Consumables for use with aerosol delivery devices

Abstract

A method is provided for making consumables (24) for use with a non-combustible aerosol delivery device. Each consumable (24) includes a portion of a medium (30) onto which an aerosol-forming material (26) is applied. The method includes the steps of (a) providing the medium (30), (b) applying the aerosol-forming material (26) to a surface of the medium (30), (c) configuring the medium (30) and the aerosol-forming material (26) for storage, (d) storing the medium (30) and the aerosol-forming material (26), and (e) separating the medium (30) and the aerosol-forming material (26) into portions of desired size.

Description

[Technical field]

[0001] The present disclosure relates to the field of non-combustible aerosol delivery systems, and in particular to consumables for use with aerosol delivery devices, methods of manufacturing consumables for use with aerosol delivery devices, and aerosol delivery systems including consumables and aerosol delivery devices. [Background technology]

[0002] (background) Smoking articles, such as cigarettes, cigars, and the like, burn tobacco to produce tobacco smoke when in use. Alternatives to these types of articles release inhalable aerosols or vapors by releasing compounds from a substrate material through heating rather than combustion. These can be referred to as non-combustion smoking articles, aerosol generating assemblies, or aerosol delivery devices.

[0003] One example of such a product is a heating device that releases a compound by heating, without combustion, an aerosolizable material, which may be referred to as a solid aerosol-generating material. The solid aerosol-generating material in some cases includes tobacco material. Upon heating, at least one component of the material is volatilized, usually forming an inhalable aerosol. These products may be referred to as non-combustion heating devices, tobacco heating devices, or tobacco heating products. A variety of different configurations are known for volatilizing at least one component of a solid aerosol-generating material.

[0004] Another example is a hybrid device, which includes a liquid source (which may or may not contain nicotine) that is vaporized by heating to produce an inhalable vapor or aerosol. The device further includes a solid aerosol-forming material (which may or may not contain tobacco material), the components of which are entrained in the inhalable vapor or aerosol to produce the inhaled medium. Summary of the Invention

[0005] (overview) According to a first aspect of the present disclosure, there is provided a method of manufacturing consumables for use with a non-combustible aerosol delivery device, each consumable including a portion of a medium to which an aerosol-generating material is applied, the method comprising: (a) a medium is provided; (b) applying an aerosol-generating material to a surface of a medium; (c) configuring the medium and the aerosol-generating material for storage; (d) storing the medium and the aerosol-generating material; (e) separating the medium and aerosol-forming material into portions of a desired size; Includes.

[0006] According to a second aspect of the present disclosure, there is provided an article of manufacture for use in the manufacture of a consumable for use with an apparatus for heating an aerosol-forming material to volatilize at least one component of the aerosol-forming material, the article comprising: a medium and an aerosol-forming material; the aerosol-generating material is supported on a surface of the medium; the medium and the aerosol-generating material are configured for storage; The medium can be separated into portions of desired size.

[0007] 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 volatilize at least one component of the aerosol-generating material, the consumable comprising at least one portion of a product according to the second aspect of the present disclosure.

[0008] According to a fourth aspect of the present disclosure, there is provided a kit for making a consumable comprising a support and multiple portions of a medium onto which an aerosol-generating material produced using the method of the first aspect of the present disclosure is applied.

[0009] According to a fifth aspect of the present disclosure, there is provided an aerosol delivery device for use with a consumable manufactured by a method according to the first aspect of the present disclosure, the device comprising a heater assembly configured to heat at least a portion of an aerosol-generating material supported on the consumable.

[0010] According to a sixth aspect of the present disclosure, there is provided an aerosol delivery system comprising an aerosol delivery device and a consumable manufactured by the method according to the first aspect of the present disclosure.

[0011] According to a seventh aspect of the present disclosure, there is provided a method of generating an aerosol from a consumable according to the first aspect of the present disclosure using an aerosol generation device having at least one aerosol generator arranged to heat the consumable in use without burning it, wherein the at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.

[0012] 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 with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0013] [Figure 1] 1A-1C are schematic diagrams of an embodiment of an aerosol delivery device and an embodiment of a consumable manufactured according to a first embodiment of the method of the present disclosure. [Diagram 2] 2A-2C illustrate a first embodiment of a medium used in the manufacture of the consumable product of FIG. 1. [Diagram 3] 3 illustrates the medium of FIG. 2 after an aerosol-generating material has been applied to the medium. [Figure 4] FIG. 4 is a cross-sectional view of the medium of FIG. 3 along section line AA′. [Diagram 5] 4 is a cross-sectional view of the medium of FIG. 3 in a first embodiment of a storage configuration for medium and aerosol-generating material along section line AA'. [Figure 6] FIG. 4 shows the medium of FIG. 3 separated into several portions. [Figure 7] FIG. 2 illustrates an embodiment of the consumable of FIG. 1. [Figure 8] 4 is a cross-sectional view of the medium of FIG. 3 in a second embodiment of the method of the present disclosure taken along section line AA′. [Figure 9] 4 is a cross-sectional view of the medium of FIG. 3 in a second embodiment of the storage configuration for the medium and aerosol-generating material in a second embodiment of the method of the present disclosure taken along section line AA′. [Figure 10] 9 is a schematic exploded view of an alternative embodiment of the medium of FIG. 8. [Figure 11] FIG. 3 illustrates a second embodiment of the medium of FIG. 2 after an aerosol-generating material has been applied to the medium in a third embodiment of the method of the present disclosure. [Figure 12] FIG. 12 is a cross-sectional view of the medium of FIG. 11 taken along section line BB'. [Figure 13] A cross-sectional view of the medium of FIG. 11 in the process of being reconstituted into a third embodiment of a storage configuration for medium and aerosol-generating material in a third embodiment of the method of the present disclosure along section line BB'. [Figure 14] A cross-sectional view of the medium of FIG. 11 in a third embodiment of the storage configuration for the medium and aerosol-generating material in a third embodiment of the method of the present disclosure taken along section line BB'. [Figure 15] FIG. 12 shows the medium of FIG. 11 and a second medium separated into a number of portions. [Figure 16] FIG. 13 illustrates a second embodiment of a consumable. [Figure 17] 12 is a cross-sectional view of an alternative embodiment of the medium of FIG. 11 taken along section line BB'. [Figure 18] FIG. 1 shows a schematic representation of a method for drying an aerosol-generating material according to a first embodiment of the method of the present disclosure. [Figure 19] FIG. 2 shows a schematic representation of a method for drying an aerosol-generating material according to a second embodiment of the method of the present disclosure. [Figure 20] FIG. 1 shows a schematic representation of a method for drying an aerosol-generating material according to a third embodiment of the method of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] (Detailed Description) Consumables herein may alternatively be referred to as articles.

[0015] In some embodiments, the consumable comprises an aerosol-generating material. The consumable can include an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, an aerosol modifier, one or more active ingredients, one or more flavorings, one or more aerosol former materials, and / or one or more other functional materials.

[0016] An apparatus for heating the aerosol generating material used with the consumable is part of the non-combustion aerosol delivery system.

[0017] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the aerosol-generating components of the aerosol delivery system (or components thereof) are not combusted or burned to facilitate delivery of at least one substance to a user.

[0018] In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as a powered non-combustible aerosol delivery system.

[0019] In some embodiments, the non-combustion aerosol delivery system is an e-cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0020] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system, an example of such a system is a tobacco heating system.

[0021] In some embodiments, the non-combustion aerosol delivery system is a mixing system for generating an aerosol using a combination of aerosol-generating materials, where one or more of the aerosol-generating materials can be heated. Each of the aerosol-generating materials can be, for example, in solid, liquid or gel form, and may or may not contain nicotine. In some embodiments, the mixing system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material can include, for example, tobacco or a non-tobacco product.

[0022] Typically, a non-combustion aerosol delivery system can include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0023] In some embodiments, the present disclosure relates to consumables, sometimes referred to as articles throughout this disclosure, that include aerosol generating materials and are configured for use with non-combustible aerosol delivery devices.

[0024] In some embodiments, a non-combustion aerosol delivery system, such as a non-combustion aerosol delivery device of a non-combustion aerosol delivery system, can include a power source and a controller. The power source can be, for example, a power source or a heat source. In some embodiments, the heat source includes a carbon substrate that can be activated to dissipate power in the form of heat to an aerosol-generating material or a heat transfer material in proximity to the heat source.

[0025] In some embodiments, the non-combustible aerosol delivery device may include an area for receiving a consumable, an aerosol generator, an aerosol generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0026] In some embodiments, consumables for use with the non-combustion aerosol delivery device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transport component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0027] According to a first aspect of the present disclosure, there is provided a method of manufacturing consumables for use with a non-combustible aerosol delivery device, each consumable including a portion of a medium to which an aerosol-generating material is applied, the method comprising: (a) a medium is provided; (b) applying an aerosol-generating material to a surface of a medium; (c) configuring the medium and the aerosol-generating material for storage; (d) storing the medium and the aerosol-generating material; (e) separating the medium and aerosol-forming material into portions of a desired size; Includes.

[0028] In some embodiments, the properties of the medium, such as stiffness, are such that the medium and portions of the aerosol-generating material are suitable for use in an aerosol generating device without further processing of the medium and the aerosol-generating material, which has the advantage of minimizing processing steps in the manufacture of consumables.

