Consumables for use with aerosol delivery devices - Patent application

Abstract

A method is provided for making an article (2) for use in manufacturing an article for use in a non-combustible aerosol delivery system. The article (2) comprises an aerosol-forming material (20) and a carrier (4). The carrier (4) includes a base layer (6) and a carrier layer (8), the carrier layer (8) being releasably attached to the base layer (6). The method includes the steps of (a) providing a carrier (4), (b) applying an aerosol-forming material (20) to a support surface (10) of the carrier layer (8) of the carrier (4), and (c) configuring the carrier (4) and aerosol-forming material (20) for storage.

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 and products for making such consumables, methods for manufacturing consumables for use with aerosol delivery devices and products for manufacturing such consumables, and aerosol delivery systems including the 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, typically 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 a product for use in the manufacture of 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 product comprising an aerosol-generating material and a carrier, the carrier comprising a base layer and a carrier layer, the carrier layer releasably attached to the base layer, The method is: (a) providing a carrier; (b) applying an aerosol-generating material slurry to a support surface of a carrier layer of a carrier; (c) configuring the carrier and the aerosol-forming material for storage; 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-generating material to volatilize at least one component of the aerosol-generating material, the article of manufacture comprising an aerosol-generating material and a carrier; the carrier includes a base layer and a carrier layer; The carrier layer is releasably attached to the base layer; At least one distinct portion of the aerosol-forming material is supported on a support surface of a carrier layer of the carrier.

[0007] According to a third aspect of the present disclosure, there is provided a method of making a consumable for use with an apparatus for heating an aerosol-generating material, the method comprising: (i) providing at least one product according to the second aspect of the present disclosure; (ii) peeling at least a portion of the carrier layer from the base layer of the at least one product; Includes.

[0008] According to a fourth aspect of the present disclosure, there is provided an aerosol delivery device for use with a consumable made according to the third 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.

[0009] According to a fifth aspect of the present disclosure, there is provided an aerosol delivery system comprising an aerosol delivery device and a consumable made according to the third aspect of the present disclosure.

[0010] According to a sixth aspect of the present disclosure, there is provided a method of generating aerosol from a consumable made according to the third 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, the at least one aerosol generator being a resistive heater element or a magnetic field generator and a susceptor.

[0011] 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]

[0012] [Figure 1] 1 is a schematic diagram of a representative portion of a first embodiment of a product according to the present disclosure during manufacture. [Diagram 2] FIG. 2 is a development view of a portion of FIG. [Diagram 3] FIG. 2 is a further schematic view of a portion of FIG. [Figure 4] 1 is a schematic diagram of a first embodiment of a product according to the present disclosure. [Diagram 5] FIG. 5 is a second schematic diagram of the product of FIG. 4. [Figure 6] FIG. 5 is a schematic diagram of a consumable from the product of FIG. [Figure 7] FIG. 7 is a schematic diagram of an aerosol delivery device for use with the consumable of FIG. [Figure 8] 1 is a schematic diagram of a representative portion of a first embodiment of a product according to the present disclosure during manufacture. [Figure 9] FIG. 9 is a further schematic view of a portion of FIG. 8. [Figure 10] FIG. 2 is a schematic side view of a second embodiment of a product according to the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] (Detailed Description) Consumables herein may alternatively be referred to as articles.

[0014] In some embodiments, the consumable comprises an aerosol-generating material. The consumable can include an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, an aerosol modifier, one or more active components, one or more flavorings, one or more aerosol former materials, and / or one or more other functional materials.

[0015] The device for heating the aerosol-forming material used with the consumable is part of a non-combustion aerosol delivery system that releases compounds from the aerosol-forming material without burning the aerosol-forming material, such as e-cigarettes, tobacco heating products, and mixing systems for generating aerosols using combinations of aerosol-forming materials.

[0016] 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 the substance to be delivered to a user.

[0017] In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as a powered non-combustible aerosol delivery system.

