Consumables for use with aerosol delivery devices

Abstract

A method is provided for making an article, the article comprising a substrate and an aerosol-generating material (56), the method comprising the steps of (a) providing a mold body (40), (b) forming one or more mold recesses (42) extending inwardly into a first surface (30) of the mold body, and (c) applying at least one discrete portion of the aerosol-generating material to the first surface of the mold body, each mold recess extending inwardly into the first surface of the mold body such that the at least one discrete portion of the aerosol-generating material at least partially overlies the mold recess or such that the at least one discrete portion of the aerosol-generating material at least partially overlies a location where the mold recess will be formed in step (b).

Description

[Technical field]

[0001] The present disclosure relates to the field of non-combustion 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, and the like, burn tobacco to produce tobacco smoke when in use. Alternatives to these types of articles emit inhalable aerosols or vapors by releasing compounds from a substrate material through heating without combustion. These are sometimes referred to as non-combustion smoking articles, aerosol generating assemblies, or aerosol delivery devices.

[0003] One example of such a product is a heating device that releases compounds by heating, but not burning, an aerosolizable material, sometimes referred to as a solid aerosol-generating material. The solid aerosol-generating material may, in some cases, include tobacco material. The heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as non-combustion heating devices, tobacco heating devices, or tobacco heating products. A variety of different configurations are known 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 include nicotine) that is volatilized by heating to create an inhalable vapor or aerosol. The device further includes a solid aerosol-forming material (which may or may not include tobacco material), the components of which are entrained in the inhalable vapor or aerosol to create the inhalation medium. Summary of the Invention

[0005] According to a first aspect of the present disclosure, there is provided a method for manufacturing an article, the article comprising a substrate and an aerosol-generating material, the method comprising: (a) providing a mold body; (b) forming one or more inwardly extending mold recesses in a first surface of the mold body; (c) applying at least one discrete portion of an aerosol-generating material to a first surface of the mold body; Including, each mold recess extends inwardly from the first surface of the mold body; A method of manufacturing is provided in which at least one discrete portion of the aerosol-generating material at least partially overlies the mold recess or at least one discrete portion of the aerosol-generating material at least partially overlies the location where the mold recess is formed in step (b).

[0006] According to a second aspect of the present disclosure, there is provided a consumable for use with an apparatus for heating an aerosol-generating material, the consumable comprising a support and an aerosol-generating material, the consumable being manufactured according to the manufacturing 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 system comprising an aerosol delivery device and a consumable according to the second aspect of the present disclosure.

[0008] According to a fourth aspect of the present disclosure, there is provided a method of generating an aerosol from a consumable according to the second aspect of the present disclosure using an aerosol generating device having at least one aerosol generator arranged to heat, but not combust, the consumable according to the second aspect of the present disclosure during use.

[0009] According to a fifth 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 on the consumable.

[0010] Further features and advantages of the present disclosure will become apparent from the following description of embodiments of the present disclosure, given by way of example only, and with reference to the accompanying drawings. [Brief description of the drawings]

[0011] [Figure 1] 1 shows a schematic diagram of an embodiment of an aerosol delivery device and an embodiment of a consumable made according to an embodiment of a method according to the present disclosure. [Diagram 2] FIG. 2 shows a diagram of one embodiment of a mould body used according to a first embodiment of the method according to the present disclosure. [Diagram 3] FIG. 2 shows a schematic diagram of a debossing device used according to a first embodiment of the method according to the present disclosure. [Figure 4] 3 shows a view of the mold body of FIG. 2 after being debossed. [Diagram 5] 5 shows a cross section taken along line A-A' in FIG. 4 after application of the aerosol-generating material. [Figure 6] 5 shows a cross section taken along line A-A' in FIG. 4 while excess aerosol-generating material is being removed from the mold body. [Figure 7] 5 shows a cross section taken along line A-A' in FIG. 4 after a sheet material has been placed over the first surface of the mold body. [Figure 8] 8 shows a cross-section of the sheet material of FIG. 7 being removed from the mould body. [Figure 9] 2 shows a cross-section of the consumable of FIG. 1 manufactured using a first embodiment of the method according to the present disclosure taken along line BB'. [Figure 10] 2 shows a cross-section of an alternative embodiment of the consumable of FIG. 1, manufactured using a first embodiment of the method according to the present disclosure, taken along line B-B'. [Figure 11] FIG. 2 shows a schematic diagram of a vacuum blister forming machine used according to a second embodiment of the method according to the present disclosure. [Figure 12]12 shows one embodiment of a cross-section corresponding to the cross-section along line A-A' in FIG. 4 after a mold body used according to a second embodiment of the method of the present disclosure has been processed using the vacuum blister molding machine of FIG. [Figure 13] 13 illustrates a cross-section of the embodiment of the mold body of FIG. 12 after application of an aerosol-generating material. [Figure 14] 13 illustrates a cross-section of the embodiment of the mold body of FIG. 12 while excess aerosol-generating material is being removed from the mold body. [Figure 15] 2 shows a cross-section of the consumable of FIG. 1 manufactured using a second embodiment of the method according to the present disclosure taken along line B-B'. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

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

[0013] In some embodiments, the consumable comprises an aerosol-generating material. The consumable can 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 ingredients, one or more flavorings, one or more aerosol former materials, and / or one or more other functional materials.

[0014] A device that heats 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 using a combination of aerosol-generating materials, release compounds from the aerosol-generating material without combusting the aerosol-generating material.

[0015] According to this disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials of the aerosol delivery system (or its components) are not combusted or burned to facilitate delivery of at least one substance to a user.

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

[0017] In some embodiments, the non-combustion aerosol delivery system is an e-cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[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-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may 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] Typically, a non-combustion aerosol delivery system can include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0021] In some embodiments, the present disclosure relates to consumables that include an aerosol generating material and are configured for use with a non-combustion aerosol delivery device. These consumables may be referred to as articles throughout this disclosure.

[0022] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, a power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that can be excited to deliver power in the form of heat to an aerosol generating material or a heat transfer material proximate the heat generating power source.

[0023] In some embodiments, the non-combustion aerosol delivery system can include a region containing a consumable, an aerosol generator, an aerosol-generating region, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0024] In some embodiments, consumables for use with non-combustion aerosol delivery devices can include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier. According to a first aspect of the present disclosure, there is provided a method for manufacturing an article, the article comprising a substrate and an aerosol-generating material, the method comprising: (a) providing a mold body; (b) forming one or more inwardly extending mold recesses in a first surface of the mold body; (c) applying at least one discrete portion of an aerosol-generating material to a first surface of the mold body; Each mold recess extends inwardly from the first surface of the mold body; A method of manufacturing is provided in which at least one discrete portion of the aerosol-generating material at least partially overlies the mold recess or at least one discrete portion of the aerosol-generating material at least partially overlies the location where the mold recess is formed in step (b).

[0025] In some of the above embodiments, the article is shaped and dimensioned for use as a consumable for use with a device that heats an aerosol-forming material to volatilize at least one component of the aerosol-forming material. In some alternative embodiments of the above embodiments, the article is larger than a consumable for use with a device that heats an aerosol-forming material to volatilize at least one component of the aerosol-forming material, and the method of manufacture includes: (d) separating the article into two or more consumable portions. Further comprising: Each consumable portion is shaped and sized for use as a consumable for use with a device that heats an aerosol-generating material to volatilize at least one component of the aerosol-generating material. In such embodiments, the article can be large and separable into multiple consumable portions. This can have the advantage of manufacturing efficiency.

[0026] In some embodiments of any of the above embodiments, the aerosol-generating material applied to the first surface of the mold body in step (c) is an aerosol-generating material slurry. An advantage of applying the aerosol-generating material as an aerosol-generating material slurry is that the slurry easily conforms to any three-dimensional side of the surface to which it is applied.

[0027] In some embodiments of any of the above embodiments, the method of manufacturing comprises: (e) the further method step of allowing the aerosol-generating material slurry to harden or hardening the aerosol-generating material slurry. Including, The aerosol-generating slurry hardens to form an aerosol-generating material, and step (e) occurs after step (c).

