the method further comprises forcibly cooling the support and aerosol generating material after allowing or causing the aerosol generating material slurry applied to the support to at least partially set.

An advantage of forcibly cooling the support and aerosol generating material is that by such cooling the rate of evaporation of any remaining solvent in the aerosol generating material (the solvent having been present in the formation of the aerosol generating material slurry), or the rate of volatilisation of any volatile elements in the aerosol generating material will be lowered relative to when the support and aerosol generating material is at a higher, uncooled, temperature. This both helps preserve the aerosol generating material in the state it is in at the time of cooling, and minimises any disruption to any further processing of the product after the cooling step. For example, the cooling can help prevent evaporation of the solvent interfering with the functioning of an adhesive used in adhering the mask to the support and aerosol generating material.

In an embodiment of any of the above embodiments, the forcible cooling can be achieved by the playing of a stream of cooled gas or a cooled mixture of gases on one or both of the support and the aerosol generating material in an embodiment of any of the above embodiments. In some embodiments, the cooled gas or mixture of gasses may be treated to remove water vapour or any undesirable gasses from the gas before it is used to cool the support and I or aerosol generating material.

In an embodiment of any of the above embodiments the method further comprises the formation of one or more perforations that extend through one or both of the support and the aerosol generating material. The perforations are of a small size, for example less than 0.5 mm, in the plane of the surface of the support on which the aerosol generating material is supported. The perforations are located in positions where the ends of the perforations closest to the mask are overlaid by an aperture. The perforations have an advantage in that they lessen the likelihood of the aerosol generating material delaminating from the support when a consumable made from the product of the present disclosure is used. This is because they minimise the aerosol that can build up between the support and aerosol generating material.

In an embodiment of any of the above embodiments, the support is a discontinuous sheet in which the support is configured to be present in all the locations of the support areas and to be fixed to portions of the mask adjacent to the edges of the mask that define the support areas.

In an embodiment of any of the above embodiments, the method further comprises configuring the product for storage. In an embodiment of any of the above embodiments, the mask is applied to the first surface of the support and configuring the product for storage comprises rolling the product onto a bobbin, folding the product into a concertina, or cutting the product into sheets for flat storage.

If it is intended to roll the product onto a bobbin for storage, it is desirable that the thickness of the mask relative to the thickness of the aerosol generating material that at least partially covers at least one support area is selected so as to allow for any dimensional change, for example an increase in thickness, the aerosol generating material may undergo as a result of the rolling.

In an embodiment of any of the above embodiments, the product is cut into sheets for storage, the mask is applied to the second surface of the support, and the distance between the cuts and the configuration of the mask are such that the support areas of a first sheet are adjacent to the parts of the second surface of the support of a second sheet that are not covered by the mask applied to the second sheet when the second sheet is placed on top of the first sheet and the edges of the support of the first and second sheets are adjacent and parallel to each other.

In an embodiment of any of the above embodiments, configuring the product for storage further includes slitting the product into longitudinally extending strips.

In an embodiment of any of the above embodiments, the product is larger than is compatible for use with a non-combustible aerosol provision system, in which the method further comprises separating the product into two or more product portions, in which each product portion is shaped and dimensioned for use as a consumable for use with a non-combustible aerosol provision system. The separation of the product into two or more product portions may occur directly or soon after the mask has been overlaid onto the support and aerosol generating material, or it may occur after the product has been configured for storage, stored, and retrieved from storage.

In an embodiment of any of the above embodiments, the separation of the product into two or more product portions includes shaping the product portions to an appropriate shape and discarding any excess material from the product. In an embodiment of any of the above embodiments, the product is shaped and dimensioned for use as a consumable for use with an a non-combustible aerosol provision system.

In an embodiment of any of the above embodiments, the provision of the support and the application of the aerosol generating material can be performed separately from the other parts of the method of manufacturing the product. Such an approach to the method of manufacturing the product has an advantage in that the application of the aerosol generating material to the support and subsequent allowing or causing the aerosol generating material to set is a process that may proceed at a rate of production that is slower than the rate that the support and aerosol generating material are used in the rest of the method.

In an embodiment of any of the above embodiments, the provision of the support and the application of the aerosol generating material can be achieved by using two or more sets of apparatus for application and setting of the aerosol generating material on the support.

In an embodiment of the above embodiment, the mask is applied to the first surface of the support. In an embodiment of the above embodiment, the mask is applied to the second surface of the support

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

In an embodiment of any of the above embodiments, the aerosol generating material is in the form of at least one discrete portion of aerosol generating material.

In an embodiment of any of the above embodiments, the aerosol generating material is in the form of at least two discrete portions of aerosol generating material.

In an embodiment of any of the above embodiments, there are at least two support areas, and at least two support areas are at least partially covered by the same quantity of aerosol generating material as each other, and the quantity of aerosol generating material is determined by the surface area in the plane of the first surface of the support, mass, or volume.