[0018] 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.

[0019] 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.

[0020] 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.

[0021] 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.

[0022] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, 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.

[0023] 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.

[0024] According to a first aspect of the present disclosure, there is provided a method of manufacturing an article for use in the manufacture of 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 article comprising an aerosol-generating material and a carrier, the carrier comprising a base layer and a carrier layer, the carrier layer releasably attached to the base layer, the method comprising: (a) providing a carrier; (b) applying an aerosol-generating material to a surface of a carrier layer of the carrier; (c) configuring the carrier and the aerosol-forming material for storage; Includes.

[0025] In one of the above embodiments, the application of the aerosol-forming material in step (b) is the application of a slurry of the aerosol-forming material.

[0026] In one of the above embodiments, the method includes the further step of allowing or causing the aerosol-generating material slurry to solidify into an aerosol-generating material, which step occurs between steps (b) and (c). In some embodiments, the aerosol-generating material slurry solidifies into an aerosol-generating material in the form of an aerosol-generating film.

[0027] 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.

[0028] 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.

[0029] The aerosol-generating material may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a delivery substance and / or a 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.

[0030] 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.

[0031] 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.

[0032] The aerosol-generating film can be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-forming agent, and one or more other ingredients, such as 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.

[0033] The slurry can be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent.

[0034] 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.

[0035] The amorphous solid may be substantially free of plant material.The amorphous solid may be substantially free of tobacco.

[0036] In one embodiment of any of the above embodiments, the application of the aerosol-forming material in step (b) is the application of discrete portions of the aerosol-forming material.

[0037] In one embodiment of any of the above embodiments, there are at least two separate portions of aerosol-generating material, and the at least two separate portions of aerosol-generating material have 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.

[0038] In one embodiment of any of the above embodiments, there are three or more separate portions of aerosol-forming material, and the separate portions are applied to the surface of the carrier layer in a grid pattern.

[0039] In one embodiment of any of the above embodiments, one or more of the discrete portions of aerosol-generating material applied in step (b) are in the shape of a substantially circular longitudinally extending stripe, a stripe including at least one curve or corner, or a tessellated shape in the plane of the support surface of the carrier layer.

[0040] In one embodiment of any of the above embodiments, at least one separate portion of aerosol-generating material applied in step (b) is of a shape and / or color indicative of the composition of the aerosol-generating material forming the separate portion.

[0041] 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.

[0042] In one embodiment of any of the above embodiments, the releasable attachment of the carrier layer to the base layer includes the use of an adhesive, which allows the carrier layer to be peeled away from the base layer, hi some embodiments, the adhesive is a pressure adhesive.

[0043] In one embodiment of any of the above embodiments, the carrier layer comprises a sheet material, the sheet material comprising at least one of paper, card, a plastic material, or a metal material, hi some embodiments, the carrier comprises a sheet material that is not susceptible to damage due to bending of the material.

[0044] In one embodiment of any of the above embodiments, the support surface of the carrier layer is one of the major or largest surfaces of the carrier layer, and the other of the major surfaces of the carrier layer is the surface that is adhered to the base layer.

[0045] In one embodiment of any of the above embodiments, the method includes the further step of (d) introducing at least one separation line into at least a portion of the carrier, each separation line being a predetermined line along which at least a portion of the carrier will separate or tear.

[0046] The introduction of at least one separation line has the advantage that the separation or tearing is more controlled than in the case of a separation or tearing of a part of the carrier layer that does not include a separation line. More controlled is understood to mean that when the carrier layer is separated by tearing, the tearing of the carrier layer follows the separation line. This is in contrast to tearing a part of the carrier layer where no separation line is present, where the tear line would be expected to follow a line of weakness in the carrier layer or to reflect the shape and magnitude of the force applied to the carrier layer that causes the tearing.

[0047] In one embodiment of any of the above embodiments, the at least one separation line is a predetermined line along which the carrier layer will separate or tear.

