WO2023118225A1

WO2023118225A1 - A method of manufacturing a product comprising aerosol generating material

Info

Publication number: WO2023118225A1
Application number: PCT/EP2022/087113
Authority: WO
Inventors: Joanna SOFFE
Original assignee: Nicoventures Trading Limited
Priority date: 2021-12-20
Filing date: 2022-12-20
Publication date: 2023-06-29

Abstract

An article (2) for use with a non-combustible aerosol provision device is disclosed. The article (2) comprises aerosol generating material and a support (8). The support (8) has first and second opposing surfaces (10, 12), at least one discrete portion (6) of aerosol generating material is supported on the first surface (10), and at least one discrete portion (6) of aerosol generating material is supported on the second surface (12).

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-provision systems generate aerosol an inhalable aerosol or vapour during use by releasing compounds from an aerosol-generating-material. These may be referred to as non-combustible smoking articles, aerosol generating assemblies, or aerosol provision devices, for example.

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

As another example, there are hybrid devices. These hybrid devices contain a liquid aerosol-generating material which is vaporised by heating to produce an inhalable vapour or aerosol. The device additionally contains a solid aerosolgenerating 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 an article for use with a non-combustible aerosol provision device in which the article comprises aerosol generating material and a support, the support has first and second opposing surfaces, at least one discrete portion of aerosol generating material is supported on the first surface, and at least one discrete portion of aerosol generating material is supported on the second surface.

According to a second aspect of the present disclosure there is provided a consumable for use with a non-combustible aerosol provision device in which the consumable comprises a portion of the article of the first aspect of the present disclosure in and the portion of the article has been configured to a shape and size suitable for use with the device.

According to a third aspect of the present disclosure there is provided a method of manufacturing an article in which the article comprises aerosol generating material and a support, in which the method comprises providing a support, applying aerosol generating material to at least one predetermined area on a first surface of the support, applying aerosol generating material to at least one predetermined area on a second surface of the support.

According to a fourth aspect of the present disclosure there is provided an aerosol provision device for use with a consumable according to the second 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 part of a first embodiment of an article according to the present disclosure;

Figure 2 shows a sectional view of the article of Figure 1 along section line A-A’; Figure 3 shows a perspective view of a first embodiment of a consumable made from the article of Figure 1 ;

Figure 4 shows a schematic perspective view of a part of a second embodiment of an article according to the present disclosure;

Figure 5 shows a second schematic perspective view of the article of Figure 4; Figure 6 shows a sectional view of the article of Figure 4 along section line B-B’; Figure 7 shows a schematic perspective view of a first embodiment of a consumable made from the article of Figure 4; and

Figure 8 shows a schematic perspective view of a method of making a set or partially set aerosol generating material film.

Detailed Description

An article of the present description may be a consumable, a component of a consumable, or a product from which a consumable may be made.

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 noncombustible aerosol provision device and a consumable for use with the noncombustible 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.

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.

In an embodiment of the above embodiment, the article is self supporting, wherein an article is self supporting when in at least one direction across the first or second surface of the support a length of the article can be gripped at one end of the length and the article can extend unsupported and horizontally from that grip.

An advantage of the article of the present disclosure is that it allows the use of a support which is insufficiently rigid to be self supporting. The combination of the at least one discrete portion of aerosol generating material on the first surface, the support, and the at least one discrete portion of aerosol generating material on the second surface results in an article which is sufficiently rigid to be self supporting as described above. As a result, the support in the article may be thinner than is possible in known articles and will use less material than known articles which has at least economic benefits. The use of thinner material for the support also has an advantage that when a consumable made from the article of the present disclosure is heated during use, and specifically when the aerosol generating material supported on the support is heated, the support requires less energy to be heated than a thicker support. This leads to an aerosol provision device with an increased energy efficiency and, for battery or similar powered devices, a longer battery life or period between the need to recharge the device’s power source.

It has previously been the case that the thickness of articles (and consumables made therefrom) was, at least in part, dictated by the need for the article I consumable to be sufficiently rigid that it could be handled by a user and inserted into a non-combustible aerosol provision device without damage. This limited how thin the support could be. The article I consumable of the present disclosure lowers the limit to how thin the support can be. It is noted that the need for rigidity in the support is lessened or ceases altogether once the article I consumable has been used, that is all the aerosol generating material supported on the support has been heated and will not give off any significant further aerosol (or vapour which then transforms into aerosol). This is because the article I consumable will then be disposed of and any bending or damage to the spent article I consumable will be unimportant. In an embodiment of the above embodiment, the article is comprised of the aerosol generating material and the support.

