Technical Field

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

Background

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

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

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

According to a first aspect of the present disclosure there is provided a method of manufacture of a consumable for use with a non-combustible aerosol provision device, in which each consumable comprises a portion of a media to which is applied an aerosol generating material, in which the method comprises the following steps

(a) a media is provided,

(b) aerosol generating material is applied to a surface of the media,

(c) the media and aerosol generating material is configured for storage,

(d) the media and aerosol generating material is stored, and

(e) the media and aerosol generating material is separated into portions of a desired dimension.

According to a second aspect of the present disclosure there is provided a product for use in the manufacture of a consumable for use with an apparatus for heating an aerosol generating material to volatilise at least one component of the aerosol generating material, in which the product comprises a media and aerosol generating material, in which aerosol generating material is supported on a surface of the media, the media and aerosol generating material is configured for storage, and the media is separable into portions of desired dimensions.

According to a third aspect of the present disclosure there is provided a consumable for use with an apparatus for heating an aerosol generating material to volatilise at least one component of the aerosol generating material, in which the consumable comprises at least one portion of the product according to the second aspect of the present disclosure.

According to a fourth aspect of the present disclosure there is provided a kit for making a consumable comprising a number of portions of media to which is applied an aerosol generating material manufactured using the method of the first aspect of the present disclosure, and a support. According to a fifth aspect of the present disclosure there is provided an aerosol provision device for use with a consumable manufactured by a method according to the first aspect of the present disclosure, in which the device comprises a heater assembly configured to heat at least a portion of the aerosol generating material supported on the consumable.

According to a sixth aspect of the present disclosure there is provided an aerosol provision system comprising an aerosol provision device and a consumable manufactured by a method according to the first aspect of the present disclosure.

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

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

Drawings

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

Figure 2 shows a first embodiment of the media used in the manufacture of the consumable of Figure 1 ;

Figure 3 shows the media of Figure 2 after aerosol generating material has been applied to the media;

Figure 4 shows a section of the media of Figure 3 along section-line AA’; Figure 5 shows a section of the media of Figure 3 in a first embodiment of a storage configuration of the media and aerosol generating material along section-line AA’; Figure 6 shows the media of Figure 3 separated into a plurality of portions;

Figure 7 shows an embodiment of the consumable of Figure 1 ;

Figure 8 shows a section of the media of Figure 3 in a second embodiment of the method of the present disclosure along section-line AA’;

Figure 9 shows a section of the media of Figure 3 in a second embodiment of a storage configuration of the media and aerosol generating material in a second embodiment of the method of the present disclosure along section-line AA’;

Figure 10 shows a schematic exploded view of an alternative embodiment of the media of Figure 8;

Figure 11 shows a second embodiment of the media of Figure 2 after aerosol generating material has been applied to the media in a third embodiment of the method of the present disclosure;

Figure 12 shows a section of the media of Figure 11 along section-line BB’;

Figure 13 shows a section of the media of Figure 11 in the process of being reconfigured into a third embodiment of a storage configuration of the media and aerosol generating material in a third embodiment of the method of the present disclosure along section-line BB’;

Figure 14 shows a section of the media of Figure 11 in the third embodiment of a storage configuration of the media and aerosol generating material in a third embodiment of the method of the present disclosure along section-line BB’;

Figure 15 shows the media of Figure 11 and a second media separated into a plurality of portions;

Figure 16 shows a second embodiment of a consumable;

Figure 17 shows a section of an alternative embodiment of the media of Figure 11 along section-line BB’;

Figure 18 shows a schematic representation of a method of drying the aerosol generating material according to a first embodiment of the method of the present disclosure;

Figure 19 shows a schematic representation of a method of drying the aerosol generating material according to a second embodiment of the method of the present disclosure; and Figure 20 shows a schematic representation of a method of drying the aerosol generating material according to a third embodiment of the method of the present disclosure.

Detailed Description

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

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

The apparatus for heating the aerosol-generating material with which the consumable is to be used is a part of a non-combustible aerosol provision system. According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

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

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

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

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

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

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

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

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

According to a first aspect of the present disclosure there is provided a method of manufacture of a consumable for use with a non-combustible aerosol-provision device, in which each consumable comprises a portion of a media to which is applied an aerosol generating material, in which the method comprises the following steps

(a) a media is provided,

(b) aerosol generating material is applied to a surface of the media,

(c) the media and aerosol generating material is configured for storage,

(d) the media and aerosol generating material is stored, and

(e) the media and aerosol generating material is separated into portions of a desired dimension.

In some embodiments the characteristics, for example stiffness, of the media are such that portions of the media and aerosol generating material are suitable for use in an aerosol generating device without any further processing of the media and aerosol generating material. This has an advantage of minimising processing steps in the manufacture of the consumable.