[0048] In one embodiment of any of the above embodiments, the one or more separation lines are positioned such that the carrier layer can be separated along at least one separation line into at least two portions of a predetermined size and shape. In some embodiments, the at least two portions of a predetermined size and shape are all the same size and shape. In some other embodiments, the at least two portions of a predetermined size and shape are of different predetermined sizes and / or shapes.

[0049] In one embodiment of any of the above embodiments, the at least one separation line of step (d) comprises a perforation. In some embodiments, the perforation extends only through the carrier layer. In some embodiments, the perforation extends through the carrier layer and the base layer. In some embodiments, the perforation extends from the support surface into the carrier layer but not through the entire carrier layer.

[0050] In one embodiment of any of the above embodiments, the at least one separation line of step (d) comprises a cut line. In some embodiments, the cut line may be a cut that extends the entire depth of the carrier layer. In some embodiments, the cut line may be a cut that extends from the support surface into the carrier layer but does not pass entirely through the carrier layer.

[0051] In one embodiment of any of the above embodiments, the cut lines are formed using a kiss cut technique.

[0052] In one embodiment of any of the above embodiments, at least one separation line extends between at least two separate portions of the aerosol-generating material or between at least two locations to which separate portions of the aerosol-generating material will be applied in step (b).

[0053] In one embodiment of any of the above embodiments, at least a portion of the at least one separation line extends through the aerosol-generating material applied to the carrier layer or the location where the aerosol-generating material will be applied in step (b).

[0054] In one embodiment of any of the above embodiments, the carrier is a sheet of material and the configuring of step (c) includes stacking two or more sheets of the carrier into a pile.

[0055] In one embodiment of any of the above embodiments, the carrier is a longitudinally extending sheet of material, and configuring step (c) includes forming at least one fold line in the carrier and then folding the carrier about at least one of the fold lines.

[0056] In one embodiment of any of the above embodiments, the fold line corresponds to the separation line.

[0057] In one embodiment of any of the above embodiments, the carrier is accordion-folded.

[0058] In one embodiment of any of the above embodiments, the forming of step (c) includes forming the carrier into a roll.

[0059] In one embodiment of any of the above embodiments, the carrier is wound around a core, hi some embodiments, the core is a spool, bobbin, or other structure that supports the carrier and around which the carrier can be wound.

[0060] In one embodiment of any of the above embodiments, the method comprises: (e) disposing a sheet of a barrier material over the support surface of the carrier layer and the aerosol-forming material, where step (e) is performed before step (c).

[0061] In some embodiments, the barrier material is one to which the aerosol-generating material may only weakly adhere, if at all, to the barrier material For purposes of this disclosure, adhesion to a barrier material may be considered weak if the aerosol-generating material that is adhered to the barrier material and supported on the support surface of the carrier layer is more strongly attached to the support surface of the carrier layer than it adheres to the barrier material.

[0062] 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-generating material to volatilize at least one component of the aerosol-generating material, the article of manufacture comprising an aerosol-generating material and a carrier; the carrier includes a base layer and a carrier layer; a carrier layer releasably attached to the base layer; At least one distinct portion of the aerosol-forming material is supported on the support surface of the carrier layer.

[0063] In one embodiment of any of the above embodiments, the aerosol-forming material is an aerosol-forming film.

[0064] In one embodiment of any of the above embodiments, there are at least two distinct portions of aerosol-forming material, and the at least two distinct portions of aerosol-forming material have different compositions from one another.

[0065] In one embodiment of any of the above embodiments, there are three or more separate portions of aerosol-forming material, and the separate portions are applied to the support surface of the carrier layer in a grid pattern.

[0066] In one embodiment of any of the above embodiments, one or more of the separate portions of aerosol-generating material are shaped as substantially circular longitudinally extending stripes, stripes including at least one curve or corner, or tessellated in the plane of the support surface of the carrier layer.

