Technical Field

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

Background

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

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

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

Summary

According to a first aspect of the present disclosure there is provided a method of making a consumable for use with a non-combustible aerosol provision system in which the consumable comprises aerosol generating material, a support, and a cover, in which a support is provided, a cover is provided, and a cover support is provided. The cover support is positioned adjacent the support between a portion of a first surface of the support and the cover in a cover position, and the cover is fixed to the support. At least one discrete portion of aerosol generating material is applied to the first surface of the support, and the cover support when located in the cover position overlies at least one discrete portion of aerosol generating material.

According to a second aspect of the present disclosure there is provided a consumable for use with a non-combustible aerosol provision system in which the consumable is a product of the method of the first aspect of the present disclosure.

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

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

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

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

Figure 1 shows a schematic view of a first embodiment of a consumable manufactured according to the method of the present disclosure;

Figure 2 shows an end view of the consumable of Figure 1;

Figure 3 shows a schematic exploded perspective view of the consumable of Figure 1 during manufacture;

Figures 4A to 4D shows an end view of the consumable of Figure 1 during different stages of the manufacture of that consumable;

Figure 5 shows a schematic view of an alternative embodiment of a cover support for use in the manufacture of a second embodiment of a consumable manufactured according to the method of the present disclosure;

Figure 6 shows a schematic view of a third embodiment of a consumable manufactured according to the method of the present disclosure;

Figure 7 shows a schematic view of a second method of manufacture of a consumable according to the present disclosure;

Figure 8 shows a side view of the method of Figure 7;

Figure 9 shows a schematic view of a third method of manufacture of a consumable according to the present disclosure; and

Figure 10 shows a side view of the method of Figure 9.

Detailed Description

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

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

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

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

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

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

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

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

Typically, the non-combustible aerosol provision system may comprise a non- combustible aerosol provision device and a consumable for use with the non- combustible aerosol provision device. In some embodiments, the disclosure relates to consumables comprising aerosolgenerating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

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

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

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

According to a first aspect of the present disclosure there is provided a method of making a consumable for use with a non-combustible aerosol provision system in which the consumable comprises aerosol generating material, a support, and a cover, in which a support is provided, and a cover is provided, a cover support is provided. The cover support is positioned adjacent the support between a portion of a first surface of the support and the cover in a cover position, and the cover is fixed to the support. At least one discrete portion of aerosol generating material is applied to the first surface of the support, and the cover support when located in the cover position overlies at least one discrete portion of aerosol generating material. The consumable resultant from the method of the present disclosure forms an essentially tubular consumable with the outer surfaces of the consumable formed by the support and the cover. In some embodiments, the tube has a square or a rectangular or approximately square or a rectangular cross-section. In some embodiments, the tube has a circular or approximately circular cross-section. In other embodiments the tube has alternative cross-sections.

In an embodiment of the above embodiment, the cover support comprises a first surface portion and a second surface portion, the first surface portion faces toward the support and the second surface portion does not face toward the support when the cover support is in the cover position, and the fixing of the cover to the support comprises placing at least part of the cover over at least a part of the second surface portion of the cover support.

In an embodiment of any of the above embodiments, the cover may by placed over the whole of the second surface portion of the cover support.

In an embodiment of any of the above embodiments, the cover may be substantially rectangular and the cover support so dimensioned that when the cover is placed on the second surface portion of the cover support the cover support supports the cover from one edge of the cover to the opposite edge of the cover. In an alternative embodiment the cover could be of an alternative shape.

In an alternative embodiment of any of the above embodiments, the cover may be substantially rectangular and the cover support so dimensioned that when the cover is placed on the second surface portion of the cover support the cover support supports the cover from one edge of the cover to a location between the one edge and the opposite edge of the cover. In an alternative embodiment the cover could be of an alternative shape.