In an embodiment of any of the above embodiments, each support area is at least partially covered by the same quantity of aerosol generating material as each other.

In an embodiment of any of the above embodiments, at least one support area is wholly covered by aerosol generating material.

In an embodiment of any of the above embodiments, in at least one of the support areas the aerosol generating material extends out of the support area. The aerosol generating material may extend out of all of the support areas or less than all but at least one support area. In an embodiment of any of the above embodiments, the aerosol generating material extends between at least two support areas.

In an embodiment of any of the above embodiments, the mask is fixed to one or both of the support and the aerosol generating material.

In an embodiment of any of the above embodiments, an adhesive is used to fix the mask to one or both of the support and the aerosol generating material.

In an embodiment of any of the above embodiments, the adhesive is aerosol generating material slurry.

In an embodiment of any of the above embodiments, ultrasound welding is used to fix at least part of the mask to one or both of the support and the aerosol generating material.

In an embodiment of any of the above embodiments, the mask comprises a material that is a relatively flexible material in comparison to stiff card, that is plastically deformable, or that is elastically deformable.

In an embodiment of any of the above embodiments, the mask comprises a material that is porous or non-porous, water repellent, or that absorbs or adsorbs water. In an embodiment of any of the above embodiments, the mask comprises a surface that can be printed on. In some embodiments the mask may have print applied to a surface of the mask before the mask is applies to a surface of the support.

In an embodiment of any of the above embodiments, the thickness of the mask, in a direction perpendicular to the first surface of the support when the mask is applied to the support, is equal to or greater than the thickness of the aerosol generating material applied to the first surface of the support.

In an embodiment of any of the above embodiments, the thickness of the aerosol generating material is measured when the aerosol generating material is set, or at least partially set. In some embodiments the thickness of the set aerosol generating material is in the range of 0.1 mm to 2.0 mm, 0.05 mm to 1.5 mm, 0.05 mm to 1.0 mm, 0.1 mm to 0.8 mm, or 0.05 mm to 0.5 mm.

In an embodiment of any of the above embodiments, the mask is between 0.5 mm and 2.5 mm thick.

A further advantage of the mask being of the same or greater thickness than the set aerosol generating material is that because the aerosol generating material does not extend higher than the surface of the mask remote from the support the combined support / aerosol generating material I mask can, when the mask is applied to the first surface of the support, be rolled, folded, or otherwise configured into a stack of multiple layers of support I aerosol generating material I mask without any danger of any stickiness of the aerosol generating material causing adjacent layers of support I aerosol generating material I mask to adhere to each other.

In an embodiment of any of the above embodiments, the mask is not of a substantially even thickness, and at least a part of at least one portion of the mask that is adjacent a support area if the mask were applied to the first surface of the support in an application orientation relative to the support is equal to or greater than the thickness of the aerosol generating material applied to the first surface of the support in a direction perpendicular to the first surface of the support when the mask is applied to the support.

In an embodiment of any of the above embodiments, the mask is not of a substantially even thickness, and at least a portion of the mask is configured to include one or more grooves, channels or ridges across a portion of the surface of the mask not in contact with the support when measured in a direction perpendicular to the first surface of the support. In some embodiments the mask includes thick regions and thin regions.

An advantage of such an arrangement is that the grooves, channels or ridges, thick regions and thin regions can add structural rigidity to the mask. A further advantage is that the channels or ridges can assist in direction of aerosol around or across the surface of the mask when the consumable including such a mask is in use.

In an embodiment of any of the above embodiments, the support is one of aluminium foil, a metallic foil, a metallic film, a plastics film, or a laminate comprising at least two layers. In an embodiment of any of the above embodiments, the support is aluminium foil. In some other embodiments the support comprises one or more of a flexible sheet material, a metallic foil, a metallic film, a plastics film, or aluminium foil. In some embodiments the support is a laminate material. In some embodiments the laminate material comprises at least two layers, and one of the layers is a metallic foil, a metallic film, a plastics film, or aluminium foil.

In an embodiment of any of the above embodiments, the mask is sufficiently thick in the direction perpendicular to the first surface of the support that the mask alone is sufficiently rigid to be handled without bending, folding or being damaged, for example a material of between 0.5 mm and 2.5 mm. In such embodiments the support does not need to contribute any rigidity to a consumable made from a product of the present disclosure. The support may have a thickness of between 0.005 mm and 0.040 mm, for example an aluminium foil with a thickness of 0.007 mm.

In an embodiment of any of the above embodiments the product further comprises one or more perforations that extend through one or both of the support and the aerosol generating material. The perforations are of a small size, for example less than 0.5 mm, in the plane of the surface of the support on which the aerosol generating material is supported. The perforations are located in positions where the ends of the perforations closest to the mask are overlaid by an aperture. The perforations have an advantage in that they lessen the likelihood of the aerosol generating material delaminating from the support when a consumable made from the product of the present disclosure is used. This is because they minimise the aerosol that can build up between the support and aerosol generating material.