[0029] In other embodiments, the properties of the medium are such that portions of the medium and aerosol-generating material are not suitable for use in an aerosol generating device without further processing of the medium and aerosol-generating material. For example, in some embodiments, the medium is a material that is thinner and / or less robust than required for use as a consumable in an aerosol generating device. In such embodiments, the medium and aerosol-generating material may be easier to handle, configure for storage, and / or take up less space when stored than if the medium had the properties that made them suitable for use as a consumable. In such embodiments, the medium and aerosol-generating material are combined with a support.

[0030] In one of the above embodiments, the method comprises: (f) the further step of associating the medium and at least one portion of the aerosol-forming material with a support.

[0031] The support may be of any material suitable for forming a substrate, for example, the support may be or include paper, card, corrugated board, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or alloy.

[0032] In one embodiment of any of the above embodiments, the support comprises a plastic material capable of withstanding temperatures typically encountered in non-combustion aerosol delivery devices. In some embodiments, the support comprises polyetheretherketone (PEEK). Such an embodiment has the advantage that the support can be reused and the consumable is less susceptible to any condensation in non-combustion aerosol delivery devices than consumables that include supports that include the use of sorbent materials for structural purposes.

[0033] In one embodiment of any of the above embodiments, the medium provided in step (a) is a longitudinally extending medium, step (b) is performed prior to step (c), and the storage configuration in step (c) is forming the medium and aerosol generating material into a roll or bellows shape. Advantages of forming the medium and aerosol generating material into a roll or bellows shape for storage are that such a storage configuration is easy to handle, relatively compact, and likely to protect the medium and aerosol generating material from damage during storage.

[0034] In one embodiment of any of the above embodiments, step (b) includes applying the aerosol-forming material to the medium as two or more separate portions of aerosol-forming material.

[0035] In one embodiment of any of the above embodiments, at least two of the separate portions of aerosol-generating material are formed from aerosol-generating materials having different compositions from one another. This has the advantage that a user of a consumable manufactured in accordance with the present disclosure can have a different experience when the different separate portions of aerosol-generating material on the consumable are aerosolized. This can make use of the consumable more enjoyable and / or interesting than use of a consumable having an aerosol-generating material of only one composition.

[0036] In one embodiment of any of the above embodiments, step (b) is performed two or more times. This may have the effect of creating a thicker layer of aerosol-generating material on the medium than a single application of the aerosol-generating material. The increased thickness may result in a greater amount of aerosol generated by the aerosol-generating material and / or a longer delivery of the aerosol than if only a single application of the aerosol-generating material were applied.

[0037] In one embodiment of any of the above embodiments, the method comprises: (g) placing a protective sheet over the medium and the aerosol-forming material; Step (g) is carried out after step (b) and before step (c). This has the advantage of minimizing the risk that any of the aerosol-generating material will adhere to any part of the medium other than the part it is intended to adhere to during storage. This also has the advantage of helping to protect the aerosol-generating material from damage due to friction with the medium while the medium and aerosol-generating material are configured for storage.

[0038] In one embodiment of any of the above embodiments, the protective sheet includes one or more apertures extending therethrough.

[0039] In one embodiment of any of the above embodiments, the number of apertures is the same as the number of separate portions of aerosol-generating material, and when the protective sheet is laid over the medium and the aerosol-generating material, the configuration and location of the apertures coincide with at least a portion of each separate portion of the aerosol-generating material.

[0040] In one embodiment of any of the above embodiments, step (a) includes selecting or creating a medium having first and second opposing surfaces; the first surface and the aerosol-generating material are adhered to one another with a first adhesive strength; the second surface and the aerosol-generating material are adhered to one another with a second adhesive strength; The first adhesive strength is greater than the second adhesive strength; In step (b), an aerosol-forming material is applied to a first surface of the medium.

[0041] In some of the above embodiments, the second adhesive strength is less than the force required to tear the aerosol-generating material into two portions, i.e., when the aerosol-generating material is adhered to both the first and second surfaces, moving one surface away from the other does not tear the aerosol-generating material.

[0042] An advantage of this embodiment is that when the aerosol-generating material is applied to a first surface, the greater adhesive strength of the aerosol-generating material to the first surface of the medium means that when the medium and aerosol-generating material are formed into a configuration for storage and the aerosol-generating material contacts a second surface of the medium, when the medium and aerosol-generating material are reconstituted to exit the storage configuration, the aerosol-generating material will remain adhered to the first surface.

[0043] In one 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 1 week, or at least 1 month. This has the advantage of allowing the production of the medium and aerosol-generating materials to be separate from the demand for use of the consumables made according to the present disclosure. This can increase the efficiency of the production process and allow peaks in demand for the consumables to be met more easily.

[0044] In one embodiment of any of the above embodiments, step (d) includes transporting the medium and aerosol-generating materials between different locations, which may be separated by significant distances, which may also increase the efficiency of production of the consumables.

[0045] In one embodiment of any of the above embodiments, the separation in step (e) is performed by cutting the medium. Known cutting means can be used to cut the medium. In another embodiment, the medium is perforated and the separation is performed by tearing the medium along the perforations.

[0046] In one embodiment of any of the above embodiments, associating the portion of the medium and the aerosol-generating material with the support in step (f) includes attaching at least one portion of the medium and the aerosol-generating material to the support using one or more of an adhesive, at least one element clamping a portion of the portion of the medium to the support, or inserting a portion of the portion of the medium into a slot. Each of these techniques holds the portion of the medium and the aerosol-generating material in a fixed position on the support, allowing the combined support, medium and aerosol-generating material to be used as a consumable item. In some embodiments, the adhesive may be a pressure adhesive, a releasable adhesive, a repositionable adhesive, a low tack adhesive, or another suitable adhesive.

[0047] In one embodiment of any of the above embodiments, step (a) includes providing at least two separate media. Step (b) includes applying the differently contained aerosol-forming materials to a surface of each of the separate media; Step (c) includes configuring each of the medium and the aerosol-forming material for storage; Step (d) includes storing each of the medium and the aerosol-forming material; Step (e) includes separating each of the medium and aerosol-forming material into portions of a desired size; Step (f) includes associating the at least two different media and at least one portion of the aerosol-forming material with a support.

[0048] In this embodiment, each of the separate media may be the same as each other. Each of the differently contained aerosol-forming materials has a different composition. This can have the result that the aerosols form with different aerosol-forming material compositions, thereby providing the user with a different user experience, for example, a different flavoring of the aerosol.

[0049] In some of the above embodiments, the different portions of the medium and aerosol-generating material in step (e) are arranged in a pattern on the support, and the position of each portion of the medium and aerosol-generating material within the pattern indicates the composition of the aerosol-generating material in each portion of the medium and aerosol-generating material, thereby enabling a user-controlled or automated aerosol generating system to select a particular composition of aerosol-generating material by choosing to generate aerosol from a specifically arranged portion of the aerosol-generating material, or from a specifically arranged portion of the medium and aerosol-generating material.

[0050] In one embodiment of any of the above embodiments, the aerosol-forming material is in the form of an aerosol-forming film or an aerosolizable gel.

[0051] An aerosol-forming material is a material capable of generating an aerosol when activated, for example, by heating, irradiation, or in any other manner. The aerosol-forming material can be, for example, in solid, liquid, or semi-solid (such as a gel) form, and may or may not contain active substances and / or flavorings.

[0052] The aerosol-generating materials may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0053] The aerosol-generating material may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a delivery substance and / or bulking agent may also be present. Optionally, a solvent, such as water, may also be 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 of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0054] The aerosol-generating material may include or take the form of an aerosol-generating film. The aerosol-generating film may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a delivery substance and / or a filler may also be present. The aerosol-generating film may be substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0055] The aerosol-generating film may have a thickness of from about 0.015 mm to about 1 mm. For example, the thickness may be in the range of from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

[0056] The aerosol-generating film can be formed by combining a binder, such as a gelling agent, with one or more other components, such as a solvent, such as water, an aerosol-forming agent, and one or more substances to be delivered, to form a slurry, and then heating the slurry to volatilize at least some of the solvent and form the aerosol-generating film.

[0057] The slurry can be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent.

[0058] The aerosol-generating material includes or may be an "amorphous solid." In some embodiments, the aerosol-generating material includes 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 dry gel. An amorphous solid is a solid material that can hold some fluid within it, such as a liquid. In some embodiments, the amorphous solid may include, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0059] The amorphous solid may be substantially free of plant material.The amorphous solid may be substantially free of tobacco.

[0060] In one embodiment of any of the above embodiments, the medium comprises a susceptor, hi some embodiments, the medium is a laminate and at least one layer of the laminate is a susceptor.

[0061] In one embodiment of any of the above embodiments, when the medium includes a susceptor, the support is formed from a material that does not function as a susceptor.

[0062] In one embodiment of any of the above embodiments, the support comprises a susceptor, hi some embodiments, the support is a laminate and at least one layer of the laminate is a susceptor.

[0063] The susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, the penetration of which causes inductive heating of the susceptor by resistive heating as a result of eddy currents. The susceptor may be a magnetic material, the penetration of which causes magnetic hysteresis heating of the susceptor. The susceptor may be both conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. A device configured to generate a varying magnetic field is called a magnetic field generator.

[0064] 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 exemplary ferromagnetic metals are 400 series stainless steel, such as grade 410 stainless steel, or grade 420 stainless steel, or grade 430 stainless steel, or similar grade stainless steel. Alternatively, the susceptor may comprise a suitable non-magnetic, particularly paramagnetic, conductive material, such as aluminum. In paramagnetic conductive materials, induction heating occurs only 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 generated only by hysteresis losses. The susceptor may include commercially available alloys such as Phytherm 230 (having a composition (in weight %=wt%) of 50 wt% Ni, 10 wt% Cr, and the balance Fe) or Phytherm 260 (having a composition (in weight %=wt%) of 50 wt% Ni, 9 wt% Cr, and the balance Fe).