The use of the cover support has an advantage in that it supports the cover during the manufacture of the consumable with the result that the potential for damage of the consumable and the cover in particular during the manufacturing process is reduced. It has a further advantage that the structural strength of the cover may be lower than in methods of manufacture that do not include use of a cover support. In an embodiment of any of the above embodiments, the cover comprises at least one contact portion, fixing of the cover to the support comprises causing the at least one contact portion of the cover to contact the support, and fixing the at least one contact portion of the cover to the support.

In an embodiment of any of the above embodiments, the cover comprises two contact portions. In some embodiments those two contact portions extend in substantially parallel directions.

In an embodiment of any of the above embodiments, the cover comprises at least two contact portions. In some embodiments those at least two contact portions extend in substantially parallel directions. In some embodiments the cover comprises three or four contact portions which extend in substantially parallel directions. In such embodiments one or two separate contact portions are fixed to the first surface of the support, and one or more contact portions are fixed to the second surface of the support.

In an embodiment of any of the above embodiments, the cover comprises three contact portions. In some embodiments, two of those contact portions extend in substantially parallel directions and the third contact portion extends between the other two contact portions.

In some embodiments, the contact portion or portions are integral with the cover. In some embodiments the contact portions are connected to the main portion of the cover by a fold line, and the contact portions are of sufficient size that the cover can be securely fixed to the support.

In an embodiment of any of the above embodiments, the fixing of the cover to the support comprises impelling, forcing or compressing at least one contact portion of the cover against the support after the at least one contact portion of the cover has been fixed to the support. This has an advantage in that it may increase the strength of the fixing of the cover to the support and make it less likely that the cover will separate from the support. In an embodiment of any of the above embodiments, the cover support extends in a first direction, the cover is fixed to the support by a first and a second contact portion, the first and second contact portions have a long dimension and a short dimension, and the long dimension of at least one of the first and second contact portions is approximately parallel to the first direction. In some embodiments the long dimension of each of the first and second contact portions is approximately parallel to the first direction.

In an embodiment of any of the above embodiments, at least one of the first and second contact portions of the cover is fixed to the first surface of the support adjacent to an edge of the support.

In an embodiment of any of the above embodiments, the support has a second surface, and at least part of at least one of the first and second contact portions of the cover is fixed to the second surface of the support adjacent to an edge of the support.

In an embodiment of any of the above embodiments, the support has a second surface, and at least part of at least one of the first and second contact portions of the cover is fixed to the second surface of the support. In some embodiments the cover at least partially covers the second surface of the support. In some embodiments the cover covers more than 20%, more than 50%, more than 75% or more than 90% of the surface area of the second surface of the support.

In an embodiment of any of the above embodiments, the support is a sheet material, and the first surface of the support is one of the major surfaces of the sheet material.

In an embodiment of any of the above embodiments, the support is a sheet material and the first and second surfaces of the support are the two major surfaces of that sheet material.

In an embodiment of any of the above embodiments, at least one contact portion of the cover is folded around an edge of the support and partially fixed to the first surface of the support and partially fixed to the second surface of the support. Such an arrangement provides a strong fixing of the cover to the support. The folding of the or each contact portion around the edge of the support also results in an increased rigidity for the or each edge of the support around which a contact portion is folded.

In an embodiment of any of the above embodiments, the first and second contact portions of the cover are spaced from each other, the cover is not fixed to the support between the first and second contact portions of the cover, and the cover and support together define a passage with first and second ends.

In an embodiment of any of the above embodiments, the method further comprises locating at least one element of air flow inhibiting material on the first surface of the support or the cover at or adjacent to a position where an end of a passage will be formed once the cover has been fixed to the support.

In an embodiment of any of the above embodiments, the locating of the air flow inhibiting element is performed before positioning the cover support in the cover position or the cover on the cover support, and the cover support at least partially retains the at least one element of air flow inhibiting material in position whilst the cover is fixed to the support.

In an embodiment of any of the above embodiments, the airflow inhibiting material may be a porous material, for example, but without limitation, cellulose acetate, airlaid paper, a cotton based material, shredded paper, or a cut rag tobacco.

