Consumables for use with aerosol delivery devices

Abstract

A method of manufacturing an article comprising an aerosol-generating material and a support (30) is provided, the method including the steps of (a1) modifying at least a portion of a surface (28) of the support to form at least one modified area (42) or (a2) providing a support having at least a portion of its surface modified to form at least one modified area, and (b) applying the aerosol-generating material to at least one application area (40) on the surface of the support, the at least one application area being associated with the at least one modified area.

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to the field of non-flammable 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] Smoking articles, such as cigarettes, cigars, etc., burn tobacco during use to produce tobacco smoke. Alternatives to these types of articles release compounds from a substrate material through heating without combustion, thereby emitting an inhalable aerosol or vapor. These are sometimes referred to as non-combustible smoking articles, aerosol generating assemblies, or aerosol delivery devices.

[0003] One example of such a product is a heating device that releases compounds by heating, without combustion, an aerosolizable material, sometimes referred to as a solid aerosol-generating material, which may optionally include tobacco material. Upon heating, at least one component of the material is volatilized, typically forming an inhalable aerosol. These products may also be referred to as non-combustion heating devices, tobacco heating devices, or tobacco heating products. A variety of different configurations are known that volatilize 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 upon heating to produce an inhalable vapor or aerosol, and a solid aerosol-forming material (which may or may not contain tobacco material) whose components are entrained in the inhalable vapor or aerosol to produce the inhalation medium. Summary of the Invention

[0005] According to a first aspect of the present disclosure, there is provided a method of making an article comprising an aerosol-generating material and a support, the method comprising the steps of: (a1) modifying at least a portion of a surface of a support to form at least one modified area; (b) applying an aerosol-generating material to at least one application area on a surface of a support; Including, A method is provided in which at least one application area is associated with at least one modified area. According to a second aspect of the present disclosure, there is provided a method of making an article comprising an aerosol-generating material and a support, the method comprising the steps of: (a2) providing a support having at least a portion of its surface modified to form at least one modified area; (b) applying an aerosol-generating material to at least one application area on a surface of a support; Including, A method is provided in which at least one application area is associated with at least one modified area. According to a third aspect of the present disclosure, there is provided an article comprising a support and an aerosol-generating material, a first surface of the support comprising at least one application area and at least one modification area; The surface of the support in at least one modified area is modified; An article is provided in which an aerosol-forming material is applied to at least one application area.

[0006] According to a fourth aspect of the present disclosure, there is provided an aerosol delivery device for use with a consumable formed by the article of the third aspect of the present disclosure, the aerosol delivery device comprising an aerosol generator configured to heat at least a portion of an aerosol-generating material supported by the consumable.

[0007] According to a fifth aspect of the present disclosure, there is provided an aerosol delivery system comprising an aerosol delivery device and a consumable formed from an article according to the third aspect of the present disclosure.

[0008] According to a sixth aspect of the present disclosure, there is provided a method for generating an aerosol from a consumable using an aerosol generation device comprising at least one aerosol generator arranged to heat, in use, the consumable formed by an article according to the third aspect of the present disclosure without burning the consumable, wherein the at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.

[0009] Further features and advantages of the present disclosure will become apparent from the following description of embodiments thereof, given by way of example only and with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0010] [Figure 1] 1 is a schematic diagram of an embodiment of an aerosol delivery device and an embodiment of a consumable manufactured according to an embodiment of a method of the present disclosure. [Diagram 2] 2A and 2B show a first embodiment of a support for use in the manufacture of the consumable product of FIG. 1; [Diagram 3] FIG. 3 shows the support of FIG. 2 in the process of being surface treated according to a first embodiment of the method of the present disclosure. [Figure 4] FIG. 3 shows the support of FIG. 2 in the process of being surface treated according to a first embodiment of the method of the present disclosure. [Diagram 5] 5 shows a cross-section along line AA' of the support of FIG. 4 to which a slurry including a binder and an aerosol forming agent has been applied. [Figure 6] FIG. 13 shows a representative portion of a support in a second embodiment of the method of the present disclosure. [Figure 7] FIG. 4 shows a primary mask used in a second embodiment of the method of the present disclosure. [Figure 8]FIG. 4 shows a secondary mask used in a second embodiment of the method of the present disclosure. [Figure 9] FIG. 7 shows a representative portion of the support of FIG. 6 after it has been surface treated according to a first embodiment of the method of the present disclosure. [Figure 10] FIG. 10 shows a representative portion of the support of FIG. 9 to which a slurry including a binder and an aerosol former has been applied. [Figure 11] FIG. 13 shows a support section in a third embodiment of the method of the present disclosure. [Figure 12] FIG. 13 shows a support section in a third embodiment of the method of the present disclosure. [Figure 13] FIG. 11 is an exploded schematic diagram of one embodiment of a support and sheet of modifying material according to a fourth embodiment of the present disclosure. [Figure 14] FIG. 14 is a first view of the support and modified sheet of material of FIG. 13 attached to one another. [Figure 15] FIG. 14 is a second view of the support and modified sheet of material of FIG. 13 attached to one another. [Figure 16] 16 is a cross-sectional view of the support and modified sheet of material of FIG. 15 along line BB'. [Figure 17] 16 is a cross-sectional view of the support and modified sheet of material of FIG. 15 along line BB'. [Figure 18] FIG. 13 illustrates an article according to a fifth embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Consumables herein may alternatively be referred to as articles.

[0012] In some embodiments, the consumable includes an aerosol-generating material, which may include an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, an aerosol modifier, one or more active constituents, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0013] The device for heating the aerosol-generating material with which the consumable is used is part of a non-combustion aerosol delivery system. Non-combustion aerosol delivery systems (such as e-cigarettes, tobacco heating products, and hybrid systems that generate aerosols through a combination of aerosol-generating materials) release compounds from the aerosol-generating material without combustion.

[0014] According to the present disclosure, a "non-flammable" aerosol delivery system is one in which the aerosol-generating material (or components thereof) that constitute the aerosol delivery system is not combusted to facilitate delivery of at least one substance to a user.

[0015] In some embodiments, the delivery system is a non-flammable aerosol delivery system, such as a powered non-flammable aerosol delivery system.

[0016] In some embodiments, the non-combustible aerosol delivery system is an e-cigarette, also known as a vaping device or electronic nicotine delivery system (END), although the presence of nicotine in the aerosol-generating material is not a requirement.

[0017] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0018] In some embodiments, the non-combustible aerosol delivery system is a hybrid system that generates aerosol by a combination of aerosol-generating materials, one or more of which may be adapted to be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0019] Generally, a non-flammable aerosol delivery system may include a non-flammable aerosol delivery device and a consumable item for use with the non-flammable aerosol delivery device.

[0020] In some embodiments, the present disclosure relates to consumables that include aerosol generating materials and are configured for use with non-flammable aerosol delivery devices. Throughout this disclosure, these consumables may be referred to as articles.

[0021] In some embodiments, the non-flammable aerosol delivery system (e.g., the non-flammable aerosol delivery device) can include a power source and a controller. The power source can be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that can be energized to provide power in the form of heat to an aerosol-generating material or a heat transfer material in proximity to the heat generating power source.

[0022] In some embodiments, the non-flammable aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0023] In some embodiments, consumables for use with the non-flammable aerosol delivery device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier. According to a first aspect of the present disclosure, there is provided a method of making an article comprising an aerosol-generating material and a support, the method comprising the steps of: (a1) modifying at least a portion of a surface of a support to form at least one modified area; (b) applying an aerosol-generating material to at least one application area on a surface of a support; Including, A method is provided in which at least one application area is associated with at least one modified area.

[0024] According to a second aspect of the present disclosure, there is provided a method of making an article comprising an aerosol-generating material and a support, the method comprising the steps of: (a2) providing a support having at least a portion of its surface modified to form at least one modified area; (b) applying an aerosol-generating material to at least one application area on a surface of a support; Including, Methods are provided in which at least one application area is associated with at least one modification area, in which modification of the surface of the support can be performed at a different location and / or by different parties than those performing other parts of the method.