[0065] The susceptor may be a metal foil or film, optionally an aluminum foil or film or an iron foil or film, in some embodiments of any of the above embodiments. Alternatively, the susceptor may be any conductor that can be sprayed or any vapor that is deposited on the material that forms the support, in some embodiments of any of the above embodiments.

[0066] In one embodiment of any of the above embodiments, the support is a reusable substrate and step (f) is performed by a consumer prior to use of the consumable. In one embodiment of any of the above embodiments, the method comprises: (h) the further step of drying the aerosol-forming material using a heat source; Step (b) includes applying the aerosol-forming material to the medium in a solvent form, and step (h) is performed after step (b) and before step (c).

[0067] In one of the above embodiments, the heat source is a dielectric heat source. In some embodiments, the heat source is a microwave radiation source, and the microwave radiation has a frequency of about 915 MHz or 2.45 GHz. In some embodiments, the heat source is a radio frequency heat source.

[0068] In one embodiment of any of the above embodiments, step (h) includes passing the medium and the aerosol-generating material through a longitudinally extending zone in which the medium and the aerosol-generating material are heated by a dielectric heat source.

[0069] In one embodiment of any of the above embodiments, the heat source is at least one of a magnetic field generator and a susceptor.

[0070] In one embodiment of any of the above embodiments, the medium includes a susceptor, and step (h) includes passing the medium and the aerosol-generating material through a longitudinally extending alternating magnetic field and heating the susceptor sufficiently to dry the aerosol-generating material.

[0071] In one embodiment of any of the above embodiments, the medium includes a susceptor, and step (h) includes sequentially passing the medium and the aerosol-generating material through a plurality of alternating magnetic fields and repeatedly heating the susceptor sufficiently to dry the aerosol-generating material.

[0072] In one embodiment of any of the above embodiments, the heat source is at least one magnetic field generator and at least one susceptor that is not connected to the medium and the aerosol-generating material, hi some embodiments, the susceptor extends longitudinally and the medium and the aerosol-generating material pass through a zone along the length of the susceptor that is heated by the susceptor.

[0073] In one embodiment of any of the above embodiments, the heat source is a thermal radiation source. In some embodiments, the thermal radiation source extends in a longitudinal direction, and step (h) includes passing the medium and the aerosol-forming material along a path such that the medium and the aerosol-forming material are exposed to the thermal radiation source.

[0074] In one embodiment of any of the above embodiments, the heat source is a heated material. In some embodiments, the heated material extends in a longitudinal direction, and step (h) includes passing the medium and the aerosol-generating material along, in contact with, or near the heated material.

[0075] In one embodiment of any of the above embodiments, step (h) further includes monitoring a temperature of the aerosol-generating material and preventing heating of the aerosol-generating material above a predetermined maximum temperature, which may be a temperature below which the aerosol-generating material will aerosolize.

[0076] In one embodiment of any of the above embodiments, the method steps are performed in the order (a), (b), (e), (f), (c), and (d), or in the order (a), (b), (f), (e), (c), and (d). In such an embodiment, the configuration of the medium and aerosol-generating material for storage is a configuration during which the medium and aerosol-generating material are associated with the support. This allows for storage of the medium, aerosol-generating material, and support in a form close to or ready for sale to a consumer of the consumable product.

[0077] According to a second aspect of the present disclosure, there is provided an article of manufacture for use in the manufacture of a consumable for use with a non-combustible aerosol delivery device, the article comprising a medium and an aerosol-generating material; the aerosol-generating material is supported on a surface of the medium; the medium and the aerosol-generating material are configured for storage; The medium can be separated into portions of desired size.

[0078] In one embodiment of any of the above embodiments, the medium is a longitudinally extending material and the storage arrangement of the medium and aerosol-generating material is in a roll or bellows shape.

[0079] In one embodiment of any of the above embodiments, two or more separate portions of aerosol-forming material are supported on a surface of the medium.

[0080] In one embodiment of any of the above embodiments, at least two of the separate portions of aerosol-forming material are formed from aerosol-forming materials having different compositions from one another.

[0081] In one embodiment of any of the above embodiments, the aerosol-forming material is comprised of two or more layers of aerosol-forming material.

[0082] In one embodiment of any of the above embodiments, the product further comprises a protective sheet, the protective sheet being laid over the medium and the aerosol-forming material, and when the product is in a storage configuration with the layers of the carrier overlying one another, the protective sheet is between the layers of the carrier.

[0083] In one embodiment of any of the above embodiments, the protective sheet includes one or more apertures extending therethrough.

[0084] In one embodiment of any of the above embodiments, the number of apertures is the same as the number of separate portions of aerosol-generating material, and when the protective sheet is laid over the medium and the aerosol-generating material, the configuration and location of the apertures coincide with at least a portion of each separate portion of the aerosol-generating material.

[0085] In one embodiment of any of the above embodiments, the medium has first and second opposing surfaces; the first surface and the aerosol-generating material are adhered to one another with a first adhesive strength; the second surface and the aerosol-generating material are adhered to one another with a second adhesive strength; The first adhesive strength is greater than the second adhesive strength; The aerosol-forming material is applied to a first surface of the medium.

[0086] In one embodiment of any of the above embodiments, the support includes a susceptor.

[0087] In one embodiment of any of the above embodiments, the support is a laminate and at least one layer of the laminate is a susceptor.

[0088] In one embodiment of any of the above embodiments, the susceptor is one of a metal, a metal foil, or a metal film.

[0089] According to a third aspect of the present disclosure, there is provided a consumable for use with a non-combustible aerosol delivery device, the consumable comprising at least a portion of a product according to the second aspect of the present disclosure.

[0090] In one embodiment of any of the above embodiments, the consumable further comprises a support, at least one portion of the product being supported on the support.

[0091] In one embodiment of any of the above embodiments, at least one portion of the product is attached to the support using one or more of adhesive, at least one element that fastens a portion of the product portion to the support, or insertion of a portion of the product portion into a slot in the support.

[0092] In one embodiment of any of the above embodiments, the consumable includes at least one portion from each of at least two products according to the third aspect of the present disclosure, each product supporting an aerosol-generating material of a different composition than the composition of the aerosol-generating material supported on the other product.

[0093] In one embodiment of any of the above embodiments, a plurality of different portions of the product are arranged in a pattern on the support, and the position of each portion of the product within the pattern indicates the composition of the aerosol-generating material supported on each portion of the product.

[0094] In one embodiment of any of the above embodiments, the support includes a susceptor.

[0095] In one embodiment of any of the above embodiments, the support is a laminate and at least one layer of the laminate is a susceptor.

[0096] In one embodiment of any of the above embodiments, the susceptor is one of a metal, a metal foil, or a metal film.

[0097] In one embodiment of any of the above embodiments, the aerosol-forming material is in the form of an aerosol-forming film or an aerosolizable gel.

[0098] According to a fourth aspect of the present disclosure, there is provided a kit for making a consumable comprising one or more portions of the product of the second aspect of the present disclosure and a support. In some embodiments, the support is reusable in that while the medium and aerosol-generating material are associated with the support, the material from which the support is formed is not damaged by aerosolization of the aerosol-generating material.

[0099] In one embodiment of any of the above embodiments, the aerosol forming material includes an active agent.

[0100] As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. An active substance may be selected from, for example, dietary supplements, nootropics, psychoactive substances. An active substance may be naturally derived or synthetically obtained. An active substance may include, for example, nicotine, caffeine, taurine, non-cannabinoid derived terpenes, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. An active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance.

[0101] The active substance may include one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0102] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0103] The active material may comprise or be derived from one or more botanical materials, or components, derivatives, or extracts thereof. As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, the material may comprise synthetically obtained active compounds naturally occurring in the botanical material. The material may be in the form of a liquid, gas, solid, powder, fine powder, ground particles, granules, pellets, pieces, strips, sheets, etc. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, bell pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, kavi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arvensis, Grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), Peppermint (Mentha piperita), Lime mint (Mentha piperita citrata cv), Chocolate mint (Mentha piperita cv), Curly mint (Mentha spicata crispa), Wild mint (Mentha cardifolia), Horse mint (Mentha longifolia), Pineapple mint (Mentha suaveolens variegata), Pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and Apple mint (Mentha suaveolens).

[0104] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substance is tobacco.

[0105] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0106] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0107] In some embodiments, the aerosol-forming material comprises a fragrance or flavoring.

[0108] As used herein, the terms "flavor" and "flavoring agent" refer to materials that may be used, where local regulations permit, to create a desired taste, odor, or other somatosensory sensation in products intended for adult consumers.These materials may be naturally derived flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, etc.) citrus, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus, drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-yi Orchid, sage, fennel, wasabi, pimenta, ginger, coriander, coffee, hemp, oil of any species of mint from the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.The materials may be replicas, synthetic or natural ingredients, or mixtures thereof. The materials may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

[0109] In some embodiments, the flavor comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavor comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises a flavor component extracted from tobacco. In some embodiments, the flavor comprises a flavor component extracted from cannabis.

[0110] In some embodiments, the flavorings may include sensory elicitors intended to achieve somatosensory sensations that are typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and may include agents that provide heating, cooling, tingling, and anesthetic effects. Suitable heat effect agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucalyptol, WS-3.

[0111] The aerosol generating material includes an aerosol generating agent. In some embodiments, the aerosol generating agent can include one or more components capable of forming an aerosol. In some embodiments, the aerosol generating agent can include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In certain examples, the aerosol generating agent includes glycerol.