In an embodiment of any of the above embodiments, the article is self supporting when in a direction across the first or second surface of the support, up to 30%, up to 40%, up to 50%, up to 60%, up to 70%, up to 80%, up to 90% or up to 99% of the dimension of the article in that direction can extend unsupported and horizontally from a grip that is gripping the article when the article is dimensioned to be a consumable.

In an embodiment of any of the above embodiments, the location shape and dimensions of each of the at least one discrete portions of aerosol generating material on the first surface, and the location shape and dimensions of each of the at least one discrete portion of aerosol generating material on the second surface are such that the discrete potions on the first and second surfaces at least partially correspond to each other. In such an embodiment, and when viewed from a direction perpendicular to one of the first and second surfaces the at least partial correspondence between each of the at least one discrete portions on the first and second surfaces means that the discrete portions at least partially overlap each other. In some embodiments, for example, one of the discrete portions on one surface may have larger dimensions than the discrete portions on the other surface. As such when viewed from a position perpendicular to one of the surfaces the discrete portions on one surface may appear to be wholly within the outer perimeter of the discrete portions of the other surface.

In an embodiment of any of the above embodiments, the location shape and dimensions of each of the at least one discrete portions of aerosol generating material on the first surface, and the location shape and dimensions of each of the at least one discrete portion of aerosol generating material on the second surface correspond to each other. In such an embodiment, and when viewed from a direction perpendicular to one of the first and second surfaces the correspondence between each of the at least one discrete portions on the first and second surfaces means that the discrete portions fully overlap each other. In such instances, the discrete portions on the first and second surfaces have the same dimensions and shape, and when viewed from a position perpendicular to one of the surfaces, the perimeters of the discrete portions on each surface overlie each other.

In an embodiment of any of the above embodiments, the location shape and dimensions of at least one of discrete portions of aerosol generating material on the first surface, and the location shape and dimensions of at least one discrete portion of aerosol generating material on the second surface are different. In such embodiments the arrangement of the discrete portions of aerosol generating material on the first surface of the support may be a little to very different from the arrangement of the discrete portions of aerosol generating material on the second surface of the support. For example, the discrete portions of aerosol generating material on the first surface of the support may be arranged as at least one set of substantially parallel longitudinally extending strips. Such strips offer resistance to bending of the support about an axis substantially perpendicular to the longitudinally extending strips. On the second surface of the support the aerosol generating material may be arranged of in a rectangular array of substantially circular portions. In some embodiments the first surface may include a second set of substantially parallel longitudinally extending strips which intersect the first set of substantially parallel longitudinally extending strips at an angle of between 0 degrees and 90 degrees, for example one of 30, 45, 60 or 90 degrees.

In an embodiment of any of the above embodiments, the article or the consumables that are to be made from the article is to be used in a non-combustible aerosol provision device that is configured to heat the aerosol generating material on the first and second faces of the support. The device is configured to allow such vapour and aerosol that has transformed from vapour to aerosol to be inhaled by a user irrespective of the surface of the support the vapour/aerosol originates from.

In an embodiment of any of the above embodiments, the support includes a plurality of perforations or apertures extending between the first and second surfaces of the support which allow aerosol and vapour to pass from one side of the support to the other.

In an embodiment of any of the above embodiments, the composition of the aerosol generating material of at least one discrete portion of aerosol generating material on the first surface is different to the composition of at least one discrete portion of aerosol generating material on the second surface. This can lead to an enhanced and or changing user experience when using the consumable.

In an embodiment of any of the above embodiments, the thickness of the at least one discrete portions of aerosol generating material on the first surface is different to the thickness of the at least one discrete portions of aerosol generating material on the second surface.

In an embodiment of any of the above embodiments, the thickness of the at least one discrete portion of aerosol generating material on the first surface is substantially the same as the thickness of at least one discrete portion of aerosol generating material on the second surface.

In an embodiment of the above embodiments, each discrete portion of aerosol generating material on a surface of the support is of substantially the same thickness.