[0028] In some embodiments of any of the above embodiments, the aerosol-forming material is an aerosol-forming film.

[0029] An aerosol-forming material is a material capable of generating an aerosol when excited in any other way, e.g., by heating, irradiation, or the like. The aerosol-forming material may be, for example, in the form of a solid, liquid, or semi-solid (e.g., a gel), and may or may not contain active substances and / or flavorings.

[0030] The aerosol-generating materials may include one or more active agents and / or flavorings, one or more aerosol former materials, and optionally one or more other functional materials.

[0031] The aerosol-generating material may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a substance to be delivered and / or a filler may also be present. Optionally, a solvent, such as water, may also be present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant matter. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0032] 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 delivered 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.

[0033] The aerosol-generating film may have a thickness of from about 0.015 mm to about 1 mm. For example, the thickness may be in the range of from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

[0034] 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, such as the substance or substances to be delivered, to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent to form the aerosol-generating film.

[0035] The slurry can be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent.

[0036] 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 can retain some fluid, such as a liquid, within it. In some embodiments, the amorphous solid may include, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0037] The amorphous solid may be substantially free of plant matter.The amorphous solid may be substantially free of tobacco.

[0038] In some of the above embodiments, the mold body can be a sheet material that can be deformed to form the mold recess. In some embodiments, the sheet material is less than 1.0 mm thick, less than 0.9 mm thick, less than 0.8 mm thick, less than 0.7 mm thick, less than 0.6 mm thick, less than 0.5 mm thick, less than 0.4 mm thick, less than 0.3 mm thick, less than 0.2 mm thick, or less than 0.1 mm thick. In such embodiments, the mold recess can have the form of a depression in one of the major surfaces of the sheet material. The depression extends through the sheet material and forms a bump or upstanding portion in the other of the major surfaces of the sheet material. The deformation of the material to form the mold recess can be permanent. Alternatively, the deformation can be temporary in that the formation of the mold recess is an elastic deformation of the mold body, and the mold recess remains present for a sufficient time to complete the method of the present disclosure, but the mold body eventually returns to its original shape or approximately its original shape.

[0039] In some of the above embodiments, the mold recess is formed by use of known debossing or embossing techniques. In other embodiments, the mold recess may be formed using known vacuum forming techniques. In some of the above embodiments, other known techniques may be used to form the recess.

[0040] In some other of the above embodiments, the sheet material may have a thickness sufficient to allow the mold recess to be formed in the mold body, i.e., without causing deformation of any of the exterior surfaces of the mold body other than the surface in which the mold recess is formed. In such embodiments, the thickness may be greater than 0.2 mm, greater than 0.3 mm, greater than 0.4 mm, greater than 0.5 mm, greater than 0.6 mm, greater than 0.7 mm, greater than 0.8 mm, greater than 0.9 mm, or greater than 1.0 mm.

[0041] In such embodiments, the mold recess may be formed by compression of the material of the mold body, for example by using known embossing techniques, or by removal of a portion of the mold body, for example by using known drilling or milling techniques.

[0042] In some other of the above embodiments, the mold body has a mold recess formed therein, such that steps (a) and (b) occur substantially simultaneously.

[0043] In some embodiments of any of the above embodiments, steps (a) and (b) are performed before step (c).

[0044] In some embodiments of any of the above embodiments, steps (a) and (b) are performed as a separate process relative to step (c), and the products of steps (a) and (b) are stored and / or transported between various locations before step (c) is performed. Such an approach may have the advantage that the mold bodies and mold recesses herein can be produced by a specialized manufacturer of such items and then shipped to the party performing the remainder of the disclosed method. This results in efficiencies in the performance of the disclosed method.

[0045] In some embodiments of any of the above embodiments, step (c) is carried out after step (a) and before step (b). This approach is advantageous when the mold recess is formed using a vacuum blister former or the like, as in such a situation the aerosol-generating material is drawn into the blister as the blister is formed.

[0046] In some embodiments of any of the above embodiments, the method of manufacturing comprises: (f) passing a scraper over at least a portion of the first surface of the mold body after step (c) has been performed. Step (f) may be performed before step (e) is performed or after step (e) is performed.

[0047] Performing step (f) has the advantage of ensuring that the aerosol-generating material is confined to the mold recesses. In other words, passing the scraper across the first surface of the mold body ensures that the aerosol-generating material is distributed to the mold body as one or more discrete regions of aerosol-generating material. A further advantage is that passing the scraper across the first surface of the mold body can force the aerosol deposited on the first surface of the mold body into the mold recesses if they are not already filled with aerosol-generating material. This helps ensure that each mold recess is filled to capacity (and thus ensures that the intended amount or quantity of aerosol-generating material is deposited within each mold recess) while minimizing the amount of aerosol-generating material used.

[0048] In some embodiments of any of the above embodiments, the scraper can be a doctor blade.

[0049] In some of any of the above embodiments, step (c) includes applying the aerosol-generating material to at least a portion of the first surface of the mold body that includes the mold recess. In some alternative embodiments, step (c) includes applying the aerosol-generating material to substantially the entire first surface of the mold body.

[0050] In some embodiments of any of the above embodiments, the method of manufacturing comprises: (g) placing a layer of material over the first surface of the mold body. Further includes:

[0051] In some embodiments of any of the above embodiments, step (g) is performed after step (c) and, if step (f) is performed, after step (f).

[0052] In some embodiments of any of the above embodiments, the method of manufacturing comprises: (h) bonding the aerosol-generating material to the material layer. Further comprising: Step (h) is performed after step (g).

[0053] In some embodiments of any of the above embodiments, the method of manufacturing comprises: (i) applying a release agent to a first surface of the mold body; (j) removing the layer of material having the aerosol-generating material attached thereto from the mold; Further comprising: Step (i) is performed before step (c) and step (j) is performed after step (h).

[0054] In some embodiments of any of the above embodiments, the layer of material is attached to a support after step (j).

[0055] In some of any of the above embodiments, the layer of material is attached to the support with the side of the layer of material having the aerosol-forming material bonded to it facing away from the support.

[0056] In some embodiments of any of the above embodiments, the material layer comprises a susceptor, hi other embodiments, the material layer can be a material suitable for use in connection with a resistive heater.

[0057] In some embodiments of any of the above embodiments, the support includes a layer of material.

[0058] In some embodiments of any of the above embodiments, the support comprises a mold body or a portion of a mold body.

[0059] In some embodiments of any of the above embodiments, the support includes a susceptor. In some embodiments of any of the above embodiments, the manufacturing method comprises: (k) applying a susceptor layer to a first surface of the mold. Further comprising: Step (k) is performed after step (b) and before step (d).In such embodiments, the susceptor is applied to a portion of the surface of the mold body that defines the mold recess.

[0060] The support can be formed from a material suitable for forming a substrate. The support may be or include, for example, paper, card, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support includes a susceptor. In some embodiments, the susceptor is embedded within the support. In some alternative embodiments, the susceptor is on or attached to one or both sides or surfaces of the support material.

[0061] In some embodiments of any of the above embodiments, the susceptor is a metal or metal alloy.

[0062] In some embodiments of any of the above embodiments, the susceptor is a metal foil or film, for example an aluminum foil or film. In some embodiments of any of the above embodiments, the manufacturing method comprises: (m) perforating one or more of the mold body (if present), the aerosol-generating material, the support (if present), the susceptor (if present), and the material layer (if present). Further includes:

[0063] In some of the above embodiments, the perforations extend between two surfaces of the consumable. In some other of the above embodiments, the perforations have one end that is open to the atmosphere surrounding the consumable and one end that is a dead end. The blind end is blocked by one of the mold body (if present), the aerosol-generating material, the support (if present), the susceptor (if present), or the material layer (if present).

