Technical Field

This disclosure relates to the field of non-combustible aerosol-provision devices, in particular the structure of such devices, consumables for use with such devices, and an aerosol provision system including such devices and a consumable.

Background

Aerosol-generating articles release an inhalable aerosol or vapour by releasing compounds from a substrate material by heating without burning. These may be referred to as non-combustible articles, aerosol generating assemblies, or aerosol provision devices.

One example of such a product is a heating device which release compounds by heating an aerosolisable material, which may be referred to as a solid aerosolgenerating material. The heating volatilises at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as heat- not-burn devices.

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

Summary

According to a first aspect of the present disclosure there is provided a non- combustible aerosol provision device suitable for use with a consumable, in which the device comprises a receiver for a consumable and a compression element, in which the receiver is configured to allow a consumable to be inserted into and removed from the receiver, and the compression element is configured to wipe or apply compressive force to at least part of the consumable whilst the consumable is being removed from the receiver.

According to a second aspect of the present disclosure there is provided a consumable in which at least a part of the consumable is porous.

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

According to a fourth aspect of the present disclosure there is provided a method of generating aerosol from a consumable according to the second aspect of the present disclosure using an aerosol-generating device according to the first aspect of the present disclosure.

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

Drawings

Figure 1 shows a schematic view of a first embodiment of a device according to the present disclosure;

Figure 2 shows a sectional view of the device of Figure 1 along the section line A- A’;

Figure 3 shows a schematic view of a first detail of a second embodiment of a device according to the present disclosure;

Figure 4 shows a second detail of the device of Figure 3;

Figure 5 shows a third detail of the device of Figure 3;

Figure 6 shows a schematic perspective view of an embodiment of a consumable for use with a device according to the present disclosure; and Figure 7 shows a sectional view of the consumable of Figure 6 along the section line B-B’.

Detailed Description

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

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

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

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

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

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

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

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

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

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

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

According to a first aspect of the present disclosure there is provided a noncombustible aerosol provision device suitable for use with a consumable, in which the device comprises a receiver for a consumable and a compression element, in which the receiver is configured to allow a consumable to be inserted into and removed from the receiver, and the compression element is configured to wipe or apply compressive force to at least part of the consumable whilst the consumable is being removed from the receiver.

When a non-combustible aerosol provision device adapted to be used in connection with consumables is used, a consumable is placed within the device, often within a receiver within the device. The receiver is typically a chamber that includes an aperture to allow aerosol generated within the receiver to be drawn out of the receiver by a user, and one or more apertures that allow air to flow into the receiver when the user is drawing the aerosol out of the receiver.

The purpose of the receiver is typically both to hold a consumable in the correct position for use, and to contain the aerosol generated during use and prevent it from entering other parts of the device.

Aerosol is generated by the device when at least a part of the consumable is heated to cause aerosol generating material that forms part of the consumable to vaporise. At least part of that vapour subsequently transitions into aerosol. The aerosol may be retained in the receiver for a period of time before being drawn out of the chamber by a user. Alternatively or additionally a user drawing on the device may not draw all of the aerosol out of the receiver and as such the receiver may be left containing residual aerosol. It has been found that some of the vapour I aerosol generated within the receiver will condense within the consumable I within the receiver to form a condensate. It has been further found that the condensate may be drawn or transported out of the receiver when the consumable is removed from the receiver after the consumable has been used. This may cause condensate to be transferred to the outside of the device, the user and I or the user’s clothing when the consumable is removed from the receiver I the device. This transfer of condensate is undesirable.

An advantage of the device of the present disclosure is that the wiping of the surface of the consumable or the application of compressive force to the consumable by the compression element as the consumable is withdrawn from the receiver has the effect of removing or squeezing out a proportion of the condensate from the consumable before the user has to handle that consumable. This reduces the quantity of, or prevents, the condensate being transferred to the outside of the device, the user or the user’s clothes.

In an embodiment of the above embodiment, the consumable moves relative to the compression element and the receiver when the consumable is removed from the receiver. In some embodiments, the compression element applies a compressive force to only a portion of the consumable at any one time and, as a result, the consumable is progressively subject to compression as the consumable is removed from the receiver. This configuration has the advantage that the compression element may be significantly smaller than the consumable and as a result occupy only a little space in the device.

In some alternative embodiments, the compression element applies a compressive force to the whole of the consumable at the same time during the process of removing the consumable from the receiver.

