Consumables for use with aerosol delivery devices

Abstract

A method of manufacturing a consumable (24) for use with a non-flammable aerosol delivery system is provided, the consumable comprising a support (30) and an aerosol-generating material (32). The method includes the steps of (a) providing the support, (b) surface treating at least a portion of a first surface (28) of the support, and (c) applying the aerosol-generating material to at least a portion of the first surface of the support. The surface treating in step (b) includes altering one or more chemical or physical properties of the surface, the alteration of the physical properties of the surface being achieved by one or more processes that do not include perforating or embossing the support.

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: (a) providing a support; (b) surface treating at least a portion of the first surface of the support; (c) applying an aerosol-generating material to at least a portion of a first surface of the support; Including, A method is provided in which the surface treatment of step (b) comprises altering one or more chemical or physical properties of the surface, and the alteration of the physical properties of the surface is achieved by one or more processes that do not involve perforating or embossing the support.

[0006] According to a second aspect of the present disclosure, there is provided a consumable product comprising a support and an aerosol-generating material, the consumable product being manufactured according to the method of the first aspect of the present disclosure.

[0007] According to a third aspect of the present disclosure, there is provided an aerosol delivery device for use with a consumable manufactured by a method according to the first aspect of the present disclosure, the aerosol delivery device comprising a heating assembly 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 product manufactured by the method according to the first 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 heat the consumable according to the first aspect of the present disclosure without combustion in use, 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 an embodiment of a method of the present disclosure. [Diagram 2] 2A and 2B show a first embodiment of a support for use in the manufacture of the consumable product of FIG. 1; [Diagram 3] FIG. 3 shows the support of FIG. 2 surface treated according to a first embodiment of the method of the present disclosure. [Figure 4] 4 illustrates the support of FIG. 3 with an aerosol-generating material applied to the support. [Diagram 5] FIG. 3 shows the support of FIG. 2 surface treated according to a second embodiment of the method of the present disclosure. [Figure 6] 6 shows the support of FIG. 5 with an aerosol-generating material applied to the support. [Figure 7] FIG. 7 shows the support of FIG. 6 separated into two consumables. [Figure 8] FIG. 3 shows the support of FIG. 2 in the process of being surface treated according to a third embodiment of the method of the present disclosure. [Figure 9] 6 shows the support of FIG. 5 with an aerosol-generating material 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 an apparatus for heating a non-flammable aerosol delivery system, the consumable comprising a support and an aerosol-generating material, the method comprising: (a) providing a support; (b) surface treating at least a portion of the first surface of the support; (c) applying an aerosol-generating material to at least a portion of a first surface of the support; Including, A method is provided in which the surface treatment of step (b) comprises altering one or more chemical or physical properties of the surface, and the alteration of the physical properties of the surface is achieved by one or more processes that do not involve perforating or embossing the support.

[0026] In one embodiment of any of the above embodiments, the surface treatment in step (b) increases the strength of the bond formed between the aerosol-generating material and the treated portion of the first surface of the support relative to the strength of the bond formed between the aerosol-generating material and an untreated portion of the first surface of the support.

[0027] The strength of the bond between an aerosol-generating material and the surface of the support to which it is applied can be measured by assessing the maximum tensile stress required to detach or pull the aerosol-generating material from the surface when pulled in a direction perpendicular to the surface. The maximum tensile stress is the tensile stress required to initiate detachment of the aerosol-generating material from the surface. Once detachment has been initiated, the tensile stress required to continue detachment of the aerosol-generating material from the surface will be less than the tensile stress required to initiate detachment.

[0028] Increasing the strength of the bond of the first surface of the support to the treatment portion is advantageous because it reduces the likelihood of delamination or unintentional detachment of the aerosol-forming material from the surface of the support, which in turn increases the shelf life of the consumable or the period during which the consumable can be stored without delamination.