In an embodiment of any of the above embodiments, the method further comprises locating a mouth piece or a socket, with which a mouth piece can be engaged, on the first surface of the support or the cover at or adjacent to a position where an end of a passage will be formed once the cover is fixed to the support. The mouth piece will allow a user to draw aerosol out from between the support and the cover when the consumable is in use.

In an embodiment of any of the above embodiments, the locating of the mouth piece or the socket is performed before positioning the cover support in the cover position or the cover on the cover support, and the cover support at least partially retains the mouth piece or socket in position whilst the cover is fixed to the support.

In an embodiment of any of the above embodiments, the method further comprises placing the consumable into packaging.

In an embodiment of any of the above embodiments, the method further comprises sealing the consumable in the packaging.

In an embodiment of any of the above embodiments, the packaging is the packaging that will be used in the storage and subsequent sale of the consumable to a user of the consumable. Placing the consumable in packaging serves to protect the consumable from damage.

In an embodiment of any of the above embodiments, the method comprises removing the cover support from between the cover and the support.

In an embodiment of any of the above embodiments, the method comprises at least partially filling the passage formed between the support and the cover with a porous or permeable material once the cover support has been removed from between the cover and the support.

In an embodiment of any of the above embodiments, the porous or permeable material is placed into the passage at the same time as the cover support is removed from between the cover and the support. The porous or permeable material, for example but without limitation, may be or include one of cellulose acetate, air-laid paper, a cotton based material, shredded paper, or cut rag tobacco or a mixture of two or more of these materials.

In an embodiment of any of the above embodiments, the cover support has a structure that may be penetrate by an aerosol, and the cover support is retained between the support and the cover.

In an embodiment of any of the above embodiments, the cover support is retained between the support and the cover, and the cover support is adapted to be removed from between the support and the cover by a user prior to use of the consumable. This has an advantage in that the cover is supported and thus unlikely to be damaged and I or pushed against the support until just before the consumable is used.

In an embodiment of any of the above embodiments, the method further comprises introducing at least one perforation in the cover material.

In an embodiment of any of the above embodiments, the passage between the cover and the support is a blind passage with the cover being fixed to the support along the sides and one end of the passage.

In an embodiment of any of the above embodiments, the passage between the cover and the support is a blind passage with the cover being fixed to the support along the sides and one end of the passage, and the cover includes one or more perforations in the cover at or adjacent to the blind end of the passage. The number of apertures in the cover will affect the pressure drop within the consumable whilst it is in use and a user is drawing aerosol and air through the consumable. The number and I or size of the apertures may be altered to provide a desired level of pressure drop.

In an embodiment of any of the above embodiments, the support is a longitudinally extending strip of material, the support supports at least two discrete portions of aerosol generating material, and the discrete portions of aerosol generating material are so located on the support that they are spaced from each other. At least two cover supports and covers are provided, each cover support is located adjacent a portion of the support in a cover position, the covers are fixed to the support to form a passage between the support and each of the covers, and each cover support is positioned between a portion of the support and a cover once the covers have been fixed to the support.

In an embodiment of any of the above embodiments, the covers are provided in a single longitudinally extending strip of cover material and the plurality of covers are formed during the performance of the method. In an embodiment of any of the above embodiments, the discrete portions of aerosol generating material are bunched into two or more groups of portions, and each group is so located on the first surface of the support that each one of the cover supports overlies one of the groups of portions.

In an embodiment of any of the above embodiments, the method further comprises separating the support into at least two portions of support, and each separation occurs in a space on the support between the adjacent groups of aerosol generating material.

In an embodiment of any of the above embodiments, the separation is caused by cutting the support with a suitable cutting means, for example but without limitation, a knife or a pair of blades.

In an embodiment of any of the above embodiments, at least one separation occurs after at least one cover has been fixed to the support.

In an embodiment of any of the above embodiments, at least one separation passes through a region in which the cover material is fixed to the support.

In an embodiment of any of the above embodiments, at least one separation occurs before at least one cover has been fixed to the support.

In an embodiment of any of the above embodiments, each separation forms at least one edge of the support.