[0067] In one embodiment of any of the above embodiments, at least one separate portion of aerosol-forming material is of a shape and / or color indicative of the composition of the aerosol-forming material forming the separate portion.

[0068] In one embodiment of any of the above embodiments, the releasable attachment of the carrier layer to the base layer includes the use of an adhesive, which allows the carrier layer to be peeled away from the base layer, hi some embodiments, the adhesive is a pressure adhesive.

[0069] In one embodiment of any of the above embodiments, the carrier layer comprises an adhesive-backed sheet material, the sheet material comprising at least one of paper, card, a plastic material, or a metal material.

[0070] In one embodiment of any of the above embodiments, the carrier includes at least one separation line, each separation line being a predetermined line along which at least a portion of the carrier will separate or tear.

[0071] In one embodiment of any of the above embodiments, the at least one separation line is a predetermined line along which the carrier layer will separate or tear.

[0072] In one embodiment of any of the above embodiments, the at least one separation line includes a perforation.

[0073] In one embodiment of any of the above embodiments, the at least one separation line includes a cut line.

[0074] In one embodiment of any of the above embodiments, at least one cut line is the result of a kiss cut.

[0075] In one embodiment of any of the above embodiments, at least one separation line extends between at least two separate portions of aerosol-forming material.

[0076] In one embodiment of any of the above embodiments, at least a portion of the at least one separation line extends through the aerosol-forming material applied to the carrier layer.

[0077] In one embodiment of any of the above embodiments, the carrier is a sheet material.

[0078] In one embodiment of any of the above embodiments, the carrier is a longitudinally extending sheet of material, the carrier includes at least one fold line, and the carrier is folded about at least one of the fold lines.

[0079] In one embodiment of any of the above embodiments, the fold line corresponds to the separation line.

[0080] In one embodiment of any of the above embodiments, the carrier is accordion-folded.

[0081] In one embodiment of any of the above embodiments, the carrier is wound into a roll.

[0082] In one embodiment of any of the above embodiments, the roll of carrier is wrapped around a core.

[0083] In one embodiment of any of the above embodiments, the product further comprises a sheet of barrier material disposed over the carrier layer and the aerosol-forming material.

[0084] In one embodiment of any of the above embodiments, the adhesive that bonds the carrier layer to the base layer may be a pressure adhesive.

[0085] In one embodiment of any of the above embodiments, the surfaces of the base layer and carrier layer that are adhered to one another are such that when the carrier layer is peeled or removed from the base layer, all or at least 95% by weight of the adhesive remains on the base. According to a third aspect of the present disclosure, there is provided a method of making a consumable for use with an apparatus for heating an aerosol-generating material, the method comprising: (i) providing at least one product according to the second aspect of the present disclosure; (ii) peeling at least a portion of the carrier layer from the base layer of the at least one product; Including, Separate portions of the carrier layer support the aerosol-generating material. In some embodiments, separate portions of the carrier support two or more separate portions of the aerosol-generating material. In some embodiments, two or more dots of the aerosol-generating film.

[0086] The separate portions of the carrier layer can be used in conjunction with an appropriately configured aerosol generating device, and thus the separate portions of the carrier film can be understood to be consumables.

[0087] According to a fourth aspect of the present disclosure, there is provided an aerosol delivery device for use with a consumable made according to the third aspect of the present disclosure, the device comprising an aerosol generator configured to heat at least a portion of an aerosol-generating material supported on the consumable.

[0088] In one embodiment of any of the above embodiments, the aerosol generator comprises a heatable plate adapted to support a consumable made according to the third aspect of the disclosure. In some embodiments, the heatable plate is configured to receive and hold separate portions of the carrier layer. In some embodiments, the heatable plate is adapted to heat different portions of the separate portions of the carrier layer at different times. In some embodiments, the arrangement of the aerosol generating material on the surfaces of the separate portions of the carrier layer corresponds to the arrangement of the separately heatable portions of the heater plate.