In an embodiment of any of the above embodiments, the compression element at least partially defines a compression zone through which at least part of the consumable passes whilst it is removed from the receiver. The compression zone is so configured that the consumable is progressively wiped or subject to a compressive force, for example from one end to the other, as it passes through the compression zone. In some embodiments the compression zone is a volume, the volume having at least two opposing sides (sides that are on the opposite sides of the volume to each other), the distance between the opposing sides being such that the consumable has to be compressed to pass between the two opposing sides, and at least one of the opposing sides of the volume is formed by at least part of the compression element.

In an embodiment of any of the above embodiments, the compression zone is of fixed dimensions.

In an embodiment of any of the above embodiments, at least one dimension of the compression zone may be variable. In some embodiments at least one dimension of the compression zone may be varied, the variation of the or each dimension being determined by the dimensions of the consumable.

In an embodiment of any of the above embodiments, the compression element is biased towards the consumable by a biasing means. Such an arrangement allows for the consumable to have a variable dimension in the direction in which the compression element applies a compressive force to the consumable.

In an embodiment of any of the above embodiments, the compression element is configured to exert a predetermined level of compression on the consumable whilst the consumable is being removed from the receiver. In some embodiments the compression element is biased towards the consumable by a constant force biasing means.

In an embodiment of any of the above embodiments, the compression element is configured to apply compressive force to the consumable whilst the consumable is being removed from the receiver that is within a predetermined range of forces.

In an embodiment of any of the above embodiments, the compression element comprises an active portion and a fixed portion, and the active portion may move towards or away from the fixed portion. In this arrangement the consumable passes between the active and fixed portions of the compression element and the active portion of the compression element pushes the consumable against the fixed portion as it wipes or applies compressive force to the consumable. In an embodiment of any of the above embodiments, the compression element comprises one or more rollers. The use of one or more rollers can reduce frictional forces experienced between the consumable and the compression element as the consumable is being removed from the receiver. In some embodiments the rollers are configured to rotate around an axle on which the roller is mounted freely. In other embodiments the rollers are configured to offer resistance to rotating about the axle on which the roller is mounted.

In an embodiment of any of the above embodiments, the compression element comprises a pair of rollers, and the consumable passes between the rollers whilst the consumable is being removed from the receiver.

In an embodiment of any of the above embodiments, the compression element comprises one or more wiper blades. In some embodiments the wiper blades are of an elastically deformable material. For example, but without limitation, silicone rubber.

In an embodiment of any of the above embodiments, at least one part of the compression element is biased towards a different part of the compression element whilst the consumable is being removed from the receiver.

In an embodiment of any of the above embodiments, the compression element is configured to allow the consumable to be inserted into and removed from the receiver through the compression element, the compression element exerts a first compressive force to the consumable when the consumable is being inserted into the receiver, the compression element exerts a second compressive force to the consumable when the consumable is being removed from the receiver, and the second compressive force is greater than the first compressive force. Alternatively expressed, the consumable experiences greater compressive force when being removed from the receiver than when being inserted into the receiver.

In some embodiments the compression element comprises an arm having first and second ends, the first end of the arm is adapted to wipe or apply compressive force to the consumable, the second end of the arm is pivotally attached to a part of the device via a pivotal attachment element, the arm and pivotal attachment element are so configured and located that insertion of the consumable into the receiver through the compression element causes the arm to pivot around the pivotal attachment so that the first end of the arm moves in a direction that is away from the consumable, and removal of the consumable out of the receiver through the compression element causes the arm to pivot around the pivotal attachment so that the first end of the arm is impelled to move in a direction that is towards the consumable. In some embodiments the first end of the arm is biased towards the consumable or the position where the consumable will be when it is being placed into or withdrawn from the receiver.

In an embodiment of any of the above embodiments, an element of the compression element is formed of an elastically flexible material, a first part of the elastically flexible element is adapted to wipe or apply compressive force to the consumable, a second part of the elastically flexible element is fixed to a fixed part of the device, the elastically flexible element is so configured and located that insertion of the consumable into the receiver through the compression element pushes the elastically flexible element so that the first part moves in a direction that is away from the consumable, and removal of the consumable out of the receiver through the compression element causes the a first part of the elastically flexible element to be impelled to move in a direction that is towards the consumable. In some embodiments the first part of the elastically flexible element is biased towards the consumable or the position where the consumable will be when it is being placed into or withdrawn from the receiver.

In an embodiment of any of the above embodiments, the receiver is configured to have the consumable inserted into the receiver through a first aperture, and the consumable removed from the receiver through a second aperture.

