Consumables for use with aerosol delivery devices

Abstract

A method is provided for manufacturing a consumable (124) for use with a non-flammable aerosol delivery system, the consumable comprising a support (30) and an aerosol-generating material (32A, 32B), the method including providing the support, forming at least one enhanced area (40A, 40B) on the support, and applying the aerosol-generating material to the support at least one location corresponding to at least a portion of the at least one enhanced 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 manufacturing a consumable for use with a non-flammable aerosol delivery system, the consumable comprising a support and an aerosol-generating material, the method comprising: Providing a support; forming at least one enhanced area on a support; applying an aerosol-generating material to a support at at least one location corresponding to at least a portion of at least one enhancement area; A method is provided, comprising:

[0006] According to a second aspect of the present disclosure, there is provided a consumable for use with a non-flammable aerosol delivery system, the consumable comprising a support, at least one enhanced area on the support, and an aerosol-generating material supported on the support at at least one location corresponding to at least a portion of the at least one enhanced area.

[0007] According to a third aspect of the present disclosure, there is provided an aerosol delivery device for use with a consumable according to the second 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.

[0008] According to a fourth aspect of the present disclosure, there is provided an aerosol delivery system comprising an aerosol delivery device and a consumable according to the second aspect of the present disclosure.

[0009] According to a fifth 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, in use, heat the consumable according to the second aspect of the present disclosure without burning it, wherein the at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.

[0010] 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]

[0011] [Figure 1] 1 is a schematic diagram of an embodiment of an aerosol delivery device and an embodiment of a consumable manufactured according to a first embodiment of the method of the present disclosure. [Diagram 2] 2A 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 with an enhanced area formed thereon according to the first embodiment. [Figure 4] 4 shows the support of FIG. 3 after an aerosol-generating material has been applied to the support. [Diagram 5] 3 shows the support of FIG. 2 during formation of the enhanced area of ​​the second embodiment. [Figure 6] 3 shows the support of FIG. 2 during formation of the enhanced area of ​​the second embodiment. [Figure 7] 7 shows the support of FIGS. 5 and 6 after an aerosol-generating material has been applied to the support. FIG. [Figure 8] 7 shows the support of the second embodiment of FIGS. 5 and 6 after an aerosol-generating material has been applied to the support. FIG. [Figure 9] 2 during formation of an enhanced area of ​​the third embodiment. FIG. [Figure 10] 2 during formation of an enhanced area of ​​the third embodiment. FIG. [Figure 11] FIG. 13 illustrates a portion of a susceptor that can be used to form an enhanced area of ​​a third embodiment. [Figure 12] 11 shows the support of FIGS. 9 and 10 after an aerosol-generating material has been applied to the support. FIG. [Figure 13] 2A and 2B show a second embodiment of a support for use in the manufacture of the consumable product of FIG. 1. [Figure 14]2A and 2B show a second embodiment of a support for use in the manufacture of the consumable product of FIG. 1. [Figure 15] 15A and 15B show the support of FIGS. 13 and 14 during formation of the enhanced area of ​​the fourth embodiment. [Figure 16] 15A and 15B show the support of FIGS. 13 and 14 during formation of the enhanced area of ​​the fourth embodiment. [Figure 17] 15A and 15B show the support of FIGS. 13 and 14 during formation of the enhanced area of ​​the fourth embodiment. [Figure 18] 15A and 15B show the support of FIGS. 13 and 14 during formation of the enhanced area of ​​the fourth embodiment. [Figure 19] FIG. 19 shows the support of FIGS. 13-18 after an aerosol-generating material has been applied to the support. [Figure 20] FIG. 19 shows the support of FIGS. 13-18 after an aerosol-generating material has been applied to the support. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Consumables herein may alternatively be referred to as articles.

[0013] 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.

[0014] 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.

[0015] 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.

[0016] In some embodiments, the delivery system is a non-flammable aerosol delivery system, such as a powered non-flammable aerosol delivery system.

[0017] 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.

[0018] 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.

[0019] 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.

[0020] 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.

[0021] 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.

[0022] 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.

[0023] 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.

[0024] 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.

[0025] According to a first aspect of the present disclosure, there is provided a method of manufacturing a consumable for use with a non-flammable aerosol delivery system, the consumable comprising a support and an aerosol-generating material, the method comprising: Providing a support; forming at least one enhanced area on a support; applying an aerosol-generating material to a support at at least one location corresponding to at least a portion of at least one enhancement area; A method is provided, comprising:

[0026] In one embodiment of the above embodiments, the aerosol-forming material is applied to the surface of the support as a slurry of aerosol-forming material.

[0027] An aerosol-forming material is a material that is capable of generating an aerosol when energized, e.g., by heating, irradiating, or in any other manner. The aerosol-forming material may be, for example, in solid, liquid, or semi-solid (e.g., gel) form, and may or may not contain active substances and / or flavorings.

[0028] 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.

[0029] The aerosol-generating material may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a delivery substance and / or a filler may also be present. Optionally, a solvent, such as water, may also be present, in which one or more other components of the aerosol-generating material may or may not be soluble. In some embodiments, the aerosol-generating material is substantially free of plant matter. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0030] 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.

[0031] 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.

[0032] The aerosol-generating 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.

[0033] 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.