In an embodiment of any of the above embodiments, the support is a discontinuous sheet in which the support is configured to be present in all the locations of the support areas and to be fixed to portions of the mask adjacent to the edges of the mask that define the support areas. In such embodiments the amount of support used is minimised and limited to positions where the support is required.

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

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

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

The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be about 0.05 mm, 0.1 mm, 0.15 mm, 0.2 mm, or 0.3 mm, or in the range of about 0.015 mm to 0.3 mm, 0.015 mm to 0.25 mm, or 0.015 mm to 0.2 mm.

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

The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.

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

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

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically- conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the susceptor by resistive heating as a result of electric eddy currents. The susceptor may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the susceptor. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator.

The susceptor may comprise a ferromagnetic metal such as iron or an iron alloy such as steel or an iron nickel alloy. Some example ferromagnetic metals are a 400 series stainless steel such as grade 410 stainless steel, or grade 420 stainless steel, or grade 430 stainless steel, or stainless steel of similar grades. Alternatively, the susceptor may comprise a suitable non-magnetic, in particular paramagnetic, conductive material, such as aluminium. In a paramagnetic conductive material inductive heating occurs solely by resistive heating due to eddy currents. Alternatively, the susceptor may comprise a non-conductive ferrimagnetic material, such as a non-conductive ferrimagnetic ceramic. In that case, heat is only generated by hysteresis losses. The susceptor may comprise a commercial alloy like Phytherm 230 (with a composition (in % by weight = wt %) with 50 wt % Ni, 10 wt % Cr and the rest Fe) or Phytherm 260 (with a composition with 50 wt % Ni, 9 wt % Cr and the rest Fe).

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

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

The active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes. In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

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

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

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

In some embodiments, the aerosol-generating material comprises a flavour or flavourant.

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

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

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

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

In some embodiments, the aerosol generating agent comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and/or aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. In some embodiments, the aerosol generating material may comprise from about 0.1wt%, 0.5wt%, 1wt%, 3wt%, 5wt%, 7wt% or 10% to about 50wt%, 45wt%, 40wt%, 35wt%, 30wt% or 25wt% of an aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticiser. For example, the aerosol generating material may comprise 0.5-40wt%, 3-35wt% or 10- 25wt% of an aerosol generating agent.

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

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

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

In some embodiments, the gelling agent comprises one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum and mixtures thereof. In some embodiments, the cellulosic gelling agent is selected from the group consisting of: hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP) and combinations thereof.

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

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

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

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

In some embodiments, the aerosol generating material comprises from about 20wt% 22wt%, 24wt% or 25wt% to about 30wt%, 32wt% or 35wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 20-35wt% or 25-30wt% of a gelling agent. In some cases, the aerosol generating material may comprise from about 1wt%, 5wt%, 10wt%, 15wt% or 20wt% to about 60wt%, 50wt%, 40wt%, 30wt% or 25wt% of a gelling agent (DWB). For example, the aerosol generating material may comprise 10-40wt%, 15-30wt% or 20-25wt% of a gelling agent (DWB).

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

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

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

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

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

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

The (b) forming a layer of the slurry typically comprises spraying, casting or extruding the slurry. In examples, the slurry layer is formed by electrospraying the slurry. In examples, the slurry layer is formed by casting the slurry.

In some examples, (b) and/or (c) and/or (d), at least partially, occur simultaneously (for example, during electrospraying). In some examples, (b), (c) and (d) occur sequentially.

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

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

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

In examples, the setting agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the setting agent comprises or consists of calcium formate and/or calcium lactate. In particular examples, the setting agent comprises or consists of calcium formate. 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 has a thickness of 0.2mm.

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

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

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

The aerosol generating material may comprise a filler.

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

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

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

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

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

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

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

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 an aerosol generating material, the aerosol generating material comprising:

1-60 wt% of a gelling agent;

5-60 wt% of an aerosol generating agent; and 10-60 wt% of a tobacco extract; 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 found that if the aerosol-generating material is too thick, then heating efficiency is compromised. This adversely affects the power consumption in use. Conversely, if the aerosol-generating material is too thin, it is difficult to manufacture and handle; a very thin material is harder to cast and may be fragile, compromising aerosol formation in use.

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

In some examples, the aerosol generating material in sheet form 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 350 g/m2. In some cases, the sheet may have a mass per unit area of 50-250 g/m2, or from about 70 to 210 g/m2, or from about 90 to 190 g/m2, or suitably about 100 g/m2 (so that it has a similar density to cut rag tobacco and a mixture of these substances will not readily separate). In some cases, the sheet may have a mass per unit area of about 30 to 70 g/m2, 40 to 60 g/m2, or 25-60 g/m2 and may be used to wrap an aerosolisable material such as tobacco.