[0112] In some embodiments, the aerosol generating agent comprises one or more of polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butylene glycol, 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.

[0113] In some embodiments, the aerosol-generating material may comprise from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10% to about 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of the aerosol-generating agent (all calculated on a dry weight basis). The aerosol-generating agent may act as a plasticizer. For example, the aerosol-generating material may comprise from 0.5 to 40 wt%, from 3 to 35 wt%, or from 10 to 25 wt% of the aerosol-generating agent.

[0114] In some embodiments, the aerosol-generating material may comprise from about 5 wt%, 10 wt%, 20 wt%, 25 wt%, 27 wt%, or 30 wt% to about 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of the aerosol-generating agent (DWB). For example, the aerosol-generating material may comprise from 10 to 60 wt%, 20 to 50 wt%, 25 to 40 wt%, or 30 to 35 wt% of the aerosol-generating agent.

[0115] In some embodiments, the aerosol-forming material may include up to about 80 wt% aerosol-generating agent (DWB), such as about 40-80 wt%, 40-75 wt%, 50-70 wt%, or 55-65 wt%.

[0116] The aerosol-generating material may also include a gelling agent. In some embodiments, the gelling agent includes a hydrocolloid. In some embodiments, the gelling agent includes one or more compounds selected from the group including alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohols, and combinations thereof. For example, in some embodiments, the gelling agent includes one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the gelling agent includes alginates and / or pectins, which may be combined with a solidifying agent (such as a calcium source) during formation of the aerosol-generating material. In some cases, the aerosol-generating material may include calcium cross-linked alginic acid and / or calcium cross-linked pectin.

[0117] 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.

[0118] In some embodiments, the cellulosic gelling agent is selected from the group consisting of hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0119] In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia gum.

[0120] 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, alginic acid, and combinations thereof. In preferred embodiments, the non-cellulose based gelling agent is alginic acid or agar.

[0121] In some embodiments, the gelling agent comprises alginic acid, and the alginic acid is present in the aerosol-forming material in an amount of 10-30 wt % (calculated on a dry weight basis) of the aerosol-forming material. In some embodiments, the alginic acid is the only gelling agent present in the aerosol-forming material. In other embodiments, the gelling agent comprises alginic acid and at least one additional gelling agent, such as pectin.

[0122] In some embodiments, the aerosol-forming material comprises from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of gelling agent (all calculated on a dry weight basis). For example, the aerosol-forming material may comprise from 1 to 50 wt%, 5 to 45 wt%, 10 to 40 wt%, or 20 to 35 wt% of gelling agent.

[0123] In some embodiments, the aerosol-forming material comprises from about 20 wt%, 22 wt%, 24 wt%, or 25 wt% to about 30 wt%, 32 wt%, or 35 wt% of the gelling agent (all calculated on a dry weight basis). For example, the aerosol-forming material may comprise from 20 to 35 wt%, or from 25 to 30 wt% of the gelling agent.

[0124] In some cases, the aerosol-forming material may include from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, or 20 wt% to about 60 wt%, 50 wt%, 40 wt%, 30 wt%, or 25 wt% of the gelling agent (DWB). For example, the aerosol-forming material may include from 10 to 40 wt%, 15 to 30 wt%, or 20 to 25 wt% of the gelling agent (DWB).

[0125] In examples, the aerosol-generating material comprises the gelling agent and the bulking agent in an amount, combined, of about 10 wt%, 20 wt%, 25 wt%, 30 wt%, or 35 wt% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the aerosol-generating material. In examples, the aerosol-generating material comprises the gelling agent and the bulking agent in an amount, combined, of about 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt% of the aerosol-generating material.

[0126] In examples, the aerosol-generating material comprises gelling agent in an amount of about 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, or 35 wt% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the aerosol-generating material (i.e., not taking into account the amount of filler). In examples, the aerosol-generating material comprises gelling agent in an amount of about 5-60 wt%, 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt% of the aerosol-generating material (i.e., not taking into account the amount of filler).

[0127] In some examples, the alginic acid is included in the gelling agent in an amount of about 5-40 wt %, or 15-40 wt %, of the aerosol-generating material. That is, the aerosol-generating material includes alginic acid in an amount of about 5-40 wt %, or 15-40 wt %, by dry weight of the aerosol-generating material. In some examples, the aerosol-generating material includes alginic acid in an amount of about 20-40 wt %, or about 15 wt % to 35 wt %, of the aerosol-generating material.

[0128] In some examples, the pectin is included in the gelling agent in an amount of about 3-15 wt % of the aerosol-forming material, i.e., the aerosol-forming material comprises pectin in an amount of about 3-15 wt % by dry weight of the aerosol-forming material, in some examples, the aerosol-forming material comprises pectin in an amount of about 5-10 wt % of the aerosol-forming material.

[0129] In some examples, the guar gum is included in the gelling agent in an amount of about 3-40 wt% of the aerosol-generating material. That is, the aerosol-generating material includes guar gum in an amount of about 3-40 wt% by dry weight of the aerosol-generating material. In some examples, the aerosol-generating material includes guar gum in an amount of about 5-10 wt% of the aerosol-generating material. In some examples, the aerosol-generating material includes guar gum in an amount of about 15-40 wt%, or about 20-40 wt%, or about 15-35 wt% of the aerosol-generating material.

[0130] In examples, the alginic acid is present in an amount of at least about 50 wt% of the gelling agent. In examples, the aerosol-forming material includes alginic acid and pectin, and the ratio of alginic acid to pectin is 1:1 to 10:1. The ratio of alginic acid to pectin is typically >1:1, i.e., alginic acid is present in an amount greater than the amount of pectin. In examples, the ratio of alginic acid to pectin is about 2:1 to 8:1, or about 3:1 to 6:1, or approximately 4:1.

[0131] The aerosol-forming material can be formed by (a) forming a slurry including components of the aerosol material or its precursor, (b) forming a layer of the slurry, (c) solidifying the slurry to form a gel, and (d) drying to form the aerosol-forming material.

[0132] (b) Forming the layer of the slurry typically involves spraying, casting, or extruding the slurry. In an example, the slurry layer is formed by electrostatically spraying the slurry. In an example, the slurry layer is formed by casting the slurry.

[0133] In some instances, (b) and / or (c) and / or (d) are performed at least partially simultaneously (e.g., during electrostatic spraying). In some instances, (b), (c) and (d) are performed sequentially.

[0134] In some instances, the slurry is applied to a substrate and a layer can be formed on the substrate.

[0135] In an example, the slurry includes a gelling agent, an aerosol former material, and an active agent. The slurry can include these components in any of the ratios provided herein for the composition of the aerosol-generating material. For example, the slurry can include (on a dry weight basis): a gelling agent and optionally a filler, the gelling agent and the filler together amounting to about 10-60 wt % of the slurry; comprising an aerosol former material in an amount of about 40-80 wt% of the slurry; Optionally, the active material may be included in an amount of up to about 20 wt% of the slurry.

[0136] Solidifying the gel (c) can include providing a solidifying agent to the slurry. For example, the slurry can include sodium alginate, potassium alginate, ammonium alginate as gel precursors, and a solidifying agent including a calcium source (such as calcium chloride) can be added to the slurry to form a calcium alginate gel.

[0137] In examples, the solidifying agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or combinations thereof. In some examples, the solidifying agent comprises or consists of calcium formate and / or calcium lactate. In particular examples, the solidifying agent comprises or consists of calcium formate. The inventors have determined that using calcium formate as the solidifying agent typically results in aerosol-generating materials having higher tensile strength and higher resistance to elongation.

[0138] The total amount of solidifying agent, such as a calcium source, may be 0.5 to 5 wt % (calculated on a dry weight basis). Suitably, the total amount may be from about 1 wt %, 2.5 wt % or 4 wt % to about 4.8 wt % or 4.5 wt %. The inventors have found that adding too little solidifying agent may result in an aerosol-generating material that does not stabilize the aerosol-generating material components, such that these components fall off the aerosol-generating material. The inventors have found that adding too much solidifying agent may result in an aerosol-generating material that is very sticky and therefore difficult to handle.

[0139] When the aerosol-forming material does not contain tobacco, a larger amount of solidifying agent may need to be applied. Thus, in some cases, the total amount of solidifying agent may be from 0.5 to 12 wt%, such as from 5 to 10 wt%, calculated on a dry weight basis. Suitably, the total amount may be from about 5 wt%, 6 wt%, or 7 wt% to about 12 wt% or 10 wt%. In this case, the aerosol-forming material will typically not contain tobacco.

[0140] In an example, providing the solidifying agent to the slurry includes spraying the solidifying agent onto the slurry, such as onto a top surface of the slurry.

[0141] Alginates are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) linked by (1,4)-glycosidic bonds to form a polysaccharide. In addition to calcium cations, alginic acid crosslinks to form a gel. Alginates with high G monomer content have been found to form gels more readily upon addition of a calcium source. Thus, in some cases, the gel precursor may include alginate, where at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginic acid copolymer are α-L-guluronic acid (G) units.

[0142] In examples, drying (d) removes from about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% to about 80 wt%, 90 wt%, or 95 wt% (WWB) of the water in the slurry.

[0143] In examples, drying (d) reduces the thickness of the cast material by at least 80%, preferably 85% or 87%. For example, the slurry is cast at a thickness of 2 mm and the resulting dried aerosol-generating material has a thickness of 0.2 mm.