In other embodiments, the characteristics of the media are such that portions of the media and aerosol generating material are not suitable for use in an aerosol generating device without further processing of the media and aerosol generating material. For example, in some embodiments the media is a material that is one or both of thinner and less robust than is required for use as a consumable in an aerosol generating device. In such embodiments the media and aerosol generating material may be easier to handle, configure for storage, and I or occupy less space in storage than would be the case if the media had characteristics that rendered the media and aerosol generating material suitable for use as a consumable. In such embodiments, the media and aerosol generating material are combined with a support.

In an embodiment of the above embodiment, the method includes a further step of (f) at least one portion of the media and aerosol generating material is associated with a support.

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

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

In an embodiment of any of the above embodiments, the media provided in step (a) is a longitudinally extending material, step (b) is performed before step (c), and the storage configuration of step (c) is forming the media and aerosol generating material into a roll or a concertina. An advantage of forming the media and aerosol generating material into a role or concertina for storage is that such storage configurations are easily handled, relatively compact, and likely to protect the media and aerosol generating material from damage during storage.

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

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

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

(g) laying a protection sheet over the media and aerosol generating material, in which step (g) is performed after step (b) and before step (c). This has the advantage of minimising the risk during storage that any of the aerosol generating material adheres to any part of the media other than the part to which it is intended to be adhered. It also has the advantage of helping to protect the aerosol generating material from damage from rubbing by the media whilst the media and aerosol generating material is configured for storage.

In an embodiment of any of the above embodiments, the protection sheet comprises one or more apertures which extend through the protection sheet.

In an embodiment of any of the above embodiments, the number of apertures is the same as the number of discrete portions of aerosol generating material, and the configuration and location of the apertures coincides with at least part of each discrete portion of aerosol generating material once the protection sheet has been laid over the media and aerosol generating material.

In an embodiment of any of the above embodiments, step (a) comprises selecting or creating a media that has first and second opposing surfaces, in which the first surface and the aerosol generating material adhere to each other with a first adhesive strength, the second surface and the aerosol generating material adhere to each other with a second adhesive strength, the first adhesive strength is greater than the second adhesive strength, and in step (b) the aerosol generating material is applied to the first surface of the media.

In some embodiments of the above embodiment, the second adhesive strength is lower than the force required to pull the aerosol generating material into two portions. That is, if the aerosol generating material is adhered to both the first and second surfaces, moving one surface away from the other will not tear the aerosol generating material.

An advantage of this embodiment is that when the aerosol generating material is applied to the first surface the greater adhesive strength of the aerosol generating material to the first surface of the media means that if the media and aerosol generating material are formed into a configuration for storage where the aerosol generating material contacts the second surface of the media, then when the media and aerosol generating material is reconfigured out of its storage configuration, the aerosol generating material will remain adhered to the first surface.

In an embodiment of any of the above embodiments, step (d) has a duration of at least 1 hour, at least 12 hours, at least 1 day, at least one week, or at least one month. This has the advantage of allowing the manufacture of the media and aerosol generating material to be separated from the demand for use of that consumables made according to the present disclosure. This may increase the efficiencies of the manufacturing process, and allow peaks of demand for consumables to be easily met.

In an embodiment of any of the above embodiments, step (d) comprises transportation of the media and aerosol generating material between different locations. Those locations may be considerable distances apart and again may increase the efficiencies of manufacture of the consumables.

In an embodiment of any of the above embodiments, the separation of step (e) is performed by cutting the media. Known cutting means may be used to cut the media. In other embodiments the media is perforated and the separation performed by tearing the media along a line of perforations.

In an embodiment of any of the above embodiments, the association of the portions of media and aerosol generating material and the support of step (f) comprises the attachment of at least one portion of the media and aerosol generating material to the support using one or more of an adhesive, at least one element that clamps a part of the portion of the media to the support, or insertion of a part of the portion of the media into a slot. Each of these techniques will hold a portion of media and aerosol generating material in a fixed position on the support so that the combined support, media and aerosol generating material can be used as a consumable. In some embodiments the adhesive may be a pressure adhesive, a peel-able adhesive, a repositionable adhesive, a low tack adhesive or another appropriate adhesive.

In an embodiment of any of the above embodiments, step (a) comprises providing at least two separate media, step (b) comprises application of a differently comprised aerosol generating material to a surface of each of the separate media, step (c) comprises configuring each media and aerosol generating material for storage, step (d) comprises storing each media and aerosol generating material, step (e) comprises separating each media and aerosol generating material into portions of desired dimensions, and step (f) comprises associating at least one portion of at least two different media and aerosol generating materials with one support.