In an embodiment of any of the above embodiments, the receiver is configured to have the consumable inserted into the receiver and removed from the receiver through a single aperture. In an embodiment of any of the above embodiments, the compression element is located in or adjacent to the aperture through which the consumable is removed from the receiver.

In an embodiment of any of the above embodiments, the device comprises a liquid collection element, in which the liquid collection element is adapted to collect liquid wiped off or squeezed out of the consumable by the compression element as the consumable is removed from the receiver.

In an embodiment of any of the above embodiments, the liquid collection element comprises a liquid storage element. This enables collected condensate to be held in an appropriate location until a user is ready to dispose of the condensate.

In an embodiment of any of the above embodiments, the liquid collection element is emptiable by a user.

In an embodiment of any of the above embodiments, the liquid collection element may be replaced by a user.

According to a second aspect of the present disclosure there is provided a consumable for use with a device according to the first aspect of the present disclosure in which the consumable is at least partially deformable under compression. In some embodiments, the consumable is at least partially deformable under compression after the consumable has been used. The deformable nature of at least part of the consumable allows condensate to be squeezed out of the consumable when the compression element is configured to apply compressive force to at least part of the consumable whilst the consumable is being removed from the receiver.

In an embodiment of any of the above embodiments, the consumable is at least partially resiliently deformable under compression.

In an embodiment of any of the above embodiments, at least part of the consumable is configured to absorb condensate. In an embodiment of any of the above embodiments, at least part of the consumable is porous.

In an embodiment of any of the above embodiments, at least the porous part of the consumable is deformable under compression.

In an embodiment of any of the above embodiments, at least part of the consumable comprises one or more of cellulose acetate, air-laid paper, cotton based material, shredded paper, and cut rag tobacco or a mixture of two or more of these materials. In some embodiments, the porous part of the consumable is formed from one or a mixture of two or more of those materials.

In an embodiment of any of the above embodiments, the one or more of cellulose acetate, air-laid paper, cotton based material, shredded paper, cut rag tobacco are longitudinally extending strips or shreds and the strips or shreds are intertwined to form a matrix from the strips or shreds.

In an embodiment of any of the above embodiments, at least the porous part of the consumable is deformable under compression.

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.

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.

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.

In a second 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 11 to 40wt% of the slurry; aerosol-former material in an amount of about 12 to 42wt% of the slurry; and optionally, active substance in an amount of about 32 to 70wt% of the slurry.

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

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

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

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

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

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

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

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

The aerosol generating material may comprises a flavour. Suitably, the aerosol generating material may comprise up to about 80wt%, 70wt%, 60wt%, 55wt%, 50wt% or 45wt% of a flavour. In some cases, the aerosol generating material may comprise at least about 0.1wt%, 1wt%, 10wt%, 20wt%, 30wt%, 35wt% or 40wt% of a flavour (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 1-80wt%, 10-80wt%, 20-70wt%, 30-60wt%, 35- 55wt%, 30-45wt% or 7-14wt% of a flavour. In some cases, the flavour comprises, consists essentially of or consists of menthol.

The aerosol generating material may comprise a filler.

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

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

In some such cases the aerosol generating material comprises at least 1 wt% of the filler, for example, at least 5 wt%, at least 10wt%, at least 20wt% at least 30wt%, at least 40wt%, or at least 50wt% of the filler. In some embodiments, the aerosol generating material comprises 5-25wt% of the filler. The filler, if present, may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic sorbents, such as molecular sieves. The filler may comprise one or more organic filler materials such as wood pulp, cellulose and cellulose derivatives (such as methylcellulose, hydroxypropyl cellulose, and carboxymethyl cellulose (CMC)). In particular cases, the aerosol generating material comprises no calcium carbonate such as chalk.

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

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

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

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

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

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

In some embodiments the aerosol generating material comprises no tobacco material but does comprise nicotine. In some such cases, the aerosol generating material may comprise from about 1wt%, 2wt%, 3wt% or 4wt% to about 20wt%, 18wt%, 15wt% or 12wt% (calculated on a dry weight basis) of nicotine. For example, the aerosol generating material may comprise 1-20wt%, 2-18wt% or 3- 12wt% of nicotine. In some cases, the total content of active substance and/or flavour may be at least about 0.1wt%, 1wt%, 5wt%, 10wt%, 20wt%, 25wt% or 30wt%. In some cases, the total content of active substance and/or flavour may be less than about 90wt%, 80wt%, 70wt%, 60wt%, 50wt% or 40wt% (all calculated on a dry weight basis).