[0064] In some embodiments of any of the above embodiments, the perforations are at least 0.01 mm 2 , at least 0.05 mm 2 , at least 0.1 mm 2 , at least 0.5 mm 2 , at least 1 mm 2 , at least 2 mm 2 , or at least 3 mm 2 has a cross-sectional area of

[0065] In some of the above embodiments, the at least one mold recess intersects the first surface of the mold body and has a longitudinally extending shape that is one of a rectangle, a circle, or an oval.

[0066] In some of the above embodiments, step (c) includes applying at least two separate portions of aerosol-generating material to the first surface of the mold body, the separate portions of aerosol-generating material having compositions different from one another.

[0067] The aerosol generator or aerosol former material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol former material 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 suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0068] In some embodiments, the support is a laminate, the laminate comprising at least a first substrate and a second substrate, In some embodiments, at least one substrate of the laminate may be present for structural purposes, in particular to provide the consumable with desired processing characteristics, for example to provide a degree of elastic recovery against deformation of the consumable and / or to provide stiffness.

[0069] In some embodiments of any of the above embodiments, a surface of the support is formed from an impermeable material.

[0070] In some embodiments of any of the above embodiments, one of the surfaces of the support is formed from a susceptor.

[0071] In some embodiments of any of the above embodiments, the support is a stack including at least three substrates, and a substrate that does not form the first surface or the second surface of the support is a susceptor.

[0072] The susceptor is a material that can be heated by penetration by a varying magnetic field, such as an alternating magnetic field. The susceptor can be a conductive material, such that penetration of the conductive material by the varying magnetic field causes inductive heating of the susceptor by resistive heating as a result of eddy currents. The susceptor can be a magnetic material, such that penetration of the magnetic material by the varying magnetic field causes magnetic hysteresis heating of the susceptor. The susceptor can be both conductive and magnetic, such that the susceptor can be heated by both heating mechanisms. A device configured to generate a varying magnetic field is called a magnetic field generator.

[0073] The susceptor may comprise a ferromagnetic metal such as iron or an iron alloy such as steel or an iron-nickel alloy. Some exemplary ferromagnetic metals are 400 series stainless steel such as grade 410 stainless steel, or grade 420 stainless steel, or grade 430 stainless steel, or similar grade stainless steel. Alternatively, the susceptor may comprise a suitable non-magnetic, especially paramagnetic, conductive material such as aluminum. With paramagnetic conductive materials, induction heating is caused exclusively by resistive heating due to eddy currents. Alternatively, the susceptor may comprise a non-conductive ferrimagnetic material such as a non-conductive ferrimagnetic ceramic. In that case, heat is generated only by hysteresis losses. The susceptor may comprise a commercially available alloy such as phytherm 230 (having a composition (in weight %=wt%) of 50 wt% Ni, 10 wt% Cr, and the remainder Fe) or phytherm 260 (having a composition (in weight %=wt%) of 50 wt% Ni, 9 wt% Cr, and the remainder Fe).

[0074] The susceptor may be a metal foil or film, optionally an aluminum foil or film, or an iron foil or film, in some embodiments of any of the above embodiments. Alternatively, the susceptor may be any conductor or vapor that can be sprayed or deposited onto the material forming the support, onto the uncovered portion of the aerosol-generating material disposed in the mold recess, or onto the surface of the mold recess, in some embodiments of any of the above embodiments.

[0075] A susceptor is required when the aerosol-generating material is heated using magnetic induction techniques or a combination of magnetic induction and resistive heating techniques. If the consumable is heated using resistive heating techniques only, a susceptor need not be provided but may be present.

[0076] In some embodiments of any of the above embodiments, the support comprises a substrate of support material, the support material comprising one or more of paper, card, paperboard, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or metal alloy.

[0077] In one embodiment of any of the above embodiments, the support comprises a plastic material that can withstand temperatures typically encountered in non-combustion aerosol delivery devices. In some embodiments, the support comprises polyetheretherketone (PEEK). Such an embodiment has the advantage that the support can be reused and that the consumable is less affected by any condensation in non-combustion aerosol delivery devices than consumables that include supports that include the use of adsorbent materials for structural purposes.

[0078] In some of any of the above embodiments, the aerosol-generating material is supported on a surface of a support that is not formed from an adsorbent material. Such an arrangement has the effect that during manufacture and subsequent storage and use of the consumable, neither the aerosol-generating material nor any components of the aerosol-generating material are adsorbed / absorbed onto the support.

[0079] According to a second aspect of the present disclosure, there is provided a consumable for use with an aerosol delivery device, the consumable comprising a support and an aerosol-generating material, the consumable being formed using a method according to the first aspect of the present disclosure.

[0080] In some embodiments of any of the above embodiments, step (e) includes the use of one or more of time, conducted heat, radiant heat, or air movement across the exposed surface of the aerosol-generating material.

[0081] In some embodiments of any of the above embodiments, the aerosol-forming material includes an active agent.

[0082] An active substance as used herein can be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance can be selected from, for example, functional foods, nootropics, psychotropic drugs. The active substance can be naturally occurring or synthetically obtained. The active substance can include, for example, nicotine, caffeine, taurine, non-cannabinoid derived terpenes, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance can include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance.

[0083] The active substance may include one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0084] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0085] The active material may comprise or be derived from one or more botanical materials, or components, derivatives or extracts thereof. As used herein, the term "botanical material" includes any material derived from a plant, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, pods, etc. Alternatively, the material may comprise a synthetically obtained active compound that is naturally present in a plant. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, chips, pieces, sheets, etc. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cacao, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, liquorice (licorice), matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed (aniseed), basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, and the like. The active ingredient in the composition is selected from the group consisting of laurel, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, kavi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arventis, Grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), Peppermint (Mentha piperita), Lime mint (Mentha piperita citrata cv), Chocolate mint (Mentha piperita cv), Curly mint (Mentha spicata crispa), Wild mint (Mentha cardifolia), Horse mint (Memtha longifolia), Pineapple mint (Mentha suaveolens variegata), Pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and Apple mint (Mentha suaveolens).

[0086] In some embodiments, the active substance comprises or is derived from one or more botanical substances, or components, derivatives or extracts thereof, and the botanical substance is tobacco.

[0087] In some embodiments, the active agent comprises or is derived from one or more botanical substances, or components, derivatives or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0088] In some embodiments, the active agent comprises or is derived from one or more botanical substances, or components, derivatives or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0089] In some embodiments, the aerosol-forming material comprises a fragrance or flavoring.

[0090] As used herein, the terms "flavor" and "flavoring agent" refer to materials that can be used to create a desired taste, odor, or other somatic sensation in products for adult consumers, where local regulations permit.They may be naturally occurring flavoring materials, botanical substances, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, liquorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime). , tropical fruits, 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, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine , ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of the mint genus, eucalyptus, star anise, cacao, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay leaf, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, da mian, marjoram, olive, lemon balm, lemon basil, chive, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be simulated, synthetic or natural ingredients, or blends thereof. They may be in any suitable form, for example a liquid such as an oil, a solid such as a powder, or a gas.

[0091] 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 ingredients. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavor ingredients extracted from tobacco. In some embodiments, the flavoring comprises flavor ingredients extracted from cannabis.

[0092] In some embodiments, the flavoring may include sensates intended to achieve somatic sensations, usually chemically induced and perceived, by stimulation of 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 warming, cooling, tingling, or numbing effect. A suitable warming agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol, WS-3.

[0093] The aerosol-generating material includes an aerosol forming agent.

[0094] In some embodiments, the aerosol generating agent may include one or more components capable of forming an aerosol. In some embodiments, the aerosol generating agent may include one or more of glycerol, propylene glycol, diethyl glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In a particular example, the aerosol generating agent includes glycerol. 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, glycerol diacetate, or glycerol triacetate; and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0095] In some embodiments, the amorphous solid 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 amorphous solid may comprise from 0.5 to 40 wt%, from 3 to 35 wt%, or from 10 to 25 wt% of the aerosol generating agent.