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

As used herein, the term “sheet” denotes an element having a width and length substantially greater than a thickness thereof. A major surface of the sheet is a surface which extends in both width and length dimensions then the sheet is flat. The sheet may be a strip, for example.

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

A variety of colourants may be used depending on the desired colour of the aerosol generating material. The colour of aerosol generating material may be, for example, white, green, red, purple, blue, brown or black. Other colours are also envisaged. Natural or synthetic colourants, such as natural or synthetic dyes, 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 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, a product 2 for use in the manufacture of a consumable for use with an a non-combustible aerosol provision system is shown. The product 2 includes a support 4, aerosol generating material 6, and a mask 8. The aerosol generating material 6 is supported on a first surface 10 of the support 4. In an alternative non-illustrated embodiment the aerosol generating material 6 is supported on a second surface 11 of the support 4

The support 4 and mask 8 are sheet materials and may be of any appropriate dimensions in the plane of the major (larger) surfaces of those materials. The support 4 and mask 8 are of substantially the same size and shape.

The mask 8 includes a number of apertures 12 that extend between the major surfaces of the mask 8 and each aperture 12 defines a support area on the first surface 10 of the support 4.

The aerosol generating material 6 is, in Figure 2, in the form of a plurality of discrete portions 6A of aerosol generating material 6. The aerosol generating material 6 is in the form of an aerosol generating material film. In Figure 2 four portions 6A of aerosol generating material are shown, the present disclosure includes other numbers of portions 6A ranging from one to many portions. The number of portions may be limited only by the dimensions of the mask 8 and the surface 10 of the support 4, the desired spacing of the apertures 12 from each other, and the practicality of handling the support 4 and mask 8.

The portions 6A of aerosol generating material are shown as being rectangular in the plane of the surface 10 of the support 4. The present disclosure includes the portions 6A having other shapes, or a variety of shapes.

The portions 6A of the aerosol generating material are disposed on the surface 10 in the support areas defined by the apertures 12 in the mask 8. The apertures 12 are in a spatial arrangement relative to each other that is an approximately square grid pattern resulting in support areas on the surface 10 of the support having the same pattern. Portions of the surface 10 of the support 4 that are not within a support area separate the support areas. The support 4 has the mask 8 applied to the first surface 10, and the portions 6A of the aerosol generating material each cover a portion of a support area and are spaced from the perimeter of the support area shown by line 12A.

With reference to Figure 3, the surface 10 of the support 4 is shown in plan view with portions 6A of the aerosol generating material disposed on the surface 10. The dashed lines 12A represent the edges of the apertures 12 and the perimeter of the support areas when the mask 8 is applied to the surface 10. As may be seen in Figures 3 and 4, the portions 6A are so shaped and dimensioned that the faces of the mask 8 that define the faces that define apertures 12 closely surround each of the portions 6A.

The mask 8 has a first and second surface 16, 20 which are the first and second major surfaces of the mask 8. The second surface 20 is intended to be adjacent the surface 10 of the support 4 and the first surface 16 is further from the surface 10 of support 4 than the second surface 20 when the mask is applied to the first surface 10 of the support 4. The mask is of a thickness (the distance between the first and second surfaces 16, 20 of the mask 8 in a direction perpendicular to the surface 10 of the support 4)) that is greater than the maximum thickness (in a direction perpendicular to the surface 10 of the support 4) of the portions 6A of aerosol generating material. This has the result, as illustrated in Figure 4, that the surface 14 of the portions 6A is closer to the surface 10 of the support 4 than the surface 16 of the mask 8, and that the portions 6A are at least partially protected from contact and damage by external objects by the mask 8. It also has the result that the product 2 can be stacked or rolled without the aerosol generating material 6 contacting and potentially adhering to the next layer of product 2.

The surface 16 of the mask 8 can be used to carry branding, user instructions, product information, and I or decorative materials.

The mask 8 is adhered to the support 4 by an adhesive 18. With further reference to Figure 4, the adhesive 18 is in this first embodiment, applied so that there is a layer of adhesive between the surface 10 of the support 4 and the second surface 20 of the mask 8. An aerosol generating material is used as the adhesive 18 because aerosol generating material is sufficiently sticky to achieve the strength of adhesion required between the mask 8 and support 4, and because of the known properties of the aerosol generating material if the adhesive 18 were to be heated.

With reference to Figures 5 and 6, in a second embodiment the product 102 is of a similar structure to product 2 described above with the following differences. As shown in Figure 5, the surface 10 of the support 4 is shown in plan view with portions 6A of the aerosol generating material disposed on the surface 10. The dashed lines 112A represent the edges of the apertures 112 / the support areas when the mask 108 is applied to the surface 10. As may be seen in Figures 5 and 6, the apertures 112 are so shaped and dimensioned that the faces of the mask 108 that define the apertures 112 surround each of the portions 6A but are spaced from the portions 6A. As a result, the apertures 112 overlie the portions 6A and a portion of the surface 10 of the support 4 that surrounds the portions 6A.