[0144] In some examples, the slurry solvent consists essentially of or consists of water, hi some examples, the slurry comprises about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% solvent (WWB).

[0145] In instances where the solvent comprises water, the dry weight content of the slurry can match the dry weight content of the aerosol-forming material, and thus, any discussion herein relating to solids compositions is expressly disclosed in conjunction with the slurry aspects of the invention.

[0146] The aerosol-forming material may include a flavoring. Suitably, the aerosol-forming material may include up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% flavoring. In some cases, the aerosol-forming material may include at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% flavoring (all calculated on a dry weight basis). For example, the aerosol-forming material may include 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% flavoring. In some cases, the flavoring consists essentially of or consists of menthol.

[0147] The aerosol-forming material may include a bulking agent.

[0148] In some embodiments, the aerosol-forming material contains less than 60 wt% filler, such as between 1 wt% and 60 wt%, or between 5 wt% and 50 wt%, or between 5 wt% and 30 wt%, or between 10 wt% and 20 wt%.

[0149] In other embodiments, the aerosol-forming material contains less than 20 wt%, preferably less than 10 wt% or less than 5 wt% of a filler. In some cases, the aerosol-forming material contains less than 1 wt% of a filler, and in some cases, no filler.

[0150] In some such cases, the aerosol-forming material comprises at least 1 wt% filler, e.g., at least 5 wt%, at least 10 wt%, at least 20 wt%, at least 30 wt%, at least 40 wt%, or at least 50 wt% filler, hi some embodiments, the aerosol-forming material comprises between 5 and 25 wt% filler.

[0151] When present, the filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, 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, hydroxypropylcellulose, and carboxymethylcellulose (CMC). In certain cases, the aerosol-generating material does not include calcium carbonate, such as chalk.

[0152] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fiber, cellulose or a cellulose derivative (such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)).

[0153] Without wishing to be bound by theory, it is believed that the inclusion of fibrous fillers within the aerosol-generating material can increase the tensile strength of the material, which can be particularly advantageous in instances where the aerosol-generating material is provided as a sheet, such as when the sheet surrounds a rod of aerosolizable material.

[0154] In some embodiments, the aerosol-forming material does not include tobacco fibers, hi certain embodiments, the aerosol-forming material does not include fibrous materials.

[0155] The aerosol-generating materials may include one or more active agents and / or flavorings, one or more aerosol former materials, and optionally one or more other functional materials.

[0156] In some embodiments, the aerosol-forming material further comprises an active agent. For example, in some cases, the aerosol-forming material further comprises tobacco material and / or nicotine. In some embodiments, the aerosol-forming material comprises powdered tobacco and / or nicotine and / or a tobacco extract.

[0157] In some cases, the aerosol-forming material may comprise between 5 and 60 wt% (calculated on a dry weight basis) of tobacco material and / or nicotine. In some cases, the aerosol-forming material may comprise between about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of an active substance. In some cases, the aerosol-forming material may comprise between about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of tobacco material. For example, the aerosol-forming material may include 10-50 wt%, 15-40 wt%, or 20-35 wt% tobacco material. In some cases, the aerosol-forming material may include about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% nicotine (calculated on a dry weight basis). For example, the aerosol-forming material may include 1-20 wt%, 2-18 wt%, or 3-12 wt% nicotine.

[0158] In some cases, the aerosol-generating material includes an active agent such as a tobacco extract. In some cases, the aerosol-generating material may include 5-60 wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the aerosol-generating material may include about 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of tobacco extract. For example, the aerosol-generating material may include 10-50 wt%, 15-40 wt%, or 20-35 wt% of tobacco extract. The tobacco extract may contain nicotine in a concentration such that the aerosol-forming material contains from 1 wt%, 1.5 wt%, 2 wt%, or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt%, or 4 wt% nicotine (calculated on a dry weight basis). In some cases, there may be no nicotine present in the aerosol-forming material other than that resulting from the tobacco extract.

[0159] In some embodiments, the aerosol-forming material does not include tobacco material and does include nicotine. In some such cases, the aerosol-forming material may include from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% nicotine (calculated on a dry weight basis). For example, the aerosol-forming material may include from 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% nicotine.

[0160] In some cases, the total content of actives and / or fragrances may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or fragrances may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0161] In some cases, the total content of tobacco material, nicotine and flavorings may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or flavorings may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0162] The aerosol-generating composition may include one or more active agents. In examples, the aerosol-generating material includes, for example, up to about 20 wt% of the aerosol-generating material of the one or more active agents. In examples, the aerosol-generating material includes the active agents in an amount of about 1 wt%, 5 wt%, 10 wt%, or 15 wt% to about 20 wt%, 15 wt%, 15 wt%, or 5 wt% of the aerosol-generating material.

[0163] Active substances can include physiologically and / or olfactory active substances that are included in the aerosol generating composition to achieve a physiological and / or olfactory response.

[0164] The tobacco material may be present in the aerosol-forming composition in an amount of about 50-95 wt%, or about 60-90 wt%, or about 70-90 wt%, or about 75-85 wt%.

[0165] The tobacco material may be present in any form, but is typically shredded (e.g., shredded). The shredded tobacco material can advantageously be mixed with the aerosol-forming material to provide an aerosol-forming composition having a uniform distribution of the tobacco material and aerosol-forming material throughout the aerosol-forming composition.

[0166] In examples, the tobacco material comprises one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extract. Surprisingly, the inventors have determined that it is possible to use relatively large amounts of laminar tobacco in an aerosol-generating composition and still provide an acceptable aerosol when heated by a non-combustion aerosol delivery system. Laminar tobacco typically provides superior organoleptic properties. In examples, the tobacco material comprises laminar tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material. In certain examples, the tobacco material comprises shredded tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material.

[0167] The tobacco used to make the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia and / or Burley and / or Orient varieties.

[0168] In some embodiments, the one or more other functional ingredients can include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0169] In some cases, the aerosol-forming material may further include an emulsifier that emulsifies the molten flavoring during manufacture. For example, the aerosol-forming material may include about 5 wt% to about 15 wt%, preferably about 10 wt%, of an emulsifier (calculated on a dry weight basis). The emulsifier may include gum acacia.

[0170] In some embodiments, the aerosol-forming material is a hydrogel and contains less than about 20 wt% water, calculated on a wet weight basis. In some cases, the hydrogel may contain less than about 15 wt%, 12 wt%, or 10 wt% water, calculated on a wet weight basis. In some cases, the hydrogel may contain at least about 1 wt%, 2 wt%, or at least about 5 wt% water (WWB).

[0171] The aerosol-forming material can have any suitable water content, such as from 1 wt% to 15 wt%. Preferably, the water content of the aerosol-forming material is from about 5 wt%, 7 wt%, or 9 wt% to about 15 wt%, 13 wt%, or 11 wt% (WWB), most preferably about 10 wt%. The water content of the aerosol-forming material can be determined, for example, by Karl Fischer titration or gas chromatography with thermal conductivity detection (GC-TCD).

[0172] In some cases, the aerosol-forming material may consist essentially of or consist of a gelling agent, water, an aerosol-forming agent, a flavoring agent, and optionally an active agent.

[0173] In some cases, the aerosol-forming materials may consist essentially of or consist of a gelling agent, water, an aerosol-forming agent, flavorings, and optionally tobacco materials and / or a nicotine source.

[0174] In examples, the aerosol-forming material may consist essentially of or consist of a gelling agent, an aerosol-forming agent, an active agent, and water. In examples, the aerosol-forming material consists essentially of or consists of a gelling agent, an aerosol-forming agent, and water.

[0175] In instances, the aerosol-forming material does not include a flavorant, and in certain instances, the aerosol-forming material does not include an active agent.

[0176] In some embodiments, the aerosol-forming material comprises: 1-60 wt% of a gelling agent; 0.1 to 50 wt. % of an aerosol generating agent, and 0.1-80wt% fragrance, and these weights are calculated on a dry weight basis.

[0177] In some embodiments, the aerosol-forming material comprises 1-80 wt% flavoring (on a dry weight basis).

[0178] In some embodiments, the aerosol-forming material comprises: 1-50 wt% of a gelling agent; 0.1 to 50 wt. % of an aerosol generating agent, and 30-60wt% fragrance, and these weights are calculated on a dry weight basis.

[0179] In an alternative embodiment of the aerosol-forming material, the aerosol-forming material comprises an aerosol-forming material, the aerosol-forming material comprising: 1-60 wt% of a gelling agent; 5-60 wt. % of an aerosol generating agent, and 10-60 wt% tobacco extract, and these weights are calculated on a dry weight basis.

[0180] In some embodiments, the aerosol-forming material comprises: 1-60 wt% of a gelling agent; 20-60 wt. % of an aerosol generating agent, and 10-60 wt% tobacco extract, and these weights are calculated on a dry weight basis.

[0181] In some embodiments, the aerosol-forming material comprises 20-35 wt% gelling agent, 10-25 wt% aerosol former material, 5-25 wt% filler including fibers, and 35-50 wt% flavoring and / or active agent.

[0182] In some cases, the aerosol-forming materials may consist essentially of or consist of a gelling agent, an aerosol-forming agent, a tobacco extract, water, and optionally a flavoring. In some cases, the aerosol-forming materials may consist essentially of or consist of glycerol, alginic acid and / or pectin, a tobacco extract, and water.