[0089] In one embodiment of any of the above embodiments, the aerosol forming material includes an active agent.

[0090] 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.

[0091] The active substance may include one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0092] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0093] 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).

[0094] 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.

[0095] 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.

[0096] 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.

[0097] In some embodiments, the aerosol-forming material comprises a fragrance or flavoring.

[0098] 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.

[0099] 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.

[0100] 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.

[0101] 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 may be in the form of, for example, a solid, liquid, or gel, and may or may not contain active substances and / or flavorings.

[0102] The aerosol-generating material includes an aerosol forming agent.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] 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.

[0107] 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%.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] 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.

[0114] 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.

[0115] 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.

[0116] 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).

[0117] 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.

[0118] 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).

[0119] 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.

[0120] 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.

[0121] 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.

[0122] 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.

[0123] 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.

[0124] (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.

[0125] 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.

[0126] In some instances, the slurry is applied to a substrate and a layer can be formed on the substrate.

[0127] 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.

[0128] 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. 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.

[0129] 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.

[0130] 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.

[0131] 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.

[0132] 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.

[0133] 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.

[0134] 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.

[0135] 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).

[0136] 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.

[0137] 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.

[0138] The aerosol-forming material may include a bulking agent.

[0139] 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%.

[0140] 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.

[0141] 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.

[0142] 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.

[0143] 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)).

[0144] 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.

[0145] In some embodiments, the aerosol-forming material does not include tobacco fibers, hi certain embodiments, the aerosol-forming material does not include fibrous materials.

[0146] 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.

[0147] 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.

[0148] 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.

[0149] 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.

[0150] 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.

[0151] 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).

[0152] 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).

[0153] 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.

[0154] 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.

[0155] 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%.

[0156] 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.

[0157] 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.

[0158] 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.

[0159] 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.

[0160] 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.

[0161] 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).

[0162] 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).

[0163] 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.

[0164] 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.

[0165] 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.

[0166] 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.

[0167] In some embodiments, the aerosol-forming material comprises an aerosol-forming material, the aerosol-forming material comprising: 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.

[0168] In some embodiments, the aerosol-forming material comprises 1-80 wt% flavoring (on a dry weight basis).

[0169] 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.

[0170] In an alternative embodiment of the aerosol-forming material, the aerosol-forming material comprises: 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.

[0171] 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.

[0172] 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.

[0173] 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.

[0174] 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).

[0175] 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).

[0176] 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.

[0177] 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.

[0178] 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.

[0179] 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.

[0180] It has been found that if an aerosol-generating material or aerosol generating material is too thick, the heating efficiency is compromised, which has a negative impact on power consumption during use. Conversely, if an aerosol-generating material or aerosol generating material is too thin, it may be difficult to manufacture and handle, very thin materials may be more difficult to cast, may be prone to breakage, and may impair aerosol formation during use.

[0181] 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.

[0182] 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.

[0183] 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.

[0184] 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.

[0185] 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.

[0186] 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.

[0187] 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 improve the visual appearance of the aerosol-generating material and the aerosol-generating material. By adding a colorant to the aerosol-generating material, the aerosol-generating material may match the color of other components of the aerosol-generating material or the article that includes the aerosol-generating material.

[0188] 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 (such as tobacco material) in the aerosol-generating material that comprises the aerosol-generating material. In some embodiments, the addition of a colorant to the aerosol-generating material makes it visually indistinguishable from other components within the aerosol-generating material.

[0189] 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).

[0190] 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.

[0191] 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.

[0192] 1 and 2, to begin creating the product 2, a carrier 4 is provided. The carrier 4 extends in a longitudinal direction, and a representative portion of the carrier 4 is shown in FIGS. 1-3. The carrier 4 is comprised of a base layer 6 and a carrier layer 8. The base layer 6 comprises paper, and the carrier layer 8 comprises a thin card. In other non-illustrated examples, the carrier layer may comprise paper, a plastic material, or a metal material.