The mask 108 is adhered to the support 4 by an adhesive 118. With further reference to Figure 6, the adhesive 118 is, in this embodiment, applied so that a bead or thin strip of adhesive 118 extends across the portions of surface 10 of the support 4 that do not support aerosol generating material 6. The bead of adhesive 118 extends between the surface 10 of the support 4 and the second surface 120 of the mask 108. The bead of adhesive 118 is shown by the long dashed lines 118 in Figure 5.

With reference to Figures 7 and 8, in a third embodiment the product 202 is of a similar structure to product 2 described above with the following differences. As shown in Figure 7, the surface 10 of the support 4 is shown in plan view with portions 206A of the aerosol generating material disposed on the surface 10. The dashed lines 212A represent the edges of the apertures 212 / the support areas when the mask 208 is overlaid onto the surface 10 and portions 206A of the aerosol generating material. As may be seen in Figures 7 and 8, the apertures 212 are so shaped and dimensioned that the faces of the mask 208 that define the apertures 212 surround only a portion of a portion 206A of the aerosol generating material and the portions 206A each extend between adjacent support areas. As a result, no part of the surface 10 of the support 4 is accessible through any of the apertures 212. The mask 208 is adhered to the support 4 and portions 206A of the aerosol generating material by an adhesive 218. The adhesive 218 is, in this embodiment, applied so that adhesive 218 extends between the face 220 of the mask 208 and the portions of surface 10 of the support 4 that do not support portions 206A of aerosol generating material and the portions of portions 206A of the aerosol generating material that are not overlaid by an aperture 212.

In an alternative adhesive configuration to that shown in Figure 8, and as shown in Figure 9, the mask 208 is adhered to the support 4 and portions 206A of the aerosol generating material by an adhesive 218. The adhesive 218 is, in this embodiment, applied so that adhesive 218 extends between the face 220 of the mask 208 and the portions of surface 10 of the support 4 that do not support portions 206A of aerosol generating material.

The portions 206A of aerosol generating material includes one or more perforations 240 that extend through the support 4 and the portions 206A of the aerosol generating material. The perforations 240 are of a small size in the plane of the surface 10 of the support 4 and are located in positions where the ends of the perforations 240 closest to the surface 216 of the mask 208 are overlaid by an aperture 212. The perforations 240 lessen the likelihood of the aerosol generating material delaminating from the support 4 when the consumable made from the product 202 is used in a non-combustible aerosol provision system.

With reference to Figure 10, to manufacture a product 2, 102, 202 as discussed above, a support 4 in the form of a roll 22 of support 4 is provided. The roll 22 is of a width (in the axial direction of the roll 22) that is one or more products 2, 102, 202 wide. The roll 22 is supported on an axle that is part of a manufacturing apparatus (not shown). The support 4 is continuously fed off the roll 22 with the surface 10 of the support uppermost (arrow 26 points upwards) and along a flat bed 24 that supports the support 4. The flat bed 24 keeps the support 4 from deflecting or changing position as it travels along the bed 24.

As the support 4 travels along the flat bed 24 portions 6A of aerosol generating material (for clarity not all of the portions 6A are labelled) are applied to the surface 10 of the support 4 in a predetermined pattern. The pattern includes areas of the surface 10 of the support 4 without any aerosol generating material 6 which lie between the portions 6A of aerosol generating material.

The portions 6A of aerosol generating material are applied to the support 4 in the form of an aerosol generating material slurry by an appropriate application technique, for example rotary screen printing, using appropriate application apparatus (not shown). The portions 6A may be rectangular as illustrated or of an alternative shape. They may contain a predetermined volume of aerosol generating material.

Once the portions 6A of aerosol generating material have been applied to the support 4 the portions 6A of aerosol generating material are allowed or caused to set or at least partially set. This can be achieved by having a long period of travel for the portions 6A of aerosol generating material before further processing of the support I portions 6A occurs (for ease of representation the long bed over which the support 4 travels in this time is not illustrated).

Alternatively, the support 4 and portions 6A can be exposed to one or more environmental conditions or energy sources (not illustrated) that will increase and I or control the rate at which the portions 6A of aerosol generating material set. For example, the portions 6A may be exposed to infrared radiation to increase the rate of setting the portions 6A. The ability to control the rate of setting of the portions 6A of aerosol generating material has the result that the quality and characteristics of the set or partially set of aerosol generating material can be controlled. For example, if the setting rate may be kept at a rate which does not induce the formation of cracks or other discontinuities in the aerosol generating material.