[0183] In some embodiments, the aerosol generating material can have a composition (DWB) of a gelling agent (preferably including alginic acid) in an amount of about 5 wt% to about 40 wt%, or about 10 wt% to 30 wt%, or about 15 wt% to about 25 wt%, a tobacco extract in an amount of about 30 wt% to about 60 wt%, or about 40 wt% to 55 wt%, or about 45 wt% to about 50 wt%, and an aerosol generating agent (preferably including glycerol) in an amount of about 10 wt% to about 50 wt%, or about 20 wt% to about 40 wt%, or about 25 wt% to about 35 wt% (DWB).

[0184] In one embodiment, the aerosol forming material comprises about 20 wt% alginate gelling agent, about 48 wt% Virginia tobacco extract, and about 32 wt% glycerol (DWB).

[0185] The "thickness" of an aerosol-generating material describes the shortest distance between a first surface and a second surface. In embodiments in which 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 that is opposite the first planar surface of the sheet.

[0186] In some cases, the layer of aerosol-generating material that forms the aerosol has a thickness of from about 0.015 mm to about 1.5 mm, preferably from about 0.05 mm to about 1.5 mm or 0.05 mm to about 1.0 mm. Preferably, the thickness may be in the range of from about 0.1 mm or 0.15 mm to about 1.0 mm, 0.5 mm or 0.3 mm.

[0187] In some cases, the aerosol-forming material may have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

[0188] Materials having a thickness of 0.2 mm are particularly suitable. The aerosol-generating material may have two or more layers, and the thicknesses mentioned herein refer to the aggregate thicknesses of these layers.

[0189] It has been found that if the aerosol-generating material is too thick, the heating efficiency is compromised, which has a negative impact on power consumption during use. Conversely, aerosol-generating materials can be difficult to manufacture and handle, and very thin materials can be more difficult to cast and can be fragile, impairing aerosol formation during use.

[0190] The thicknesses defined herein are the average thickness of the material. In some cases, the thickness of the aerosol-generating material may vary by 25%, 20%, 15%, 10%, 5%, or 1% or less.

[0191] In some examples, the aerosol-generating material in sheet form may have a tensile strength of about 200 N / m to about 900 N / m. In some examples, such as when the aerosol does not include a filler, the aerosol-generating material may have a tensile strength of 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or about 250 N / m.

[0192] Such tensile strength may be particularly suitable for embodiments in which the aerosol-generating material is formed as a sheet, which is then torn and incorporated into the aerosol-generating article. In some instances, such as when the aerosol-generating material includes a filler, the aerosol-generating material may have a tensile strength of 600 N / m to 900 N / m, or 700 N / m to 900 N / m, or about 800 N / m. Such tensile strength may be particularly suitable for embodiments in which the aerosol-generating material is included in the aerosol-generating article / assembly as a rolled sheet, preferably in the form of a tube.

[0193] In some examples, the aerosol generating material in sheet form may have a tensile strength of about 200 N / m to about 2600 N / m. In some examples, the aerosol generating material may have a tensile strength of 600 N / m to 2000 N / m, or 700 N / m to 1500 N / m, or about 1000 N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol generating material comprising the aerosol generating material is formed as a sheet and incorporated into an aerosol generating consumable.

[0194] The aerosol-generating material, including the aerosol-generating material, has a density of 30 to 120 g / m 2 In some cases, the sheet may have any suitable areal density of 80 to 120 g / m 2 , or about 70 to 110 g / m 2 , or in particular about 90 to 110 g / m 2 or preferably about 100 g / m 2 (having a density similar to that of cut rag tobacco, so that mixtures of these materials do not easily separate). In some cases, the sheets may have a mass per unit area of ​​about 30 to 70 g / m 2 , 40~60g / m 2 , or 25 to 60 g / m 2 and may be used to encase aerosolizable material such as tobacco.

[0195] All weight percentages (expressed by wt%) described herein are calculated on a dry weight basis unless expressly indicated otherwise. All weight ratios are also calculated on a dry weight basis. Weights quoted on a dry weight basis refer to the entire extract or slurry or material, other than water, and may include components that are themselves liquids at room temperature and pressure, such as glycerol. Conversely, weight percentages quoted on a wet weight basis refer to all components, including water.

[0196] The aerosol-generating material may include a colorant. The addition of a colorant may change the visual appearance of the aerosol-generating material. The presence of a colorant in the aerosol-generating material may enhance the visual appearance of the aerosol-generating material. By adding a colorant to the aerosol-generating material, the aerosol-generating material may match in color to other components of the article that includes the aerosol-generating material.

[0197] A wide variety of colorants may be used depending on the desired color of the aerosol-generating material. The color of the aerosol-generating material may be, for example, white, green, red, purple, blue, brown, or black. Other colors are contemplated. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food grade colorants, and pharmaceutical grade colorants. In some embodiments, the colorant is caramel, which may impart a brown appearance to the aerosol-generating material. In such embodiments, the color of the aerosol-generating material may resemble the color of other components in the aerosol generation, such as the tobacco material.

[0198] The colorant can be incorporated into the aerosol-generating material during its formation (e.g., when forming a slurry with the materials that form the aerosol-generating material) or can be applied to the aerosol-generating material after its formation (e.g., by spraying it onto the aerosol-generating material).

[0199] In some embodiments of any of the above embodiments, talcum powder, calcium carbonate powder, or other powder is applied to an exposed surface of at least one distinct portion of the aerosol-generating material, which may reduce the level of tackiness or adhesiveness of the aerosol-generating material.

[0200] In the following discussion of the accompanying drawings, where the same element is present in more than one embodiment, the same reference number is used throughout for that element, and where similar elements are present, like reference numbers (the same number plus a multiple of 100) are used.

[0201] 1, an aerosol delivery device 2 includes 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.

[0202] The heating chamber 8 defines an opening or mouth 12 at a first end of the heating chamber 8. At an opposing end of the heating chamber 8 is an aperture 14. The aperture 14 is in fluid communication with a mouthpiece 16 via a conduit 18.

[0203] Also located within the casing 4 is a controller 20 in electronic communication with the heater 10 and controlling the functioning of the heater 10. The controller 20 may include a memory (not shown) capable of storing one or more tables relating to the operation of the heater 10. The heater 10 and the 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 suitable power sources.

[0204] The aerosol delivery device 2 is suitable for use with a consumable 24. The consumable 24 is comprised of one or more separate portions of an aerosol-generating material 32 supported on a first surface 28 of the consumable 24. The separate portions of the aerosol-generating material 32 are supported on the surface 28 in a square grid pattern. Other non-illustrated embodiments of the consumable 24 can include more or fewer separate portions of the aerosol-generating material 32 than shown in FIG. 1, including a single portion of the aerosol-generating material 32, and these portions can be distributed on the surface 28 in any pattern. The separate portions of the aerosol-generating material 32 are shown in FIG. 1 as having a generally circular shape, but may be other shapes in other embodiments. Examples of how to make or manufacture the consumable 24 are described below.

[0205] With reference to Figure 2, to begin fabrication of the consumable 24, a medium 30 is provided. The medium 30 comprises a longitudinally extending sheet of flexible material, and in the embodiment shown, the medium is a sheet of aluminum foil 34. In other non-illustrated embodiments, the material can be another suitable material, such as paper. The length and width of the medium 30 as shown in Figure 2 are for illustrative purposes only. The medium 30 can have different lengths and widths without departing from the scope of the present disclosure.

[0206] 2 is first surface 36 and the major surface not visible is second surface 38. In this embodiment, first surface 36 of foil 34 is formed or treated to have surface properties such that first surface 36 provides an aerosol-generating material applied to first surface 36 with a higher peel stress and adhesive strength than an aerosol-generating material applied to second surface 38.

[0207] In other embodiments, the second surface 38 of the foil 34 is formed or treated to have surface characteristics such that the second surface 38 causes an aerosol-generating material applied to the second surface 38 to have a lower peel stress and adhesive strength than an aerosol-generating material applied to the first surface 36.

[0208] 3 and 4, a plurality of separate portions (for clarity, only three portions are labeled) of aerosol-generating material 32 are applied to a first surface 36 of a foil 34. In FIG. 3, thirty portions of aerosol-generating material 32 are shown, arranged in a square grid pattern on the first surface 36 of the foil 34. In other non-illustrated embodiments, the number of portions of aerosol-generating material 32 applied to the surface of the medium 30, and the pattern in which they are arranged, may vary.

[0209] The portions of the aerosol-generating material 32 are applied to the first surface 36 of the foil 34 as a slurry of aerosol-generating material using known aerosol-generating material application techniques, such as extruding the aerosol-generating material slurry from multiple nozzles (not shown). In some embodiments (not shown), multiple layers of the aerosol-generating material slurry are applied to the same locations on the first surface 36 of the foil 34. The portions of the aerosol-generating material 32 are then dried or allowed to dry. Drying of the portions of the aerosol-generating material 32 is discussed further below. One or more of the portions of the aerosol-generating material 32 can have a different composition relative to at least one other of the portions of the aerosol-generating material 32.

[0210] 5, after the portion of aerosol-generating material 32 has dried, an edge 40 of the foil 34 is inserted into a longitudinal slot 42 that extends axially along the bobbin 44. The foil 34 is wrapped around the bobbin 44 in a loose coil. The foil 34 is wrapped around the bobbin such that the portion of the aerosol-generating material 32 faces radially inward on the coil. This results in a blank outer surface of the coil, protecting the portion of the aerosol-generating material 32 attached to the portion of the medium that constitutes the outer surface of the coil from abrasion, for example, by the foil 34. In other embodiments, the foil may be wrapped around the bobbin 44 such that the portion of the aerosol-generating material 32 faces radially outward.