[0034] 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.

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

[0036] In one embodiment of any of the above embodiments, the method further comprises allowing or causing the slurry of aerosol-generating material to harden. The slurry of aerosol-generating material may be hardened using known techniques for hardening aerosol-generating material slurries.

[0037] In one embodiment of any of the above embodiments, the slurry of aerosol-generating material hardens into an aerosol-generating material in the form of an aerosol-generating film.

[0038] The support may be of any material suitable for the construction of the substrate, for example the support may be or include paper, cardboard, paperboard, cardboard, recycled materials, plastic materials, ceramic materials, composites, glass, metals, or alloys.

[0039] 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.

[0040] An augmented area on the surface of a support is (i) an unaugmented area on the surface of the support and / or (ii) an area of ​​the support that has more desirable or different properties than the equivalent properties of an area on the surface of the support prior to augmentation.

[0041] In one embodiment of any of the above embodiments, the augmented areas are areas that have been augmented such that the stiffness of the haptic is greater than the stiffness of the haptic in areas of the haptic that are not augmented, and forming the at least one augmented area includes increasing the stiffness of the haptic in at least a portion of the at least one augmented area, hi some embodiments, the stiffness of the haptic is increased throughout substantially the entirety of the at least one augmented area.

[0042] An advantage of increasing the stiffness of at least a portion of at least one augmented area is that such area is less likely to sag or distort over time than a less stiff, non-augmented portion of the support. As a result, aerosol-generating material applied to such an augmented area is less likely to delaminate (separate) from the support than if the aerosol-generating material were applied to a less stiff, non-augmented portion of the support. This increases the useful life of consumables manufactured according to the present disclosure.

[0043] In one embodiment of any of the above embodiments, the augmented areas are areas where at least a portion of a surface of the area is molded and enhanced, and forming the at least one augmented area includes embossing or debossing the support in at least a portion of the at least one augmented area, hi some embodiments, the embossing or debossing of the support extends over substantially the entirety of the at least one augmented area.

[0044] An advantage of embossing or debossing the support is that the aerosol-generating material adheres better or stronger to the support on a molded surface (such as a surface created by embossing or debossing) than to a smooth, non-molded surface. Another advantage is that the reinforcement areas are more rigid, which provides the advantages discussed above.

[0045] Another possible advantage of embossing or debossing the support in at least a portion of at least one of the enhancement areas is that it may aid in positioning the aerosol-generating material applied to the embossed or debossed area relative to one or more means for heating the aerosol-generating material when the consumable is in use. Embossing or debossing may, for example, bring the aerosol-generating material closer to the heating means than other parts of the support. This has the advantage that the aerosol-generating material is heated more efficiently than if the aerosol-generating material were further away from the heater. Furthermore, there is more space around the aerosol-generating material than between the aerosol-generating material and the heater, allowing the generated aerosol to move away from the aerosol-generating material and towards the desired destination of the aerosol.

[0046] In one embodiment of any of the above embodiments, the augmented area is an area that has been augmented such that a thermal conductivity of the support is higher than a thermal conductivity of the support in an area of ​​the support that is not augmented, and forming the at least one augmented area includes increasing the thermal conductivity of at least a portion of the at least one augmented area. In some embodiments, the thermal conductivity of the support is increased throughout substantially the entirety of the at least one augmented area.

[0047] An advantage of having a high rate of heat transfer in the enhancement area is that it provides a greater efficiency in heating the aerosol-forming material applied to the enhancement area when it is desired to generate an aerosol from the aerosol-forming material.

[0048] In one embodiment of any of the above embodiments, the heat transfer coefficient is increased for at least a portion of a surface of the support in at least a portion of at least one enhanced area.

[0049] In one embodiment of any of the above embodiments, the augmented areas are areas that have been augmented such that a thickness of the haptic is greater than a thickness of the haptic in an area of ​​the haptic that is not augmented, and forming the at least one augmented area includes increasing the thickness of the haptic in at least a portion of the at least one augmented area, hi some embodiments, the thickness of the haptic is increased over substantially the entirety of the at least one augmented area.

[0050] The advantage of thickening the support in at least a portion of the at least one enhancement area may be that it aids in positioning the aerosol-generating material applied to the thick area relative to one or more means for heating the aerosol-generating material when the consumable is in use. The thickening may, for example, bring the aerosol-generating material closer to the heating means than other parts of the support. This has the advantage that the aerosol-generating material is heated more efficiently than if the aerosol-generating material were further away from the heater. Furthermore, there is more space around the aerosol-generating material than between the aerosol-generating material and the heater, allowing the generated aerosol to move away from the aerosol-generating material and towards the desired destination of the aerosol.

[0051] Another advantage of making the support thicker is that it becomes more rigid, for the reasons mentioned above.

[0052] In one embodiment of any of the above embodiments, the enhanced area is an area that is enhanced by including a susceptor, and the step of forming the at least one enhanced area includes applying a susceptor to at least a portion of the at least one enhanced area.

[0053] In one embodiment of any of the above embodiments, the step of forming the at least one augmented area includes applying a susceptor to a surface of the support in at least a portion of the at least one augmented area, in this embodiment, the susceptor is not applied to portions of the support other than the portions of the augmented area.