[0096] In some embodiments, the amorphous solid can 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% (dry weight basis (DWB)) of the aerosol generating agent. For example, the amorphous solid can comprise from 10 to 60 wt%, 20 to 50 wt%, 25 to 40 wt%, or 30 to 35 wt% of the aerosol generating agent.

[0097] In some embodiments, the amorphous solid can 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%.

[0098] The amorphous solid may also include a gelling agent.

[0099] In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group comprising alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the gelling agent comprises alginate and / or pectin, which may be combined with a hardening agent (such as a calcium source) during the formation of the amorphous solid. In some cases, the amorphous solid may comprise calcium cross-linked alginate and / or calcium cross-linked pectin.

[0100] 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.

[0101] In some embodiments, the cellulosic gelling agent is selected from the group consisting of hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0102] 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 gum acacia.

[0103] 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.

[0104] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of 10-30 wt% (calculated on a dry weight basis) of the amorphous solid. In some embodiments, the alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one additional gelling agent, such as pectin.

[0105] In some embodiments, the amorphous solid 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 the gelling agent (all calculated on a dry weight basis). For example, the amorphous solid can comprise from 1 to 50 wt%, 5 to 45 wt%, 10 to 40 wt%, or 20 to 35 wt% of the gelling agent.

[0106] In some embodiments, the amorphous solid 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 amorphous solid may comprise from 20 to 35 wt% or from 25 to 30 wt% of the gelling agent.

[0107] In some cases, the amorphous solid may comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, or 20 wt% to about 60 wt%, 50 wt%, 40 wt%, 30 wt%, or 25 wt% of the gelling agent (DWB). For example, the amorphous solid may comprise from 10 to 40 wt%, 15 to 30 wt%, or 20 to 25 wt% of the gelling agent (DWB).

[0108] In examples, the amorphous solids include gelling agents and fillers in an amount, taken as a whole, of about 10 wt%, 20 wt%, 25 wt%, 30 wt%, or 35 wt% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the amorphous solids. In examples, the amorphous solids include gelling agents and fillers in an amount, taken as a whole, of about 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt% of the amorphous solids.

[0109] In examples, the amorphous solid comprises the gelling agent in an amount of about 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, or 35 wt% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the amorphous solid (i.e., without taking into account the amount of filler). In examples, the amorphous solid comprises the 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 amorphous solid (i.e., without taking into account the amount of filler).

[0110] 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 amorphous solid, i.e., the amorphous solid comprises alginate in an amount of about 5-40 wt% or 15-40 wt% by dry weight of the amorphous solid, in some examples, the amorphous solid comprises alginate in an amount of about 20-40 wt% or about 15 wt% to 35 wt% of the amorphous solid.

[0111] In some instances, pectin is included in the gelling agent in an amount of about 3-15 wt% of the amorphous solid, i.e., the amorphous solid comprises pectin in an amount of about 3-15 wt% by dry weight of the amorphous solid, in some instances, the amorphous solid comprises pectin in an amount of about 5-10 wt% of the amorphous solid.

[0112] In some examples, the guar gum is included in the gelling agent in an amount of about 3-40 wt% of the amorphous solids. That is, the amorphous solids include guar gum in an amount of about 3-40 wt% by dry weight of the amorphous solids. In some examples, the amorphous solids include guar gum in an amount of about 5-10 wt% of the amorphous solids. In some examples, the amorphous solids include guar gum in an amount of about 15-40 wt% or about 20-40 wt% or about 15-35 wt% of the amorphous solids.

[0113] In an example, the alginate is present in an amount of at least about 50 wt% of the gelling agent. In an example, the amorphous solid comprises alginate and pectin, and the ratio of alginate to pectin is 1:1 to 10:1. The ratio of alginate to pectin is typically greater than 1:1, i.e., the alginate is present in an amount greater than the amount of pectin. In an example, the ratio of alginate to pectin is about 2:1 to 8:1, or about 3:1 to 6:1, or approximately 4:1.

[0114] The amorphous solid may be formed by (a) forming a slurry including components of the amorphous solid 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 amorphous solid. Step (b) of forming the layer of the slurry typically includes spraying, casting or extruding the slurry. In examples, the slurry layer is formed by electrospraying the slurry. In some examples, the slurry layer is formed by casting the slurry.

[0115] In some instances, (b) and / or (c) and / or (d) are performed at least partially simultaneously (e.g., during electrospraying). In some instances, (b), (c) and (d) are performed sequentially.

[0116] In some embodiments, the slurry is applied to the mold body. A layer may be formed on the mold body. In an example, the slurry includes a gelling agent, an aerosol former material, and an active agent. The slurry may include these components in any of the proportions set forth herein relative to the composition of the amorphous solid. For example, the slurry may include the following (on a dry weight basis): a gelling agent and optionally a filler, the amount of the gelling agent and the filler taken together being about 10-60 wt% of the slurry; an aerosol former 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 include.

[0117] The step (c) of hardening the gel 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 a hardening agent including a calcium source (such as calcium chloride) may be added to the slurry to form a calcium alginate gel.

[0118] In examples, the hardening agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or combinations thereof. In some examples, the hardening agent comprises or consists of calcium formate and / or calcium lactate. In certain examples, the hardening agent comprises or consists of calcium formate. The inventors have found that the use of calcium formate as a hardening agent typically results in an amorphous solid having higher tensile strength and higher resistance to elongation.

[0119] The total amount of hardening agent, such as calcium source, can be 0.5-5 wt% (calculated on a dry weight basis). Suitably, the total amount can be from about 1 wt%, 2.5 wt% or 4 wt% to about 4.8 wt% or 4.5 wt%. The inventors have found that adding too little hardening agent can result in an amorphous solid that does not stabilize the amorphous solid components and these components fall off the amorphous solid. The inventors have found that adding too much hardening agent can result in an amorphous solid that is very sticky and therefore poorly handled.

[0120] If the amorphous solid does not contain tobacco, it may be necessary to add a larger amount of hardener. Thus, in some cases, the total amount of hardener may be 0.5-12 wt%, for example 5-10 wt%, calculated on a dry weight basis. Suitably, the total amount may be about 5 wt%, 6 wt%, or 7 wt% to about 12 wt% or 10 wt%. In this case, the amorphous solid generally does not contain tobacco.

[0121] In an example, the step of providing the slurry with a hardening agent includes spraying the hardening agent onto the slurry, for example onto a top surface of the slurry.

[0122] 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 gels. It has been found that alginates with high G monomer content form gels more readily upon addition of a calcium source. Thus, in some cases, the gel precursor may include alginates in which at least about 40%, 45%, 50%, 55%, 60% or 70% of the monomer units in the alginate copolymer are α-L-guluronic acid (G) units.

[0123] In examples, the drying step (d) removes from about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% to about 80 wt%, 90 wt%, or 95 wt% (wet weight basis (WWB)) of the water in the slurry. In examples, the drying step (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 amorphous solid material has a thickness of 0.2 mm.

[0124] In some examples, the slurry solvent consists essentially of or consists of water, hi some examples, the slurry comprises from about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% (WWB) solvent.

[0125] In instances where the solvent consists of water, the dry weight content of the slurry can match the dry weight content of the amorphous solids. Thus, any discussion herein regarding solids composition is expressly disclosed in conjunction with the slurry aspects of the invention.

[0126] The amorphous solid may include a flavoring. Suitably, the amorphous solid may include up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% flavoring. In some cases, the amorphous solid may include at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% flavoring (all calculated on a dry weight basis). For example, the amorphous solid may include 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% flavoring. In some cases, the flavoring includes, consists essentially of, or consists of menthol.

[0127] The amorphous solid may include a filler.

[0128] In some embodiments, the amorphous solid comprises less than 60 wt% of the filler, for example, 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%.

[0129] In other embodiments, the amorphous solid comprises less than 20 wt%, preferably less than 10 wt% or less than 5 wt% of filler. In some cases, the amorphous solid comprises less than 1 wt% of filler, and in some cases no filler. In some such cases, the amorphous solid comprises at least 1 wt% of 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% of filler. In some embodiments, the amorphous solid comprises 5-25 wt% of filler.