[0025] In one embodiment of any of the above embodiments, the article is shaped and dimensioned for use as a consumable for use with a non-flammable aerosol delivery system, in this embodiment, the article acts as a consumable without any dimensional change. In one embodiment of any of the above embodiments, the article is larger than is compatible for use with the non-flammable aerosol delivery system; The method further includes (c) separating the article into two or more article portions; Each article portion is shaped and sized for use as a consumable with an apparatus for heating an aerosol-generating material to volatilize at least one component of the aerosol-generating material. In this embodiment, the article may be a material unit that is larger or substantially larger than the size of a consumable for use with an apparatus for heating an aerosolizable material. Producing a larger article than needed and separating the article into consumable-sized article portions may result in a simpler and more efficient manufacturing technique than constructing consumable-sized articles.

[0026] In one embodiment of any of the above embodiments, applying the aerosol-forming material in step (b) comprises applying a slurry of the aerosol-forming material. In one embodiment of any of the above embodiments, the method further comprises (d) allowing or allowing the aerosol-forming material slurry to harden; The aerosol-forming material hardens as the aerosol-forming material hardens.

[0027] In one embodiment of any of the above embodiments, the aerosol-forming material is an aerosol-forming film.

[0028] The aerosol-generating material may include or be in 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 matter. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0029] The aerosol-generating film may have a thickness of from about 0.015 mm to about 1 mm. For example, 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.

[0030] The aerosol-generated film may 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 (e.g., one or more delivery substances) to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent. The slurry is thus a precursor to the aerosol-generated film.

[0031] The slurry may be adapted such that at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent is removed by heating.

[0032] The aerosol-generating material may include or 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 is capable of retaining some fluid therein, such as a liquid. In some embodiments, the amorphous solid may include, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0033] The amorphous solid may be substantially free of plant matter.The amorphous solid may be substantially free of tobacco.

[0034] In one embodiment of any of the above embodiments, modifying the surface of the support in the modified area comprises changing one or more properties of the surface of the support in that area, hi some embodiments of the above embodiments, the property that is changed is the attraction or repulsion of the surface to water, i.e., the hydrophilicity or hydrophobicity of the surface.

[0035] The modification may be achieved by the addition of one or more layers or coatings of a modifying material that will have the desired surface properties after application to the surface of the support in at least one modification area. Application may be achieved by known application techniques, such as, but not limited to, the use of a brush or spraying an aerosol of the substance.

[0036] In one embodiment of any of the above embodiments, applying the modification material to the surface of the support in step (a1) or (a2) comprises applying a liquid, paste, or gel of the material that provides the desired modification to the surface of the support in at least one modification area.

[0037] In one embodiment of any of the above embodiments, the method further comprises the step of (e) allowing or causing the liquid, paste, or gel to harden or thicken.

[0038] In one embodiment of any of the above embodiments, applying the modifying material to the surface of the support in step (a1) or (a2) comprises applying a layer of the modifying material.

[0039] In one embodiment of any of the above embodiments, the layer of modified material is a sheet or film of modified material.

[0040] In one embodiment of any of the above embodiments, the layer of modified material is attached to a surface of the support.

[0041] In one embodiment of any of the above embodiments, the layer of modified material comprises an adhesive substrate on one surface of the layer, and the layer of adhesive is positioned against a surface of the support to form an attachment between the support and the layer of modified material.

[0042] In one embodiment of any of the above embodiments, the layer of modified material is discontinuous. In one embodiment of any of the above embodiments, the discontinuities in the layer of modified material correspond to the application area. In some embodiments, the perimeter of the discontinuities is cut as a sheet of modified material, and after the entire sheet of modified material is applied to the support, the portion of the sheet within the perimeter of the discontinuities is peeled off from the surface of the support. In such embodiments, the adhesive that attaches the sheet to the support is a release adhesive.

[0043] In one embodiment of any of the above embodiments, the support comprises a susceptor.

[0044] In one embodiment of any of the above embodiments, the support is a laminate, the laminate including at least two layers, a first layer of the laminate constituting the first surface of the support and being a susceptor.

[0045] In one embodiment of any of the above embodiments, the first surface of the support comprises a metal or alloy, hi some embodiments, the first surface of the support comprises a metal or alloy foil or film.

[0046] In one embodiment of any of the above embodiments, the first surface of the support comprises aluminum or an aluminum alloy, hi some embodiments, the first surface of the support comprises an aluminum or aluminum alloy foil or film.

[0047] In one embodiment of any of the above embodiments, the support comprises a second layer formed of a material suitable for constructing the substrate, for example the second layer may be or include cardboard, paperboard, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or alloy.

[0048] In one embodiment of any of the above embodiments, the support comprises a plastic material capable of withstanding temperatures typically encountered in a non-flammable aerosol delivery device. In some embodiments, the support comprises polyetheretherketone (PEEK). Such an embodiment has the advantage that the support is reusable and the consumable is less susceptible to condensation in a non-flammable aerosol delivery device than consumables with supports that use adsorbent materials for structural purposes.

[0049] In one embodiment of any of the above embodiments, the modification of the at least one modification area in step (a1) or (a2) comprises application of a modification material to the surface of the support in the at least one modification area. In some embodiments, application of the modification material may be by electrostatic coating techniques. In other embodiments, the modification material may be adapted to be applied as a thin film.

[0050] In one embodiment of any of the above embodiments, two or more layers of modified material may be applied to the surface of the support in at least one modified area.

[0051] In one embodiment of any of the above embodiments, the modification of the at least one modified area in step (a1) or (a2) comprises a process that leads to a modification of the surface of the support in the at least one modified area, which may activate the surface chemistry of the support or may physically change the surface of the support, which may be on a microscopic scale.

[0052] In one embodiment of any of the above embodiments, the process includes plasma treatment of the surface of the support, using known techniques. Advantages of using plasma treatment techniques to modify the surface of the support include that such techniques are environmentally friendly, do not result in waste chemicals, can be fine-tuned to provide the desired modifications, do not require temperatures that may damage the support, and are economical.

[0053] In one embodiment of any of the above embodiments, the modification of the at least one modification area in step (a1) or (a2) renders the modified surface of the support hydrophobic.

[0054] In one embodiment of any of the above embodiments, the hydrophobicity of the modified area after modification is higher than the hydrophobicity of the application area.

[0055] In one embodiment of any of the above embodiments, at least one modified area having a hydrophobic surface is positioned relative to the application area so as to prevent slurry applied to the application area from diffusing away from the application area.

[0056] In one embodiment of any of the above embodiments, the at least one modified area of ​​step (a1) or (a2) at least partially surrounds the at least one application area.

[0057] In one embodiment of any of the above embodiments, the at least one modified area of ​​step (a1) or (a2) constitutes a band around the application area.

[0058] In some of the above embodiments, the multiple modified areas, each having a hydrophobic surface, are positioned relative to the application area such that together they prevent slurry applied to the application area from diffusing away from the application area.

[0059] These embodiments are advantageous because the hydrophobicity of the surface of each modified area prevents the slurry from spreading onto that modified area, which allows the position of the slurry to be controlled without the need to place other physical barriers to the flow of the slurry onto the surface of the support. Another advantage is that the plasma treatment of the surface can be performed through a mask or template that allows for the formation of precise and / or complex shapes of modified areas on the surface of the support.

[0060] When the slurry hardens or at least partially dehydrates (the concentration of water decreases), the viscosity of the other components, such as the binder, will increase until an aerosol-generating material is formed in the form of an aerosol-generating film having more or less fixed dimensions. The hydrophobicity of the modified area will then not affect the shape of the aerosol-generating film. However, if the aerosol is being generated in the aerosol generating device during use of the consumable, the hydrophobicity of the modified area may still be used to maintain the consumable, since condensation may form in the aerosol generating device. Even if condensation forms on the surface of the support, it will not form on the hydrophobic surface of the modified area and will not flow easily through these areas. The modified area may thus prevent the condensation from reaching and penetrating the aerosol-generating film that has not yet been aerosolized.

[0061] In one embodiment of any of the above embodiments, at least one modified area having a hydrophobic surface is disposed on at least one portion of the surface of the support that is preferably free of aerosol-generating material, such that any aerosol-generating material or precursors thereof will not flow into said area, and any aerosol-generating material or precursors thereof that are unintentionally deposited in said area can be easily removed, for example by peeling, since any bond formed between the aerosol-generating material and the surface of the modified area will be of low strength.