In an embodiment of any of the above embodiments, the support has a thickness that is less than or equal to 0.025 mm. In some embodiments the support has a thickness of less than 0.020 mm, less than 0.015 mm, less than 0.010 mm, around 0.020 mm, or around 0.007 mm.

In an embodiment of any of the above embodiments, the thickness of the article is between 0.100 mm and 0.610 mm. In some embodiments the support may be in the range of 0.005 mm to 0.020 mm thickness, and the thickness of the aerosol generating material is between 0.040 mm and 0.301 mm on each of the first and second surfaces of the support. In some other embodiments the support may be in the range of 0.005 mm to 0.020 mm thickness, and the cumulative thickness of the aerosol generating material on the first and second surface of the support is between 0.080 mm and 0.602 mm.

The thickness of the article is to be understood to be maximum thickness of the article measured in a direction perpendicular to the first or second surface of the support at the position the measurement is made. According to a second aspect of the present disclosure there is provided a consumable for use with a non-combustible aerosol provision device in which the consumable comprises a portion of the article of the first aspect of the present disclosure, and the portion of the article has been configured to a shape and size suitable for use with the device.

According to a third aspect of the present disclosure there is provided a method of manufacturing a article in which the article comprises aerosol generating material and a support, in which the method comprises providing a support, applying aerosol generating material to at least one predetermined area on a first surface of the support, applying aerosol generating material to at least one predetermined area on a second surface of the support.

In an embodiment of the above embodiment, the article is self supporting. An article is self supporting when a length of the article in at least one direction across the first or second surface of the support can be griped at one end of the length and the product can extend unsupported and horizontally from that grip.

In an embodiment of any of the above embodiments, the article is comprised of the aerosol generating material and the support.

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

In an embodiment of any of the above embodiments, the method further comprises allowing or causing the aerosol generating material slurry applied to the first surface of the support to set, and the aerosol generating material slurry sets as aerosol generating material. When the aerosol generating material sets it loses a significant portion of its volume, and hence thickness, as a result of the evaporation of the solvent used in the formation of the 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 first surface of the support to set or at least partially set before aerosol generating material slurry is applied to the second surface of the support.

In an embodiment of any of the above embodiments, causing the aerosol generating material slurry applied to the first surface of the support to set comprises use of ultraviolet radiation. This helps to accelerate setting of the aerosol generating material slurry. In other embodiments alternative or additional known techniques for enhancing the speed of setting of the aerosol generating material slurry may be used.

In an embodiment of any of the above embodiments, the application of aerosol generating material to the first surface of the support and allowing or causing the aerosol generating material slurry applied to the first surface of the support to set or at least partially set are repeated one or more times. In such embodiments there may be a predetermined thickness of aerosol generating material that is desired. In such embodiments, the aerosol generating material may be applied in two or more layers because that allows better control of the final thickness than a single application of aerosol generating material. Additionally thinner layers of aerosol generating material have been found to set in a more even and constant fashion than thicker layers of aerosol generating material. Such thinner layers are also found to have a lower cumulative setting time than thicker layers that ultimately lead to the same final thickness.

In an embodiment of any of the above embodiments, the method further comprises measuring the thickness of the set or partially set aerosol generating material applied to the first surface of the support. In an embodiment of any of the above embodiments, the method further comprises formation of a set or partially set film of aerosol generating material on a film formation surface, and then separating the set or partially set film of aerosol generating material from the film formation surface. The application of aerosol generating material to the first surface of the support comprises application of the set or partially set film of aerosol generating material to the first surface of the support. In such embodiments, the set or partially set film is formed on a separate surface, this has an advantage that the formation of the film can occur separately to the manufacture of the article of the current disclosure. This is advantageous because the use of the set or partially set film in the manufacture of the article of the present disclosure is likely to be faster than the production of the set or partially set film.

In an embodiment of any of the above embodiments, the method further comprises providing a set or partially set film of aerosol generating material, in which the application of aerosol generating material to the first surface of the support comprises application of the set or partially set film of aerosol generating material to the first surface of the support. In such embodiments, the set or partially set film is formed on a separate surface, this has an advantage that the formation of the film occur separately to the manufacture of the article of the current disclosure. This is advantageous because the use of the set or partially set film in the article of the present disclosure is likely to be faster than the production of the set or partially set film.

In an embodiment of any of the above embodiments, the method further comprises measuring the thickness of the set or partially set film of aerosol generating material.