[0029] In one embodiment of any of the above embodiments, the surface treatment of step (b) provides a treated surface that is less reactive than an untreated surface. In some embodiments, the reactivity results in a reduced likelihood of chemical corrosion of the treated portion of the surface. It is advantageous to reduce the reactivity of the surface, since it is undesirable for the treated surface to react with the aerosol-generating material applied to the surface, the aerosol generated upon heating of the aerosol-generating material, or condensate resulting from the generation of the aerosol. Such reactions may result in chemical corrosion of the first surface of the support. Chemical corrosion of the first surface of the support may impair aesthetics or may impair the proper functioning of the consumable and / or the non-flammable aerosol delivery system.

[0030] In one embodiment of any of the above embodiments, the change in the physical properties of the treated surface according to step (b) comprises a change on a microscopic scale.

[0031] In one embodiment of any of the above embodiments, the support is a laminate, the laminate comprising at least two layers, a first layer of the laminate constituting a first surface of the support.

[0032] In one embodiment of any of the above embodiments, the first surface of the support comprises a metal or alloy, hi some embodiments, the first surface of the support comprises a metal or alloy foil or film.

[0033] In one embodiment of any of the above embodiments, the first surface of the support comprises aluminum or an aluminum alloy, hi some embodiments, the first surface of the support comprises an aluminum or aluminum alloy foil or film.

[0034] In one embodiment of any of the above embodiments, the support comprises a second layer formed of a material suitable for constructing the substrate, for example the second layer may be or include cardboard, paperboard, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or alloy.

[0035] 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.

[0036] In one embodiment of any of the above embodiments, the method further comprises the step of (d) separating the support into two or more smaller portions of a desired shape and size. This step has the advantage of processing the support at a size that allows for easy handling and efficient and economical processing. The subsequent separation of the support into a plurality of smaller portions may be separation into portions of a size suitable for use as a consumable or portions that can later be further separated into a plurality of consumables.

[0037] In one embodiment of any of the above embodiments, the surface treatment of step (b) comprises electrostatic coating of at least a portion of the first surface of the support. In some embodiments, the electrostatic coating comprises electrostatic coating of at least a portion of the first surface of the support with a primer, and the surface treatment of step (b) further comprises the step of (e) curing at least a portion of the primer, where step (e) is performed after step (b) and before step (c).

[0038] In some embodiments where the electrostatic coating includes electrostatic coating of at least a portion of the first surface of the support with a primer, and the primer is subsequently cured, this curing may be in the form of baking the support.

[0039] Electrostatic coating of at least a portion of the support is a preferred method of treating the support because it allows the support to be configured to be flat or substantially flat without surface features that promote a disproportionately or undesirably large amount of electrostatic deposition. For example, sharp edges promote a disproportionately large amount of electrostatic deposition. Additionally, the support can be configured to be free of surface features that promote a disproportionately or undesirably small amount of electrostatic deposition. For example, recesses promote a disproportionately small amount of electrostatic deposition.

[0040] In one embodiment of any of the above embodiments, the surface treatment of step (b) comprises chemically treating at least a portion of the first surface of the support.

[0041] In one embodiment of any of the above embodiments, the chemical treatment of step (b) comprises chemically etching at least a portion of the first surface of the support. Chemically etching at least a portion of the surface of the support has the advantage that, at a microscopic level, the surface area of ​​the etched portion of the first surface of the support is increased, thereby enhancing bonding between the aerosol-generating material and the surface of the support.

[0042] In one embodiment of any of the above embodiments, the surface treatment of step (b) comprises exposing at least a portion of the first surface of the support or at least a portion of the coated first surface of the support to an ultraviolet radiation source.

[0043] In one embodiment of any of the above embodiments, exposing at least a portion of the first surface of the support or at least a portion of the coated first surface to an ultraviolet radiation source in step (b) results in modification of the structure or surface chemistry of the exposed first surface of the support. Coating the first surface of the support may promote or alter the characteristics of the surface structure or surface chemistry of the treatment portion of the first surface of the support. Such changes in surface structure or surface chemistry may promote stronger bonding between the aerosol-generating material and the first surface of the support.