[0193] The carrier layer 8 has a support surface 10 and a carrier adhesive surface 12. The base layer 6 has a base adhesive surface 14 and a base surface 15. The carrier layer 8 and the base layer 6 are adhered to one another by an adhesive (not shown) which acts on the carrier and base adhesive surfaces 12, 14. The adhesive is a releasable adhesive, and the properties of each of the carrier and base adhesive surfaces 12, 14 are such that when the carrier layer 8 and the base layer 6 are peeled or peeled away from one another, the adhesive remains on the base adhesive surface 14 and is released from the carrier adhesive surface 12.

[0194] The length and width of the carrier 4 as shown in Figures 1-6 are for example purposes only. The carrier 4 can have different lengths and widths without departing from the scope of the present disclosure.

[0195] A plurality of separation lines 16, 18 are introduced into the carrier layer 8 before the carrier layer 8 is bonded to the base layer 6. The separation lines 16 are perforations that extend longitudinally along the carrier layer 8. The separation lines 18 are perforations that extend in a direction generally perpendicular to the longitudinal direction and are generally uniformly spaced longitudinally along the carrier layer 8. The perforations in each of the perforations 16, 18 are such that a tear that begins at an end of the perforation 16, 18 will tend to follow the perforation until the tear ends or the end of the perforation is reached.

[0196] The perforations 16, 18 divide the support surface 10 of the carrier layer 8 into a plurality of partial areas 22 (for clarity, not all partial areas 22 are labeled in all drawings). In the example shown, each of the partial areas 22 is the same size and shape. In other non-shown examples of the present disclosure, the partial areas may not all be the same size and / or shape.

[0197] Once the carrier layer 8 is adhered to the base layer 6, a plurality of dots of aerosol-generating material slurry 20 (for clarity, not all dots of slurry 20 are labeled) are applied to the support surface 10 of the carrier layer 8, as shown in Figure 3. The dots of slurry 20 are arranged in a square grid pattern on the support surface 10, such that six dots of slurry are supported on the support surface 10 in each sub-area 22. The relationship between the arrangement of the dots of slurry 20 and the perforations 16, 18 is such that, for each sub-area 22, the dots of slurry 20 in that sub-area are in the same location relative to the edge of that sub-area as in the other sub-areas.

[0198] Once the dots of slurry 20 are applied to the carrier layer 8, time is allowed to allow the dots of slurry to solidify and form dots of aerosol-generating film 20 A. Alternatively and / or in addition, the carrier 4 is subjected to conditions, such as heat and / or a low humidity environment, which reduces the time it takes for the dots of slurry 20 to solidify.

[0199] 4, once the dots of slurry 20 have solidified into aerosol-generating film dots 20A, the carrier 4 and aerosol-generating film dots 20A form the product 2. The carrier 4 is wrapped around a core 22 to form a roll, configuring the product 2 for storage, where it can be stored until needed.

[0200] 5, when it is desired to use the product 2 to make one or more consumable products, the roll of carrier 4 is partially unwound so that one or more partial areas 22 are accessible to a user. The user can then peel at least one partial area 22 from the base layer 6. During the peeling of the partial area, the perforations 16, 18 bordering the partial area 22 are torn, leaving the unpeeled partial area adhered to the base layer 6.

[0201] Once the partial area 22 is peeled away, the user has a portion 24 of the carrier layer 8, as shown in Figure 6. The portion 24 of the carrier layer 8 may be used as a consumable 26 for use with an aerosol delivery device 30.

[0202] 7, aerosol delivery device 30 includes a casing 32 within which is located a heater assembly 34. Heater assembly 34 is comprised of a heating chamber 36 and a heater 38. Heater 38 can be an electrical resistance heater, or a magnetic field generator and susceptor.