[0054] In one embodiment of any of the above embodiments, the susceptor is applied to substantially the entirety of the at least one enhanced area.

[0055] Applying a susceptor to some or all of one or more augmentation areas has the advantage that when the susceptor is heated during use of the consumable, the heating by the susceptor is limited to only those parts of the support that are intended to be heated, i.e., those parts of the augmentation area to which the susceptor is applied, thereby increasing the efficiency of heating of the consumable, since those parts of the support that are not intended to be heated are not heated.

[0056] In one embodiment of any of the above embodiments, applying the susceptor to the support includes applying one or more preforms of the susceptor. The susceptor preforms are cut or otherwise preformed into one or more predetermined shapes prior to application to the support. In some embodiments, all of the susceptor preforms are the same shape. In other embodiments, each of the susceptor preforms is one of many (two or more) different shapes.

[0057] In one embodiment of any of the above embodiments, the susceptor preform is applied to the support in a predetermined pattern, hi some embodiments, the predetermined pattern includes two or more susceptor preforms applied to the same enhanced area of ​​the support.

[0058] The configuration of one or more preforms of a susceptor on a surface of the support can be optimized to minimize the energy required to achieve a predetermined level of heating of the aerosol-generating material applied to the support.

[0059] In one embodiment of any of the above embodiments, applying the susceptor to the support includes applying a sheet of susceptor to the support, kiss-cutting the susceptor to form at least one predetermined closed cut line in the susceptor, and then removing a portion of the susceptor outside the closed cut line, the cut line coinciding with or contained within a perimeter of the at least one enhanced area. A cut line is closed when it has no end point and no start point. For example, a line representing a circle is closed because it has no start point and no end point. In some embodiments, the kiss-cutting of the susceptor may include one or more other cut lines disposed within an area defined by the closed cut line.

[0060] In one embodiment of any of the above embodiments, the susceptor comprises a metal or metal alloy. In some embodiments, the susceptor is a metal or metal alloy foil or film, for example an aluminum foil or film.

[0061] In one embodiment of any of the above embodiments, applying the susceptor to at least a portion of the at least one enhanced area includes using a hot foil stamping technique. The use of such a hot foil stamping technique advantageously allows for precise placement of the foil, thereby reducing the need to oversize the susceptor to account for inaccuracies in the application of the susceptor, thereby resulting in economic and environmental savings as less susceptor is used.

[0062] Another advantage of using hot foil stamping techniques is that in embodiments where enhanced areas are created by embossing or debossing, the embossing / debossing can be performed simultaneously with the hot foil stamping by adapting the embossing or debossing tool to also perform the hot foil stamping. Another benefit of such a configuration is that the embossing or debossing and application of the susceptor occur simultaneously, eliminating the need for separate alignment of the susceptor with respect to the embossed or debossed area.

[0063] 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.

[0064] 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).

[0065] In some embodiments of any of the above embodiments, the susceptor may be a metal foil, optionally an aluminum foil, or an iron foil, or, 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.

[0066] In one embodiment of any of the above embodiments, the at least one enhancement area includes two or more enhancements.

[0067] In one embodiment of any of the above embodiments, the step of forming at least one enhancement area includes forming at least two separate enhancement areas.

[0068] In one embodiment of any of the above embodiments, the at least two distinct enhancement areas of the at least two distinct enhancement areas are distinguishable from one another by a human or an automated observer. In this context, a human is understood to be a human of average vision who does not suffer from color blindness or similar conditions. In some embodiments, each enhancement area is a different shape or color.

[0069] In one embodiment of any of the above embodiments, the step of applying the aerosol-generating material includes applying the aerosol-generating material to at least a portion of each enhanced area of ​​the support, and not applying the aerosol-generating material to portions of the support that do not form the enhanced areas.

[0070] In one embodiment of any of the above embodiments, the step of applying the aerosol-generating material includes applying the aerosol-generating material to the entirety of each enhanced area of ​​the support, and not applying the aerosol-generating material to portions of the support that do not form the enhanced areas.

[0071] In one embodiment of any of the above embodiments, the step of applying the aerosol-generating material includes applying the aerosol-generating material to the entirety of each augmentation area of ​​the support and to at least a portion of the support surrounding each augmentation area, without applying the aerosol-generating material to the remaining portions of the support that do not form the augmentation area. An advantage of this configuration is that the aerosol-generating material on the support surrounding each augmentation area utilizes heat that is applied to the augmentation area and exits the augmentation area by conduction, thereby maximizing the amount of aerosol generated per Joule (J) of thermal energy applied to the augmentation area.

[0072] In one embodiment of any of the above embodiments, at least a portion of the support surrounding each augmented area is a zone that extends less than 1 mm, less than 2 mm, less than 3 mm, less than 4 mm, less than 5 mm, less than 6 mm, less than 8 mm, or less than 10 mm from the perimeter of the augmented area.

[0073] In one embodiment of any of the above embodiments, the step of applying the aerosol-generating material includes applying the aerosol-generating material to substantially the entirety of the support, which has the advantage of eliminating the need to precisely position the aerosol-generating material on the surface of the support to coincide with the location of each enhancement area.

[0074] In one embodiment of any of the above embodiments, the step of applying the aerosol-generating material includes applying the aerosol-generating material using a transfer wheel.