[0130] When present, the filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic sorbents such as molecular sieves. The filler may comprise one or more organic filler materials, such as wood pulp, cellulose and cellulose derivatives, such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC).

[0131] In certain cases, the amorphous solid does not include calcium carbonate, such as chalk.

[0132] In certain embodiments that include a filler, the filler is fibrous. For example, the filler can be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose or a cellulose derivative, such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC).

[0133] Without wishing to be bound by theory, it is believed that including a fibrous filler in the amorphous solid may increase the tensile strength of the material, which may be particularly advantageous in instances where the amorphous solid is provided as a sheet, for example, where the amorphous solid sheet surrounds a rod of aerosolizable material.

[0134] In some embodiments, the amorphous solid does not include tobacco fiber. In particular embodiments, the amorphous solid does not include fibrous material. In some embodiments, the aerosol-forming material does not include tobacco fiber. In particular embodiments, the aerosol-forming material does not include fibrous material.

[0135] The aerosol-generating materials may include one or more active agents and / or flavorings, one or more aerosol former materials, and optionally one or more other functional materials.

[0136] In some embodiments, the amorphous solid further comprises an active agent. For example, in some cases, the amorphous solid further comprises tobacco material and / or nicotine. In some embodiments, the amorphous solid comprises powdered tobacco and / or nicotine and / or tobacco extract.

[0137] In some cases, the amorphous solid may comprise between 5 and 60 wt% (calculated on a dry weight basis) of tobacco material and / or nicotine. In some cases, the amorphous solid 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 amorphous solid 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 amorphous solid may comprise 10-50 wt%, 15-40 wt%, or 20-35 wt% tobacco material. In some cases, the amorphous solid may comprise 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 amorphous solid may comprise 1-20 wt%, 2-18 wt%, or 3-12 wt% nicotine.

[0138] In some cases, the amorphous solid comprises an active substance such as tobacco extract. In some cases, the amorphous solid may comprise 5-60 wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid may comprise about 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of tobacco extract. For example, the amorphous solid may comprise 10-50 wt%, 15-40 wt%, or 20-35 wt% of tobacco extract. The tobacco extract may contain nicotine in a concentration such that the amorphous solids contain from 1 wt%, 1.5 wt%, 2 wt%, or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt%, or 4 wt% nicotine (calculated on a dry weight basis). In some cases, there may be no nicotine present in the amorphous solids other than the nicotine originating from the tobacco extract.

[0139] In some embodiments, the amorphous solid does not contain tobacco material but does contain nicotine. In some such cases, the amorphous solid may contain 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 amorphous solid may contain from 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% nicotine.

[0140] 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 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.

[0141] The aerosol-generating composition may include one or more active agents. In examples, the amorphous solid includes one or more active agents, for example, up to about 20% of the amorphous solid. In examples, the amorphous solid includes the active agents in an amount of about 1 wt%, 5 wt%, 10 wt%, or 15 wt% to about 20 wt%, 15 wt%, 15 wt%, or 5 wt% of the amorphous solid.

[0142] 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.

[0143] 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%.

[0144] The tobacco material may be present in any form, but is typically shredded (e.g., chopped into fine pieces). The shredded tobacco material may be advantageously blended with amorphous solids to provide an aerosol-forming composition having a uniform distribution of tobacco material and amorphous solids throughout the aerosol-forming composition.

[0145] In examples, the tobacco material comprises one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extract. Surprisingly, the inventors have found that it is possible to use relatively large amounts of laminar tobacco in an aerosol-generating composition and still produce an acceptable aerosol when heated by a non-combustion aerosol delivery system. Laminar tobacco typically provides superior sensory properties. In examples, the tobacco material comprises laminar tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material. In certain examples, the tobacco material comprises 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.

[0146] The tobacco used to produce the tobacco material can be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia and / or Burley and / or Oriental.

[0147] 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.

[0148] In some cases, the amorphous solids may further comprise an emulsifier, which emulsifies the molten flavor during manufacture. For example, the amorphous solids may comprise about 5 wt% to about 15 wt% (calculated on a dry weight basis) of an emulsifier, preferably about 10 wt%. The emulsifier may include gum acacia.

[0149] In some embodiments, the amorphous solid is a hydrogel and contains less than about 20 wt% water calculated on a wet weight basis. In some cases, the hydrogel may contain less than about 15 wt%, 12 wt%, or 10 wt% water calculated on a wet weight basis. In some cases, the hydrogel may contain at least about 1 wt%, 2 wt%, or at least about 5 wt% water (WWB).

[0150] The amorphous solid may have any suitable water content, such as from 1 wt% to 15 wt%. The water content of the amorphous solid is preferably from about 5 wt%, 7 wt%, or 9 wt% to about 15 wt%, 13 wt%, or 11 wt% (WWB), most preferably about 10 wt%. The water content of the amorphous solid may be determined, for example, by Karl Fischer titration or gas chromatography with a thermal conductivity detector (GC-TCD).

[0151] In some cases, the amorphous solid may consist essentially of or consist of the gelling agent, water, aerosol generating agent, flavoring, and optionally the active agent.

[0152] In some cases, the amorphous solid may consist essentially of or consist of gelling agents, water, aerosol forming agents, flavorings, and optionally tobacco materials and / or a nicotine source.

[0153] In examples, the amorphous solid consists essentially of or consists of a gelling agent, an aerosol generating agent, an active agent, and water.In examples, the amorphous solid consists essentially of or consists of a gelling agent, an aerosol generating agent, and water.

[0154] In examples, the amorphous solid does not include flavorings, and in certain examples, the amorphous solid does not include an active agent. In some embodiments, the aerosol-forming material comprises an amorphous solid, the amorphous solid comprising: 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.

[0155] In some embodiments, the amorphous solid comprises 1-80 wt % (dry weight basis) of flavor. In some embodiments, the amorphous solid is 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. In an alternative embodiment of the aerosol-forming material, the aerosol-forming material comprises an amorphous solid, the amorphous solid comprising: 1 to 60 wt % of a gelling agent; 5 to 60 wt % of an aerosol generating agent; 10-60 wt% tobacco extract; Including, These weights are calculated on a dry weight basis. In some embodiments, the amorphous solid is 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.

[0156] In some embodiments, the amorphous solid comprises 20-35 wt% gelling agent, 10-25 wt% aerosol former material, 5-25 wt% filler including fiber, and 35-50 wt% flavoring and / or active. In some cases, the amorphous solid may consist essentially of the gelling agent, the aerosol generating agent, the tobacco extract, water, and optionally flavoring, or may consist of the gelling agent, the aerosol generating agent, the tobacco extract, water, and optionally flavoring. In some cases, the amorphous solid may consist essentially of glycerol, alginate and / or pectin, tobacco extract, and water, or may consist of glycerol, alginate and / or pectin, tobacco extract, and water.

[0157] In some embodiments, the amorphous solid may have the following composition (DWB): 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%, 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 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%. In one embodiment, the amorphous solid comprises (in DWB) about 20 wt% alginate gelling agent, about 48 wt% Virginia tobacco extract, and about 32 wt% glycerol.

[0158] The "thickness" of an amorphous solid refers to the shortest distance between a first surface and a second surface. In embodiments where the amorphous solid is in the form of a sheet, the thickness of the amorphous solid is the shortest distance between a first planar surface of the sheet and a second planar surface of the sheet opposite the first planar surface of the sheet.

[0159] In some cases, the aerosol-forming amorphous solid layer 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. Suitably, the thickness can 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.

[0160] In some cases, the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

[0161] Particularly suitable is a material having a thickness of 0.2 mm. The amorphous solid may comprise two or more layers, and the thicknesses mentioned herein refer to the combined thicknesses of the layers.

[0162] It has been found that if the aerosol-generating material or amorphous solid is too thick, the heating efficiency is compromised, which has a negative impact on power consumption during use. Conversely, if the aerosol-generating material or amorphous solid is too thin, it is difficult to manufacture and handle, and very thin materials are more difficult to cast and prone to breaking, which can impair aerosol formation during use.