[0211] Here, the coil of foil 34 and the portion of aerosol-generating material 32 can be stored until needed. The storage period can be at least 1 hour, at least 12 hours, at least 1 day, at least 1 week, or at least 1 month. The location of the coil can vary in that the coil can be made at a first manufacturing facility and then transported to a second manufacturing facility for further processing if desired.

[0212] When it is desired to make the consumable 24, the coil of foil 34 and the portion of aerosol-generating material 32 are unwound. As a result of the treatment of the first surface 36 of the foil 34, even if a portion of the aerosol-generating material 32 contacts the second surface 38 of the foil 34 during storage of the coil, the portion of the aerosol-generating material 32 will remain adhered to the first surface 36 of the coil upon unwinding of the coil, rather than moving away from the first surface 36 and adhering to the second surface 38.

[0213] 6, the foil 34 is cut into foil portions 46 using a standard blade (not shown). Each foil portion 46 carries a predetermined number of portions of aerosol-generating material 32 on its surface. In the example shown, this is six portions of aerosol-generating material 32. The number of portions of aerosol-generating material 32 may be different in different embodiments.

[0214] The foil portion 46 is cut to an asymmetric shape that allows the orientation of the foil portion 46 to be controlled, if necessary. In FIG. 6, the asymmetry is created by the removal of a corner 48 of the foil portion 46. Other asymmetries may 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 makes up one or more of the portions of the 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 makes up one or more of the portions of the aerosol-generating material 32 on that foil portion by referencing the positions of those portions relative to a predetermined point or position indicated by the asymmetry.

[0215] 7, to form the consumable 24, the foil portion 46 is attached to the support 50. In this embodiment, the support 50 is formed from card and has a higher rigidity than the foil portion 46. The attachment of the foil portion 46 may be by the use of an adhesive. The support 50 is generally rectangular with corners 52 cut off to introduce asymmetry. The asymmetry is introduced in the support 50 for the same reasons as discussed in relation to the foil portion 46. The support 50 is dimensioned to make it suitable for use in the aerosol delivery device 2 of FIG. 1. In other, not shown, embodiments, the foil portion 46 is attached to the support 50 by using at least one element that clamps a portion of the foil portion 46 to the support 50 or by inserting a portion of the foil portion 46 into a slot in the support 50.

[0216] 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.

[0217] In some embodiments of the aerosol delivery device 2, the aerosol delivery device includes a resistive heater as a heat source. In such embodiments, the consumable 24 is disposed proximate to the resistive heater, and depending on the size of the resistive heater and the relative placement of the resistive heater and the consumable 24, one or more portions of the aerosol-generating material 32 will generate an aerosol.

[0218] In an alternative embodiment of the aerosol delivery device 2, the aerosol delivery device includes a magnetic field generator that combines with a susceptor to provide a heat source. The foil 34 of the foil portion 46 acts as a susceptor and thus, depending on the size of the magnetic field generated by the magnetic field generator and the relative placement of the consumable 24, causes heating of one or more portions of the aerosol-generating material 32 to generate an aerosol.

[0219] In an alternative embodiment that can be illustrated by Figures 2-6, the medium 30 is formed from a sheet of material that does not function as a susceptor, such as a sheet of paper 34. The embodiment is the same as that described above, except that portion 46 is a paper portion rather than a foil portion.

[0220] To create the consumable 24 using the paper portion 46, the paper portion 46 is attached to a support 50. If the consumable 24 is to be used with a heat source or aerosol generator that includes a magnetic field generator and a susceptor, the material for the support 50 can be selected to include or consist of a susceptor. The susceptor can be, for example, a metal foil or film, such as an aluminum foil or film. The support can be a laminate and the susceptor can be a layer in the laminate.

[0221] 8 and 9, there is shown a cross-sectional view of a medium 30 supporting multiple portions of an aerosol-generating material 32. The medium 30 takes the form of a sheet of aluminum foil 34. The foil 34 has first and second major surfaces 36 and 38. In FIG. 4, the portions of the 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 shown in FIGs. 8 and 9, neither the first nor second surfaces 36, 38 of the foil 34 need to be surface treated.

[0222] Once the portion of aerosol-generating material 32 is dry, a protective sheet 54 is laid over the first surface 36 of the foil 34 and the portion of aerosol-generating material 32. The protective sheet is formed from a material to which the portion of aerosol-generating material 32 will not adhere or that will adhere to the portion of aerosol-generating material 32 with a lower peel stress than exists between the portion of aerosol-generating material 32 and the first surface 36 of the foil 34.

[0223] To reconstitute the medium 30 into a storage configuration, the edge 40 of the foil 34 and the edge 56 of the protective sheet 54 are inserted into the longitudinal slot 42 that extends axially along the bobbin 44. The foil 34 and the protective sheet 54 are wrapped around the bobbin 44 into a loose coil. The foil 34 and the protective sheet 54 are wrapped around the bobbin 44 such that the portion of the aerosol-generating material 32 faces radially inward in the coil. This results in a blank outer surface of the coil, and the portions of the aerosol-generating material 32 attached to the portions of the foil that make up the outer surface of the coil are protected from abrasion by, for example, the foil 34.

[0224] In other embodiments, the foil 34 and protective sheet 54 may be wrapped around the bobbin 44 such that the portion of the aerosol-forming material 32 faces radially outward in the coil. In these embodiments, the protective sheet 54 protects the portion of the aerosol-forming material 32 on the outer surface of the coil.

[0225] 5, the coil of foil 34 and the portion of aerosol-generating material 32 can now be stored until needed. The location of the coil can be varied in that the coil can be made at a first manufacturing facility and then transported to a second manufacturing facility for further processing if desired.

[0226] When it is desired to make the consumable 24, the foil 34, protective sheet 54, and coil of portions of aerosol-forming material 32 are unwound and used as described above in connection with FIGS.

[0227] 10, in some embodiments, the protective sheet 54 includes one or more apertures 55 extending therethrough. The number of apertures 55 is the same as the number of distinct portions of the aerosol-generating material 32, and when the protective sheet 55 is laid down over the foil 34 and the aerosol-generating material 32, the configuration and location of the apertures 55 correspond to each distinct portion of the aerosol-generating material 52. When the protective sheet 54 is laid down over the foil 34, dashed lines 57 connect the corners that come into contact with each other. The medium 30 can then be used in the same format as the medium 30 shown in FIGS. 8 and 9.

[0228] In some embodiments (not shown), one or more of the apertures 55 is smaller in the plane of the foil 34 than the portion of the aerosol-generating material 32 it corresponds to.

[0229] 11 and 12, a medium 130 is provided. The medium 130 comprises a longitudinally extending sheet of material, and in the embodiment shown, the medium 130 is a sheet of aluminum foil 134. In other non-illustrated embodiments, the material can be another suitable material, such as paper. The length and width of the medium 130 as shown in FIG. 11 are for illustrative purposes only. The medium 130 can have different lengths and widths without departing from the scope of the present disclosure.

[0230] The foil 134 has first and second major surfaces, the surface shown in FIG. 11 is first surface 136 and the major surface not visible is second surface 138.

[0231] A plurality of separate portions (for clarity, only three portions are labeled) of aerosol-generating material 32 are applied to a first surface 136 of the foil 134. In Figure 11, thirty portions of aerosol-generating material 32 are shown, arranged in a square grid pattern on the first surface 136 of the foil 134. In other non-illustrated embodiments, the number of portions of aerosol-generating material 32 applied to the surface of the medium 130 and the pattern in which they are arranged may vary.

[0232] Portions of the aerosol-generating material 32 are applied to the first surface 136 of the foil 134 using known aerosol-generating material application techniques, such as extruding the aerosol-generating material from multiple nozzles (not shown). In some embodiments (not shown), multiple layers of the aerosol-generating material are applied to the same location on the surface 36 of the foil 134.

[0233] The foil 134 is perforated by perforations 158. The perforations 158 extend substantially perpendicular to the longitudinal axis of the media 130 / foil 134 and define a plurality of panels 146 of the foil 134.

[0234] The longitudinal location of the perforation 158 along the foil 134 is determined by two factors. The first factor is the relative location of the portions of the aerosol-generating material 32 longitudinally on either side of the perforation 158. When the foil 134 is folded with the fold lines aligned with the perforation 158, it is desirable that the portions of the aerosol-generating material 32 on the panel 146 on either side of the perforation 158 not overlap each other.

[0235] The second factor is that when the consumable 24 is to be produced, the perforations 158 are used to split the media 130 into a plurality of separated panels 146. Thus, the spacing of the perforations 158 will determine the dimensions of the separated panels 146.

[0236] The portions of aerosol-forming material 32 are then dried or allowed to dry. Drying the portions of aerosol-forming material 32 is discussed further below.

[0237] 13 and 14, to configure the medium 130 / foil 134 and portions of aerosol-generating material 32 into a storage configuration, the foil 134 is folded into an accordion configuration by folding the foil 134 at each perforation 158. To form the accordion shape, the folding at the perforations 158 alternates between folding the first surfaces 136 of the panels 146 on either side of the fold perforation 158 toward one another and folding these first surfaces away from one another. In FIG. 13, the medium 130 is in the process of being folded, and in FIG. 14, the medium 130 is fully folded.

[0238] 15 and 16, a further embodiment of a method of manufacturing a consumable product according to the present disclosure includes providing a portion of a first medium and aerosol-generating material 232 and a portion of a second medium and aerosol-generating material 332. Each of these portions of medium and aerosol-generating material are prepared as described in one of the embodiments described with respect to Figures 2-14. The difference between the portions of aerosol-generating material 232, 332 is that the compositions of the aerosol-generating materials 232, 332 are different in that the aerosol generated from aerosol-generating material 232 has a first flavoring and the aerosol generated from aerosol-generating material 332 has a second flavoring.