In an embodiment of any of the above embodiments, the support and at least one cover support passes along a longitudinally extending manufacturing path, and at least one cover is laid over at least part of at least one cover support and the support whilst the at least one cover support and the support moves along the manufacturing path.

In an embodiment of any of the above embodiments, the or each cover support is adjacent to but not in contact with the support, the or each cover support is held in position by a supporting apparatus, and the supporting apparatus causes the or each cover support to remain in a substantially fixed position relative to the support as the support passes along the manufacturing path.

In an embodiment of any of the above embodiments, each cover support has a longitudinal extent, and the longitudinal extent of each cover support is orientated in substantially the same direction as the direction of travel of the support along the manufacturing path.

In an embodiment of any of the above embodiments, each cover support has a longitudinal extent, and the longitudinal extent of each cover support is orientated at an angle to the direction of travel of the support along the manufacturing path. In some embodiments the angle is between 45 and 90 degrees. In some embodiments the angle is about 90 degrees.

In an embodiment of any of the above embodiments, the method further comprises measuring the temperature of one or both of the support and the aerosol generating material, and cooling one or both of the support and the aerosol generating material if the temperature of one or both of the support and aerosol generating material exceeds a predetermined temperature.

In an embodiment of any of the above embodiments, the temperature measurement and the cooling, if that occurs, is performed at a fixed position on the manufacturing path and the measurement and cooling, if that occurs, occurs at predetermined times.

In an embodiment of any of the above embodiments, the temperature measurement and the cooling, if that occurs, is performed at a fixed position on the manufacturing path and the measurement and cooling, if that occurs, occurs at intervals. The intervals are determined by the speed of the support along the manufacturing path and cause the temperature measurement and cooling, if that occurs, to occur at a predetermined spacing along the support in the direction of the manufacturing path.

In an embodiment of any of the above embodiments, the temperature measurement and the cooling, if that occurs, is performed at a first and a second fixed position respectively on the manufacturing path and the temperature measurement is continuous or effectively continuous and the cooling occurs whenever the measured temperature exceeds a predetermined temperature.

In an embodiment of any of the above embodiments, the temperature measurement is made at a first position on the support, and the cooling, if that occurs, is performed before at least one cover has been fixed to the support at the first position on the support.

In an embodiment of any of the above embodiments, the or each cover is formed from a sheet material.

In an embodiment of any of the above embodiments, the sheet material comprises one or more of card, paper and a plastics material.

In an embodiment of any of the above embodiments, the cover is formed of a laminate material and the laminate comprises two or more layers of sheet material.

In an embodiment of any of the above embodiments, the cover comprises a composite material, and the composite material comprises one or more stiffening elements.

In an embodiment of any of the above embodiments, the cover is self supporting when the support is removed from between the support and the cover.

In an embodiment of any of the above embodiments, the cover is sufficiently rigid that the consumable may be inserted into and removed from an aerosol provision device without damage.

In an embodiment of any of the above embodiments, the material forming the or each cover is a foldable material.

In an embodiment of any of the above embodiments, the material forming the or each cover is a permeable or porous material. In an embodiment of any of the above embodiments, the material forming the or each cover comprises one or more fold lines.

In an embodiment of any of the above embodiments, the material forming the or each cover comprises one or more corrugations.

In an embodiment of any of the above embodiments, the material forming the or each cover comprises one or more folds or structural features that stiffen all or part of the cover.

An advantage of the cover material including one or more corrugations or other structural features that stiffen all or part of the cover is that there is an ability to use a thinner material to achieve a required degree of stiffness for the cover than would be possible for a cover which does not include any stiffening features.

In an embodiment of any of the above embodiments, the fold lines, corrugations or other structural features are formed during the performance of the method.

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

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

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

In an embodiment of any of the above embodiments, the support comprises a laminate material and the laminate material comprises at least two layers.

In an embodiment of any of the above embodiments, at least one cover is fixed to the support using an adhesive.