[0044] In one embodiment of any of the above embodiments, the surface treatment in step (b) comprises a plasma surface treatment of at least a portion of the first surface of the support.

[0045] In one embodiment of any of the above embodiments, the plasma surface treatment of step (b) includes one or more of: surface cleaning of the support, surface activation of the support, coating of the support, and etching of the support. Such surface treatment also promotes stronger bonding between the aerosol-generating material and the first surface of the support.

[0046] In one embodiment of any of the above embodiments, step (b) includes applying the aerosol-forming material to the first surface of the support as two or more discrete portions of aerosol-forming material.

[0047] In one embodiment of any of the above embodiments, the application of the aerosol-forming material to at least a portion of the support is the application of a slurry of the aerosol-forming material.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] The amorphous solid may be substantially free of plant matter.The amorphous solid may be substantially free of tobacco.

[0057] In one embodiment of any of the above embodiments, the method further comprises (g) allowing or causing the aerosol-forming material slurry to harden; The aerosol-generating slurry hardens to form an aerosol-generating material.

[0058] In one embodiment of any of the above embodiments, the aerosol-forming material is an aerosol-forming film.

[0059] In one embodiment of any of the above embodiments, the surface treating of step (b) comprises surface treating one or more discrete portions of the first surface of the support, and the applying of the aerosol-generating material of step (c) comprises applying the aerosol-generating material to the one or more discrete portions of the surface-treated first surface of the support.

[0060] In one embodiment of any of the above embodiments, the surface treating of step (b) comprises surface treating substantially all of the first surface of the support, and the applying of the aerosol-generating material in step (c) comprises applying the aerosol-generating material to one or more discrete portions of the first surface of the support.

[0061] In one embodiment of any of the above embodiments, applying the aerosol-generating material in step (c) includes applying the aerosol-generating material to three or more discrete portions on a first surface of the support, the discrete portions being arranged on the first surface of the support in a grid pattern.

[0062] In one embodiment of any of the above embodiments, one or more of the discrete portions of aerosol-generating material applied in step (c) have a shape that, in the plane of the first surface of the support, is substantially circular, longitudinally extending stripes, stripes including at least one curve or angle, or a mosaic.

[0063] In one embodiment of any of the above embodiments, the at least two discrete portions of aerosol-generating material applied in step (c) have a different composition from each other. This has the advantage that a user of the consumable may have a different experience with the different discrete portions of aerosol-generating material on the consumable. This may make use of the consumable more enjoyable and / or more interesting compared to use of a consumable having an aerosol-generating material of only one composition.

[0064] In one embodiment of any of the above embodiments, the application of the aerosol-generating material is performed two or more times. This can have the effect of providing a thicker layer of the aerosol-generating material on the support than would be achieved if the aerosol-generating material were applied only once. The increased thickness can allow a larger amount of aerosol to be generated by the aerosol-generating material and / or for a longer period of time than would be achieved if only a single application of the aerosol-generating material were applied.

[0065] In one embodiment of any of the above embodiments, at least one discrete portion of aerosol-forming material applied in step (c) is of a shape and / or colour indicative of the composition of the aerosol-forming material that makes up the discrete portion.

[0066] In one embodiment of any of the above embodiments, the method further comprises the method step of (f) treating the support with further processing, the further processing comprising perforating or embossing at least a portion of the support.

[0067] In one embodiment of any of the above embodiments, the support comprises a susceptor. In some embodiments, the support is a laminate, at least one layer of the laminate is a susceptor, and the treated first surface of the support is a susceptor.

[0068] 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.

[0069] 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).

[0070] In some embodiments of any of the above embodiments, the susceptor may be a metal or alloy. In some embodiments of any of the above embodiments, the susceptor may be a metal foil, optionally an aluminum foil, or an iron foil. Alternatively, in some embodiments of any of the above embodiments, the susceptor may be any conductive material that can be sprayed or deposited onto the material that makes up the support.