[0163] The thicknesses defined herein are the average thickness of the material. In some cases, the thickness of the amorphous solid may vary by 25%, 20%, 15%, 10%, 5%, or 1% or less.

[0164] In some examples, the amorphous solid 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 amorphous solid does not include a filler, the amorphous solid 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. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is formed as a sheet and then chopped and incorporated into an aerosol product article. In some examples, such as when the amorphous solid includes a filler, the amorphous solid may have a tensile strength of 600 N / m to 900 N / m, or 700 N / m to 900 N / m, or about 800 N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is included in an aerosol product article / assembly as a rolled sheet, preferably in the form of a tube.

[0165] In some examples, the amorphous solid in sheet form may have a tensile strength of about 200 N / m to about 2600 N / m. In some examples, the amorphous solid may have a tensile strength of 600 N / m to 2000 N / m, or 700 N / m to 1500 N / m, or about 1000 N / m. Such tensile strengths may be particularly suitable for embodiments in which an aerosol generating material comprising the amorphous solid is formed and incorporated into an aerosol generating consumable as a sheet.

[0166] Aerosol-forming materials containing amorphous solids have a density of 30 g / m 2 ~120g / m2 In some cases, the sheet may have any suitable areal density, such as 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 (so that the sheet has a density similar to cut rag tobacco and mixtures of these materials do not easily separate). In some cases, the sheet has a mass per unit area of ​​about 30 to 70 g / m 2 , 40~60g / m 2 , or 25 to 60 g / m 2 and may be used to wrap aerosolizable material such as cigarettes.

[0167] All weight percentages (wt%) described herein are calculated on a dry weight basis unless otherwise specified. All weight ratios are also calculated on a dry weight basis. Weights listed on a dry weight basis refer to the totality of the extract or slurry or material, except for water, and may include ingredients that are themselves liquid at room temperature and pressure, such as glycerol. In contrast, weight percentages listed on a wet weight basis refer to all ingredients, including water.

[0168] The amorphous solid may include a colorant. The addition of a colorant can change the appearance of the amorphous solid. The presence of a colorant in the amorphous solid can enhance the appearance of the amorphous solid and the aerosol-forming material. By adding a colorant to the amorphous solid, the amorphous solid can be color-matched to other components of the aerosol-forming material or to other components of an article that includes the amorphous solid.

[0169] Depending on the desired color of the amorphous solid, various colorants can be used. The color of the amorphous solid can be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated. Natural or synthetic colorants can be used, such as natural or synthetic dyes, food grade colors, and pharmaceutical grade colors. In certain embodiments, the colorant is caramel, which can give the amorphous solid a brown appearance. In such embodiments, the color of the amorphous solid can be similar to the color of other components in the aerosol-forming material that includes the amorphous solid, such as the tobacco material. In some embodiments, the colorant is added to the amorphous solid to make the amorphous solid visually indistinguishable from other components in the aerosol-forming material.

[0170] The colorant can be incorporated at the time the amorphous solid is formed (e.g., when forming a slurry containing the materials that will form the amorphous solid) or can be added to the amorphous solid after it is formed (e.g., by spraying it onto the amorphous solid).

[0171] In some embodiments of any of the above embodiments, talcum powder, calcium carbonate powder, or other powder is applied to an exposed surface of at least one discrete portion of the aerosol-generating material, which may reduce the level of stickiness or tackiness of the aerosol-generating material.

[0172] In the following discussion of the accompanying drawings, when the same 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 numbers plus a multiple of 100) are used.

[0173] 1, an aerosol delivery device 2 includes a casing 4 in which a heater assembly 6 is disposed. The heater assembly 6 consists of a heating chamber 8 and a heater 10. The heater 10 can be an electrical resistance heater or a magnetic field generator for use with a susceptor.

[0174] 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 a bore 14. The bore 14 is in fluid communication with a mouthpiece 16 via a conduit 18.

[0175] Also disposed within the casing 4 is a controller 20 in electronic communication with and controlling the functioning of the heater 10. The controller 20 may include a memory (not shown) capable of storing one or more tables relating to the operation of the heater 10. The heater 10 and 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 source of electrical power.

[0176] The aerosol delivery device 2 is suitable for use with a consumable 24. The consumable 24 comprises one or more discrete portions 26 of aerosol-generating material supported on a first surface 30 of a support 28. The discrete portions 26 of aerosol-generating material are supported on the support 28 in a square grid pattern. Other non-illustrated embodiments of the consumable 24 may include more or fewer discrete portions 26 of aerosol-generating material than shown in FIG. 1, including a single portion 26 of aerosol-generating material, and the portions may be distributed in any pattern on the surface of the support 28. Although the discrete portions 26 of aerosol-generating material are shown in FIG. 1 as having a generally circular shape, in other embodiments they may be other shapes.

[0177] 2 to 8, a first embodiment of a method for manufacturing the consumable item 24 is as follows.

[0178] 2 and 4, a mold body 40 is provided. The mold body 40 is a sheet material of uniform thickness t formed from a material that can be debossed or embossed. One example of such a material is cardboard. The mold body 40 has a first surface 30 in which one or more mold recesses 42 are formed. Nine mold recesses 42 are shown in FIGS. 1-8 (although not all are numbered for clarity). It should be understood that fewer or more mold recesses 42 may be formed in the surface 30 of the mold body 40, if desired. It should also be understood that the mold body 40 can be larger than a single consumable 24, and that, if applicable, a single mold body 40 can be used to make more than one consumable 24.

[0179] 3, a first embodiment of a method for manufacturing a consumable 24 uses a debossing apparatus 44, as shown generally in FIG. 3, to form mold recesses 42 in surface 30 of a mold body 40. Debossing apparatus 44 includes a debossing cylinder 46 and a flat surface 48. Debossing cylinder 46 has a plurality of raised portions 50 (not all of which are numbered) distributed about a cylindrical surface 52 of debossing cylinder 46.

[0180] The raised portions 50 are square or rectangular in the illustrated embodiment and are all the same shape and size, in other non-illustrated embodiments the raised portions may be various shapes, such as longitudinally extending circles or ovals, and / or not all the raised portions are the same shape as each other.

[0181] The cylindrical surface 52 of the debossing cylinder 46 is spaced from the flat surface 48 by a distance approximately equal to the thickness t. The raised portions 50 of the debossing cylinder 46 protrude from the cylindrical surface 52 by a distance less than the thickness t. The debossing cylinder 46 is rotated about a central axis 54 by a source of rotational motion (not shown). As the debossing cylinder 46 rotates, the mold body 40 is fed into the gap between the debossing cylinder 46 and the flat plate 48. The rotation of the debossing cylinder 46 draws the mold body through the gap, with the raised portions 50 forming a plurality of mold recesses 42 in the surface 30 of the mold body 40.

[0182] A release agent (not shown) is then applied to at least the surfaces of the mold recess 42. Application can be by spraying the release agent. In some examples, the release agent may be sprayed over the entire surface 30 and the surfaces of the mold recess 42. The release agent is selected such that when the aerosol-generating material 56 is later applied to the mold recess 42, the aerosol-generating material 56 will release from the surfaces of the mold recess at a pull-out stress, e.g., a stress of X Pascals (Pa), below a stress that would cause damage to the aerosol-generating material 56.

[0183] 5, a source of aerosol-generating material 56 (not shown) supplies the aerosol-generating material 56 to one or more nozzles 58 (only one is shown in FIG. 5 for clarity). The nozzles 58 apply a portion of the aerosol-generating material 46 to the surface 30 of the mold body 40 in and around each of the mold recesses 42. The number of nozzles 58 may be equal to or a multiple of the number of mold recesses 42. In some non-illustrated embodiments, there may be more than one source of aerosol-generating material 56, with at least two of the sources including aerosol-generating material 56 having different compositions from each other. The different compositions may include different actives and / or flavors.