In this embodiment, each of the separate media may be the same as each other. Each of the differently comprised aerosol generating material have different compositions. This may have the result that the aerosol form the different aerosol generating material compositions gives a user different user experiences, for example different flavours of aerosol.

In an embodiment of the above embodiment, the different portions of media and aerosol generating material of step (e) are arranged on the support in a pattern where the position of each portion of media and aerosol generating material within the pattern is indicative of the composition of the aerosol generating materials on each portion of media and aerosol generating material. This will allow a user controlled or automated aerosol generating system to select a particular composition of aerosol generating material by choosing to generate aerosol from a particularly positioned portion of aerosol generating material or a particularly positioned portion of media and aerosol generating material.

In an embodiment of any of the above embodiments, the aerosol generating material has the form of an aerosol generating film or an aerosolisable gel.

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.

In an embodiment of any of the above embodiments, the media comprises a susceptor. In some embodiments the media is a laminate, and at least one layer of the laminate is a susceptor.

In an embodiment of any of the above embodiments, when the media comprises a susceptor, the support is formed from a material that does not function as a susceptor.

In an embodiment of any of the above embodiments, the support comprises a susceptor. In some embodiments the support is a laminate, and at least one layer of the laminate is a susceptor

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

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

The susceptor may in some embodiments of any of the above embodiments be a metal foil or film, optionally an aluminium foil or film or a ferrous foil or film. Alternatively, the susceptor may in some embodiments of any of the above embodiments be any conductor that could be sprayed or vapour deposited on a material that forms the support.

In an embodiment of any of the above embodiments, the support is a reusable support and step (f) is performed by a consumer prior to use of the consumable.

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

(h) drying the aerosol generating material using a heat source, in which step (b) comprises applying the aerosol generating material to the media in a solvated form, and step (h) is performed after step (b) and before step (c).

In an embodiment of the above embodiment, the heat source is a dielectric heat source. In some embodiments the heat source is a source of microwave radiation, and the microwave radiation has a frequency of around 915 MHz or 2.45 GHz. In some embodiments the heat source is a radio frequency heating source.

In an embodiment of any of the above embodiments, step (h) comprises passing the media and aerosol generating material through a longitudinally extending zone within which the media and aerosol generating material is heated by the dielectric heat source.

In an embodiment of any of the above embodiments, the heat source is at least one magnetic field generator and a susceptor.

In an embodiment of the above embodiment, the media comprises a susceptor and step (h) comprises passing the media and aerosol generating material through a longitudinally extending alternating magnetic field causing the susceptor to heat sufficiently to cause drying of the aerosol generating material.

In an embodiment of any of the above embodiments, the media comprises a susceptor and step (h) comprises passing the media and aerosol generating material sequentially through a plurality of alternating magnetic fields causing the susceptor to repeatedly heat sufficiently to cause drying of the aerosol generating material.

In an embodiment of any of the above embodiments, the heat source is at least one magnetic field generator and at least one susceptor that is unconnected to the media and aerosol generating material. In some embodiments the susceptor is longitudinally extending and the media and aerosol generating material pass along the length of the susceptor through a zone heated by the susceptor.

In an embodiment of any of the above embodiments, the heat source is a source of thermal radiation. In some embodiments the source of thermal radiation is longitudinally extending and step (h) comprises passing the media and aerosol generating material along a path which causes the media and aerosol generating material to be exposed to the source of thermal radiation.

In an embodiment of any of the above embodiments, the heat source is a heated material. In some embodiments the heated material is longitudinally extending and step (h) comprises passing the media and aerosol generating material along the heated material in contact with or close to the heated material. In an embodiment of any of the above embodiments, step (h) further comprises monitoring the temperature of the aerosol generating material and preventing the heating of the aerosol generating material above a predetermined maximum temperature. The predetermined maximum temperature may be a temperature lower than the temperature at which the aerosol generating material will aerosolise.

In an embodiment of any of the above embodiments, the steps of the method are performed in the order (a), (b), (e), (f), (c), (d) or in the order (a), (b), (f), (e), (c), (d). In such embodiments the configuration of the media and aerosol generating material for storage is configuration whilst the media and aerosol generating material is associated with a support. This allows the storage of the media, aerosol generating material and support to be storage in a form close to or in a form ready for sale to a consumer of consumables.

According to a second aspect of the present disclosure there is provided a product for use in the manufacture of a consumable for use with a non-combustible aerosolprovision device, in which the product comprises a media and aerosol generating material, in which aerosol generating material is supported on a surface of the media, the media and aerosol generating material is configured for storage, and the media is separable into portions of desired dimensions.

In an embodiment of any of the above embodiments, the media is a longitudinally extending material, and the storage configuration of the media and aerosol generating material is a roll or a concertina.

In an embodiment of any of the above embodiments, two or more discrete portions of aerosol generating material are supported on the surface of the media.