[0071] In one embodiment of any of the above embodiments, the aerosol forming material includes an active agent.

[0072] 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.

[0073] The active substance may include one or more constituents, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0074] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] In some embodiments, the aerosol-forming material comprises a fragrance or flavoring.

[0080] 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.

[0081] 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.

[0082] 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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%.

[0088] 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.

[0089] 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.

[0090] 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.

[0091] 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.

[0092] 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.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] 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).

[0097] 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.

[0098] 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).

[0099] 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.

[0100] 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.

[0101] 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.

[0102] 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.

[0103] The aerosol-generating material may be formed by (a) forming a slurry including 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.

[0104] (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.

[0105] 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.

[0106] In some instances, the slurry may be applied to a support such that a layer is formed on the support. 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

[0107] 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.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] 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.

[0114] 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).

[0115] 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.

[0116] 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.

[0117] The aerosol-forming material may include a bulking agent.

[0118] 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%.

[0119] 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.

[0120] 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.

[0121] 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.

[0122] 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)).

[0123] 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.

[0124] In some embodiments, the aerosol-forming material does not include tobacco fibers, hi certain embodiments, the aerosol-forming material does not include fibrous materials.

[0125] 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.

[0126] 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.

[0127] 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.

[0128] 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.

[0129] 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.

[0130] 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).

[0131] 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.

[0132] 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.

[0133] 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%.

[0134] 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.

[0135] 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.

[0136] 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.

[0137] 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.

[0138] 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.

[0139] 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).

[0140] 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).

[0141] 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.

[0142] 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.

[0143] 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.

[0144] As an example, the aerosol-forming material does not include flavorants. In certain instances, the aerosol-forming material does not include active agents. 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.

[0145] In some embodiments, the aerosol-forming material comprises 1-80 wt % (dry weight basis) of flavoring.

[0146] 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.

[0147] 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.

[0148] 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.

[0149] 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.

[0150] 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.

[0151] 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).

[0152] 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).

[0153] 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.

[0154] 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.

[0155] 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.

[0156] 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.

[0157] 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.

[0158] 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%.

[0159] 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.

[0160] 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.

[0161] In some examples, the aerosol-generating material in sheet form may have a tensile strength of around 200 N / m to around 2600 N / m. In some examples, the aerosol-generating material may have a tensile strength of around 600 N / m to around 2000 N / m, or 700 N / m to 1500 N / m, or around 1000 N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is formed and incorporated into an aerosol-generating consumable as a sheet.

[0162] The aerosol-generating material is 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 and 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.

[0163] 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.

[0164] 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.

[0165] Depending on the desired color of the aerosol-generating material, a variety of colorants may be used. 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 generation, 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.

[0166] 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).

[0167] 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.

[0168] 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.

[0169] 1, the aerosol delivery device 2 comprises a casing 4 within which a heating assembly 6 is disposed. The heating assembly 6 is comprised of a heating chamber 8 and an aerosol generator 10. The aerosol generator 10 can be an electrical resistance heater or a magnetic field generator used with a susceptor.

[0170] 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.

[0171] Also disposed within the casing 4 is a controller 20 in electronic communication with the aerosol generator 10 to control its function. The controller 20 may include a memory (not shown) in which one or more tables relating to the operation of the heater 10 may be stored. The aerosol generator 10 and the controller 20 are powered by a power source 22. The power source 22 is a rechargeable battery. In other embodiments, the power source may be another suitable power source.

[0172] The aerosol generating device 2 is suitable for use with a consumable 24. The consumable 24 has one or more discrete portions 32 of aerosol-generating material supported on a first surface 28 of the consumable 24. The discrete portions 32 of aerosol-generating material are supported on the first surface 28 in a square grid pattern. Other embodiments of the consumable 24 (not shown) may include more or fewer discrete portions 32 of aerosol-generating material than shown in FIG. 1, including a single portion 32 of aerosol-generating material, and these portions may be distributed in any pattern on the first surface 28. Although the discrete portions 32 of aerosol-generating material are shown in FIG. 1 as having a generally circular shape, they may have other shapes in other embodiments. Examples of methods of generating or manufacturing the consumable 24 are described below.