[0239] 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 removed from each foil portion 246. The foil portions 346 of the second media are identified by a notch 348 removed from the edge of each foil portion 346.

[0240] The consumable 124 is created by attaching one foil portion 246 from the first medium and one foil portion 346 from the second medium to a support 150. Attachment is performed using an adhesive. The resulting consumable 124 includes six portions of aerosol-generating material 232 having a first flavoring and six portions of aerosol-generating material 332 having a second flavoring.

[0241] 17, which shows a cross-sectional view through an alternative medium 430. Medium 430 is a laminate including a first layer 460 and a second layer 462.

[0242] The first layer 460 is a metal foil or film, in the example shown in Figure 17, an aluminum foil or film. Because layer 460 is not required to have the structural properties required to be possessed by foils 34 and 134, particularly strength and resistance to damage, layer 460 can be thinner than the foils 34 or 134 discussed in the embodiments discussed above.

[0243] The second layer 462 is a structural layer and is required to provide the media 430 with the necessary strength and resistance to damage to enable it to be handled and stored in a storage configuration. The second layer 462 may be of a material suitable for forming a substrate. The second layer 462 may be or include, for example, paper, card, corrugated board, cardboard, recycled materials, plastic materials, ceramic materials, composite materials, or glass.

[0244] Medium 430 can be used in the same manner as medium 30 or 130 described above.

[0245] The portions of aerosol-generating material 32, 232, 332 are applied to the medium 30, 130 in the form of a slurry in embodiments of the present disclosure. Once applied to the medium, the slurry is required to dry or be allowed to dry before the medium can be configured into a storage configuration. The medium could simply be allowed to dry over time, but such an approach makes the preparation of the medium and portions of aerosol-generating material 32, 232, 332 inefficient.

[0246] To make the creation of the portions of medium and 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, the drying system includes a stage 70 adapted to support the portions of medium and aerosol-generating material 32, 232, 234 (collectively designated as medium and material 72) as they travel in a direction 74 across a surface of the stage 70. The portions of aerosol-generating material 32, 232, 332 are disposed on a surface of the medium that is not in contact with the stage 70.

[0247] A heat source 76 is spaced above the platform 70. The heat source 76 is spaced from the platform 70 a sufficient distance to allow the medium and material 72 to pass between the platform 70 and the heat source 76 without contact between the medium and material 72 and the heat source. A temperature sensor 78 measures the temperature of the medium and material as it passes between the platform 70 and the heat source 76. The temperature sensor 78 controls the heat source 76 to prevent the medium and material 72 from exceeding a predetermined temperature.

[0248] 18, the heat source 76 is a dielectric heat source. In one embodiment, the dielectric heat source is a microwave radiation source having a frequency of about 915 MHz or 2.45 GHz. In an alternative embodiment, the heat source is a radio frequency heat source. The electromagnetic waves for the dielectric heat source 76 cause heating of the slurry and promote evaporation of solvent from the slurry as the medium and material 72 pass between the heat source 76 and the stage 70.

[0249] 18, the heat source 76 is a thermal radiation source. In one embodiment, the heat 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 medium and material 72 passes between the heat source 76 and the platform 70.

[0250] 19, the second drying system includes a platform 170 adapted to support portions of the medium and aerosol-generating material 32, 232, 234 (collectively designated as medium and material 72) as they travel in a direction 74 across a surface of the platform 170. The portions of the aerosol-generating material 32, 232, 332 are disposed on a surface of the medium that is not in contact with the platform 170.

[0251] The platform 70 includes a heated material in the form of a resistively heated hot plate 176. The media and materials 72 pass over the hot plate 176 and are thereby heated. This heating causes the slurry to heat up and promotes evaporation of the solvent from the slurry. A temperature sensor 78 measures the temperature of the media and materials 72 as they exit through the hot plate 176. The temperature sensor 78 controls the hot plate 176 to prevent the media and materials 72 from exceeding a predetermined temperature.

[0252] 20, a third drying system includes a platform 270 adapted to support portions of the medium and aerosol-generating material 32, 232, 234 (collectively designated as medium and material 72) as they travel in direction 74 across a surface of the platform 270. Portions of the aerosol-generating material 32, 232, 332 are disposed on a surface of the medium that is not in contact with the platform 270.

[0253] The pedestal 270 includes a susceptor 280. Proximate to the pedestal 270 is a magnetic field generator 276 that generates an alternating magnetic field. The alternating magnetic field causes the susceptor 280 to have an elevated temperature relative to the temperature of the surroundings. The medium and material 72 passes over the susceptor 280 and is thereby heated. This heating causes the slurry to heat up and promotes evaporation of the solvent from the slurry. A temperature sensor 78 measures the temperature of the medium and material 72 as it exits through the susceptor 280. The temperature sensor 78 controls the magnetic field generator 276 to prevent the medium and material 72 from exceeding a predetermined temperature.

[0254] The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. It is understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably include, consist of, or essentially consist of suitable combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, the present disclosure may include other inventions not claimed herein but which may be claimed in the future.

Claims

1. A method of manufacturing a consumable for use with a non-combustible aerosol supply device, each consumable including a portion of a medium onto which an aerosol generating material is applied, the method comprising: (a) providing a medium; (b) applying an aerosol generating material to the surface of the medium; (c) configuring the medium and the aerosol generating material for storage; (d) storing the medium and the aerosol generating material; (e) separating the medium and the aerosol generating material into portions of a desired dimension; A method comprising the steps of.

2. The method further comprises: (f) further associating at least one portion of the medium and the aerosol generating material with a support. The method according to claim 1.

3. The medium provided in step (a) is a longitudinally extending material, step (b) is performed before step (c), and the storage configuration of step (c) forms the medium and the aerosol generating material in a roll or bellows shape. The method according to claim 1 or 2.

4. The method further comprises: (g) laying a protective sheet over the medium and the aerosol generating material. Step (g) is performed after step (b) and before step (c). The method according to claim 1 or 2.

5. Step (a) includes selecting or creating a medium having first and second opposing surfaces, the first surface and the aerosol generating material adhere to each other with a first adhesion strength, the second surface and the aerosol generating material adhere to each other with a second adhesion strength, the first adhesion strength is greater than the second adhesion strength, In step (b), the aerosol generating material is applied to the first surface of the medium. The method according to claim 1 or 2.

6. The association in step (f) uses one or more of an adhesive, at least one element that clamps a part of the portion of the medium to the support, or insertion of a part of the portion of the medium into a slot, to attach at least one portion of the medium and the aerosol generating material to the support. The method according to claim 2.

7. The medium includes a susceptor. The method according to claim 1 or 2.

8. The support includes a susceptor. The method according to claim 2.

9. The method further comprises: including a further step of drying the aerosol-forming material using a heat source, The method according to claim 1 or 2, wherein step (b) includes applying the aerosol-forming material to the medium in solvent form, and step (h) is carried out after step (b) and before step (c).

10. The method according to claim 9, wherein the heat source is at least one magnetic field generator and a susceptor.

11. The method according to claim 10, wherein the medium includes a susceptor, and step (h) includes passing an alternating magnetic field extending in the longitudinal direction through the medium and the aerosol-forming material, and heating the susceptor sufficiently to dry the aerosol-forming material.

12. The method according to claim 10, wherein the medium includes a susceptor, and step (h) includes sequentially passing a plurality of alternating magnetic fields through the medium and the aerosol-forming material, and repeatedly heating the susceptor sufficiently to dry the aerosol-forming material.

13. The method according to claim 9, wherein step (h) further includes monitoring the temperature of the aerosol-forming material and preventing heating of the aerosol-forming material that exceeds a predetermined maximum temperature.

14. A product for use in the manufacture of a consumable for use with a non-combustible aerosol supply device, the product including a medium and an aerosol-forming material, the aerosol-forming material being supported on the surface of the medium, the medium and the aerosol-forming material being configured for storage, the medium being separable into portions of a desired dimension.

15. The product according to claim 14, wherein the medium is a longitudinally extending medium, and the storage configuration of the medium and the aerosol-forming material is in a roll shape or a bellows shape.

16. The product according to claim 14 or 15, wherein the product further includes a protective sheet, and the protective sheet is laid on the medium and the aerosol-forming material.

17. the medium having first and second opposing surfaces, the first surface and the aerosol-forming material being adhered to each other with a first adhesion strength, the second surface and the aerosol-forming material being adhered to each other with a second adhesion strength, the first adhesion strength being greater than the second adhesion strength, the aerosol-forming material being applied to the first surface of the medium.

18. The product according to claim 14 or 15, wherein the support includes a susceptor.

19. A consumable for use with an apparatus for heating an aerosol-forming material to volatilize at least one constituent of the aerosol-forming material, the consumable including at least one part of the product according to claim 14.

20. A kit for producing a consumable comprising one or more parts of the product according to claim 14 or 15 and a support.

21. An aerosol supply device for use with the consumable according to claim 19, the device comprising a heater assembly configured to heat at least a portion of the aerosol-forming material supported on the consumable.

22. An aerosol supply system comprising the aerosol supply device according to claim 21 and the consumable according to claim 19.

23. A method of generating an aerosol using an aerosol-generating device in which at least one aerosol generator is disposed to heat the consumable according to claim 19 without burning the consumable during use, wherein the at least one aerosol generator is a resistive heating element or a magnetic field generator and a susceptor.

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