In an embodiment of any of the above embodiments, application of the set or partially set film of aerosol generating material is repeated one or more times.

In an embodiment of any of the above embodiments, the application of aerosol generating material to the second surface of the support comprises application of a slurry of aerosol generating material. In an embodiment of any of the above embodiments, the method further comprises allowing or causing the aerosol generating material slurry applied to the second surface of the support to set or at least partially set, and the aerosol generating material slurry sets as aerosol generating material.

In an embodiment of any of the above embodiments, causing the aerosol generating material slurry applied to the second surface of the support to set or at least partially set comprises use of ultraviolet radiation. This helps to accelerate setting of the aerosol generating material slurry. In other embodiments alternative or additional known techniques for enhancing the speed of setting of the aerosol generating material slurry may be used.

In an embodiment of any of the above embodiments, the application of aerosol generating material to the second surface of the support and allowing or causing the aerosol generating material slurry applied to the second surface of the support to set or at least partially set are repeated one or more times. This has the advantages described above.

In an embodiment of any of the above embodiments, the method further comprises measuring the thickness of the set or at least partially set aerosol generating material applied to the second surface of the support

In an embodiment of any of the above embodiments, the method further comprises formation of a set or partially set film of aerosol generating material on a film formation surface, and separating the set or partially set film of aerosol generating material from the film formation surface, in which the application of aerosol generating material to the second surface comprises application of the set or partially set film of aerosol generating material to the second surface of the support. The advantages of this approach are as discussed above.

In an embodiment of any of the above embodiments, the method further comprises providing a set or partially set film of aerosol generating material, in which the application of aerosol generating material to the second surface comprises application of the set or partially set film of aerosol generating material to the second surface of the support. The advantages of this approach are as discussed above.

In an embodiment of any of the above embodiments, the application of aerosol generating material to the second surface of the support is repeated one or more times.

In an embodiment of any of the above embodiments, the support is less than 0.025 mm thick. In some embodiments the support has a thickness of less than 0.020 mm, less than 0.015 mm, less than 0.010 mm, around 0.020 mm, or around 0.007 mm.

In an embodiment of any of the above embodiments, the support is a metallic foil. In some embodiments the support is aluminium foil.

In an embodiment of any of the above embodiments, the application of aerosol generating material to one or both of the first and second surfaces of the support is application of discrete portions of aerosol generating material to two or more predetermined areas on one or both surfaces of the support.

In an embodiment of any of the above embodiments, the location shape and dimensions of each of the at least one discrete portions of aerosol generating material on the first surface, and the location shape and dimensions of each of the at least one discrete portion of aerosol generating material on the second surface are such that the discrete potions on the first and second surfaces at least partially correspond to each other.

In an embodiment of any of the above embodiments, the location shape and dimensions of each of the at least one discrete portions of aerosol generating material on the first surface, and the location shape and dimensions of each of the at least one discrete portion of aerosol generating material on the second surface correspond to each other.

In an embodiment of any of the above embodiments, the location shape and dimensions of at least one of discrete portions of aerosol generating material on the first surface, and the location shape and dimensions of at least one discrete portion of aerosol generating material on the second surface are different.

In an embodiment of any of the above embodiments, the composition of at least one discrete portion of aerosol generating material on the first surface is different to the composition of at least one discrete portion of aerosol generating material on the second surface.

In an embodiment of any of the above embodiments, the thickness of at least one discrete portion of aerosol generating material on the first surface is different to the thickness of at least one discrete portion of aerosol generating material on the second surface.

In an embodiment of any of the above embodiments, the thickness of at least one discrete portion of aerosol generating material on the first surface is substantially the same as the thickness of at least one discrete portion of aerosol generating material on the second surface.

In an embodiment of any of the above embodiments, the thickness of the article is between 0.085 mm and 0.610 mm.

In an embodiment of any of the above embodiments, two or more fold lines are created in the support.

In an embodiment of any of the above embodiments, the two or more predetermined areas are so located on one or both of the first and second surface of the support that fold lines may be created between the predetermined areas on one or both of the first and second surfaces of the support. In an embodiment of any of the above embodiments, the fold lines may be so spaced that the article may be folded into a concertina. This allows the article to be stored in a compact format.

In an embodiment of any of the above embodiments, the article is larger than is compatible for use with a non-combustible aerosol provision system, in which the method further comprises configuring the article for storage.