[0173] 2, a support 30 is now provided to begin production of the consumable 24. The support 30 comprises a longitudinally extending sheet of flexible laminate material including first and second layers 36, 38. The first layer 36 has a surface that is the first surface 28 comprised of a sheet of aluminum foil. The first layer has a thickness of less than 0.025 mm. In other embodiments not shown, the material of the first layer 36 may be an aluminum alloy or a different suitable material, such as a different metal or alloy.

[0174] The second layer 38 is formed from cardboard and is sufficiently rigid to support the first layer and provide a fixed structural support.

[0175] The length and width of support 30 as shown in Figures 1 and 2 are for illustrative purposes only. Support 30 may have different lengths and widths without departing from the scope of the present disclosure.

[0176] 3, substantially all of first surface 28 (area 40) is electrostatically coated with a primer using known electrostatic coating techniques. In this technique, the primer is negatively charged and first layer 36 is grounded and positively charged. The primer is sprayed towards and attracted to first surface 28. The primer is then applied to area 40 and cured by baking support 30 at a suitable temperature for a suitable time.

[0177] The primer alters one or more of the chemical and / or physical properties of at least area 40 of first surface 28. For example, the primer can increase the strength with which the aerosol-generating material binds to the surface of area 40 compared to the strength of the bond with surface 28 prior to treatment by application of the primer.

[0178] Additionally or alternatively to the above, the primer in at least area 40 renders the foil of first layer 36 less susceptible to corrosion (as a result of reaction between the aerosol-generating material and the foil, between the foil and the aerosol generated in heating chamber 8 of aerosol delivery device 2, or between the foil and any condensation in heating chamber 8) than aluminum foil of first layer 36 that has not been treated with the primer.

[0179] 4, once the primer has cured in at least areas 40, discrete portions 32 of aerosol-generating material in the form of an aerosol-generating material slurry are applied to the surface of area 40 in a grid pattern. The slurry is applied to surface 40 using known aerosol-generating material slurry application techniques, such as through one or more nozzles (not shown) from a reservoir of aerosol-generating material slurry (not shown).

[0180] The discrete portions of aerosol-generating material 32 are all substantially circular in the plane of the first surface of the support. In other non-illustrated examples of the method of the present disclosure, one or more of the discrete portions of aerosol-generating material 32 may be shaped as longitudinal stripes, stripes including at least one curve or angle, and / or tessellated.

[0181] Drying of the aerosol-generating material portions 32 may then result in the aerosol-generating material slurry being a more or less sized and shaped aerosol-generating material, ready for use of the consumable 24 in the aerosol delivery device 2. If the aerosol generator 10 in the aerosol delivery device 2 is a magnetic field generator, the foil of the first layer 36 acts as a susceptor to heat the aerosol-generating material portions 32.

[0182] 5, the support 130 is a laminate having first and second layers 136, 138. The first layer 136 has a surface that is the first surface 128 that is constructed from a sheet of aluminum foil. The first layer is less than 0.015 mm in thickness.

[0183] The second layer 138 is formed from polyetheretherketone (PEEK) and is sufficiently rigid to support the first layer 136 and provide a fixed configuration support.

[0184] The length and width of support 130 as shown in Figure 5 are for illustrative purposes only. Support 130 may have different lengths and widths without departing from the scope of the present disclosure.

[0185] Three areas 142, 144, 146 of first surface 128 of support 130 are chemically treated using a chemical that chemically etches the surface of first surface 128. The etching of areas 142, 144, 146 is on a microscopic scale, but has the effect of roughening first surface 128 in areas 142, 144, 146 relative to the remainder of first surface 128 (portions of first surface 128 not included in areas 142, 144, 146). This etching results in stronger bonds between the aerosol-generating material and surface 128 in areas 142, 144, 146 than bonds between the aerosol-generating material and the remainder of first surface 128.