[0062] In one embodiment of any of the above embodiments, the modification of the at least one modified area in step (d) renders the modified surface of the support hydrophilic. An advantage of rendering the surface of the at least one modified area hydrophilic is that when a slurry is placed in at least partial contact with such a hydrophilic surface, water in the slurry will wick from the slurry onto the hydrophilic surface. The water may then evaporate from the hydrophilic surface. This has the effect of aiding in drying of the slurry during manufacture of the consumable. It has been found that such wicking continues until the water content of the slurry reaches a certain level, in some embodiments around 10 weight percent (wt%) to 40 weight percent (wt%).

[0063] Additionally, the effect of making the surface of the at least one modified area hydrophilic is that after manufacture of the consumable product and before the aerosol-generating material generates an aerosol, a wicking effect occurs when the moisture content of the aerosol-generating material, which as a hygroscopic material absorbs moisture from the atmosphere, increases. As a result, the hydrophilic surface of the at least one modified area helps to prevent the aerosol-generating material from reabsorbing and retaining too much water. If enough water is reabsorbed and retained, the water may impair the consumable product and / or a user's experience when using the consumable product.

[0064] In one embodiment of any of the above embodiments, the method includes the step of (f) embossing or debossing at least a portion of the support in at least one modified area, where step (f) is performed after step (a1) or (a2) and before step (b). This has the advantage that the embossing or debossing may help prevent spreading of the aerosol-forming material slurry when applied to the surface of the support. As another advantage, the embossing or debossing may add structural rigidity to the support in the at least one modified area.

[0065] In one embodiment of any of the above embodiments, at least a portion of the at least one modified area of ​​step (a1) or (a2) overlaps at least a portion of the at least one application area. In some embodiments, a portion of the at least one modified area overlaps a portion of the at least one application area. Such overlap aids in wicking of water from the aerosol-forming material slurry to the hydrophilic surface of the at least one modified area.

[0066] In one embodiment of any of the above embodiments, the method includes applying the aerosol-forming material to at least two application areas.

[0067] In one embodiment of any of the above embodiments, applying the aerosol-generating material in step (b) includes applying the aerosol-generating material to three or more application areas, the application areas being in a grid pattern on the first surface of the support.

[0068] In one embodiment of any of the above embodiments, the application area of ​​step (b) is in the shape of a substantially circular longitudinally extending stripe, a stripe including at least one curve or angle, or a tessellation in the plane of the first surface of the support.

[0069] In one embodiment of any of the above embodiments, the aerosol-generating material applied to the at least two application areas in step (b) has a different composition from one another. This has the advantage that a user of the consumable may have a different experience with the different discrete portions of aerosol-generating material on the consumable. This may make use of the consumable more enjoyable and / or more interesting compared to use of a consumable having an aerosol-generating material of only one composition.

[0070] In one embodiment of any of the above embodiments, the aerosol-forming material applied to at least one application area in step (b) is of a shape and / or colour indicative of the composition of the aerosol-forming material in that application area.

[0071] In one embodiment of any of the above embodiments, the application of the aerosol-generating material is performed two or more times. This can have the effect of providing a thicker layer of the aerosol-generating material on the support than would be achieved if the aerosol-generating material were applied only once. The increased thickness can allow a larger amount of aerosol to be generated by the aerosol-generating material and / or for a longer period of time than would be achieved if only a single application of the aerosol-generating material were applied.

[0072] According to a second aspect of the present invention, there is provided an article comprising a support and an aerosol-generating material, wherein a first surface of the support comprises at least one application area and at least one modified area, the surface of the support in the at least one modified area is modified, and the aerosol-generating material is applied to the at least one application area.

[0073] In one embodiment of any of the above embodiments, the article is shaped and dimensioned for use as a consumable for use with a non-flammable aerosol delivery system.

[0074] In one embodiment of any of the above embodiments, the article is larger than is compatible for use with a non-flammable aerosol delivery system; Each article portion is shaped and dimensioned for use as a consumable with a device for heating an aerosol-forming material to volatilize at least one component of the aerosol-forming material.

[0075] In one embodiment of any of the above embodiments, the support has a first surface and a second surface, each of the first and second surfaces having at least one application area and at least one modified area, the surface of the support in the at least one modified area on each of the first and second surfaces of the support is modified, and the aerosol-generating material is applied to the at least one application area on each of the first and second surfaces of the support.

[0076] In one embodiment of any of the above embodiments, at least a portion of the at least one modified area at least partially overlaps at least a portion of the at least one application area.

[0077] In one embodiment of any of the above embodiments, the at least one modified area has a modified material applied to a surface of the support in the at least one modified area.

[0078] In one embodiment of any of the above embodiments, the modified material applied to the surface of the support is a liquid, paste, or gel that hardens or increases in viscosity.

[0079] In one embodiment of any of the above embodiments, the modifying material applied to the surface of the support is a layer of modifying material.

[0080] In one embodiment of any of the above embodiments, the layer of modifying material applied to the surface of the support is a sheet or film of the modifying material.

[0081] In one embodiment of any of the above embodiments, the layer of modified material is attached to a surface of the support.

[0082] In one embodiment of any of the above embodiments, the layer of modified material is discontinuous.

[0083] In one embodiment of any of the above embodiments, discontinuities in the layer of modified material correspond to the application area.

[0084] In one embodiment of any of the above embodiments, the surface of at least one modified area is plasma coated.

[0085] In one embodiment of any of the above embodiments, the surface of at least one modified area is physically altered relative to the surface of the support on which it is disposed and which is not included in the modified area.

[0086] In one embodiment of any of the above embodiments, the surface of at least one modified area has been one or more of plasma cleaned, plasma activated, or plasma etched.

[0087] In one embodiment of any of the above embodiments, at least one modified area has a hydrophilic surface.

[0088] In one embodiment of any of the above embodiments, at least one modified area having a hydrophilic surface at least partially overlaps at least one application area, and the hydrophilic surface enables liquid, such as water, in an aerosol-forming material applied to the application area to wick from the aerosol-forming material onto the hydrophilic surface.

[0089] In one embodiment of any of the above embodiments, the portion of each modified area that does not overlap the application area allows liquid, such as water, that is wicked from the aerosol-forming material onto the hydrophilic surface to evaporate.

[0090] In one embodiment of any of the above embodiments, at least one modified area has a hydrophobic surface.

[0091] In one embodiment of any of the above embodiments, at least one modified area having a hydrophobic surface at least partially surrounds the application area.

[0092] In one embodiment of any of the above embodiments, at least one application area has a perimeter, and one or more modified areas having a hydrophobic surface together partially surround the perimeter of the application area, with the remainder of the perimeter of the application area being surrounded by at least one modified area having a hydrophilic surface, such a configuration benefiting from the advantages of the hydrophobic and hydrophilic areas as described above.

[0093] In one embodiment of any of the above embodiments, at least one modified area has a hydrophobic surface and is disposed at a location on a surface of the support that is to be kept free of aerosol-forming material.

[0094] In one embodiment of any of the above embodiments, at least one application area is at least partially surrounded by at least one modified area.

[0095] In one embodiment of any of the above embodiments, the application area or areas are surrounded by an area of ​​modification.

[0096] In one embodiment of any of the above embodiments, the one or more application areas are each surrounded by a modified area.

[0097] In one embodiment of any of the above embodiments, each modified area constitutes a band around the surrounding application area.

[0098] In one embodiment of any of the above embodiments, at least one modified area of ​​the support is embossed or debossed. The embossing or debossing may cover the entire modified area or only a portion of the modified area.

[0099] In one embodiment of any of the above embodiments, the article comprises at least two application areas and the aerosol-forming material is applied to the at least two application areas.

[0100] In one embodiment of any of the above embodiments, the consumable comprises at least three application areas, and the aerosol-generating material is applied to the at least three application areas, the application areas being in a grid pattern on the first surface of the support.

[0101] In one embodiment of any of the above embodiments, one or more of the application areas are shaped in the plane of the first surface of the support as substantially circular longitudinally extending stripes, stripes including at least one curve or angle, or a tessellated shape.