In an embodiment of any of the above embodiments, the article is larger than is compatible for use with a non-combustible aerosol provision system, in which the method further comprises separating the article into two or more article portions, in which each article portion is shaped and dimensioned for use as a consumable for use with a non-combustible aerosol provision system.

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 in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

In examples, the setting agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the setting agent comprises or consists of calcium formate and/or calcium lactate. In particular examples, the setting agent comprises or consists of calcium formate. 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. Too much setting agent may result 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.

Supplying the setting agent to the slurry may comprise spraying the setting agent on the slurry, such as a top surface of the slurry, or combining the setting agent with the slurry before to casting 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%, 30-45wt%, or 1-30wt% 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 some 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 to 3, an article 2 for use in the manufacture of a consumable 4 for use with a non-combustible aerosol provision device comprises aerosol generating material and a support 8. The support 8 has first and second opposing surfaces 10, 12. The support 8 is a sheet material and the opposing surfaces 10, 12 are the major surfaces of the sheet.

A plurality of discrete portions 6 of aerosol generating material are supported on the first surface 10 and a plurality of discrete portions 6 of aerosol generating material are supported on the second surface 12. In Figures 1 and 2, three discreet portions 6 of aerosol generating material are supported on each of the first and second surfaces 10, 12 of the support 8. Other numbers of discreet potions from one to many more than one may be supported on the support dependent on how large the article 2 is to be.

The locations of the portions 6 on the first surface 10 and the second surface 12 correspond with each other in that when viewed from a position perpendicular to the surface 10 or 12 the portions 6 fully overlap or overlie each other and the perimeters of the portion 6 overlie each other.

The support 8 is formed of an aluminium foil of around 0.007 mm thickness. Such foil is insufficiently rigid to be self supporting. The combination, however, of the support and the discrete portions 6 of aerosol generating material on the first and second surfaces 10, 12 of the support 8 together provide an article 2 that is sufficiently rigid to be self supporting in at least one direction across the first or second surface 10, 12 of the support s. For the purposes of the present disclosure, an article 2 is self supporting when in at least one direction across the first or second surface of the support a length of the article 2 can be gripped at one end of the length and the article 2 can extend unsupported and horizontally from that grip when the article is sized to be a consumable 4.

To form the consumable 4 from the article 2, the article 2 is cut along the cut lines 16.

With reference to Figures 4 to 7, an article 102 for use in the manufacture of a consumable 104 for use with a non-combustible aerosol provision device comprises aerosol generating material and a support 8. The support 8 has first and second opposing surfaces 10, 12. A plurality of discrete portions 106A of aerosol generating material are supported on the first face 10. A plurality of discrete portions 106B of aerosol generating material are supported on the second face 12. In Figures 4 to 6, three discreet portions 106A of aerosol generating material are shown as supported on the first surface 10, and seven discreet portions 106B of aerosol generating material are shown as supported on the second surface 12 of the support 8. Other numbers of discreet potions from one to many more than one may be supported on either of the first and second surfaces of the support 8 dependent on how large the article 102 is to be.

The discrete portions 106A of aerosol generating material are longitudinally extending strips of material with their longitudinal axes being orientated in a first direction. The discrete portions 106B of aerosol generating material are longitudinally extending strips of material with their longitudinal axes being orientated in a second direction. The second direction is, in Figures 4 to 7 approximately perpendicular to the first direction. In other embodiments, the discrete portions 106A and 106B of aerosol generating material may be orientated relative to each other at different angles.

In the embodiment shown in Figures 4 to 7 the discrete portions 106A of aerosol generating material on the first surface 10 partially correspond with the discrete portion 106B of aerosol generating material on the second surface 12 in that parts of those portions 106A 1 106B overlie each other when viewed from a position perpendicular to the surface 10 or 12.

The support 8 includes a plurality of apertures 118 (shown only on figure 4 and not all labelled for clarity) that extend between the first and second surface 10, 12 of the support 8. The apertures 118 allow aerosol or vapour to travel from one side of the support 8 to the other.

The support 8 is formed of an aluminium foil of around 0.020 mm thickness. Such foil is insufficiently rigid to be self supporting. The combination, however, of the support and the discrete portions 106A and 106B of aerosol generating material on the first and second surfaces 10, 12 of the support together provide an article 102 that is sufficiently rigid to be self supporting in at least one direction across the first or second surface of the support. To form the consumable 104 from the article 102, the article 102 is cut along the cut lines 116.