[0184] 6, once aerosol-generating material 56 has been applied to each mold recess 42, a scraper in the form of a doctor blade 60 is passed across surface 30. Doctor blade 60 removes any excess aerosol-generating material 56 from surface 30 of mold body 40 relative to the aerosol-generating material 56 needed to fill mold recess 42, creating an exposed surface 66 of aerosol-generating material 56. The excess aerosol-generating material 56 may be returned to the source of aerosol-generating material 56 or may be discarded.

[0185] The mold body 40 and the aerosol-generating material 56 are then exposed to at least one condition suitable to enable, facilitate or encourage a change in a property of the aerosol-generating material 56. Such conditions can be, but are not limited to, a rest period, a predetermined curing temperature, exposure to electromagnetic radiation, or a combination thereof. In a first embodiment of the method of the present disclosure, the property of the aerosol-generating material 56 that is changed is the weight of the aerosol-generating material 56. This change is the result of the aerosol-generating material 56 being applied to the mold body 40 as a slurry and then dried after the excess aerosol-generating material 56 is removed from the surface 30 of the mold body 40. In other embodiments, the aerosol-generating material 56 is allowed to dry or partially dry before the excess aerosol-generating material 56 is scraped off the surface 30.

[0186] 7, once the desired level of change to the properties of the aerosol-generating material 56 has occurred, a sheet of material 62 having a first surface 64 and a second surface 68 is placed over the mold body 40 such that the surface 64 of the sheet of material 62 contacts the exposed surface 66 of the aerosol-generating material 56 and the portion of the surface 30 of the mold body 40 that does not form part of the mold recess 42. The surface 42 of the sheet of material 62 is then allowed to bond or is caused to bond with the exposed surface 66 of the aerosol-generating material 56. The exposed surface 66 of the aerosol-generating material typically bonds with the surface 64 of the sheet of material 62 due to an inherent viscosity in a portion of the aerosol-generating material 56 or because the exposed surface 66 of the aerosol-generating material 56 is caused to become viscous.

[0187] The sheet material 62, in the presently described embodiment, is a sheet of susceptor material, such as an aluminum foil or film. In other embodiments, the sheet material 62 may be a sheet of an alternative susceptor, a sheet of a thermal transfer material, or a sheet of an alternative material. The selection of a material for forming the sheet material 62 depends at least in part on the intended mode of heating the consumable 24 formed by the methods described herein.

[0188] 8 , the sheet material 62 is removed from the mold body 40 along with the aerosol-generating material 56 from the mold recess 42 when the bonding of the surface 64 of the sheet material 62 with the exposed surface 66 of the aerosol-generating material 56 reaches a level where the pull-out stress of the surface 64 from the exposed surface 66 reaches a value of Y Pa. The pull-out stress Y Pa is greater than the pull-out stress X Pa, which is the pull-out stress due to the interaction between the aerosol-generating material 56 and the release agent treated surface of the mold recess 42. The portions of the aerosol-generating material 56 that are bonded to the surface 64 of the sheet material 62 become the individual portions 26 of the aerosol-generating material 56 in the consumable 24.

[0189] 9, surface 68 of sheet material 62 is then attached to surface 72 of support 70 to form consumable 24. Support 70 is formed from card, a plastic material such as polyetheretherketone (PEEK), or another suitable material for forming a support for consumable 24.

[0190] Referring to Figure 10, an alternative embodiment consumable 124 is shown. The method of making the alternative embodiment consumable 124 is as shown in Figures 2-7 and described above except as noted below. The reference numbers used with respect to Figure 10 are as with Figures 2-7 where the illustrated elements are the same elements.

[0191] When making the consumable 124, there is no application of a release agent following the formation of the mold recess 42 because the aerosol-generating material 56 disposed in the mold recess 42 does not subsequently release from the mold recess 42 other than as an aerosol when the consumable 124 is used.

[0192] Optionally, prior to or simultaneously with the placement of surface 64 of sheet material 62 against exposed surface 66 of aerosol-generating material 56 and portions of surface 30 of mold body 40 that do not form part of mold recess 42, an adhesive (not shown) is applied to one or both of portions of surface 30 of mold body 40 that do not form part of mold recess 42 and surface 64 of sheet material 62.

[0193] Alternatively, the sheet material 62 may be held in place against the mold body 40 by the inherent viscosity of the aerosol-generating material 56 , causing the surface 64 to adhere to the exposed surface 66 of the aerosol-generating material 56 .

[0194] Once the sheet of material 62 is held in place against the mold body 40, the sheet of material 62, the aerosol-generating material 56, and the mold body 40 are then perforated by a suitable perforation means (not shown) to create a plurality of perforations 74. The perforations 74 should be at least 0.01 mm 2 , at least 0.05 mm 2 , at least 0.1 mm 2 , at least 0.5 mm 2 , at least 1 mm 2 , at least 2 mm 2 , or at least 3 mm 2 may have a cross-sectional area of

[0195] In an alternative, not shown, embodiment of the present disclosure, the perforations 74 do not penetrate the entire depth of the consumable 124 , but extend at least partially through the aerosol-generating material 56 and to one of the outer surfaces of the consumable 124 .

[0196] In the consumable 124, the support for the consumable is the mold body 40, which provides structural strength to the consumable 124. The sheet material 62 is a sheet of susceptor material, such as aluminum foil. In other non-illustrated embodiments, the sheet material 62 may be a sheet of an alternative susceptor, a sheet of a thermal transfer material, or a sheet of an alternative material. The selection of a material for forming the sheet material 62 depends at least in part on the intended mode of heating the consumable 124 formed by the methods described herein.

[0197] 11 to 16, in a second embodiment of the present disclosure, a mold body 240 is provided. The mold body 240 is a sheet material of uniform thickness t formed from a material capable of plastic deformation. The mold body 240 has the same appearance as the mold body 40 of FIG.

[0198] An example of such a material is.... The mold body 240 has a first surface 30 in which one or more mold recesses 242 are to be formed, and a second surface through which the mold recesses extend. Three mold recesses 242 are shown in Figures 11-16. It should be understood that fewer or more mold recesses 242 may be formed in the mold body 240, if desired. It should also be understood that the mold body 240 can be larger than a single consumable 224, and that, if applicable, a single mold body 240 can be used to make more than one consumable 224.

[0199] 11, a second embodiment of a method for manufacturing a consumable 224 uses a vacuum blister molding apparatus 244, as shown generally in FIG. 11, to form a mold recess 242 in a mold body 240. The blister molding apparatus 244 includes a bed 246 having a bed surface 248. Extending from the bed surface 248 to the bed 246 are a plurality of blister modules 250. Each blister module 250 is in fluid communication with a vacuum pump 252 via a conduit network 254.

[0200] Essentially, the mold body 240 is placed on the bed surface 248 and the vacuum pump 252 is turned on. The vacuum created by the vacuum pump 252 in the conduit network 254 and the blister module 250 causes the mold body to plastically deform and conform to the surface profile of the bed surface 248 and the blister module 250.

[0201] 12, once plastic deformation of mold body 240 is complete, mold body 242 is removed from blister molding apparatus 244. Mold body 240 now includes a plurality of mold recesses 242.

[0202] 13, a source of aerosol-generating material 56 (not shown) supplies the aerosol-generating material 56 to one or more nozzles (not shown). The nozzles apply the aerosol-generating material 56 to each of the surfaces 230 and / or mold recesses 242 of the mold body 240. In some non-illustrated embodiments, there may be more than one source of aerosol-generating material 56, with at least two of the sources including aerosol-generating material 56 having different compositions than each other. The different compositions may include different actives and / or flavorants. Aerosol-generating material 56 of different compositions may be applied to various portions of the mold body 240.

[0203] 14, once the aerosol-generating material 56 has been applied to the mold body 240, a scraper in the form of a doctor blade 256 is passed across the surface 230. The doctor blade 256 removes any excess aerosol-generating material 56 from the surface 230 of the mold body 240 relative to the aerosol-generating material 56 needed to fill the mold recess 242, creating an exposed surface 258 of aerosol-generating material 56. The excess aerosol-generating material 56 may be returned to the source of aerosol-generating material 56 or may be discarded.