[0186] With reference to Figure 6, first and second aerosol-generating material discrete portions 132A and 132B, both in the form of an aerosol-generating material slurry, are applied to the surfaces of areas 142, 144, 146 in a grid pattern as shown in Figure 6. The slurries are applied to the surfaces of areas 142, 144, 146 using known aerosol-generating material slurry application techniques, for example, via at least two nozzles (not shown) from first and second reservoirs (not shown) of aerosol-generating material slurry 132A, 132B. The first and second aerosol-generating materials 132A, 132B have different compositions, for example, each containing a different flavoring, such that when heated they produce differently flavored aerosols.

[0187] The first aerosol-generating material portions 132A are all substantially circular in the plane of the first surface 128 of the support portion 130, and the second aerosol-generating material portions 132B are all substantially square in the plane of the first surface 128 of the support portion 130. Thus, the shapes of the portions of the first and second aerosol-generating material portions 132A, 132B represent different compositions of the aerosol-generating material that make up those portions. Optionally, the first aerosol-generating material 132A is a different color than the second aerosol-generating material 132B.

[0188] Then, as the first and second discrete portions 132A, 132B of aerosol-forming material dry, the aerosol-forming material slurries 132A, 132B may become aerosol-forming material that is more or less fixed in size and shape.

[0189] 7, the support portions 130 are then separated along the separation line 148 to form the pair of consumables 124. The consumables 124 are then ready for use in the aerosol delivery device 2. When the aerosol generator 10 in the aerosol delivery device 2 is a magnetic field generator, the foil of the first layer 136 acts as a susceptor to heat the first and second aerosol-generating material portions 132A, 132B.

[0190] 8, the support 230 is a laminate having first and second layers 236, 238. The first layer 236 has a surface that is the first surface 228 that is constructed from a sheet of aluminum alloy foil. The first layer is less than 0.020 mm in thickness.

[0191] The length and width of support 230 as shown in Figure 8 are for illustrative purposes only. Support 230 may have different lengths and widths without departing from the scope of the present disclosure.

[0192] The second layer 238 is made of polyetheretherketone (PEEK) and is approximately 10 mm thick, providing the support 230 with sufficient rigidity and fixed configuration to support the first layer 236.

[0193] Overlying first surface 228 is a mask 250. Mask 250 includes four openings 252 that leave four areas 254 uncovered on first surface 228. Mask 250 is formed from a material that is not damaged by exposure to intense ultraviolet (UV) light (electromagnetic radiation having wavelengths between 10 nm and 400 nm).

[0194] The mask and area 254 on first surface 228 are exposed to intense UV light from a UV light source (not shown) to clean area 254 of first surface 228, thereby enhancing the binding of aerosol-generating material to area 254 when the aerosol-generating material is applied to first surface 228, resulting in a greater binding strength of the aerosol-generating material to first surface 228 at area 254.

[0195] In some embodiments, first layer 236 is coated with a layer of material that is activated by UV light, again to enhance binding of the aerosol-generating material to areas 254 of first surface 228.

[0196] Referring to FIG. 9 , after area 254 has been exposed to UV light for a sufficient period of time, mask 250 is removed from first surface 250 and aerosol-generating material slurry is applied to area 254 of first surface 228 to form aerosol-generating material portion 232.

[0197] Drying of the discrete portions 232 of aerosol-generating material may then result in the aerosol-generating material slurry 232 being an aerosol-generating material with a more or less fixed size and shape, ready for use of the consumable 224 in the aerosol delivery device 2. When the aerosol generator 10 in the aerosol delivery device 2 is a magnetic field generator, the foil of the first layer 236 acts as a susceptor to heat the portions 232 of aerosol-generating material.

[0198] 8 and 9, mask 250 is an etch mask used in a plasma etching process. Exposed surface 254 of first surface 228 is etched using known plasma etching techniques until the required etch depth is achieved. This roughens the surface of the foil in areas 254 and enhances the bond strength between the aerosol-generating material and surface 228 in areas 254. Support 230 is then further processed as described above to produce consumable 224.