In an embodiment of any of the above embodiments, at least two of the discrete portions of aerosol generating material are formed from aerosol generating material with compositions different to each other. In an embodiment of any of the above embodiments, the aerosol generating material is comprised of two or more layers of aerosol generating material.

In an embodiment of any of the above embodiments, the product further comprises a protection sheet, in which the protection sheet is laid over the media and aerosol generating material. The protection sheet lies between layers of the carrier when the product is in a storage configuration in which layers of carrier overlie each other.

In an embodiment of any of the above embodiments, the protection sheet comprises one or more apertures which extend through the protection sheet.

In an embodiment of any of the above embodiments, the number of apertures is the same as the number of discrete portions of aerosol generating material, and the configuration and location of the apertures coincides with at least part of each discrete portion of aerosol generating material once the protection sheet has been laid over the media and aerosol generating material.

In an embodiment of any of the above embodiments, the media has first and second opposing surfaces, the first surface and the aerosol generating material adhere to each other with a first adhesive strength, the second surface and the aerosol generating material adhere to each other with a second adhesive strength, the first adhesive strength is greater than the second adhesive strength, and the aerosol generating material is applied to the first surface of the media.

In an embodiment of any of the above embodiments, the support comprises a susceptor.

In an embodiment of any of the above embodiments, the support is a laminate, and at least one layer of the laminate is a susceptor. In an embodiment of any of the above embodiments, the susceptor is one of a metal, a metal foil or a metal film.

According to a third aspect of the present disclosure there is provided a consumable for use with a non-combustible aerosol-provision device, in which the consumable comprises at least one portion of the product according to the second aspect of the present disclosure.

In an embodiment of any of the above embodiments, the consumable further comprises a support, and at least one portion of the product is supported on the support.

In an embodiment of any of the above embodiments, at least one portion of the product is attached to the support using one or more of an adhesive, at least one element that clamps a part of a portion of the product to the support, or insertion of a part of the portion of the product into a slot in the support.

In an embodiment of any of the above embodiments, the consumable comprises at least one portion from each of at least two products according to the third aspect of the present disclosure, and each product supports an aerosol generating material of a different composition relative to the composition of aerosol generating material supported on the other products.

In an embodiment of any of the above embodiments, the different portions of product are arranged on the support in a pattern, in which the position of each portion of product within the pattern is indicative of the composition of the aerosol generating material supported on each portion of product.

In an embodiment of any of the above embodiments, the support comprises a susceptor.

In an embodiment of any of the above embodiments, the support is a laminate, and at least one layer of the laminate is a susceptor. In an embodiment of any of the above embodiments, the susceptor is one of a metal, a metal foil or a metal film.

In an embodiment of any of the above embodiments, the aerosol generating material has the form of an aerosol generating film or an aerosolisable gel.

According to a fourth aspect of the present disclosure there is provided a kit for making a consumable comprising one or more portions of product of the second aspect of the present disclosure and a support. In some embodiments the support is reusable in that he material from which the support is formed is not damaged by the aerosolisation of the aerosol generating material whilst the media and aerosol generating material are associated with the support.

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

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

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

In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12. The active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, Wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

In some embodiments, the aerosol generating material comprises from about 1wt%, 5wt%, 10wt%, 15wt%, 20wt% or 25wt% to about 60wt%, 50wt%, 45wt%, 40wt% or 35wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 1-50wt%, 5-45wt%, 10-40wt% or 20- 35wt% of a gelling agent. In some embodiments, the aerosol generating material comprises from about 20wt% 22wt%, 24wt% or 25wt% to about 30wt%, 32wt% or 35wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol generating material may comprise 20-35wt% or 25-30wt% of a gelling agent.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

The aerosol generating material may comprise a filler.

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

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

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

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

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

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

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

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:

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 comprises:

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 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, 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 120 g/m ² . In some cases, the sheet may have a mass per unit area of 80-120 g/m ² , or from about 70 to 110 g/m ² , or particularly from about 90 to 110 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.

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 the aerosol-generating material. By adding a colourant to the aerosol generating material, the aerosol generating material may be colour- matched to other components of an article comprising the aerosol generating material.

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

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

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

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

With reference to Figure 1, an aerosol provision device 2 comprises a casing 4 within which is located a heater assembly 6. The heater assembly 6 is comprised of a heating chamber 8 and a heater 10. The heater 10 can be an electrical resistance heater or a magnetic field generator for use with a susceptor.

The heating chamber 8 defines an opening or mouth 12 at a first end of the heating chamber 8. At the opposite end of the heating chamber 8 is an aperture 14. The aperture 14 is in fluid communication with a mouth piece 16 via a conduit 18.