[0203] The heating chamber 36 defines an opening or mouth 40 at a first end of the heating chamber 36. At an opposing end of the heating chamber 36 is an aperture 42. The aperture 42 is in fluid communication with a mouthpiece 46 via a conduit 44.

[0204] Also located within the casing 32 is a controller 48 in electronic communication with and controlling the function of the heater 38. The controller 48 may include a memory (not shown) that may store one or more tables relating to the operation of the heater 38. The heater 38 and the controller 48 are powered by a power source 50. The power source 50 is a rechargeable battery. In other embodiments, the power source may be another suitable power source.

[0205] In an alternative embodiment of the present disclosure, and referring to Figure 8, a carrier layer 108 is provided. The carrier layer 108 comprises a metal foil, such as aluminum foil. The carrier layer 108 has a support surface 110 and a carrier bonding surface 112. A plurality of dots of aerosol-generating material slurry 20 (for clarity, not all dots of slurry 20 are labeled) are applied to the support surface 110 of the carrier layer 108. The dots of slurry 20 are disposed on the support 110 in a square grid pattern.

[0206] Once the dots of slurry 20 are applied to the carrier layer 108, time is allowed to allow the dots of slurry to solidify and form dots of aerosol-generating film 20 A. Alternatively and / or in addition, the carrier layer 108 is subjected to conditions, such as heat and / or a low humidity environment, which reduces the time it takes for the dots of slurry 20 to solidify.

[0207] Referring to FIG. 9, once the dot of slurry 20 has solidified into an aerosol-generating film dot 20 A, the carrier layer 108 is adhered to the base layer 106 to form the carrier 104 .

[0208] The base layer 106 has a base adhesive surface 114 and a base surface 115. Prior to attachment of the carrier layer 108, a plurality of fold lines 152 were formed in the base layer 106. The fold lines 152 extend generally perpendicular to what would be the longitudinal direction of the carrier layer 108 when adhered to the base layer 106. The carrier layer 108 and the base layer 106 are adhered to one another by an adhesive (not shown) that acts on the carrier and base adhesive surfaces 112, 114. The adhesive is a releasable adhesive, and the properties of each of the carrier and base adhesive surfaces 112, 114 are such that when the carrier layer 108 and the base layer 106 are pulled or peeled away from one another, the adhesive remains on the base adhesive surface 114 and moves away from the carrier adhesive surface 112.

[0209] Once the carrier layer 108 is adhered to the base layer 106, a plurality of separation lines 116, 118 are introduced into the carrier layer 118. The separation lines 116 are cut lines that extend longitudinally along the carrier layer 108. The separation lines 118 are cut lines that extend in a direction generally perpendicular to the longitudinal direction of the carrier layer 108. The cut lines 118 are generally uniformly spaced longitudinally along the carrier layer 108 and coincide at longitudinal locations with the fold lines 152 of the base layer 106. The cut lines 116, 118 are cut by a kiss-cut technique, with the cuts extending from the support surface 110 to the carrier adhesive surface 112.

[0210] Cut lines 116, 118 divide the carrier layer 108 into a plurality of carrier portions 122 (for clarity, the carrier portions 122 are not labeled in all drawings). Each of the carrier portions 122 has eight aerosol-generating film dots 20A supported on its support surface 110. The relationship between the arrangement of the aerosol-generating film dots 20A and the cut lines 116, 118 is such that for each of the carrier portions 122, the aerosol-generating film dots 20A are in the same location relative to the edge of that carrier portion as in the other carrier portions. In the example shown, each of the carrier portions 122 is the same size and shape. In other non-illustrated examples of the present disclosure, the carrier portions may not all be the same size and / or shape.

[0211] 10, the carrier 104 is now folded in an accordion fashion about fold lines 152 in the base layer 106 to configure the product 102 for storage, where the product 102 can be stored until needed.