The manufacture of a product 2, 102, 202 as discussed above, also includes the provision of a mask 8 comprising one or more apertures 12. The mask 8 is provided in the form of a roll 28 of material which forms the mask 8 with the apertures 12 already formed in the mask 8. The formation of the apertures may be performed at a different time and I or different location from the use of the mask 8 in the manufacture of the product 2, 102, 201. The formation of the apertures may be by a known method. With reference to Figure 11 and with further reference to Figure 10, the apertures 12 (for clarity not all the apertures 12 are labelled) of the mask 8 are laid out in groups 30. Each group 30 of apertures 12 corresponds to the apertures that will be part of a product 2, 102, 202, and which will, when ultimately the product is separated into individual consumables that will be usable in connection with a noncombustible aerosol provision system, form the apertures of a consumable.

The roll 28 of the mask 8 is of the same width (in the axial direction of the roll 28) as the roll 22 of the support 4. The roll 28 is supported on an axle that is part of a manufacturing apparatus (not shown). The mask 8 is continuously fed off the roll 28 and fed along a path that causes the mask 8 to pass through an adhesive application apparatus 32.

The adhesive application apparatus 32 can be any known adhesive application means, for example a glue roller. The adhesive application apparatus 32 is configured to apply an adhesive 18 (not illustrated in Figure 10) to the parts of the surface 20 of the mask 8 that will correspond to the portions of the surface 10 of support 4 which do not support aerosol generating material 6.

The mask 8 follows a path to a position where the mask 8 overlies the support 4 and each aperture 12, in this embodiment, overlies a portion of a portion 6A of aerosol generating material. When the mask comes into that position the adhesive 18 on the surface 20 of the mask 8 comes into contact with the surface 10 of the support 4.

Thereafter, the support 4 and mask 8 pass through a compression roller (not illustrated) that forces the support 4 and mask 8 together. This ensures that the adhesive 18 sticks to the support 4.

After compression, the support 4 and mask 8 are fed onto a storage roll 34. The support 4 and mask 8 can be stored as a storage roll 34. Because the mask 8 is of such a thickness that the aerosol generating material of the portions 6A will not be thicker, in a direction perpendicular to the surface 10 of the support 4, than the distance between the surfaces 20 and 16 of the mask 8 the aerosol generating material in each aperture 12 will not contact the support 4 when the support 4 and mask 8 are on the storage roll 34.

Optionally, as the support 4 and mask 8 are being fed onto the roll 34, the support 4 and mask 8 are slit in the direction of travel of the support 4 and mask 8 so as to form a plurality of thinner roles 34A. As illustrated in Figure 12 five thinner roles 34A are formed in the illustrated embodiment.

Optionally at some time between the unwinding of the support 4 from the roll 22 and the winding of the support 4 and mask 8 onto the storage roll 34 or storage rolls 34A the support 4 passes through a perforation apparatus (not illustrated) that introduces one or more perforations 240 through one or both of the support 4 and the portions 6A of the aerosol generating material. The perforations 240 are of a small size, for example less than 0.5 mm, in the plane of the surface 10 of the support 4, and are located in positions where the ends of the perforations 240 closest to the surface 16 of the mask 8 are overlaid by an aperture 12.

The storage roll 34 or storage rolls 34A can be stored until required for the making of a plurality of consumables.

With reference to Figures 13 and 14, when it is desired to make consumables 38, a storage roll, for example a storage roll 34A, is unwound and separated along separation lines 36. Between each separation line 36 is a group 30 of apertures 12. The consumable 38 can then be used in a non-combustible aerosol provision system.

The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without departing from the scope of the invention disclosed. Still other modifications which fall within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure.

Various aspects of the method, product, and consumable disclosed in the various embodiments may be used alone, in combination, or in a variety of arrangements not specifically discussed in the embodiments described above. This disclosure is therefore not limited in its application to the details and arrangement of components set forth in the foregoing description or illustrated in the drawings. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments. Although particular embodiments have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from this invention in its broader aspects. The scope of the following claims should not be limited by the embodiments set forth in the examples, but should be given the broadest reasonable interpretation consistent with the description as a whole.

Claims

52

Claims

1 A method of manufacturing a product in which the product comprises aerosol generating material, a support, and a mask in which the method comprises providing a support, in which the support has a first surface and a second surface which are of the same size and which are on opposing surfaces of the support, providing a mask, in which the mask is so configured that if the mask were to be applied to the first surface of the support in an application orientation relative to the support there is at least one area on the first surface of the support which is not covered by the mask, each area not covered by the mask is a support area, applying aerosol generating material to the first surface of the support, in which at least one of the support areas is at least partially covered by aerosol generating material, and applying the mask to one of the first and second surfaces of the support in the application orientation.

2 A method according to claim 1 in which the mask is applied to the first surface of the support.

3 A method according to claim 1 in which the mask is applied to the second surface of the support.

4 A method according to any of claims 1 to 3 in which the application of aerosol generating material is application of an aerosol generating material slurry.

5 A method according to claim 4 in which the method further comprises allowing or causing the aerosol generating material slurry applied to the support to at least partially set, in which the aerosol generating material slurry at least partially sets as an aerosol generating material film.