Also located within the casing 4 is a controller 20 which is in electronic communication with and controls the functioning of the heater 10. The controller 20 may include a memory (not shown) within which one or more tables relating to the operation of the heater 10 may be stored. The heater 10 and controller 20 are powered by a power source 22. The power source 22 is a rechargeable battery. In other embodiments the power source may be other appropriate sources of electrical power.

The aerosol provision device 2 is suitable for use with a consumable 24. The consumable 24 comprises of one or more discrete portions of aerosol-generating material 32 supported on first surface 28 of the consumable 24. The discrete portions of aerosol-generating material 32 are supported on the surface 28 in a square grid pattern. Other, non-illustrated embodiments of the consumable 24 may include more or less discrete portions of aerosol-generating material 32 than shown in Figure 1 , including a single portion of aerosol-generating material 32, and those portions may be distributed on the surface 28 in any pattern. The discrete portions of aerosol-generating material 32 are shown to have an approximately circular shape in Figure 1 , they may, in other embodiments, be of other shapes. Examples of how to produce or manufacture the consumable 24 are described below.

With reference to Figure 2, to commence the production of a consumable 24, a media 30 is provided. The media 30 comprises a longitudinally extending sheet of flexible material, in the illustrated embodiment the media is a sheet of aluminium foil 34. In other unillustrated embodiments the material may be another suitable material, for example paper. The length and width of the media 30 as shown in Figure 2 is for illustrative purposes only. The media 30 may have different lengths and widths without departing from the scope of the present disclosure.

The foil 34 has first and second major surfaces with the surface shown in Figure 2 being first surface 36, and the unseen major surface being second surface 38. In the present embodiment first surface 36 of the foil 34 is formed or treated so that first surface 36 has surface characteristics that make aerosol generating material applied to first surface 36 have a greater pull off stress or adhesive strength than aerosol generating material applied to second surface 38. In other embodiments, second surface 38 of the foil 34 is formed or treated so that second surface 38 has surface characteristics that make aerosol generating material applied to second surface 38 have a lower pull off stress or adhesive strength than aerosol generating material applied to first surface 36.

With reference to Figures 3 and 4, a plurality of discrete portions of aerosol generating material 32 (only three of the portions are labelled for clarity) are applied to a first surface 36 of the foil 34. In Figure 3 thirty portions of aerosol generating material 32 are illustrated and disposed on the first surface 36 of the foil 34 in a square grid pattern. In other unillustrated embodiments the number of portions of aerosol generating material 32 applied to the surface of the media 30 and the pattern in which they are disposed may be different.

The portions of aerosol generating material 32 are applied to the first surface 36 of the foil 34 as a slurry of aerosol generating material using a known aerosol generating material application technique such as extrusion of aerosol generating material slurry from a plurality of nozzles (not shown). In some embodiments (not shown) a plurality of layers of aerosol generating material slurry are applied to the same positions on the first surface 36 of the foil 34. The portions of aerosol generating material 32 are then caused or allowed to dry. The drying of the portions of aerosol generating material 32 is discussed further below. One or more of the portions of aerosol generating material 32 may have a different composition to the composition of at least one other of the portions of aerosol generating material 32.

With reference to Figure 5, after the portions of aerosol generating material 32 have dried, an edge 40 of the foil 34 is inserted into a longitudinal slot 42 which extends in an axial direction along a bobbin 44. The foil 34 is wound into a loose coil around the bobbin 44. The foil 34 is wound around the bobbin so that the portions of aerosol generating material 32 face radially inwardly in the coil. This has the result that the outer face of the coil is blank and the portions of aerosol generating material 32 that are attached to the portion of media that constitutes the outer face of the coil are protected, for example from abrasion, by the foil 34. In other embodiments, the foil may be wound around the bobbin 44 so that the portions of aerosol generating material 32 face radially outward.

The coils of foil 34 and portions of aerosol generating material 32 may now be stored until they are required. The period of storage may be at least 1 hour, at least 12 hours, at least 1 day, at least one week, or at least one month. The location of the coils may be changed in that the coils could be made in a first manufacturing facility and subsequently transported to a second manufacturing facility for further processing when desired.

When it is desired to make consumables 24, the coil of foil 34 and portions of aerosol generating material 32 is unwound. The treatment of the first surface 36 of the foil 34 has the result that even if the portions of aerosol generating material 32 contacted the second surface 38 of the foil 34 whist the coil was in storage, the portions of aerosol generating material 32 will, on unwinding the coil, remains adhered to the first surface 36 of the coil rather than detaching from the first surface 36 and adhering to the second surface 38.

With reference to Figure 6, the foil 34 is cut into foil portions 46 using standard blades (not shown). Each foil portion 46 carries a predetermined number of portions of aerosol generating material 32 on its surface. In the illustrated example that is six portions of aerosol generating material 32. The number of portions of aerosol generating material 32 may be different in different embodiments.