[0075] In one embodiment of any of the above embodiments, the aerosol-forming material is applied to the surface of the support as an aerosol-forming material slurry.

[0076] In one embodiment of any of the above embodiments, the method further comprises the step of allowing or curing the aerosol-generating material slurry, where the aerosol-generating material slurry hardens into the aerosol-generating material. The aerosol-generating material may be hardened using known aerosol-generating material curing techniques.

[0077] In one embodiment of any of the above embodiments, the aerosol-forming material is applied as a hardened aerosol-forming material.

[0078] In one embodiment of any of the above embodiments, the step of applying the aerosol-generating material includes hot pressing the aerosol-generating material onto the support. Hot pressing is performed using known hot pressing techniques. In some embodiments, the temperature of the hot pressing is below the temperature at which aerosolization of the aerosol-generating material begins.

[0079] In one embodiment of any of the above embodiments, the aerosol-forming material is an aerosol-forming film.

[0080] In one embodiment of any of the above embodiments, the steps of forming at least one enhancement area on the support and applying the aerosol-generating material occur substantially simultaneously, hi some embodiments, the aerosol-generating material is heat pressed onto the support, which also forms one or more enhancement areas on the support.

[0081] In one embodiment of any of the above embodiments, the support comprises a sheet having a first and second surface, the step of forming the at least one enhancement area includes forming at least one enhancement area on one or both of the first and second surfaces of the support, and the step of applying the aerosol-generating material includes applying the aerosol-generating material to one or both of (i) at least a portion of the at least one enhancement area and (ii) at least a portion of a portion of one surface that positionally corresponds to a location of the at least one enhancement area on the other surface. This configuration has the advantage that the aerosol-generating material can be applied to one or both surfaces of the support. When the aerosol-generating material is applied to both the first and second surfaces of the support, more aerosol-generating material may be associated with the enhancement area than when the aerosol-generating material is applied to only one surface of the support.

[0082] In one embodiment of any of the above embodiments, the support comprises a sheet having a first and second surface, and the step of forming the at least one enhanced area includes forming the at least one enhanced area on the first and second surfaces of the support.

[0083] According to a second aspect of the present disclosure, there is provided a consumable for use with an apparatus for heating a non-flammable aerosol delivery system, the consumable comprising a support, at least one enhanced area on the support, and an aerosol-generating material supported on the support at at least one location corresponding to at least a portion of the at least one enhanced area.

[0084] In one embodiment of any of the above embodiments, the aerosol-forming material is in the form of an aerosol-forming film.

[0085] In one embodiment of any of the above embodiments, the augmentation in the at least one augmented area of ​​the support comprises at least a portion of the at least one augmented area of ​​the support having a higher stiffness than a portion of the support other than the portion of the augmented area.

[0086] In one embodiment of any of the above embodiments, the augmentation in the at least one augmented area of ​​the support includes at least a portion of the at least one augmented area having a higher thermal conductivity than a portion of the support other than the portion of the augmented area.

[0087] In one embodiment of any of the above embodiments, the enhancement in the at least one enhanced area of ​​the support portion, at least a portion of the at least one enhanced area is embossed or debossed.

[0088] In one embodiment of any of the above embodiments, the augmentation in the at least one augmented area of ​​the support portion includes at least a portion of the at least one augmented area having a greater thickness than a portion of the support portion other than the portion of the augmented area.

[0089] In one embodiment of any of the above embodiments, as the augmentation in the at least one augmentation area of ​​the support, the at least one augmentation area includes a susceptor.

[0090] In one embodiment of any of the above embodiments, the susceptor is a metal or alloy. In some embodiments, the susceptor is a metal or alloy foil or film, for example an aluminum foil or film.

[0091] In one embodiment of any of the above embodiments, the susceptor has a perimeter that matches the shape and size of the perimeter of the enhanced area to which it is applied.

[0092] In one embodiment of any of the above embodiments, the susceptor covers at least a portion of the augmented area, and the periphery of the augmented area surrounds the susceptor.

[0093] In one embodiment of any of the above embodiments, the at least one enhancement area includes two or more enhancements.

[0094] In one embodiment of any of the above embodiments, there are at least two distinct areas of enhancement.

[0095] In one embodiment of any of the above embodiments, at least two distinct augmented areas of the at least two distinct augmented areas are distinguishable from one another by a human or automated observer.

[0096] In one embodiment of any of the above embodiments, the aerosol-generating material is supported on at least a portion of each enhancement area, and portions of the support that do not form the enhancement areas are free of aerosol-generating material.

[0097] In one embodiment of any of the above embodiments, the entirety of each enhancement area supports aerosol-generating material, and portions of the support that do not form an enhancement area do not support aerosol-generating material.

[0098] In one embodiment of any of the above embodiments, the entirety of each enhancement area and the surrounding zone or at least a portion of the support surrounding each enhancement area supports aerosol-generating material, and portions of the support that do not form either the enhancement area or the surrounding zone do not support aerosol-generating material.

[0099] In one embodiment of any of the above embodiments, at least a portion of the support surrounding each augmented area is a zone that extends less than 1 mm, less than 2 mm, less than 3 mm, less than 4 mm, less than 5 mm, less than 6 mm, less than 8 mm, or less than 10 mm from the perimeter of the augmented area.