[0199] 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 and an aerosol-generating material, the method comprising: (a) providing a support; (b) surface treating at least a portion of a first surface of the support; (c) applying an aerosol-forming material to at least a portion of the first surface of the support; Including, the surface treatment of step (b) comprises altering one or more chemical or physical properties of the surface, and the alteration of the physical properties of the surface is achieved by one or more processes that do not involve perforating or embossing the support portion; 10. The method of claim 9, wherein the surface treatment in step (b) comprises one or more of electrostatic coating of at least a portion of the first surface of the support, exposing at least a portion of the first surface of the support or at least a portion of the coated first surface to an ultraviolet radiation source, and plasma surface treatment of at least a portion of the first surface of the support.

2. 2. The method of claim 1, wherein the surface treatment in step (b) increases the strength of the bond formed between the aerosol-generating material and the treated portion of the first surface of the support relative to the strength of the bond formed between the aerosol-generating material and the untreated portion of the first surface of the support.

3. 10. The method of claim 1, wherein the surface treatment of step (b) provides a treated surface, the treated surface having a low reactivity relative to an untreated surface.

4. The method of claim 3 , wherein the reactivity results in chemical corrosion of the surface.

5. The method of claim 1 , wherein the change in the physical properties of the treated surface by step (b) comprises a change on a microscopic scale.

6. The method of claim 1 , wherein the support is a laminate, the laminate comprising at least two layers, a first layer of the laminate comprising the first surface of the support.

7. The method of claim 1 , wherein the first surface of the support comprises a metal or alloy.

8. The method of claim 1 , further comprising the step of: (d) separating the support into two or more smaller units of a desired shape and size.

9. the electrostatic coating comprises electrostatically coating at least a portion of the first surface of the support with a primer, and the surface treating of step (b) further comprises (e) curing at least a portion of the primer; 2. The method of claim 1, wherein step (e) is performed after step (b) and before step (c).

10. The method of claim 9 , wherein step (e) comprises baking the support to cure the primer.

11. The method of claim 1 , wherein the surface treatment of step (b) comprises chemically treating at least a portion of the first surface of the support.

12. The method of claim 11 , wherein the chemical treatment of step (b) comprises chemically etching at least a portion of the first surface of the support.

13. 10. The method of claim 1, wherein the exposing of at least a portion of the first surface or at least a portion of the coated first surface to an ultraviolet radiation source in step (b) results in modification of the structure or surface chemistry of the exposed first surface of the support.

14. The method of claim 1 , wherein the plasma surface treatment of step (b) comprises one or more of: surface cleaning of the support, surface activation of the support, coating of the support, and etching of the support.

15. 10. The method of claim 1, wherein the surface treating in step (b) comprises surface treating one or more discrete portions of the first surface of the support, and wherein the applying of the aerosol-generating material in step (c) comprises applying the aerosol-generating material to the one or more discrete portions of the surface-treated first surface of the support.

16. 10. The method of claim 1, wherein the surface treating in step (b) comprises surface treating substantially all of the first surface of the support, and wherein the applying of the aerosol-generating material in step (c) comprises applying the aerosol-generating material to one or more discrete portions of the first surface of the support.

17. 17. The method of claim 15 or 16, wherein the applying of the aerosol-forming material in step (c) comprises applying the aerosol-forming material to three or more discrete portions on the first surface of the support, the discrete portions being arranged on the first surface of the support in a grid pattern.

18. the method further comprising (f) treating the support with further processing; The method of claim 1 , wherein the further processing comprises perforating or embossing at least a portion of the support.

19. 10. The method of claim 1, wherein the application of aerosol-forming material to at least a portion of the first surface of the support in step (c) is application of an aerosol-forming material slurry.

20. the method further comprising (g) allowing or causing the aerosol-forming material slurry to harden; 20. The method of claim 19, wherein the aerosol-generating slurry hardens to form an aerosol-generating material.

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