[0102] In one embodiment of any of the above embodiments, the aerosol-forming materials applied to the at least two application areas have different compositions from each other.

[0103] In one embodiment of any of the above embodiments, the aerosol-forming material applied to at least one application area is of a shape and / or color indicative of the composition of the aerosol-forming material.

[0104] In one embodiment of any of the above embodiments, the aerosol-forming material is an aerosol-forming film or an aerosolizable gel.

[0105] In one embodiment of any of the above embodiments, the support comprises a susceptor.

[0106] In one embodiment of any of the above embodiments, the susceptor constitutes a first surface of the support.

[0107] In one embodiment of any of the above embodiments, the susceptor is one of a metal, an alloy, a metal or alloy film, or a metal or alloy foil.

[0108] A 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, such that the penetration of a varying magnetic field causes inductive heating of the susceptor by resistive heating as a result of eddy currents. The susceptor may be a magnetic material, such that the penetration of a varying magnetic field causes magnetic hysteresis heating of the susceptor. The susceptor may be bi-directional, such that it can be heated by both conductive and magnetic heating mechanisms. A device configured to generate a varying magnetic field is referred to as a magnetic field generator.

[0109] 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 410 grade stainless steel, 420 grade stainless steel, 430 grade stainless steel, or similar grade stainless steel. Alternatively, the susceptor may comprise a suitable non-magnetic, particularly paramagnetic, conductive material, such as aluminum. In a paramagnetic conductive material, induction heating occurs solely through resistive heating due to eddy currents. Alternatively, the susceptor may comprise a non-conductive ferrimagnetic material, such as a non-conductive ferrimagnetic ceramic. In this case, heat is generated solely through hysteresis losses. The susceptor may comprise a commercially available alloy, such as Phytherm 230 (composition including 50 wt% Ni, 10 wt% Cr, and the rest Fe (weight % = wt%) or Phytherm 260 (composition including 50 wt% Ni, 9 wt% Cr, and the rest Fe).

[0110] In some embodiments of any of the above embodiments, the susceptor may be a metal or alloy. In some embodiments of any of the above embodiments, the susceptor may be a metal foil, optionally an aluminum foil, or an iron foil. Alternatively, in some embodiments of any of the above embodiments, the susceptor may be any conductive material that can be sprayed or deposited onto the material that makes up the support.

[0111] In one embodiment of any of the above embodiments, the aerosol forming material includes an active agent.

[0112] As used herein, an active substance may be a physiologically active material (a material intended to produce or enhance a physiological response). The active substance may be selected from, for example, dietary supplements, psychotropic drugs, psychoactive agents. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, terpenes of non-cannabinoid origin, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may include one or more constituents, derivatives, or extracts of tobacco, cannabis, or another plant.

[0113] The active substance may include one or more constituents, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0114] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0115] The active material may include or be derived from one or more botanical substances or constituents, derivatives or extracts thereof. As used herein, the term "botanical" may include any material derived from a plant, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, pods, etc. Alternatively, the material may include active compounds naturally present in plants or synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, chips, strips, sheets, etc. Exemplary plants 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 skin, 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, Lavender, lemon peel, mint, juniper, elderberry, vanilla, wintergreen, sedge, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiene, marjoram, olive, lemon balm, lemon basil, chives, ribeye, 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 arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0116] In some embodiments, the active agent comprises or is derived from one or more botanical substances or constituents, derivatives or extracts thereof, and the plant is tobacco.

[0117] In some embodiments, the active agent comprises or is derived from one or more botanical substances or constituents, derivatives or extracts thereof, the plant being selected from eucalyptus, star anise, cocoa, and hemp.

[0118] In some embodiments, the active agent comprises or is derived from one or more botanical substances or constituents, derivatives or extracts thereof, the plant being selected from rooibos and fennel.

[0119] In some embodiments, the aerosol-forming material comprises a fragrance or flavoring.

[0120] As used herein, the terms "flavour" and "flavourant" refer to materials that can be used to produce a desired flavour, aroma, or other sensory experience in products intended for adult consumers, where local regulations permit.These include naturally occurring flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, heat, spices, flavors, aromas, flavor ... Belly fruit, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberries, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pineapple, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, i Lang ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil of any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, yerba mate, orange skin, rose, tea such as green or black tea, thyme, juniper, elderberry, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiogamag ... damiene, marjoram, olive, lemon balm, lemon basil, chives, ribes, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulators, 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.These may be of imitation, synthetic or natural origin, or a mixture thereof. They may be in any suitable form, for example a liquid such as an oil, a solid such as a powder, or a gel.

[0121] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavor components extracted from tobacco. In some embodiments, the flavoring comprises flavor components extracted from cannabis.

[0122] In some embodiments, the fragrance may include sensates intended to achieve the sensations usually chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves, and these may include agents that produce a heating, cooling, tingling, or numbing effect.Suitable heating agents may be, but are not limited to, vanillyl ethyl ether.Suitable cooling agents may be, but are not limited to, eucalyptol, WS-3.

[0123] An aerosol-forming material is a material that is capable of generating an aerosol when energized, for example by heating, irradiating, 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.

[0124] The aerosol-generating material includes an aerosol forming agent.

[0125] In some embodiments, the aerosol generating agent may include one or more constituents capable of forming an aerosol. In some embodiments, the aerosol generating agent may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl sulfate, 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.

[0126] In some embodiments, the aerosol generating agent comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols, such as glycerol monoacetate, diacetate, or triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0127] 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 wt% 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.

[0128] 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.

[0129] 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%.

[0130] 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 embodiments, the gelling agent includes alginates and / or pectins, which are combined with a hardening agent (such as a calcium source) during formation of the aerosol-generating material. In some embodiments, the aerosol-generating material may include calcium cross-linked alginates and / or calcium cross-linked pectins.

[0131] 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.

[0132] In some embodiments, the cellulose 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.

[0133] 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.

[0134] In some embodiments, the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In preferred embodiments, the non-cellulosic gelling agent is alginate or agar.

[0135] In some embodiments, the gelling agent comprises alginate, and the alginate 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 only gelling agent present in the aerosol-forming material is alginate. In other embodiments, the gelling agent comprises alginate and at least one other gelling agent, such as pectin.

[0136] 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 a 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 a gelling agent.

[0137] 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.

[0138] In some cases, the aerosol-forming material may include from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, or 20% 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).

[0139] For example, the aerosol-forming material may comprise, in total, the gelling agent and the bulking agent in an amount of about 10 wt%, 20 wt%, 25 wt%, 30 wt%, or 35% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the aerosol-forming material. For example, the aerosol-forming material may comprise, in total, the gelling agent and the bulking agent in an amount of about 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt% of the aerosol-forming material.

[0140] By way of example, the aerosol-forming material may comprise a gelling agent in an amount of about 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, or 35% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the aerosol-forming material (i.e., not taking into account the amount of filler). By way of example, the aerosol-forming material may comprise a 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-forming material (i.e., not taking into account the amount of filler).

[0141] In some examples, the alginate is included in the gelling agent in an amount of about 5-40 wt% or 15-40 wt% of the aerosol-forming material, i.e., the aerosol-forming material comprises alginate in an amount of about 5-40 wt% or 15-40 wt% of the aerosol-forming material by dry weight, in some examples, the aerosol-forming material comprises alginate in an amount of about 20-40 wt% or about 15 wt% to 35 wt% of the aerosol-forming material.

[0142] 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% of the aerosol-forming material by dry weight, hi some examples, the aerosol-forming material comprises pectin in an amount of about 5-10 wt% of the aerosol-forming material.

[0143] In some examples, the guar gum is present in the gelling agent in an amount of about 3-40 wt% of the aerosol-generating material. That is, the aerosol-generating material comprises guar gum in an amount of about 3-40 wt% of the aerosol-generating material by dry weight. In some examples, the aerosol-generating material comprises guar gum in an amount of about 5-10 wt% of the aerosol-generating material. In some examples, the aerosol-generating material comprises 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.

[0144] For example, the alginate is present in an amount of at least about 50 wt% of the gelling agent. For example, the aerosol-forming material includes alginate and pectin, and the ratio of alginate to pectin is 1:1 to 10:1. The ratio of alginate to pectin is usually greater than 1:1. That is, the alginate is present in an amount greater than the amount of pectin. For example, the ratio of alginate to pectin is about 2:1 to 8:1, or about 3:1 to 6:1, or about 4:1.