[0100] In one embodiment of any of the above embodiments, substantially the entire support supports the aerosol-generating material, it being understood in this context that substantially the entire support refers to the entirety of one surface of the support if the one or more enhancement areas are formed on only one surface of the support, or the entirety of two or more surfaces of the support if the one or more enhancement areas are formed on two or more surfaces of the support.

[0101] In one embodiment of any of the above embodiments, the aerosol-forming material comprises an aerosol-forming gel.

[0102] In one embodiment of any of the above embodiments, the support comprises a sheet having first and second surfaces, at least one enhancement area is disposed on one or both of the first and second surfaces of the support, and the aerosol-generating material is supported on one or both of: (i) at least a portion of the at least one enhancement area and (ii) at least a portion of a portion of one surface that positionally corresponds to the location of the enhancement area on the other surface.

[0103] In one embodiment of any of the above embodiments, the support comprises a sheet having a first and second surface, and at least one enhancement area is disposed on each of the first and second surfaces of the support.

[0104] In one embodiment of any of the above embodiments, the aerosol forming material includes an active agent.

[0105] 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.

[0106] The active substance may include one or more constituents, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0107] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] 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.

[0112] In some embodiments, the aerosol-forming material comprises a fragrance or flavoring.

[0113] 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.

[0114] 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.

[0115] 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.

[0116] The aerosol generating material includes an aerosol generating agent. 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.

[0117] 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.

[0118] 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.

[0119] 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.

[0120] 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%.

[0121] 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.

[0122] 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.

[0123] 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.

[0124] 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.

[0125] 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.

[0126] 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.

[0127] 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.

[0128] 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.

[0129] 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).

[0130] 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.

[0131] 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).

[0132] 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.

[0133] 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.

[0134] 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.

[0135] 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.

[0136] 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.

[0137] (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.

[0138] 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.

[0139] In some instances, the slurry may be applied to a support such that a layer is formed on the support.

[0140] 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

[0141] 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.

[0142] 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.

[0143] 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.

[0144] 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.

[0145] 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.

[0146] 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.

[0147] 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.

[0148] 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).

[0149] 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.

[0150] 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.

[0151] The aerosol-forming material may include a bulking agent.

[0152] 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%.

[0153] 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.

[0154] 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.

[0155] 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.

[0156] 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)).

[0157] 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.

[0158] In some embodiments, the aerosol-forming material does not include tobacco fibers, hi certain embodiments, the aerosol-forming material does not include fibrous materials.

[0159] 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.

[0160] 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.

[0161] 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.

[0162] 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.

[0163] 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.

[0164] 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).

[0165] 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.

[0166] 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.

[0167] 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%.

[0168] 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.

[0169] 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.

[0170] 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.

[0171] 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.

[0172] 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.

[0173] 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).

[0174] 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).

[0175] 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.

[0176] 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.

[0177] 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.

[0178] As an example, the aerosol-forming material does not include flavorants. In certain instances, the aerosol-forming material does not include active agents.

[0179] 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 and include aerosol-forming materials.

[0180] In some embodiments, the aerosol-forming material comprises 1-80 wt % (dry weight basis) of flavoring.

[0181] 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.

[0182] 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.

[0183] 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.

[0184] 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.

[0185] 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.

[0186] 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).

[0187] 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).

[0188] 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.

[0189] 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.

[0190] 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.

[0191] 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.

[0192] It has been found that if the aerosol-generating material is too thick, it will heat less efficiently, which will have a negative impact on power consumption during use. Conversely, if the aerosol-generating material is too thin, it will be difficult to manufacture and handle. If the material is too thin, it will be more difficult to mold and may even be fragile, compromising aerosol formation during use.

[0193] 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%.

[0194] 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.

[0195] 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.

[0196] 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.

[0197] 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.

[0198] 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.

[0199] 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.

[0200] 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 colorants, and pharmaceutical grade colorants. In certain embodiments, the colorant may be caramel, giving the aerosol-generating material a brown appearance. In such embodiments, 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. In some embodiments, the colorant is added to the aerosol-generating material such that it is visually indistinguishable from other ingredients in the aerosol-generating material.

[0201] 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).

[0202] 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.

[0203] 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.

[0204] 1, the aerosol delivery device 2 includes a casing 4 within which a heating assembly 6 is disposed. The heating assembly 6 is comprised of a heating chamber 8 and a heater 10. The heater 10 can be an electrical resistance heater or a magnetic field generator used in conjunction with a susceptor.

[0205] 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.

[0206] Also disposed within the casing 4 is a controller 20 in electronic communication with the heater 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 heater 10 and the controller 20 are powered by a power source 22. The power source 22 is a rechargeable battery. In other embodiments, the power source may be another suitable power source.

[0207] 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 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 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.

[0208] With reference to FIG. 2, to begin manufacturing of the consumable 24, a support 30 is provided. The support 30 comprises a longitudinally extending sheet of material, and in the illustrated embodiment, the support 30 is a cardboard sheet 34. In other embodiments not shown, the material may be another suitable material (e.g., paper, cardboard, paperboard, cardboard, recycled material, plastic material, ceramic material, composite material, or glass). The length and width of the support 30 as shown in FIG. 2 are for illustrative purposes only. The support 30 may have different lengths and widths without departing from the scope of the present disclosure.