The foil portions 46 are cut so that they are asymmetric in shape to allow the orientation of the foil portions 46 to be controlled if that is required. In Figure 6 the asymmetry is produced by the removal of a corner 48 of the foil portions 46. Other asymmetries could be introduced instead of the removal of the corner 48. In some embodiments of the present disclosure the introduced asymmetry may also be used as an indicator of the composition of the aerosol generating material that constitutes one or more of the portions of aerosol generating material 32 on that foil portion. In other embodiments of the present disclosure the introduced asymmetry may also be used as an indicator of the composition of the aerosol generating material that constitutes one or more of the portions of aerosol generating material 32 on that foil portion by reference to the positions of those portions relative to a predetermined point or position indicated by the asymmetry.

With reference to Figure 7, to form the consumable 24 a foil portion 46 is attached to a support 50. The support 50 is, in this embodiment, formed from card and has a greater rigidity than the foil portion 46. The attachment of the foil portion 46 may be by use of an adhesive. The support 50 is substantially rectangular with a corner 52 cut off to introduce asymmetry. The asymmetry is introduced to the support 50 for the same reasons as those discussed in connection with the foil portion 46. The support 50 is dimensioned to make it suitable for use in the aerosol provision device 2 of Figure 1. In other, unillustrated embodiments, the foil portion 46 is attached to the support 50 by using at least one element that clamps a part of the foil portion 46 to the support 50, or by insertion of a part of the foil portion 46 into a slot in the support 50.

The attachment of the foil portion 46 to the support 50 may be performed by a user of the consumable. In some embodiments the consumable 50 is reusable.

In some embodiments of the aerosol provision device 2, the aerosol provision device includes a resistive heater as a heat source. In such embodiments the consumable 24 is placed in proximity to the resistive heater and, depending on the size of the resistive heater and the relative positioning of the resistive heater and consumable 24, one or more portions of the aerosol generating material 32 will generate an aerosol.

In alternative embodiments of the aerosol provision device 2, the aerosol provision device includes a magnetic field generator. The magnetic field generator combines with a susceptor to provide a heat source. The foil 34 of the foil portion 46 acts as the susceptor and thus causes the heating, depending on the size of the magnetic field generated by the magnetic field generator and the relative positioning of the magnetic field and consumable 24, of one or more portions of the aerosol generating material 32 to generate an aerosol. In an alternative embodiment, which can be illustrated by Figures 2 to 6, the media 30 is formed from a sheet of material that does not act as a susceptor, for example a sheet of paper 34. The embodiment is the same as that described above with the exception that portion 46 is a paper portion rather than foil portion.

To make a consumable 24 using a paper portion 46, that paper portion 46 is attached to the support 50. If the consumable 24 is to be used with a heat source or aerosol generator comprising a magnetic field generator and a susceptor, the material for the support 50 may be selected so that it comprises or consists of a susceptor. The susceptor may, for example be a metal foil or film, for example an aluminium foil or film. The support may be a laminate and the susceptor may be a layer in that laminate.

With reference to Figures 8 and 9, a section view of the media 30 supporting a plurality of portions of aerosol generating material 32 is shown. The media 30 is in the form of a sheet of aluminium foil 34. The foil 34 has first and second major surfaces 36 and 38. As in Figure 4, the portions of aerosol generating material 32 are disposed on the first surface 36 of the foil 34. In the embodiment of the method of the present disclosure illustrated in Figures 8 and 9 there is no need to surface treat either of the first or second surfaces 36, 38 of the foil 34.

Once the portions of aerosol generating material 32 have dried, a protection sheet 54 is laid over the first surface 36 of the foil 34 and the portions of aerosol generating material 32. The protection sheet is formed from a material which the portions of aerosol generating material 32 will not adhere to or which will adhere to the portions of aerosol generating material 32 with a lower pull off stress than is present between the portions of aerosol generating material 32 and the first surface 36 of the foil 34.

To reconfigure the media 30 into a storage configuration an edge 40 of the foil 34 and an edge 56 of the protection sheet 54 are inserted into a longitudinal slot 42 which extends in an axial direction along a bobbin 44. The foil 34 and protection sheet 54 are wound into a loose coil around the bobbin 44. The foil 34 and protection sheet 54 are wound around the bobbin 44 so that the portions of aerosol generating material 32 face radially inwardly in the coil. This has the results that the outer face of the coil is blank and the portions of aerosol generating material 32 that are attached to the portion of foil that constitutes the outer face of the coil are protected, for example form abrasion, by the foil 34.

In other embodiments, the foil 34 and protection sheet 54 may be wound around the bobbin 44 so that the portions of aerosol generating material 32 face radially outward. In these embodiments, the protection sheet 54 protects the portions of aerosol generating material 32 on the outside face of the coil.