In an embodiment of any of the above embodiments, the adhesive is an aerosol generating material slurry. In an embodiment of any of the above embodiments, at least one cover is fixed to the support using ultrasonic welding techniques.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

In some embodiments, the aerosol generating material may comprise from about 5wt%, 10wt%, 20wt%, 25wt%, 27wt% or 30wt% to about 60wt%, 55wt%, 50wt%, 45wt%, 40wt%, or 35wt% of an aerosol generating agent (DWB). For example, the aerosol generating material may comprise 10-60wt%, 20-50wt%, 25-40wt% or 30- 35wt% of an aerosol generating agent. In some embodiments, the aerosol generating material may comprise up to about 80wt%, such as about 40 to 80wt%, 40 to 75wt%, 50 to 70wt%, or 55 to 65wt% of an aerosol generating agent (DWB).

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

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

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

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

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

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

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

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

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

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

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

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

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

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

In examples, the alginate is present in an amount of at least about 50wt% of the gelling agent. In examples, the aerosol generating material comprises alginate and pectin, and the ratio of the alginate to the pectin is from 1:1 to 10:1. The ratio of the alginate to the pectin is typically >1 :1 , i.e. the alginate is present in an amount greater than the amount of pectin. In examples, the ratio of alginate to pectin is from about 2:1 to 8:1 , or about 3:1 to 6:1, or is approximately 4:1. The aerosol generating material may be formed by (a) forming a slurry comprising components of the aerosol generating material or precursors thereof, (b) forming a layer of the slurry, (c) setting the slurry to form a gel, and (d) drying to form an aerosol generating material.

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

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

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

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

The setting the gel (c) may comprise supplying a setting agent to the slurry. For example, the slurry may comprise sodium, potassium or ammonium alginate as a gel-precursor, and a setting agent comprising a calcium source (such as calcium chloride), may be added to the slurry to form a calcium alginate gel. In examples, the setting agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium hydrogencarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the setting agent comprises or consists of calcium formate and/or calcium lactate. In particular examples, the setting agent comprises or consists of calcium formate. The inventors have identified that, typically, employing calcium formate as a setting agent results in an aerosol generating material having a greater tensile strength and greater resistance to elongation.

The total amount of the setting agent, such as a calcium source, may be 0.5-5wt% (calculated on a dry weight basis). Suitably, the total amount may be from about 1wt%, 2.5wt% or 4wt% to about 4.8wt% or 4.5wt%. The inventors have found that the addition of too little setting agent may result in an aerosol generating material which does not stabilise the aerosol generating material components and results in these components dropping out of the aerosol generating material. 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 an aerosol generating material, the aerosol generating material comprising:

1-60 wt% of a gelling agent;

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

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

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

In some embodiments, the aerosol generating material comprising:

1-50 wt% of a gelling agent; 0.1-50 wt% of an aerosol generating agent; and 30-60 wt% of a flavour; wherein these weights are calculated on a dry weight basis.

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

1-60 wt% of a gelling agent;

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

In some embodiments, the aerosol generating material comprises:

1-60 wt% of a gelling agent;

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

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

In some embodiments, the aerosol generating material may have the following composition (DWB): gelling agent (preferably comprising alginate) in an amount of from about 5wt% to about 40wt%, or about 10wt% to 30wt%, or about 15wt% to about 25wt%; tobacco extract in an amount of from about 30wt% to about 60wt%, or from about 40wt% to 55wt%, or from about 45wt% to about 50wt%; aerosol generating agent (preferably comprising glycerol) in an amount of from about 10wt% to about 50wt%, or from about 20wt% to about 40wt%, or from about 25wt% to about 35wt% (DWB). In one embodiment, the aerosol generating material comprises about 20wt% alginate gelling agent, about 48wt% Virginia tobacco extract and about 32wt% glycerol (DWB).

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

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

In some cases, the aerosol generating material may have a thickness of about 0.015mm to about 1.0mm. Suitably, the thickness may be in the range of about 0.05mm, 0.1mm or 0.15mm to about 0.5mm or 0.3mm.

A material having a thickness of 0.2mm is particularly suitable. The aerosol generating material may comprise more than one layer, and the thickness described herein refers to the aggregate thickness of those layers.