[0145] The aerosol-generating material may be formed by (a) forming a slurry containing components of the aerosol-generating material or a precursor thereof, (b) forming a layer of the slurry, (c) curing the slurry to form a gel, and (d) drying to form the aerosol-generating material.

[0146] (b) Forming the slurry layer typically involves spraying, casting, or extruding the slurry. For example, the slurry layer may be formed by electrospraying the slurry. For example, the slurry layer may be formed by casting the slurry.

[0147] In some instances, (b), and / or (c), and / or (d) occur at least partially simultaneously (e.g., in an electrospray). In some instances, (b), (c), and (d) occur sequentially.

[0148] In some instances, the slurry may be applied to a support such that a layer is formed on the support.

[0149] By way of example, the slurry may include a gelling agent, an aerosol-forming material, and an active agent. The slurry may include these components in any of the proportions described herein for the composition of the aerosol-generating material. For example, the slurry may include (on a dry weight basis): a gelling agent and optionally a filler, the amount of gelling agent and filler together being about 10-60 wt% of the slurry; an aerosol-forming material in an amount of about 40-80 wt % of the slurry; Optionally, an active material in an amount of up to about 20 wt. % of the slurry; and may also include

[0150] Hardening the gel (c) may include providing a hardening agent to the slurry, for example the slurry may include sodium, potassium or ammonium alginate as a gel precursor and the addition of a hardening agent to the slurry including a calcium source (such as calcium chloride) to form a calcium alginate gel.

[0151] By way of example, the sclerosing agent may include or consist of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the sclerosing agent may include or consist of calcium formate and / or calcium lactate. In certain examples, the sclerosing agent may include or consist of calcium formate. The inventors have determined that when calcium formate is employed as a sclerosing agent, the aerosol generating material typically exhibits higher tensile strength and resistance to elongation.

[0152] The total amount of hardening agent, such as a calcium source, may be 0.5 to 5 wt % (calculated on a dry weight basis). Preferably, the total amount is about 1 wt %, 2.5 wt %, or 4 wt % to about 4.8 wt % or 4.5 wt %. The inventors have found that if too little hardening agent is added, the components of the aerosol-generating material may not be stable and may drop out of the aerosol-generating material. The inventors have also found that if too much hardening agent is added, the aerosol-generating material may become very sticky and difficult to handle.

[0153] If the aerosol-forming material does not contain tobacco, it may be necessary to apply more stiffening agent. Thus, in some cases, the total amount of stiffening agent may be 0.5 to 12 wt %, such as 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 generally not contain any tobacco.

[0154] As an example, applying the hardener to the slurry includes spraying the hardener onto the slurry, such as onto the top surface of the slurry.

[0155] 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 together by (1,4)-glycosidic bonds to form a polysaccharide. Upon addition of calcium cations, alginates crosslink to form a gel. Alginates with a high G monomer content have been found to gel more readily with the addition of a calcium source. Thus, in some cases, the gel precursor may include an alginate in which at least about 40%, 45%, 50%, 55%, 60%, or 70% of the monomer units in the alginic acid copolymer are α-L-glucuronic acid (G) units.

[0156] For example, 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. For example, drying (d) reduces the thickness of the cast material by at least 80%, preferably 85% or 87%. For example, the slurry is cast to a thickness of 2 mm and the resulting dried aerosol-generating material has a thickness of 0.2 mm.

[0157] 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).

[0158] In instances where the solvent comprises water, the dry weight content of the slurry may correspond to the dry weight content of the aerosol-forming material, such that any discussion herein of solid components is expressly disclosed in conjunction with the slurry aspects of the invention.

[0159] The aerosol-forming material may include a flavoring. The aerosol-forming material may include up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% of 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% of 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% of flavoring. In some cases, the flavoring includes, consists essentially of, or consists of menthol.

[0160] The aerosol-forming material may include a bulking agent.

[0161] 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%.

[0162] 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. Optionally, the aerosol forming material contains less than 1 wt% of a filler, and optionally no filler.

[0163] In some 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.

[0164] When present, the filler may include 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 also include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives (e.g., methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). In certain cases, the aerosol-generating material does not include calcium carbonate, such as chalk.

[0165] 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 (e.g., methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)).

[0166] Without being bound by theory, it is believed that including a fibrous filler in the aerosol-generating material may increase the tensile strength of the material, which may be particularly advantageous in instances where the aerosol-generating material is provided as a sheet, such as when the sheet defines a rod of aerosolizable material.

[0167] In some embodiments, the aerosol-forming material does not include tobacco fibers, hi certain embodiments, the aerosol-forming material does not include fibrous materials.

[0168] The aerosol-generating material may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0169] In some embodiments, the aerosol-forming material further comprises an active agent. For example, the aerosol-forming material optionally further comprises tobacco material and / or Nichicon. In some embodiments, the aerosol-forming material further comprises powdered tobacco, and / or nicotine, and / or tobacco extract.

[0170] 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.

[0171] In some cases, the aerosol-forming material includes an active agent such as a tobacco extract. In some cases, the aerosol-forming material may include 5-60 wt% tobacco extract (calculated on a dry weight basis). In some cases, the aerosol-forming 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% tobacco extract (calculated on a dry weight basis). For example, the aerosol-forming material may include 10-50 wt%, 15-40 wt%, or 20-35 wt% 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, no nicotine may be present in the aerosol-forming material other than the nicotine from the tobacco extract.

[0172] In some embodiments, the aerosol-forming material does not include tobacco material and does include nicotine. In some 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.

[0173] In some cases, the total content of actives and / or 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). 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 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).

[0174] The aerosol-generating composition may include one or more active agents. In some examples, the aerosol-generating material includes one or more active agents (e.g., up to about 20 wt% of the aerosol-generating material). For example, the aerosol-generating material includes active agents in an amount of about 1 wt%, 5 wt%, 10 wt%, or 15% to about 20 wt%, 15 wt%, 15 wt%, or 5 wt% of the aerosol-generating material.

[0175] The active substances may include physiologically and / or olfactory active substances that are included in the aerosol forming composition to achieve a physiological and / or olfactory response.

[0176] 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%.

[0177] The tobacco material may be in any form, but is typically shredded (e.g., cut into small pieces). Shredded tobacco material is advantageous because it can be mixed with an aerosol-forming material to provide an aerosol-forming composition having a uniform distribution of tobacco material and aerosol-forming material throughout.

[0178] By way of example, 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 relatively large amounts of laminar tobacco can be used in the aerosol-generating composition and still provide an acceptable aerosol when heated by a non-combustible aerosol delivery system. Laminar tobacco typically provides superior sensory properties. By way of example, 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 cut 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.

[0179] The tobacco used to produce 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 Oriental.

[0180] In some embodiments, the one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0181] Optionally, the aerosol-forming material may additionally include an emulsifier to emulsify the molten flavoring during preparation. For example, the aerosol-forming material may include about 5 wt% to about 15 wt%, preferably about 10 wt% (calculated on a dry weight basis) of an emulsifier. The emulsifier may include gum acacia.

[0182] In some embodiments, the aerosol-forming material is a hydrogel and contains less than about 20 wt% water, calculated on a wet weight basis. Optionally, the hydrogel contains less than about 15 wt%, 12 wt%, or 10 wt% water, calculated on a wet weight basis. Optionally, the hydrogel contains at least about 1 wt%, 2 wt%, or at least about 5 wt% water (WWB).

[0183] The aerosol-forming material may have any suitable water content, such as between 1 wt% and 15 wt%. Preferably, the water content of the aerosol-forming material is between about 5 wt%, 7 wt%, or 9 wt% and about 15 wt%, 13 wt%, or 11 wt% (WWB), most preferably about 10 wt%. The water content of the aerosol-forming material may be determined, for example, by Karl-Fischer titration or Gas Chromatography with Thermal Conductivity Detector (GC-TCD).

[0184] 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.

[0185] In some cases, the aerosol-forming materials may consist essentially of or consist of gelling agent, water, aerosol-forming agent, flavorings, and optionally tobacco materials and / or a nicotine source.