[0209] The cardboard 34 has two major surfaces, a first surface 36 and a second surface 38. The distance between the first and second surfaces 36, 38 is a thickness t.

[0210] The first surface 36 of the support 30 is designated as having first and second augmented areas 40A, 40B.

[0211] 3, the support 30 is embossed with male and female dies (not shown) to form a plurality of parallel ridges 42 (only two of which are numbered for clarity) extending across the reinforcement areas 40A, 40B. The male and female dies are disposed adjacent the second and first faces 38, 36 of the support 30, respectively. The dies are oriented such that the profiles of the male and female dies match each other, and then pressed together to form the embossments / ridges 42 of the support 30.

[0212] Forming the ridges 42 on the support portion 30 increases the stiffness, or at least the resistance to bending about the Y-axis (as shown in FIG. 2), of the reinforced areas 40A, 40B as compared to a support portion 30 that is not embossed.

[0213] 4, after embossing of the support 30, different portions of aerosol-generating material 32A, 32B are applied to the augmented areas 40A, 40B. The aerosol-generating materials 32A, 32B cover the entire augmented areas 40A, 40B and the peaks 42. The peaks 42 aid in the attachment of the aerosol-generating material to the support 30. Except for the augmented areas 40A, 40B, no aerosol-generating material is applied to the support 30.

[0214] In the embodiment of the present disclosure shown in Figures 2-4, the portions of aerosol-generating material 32A, 32B are applied to the augmentation areas 40A, 40B in the form of a slurry. The slurry applied to the augmentation areas 40A, 40B must be dried or allowed to dry before the support portion 30 and the aerosol-generating material portions 32A, 32B can function as consumables 24. The support portion 30 and the aerosol-generating material portions 32A, 32B could simply be allowed to dry over time, but such an approach may result in inefficient production of the medium and the aerosol-generating material portions 32, 232, 332. Therefore, the aerosol-generating material portions 32A, 32B can be dried by known methods for drying aerosol-generating material slurries.

[0215] Once dry, the aerosol can be generated using the aerosol delivery device 2 through the use of the consumables 24.

[0216] In an alternative embodiment of the present disclosure, not shown, embossing of the support 30 can be performed with a male and female mold, where at least the female mold is heated and the sheet of aerosol-generating material covers the surface 36 of the support 30 at least in the augmented areas 40A, 40B. Heating of the female mold causes the portions of the sheet of aerosol-generating material covering the augmented areas 40A, 40B to adhere to the surface 36 of the support 30 while at the same time forming ridges 42 as a result of the configuration of the mold. The sheet of aerosol-generating material not adhering to the augmented areas 40A, 40B can then be removed from the surface 36 of the support 30.

[0217] 5, in a second embodiment of the disclosed method for manufacturing a consumable 124, a layer 44 of susceptor material is applied to the first surface 36 of the support 30 of FIG. 2. The susceptor layer 44 is a metal foil or film (e.g., an aluminum foil or film). The susceptor layer is reversibly secured to the support 30 by a suitable fastening material (not shown).

[0218] A kiss cutter, not shown, cuts closed cut lines 46A, 46B into the susceptor layer 44. The closed cut lines 46A, 46B coincide with the perimeter of the augmented areas 40A, 40B. In another embodiment, not shown, the closed cut lines 46A, 46B are inside the perimeter of the augmented areas 40A, 40B.

[0219] Referring to FIG. 6, once the closed cut lines 46A, 46B are formed, the portions of the susceptor layer 44 outside the closed cut lines 46A, 46B are removed from the support 30, thereby leaving first and second susceptor portions 44A, 44B on the support 30 covering the enhanced areas 40A, 40B.

[0220] 7, different aerosol-generating material portions 32A, 32B are then applied to the susceptor portions 44A, 44B and the peripheral zones or areas 48A, 48B. The peripheral zones 48A, 48B are zones of the first surface 36 that extend around the augmented areas 40A, 40B. Thus, the aerosol-generating material 32A, 32B covers all of the surfaces of the susceptor portions 44A, 44B that are not facing the augmented areas 40A, 40B. In some examples of the present disclosure, the zones 48A, 48B extend less than 1 mm, less than 2 mm, less than 3 mm, less than 4 mm, less than 5 mm, less than 6 mm, less than 8 mm, or less than 10 mm from the perimeter of the augmented areas 40A, 40B, respectively.

[0221] 8, this figure illustrates an alternative embodiment of the use of support 30 and susceptor portions 44A, 44B. In this embodiment, aerosol-generating material 32 is applied to the entire first surface 36 and susceptor portions 44A, 44B. Aerosol-generating material 32 is applied to first surface 36 and susceptor portions 44A, 44B by a transfer wheel (not shown).

[0222] 7 and 8, the aerosol-generating material portions 32A, 32B / 32 are applied in the form of a slurry to the susceptor portions 44A, 44B and zones 48A, 48B / first surfaces 36 and susceptor portions 44A, 44B, similar to the application of the aerosol-generating material discussed in connection with Figures 2-4. Once the slurry of the aerosol-generating material portions 32A, 32B / 32 has dried, an aerosol can be generated using the aerosol delivery device 2 through the use of the consumables 124.