As in connection with Figure 5, the coils of foil 34 and portions of aerosol generating material 32 may now be stored until they are required. The location of the coils may be changed in that the coils could be made in a first manufacturing facility and subsequently transported to a second manufacturing facility for further processing when desired.

When it is desired to make consumables 24, the coil of foil 34, protection sheet 54 and portions of aerosol generating material 32 are unwound and used as described in connection with Figures 6 and 7 above.

With reference to Figure 10, in some embodiments the protection sheet 54 includes one or more apertures 55 which extend through the protection sheet 54. The number of apertures 55 is the same as the number of discrete portions of aerosol generating material 32, and the configuration and location of the apertures 55 coincides with each discrete portion of aerosol generating material 52 once the protection sheet 55 has been laid over the foil 34 and aerosol generating material 32. The dashed lines 57 connect the corners that are in contact with each other when the protective sheet 54 is laid onto the foil 34. The media 30 can then be used in the same fashion as the media 30 shown in Figures 8 and 9. In some embodiments (not illustrated) one or more of the apertures 55 is smaller in the plane of the foil 34 than the portion of aerosol generating material 32 with which it corresponds.

With reference to Figures 11 and 12, a media 130 is provided. The media 130 comprises a longitudinally extending sheet of material, in the illustrated embodiment the media 130 is a sheet of aluminium foil 134. In other non-illustrated embodiments the material may be another suitable material, for example paper. The length and width of the media 130 as shown in Figure 11 is for illustrative purposes only. The media 130 may have different lengths and widths without departing from the scope of the present disclosure.

The foil 134 has first and second major surfaces with the surface shown in Figure 11 being first surface 136, and the unseen major surface being second surface 138.

A plurality of discrete portions of aerosol generating material 32 (only three of the portions are labelled for clarity) are applied to first surface 136 of the foil 134. In Figure 11 thirty portions of aerosol generating material 32 are illustrated and disposed on the first surface 136 of the foil 134 in a square grid pattern. In other non-illustrated embodiments the number of portions of aerosol generating material 32 applied to the surface of the media 130 and the pattern in which they are disposed may be different.

The portions of aerosol generating material 32 are applied to the first surface 136 of the foil 134 using a known aerosol generating material application technique such as extrusion of aerosol generating material from a plurality of nozzles (not shown). In some embodiments (not illustrated) a plurality of layers of aerosol generating material are applied to the same positions on the surface 36 of the foil 134.

The foil 134 is perforated by lines of perforations 158. The lines of perforations 158 extend approximately perpendicularly to the longitudinal axis of the media 130 / foil 134, and define a plurality of panels 146 of the foil 134. The longitudinal positions of the lines of perforations 158 along the foil 134 are determined by two factors. The first factor is the relative position of the portions of aerosol generating material 32 longitudinally either side of the lines of perforations 158. It is desirable that when the foil 134 is folded, with the fold line coinciding with a line of perforations 158, the portions of aerosol generating material 32 on the panels 146 either side of that line of perforations 158 do not overlie each other.

The second factor is that the lines of perforations 158 will, when a consumable 24 is to be made, be used to tear the media 130 into a plurality of separated panels 146. As such the spacing of the lines of perforations 158 will determine the dimensions of the separated panels 146.

The portions of aerosol generating material 32 are then caused or allowed to dry. The drying of the portions of aerosol generating material 32 is discussed further below.

With reference to Figures 13 and 14, to configure the media 130 / foil 134 and portions of aerosol generating material 32 into a storage configuration the foil 134 is folded into a concertina configuration by folding the foil 134 at each line of perforations 158. To form the concertina the folds at the lines of perforations 158 alternate between folding the first surfaces 136 of the panels 146 either side of the folding line of perforations 158 towards each other and folding those first surfaces away from each other. In Figure 13 the media 130 is being folded, and in Figure 14, the media 130 is fully folded.

With reference to Figures 15 and 16, a further embodiment of the method of production of a consumable according to the present disclosure includes providing a first media and portions of aerosol generating material 232, and a second media and portions of aerosol generating material 332. Each of those media and portions of aerosol generating material are produced as described in one of the embodiments described in connection with Figures 2 to 14. The difference between the portions of aerosol generating materials 232, 332 is that the composition of aerosol generating materials 232, 332 is different in that aerosol generated from aerosol generating material 232 has a first flavour, and aerosol generated from aerosol generating material 332 has a second flavour.

After storage the first and second media are separated into foil portions 246, 346. The foil portions 246 of the first media are identified by a corner 248 being removed from each foil portion 246. The foil portions 346 of the second media are identified by a notch 348 being removed from an edge of each foil portion 346.