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

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

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

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

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

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

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

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

In some cases, the aerosol generating material may additionally comprise an emulsifying agent, which emulsified molten flavour during manufacture. For example, the aerosol generating material may comprise from about 5wt% to about 15wt% of an emulsifying agent (calculated on a dry weight basis), suitably about 10wt%. The emulsifying agent may comprise acacia gum.

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

The aerosol generating material may have any suitable water content, such as from 1wt % to 15wt%. Suitably, the water content of the aerosol generating material is from about 5wt%, 7wt% or 9wt% to about 15wt%, 13wt% or 11wt% (WWB), most suitably about 10wt%.. The water content of the aerosol generating material may, for example, be determined by Karl-Fischer-titration or Gas Chromatography with Thermal Conductivity Detector (GC-TCD). In some cases, the aerosol generating material may consist essentially of, or consist of a gelling agent, water, an aerosol generating agent, a flavour, and optionally an active substance.

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

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

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

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

1-60 wt% of a gelling agent;

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

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

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

In some embodiments, the aerosol generating material comprising:

1-50 wt% of a gelling agent;

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

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

In alternative embodiments of the aerosol generating material, the aerosol generating material comprises 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/m ² to 350 g/m ² . In some cases, the sheet may have a mass per unit area of 50-250 g/m ² , or from about 70 to 210 g/m ² , or from about 90 to 190 g/m ² , or suitably about 100 g/m ² (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/m ² , 40 to 60 g/m ² , or 25-60 g/m ² 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 when the sheet is flat. The sheet may be a strip, for example.

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

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

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

In some embodiments of any of the above embodiments, talcum powder, calcium carbonate powder or other powder is applied to the exposed surface of at least one discrete portion of aerosol-generating material. This may reduce the level of tackiness or adhesion of the aerosol-generating material. In the following discussions of the accompanying drawings, where the same element is present in a more than one embodiment the same reference numeral is used for that element throughout, where there are similar elements similar reference numerals (the same numeral plus a multiple of 100) are used.

With reference to Figures 1 and 2, a non-combustible aerosol provision device 2 includes a case 4 within which are located a receiver 6, a passage 8, a compression element 12, and a condensate storage tank 32.

The receiver 6 defines a volume within the case 4 into which a consumable 18 can be introduced and from which the consumable 18 can be removed. The consumable 18 may be introduced into and removed from the receiver 6 via an opening in an end of the receiver 6 and an adjacent opening 20 in the case 4.

Extending from an end of the receiver 6 remote from the opening 20 is a passage 8 which extends to a mouthpiece 10 which is mounted on the outer surface of the case 4. When the device 2 is in use, a user will draw aerosol from the receiver 6 through the passage 8 and out of the mouthpiece 10.

Also located within the case 4 are a power supply 14, a heater 22, and a control unit 16. The heater 22 is adjacent the receiver 6 and is used to heat the consumable 18, or at least part of the consumable 18, when the consumable 18 is in the receiver 6. The heater 22 is powered by the power supply 14, for example a rechargeable battery, via suitable wiring (not shown). The heater and, optionally, other functions of the device are controlled by the control unit 16 via suitable circuitry (not shown).

With reference to Figure 2, the compression element 12 comprises a first roller 24 and an associated first biasing means 26, and a second roller 28 and associated biasing means 30. The first and second biasing means 26, 30 each have a first end acting on the case 4 or other fixed element within the case 4, and a second end that is engaged with an axle (not shown) for their associated roller 24, 28. Each of the first and second biasing means 26, 30 biases their associated roller 24, 28 towards the other of the first and second rollers 24, 28. The first and second biasing means 26, 30 and their associated rollers 24, 28 together form a compression zone that extends between the rollers, and in which the consumable 18 is subject to a compressive force from the first and second biasing means 26, 30 and their associated rollers 24, 28.

When a consumable 18 is introduced into receiver 6, the user of the device pushes the consumable 18 through the opening 20 and against the first and second rollers 24, 28. The consumable 18 pushes the first and second rollers 24, 28 apart and the consumable then enters the receiver 6.

Once the consumable 18 is in the receiver 6 the user can use the device. The user actuates the device via the control unit 16 and the heater 22 heats at least a portion of the consumable 18. The heating of at least part of the consumable 18 causes aerosol generating material (not shown) that forms part of the consumable 18 to vaporise and the atmosphere within the receiver 6 becomes a mixture of air and vapour. At least part of that vapour will subsequently transition from vapour to droplets of aerosol (not shown) and the atmosphere within the receiver 6 becomes a mixture of air, aerosol, and vapour. The device 2 is then ready for the user to inhale the atmosphere from the receiver 6 via the passage 8 and mouthpiece 10.