In an embodiment of the article 2 or 102, the composition of the portions 61 106A of aerosol generating material on the first surface 10 is different to the composition of the portions 61 106B of aerosol generating material on the second surface 12.

In an embodiment of the article 2 or 102, the thickness of the portions 61 106A of aerosol generating material on the first surface 10 is different to the thickness of the portions 61 106B of aerosol generating material on the second surface 12.

In an alternative embodiment of the article 2 or 102, the thickness of the portions 6 1 106A of aerosol generating material on the first surface 10 is substantially the same as the thickness of the portions 61 106B of aerosol generating material on the second surface 12.

In an embodiment of any of the above embodiments, the support 8 has a thickness that is less than or equal to 0.025 mm. In some embodiments the support has a thickness of less than 0.020 mm, less than 0.015 mm, less than 0.010 mm, around 0.020 mm, or around 0.007 mm.

A method of manufacturing the article 2 / 102 comprises providing the support 8, applying discrete portions 61 106A of aerosol generating material to the first surface 10 of the support 8, and applying discrete portions 6 /106B of aerosol generating material to the second surface 12 of the support 8.

In some embodiments, the application of the portions 6, 106A, 106B of aerosol generating material comprises application of a slurry of aerosol generating material to a surface 10 / 12 of the support 8.

In such embodiments the method further comprises allowing or causing the aerosol generating material slurry applied to the first surface 10 of the support 8 to set or at least partially set. In some embodiments, the aerosol generating material slurry sets or partially sets as aerosol generating film. The discreet portions 61 106A of aerosol generating material applied to the first surface 10 of the support 8 are allowed to or caused to set or at least partially set before discreet portions 61 106B of aerosol generating material slurry are applied to the second surface 12 of the support 8.

To cause the discreet portions 61 106A 1 106B of aerosol generating material slurry to set or at least partially set those portions are exposed to ultraviolet radiation which accelerates the setting of the aerosol generating material slurry.

In some embodiments of any of the above embodiments, the application of the discreet portions 61 106A 1 106B of aerosol generating material to the first or second surfaces 10, 12 of the support 8 and allowing or causing the aerosol generating material slurry to set or at least partially set is repeated one or more times. In other words, the discreet portions 61 106A 1 106B of aerosol generating material are built up of two or more layers of aerosol generating material. The thickness of the set or at least partially set aerosol generating material may be measures after each layer is applied.

In an alternative embodiment and with reference to Figure 8, a set or partially set film 6 of aerosol generating material is formed on a film formation surface 20. The set or partially set film 6 is separated from the film formation surface and applied to a surface 10, 12 of the support 8. The thickness of the set or partially set film of aerosol generating material is then measured. The application of the set or partially set film of aerosol generating material may be repeated one or more times.

In an non-illustrated embodiment of the embodiments of Figures 1 to 3 and / or 4 to 7, two or more fold lines are created in the support 8. The fold lines are so spaced that the article 2 / 102 to be folded into a concertina. This allows the article 2 Z102 to be stored in a compact format.

When the article 2 / 102 is larger than is compatible for use with a non-combustible aerosol provision system, the article 2 / 102 may be configured for storage. Suitable configuration is folding into a concertina, forming the article 2 / 102 into a roll around a bobbin, or cutting into sheets which are stored in a stack. A suitable barrier material may be placed between the layers of article to prevent those layers potentially sticking to each other.

When the article 2 / 102 is larger than is compatible for use with a non-combustible aerosol provision system, the article 2 / 102 is separated into two or more article portions, those article portions are shaped and dimensioned for use as a consumable 4 / 104 for use with 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, article, 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

- 43 -

Claims

1 An article for use with a non-combustible aerosol provision device in which the article comprises aerosol generating material and a support, the support has first and second opposing surfaces, at least one discrete portion of aerosol generating material is supported on the first surface, and at least one discrete portion of aerosol generating material is supported on the second surface.

2 An article according to claim 1 in which the article is self supporting when in at least one direction across the first or second surface of the support a length of the article can be gripped at one end of the length and the article can extend unsupported and horizontally from that grip.

3 An article according to claim 1 or 2 in which the article is comprised of the aerosol generating material and the support.