[0223] The susceptor portions 44A, 44B of the consumable 124 have different functions in the consumable 24 depending on the nature of the aerosol delivery device 2 with which the consumable is used.

[0224] When the aerosol delivery device 2 heats the consumable 124 by induction heating, the aerosol generator 10 is a magnetic field generator, and the susceptor portions 44A and 44B are susceptors that are heated by a magnetic field from the magnetic field generator. The heat causes the aerosol-generating material portions 32A and 32B to generate aerosols.

[0225] When the aerosol delivery device 2 heats the consumable 124 by resistive heating, the aerosol generator 10 is a resistive heater and the susceptor portions 44A, 44B increase the heat transfer rate of the enhanced areas 40A, 40B by conducting thermal energy across the enhanced areas 40A, 40B.

[0226] With reference to Fig. 9, in a third embodiment of the disclosed method for manufacturing the consumable 224, thickening elements 50A, 50B are applied to the reinforced areas 40A, 40B of the support 30 of Fig. 2. The thickening elements 50A, 50B are made of an inert material and, in the example shown in Fig. 9, are not of uniform thickness throughout the reinforced areas 40A, 40B. In other examples not shown, the thickening elements 50A, 50B are of uniform thickness throughout all or part of the reinforced areas 40A, 40B. The inert material of the thickening elements 50A, 50B is inert at the temperature at which the consumable 224 is used and may be made, for example, of a matrix of wood fibers and a suitable binder.

[0227] 9 and 10, the thickening elements 50A, 50B have surfaces 52A, 52B that do not face the support portion 30. Susceptor material portions 54A, 54B are attached to the surfaces 52A, 52B of the thickening elements 50A, 50B by a suitable fixing means. The susceptor portions 54A, 54B are formed of a metal foil or film (e.g., aluminum foil or film).

[0228] 10 and 11, the susceptor portions 54A and 54B are cut into different shapes (a triangle and a rectangle, respectively) while attached to the backing sheet 56. The susceptor portions 54A and 54B are separated from the respective backing sheets 56 and attached to the surfaces 52A and 52B, respectively.

[0229] 12, different portions of aerosol-generating material 132A, 132B are then applied to the susceptor portions 54A, 54B as well as to the portions of the surfaces 52A, 52B of the thickening elements 50A, 50B that surround the susceptor portions 54A, 54B. The aerosol-generating material 132A, 132B thus covers the entire surfaces of the susceptor portions 54A, 54B that are not facing the surfaces 52A, 52B of the thickening elements 50A, 50B.

[0230] The aerosol-generating material portions 132A, 132B are applied in the form of a slurry to portions of the surfaces 52A, 52B of the susceptor portions 54A, 54B and thickening elements 50A, 50B, similar to the application of aerosol-generating material discussed above in connection with Figures 2-4. Once the slurry of the aerosol-generating material portions 132A, 132B has dried, an aerosol can be generated using the aerosol delivery device 2 through the use of the consumables 224.

[0231] 13 and 14, in a fourth embodiment of the disclosed method of manufacturing a consumable 324, a support 130 is provided. The support 130 comprises a longitudinally extending sheet of material, which in the illustrated embodiment is a cardboard sheet. In other embodiments not illustrated, the material may be another suitable material (e.g., paper, cardboard, paperboard, cardboard, recycled material, plastic material, ceramic material, composite material, or glass). The length and width of the support 130 as illustrated in FIGS. 13 and 14 are for illustrative purposes only. The support 130 may have a different length and width without departing from the scope of the present disclosure.

[0232] The support 130 has two major surfaces, a first surface 36 and a second surface 38 .

[0233] The first surface 36 of the support 130 is designated as having first and second augmented areas 140A, 140B. The second surface 38 of the support 130 is designated as having third and fourth augmented areas 140C, 140D. The first and third augmented areas 140A, 140C correspond to one another because they are located in the same positions on the first and second faces 36, 38 of the support 130. Similarly, the second and fourth augmented areas 140B, 140D correspond to one another because they are located in the same positions on the first and second faces 36, 38 of the support 130.

[0234] 15 and 16, a first layer 44 of susceptor material is placed on the first surface 36 of the support 130. The susceptor layer 44 is a metal foil or film (e.g., aluminum foil or film). The susceptor layer is reversibly secured to the support 130 by a suitable fastening material (not shown).

[0235] A kiss cutter (not shown) cuts closed cut lines 146A, 146B into the first susceptor layer 44. The closed cut lines 146A, 146B coincide with the perimeters of the enhanced areas 140A, 140B. Thereafter, or simultaneously, a second layer 44 of susceptor material is placed on the second surface 38 of the support 130. Each susceptor layer 44 is a metal foil or film (e.g., aluminum foil or film). The susceptor layers are reversibly secured to the support 130 by a suitable fastening material (not shown).

[0236] A kiss cutter (not shown) cuts closed cut lines 146C, 146D into the second susceptor layer 44. The closed cut lines 146C, 146D coincide with the periphery of the enhanced areas 140C, 140D.

[0237] 17 and 18, once the closed cut lines 146A, 146B, 146C, 146D are formed, portions of the first and second susceptor layers 44 outside the closed cut lines 146A, 146B, 146C, 146D are removed from the support 130, thereby leaving first, second, third, and fourth susceptor portions 144A, 144B, 144C, 144D on the support 130 covering the enhanced areas 140A, 140B, 140C, 140D.