[0186] By way of example, the aerosol-forming material may consist essentially of, or consist of, a gelling agent, an aerosol-forming agent, an active substance, and water.By way of example, the aerosol-forming material may consist essentially of, or consist of, a gelling agent, an aerosol-forming agent, and water.

[0187] As an example, the aerosol-forming material does not include flavorants. In certain instances, the aerosol-forming material does not include active agents.

[0188] In some embodiments, the aerosol-forming material comprises: 1 to 60 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol generating agent; 0.1 to 80 wt% of fragrance, Including, These weights are calculated on a dry weight basis.

[0189] In some embodiments, the aerosol-forming material comprises 1-80 wt % (dry weight basis) of flavoring.

[0190] In some embodiments, the aerosol-forming material comprises: 1 to 50 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol generating agent; 30-60wt% fragrance, Including, These weights are calculated on a dry weight basis.

[0191] In an alternative embodiment, the aerosol-forming material is: 1 to 60 wt % of a gelling agent; 5 to 60 wt % of an aerosol generating agent; 10 to 60 wt % of a gelling agent; Including, These weights are calculated on a dry weight basis.

[0192] In some embodiments, the aerosol-forming material comprises: 1 to 60 wt % of a gelling agent; 20 to 60 wt % of an aerosol generating agent; 10-60 wt% tobacco extract; Including, These weights are calculated on a dry weight basis.

[0193] In some embodiments, the aerosol-generating material comprises 20-35 wt.% gelling agent, 10-25 wt.% aerosol-forming material, 5-25 wt.% fiber-containing filler, and 35-50 wt.% flavoring and / or active agent.

[0194] In some cases, the aerosol-forming materials may consist essentially of or consist of a gelling agent, an aerosol-forming agent, tobacco extract, water, and optional flavorings. In some cases, the aerosol-forming materials may consist essentially of or consist of glycerol, alginate and / or pectin, tobacco extract, and water.

[0195] In some embodiments, the aerosol-generating material may have a composition (DWB) as follows: a gelling agent (preferably including alginate) 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).

[0196] 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).

[0197] The "thickness" of an aerosol-generating material refers to 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 surface of the sheet opposite the first planar surface of the sheet.

[0198] In some cases, the layer of aerosol-forming material for forming the aerosol has a thickness of about 0.015 mm to about 1.5 mm, preferably 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 about 0.1 mm or 0.15 mm to about 1.0 mm, 0.5 mm, or 0.3 mm.

[0199] In some cases, the aerosol-forming material may have a thickness of from 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.

[0200] A material having a thickness of 0.2 mm is particularly suitable. The aerosol-generating material may comprise two or more layers, and the thicknesses given herein refer to the combined thicknesses of these layers.

[0201] It has been found that if the aerosol-generating material or materials are too thick, the heating efficiency is reduced, which has a negative impact on power consumption during use. Conversely, if the aerosol-generating material or materials are too thin, they are difficult to manufacture and handle. If the material is too thin, it can be more difficult to mold and can be fragile, which impairs aerosol formation during use.

[0202] The thicknesses specified herein are the average thickness of the material. In some cases, the thickness of the aerosol-generating material may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1%.

[0203] 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-generating material 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.

[0204] Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is formed into a sheet, which is then chopped and incorporated into an aerosol product. In some instances, such as where the aerosol-generating material includes a filler, the aerosol-generating material may have a tensile strength of around 600N / m to 900N / m, or 700N / m to 900N / m, or 800N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is included in an aerosol product / assembly as a rolled sheet, preferably in the form of a tube.

[0205] 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 about 600 N / m to about 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 and incorporated into an aerosol-generating consumable as a sheet.

[0206] The aerosol-forming material, including the aerosol-forming material, has a density of 30 g / m 2 ~120g / m 2 In some cases, the mass per unit area of ​​the sheet may be 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 (which has a density similar to that of cut rag tobacco so that mixtures of these materials do not easily separate). Optionally, the mass per unit area of ​​the sheet is about 30 to 70 g / m 2 , 40~60g / m 2 , or 25 to 60 g / m 2 and may be adapted to be used to wrap an aerosolizable material such as tobacco.

[0207] All weight percentages (expressed as wt%) referred to herein are calculated on a dry weight basis unless expressly stated otherwise. All weight ratios are also calculated on a dry weight basis. Weights quoted on a dry weight basis represent the totality of the extract, or slurry, or material, excluding water, and may include ingredients that are themselves liquids at room temperature and pressure, such as glycerol. In contrast, weight percentages quoted on a wet weight basis represent all ingredients, including water.

[0208] The aerosol-generating material may include a colorant. The addition of a colorant can change the visual appearance of the aerosol-generating material. The presence of a colorant in the aerosol-generating material can enhance the visual appearance of the aerosol-generating material. By adding a colorant to the aerosol-generating material, the aerosol-generating material can be color-matched to other components of the aerosol-generating material or other components of an article that includes the aerosol-generating material.

[0209] A 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 colors, and pharmaceutical grade colors. In a particular embodiment, the colorant is caramel, which may give the aerosol-generating material a brown appearance. In such an embodiment, the color of the aerosol-generating material may be similar to the color of other components of the aerosol-generating material, such as the tobacco material.

[0210] The colorant may be incorporated into the aerosol-forming material during formation (e.g., during formation of a slurry containing the materials that make up the aerosol-forming material) or may be applied after formation of the aerosol-forming material (e.g., by spraying onto the aerosol-forming material).

[0211] In some embodiments of any of the above embodiments, talc powder, calcium carbonate powder, or other powder is applied to an exposed surface of at least one discrete portion of the aerosol-generating material, which may reduce the level of tackiness or adhesiveness of the aerosol-generating material.

[0212] In the following discussion of the accompanying drawings, when an identical element is present in more than one embodiment, the same reference number is used for that element throughout, and when similar elements are present, like reference numbers (the same number plus a multiple of 100) are used.

[0213] 1, the aerosol delivery device 2 comprises a casing 4 within which a heating assembly 6 is disposed. The heating assembly 6 is comprised of a heating chamber 8 and an aerosol generator 10. The aerosol generator 10 can be an electrical resistance heater or a magnetic field generator used with a susceptor.

[0214] The heating chamber 8 defines an opening or mouth 12 at a first end of the heating chamber 8. At an opposite end of the heating chamber 8 is an opening 14. The opening 14 is in fluid communication with a mouthpiece 16 via a conduit 18.

[0215] Also disposed within the casing 4 is a controller 20 in electronic communication with the aerosol generator 10 to control its function. The controller 20 may include a memory (not shown) in which one or more tables relating to the operation of the heater 10 may be stored. The aerosol generator 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 another suitable power source.

[0216] The aerosol generating device 2 is suitable for use with a consumable 24. The consumable 24 has one or more discrete portions 32 of aerosol-generating material supported on a first surface 28 of the consumable 24. The discrete portions 32 of aerosol-generating material are supported on the first surface 28 in a square grid pattern. Other embodiments of the consumable 24 (not shown) may include more or fewer discrete portions 32 of aerosol-generating material than shown in FIG. 1, including a single portion 32 of aerosol-generating material, and these portions may be distributed in any pattern on the first surface 28. Although the discrete portions 32 of aerosol-generating material are shown in FIG. 1 as having a generally circular shape, they may have other shapes in other embodiments. Examples of methods of generating or manufacturing the consumable 24 are described below.

[0217] With reference to FIG. 2, this starts the production of an article of the desired dimensional size for the consumable 24 that constitutes it. The consumable 24 comprises a support 30. The support 30 comprises a longitudinally extending sheet of laminate material including first and second layers 36, 38. The first layer 36 has a surface that is a first surface 28 that is composed of a sheet of aluminum foil. The first layer 36 has a thickness of less than 0.025 mm. In other embodiments not shown, the material of the first layer 36 may be an aluminum alloy or a different suitable material such as a different metal or alloy. The first layer 36 may be adapted to act as a susceptor when the consumable 24 is used in connection with an aerosol generator 10 in the form of a magnetic field generator.

[0218] The second layer 38 is formed from cardboard and is rigid enough to support the first layer, providing a support that allows it to be handled and used without damage.