4 An article according to any of claims 1 to 3 in which the location shape and dimensions of each of the at least one discrete portions of aerosol generating material on the first surface, and the location shape and dimensions of each of the at least one discrete portion of aerosol generating material on the second surface are such that the discrete potions on the first and second surfaces at least partially correspond to each other.

5 An article according to any of claims 1 to 3 in which the location shape and dimensions of each of the at least one discrete portions of aerosol generating material on the first surface, and the location shape and dimensions of each of the at least one discrete portion of aerosol generating material on the second surface correspond to each other.

6 An article according to any of claims 1 to 3 in which the location shape and dimensions of at least one of discrete portions of aerosol generating material on the first surface, and the location shape and dimensions of at least one discrete portion of aerosol generating material on the second surface are different. - 44 -

7 An article according to any of claims 1 to 6 in which the composition of the aerosol generating material of at least one discrete portion of aerosol generating material on the first surface is different to the composition of at least one discrete portion of aerosol generating material on the second surface.

8 An article according to any of claims 1 to 7 in which the thickness of the aerosol generating material of at least one discrete portion of aerosol generating material on the first surface is different to the thickness of at least one discrete portion of aerosol generating material on the second surface.

9 An article according to any of claims 1 to 8 in which the thickness of the aerosol generating material of at least one discrete portion of aerosol generating material on the first surface is substantially the same as the thickness of at least one discrete portion of aerosol generating material on the second surface.

10 An article according to any of claims 1 to 9 in which the support has a thickness that is less than or equal to 0.025 mm.

11 An article according to any of claims 1 to 10 in which the thickness of the article is between 0.085 mm and 0.610 mm.

12 A consumable for use with a non-combustible aerosol provision device in which the consumable comprises a portion of the article according to any of claims 1 to 11 , and the portion of the article has been configured to a shape and size suitable for use with the device.

13 A method of manufacturing an article in which the article comprises aerosol generating material and a support, in which the method comprises providing a support, applying aerosol generating material to at least one predetermined area on a first surface of the support, applying aerosol generating material to at least one predetermined area on a second surface of the support. - 45 -

14 A method according to claim 13 in which the article is self supporting, and an article is self supporting when in at least one direction across the first or second surface of the support a length of the article can be griped at one end of the length and the article can extend unsupported and horizontally from that grip.

15 A method according to claim 13 or 14 in which in which the article is comprised of the aerosol generating material and the support.

16 A method according to any of claims 13 to 15 in which the application of aerosol generating material comprises application of a slurry of aerosol generating material.

17 A method according to claim 16 in which the method further comprises allowing or causing the aerosol generating material slurry applied to the first surface of the support to set, and the aerosol generating material slurry sets as aerosol generating material.

18 A method according to claim 16 or 17 in which the method further comprises allowing or causing the aerosol generating material slurry applied to the first surface of the support to set or at least partially set before aerosol generating material slurry is applied to the second surface of the support.

19 A method according to claim 17 or 18 in which causing the aerosol generating material slurry applied to the first surface of the support to set comprises use of ultraviolet radiation.

20 A method according to any of claims 17 to 19 in which the application of aerosol generating material to the first surface of the support and allowing or causing the aerosol generating material slurry applied to the first surface of the support to set or at least partially set are repeated one or more times.

21 A method according to any of claims 17 to 20 in which the method further comprises measuring the thickness of the set or at least partially set aerosol generating material applied to the first surface of the support. 22 A method according to any of claims 13 to 15 in which the method further comprises formation of a set or partially set film of aerosol generating material on a film formation surface, and separating the set or partially set film of aerosol generating material from the film formation surface, in which the application of aerosol generating material to the first surface of the support comprises application of the set or semi-set film of aerosol generating material to the first surface of the support.

23 A method according to any of claims 13 to 15 in which the method further comprises providing a set or partially set film of aerosol generating material, in which the application of aerosol generating material to the first surface of the support comprises application of the set or partially set film of aerosol generating material to the first surface of the support.

24 A method according to claim 22 or 23 in which the method further comprises measuring the thickness of the set or partially set film of aerosol generating material.

25 A method according to any of claims 22 to 24 in which application of the set or partially set film of aerosol generating material is repeated one or more times.

26 A method according to any of claims 13 to 25 in which the application of aerosol generating material to the second surface of the support comprises application of a slurry of aerosol generating material.