The heating of the aerosol generating material can, in addition to producing vapour of the desired ingredients for the aerosol also produce water vapour. At least some of the water vapour and other vapour I aerosol are to be expected to condense within the receiver to form condensate. The longer that the water vapour and other vapour I aerosol are held in the receiver 6 the greater the likelihood of condensation and the greater the likely volume of condensate.

The consumable 18 is to be expected to be at least partially coated with that condensate.

When the consumable 18 has been used up, the user will want to remove the consumable 18 so that it can be replaced with a fresh consumable 18. To remove the consumable 18 the user will pull the consumable 18 out of the receiver 6 and through the opening 20. As the consumable is pulled out of the receiver 6 the part of the consumable 18 that was in the receiver 6 passes between the first and second rollers 24, 28. Those rollers are biased towards each other and as a result they apply compressive force to the part of the consumable 18 between the first and second rollers 24, 28. This tends to cause condensate on or in the consumable 18 to either transfer onto the first and second rollers 24, 28 or to be retained on the receiver 6 side of the first and second rollers 24, 28.

Close to the first and second rollers 24, 28 there are provided one or more condensate collection means (not shown) which are fluidly connected to the condensate storage tank 32 via one or more conduits 34. The condensate collection means may include one or more scrapers to assist in transferring condensate from the first and second rollers 24, 28 to the condensate collection means. Additionally or alternatively, the condensate collection means includes an open mouthed receptacle into which condensate can fall or flow when the device 2 is held in an intended use orientation and the consumable 18 is being withdrawn from the receiver 6. The compression element 12 has the effect that when the consumable 18 is removed from the case 4 it is less likely to transfer condensate onto the user or the user’s clothing.

With reference to Figures 3, 4 and 5, a device 102 has the same overall structure as device 2 described in connection with Figures 1 and 2 above other than in connection with the compression element 112. The compression element 112 includes an arm 134 which has a first end pivotally attached to the case 4 via a pivot 136 and a lug 138. Attached to or integral with the other end of the arm 134 is an axle 140 about which a roller 124 may rotate. The roller 124 is configured to be resistant to rotating about the axle 140. The resistance to rotation is because there is friction between the axle 140 and the roller 124 that means that the roller will not freely rotate around the axle 140.

A biasing means 126 is attached to and extends between an anchor 142 on the case 4, and a position 144 on the arm 134 that is between the pivot 136 and the axle 140. In Figures 3 and 4 that position 144 is about midway between the pivot 136 and the axle 140 but it could be at other positions on the arm 134. The biasing means 126 is configured to include a means (not shown) limiting the extension of the biasing means to a maximum extension. The biasing means 126 comprises, in this embodiment, a compression spring, a first connector extending between the anchor 142 and one end of the compression spring, and a second connector extending between position 144 on the arm 134 and the other end of the compression spring. The biasing means 126 is so configured that when the compression spring is in an uncompressed state, the biasing means 126 is at its maximum extension and causes the arm 134 to be in a position such that the roller 124 is in a space through which a consumable 18 at least partially passes as it is introduced into and removed from the receiver 6.

The lug 138, arm 134, roller 124 and biasing means 126 are so arranged relative to the opening 20 in the case 4 that, in the direction D (the direction the consumable 18 moves when being introduced into the case) the pivot 136 is between the opening 20 and the position 144 on the arm 134.

When the consumable 18 is introduced into the receiver 6 it is at least partially guided into the receiver 6 by a base plate 146. The base plate 146 is in a fixed position and forms a continuous surface from the opening 20 in the case 4 to within the receiver 6 where it abuts the mouth of conduit 34.

When the consumable 18 is to be introduced into the receiver 6, a first end 80A of a support 80 of the consumable 18 (see Figures 6 and 7 for greater detail as to the consumable 18) is introduced into the opening 20 in the case 4. The consumable 18 is slid along the surface of base plate 146 in the direction D (shown in Figure 6) towards the receiver 6. When the consumable 18 abuts the roller 124 which is biased into the path of the consumable 18 by biasing means 126 the consumable 18 causes the arm 134 to swing about the pivot 136 so that the roller 124 is moved out of the way of the consumable 18 and the biasing means 126, is compressed. As shown in Figure 4, the roller 124 then slides or rolls along the surface of the consumable 18 as the consumable is introduced into the receiver 6. The consumable may be elastically deformed by the biasing of the roller 124 against the consumable by the biasing means 126.