[0219] The length and width of support 30 as shown in Figures 1 and 2 are for illustrative purposes only. Support 30 may have different lengths and widths without departing from the scope of the present disclosure.

[0220] It can be seen that the first surface 28 is formed with six application areas 40 and six modified areas 42. Each application area 40 is surrounded by a modified area 42.

[0221] 2, application area 40 and modification area 42 are shown as being rectangular. The actual shape of the perimeter of application area 40 and modification area 42 may vary without departing from the scope of the present disclosure. For example, application area 40 may be shaped as a substantially circular longitudinally extending stripe, a stripe including at least one curve or angle, or a tessellated shape in the plane of the first surface of the support.

[0222] To form the application area 40 and the modified area 42, referring to FIG. 3, a first mask 50 is applied and removably secured to each of the application areas 40. The second mask 52 includes six openings 54. The second mask 52 is sized and configured to be removably secured to and cover most or all of the first surface 28 of the support 30, with the edges of the second mask 52 that define the openings 54 covering the periphery of the modified area 42. A surface coating 56 (shown in FIG. 4) is then sprayed over the combined first and second masks 50, 52 and support 30. The coating 56 covers the surface of the modified area 42.

[0223] Once the coating 56 has stabilized, for example by drying, the first and second masks 50, 52 are removed from the surface 28, leaving the coating 56 covering (and thus modifying) the modified areas 42. The remainder of the first surface 28 is unmodified. The coating 56 is selected to provide a hydrophobic surface. As a result, the surface of the modified areas 42 is hydrophobic.

[0224] Referring to FIG. 5, which shows a cross-section of the support 30 of FIG. 4, a nozzle 60 is connected to a reservoir (not shown) of a slurry containing a binder and an aerosol forming agent.

[0225] Nozzle 60 applies a predetermined amount of slurry 58 to each application area 40. Slurry 58 spreads across each application area 40 but does not flow onto surface coating 56 due to the hydrophobic nature of coating 56. The slurry is then cured by known slurry curing means.

[0226] In alternative, not shown, examples of the methods of the present disclosure, application area 40 may be different shapes, and slurry 58 will flow into and occupy those shapes, provided those shapes do not include small dimensions where surface tension or viscosity of slurry 58 would prevent slurry 58 from flowing across the shape.

[0227] Once the slurry 58 is dry, the support 30 is ready to be used as the consumable 24 in the aerosol generating device 2. Alternatively, the support 30 can now be separated into a number of smaller units which can be used as the consumable 24.

[0228] 5, there may be two or more nozzles 60, each connected to a different slurry reservoir (not shown). Each reservoir contains a slurry of a different composition (e.g., including different flavors and / or different colors). Portions of the slurries of different compositions may be applied to different application areas 40 on the support 30. In such an embodiment, the different application areas 40 may be different shapes to indicate that slurries of different compositions are being applied to the different application areas 40.

[0229] With reference to Figure 6, an article of desired dimensional size is formed for the consumable. Figure 6 illustrates a representative portion of a support 130 in an alternative embodiment of the method of the present disclosure, in which an application area 40 and first and second modified areas 42A, 42B are identified on a first surface 128 of the support 130. The support 130 generally includes multiple other application areas 40 and modified areas 42A, 42B in the same configuration as shown.

[0230] 7, a primary mask 150 is provided. The primary mask is comprised of a sheet of material 162 that is sized and shaped such that its outer edge (the minor surface extending between the major surfaces) is the same size and shape as the outer edge of the support 130. The primary mask 150 is placed on the surface 128 of the support 130 and is in its use position when the edges of the sheet 162 and the support 130 are aligned.

[0231] The sheet 162 defines a plurality of openings 154 (not all of which are numbered for clarity) that are disposed on the sheet 162 to cover intended locations of the plurality of first modified areas 42A when the primary mask 150 is in the use position.

[0232] Once the primary mask 150 is in the use position, the support 130 and primary mask 150 undergo a plasma coating process, which deposits a hydrophobic coating on the first surface 128. This results in the formation of a number of hydrophobic areas 142A, some of which are shown in Figure 9. As shown in Figure 9, the application area 40 is at least partially surrounded by four hydrophobic areas 142A. The same configuration is associated with each application area 40 on the first surface 128.

[0233] 8, a secondary mask 152 is next provided. The secondary mask is comprised of a sheet of material 164 that is sized and shaped such that its outer edge (the minor surface extending between the major surfaces) is the same size and shape as the outer edge of the support 130. The secondary mask 152 is placed on the surface 128 of the support 130 and is in its use position when the edges of the sheet 164 and the support 130 are aligned.

[0234] The sheet 164 defines a plurality of openings 166 (not all of which are numbered for clarity) that are positioned on the sheet 164 to cover intended locations of the plurality of second denatured areas 42B when the secondary mask 152 is in the use position.

[0235] When the secondary mask 152 is in the use position, the support 130 and the secondary mask 152 are subjected to a plasma coating process, which deposits a hydrophilic coating on the first surface 128. This forms a plurality of hydrophilic areas 142B as shown in FIG.

[0236] 8, the surface of modified area 42B is physically altered relative to first surface 128 of the support in areas not included in modified areas 42A, 42B. The alteration may be the result of one or more of plasma cleaning, plasma surface activation, or plasma etching.

[0237] 9, the application area 40 is partially surrounded by four hydrophilic areas 142B. The hydrophilic areas 142B extend between adjacent hydrophobic areas 142A, and the hydrophobic areas and the hydrophilic areas 142A, 142B together surround the entire application area 40.

[0238] Each of the hydrophilic areas 142B has an edge 168A (only one edge 168A is numbered for clarity). Each edge 168A overlaps a portion of the application area 40.

[0239] This configuration shown in FIG. 9 is associated with each application area 40 on the first surface 128.

[0240] Referring to FIG. 10, a nozzle (not shown) is connected to a reservoir of slurry 58 (not shown).

[0241] The nozzle applies a predetermined amount of slurry 58 to the application area 40. The slurry 58 spreads across the application area 40, but does not flow onto the hydrophobic areas 142A due to the hydrophobic nature of the coverage area 142A. The slurry 58 flows onto the ends 168A of the hydrophilic areas 142B due to the attraction of the hydrophilic surface to the water in the slurry 58. However, the slurry 58 does not flow onto the stem portions 168B or base portions 168C of the hydrophilic surface 142 because the gaps between adjacent hydrophobic areas 142A (occupied by the stem portions 168B of the hydrophilic areas 142B) are sized such that the surface tension or viscosity of the slurry 58 will not allow the slurry 58 to flow along the stem portions 168B into the gaps.

[0242] The slurry 58 is then cured by known slurry curing means, at least in part by wicking of water from the slurry 58 along the stems 168B of the hydrophilic areas 142B and onto the bases 168C. ​​Water is allowed to evaporate from the stems 168B and bases 168C of the hydrophilic areas 142B. Wicking of water from the slurry 58 continues until the slurry 58 is no longer a slurry and becomes an aerosol-generating film of more or less fixed dimensions. This is typically when the water content of the aerosol-generating material is between 10 and 40 wt % (e.g., around 10 wt %).

[0243] The wicking pathways in the stem portion 168B and base portion 168C of the hydrophilic area 142B remain effective after the consumable 124 of this embodiment of the disclosure is manufactured. As a result, the wicking pathways may wick away from the aerosol-generating film at least a portion of the water that the aerosol-generating film absorbs during manufacture and use of the consumable to aerosolize the aerosol-generating film.

[0244] In alternative, not shown, examples of the disclosed methods, application area 40 may be different shapes that the slurry will flow into and occupy, provided that in these examples the surface tension or viscosity of aerosol-forming material slurry 58 does not include small dimensions that would prevent the slurry from flowing across the shape.

[0245] Once the slurry 58 has hardened, the article is ready for use as the consumable 24 in the aerosol generating device 2. Alternatively, the article can now be separated into a number of smaller units or article portions which can be used as the consumable 24.

[0246] 11 and 12, which illustrate a dimensionally desired size article for a consumable in an alternative embodiment of the method of the present disclosure. A support 230 has a first surface 228A shown in FIG. 11 and a second surface 228B shown in FIG.