27 A method according to claim 26 in which the method further comprises allowing or causing the aerosol generating material slurry applied to the second surface of the support to set or at least partially set, and the aerosol generating material slurry sets as aerosol generating material. 28 A method according to claim 26 or 27 in which causing the aerosol generating material slurry applied to the second surface of the support to set or at least partially set comprises use of ultraviolet radiation.

29 A method according to claim 27 or 28 in which the application of aerosol generating material to the second surface of the support and allowing or causing the aerosol generating material slurry applied to the second surface of the support to set or at least partially set are repeated one or more times.

30 A method according to any of claims 27 to 29 in which the method further comprises measuring the thickness of the set or at least partially set aerosol generating material applied to the second surface of the support

31 A method according to any of claims 13 to 25 in which the method further comprises formation of a set or partially set film of aerosol generating material on a film formation surface, and separating the set or partially set film of aerosol generating material from the film formation surface, in which the application of aerosol generating material to the second surface comprises application of the set or partially set film of aerosol generating material to the second surface of the support.

32 A method according to any of claims 13 to 25 in which the method further comprises providing a set or partially set film of aerosol generating material, in which the application of aerosol generating material to the second surface comprises application of the set or partially set film of aerosol generating material to the second surface of the support.

33 A method according to claim 31 or 32 in which the method further comprises measuring the thickness of the set or semi-set film of aerosol generating material. - 48 -

34 A method according to any of claims 31 to 33 in which the application of aerosol generating material to the second surface of the support is repeated one or more times.

35 A method according to any of claims 13 to 34 in which the support is less than 0.025 mm thick.

36 A method according to any of claims 13 to 35 in which the support is a metallic foil.

37 A method according to any of claims 13 to 36 in which the application of aerosol generating material to one or both of the first and second surfaces of the support is application of discrete portions of aerosol generating material to two or more predetermined areas on one or both surfaces of the support.

38 A method according to any of claims 13 to 37 in which the location shape and dimensions of each of the at least one discrete portions of aerosol generating material on the first surface, and the location shape and dimensions of each of the at least one discrete portion of aerosol generating material on the second surface are such that the discrete potions on the first and second surfaces at least partially correspond to each other.

39 A method according to any of claims 13 to 37 in which the location shape and dimensions of each of the at least one discrete portions of aerosol generating material on the first surface, and the location shape and dimensions of each of the at least one discrete portion of aerosol generating material on the second surface correspond to each other.

40 A method according to any of claims 13 to 37 in which the location shape and dimensions of at least one of discrete portions of aerosol generating material on the first surface, and the location shape and dimensions of at least one discrete portion of aerosol generating material on the second surface are different.

41 A method according to any of claims 13 to 41 in which the composition of at least one discrete portion of aerosol generating material on the first surface is - 49 - different to the composition of at least one discrete portion of aerosol generating material on the second surface.

42 A method according to any of claims 13 to 41 in which the thickness of at least one discrete portion of aerosol generating material on the first surface is different to the thickness of at least one discrete portion of aerosol generating material on the second surface.

43 A method according to any of claims 13 to 42 in which the thickness of at least one discrete portion of aerosol generating material on the first surface is substantially the same as the thickness of at least one discrete portion of aerosol generating material on the second surface.

44 A method according to any of claims 13 to 43 in which the thickness of the article is between 0.085 mm and 0.610 mm.

45 A method according to any of claims 13 to 44 in which two or more fold lines are created in the support.

46 A method according to claim 45 in which the fold lines may be so spaced that the article may be folded into a concertina.

47 A method according to any of claims 13 to 46 in which the article is larger than is compatible for use with a non-combustible aerosol provision system, in which the method further comprises configuring the article for storage.

48 A method according to any of claims 13 to 47 in which the article is larger than is compatible for use with a non-combustible aerosol provision system, in which the method further comprises separating the article into two or more article portions, in which each article portion is shaped and dimensioned for use as a consumable for use with a non-combustible aerosol provision system. - 50 -

49 An aerosol provision device for use with a consumable according to claim

12, in which the device comprises an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable. 50 An aerosol provision system comprising an aerosol provision device according to claim 49 and a consumable according to claim 12.

51 A method of generating aerosol from a consumable according to claim 12 using an aerosol-generating device with at least one aerosol generator; wherein at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.