[0204] The mold body 240 and the aerosol-generating material 56 are now exposed to at least one condition suitable for enabling, facilitating or encouraging a change in a property of the aerosol-generating material 56. Such conditions can be, but are not limited to, a rest period, a predetermined curing temperature, exposure to electromagnetic radiation, or a combination thereof. In a first embodiment of the method of the present disclosure, the property of the aerosol-generating material 56 that is changed is the weight of the aerosol-generating material 56. This change is the result of the aerosol-generating material 56 being applied to the mold body 240 as a slurry and then allowed to dry after excess aerosol-generating material 56 is removed from the surface 230 of the mold body 240.

[0205] 15 , once the desired level of change to the properties of the aerosol-generating material 56 has occurred, a sheet of material 260 having a surface 262 is placed over the mold body 240 such that the surface 262 of the sheet of material 260 contacts the exposed surface 258 of the aerosol-generating material 56 and the portion of the surface 230 of the mold body 240 that does not form part of the mold recess 242. The surface 262 of the sheet of material 260 is then allowed to bond or is caused to bond with the exposed surface 258 of the aerosol-generating material 56. The exposed surface 258 of the aerosol-generating material typically bonds with the surface 262 of the sheet of material 260 due to an inherent viscosity in a portion of the aerosol-generating material 56 or because the exposed surface 258 of the aerosol-generating material 56 is caused to become viscous.

[0206] Optionally, prior to or simultaneously with the placement of surface 262 of sheet material 260 against exposed surface 258 of aerosol-generating material 56 and portions of surface 30 of mold body 240 that do not form part of mold recess 242, an adhesive (not shown) is applied to one or both of portions of surface 230 of mold body 240 that do not form part of mold recess 242 and surface 262 of sheet material 260.

[0207] The sheet material 260, in the presently described embodiment, is a sheet of susceptor material, such as aluminum foil. In other embodiments, the sheet material 260 may be a sheet of an alternative susceptor, a sheet of thermal transfer material, or a sheet of an alternative material. The selection of the material for forming the sheet material 260 depends at least in part on the intended mode of heating the consumable 224 formed by the methods described herein.

[0208] 16, once the sheet of material 260 is held in place against the mold body 240, the sheet of material 260, the aerosol-generating material 56, and the mold body 240 are then perforated by a suitable perforation means (not shown) to create a plurality of perforations 264. The perforations 264 should be at least 0.01 mm 2 , at least 0.05 mm 2 , at least 0.1 mm 2 , at least 0.5 mm 2 , at least 1 mm 2 , at least 2 mm 2 , or at least 3 mm 2 may have a cross-sectional area of

[0209] In an alternative, not shown, embodiment of the present disclosure, the perforations 264 do not penetrate the entire depth of the consumable 224 , but extend at least partially through the aerosol-generating material 56 and to one of the outer surfaces of the consumable 224 .

[0210] In consumable 224, the support for the consumable is mold body 240, which provides structural strength to consumable 224. Sheet material 262 is a sheet of susceptor material, such as aluminum foil. In other non-illustrated embodiments, sheet material 260 may be a sheet of an alternative susceptor, a sheet of thermal transfer material, or a sheet of an alternative material. The selection of a material for forming sheet material 260 depends at least in part on the intended mode of heating consumable 224 formed by the methods described herein.

[0211] 17, in an alternative embodiment of the second embodiment of the method according to the present disclosure, the consumable 324 includes a mold body 240 that is a laminate having a support layer 266 and a susceptor layer 268. The support layer 266 is of a suitable support material. The susceptor layer forms the surface 230 of the mold body 240. The sheet material 260 is of a material suitable for protecting the aerosol-generating material 56 prior to use of the consumable 324. The consumable also includes perforations 264 as described in connection with FIG.

[0212] In an alternative, not shown, embodiment of the consumable 324, the sheet material 264 is not present or is removed prior to use of the consumable.

[0213] Various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only as representative samples of embodiments and are not exhaustive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the disclosure defined by the claims or limitations on the equivalents of the claims, and that other embodiments can be utilized and changes can be made without departing from the scope of the disclosure as claimed. It is preferred that various embodiments of the disclosure can include, consist of, or essentially consist of suitable combinations of the disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein. In addition, the disclosure can include other disclosures that are not currently claimed but may be claimed in the future.

Claims

1. 1. A method of manufacturing an article, the article comprising a substrate and an aerosol-forming material, the method comprising: (a) providing a mold body; (b) forming one or more inwardly extending mold recesses in a first surface of the mold body; (c) applying at least one discrete portion of an aerosol-forming material to the first surface of the mold body; Including, each mold recess extends inwardly from the first surface of the mold body; at least one discrete portion of the aerosol-generating material at least partially overlies the mold recess or at least one discrete portion of the aerosol-generating material at least partially overlies the location where the mold recess will be formed in step (b); the aerosol-forming material applied to the first surface of the mold body in step (c) is an aerosol-forming material slurry; The manufacturing method comprises: (e) further comprising the further method step of allowing or curing the aerosol-forming material slurry; the aerosol-forming material slurry hardens to form the aerosol-forming material, and step (e) occurs after step (c); The manufacturing method comprises: (f) after step (c) is performed and before or after step (e) is performed, passing a scraper over at least a portion of the first surface of the mold body.

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

3. The manufacturing method comprises: (d) separating the article into two or more consumable portions. further comprising The method of claim 1 , wherein each consumable portion is shaped and sized for use as a consumable for use with a device that heats an aerosol-forming material to volatilize at least one component of the aerosol-forming material.

4. The method of claim 1 , wherein steps (a) and (b) are performed before step (c).

5. 5. The method of claim 4, wherein steps (a) and (b) are performed as separate processes relative to step (c), and the products of steps (a) and (b) are stored and / or transported between various locations before step (c) is performed.

6. The method of claim 1 , wherein step (c) is performed after step (a) and before step (b).

7. 2. The method of claim 1, wherein step (c) comprises applying an aerosol-generating material to at least a portion of the first surface of the mold body that includes a mold recess or to substantially the entire first surface of the mold body.

8. The manufacturing method comprises: (g) placing a layer of material on the first surface of the mold body; The method of claim 1 further comprising:

9. The method of claim 8 , wherein step (g) is performed after step (c) and, if step (f) is performed, after step (f).

10. The manufacturing method comprises: (h) bonding the aerosol-forming material to the layer of material. further comprising The method of claim 8 or 9, wherein step (h) is performed after step (g).

11. The manufacturing method comprises: (i) applying a mold release agent to the first surface of the mold body; (j) removing the layer of material with the aerosol-forming material bonded thereto from the mold body; further comprising The method of claim 10 , wherein step (i) is performed before step (c) and step (j) is performed after step (h).

12. The method of claim 11 , wherein the layer of material is attached to the support after step (i).

13. The method of claim 12 , wherein the layer of material is attached to the support with the surface of the layer of material having the aerosol-forming material bonded to it facing away from the support.

14. The method of claim 8 , wherein the layer of material comprises a susceptor.

15. The method of claim 8 , wherein the support comprises the layer of material.

16. The method of claim 1 , wherein the support comprises the mold body.

17. The method of claim 15 or 16, wherein the support comprises a susceptor.

18. The manufacturing method comprises: (k) applying a susceptor layer to the first surface of the mold body; further comprising The method of claim 1 , wherein step (k) is performed after step (a) and before step (c).

19. The manufacturing method comprises: (m) perforating one or more of the mold body (if present), the aerosol-generating material, the support (if present), the susceptor (if present), and the material layer (if present). The method of claim 1 further comprising:

20. 10. The method of claim 1, wherein step (c) applies at least two separate portions of aerosol-forming material to the first surface of the mold body, the separate portions of aerosol-forming material having different compositions from each other.

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