[0247] The first surface 228A includes two ring-shaped application areas 240A, a first modified area 242A, and two second modified areas 242B. The first modified area 242A covers the entire surface 228A outside the radial periphery of the application area 240A. The second modified area 242B is defined by the radial inner periphery of the application area 240A.

[0248] The entire support 230 is embossed or debossed with parallel peaks 270, 272. The parallel peaks 270 are approximately perpendicular to the parallel peaks 272. The peaks 270, 272 add stiffness to the support 230. This has the advantage that the support can be made thinner than a support of the same stiffness that is not embossed / debossed. For clarity, only one peak 270 and 272 are numbered.

[0249] The second surface 228B includes two circular application areas 240C and a third modified area 242C. The third modified area 242C covers the entire outer surface 228B around the perimeter of the application area 240C.

[0250] The first, second and third modified areas 242A, 242B, 242C are modified to have a hydrophobic surface by using a plasma coating technique. The surfaces of the application areas 240A, 240B are not treated and are therefore physically distinct from the surfaces of the first, second and third modified areas 242A, 242B, 242C.

[0251] Application areas 240A, 240B have slurry 58 applied to them. For application area 240A, second modified area 242B prevents slurry 58 from spreading to the center of the ring of application area 240A.

[0252] Once the slurry 58 is dry, the article is ready for use as a consumable in the aerosol generating device 2.

[0253] With reference to FIG. 13, to start the production of the consumable 324, an article of the desired dimensional size for the consumable is formed. The article comprises a support 330 and a modified material sheet 374. The support 330 comprises a longitudinally extending sheet of laminate material including first and second layers 336, 338. The first layer 336 has a surface that is a first surface 328 composed of a sheet of aluminum foil. The first layer 336 has a thickness of less than 0.025 mm. In other embodiments not shown, the material of the first layer 336 may be an aluminum alloy or a different suitable material such as a different metal or alloy. The first layer 336 may be adapted to act as a susceptor when the consumable 324 is used in connection with an aerosol generator 10 in the form of a magnetic field generator.

[0254] The second layer 338 is formed from cardboard and is rigid enough to support the first layer, providing a support that allows it to be handled and used without damage.

[0255] The lengths and widths of support portion 330 as shown in Figures 13-15 are for illustrative purposes only, and support portion 330 may have different lengths and widths without departing from the scope of the present disclosure.

[0256] Sheet 374 is a longitudinally extending sheet of material having at least one hydrophobic surface. The sheet has two major surfaces 376, 378. The first major surface 376 is coated with an adhesive (not shown) and is approximately the same dimensionally as surface 328 of support 330. Major surface 376 is configured to adhere to surface 328 of support 330. The adhesive is a peelable adhesive.

[0257] Extending between or substantially between major surfaces 376, 378 of sheet 374 is a cut line 380. Cut line 380 is positioned to coincide with the perimeter of intended application area 340 when sheet 374 is attached to support 330, as shown in FIG.

[0258] 15 , once sheet 374 is attached to support 330, the portions of sheet 374 within cut lines 380 are peeled away from surface 328 of support 330, exposing application areas 340 on surface 328 of support 330. In an alternative embodiment, not shown, the portions of sheet 374 within cut lines 380 are removed before sheet 374 is attached to support 330. Whether this alternative embodiment is desirable will depend on the layout and spacing of cut lines 380 and the handleability of sheet 34 after those portions are removed.

[0259] 16 and 17, once application areas 340 are exposed, aerosol-generating material slurry 58 is applied to each application area 340. As shown in FIG. 15, slurry 58 does not flow onto surface 378 of sheet 374, but forms a meniscus above each application area 340. This is due to the hydrophobic nature of the surface of sheet 374. In this manner, slurry 58 is held in the position where it is desired to remain. As slurry 58 dries, it shrinks in volume and is thereafter referred to as aerosol-generating material 58. As shown in FIG. 17, the meniscus of slurry 58 becomes smaller as the slurry dries to aerosol-generating material 58.

[0260] The item is now a consumable 324 and is ready for use.

[0261] In other embodiments of the present disclosure not shown, the combined support 330 and sheet 374 may be manufactured by a third party and the practitioner of the method of the present disclosure may purchase the combined support 330 and sheet 374 and perform the remainder of the method. In some instances, sheet 374 may not include cut lines upon application to support 330. Cut lines may be introduced later, for example, by use of a kiss-cut technique.

[0262] With reference to Figure 17, consumable 324 as discussed in connection with Figures 13-16 is the result of an article of the same dimensions as the desired dimensions for the consumable. Item 482 is larger than the desired dimensions for the consumable. In Figure 17, item 482 is shown sized to be cut along separation path 484 with a known cutting means (not shown) to produce eighteen item portions or consumables 324. It will be appreciated that different sizes for item 482 are possible.

[0263] The article 482 is formed similarly to that described for the consumable 324 as discussed in connection with Figures 13-16.

[0264] The various embodiments described herein are presented only as aids in understanding and teaching the features of the claims. These embodiments are provided as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, features, 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 it is understood that other embodiments can be utilized and improved without departing from the scope of the claimed invention. The various embodiments of the present invention may suitably include, consist of, or essentially consist of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein. The present disclosure may also include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. An article for use with an aerosol delivery device, comprising: the article comprises a support and an aerosol-forming material; the first surface of the support includes at least one application area and at least one modification area; the surface of the support in at least one modified area is modified to be either hydrophilic or hydrophobic; An article having an aerosol-forming material applied to at least one application area.

2. 10. The article of claim 1, wherein the article is shaped and sized for use as a consumable item for use with a non-flammable aerosol delivery system.

3. the article is larger than is compatible for use with a non-flammable aerosol delivery system; the article is separated into two or more article portions; 10. The article of claim 1, wherein each article portion is shaped and sized for use as a consumable with a device for heating an aerosol-forming material to volatilize at least one component of the aerosol-forming material.

4. the support has a first surface and a second surface, each of the first and second surfaces comprising at least one application area and at least one modification area; the first and second surfaces of the support are modified in at least one modified area; 10. The article of claim 1, wherein an aerosol-forming material is applied to at least one application area on each of the first and second surfaces of the support.

5. The article of claim 1 , wherein at least a portion of at least one modification area at least partially overlaps at least a portion of at least one application area.

6. The article of claim 1 , wherein at least one modified area has a modified material applied to the surface of the support in the at least one modified area.

7. 7. The article of claim 6, wherein the modifying material applied to the surface of the support is a layer of modifying material, and the layer of modifying material is discontinuous.

8. The article of claim 7 , wherein the discontinuities in the layer of modified material correspond to the application areas.

9. The article of claim 1 , wherein the surface of at least one modified area is plasma coated.

10. The article of claim 1 , wherein the surface of at least one modified area is physically altered relative to the surface of the support on which the modified area is disposed and that is not included in the modified area.

11. 11. The article of claim 10, wherein the surface of at least one modified area has been subjected to one or more of plasma cleaning, plasma surface activation, or plasma etching.

12. 2. The article of claim 1, wherein at least one modified area having a hydrophilic surface at least partially overlaps at least one application area, and the hydrophilic surface allows water in the aerosol-forming material applied to the application area to wick from the aerosol-forming material onto the hydrophilic surface.

13. 13. The article of claim 12, wherein the portion of each modified area that does not overlap an application area allows water wicked from the aerosol-forming material onto the hydrophilic surface to evaporate.

14. The article of claim 1 , wherein at least one modified area having a hydrophobic surface at least partially surrounds the application area.

15. 2. The article of claim 1, wherein at least one application area has a perimeter, and one or more modified areas having a hydrophobic surface collectively partially surround the perimeter of the application area, with the remainder of the perimeter of the application area being surrounded by at least one modified area having a hydrophilic surface.

16. 10. The article of claim 1, wherein at least one modified area has a hydrophobic surface and is disposed at a location on a surface of the support that is to be kept free of aerosol-forming material.

17. The article of claim 1 , wherein at least one application area is at least partially surrounded by at least one modified area.

18. 10. The article of claim 1, wherein one or more or each application area is surrounded by a modified area.

19. The article of claim 1 , wherein each modified area constitutes a band around the surrounding application area.

20. The article of claim 1 , wherein at least one modified area of the support is embossed or debossed.

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