6 A method according to any of claims 1 to 5 in which the application of aerosol generating material to the first surface of the support is application of at least one discrete portion of aerosol generating material. 53

7 A method according to claim 6 in which the application of aerosol generating material to the support is application of at least two discrete portions of aerosol generating material.

8 A method according to claim 6 or 7 in which at least two discrete portions of aerosol generating material each contain the same predetermined volume of aerosol generating material.

9 A method according to any of claims 1 to 8 in which there are at least two support areas, and at least two of the support areas are at least partially covered by the same quantities of aerosol generating material as each other, and the quantity of aerosol generating material is determined by one of the surface area in the plane of the first surface of the support, mass, or volume.

10 A method according to claim 9 in which each support area is covered by the same quantity of aerosol generating material as each other.

11 A method according to any of claims 1 to 10 in which at least one support area is wholly covered by aerosol generating material.

12 A method according to any of claims 1 to 10 in which each support area has a periphery and in at least one of the support areas the aerosol generating material is so configured and positioned that the aerosol generating material is spaced from the periphery of that support area.

13 A method according to any of claims 1 to 12 in which in at least one of the support areas the aerosol generating material extends out of the support area.

14 A method according to any of claims 1 to 13 in which the method further comprises use of an adhesive to adhere the mask to one or both of the support and the aerosol generating material applied to the first surface of the support.

15 A method according to claims 14 in which aerosol generating material slurry is used as the adhesive. 54

16 A method according to any of claims 1 to 15 in which the method further comprises ultrasound welding at least one part of the mask to at least one part of the first or second surface of the support.

17 A method according to any of claims 1 to 16 in which the mask is a flexible sheet material.

18 A method according to any of claims 1 to 17 in which the mask is paper or card.

19 A method according to any of claims 1 to 18 in which the thickness of the mask, in a direction perpendicular to the first surface of the support when the mask is applied to the support, is equal to or greater than the thickness of the aerosol generating material applied to the first surface of the support.

20 A method according to any of claims 1 to 19 in which the mask defines one or more apertures which extend through the mask in a direction perpendicular to the first surface of the support when the mask is applied to the support, and each aperture defines a support area.

21 A method according to any of claims 1 to 20 in which the support is a flexible sheet material.

22 A method according to claim 21 in which the support is aluminium foil.

23 A method according to any of claims 1 to 22 in which causing the aerosol generating material slurry applied to the support to at least partially set comprises exposure of the aerosol generating material slurry to infrared radiation.

24 A method according to any of claims 1 to 23 in which the method further comprises forcibly cooling the support and aerosol generating material after allowing or causing the aerosol generating material slurry applied to the support to at least partially set. 55

25 A method according to any of claims 1 to 26 in which the method further comprises configuring the product for storage.

26 A method according to claim 25 in which the mask is applied to the first surface of the support and configuring the product for storage comprises rolling the product onto a bobbin, folding the product into a concertina, or cutting the product into sheets for flat storage.

27 A method according to claim 25 in which the product is cut into sheets for storage, the mask is applied to the second surface of the support, and the distance between the cuts and the configuration of the mask are such that the support areas of a first sheet are adjacent to the parts of the second surface of the support of a second sheet that are not covered by the mask applied to the second sheet when the second sheet is placed on top of the first sheet and the edges of the support of the first and second sheets are adjacent and parallel to each other.

28 A method according to any of claims 25 to 27 in which configuring the product for storage further includes slitting the product into longitudinally extending strips.

29 A method according to any of claims 1 to 28 in which the product is larger than is compatible for use with a non-combustible aerosol provision system, in which the method further comprises separating the product into two or more product portions, in which each product portion is shaped and dimensioned for use as a consumable for use with a non-combustible aerosol provision system.

30 A method according to any of claims 1 to 28 in which the product is shaped and dimensioned for use as a consumable for use with an a non-combustible aerosol provision system.

31 A method according to any of claims 1 to 30 in which the support is a discontinuous sheet in which the support is configured to be present in all the locations of the support areas and to be fixed to portions of the mask adjacent to the edges of the mask that define the support areas. 32 A product for use in the manufacture of a consumable for use with an a noncombustible aerosol provision system in which the product comprises aerosol generating material, a support, and a mask in which the support has a first surface and a second surface which are of the same size and which are on opposing surfaces of the support, aerosol generating material is supported on the first surface of the support, the mask is so configured that if the mask were applied to the first surface of the support in an application orientation relative to the support there would be at least one area on the first surface of the support which is not covered by the mask and which is a support area, at least one of the support areas is at least partially covered by aerosol generating material, and the mask is applied to one of the first and second surfaces of the support in the application orientation.

33 A product according to claim 32 in which the mask is applied to the first surface of the support.

34 A product according to claim 32 in which the mask is applied to the second surface of the support

35 A product according to any of claims 32 to 34 in which the aerosol generating material is an aerosol generating material film.