[0238] 19 and 20, different aerosol-generating material portions 232A, 232B, 232C, 232D are then applied to the susceptor portions 144A, 144B, 144C, 144D and peripheral zones or areas 148A, 148B, 148C, 148D. Peripheral zones 148A, 148B are zones of the first surface 36 that extend around the augmented areas 140A, 140B. Peripheral zones 148C, 148D are zones of the second surface 38 that extend around the augmented areas 140C, 140D.

[0239] Thus, the aerosol-generating material portions 232A, 232B, 232C, 232D cover all surfaces of the susceptor portions 144A, 144B, 144C, 144D that are not facing the augmentation areas 140A, 140B, 140C, 140D. In some examples of the present disclosure, the peripheral zones 148A, 148B, 148C, 148D extend less than 1 mm, less than 2 mm, less than 3 mm, less than 4 mm, less than 5 mm, less than 6 mm, less than 8 mm, or less than 10 mm from the perimeter of the augmentation areas 140A, 140B, 140C, 140D, respectively.

[0240] The aerosol-generating material portions 232A, 232B, 232C, 232D are applied in the form of a slurry to the susceptor portions 144A, 144B, 144C, 144D and zones 148A, 148B, 148C, 148D, similar to the application of aerosol-generating material discussed in connection with Figures 2-4. Once the slurry in the aerosol-generating material portions 232A, 232B, 232C, 232D has dried, an aerosol can be generated using the aerosol delivery device 2 through the use of the consumables 324.

[0241] 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. 1. A method of manufacturing a consumable for use with a non-flammable aerosol delivery system, the consumable comprising: a support portion and an aerosol-generating material; providing the support; forming at least one enhanced area on the support; applying the aerosol-generating material to the support at least one location corresponding to at least a portion of the at least one enhancement area; A method comprising:

2. A consumable for use with a non-flammable aerosol delivery system, the consumable comprising: a support; at least one enhanced area on the support; and an aerosol-generating material supported on the support at least in one location corresponding to at least a portion of the at least one enhanced area.

3. The consumable product of claim 2 , wherein the reinforcement in the at least one reinforced area of the support portion causes at least a portion of the at least one reinforced area to have a higher stiffness than a portion of the support portion other than the reinforced area.

4. The consumable of claim 2 , wherein the enhancement in the at least one augmented area of the support is such that at least a portion of the at least one augmented area has a higher heat transfer coefficient than portions of the support other than the augmented area.

5. The consumable product of claim 2 , wherein the enhancement in the at least one enhanced area of the support portion is at least a portion of the at least one enhanced area being embossed or debossed.

6. The consumable of claim 2 , wherein the enhancement in the at least one augmented area of the support portion includes at least a portion of the at least one augmented area having a thickness greater than a portion of the support portion other than the augmented area.

7. The consumable of claim 2 , wherein the at least one augmented area of the support includes a susceptor as an augmentation.

8. The consumable of claim 7 , wherein the susceptor comprises a metal or alloy.

9. The consumable of claim 7 , wherein the susceptor has a perimeter that matches the shape and dimensions of the perimeter of the augmented area to which the susceptor is applied.

10. The consumable of claim 7 , wherein the susceptor covers at least a portion of the augmented area, and the periphery of the augmented area surrounds the susceptor.

11. The consumable of claim 2 , wherein at least one augmented area includes two or more augmentations.

12. The consumable of claim 2 , wherein there are at least two distinct areas of enhancement.

13. The consumable of claim 12 , wherein at least two of the at least two distinct augmented areas are distinguishable from one another by a human or automated observer.

14. 3. The consumable of claim 2, wherein an aerosol-generating material is supported on at least a portion of each of the enhancement areas, and portions of the support that do not form enhancement areas are free of aerosol-generating material.

15. 3. The consumable product of claim 2, wherein the entirety of each enhancement area supports aerosol-forming material, and portions of the support that do not form enhancement areas do not support aerosol-forming material.

16. 3. The consumable of claim 2, wherein the entirety of each enhancement area and the surrounding zone supports aerosol-generating material, and portions of the support that do not form either an enhancement area or a surrounding zone do not support aerosol-generating material.

17. 17. The consumable of claim 16, wherein the peripheral zone is a zone extending less than 1 mm, less than 2 mm, less than 3 mm, less than 4 mm, less than 5 mm, less than 6 mm, less than 8 mm, or less than 10 mm from the perimeter of the enhanced area.

18. The consumable product of claim 2 , wherein substantially the entire support portion supports the aerosol-forming material.

19. 3. The consumable product of claim 2, wherein the support comprises a sheet having first and second surfaces, at least one enhancement area is disposed on one or both of the first and second surfaces of the support, and the aerosol-generating material is supported on one or both of: (i) at least a portion of the at least one enhancement area; and (ii) at least a portion of a portion of one surface that positionally corresponds to the location of the at least one enhancement area on the other surface.

20. The consumable product of claim 2 , wherein the support comprises a sheet having first and second surfaces, and at least one reinforcement area is disposed on each of the first and second surfaces of the support.

Images