With reference to Figure 5, once the portion of the consumable 18 that supports aerosol generating material has fully entered the receiver 6 the portion of the consumable 18 along which the roller 124 has slid or rolled ceases to cause the arm 134 to be in a position where the biasing means 126 is compressed and the biasing means will return the arm 134 to a position in which the biasing means 126 is not compressed. The roller 124 will then latch the consumable 18 into the position where the consumable is in the desired position for the device to be used.

Once the use of the device and consumable 18 has been completed it is desirable for a user to replace the used consumable 18 with a fresh consumable 18. To do this the user grasps the end 80B of the consumable and pulls the consumable out of the opening 20. As the consumable 18 is pulled out of the receiver 6 the consumable initially abuts the roller 124. Because the consumable 18 is now moving in the direction opposite to direction D, the roller 124 and arm 136 do not swing round pivot 136 to move out of the way of the consumable 18. The forces on the roller 124 would, if the biasing means 126 was not at it’s maximum extension, cause the arm 134 to swing around the pivot 136 in an anticlockwise direction (as viewed in Figure 5) towards base plate 146. Because the biasing means 126 prevents the roller 124 moving as it is pushed by the consumable 18, the roller 124 is caused to apply compressive force to the portion of the consumable 18 pushing against it.

With reference to Figure 6, as the consumable 18 is withdrawn from the receiver 6, the roller 124 progressively applies a compression zone 148 to the consumable 18 as the consumable 18 passes between the roller 124 and the base plate 146. This causes condensate 150 trapped in the consumable 18 to be pushed towards the first end 80A of the consumable. As the first end 80A of the consumable 18 approaches the compression zone 148 the condensate 50 is squeezed out of the consumable 18 and flows as liquid 152 into conduit 34 and then into storage tank 32 (not shown in Figures 3 to 6).

In an unillustrated alternative embodiment, the device 102 is as described above with the exception that roller 124 is replaced by a wiper blade. The wiper blade wipes condensate off the surface of the consumable 18 as it is withdrawn from the receiver 6.

With reference to Figures 7 and 8, the consumable 18 is comprised of a support 80, a cover 82, discrete portions of aerosol generating material 84, and a compressible and absorbent material 86. The support 80 may be formed of a single material or may be a laminate of two or more layers of material. The support 80 has first and second ends 80A, 80B and supports, towards the first end 80A, a plurality of discrete portions of aerosol generating material 84. Those portions 84 are located on a surface 88 of the support 80 in a regular array.

The discrete portions of aerosol generating material 84 are overlaid by the compressible and absorbent material 86. The cover 82 is fixed to the surface 88 of the support 80 adjacent the edges of the support 80 that extend between the first and second ends 80A, 80B of the support 80. The support surface 88 and the cover 82 together define a passageway that is filled by the discrete portions of aerosol generating material 84 and compressible and absorbent material 86.

The support 80 is at least partially formed from a material that forms surface 88 of the support and that is not absorbent, and condensate from use of the consumable will not absorb into the support 80 through the surface 88 of the support. In some non-illustrated examples of the consumable 18 of the present disclosure the surface 88 may be treated so as to become non-absorbent before the discrete portions of aerosol generating material 84 are applied to the surface 88. In the consumable 18 of Figures 5 and 6 the support is a laminate (the layers of the laminate are not shown) with a paper layer and an aluminium foil layer, with the aluminium foil layer forming the surface 88 of the support 80.

The compressible and absorbent material 86 is one of or a mixture of two or more of cellulose acetate, air-laid paper, cotton based material, shredded paper, and cut rag tobacco. The one or more of cellulose acetate, air-laid paper, cotton based material, shredded paper, cut rag tobacco are in the form of longitudinally extending strips or shreds and the strips or shreds are intertwined to form a three dimensional matrix. This matrix is porous and can absorb and retain condensate that forms in the receiver.

The cover 82 is formed of a material that is not-rigid and that is porous. The cover 82 is supported by the compressible and absorbent material 86 so that the cover 82 does not collapse onto the discrete portions of aerosol generating material 84. The cover 82 covers a portion of the support 80 that extends from the first end 80A towards but not to the second end 80B. There is a portion of support 80 between the cover 82 and the second end 80B which does not support discrete portions of aerosol generating material 84 and is not overlaid by compressible and absorbent material 86. That portion is for use as a handle when a user is moving the consumable 18 into and out of the receiver 6.

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 device, 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.