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

The thickness stipulated herein is a mean thickness for the material. In some cases, the aerosol generating material thickness may vary by no more than 25%, 20%, 15%, 10%, 5% or 1%. In some examples, the aerosol generating material in sheet form may have a tensile strength of from around 200 N/m to around 900 N/m. In some examples, such as where the aerosol generating material does not comprise a filler, the aerosol generating material may have a tensile strength of from 200 N/m to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m.

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

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

The aerosol generating material comprising the aerosol generating material may have any suitable area density, such as from 30 g/m ² to 350 g/m ² . In some cases, the sheet may have a mass per unit area of 50-250 g/m ² , or from about 70 to 210 g/m ² , or from about 90 to 190 g/m ² , or suitably about 100 g/m ² (so that it has a similar density to cut rag tobacco and a mixture of these substances will not readily separate). In some cases, the sheet may have a mass per unit area of about 30 to 70 g/m ² , 40 to 60 g/m ² , or 25-60 g/m ² and may be used to wrap an aerosolisable material such as tobacco..

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

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

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

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

The colourant may be incorporated during the formation of the aerosol generating material (e.g. when forming a slurry comprising the materials that form the aerosol generating material) or it may be applied to the aerosol generating material after its formation (e.g. by spraying it onto the aerosol generating material). In some embodiments of any of the above embodiments, talcum powder, calcium carbonate powder or other powder is applied to the exposed surface of at least one discrete portion of aerosol-generating material. This may reduce the level of tackiness or adhesion of the aerosol-generating material.

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

With regard to Figures 1 and 2, a consumable 2 comprises a support 4 and a cover 6.

The support 4 is a sheet material with a first surface 8 and a second surface 10. On the first surface 8 one or more discrete portions 12 of an aerosol generating material (for clarity, not all portions 12 are labelled) are supported. The portion or portions 12 of aerosol generating material are applied to the support in an appropriate fashion in a predetermined pattern on the first surface 10 and with predetermined dimensions and configurations. Collectively the portions 12 can be described as a group of portions 12. The number of portions 12 of aerosol generating material, their shape and their positions relative to each other shown in Figures 1 and 2 are exemplary and other numbers of portions 12, other positioning of the portions 12 relative to each other, and I or other configurations of the portions 12 fall within the scope of the present disclosure.

The cover 6 is fixed to the support 4 adjacent the edges 14A, 14B of the support 4. The fixation means for fixing the cover 6 to the support is an adhesive 16 (not shown in Figures 1 and 2). In other embodiments the fixation means may be the use of aerosol generating material slurry (which can act as an adhesive if fixation occurs before the aerosol generating material sets). An alternative fixation means is the use of a melting or welding (for example ultrasonic welding) technique. Once the cover 6 is fixed to the support 4, the cover 6 and support 4 collectively define a passage 28. The passage 28 includes the group of portions 12 of aerosol generating material and a volume through which air or an aerosol may flow.

With reference to Figures 3 and 4A to 4D, to make the consumable 2 shown in Figures 1 and 2, a cover support 30 is located in the cover position. In the cover position the cover support 30 overlies the majority of the first face 8 of the support 4. The cover support 30 has a first surface portion 32 which faces towards the first surface 8 of the support 4 and a second surface portion 34 which faces away from the first surface 8 of the support 4.

The cover 6 is formed from nine rectangular portions 18, 20A, 20B, 22A, 22B, 24A, 24B, 26A, 26B of the cover each of which has a major (longitudinal) axis that is substantially parallel to the edges 14A, 14B of the support 4. Each portion of the cover is adjacent to at least one other portion of the cover and at least one longitudinally extending side of each cover portion is defined by one or two of fold lines 18F, 20F, 22F, 24F formed in the material of the cover.