A consumable 124 is produced by attaching one foil portion 246 from the first media and one foil portion 346 from the second media to a support 150. The attachment is made using an adhesive. The resultant consumable 124 includes six portions of aerosol generating material 232 which have a first flavour and six portions of aerosol generating material 332 which have a second flavour.

With reference to Figure 17, this Figure shows a section through an alternative media 430. The media 430 is a laminate which includes a first layer 460 and a second layer 462.

The first layer 460 is a metal foil or metal film, in the illustrated example of Figure 17 an aluminium foil or film. The layer 460 can be thinner than the foil 34 or 134 discussed in the above discussed embodiments because layer 460 is not required to have the structural characteristics, in particular strength and resilience to damage, that foils 34 and 134 are required to have.

The second layer 462 is a structural layer and is required to provide the media 430 with the strength and resilience to damage that it needs to allow it to be handled and stored in a storage configuration. The second layer 462 may be of a material suitable to form a substrate. The second layer 462 may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, or glass.

The media 430 may be used in the same fashion as media 30 or 130 described above. The portions of aerosol generating material 32, 232, 332 are in an embodiment of the present disclosure applied to the media 30, 130 in the form of a slurry. Once applied to the media the slurry needs to be dried or allowed to dry before the media can be configured into a storage configuration. Although the media could simply be allowed to dry over the course of time, such an approach renders the production of the media and portions of aerosol generating material 32, 232, 332 inefficient.

To render the production of the media and portions of aerosol generating material 32, 232, 332 more efficient, the slurry of aerosol generating material 32, 232, 332 is dried using a heat source. With reference to Figure 18, a drying system comprises a bed 70 which is adapted to support a media and portions of aerosol generating material 32, 232, 234 (which is collectively designated as media and material 72) as it travels across the surface of the bed 70 in a direction 74. The portions of aerosol generating material 32, 232, 332 are located on the face of the media not in contact with the bed 70.

Spaced above the bed 70 is a heat source 76. The heat source 76 is spaced from the bed 70 by a distance sufficient to allow the media and material 72 to pass between the bed 70 and heat source 76 without contact between the media and material 72 and the heat source. A temperature sensor 78 measures the temperature of the media and material as it passes out from between the bed 70 and heat source 76. The temperature sensor 78 controls the heat source 76 to prevent the media and material 72 from exceeding a predetermined temperature.

In a first embodiment of Figure 18, the heat source 76 is a dielectric heat source. In one embodiment that dielectric heat source is a source of microwave radiation with a frequency of around 915 MHz or 2.45 GHz. In an alternative embodiment the heat source is a radio frequency heating source. The electromagnetic waves for the dielectric heat source 76 cause heating of the slurry and promote evaporation of the solvent from the slurry as the media and material 72 passes between the heat source 76 and the bed 70. In a second embodiment of Figure 18, the heat source 76 is a source of thermal radiation. In one embodiment that source is an infrared heater. The thermal radiation from the heat source 76 causes heating of the slurry and promotes evaporation of the solvent from the slurry as the media and material 72 passes between the heat source 76 and the bed 70.

With reference to Figure 19, a second drying system comprises a bed 170 which is adapted to support a media and portions of aerosol generating material 32, 232, 234 (which is collectively designated as media and material 72) as it travels across the surface of the bed 170 in a direction 74. The portions of aerosol generating material 32, 232, 332 are located on the face of the media not in contact with the bed 170.

The bed 70 comprises a heated material in the form of a resistively heated hot plate 176. The media and material 72 passes over the hot plate 176 and is heated thereby. This heating causes heating of the slurry and promotes evaporation of the solvent from the slurry. A temperature sensor 78 measures the temperature of the media and material 72 as it passes off the hot plate 176. The temperature sensor 78 controls the hot plate 176 to prevent the media and material 72 from exceeding a predetermined temperature.

With reference to Figure 20, a third drying system comprises a bed 270 which is adapted to support a media and portions of aerosol generating material 32, 232, 234 (which is collectively designated as media and material 72) as it travels across the surface of the bed 270 in a direction 74. The portions of aerosol generating material 32, 232, 332 are located on the face of the media not in contact with the bed 270.

The bed 270 comprises a susceptor 280. Close to the bed 270 is a magnetic field generator 276 which generates an alternating magnetic field. The alternating magnetic field causes the susceptor 280 to have an increased temperature relative to the surrounding temperature. The media and material 72 passes over the susceptor 280 and is heated thereby. This heating causes heating of the slurry and promotes evaporation of the solvent from the slurry. A temperature sensor 78 measures the temperature of the media and material 72 as it passes off the susceptor 280. The temperature sensor 78 controls the magnetic field generator 276 to prevent the media and material 72 from exceeding a predetermined temperature.

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