[0212] When it is desired to use the product 102 to make one or more consumable products, the bellows of the carrier 104 are partially deployed such that one or more carrier portions 122 are accessible to a user. The user can then peel at least the carrier portion 122 from the base layer 106. The cut lines 116, 118 that bound the carrier portion 122 tear to ensure that adjacent carrier portions 122 are not peeled away from the base layer 106.

[0213] Once carrier portion 122 is peeled away, carrier portion 122 can be used as a consumable for use with aerosol delivery device 30 in the same manner as described above in connection with consumable 26 .

[0214] 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. 1. A method of manufacturing an article for use in manufacturing an article for use in a non-combustible aerosol delivery system, the article comprising: an aerosol-forming material and a carrier, the carrier comprising a base layer and a carrier layer, the carrier layer releasably attached to the base layer; The method comprises: (a) the carrier is provided; (b) applying an aerosol-forming material to a support surface of the carrier layer of the carrier; (c) configuring the carrier and the aerosol-forming material for storage; A method comprising:

2. 10. The method of claim 1, wherein the application of the aerosol-forming material in step (b) is the application of one or more discrete portions of aerosol-forming material.

3. The method of claim 1 , wherein the carrier layer comprises a sheet material, the sheet material comprising at least one of paper, card, a plastic material, or a metal material.

4. The method comprises:

10. The method of claim 1, comprising the further step of: (d) introducing at least one separation line into at least a portion of said carrier, each separation line being a predetermined line along which at least a portion of said carrier will separate or tear.

5. The method of claim 4 , wherein at least one separation line is a predetermined line along which the carrier layer will separate or tear.

6. The method of claim 4 or 5, wherein the at least one separation line of step (d) comprises a perforation.

7. 10. The method of claim 1, wherein the carrier is a longitudinally extending sheet of material, and wherein the configuring of step (c) comprises forming at least one fold line in the carrier and then folding the carrier about at least one of the fold lines.

8. The method of claim 7 , wherein the fold line corresponds to the separation line.

9. The method of claim 1 , wherein the configuring of step (c) includes forming the carrier into a roll.

10. The method comprises:

10. The method of claim 1, further comprising the step of: (e) disposing a sheet of a barrier material over the support surface of the carrier layer and the aerosol-forming material, wherein step (e) is performed before step (c).

11. 1. An article of manufacture for use in the manufacture of consumables for use with an article for use in a non-combustible aerosol delivery system, the article comprising an aerosol-forming material and a carrier; the carrier comprises a base layer and a carrier layer; the carrier layer is releasably attached to the base layer; At least one discrete portion of aerosol-forming material is supported on the support surface of the carrier layer.

12. 12. The article of manufacture of claim 11, wherein the carrier layer comprises an adhesive-backed sheet material, the sheet material comprising at least one of paper, card, a plastic material, or a metal material.

13. 12. The article of manufacture of claim 11, wherein the carrier includes at least one separation line, each separation line being a predetermined line along which at least a portion of the carrier will separate or tear.

14. 14. The article of manufacture of claim 13, wherein at least one separation line is a predetermined line along which the carrier layer will separate or tear.

15. 15. The product of claim 13 or 14, wherein at least one separation line comprises a perforation.

16. 14. The article of manufacture of claim 13, wherein at least one separation line extends between at least two separate portions of the aerosol-forming material.

17. 12. The article of manufacture of claim 11, wherein the carrier is a longitudinally extending sheet of material, the carrier includes at least one fold line, and the carrier is folded about at least one of the fold lines.

18. 18. The article of claim 17, wherein the fold line corresponds to the separation line.

19. The product is 12. The article of manufacture of claim 11, further comprising a sheet of barrier material disposed over the carrier layer and the aerosol-forming material.

20. 1. A method of making a consumable for use with a device for heating an aerosol-forming material, comprising: (i) providing at least one product according to claim 11; (ii) peeling at least one portion of the carrier layer from the base layer of at least one product; A method comprising:

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