During manufacture of the consumable 2, and as shown in Figures 4A to 4D, the cover 6 is folded around the fold lines 18F, 20F, 22F, 24F so that the cover portion 18 is held parallel to the support 4 by the cover portions 20A, 20B, and the cover portions 22A, 24A, 26A, and 22B, 24B, 26B wrap round the edges 14A, 14B of the support 4 respectively. The cover portions 22A, 24A, 26A, and 22B, 24B, 26B may be collectively termed the first and second contact portions of the cover 6 respectively. The faces of cover portions 22A, 24A, 26A, and 22B, 24B, 26B that are in contact with or proximal to the surface of the support 4 are the first and second contact surfaces of the cover 6. Before the folding of the cover portions 22A, 24A, 26A, and 22B, 24B, 26B around the edges 14A, 14B, adhesive 16 is applied to the first and second contact surfaces.

After the cover portions 22A, 24A, 26A, and 22B, 24B, 26B and adhesive 16 has been folded around the edges 14A, 14B of the support 4, the portions of the consumable comprised of cover portions 22A, 24A, 26A and edge 14A, and 22B, 24B, 26B and edge 14B are passed between a pair of compression rollers (not shown) or an equivalent compression means so as to maximise the fixation of the cover 6 to the support 4.

Once the adhesive 16 has set, packaging (not shown) is partially placed around the consumable 2. The cover support 30 is subsequently removed from between the cover 6 and the support 4, and the packaging sealed around the consumable.

In an alternative embodiment, the cover support 30 remains between the cover 6 and the support 4 and the packaging sealed around the consumable and cover support 30. In such an embodiment the cover support 30 is configured to be removed by a user prior to use of the consumable, for example by way of the inclusion of a tag not shown to allow a user to grip the tag and pull the cover support 30 out from between the cover 6 and the support 4.

In an alternative embodiment, the cover support 30 is configured to remain between the cover 6 and the support 4 whilst the consumable is in use. In such an embodiment the cover support 30 is formed from a porous or permeable material such as cellulose acetate, air-laid paper, a cotton based material, shredded paper, or a cut rag tobacco or a mixture of two or more of these materials.

With reference to Figure 5, an alternative cover support 130 is shown. The cover support 130 includes a recess 136 in the cover support first face 132 adjacent a first end 138 of the cover support 130. The recess is adapted to retain a portion of a porous or permeable material 140 against the first surface 108 of the support 4 when the cover support 130 is in the cover position. The cover support is used in a similar fashion to that discussed in connection with cover support 30 and Figures 3 and 4A to 4D other than the porous or permeable material 140 is placed into the desired position on the support 4 when the cover support 130 is moved into the cover position and the porous or permeable material 140 is, as a result, compressed in the position shown in Figure 5.

In this embodiment the porous or permeable material 140 is an elastically deformable material which will, when the cover 6 is fixed to the support 4 and the cover support 130 is removed from the cover position, remain in approximately the same position relative to the support 4 and expand to contact the cover 6 and the support 4 thus extending across the passage 28 formed between the cover 6 and the support 4.

With reference to Figure 6, an alternative configuration of a consumable 202 is shown. Consumable 202 is similar to consumable 2 described in connection with Figures 1 to 4D, with the following differences. The cover 206 is so configured that it is formed from seven rectangular portions 218, 220A, 220B, 222A, 222B, 242, 244. Each of portions 218, 220A, 220B, 222A, 222B has a major (longitudinal) axis that is substantially parallel to the other of portions 218, 220A, 220B, 222A, 222B. Each of portions 218, 220A, 220B, 222A, 222B of the cover 206 is adjacent to at least one other of portions 218, 220A, 220B, 222A, 222B of the cover 206 and at least one longitudinally extending side of each of portions 218, 220A, 220B, 222A, 222B is defined by one or two of fold lines 218F, 220F formed in the material of the cover. The portions 242 and 244 have a major (longitudinal) axis that is substantially perpendicular to the major (longitudinal) axis of the portions 218, 220A, 220B, 222A, 222B. At least one longitudinally extending side of each of portions 242 and 244 is defined by one or two of fold lines 218EF, 242F formed in the material of the cover. Portion 242 includes one or more apertures 246 extending through the cover material. Four apertures 246 are illustrated in Figure 6 but the present disclosure includes other numbers of apertures.