36 A product according to any of claims 32 to 35 in which the aerosol generating material is in the form of at least one discrete portion of aerosol generating material.

37 A product according to claim 36 in which the aerosol generating material is in the form of at least two discrete portions of aerosol generating material.

38 A product according to any of claims 32 to 37 in which there are at least two support areas, and at least two support areas are at least partially covered by the same quantity of aerosol generating material as each other, and the quantity of aerosol generating material is determined by the surface area in the plane of the first surface of the support, mass, or volume.

39 A product according to claim 38 in which each support area is at least partially covered by the same quantity of aerosol generating material as each other.

40 A product according to any of claims 32 to 39 in which at least one support area is wholly covered by aerosol generating material.

41 A product according to any of claims 32 to 39 in which each support area has a periphery and in at least one of the support areas the aerosol generating material is so configured and positioned that the aerosol generating material is spaced from the periphery of that support area.

42 A product according to any of claims 32 to 41 in which , in at least one of the support areas the aerosol generating material extends out of the support area.

43 A product according to any of claims 32 to 42 in which the aerosol generating material extends between at least two support areas.

44 A product according to any of claims 32 to 43 in which the mask is fixed to one or both of the support and the aerosol generating material.

45 A product according to claim 44 in which an adhesive is used to fix the mask to one or both of the support and the aerosol generating material.

46 A product according to claim 45 in which the adhesive is aerosol generating material slurry.

47 A product according to any of claims 32 to 46 in which ultrasound welding is used to fix at least part of the mask to one or both of the support and the aerosol generating material.

48 A product according to any of claims 32 to 47 in which the mask is a flexible sheet material. 58

49 A product according to claim 48 in which the mask comprises paper, card, a metal foil, aluminium foil, felt, a non-woven material, a spun material, or a woven material.

50 A product according to any of claims 32 to 49 in which the mask comprises a material relatively flexible material in comparison to stiff card, that is plastically deformable, or that is elastically deformable.

51 A product according to any of claims 32 to 50 in which the mask comprises a material that is heat resistant, or heat resistant to at least the temperatures typically experienced in an aerosol provision device.

52 A product according to any of claims 32 to 46 in which the mask comprises a surface that can be printed on.

53 A product according to any of claims 32 to 52 in which the thickness of the mask, in a direction perpendicular to the first surface of the support when the mask is applied to the support, is equal to or greater than the thickness of the aerosol generating material applied to the first surface of the support.

54 A product according to any of claims 32 to 50 in which the thickness of the aerosol generating material is measured when the aerosol generating material is set, or at least partially set and the thickness of the set aerosol generating material is in the range of 0.1 mm to 2.0 mm, 0.05 mm to 1.5 mm, 0.05 mm to 1.0 mm, 0.1 mm to 0.8 mm, or 0.05 mm to 0.5 mm.

55 A product according to any of claims 32 to 54 in which the mask is between 0.5 mm and 2.5 mm thick.

56 A product according to any of claims 32 to 55 in which the mask is not of a substantially even thickness, and at least a part of at least one portion of the mask that is adjacent a support area if the mask were applied to the first surface of the support in an application orientation relative to the support is, equal to or greater than the thickness of the aerosol generating material applied to the first surface of 59 the support, in a direction perpendicular to the first surface of the support when the mask is applied to the support.

57 A product according to any of claims 32 to 56 in which the mask is not of a substantially even thickness, and at least a portion of the mask is configured to include one or more channels or ridges across a portion of the surface of the mask not in contact with the support.

58 A product according to any of claims 32 to 57 in which the support is a flexible sheet material.

59 A product according to claim 58 in which the support is one of aluminium foil, a metallic foil, a metallic film, a plastics film, or a laminate comprising at least two layers.

60 A product according to any of claims 32 to 59 in which the mask has a thickness in the range of between 0.5 mm and 2.5 mm and the support has a thickness in the range of between 0.005 mm and 0.040 mm.

61 A product according to any of claims 32 to 60 in which the product further comprises one or more perforations that extend through one or both of the support and the aerosol generating material.

62 A product according to any of claims 32 to 61 in which the support is a discontinuous sheet in which the support is configured to be present in all the locations of the support areas and to be fixed to portions of the mask adjacent to the edges of the mask that define the support areas.

63 A consumable for use with a non-combustible aerosol provision system, in which the consumable is a portion of an product according to any of claims 32 to 62 which has been shaped and dimensioned to a desired configuration.

64 An aerosol provision device for use with a consumable according to claim 63 in which the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the support. 60

65 An aerosol provision system comprising an aerosol provision device and a consumable according to claim 63. 66 A method of generating aerosol from a consumable according to claim 63 using an aerosol-generating device with at least one aerosol generator disposed to heat, but not burn, the product in use; wherein at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.