With reference to Figures 7 and 8, the support 304 is a longitudinal strip of material fed in the direction D off a feed roll 304R. The support 304 then passes through a zone 350 in which aerosol generating material 12 is applied to the support 304. The aerosol generating material is applied as a group 312 of discrete portions 12. Each consumable 302 contains one group 312 of aerosol generating material portions 12.

Once the aerosol generating material has set, the support passes through a zone 352 in which the temperature of the support 304 and aerosol generating material is measured by a temperature measuring means (not shown) and, if the measured temperature exceeds a predetermined value, the support 304 and aerosol generating material are cooled by a cooling means (not shown).

A cover support 330 is next moved into a cover position where the cover support 330 overlies a group 312 of aerosol generating material. The cover support 330 is supported on a cover support apparatus that holds the cover support apparatus a predetermined distance from the support first surface 308, and moves the cover support 330 in direction D at the same speed as the support 304.

A cover material 306M is fed off a feed roll 306R and caused (by means not shown) to overlie and contact the second cover support surface 334 of the cover support 330, and, between adjacent cover supports 330, the first surface 308 of the support 304. After the cover material 306M leaves the feed roll 306R and before the cover material 306M is caused to contact the support 304, the cover material 306M has an adhesive 316 applied to the portions of the surface of the cover material 306M that will contact the support 304. The adhesive is an aerosol generating material gel slurry or other appropriate adhesive.

The support 304, cover material 306M, and cover support 330 continues to travel in direction D to a cutting zone 354 in which the cover material 306M and support 304 is cut through. The cuts are made in the portions where the cover material 306M is adhered to the support 304. This forms a consumable 302 with a support 304, a cover 306, and a passage 28 which at that time is substantially occupied by the cover support 330.

The consumable 302 is next partially surrounded by packaging 356 (not shown in Figure 7 for clarity) in such a fashion that the packaging 356 does not contact the cover support 330.

The cover support 330 is next withdrawn from between the support 304 and the cover 306 and the packaging sealed around the consumable 302.

With reference to Figures 9 and 10, the support 404 is a longitudinal strip of material fed in the direction D off a feed role (not shown). The support 404 then passes through a zone (not shown) in which aerosol generating material 12 is applied to the support 404. The aerosol generating material is applied as a group 412 of discrete portions 12. Each consumable 402 contains one group 412 of aerosol generating material portions 12. Once the aerosol generating material has set, the support passes through a zone (not shown) in which the temperature of the support 404 and aerosol generating material is measured by a temperature measuring means (not shown) and, if the measured temperature exceeds a predetermined value the support 404 and aerosol generating material are cooled by a cooling means (not shown).

The support 404 passes beneath a first surface 432 of a cover support 430 that has a longitudinal extent that is orientated in direction D. The cover support 430 is in a fixed position and the support 404 moves relative to the cover support 404.

A cover material 406M is fed off a feed roll (not shown) and caused to overlie and contact the second cover support surface 434 of the cover support 430. The cover material 406M starts to travel in direction D.

The cover material 406M and support 404 enter a folding zone 458 in which folding means (not shown) cause the cover material 406M to wrap around the side edges 414A and 414B of the support 404 in a similar fashion to that discussed in connection with Figures 3 and 4A to 4D. The adhesive to fix the cover material 306M to the support 404 is an aerosol generating material slurry or other appropriate adhesive.

The support 404 and cover material 406M continue to travel in direction D and enter a compression zone 460 in which the edges of the support 414A, 414B and the cover material 406M are compressed between a pair of compression rollers.

The support 404 and cover material 406M reach the end 430E of the cover support 430 and enter a cutting zone 454 in which the cover material 406M and support 404 is cut through in the portions between the aerosol generating material groups 412. This forms a consumable 402 with a support 404, a cover 406, and a passage 28.

The consumable 402 is next partially surrounded by packaging 456 (not shown in Figure 9 for clarity) and the packaging is then sealed around the consumable 402.

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