Consumables for use with aerosol delivery devices

Abstract

A consumable (24) suitable for use with a non-flammable aerosol delivery system (2) is provided. The consumable (24) includes a support (26) having a support surface (34), an aerosol-forming material (30), and a cover (28) having a cover surface (38). The cover (28) is configured to cover the covered portion of the support surface (34), such that at least one discrete portion of the aerosol-forming material (30) is supported on the covered portion of the support surface (34). The covered portion of the support surface (34) and the cover surface (38) are configured to include one or more contact zones (40), where in each contact zone (40) a portion of the covered portion of the support surface (34) and a portion of the cover surface (38) are in direct or indirect contact with one another.

Description

[Technical field]

[0001] The present disclosure relates to the field of non-flammable aerosol delivery systems, and more particularly to consumables for use with aerosol delivery devices, aerosol delivery systems including consumables and aerosol delivery devices, and methods of generating aerosols from the consumables.

[0002] Smoking articles, such as cigarettes, cigars, etc., burn tobacco during use to produce tobacco smoke. Alternatives to these types of articles release compounds from a substrate material through heating without combustion, thereby emitting an inhalable aerosol or vapor. These are sometimes referred to as non-combustible smoking articles, aerosol generating assemblies, or aerosol delivery devices.

[0003] One example of such a product is a heating device that releases compounds by heating, without combustion, an aerosolizable material, sometimes referred to as a solid aerosol-generating material, which may optionally include tobacco material. Upon heating, at least one component of the material is volatilized, typically forming an inhalable aerosol. These products may also be referred to as non-combustion heating devices, tobacco heating devices, or tobacco heating products. A variety of different configurations are known that volatilize at least one component of a solid aerosol-generating material.

[0004] Another example is a hybrid device. These hybrid devices include a liquid source (which may or may not contain nicotine) that is vaporized upon heating to produce an inhalable vapor or aerosol. The device also includes a solid aerosol-forming material (which may or may not contain tobacco material) whose components are entrained in the inhalable vapor or aerosol to produce the inhalation medium. Overview

[0005] According to a first aspect of the present disclosure, there is provided a consumable suitable for use with a non-flammable aerosol delivery system, the consumable comprising a support, an aerosol-generating material, and a cover, the support portion comprises a support surface having a covering portion; the cover having a cover surface; A cover is configured to cover the covering portion of the support surface; at least one discrete portion of aerosol-forming material is supported on a covering portion of a support surface; each discrete portion of aerosol-forming material supported on the covering portion of the support surface is supported at a portion location; One or both of the covering portion of the support surface and the cover surface are configured three-dimensionally; the covering portion of the support surface and the cover surface are configured such that, at each partial position, the cover surface is sufficiently spaced from the covering portion of the support surface such that at least a portion of the discrete portion of the aerosol-forming material at that partial position does not come into contact with the cover surface; the covering portion of the support surface and the cover surface are configured to include one or more contact zones; A consumable is provided in which, at each contact zone, a portion of the covering portion of the support surface and a portion of the cover surface are in direct or indirect contact with each other.

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

[0007] According to a third aspect of the present disclosure, there is provided an aerosol delivery system comprising an aerosol delivery device and a consumable manufactured by the method according to the first aspect of the present disclosure.

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

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

[0010] [Figure 1] FIG. 1 is a schematic diagram of one embodiment of an aerosol delivery device. [Diagram 2] FIG. 1 illustrates a first embodiment of a consumable product in accordance with the present disclosure. [Diagram 3] 3 is a cross-sectional view of the consumable of FIG. 2 taken along section line AA'. [Figure 4] FIG. 1 illustrates a second embodiment of a consumable product in accordance with the present disclosure. [Diagram 5] FIG. 13 illustrates a third embodiment of a consumable in production in accordance with the present disclosure. [Figure 6] FIG. 13 is a perspective view of a third embodiment of a consumable product in accordance with the present disclosure. [Figure 7] 7 shows a cross-section of the consumable of FIG. 6 taken along section line BB'. [Figure 8] FIG. 13 illustrates a cross-section of a fourth embodiment of a consumable according to the present disclosure. [Figure 9] FIG. 13 illustrates a fifth embodiment of a consumable in production in accordance with the present disclosure. Detailed Description

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

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

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

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

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

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

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

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

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

[0020] In some embodiments, a non-flammable aerosol delivery system (e.g., a non-flammable aerosol delivery device) can include a power source and a controller. The power source can be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that can be energized to provide power in the form of heat to an aerosol-generating material or a heat transfer material in proximity to the heat generating power source.

[0021] In some embodiments, the non-flammable aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier. According to a first aspect of the present disclosure, there is provided a consumable for use with an apparatus for heating an aerosol-generating material to volatilize at least one component of the aerosol-generating material, the consumable comprising a support, an aerosol-generating material, and a cover, the support portion comprises a support surface having a covering portion; the cover having a cover surface; A cover is configured to cover the covering portion of the support surface; at least one discrete portion of aerosol-forming material is supported on a covering portion of a support surface; each discrete portion of aerosol-forming material supported on the covering portion of the support surface is supported at a portion location; One or both of the covering portion of the support surface and the cover surface are configured three-dimensionally; the covering portion of the support surface and the cover surface are configured such that, at each partial position, the cover surface is sufficiently spaced from the covering portion of the support surface such that at least a portion of the discrete portion of the aerosol-forming material at that partial position does not come into contact with the cover surface; the covering portion of the support surface and the cover surface are configured to include one or more contact zones; A consumable is provided in which, at each contact zone, a portion of the covering portion of the support surface and a portion of the cover surface are in direct or indirect contact with each other.

[0022] According to one embodiment of the above embodiments, the aerosol-generating material is an aerosol-generating film.

[0023] In one embodiment of any of the above embodiments, a plurality of discrete portions of aerosol-forming material are supported on a covering portion of a support surface.

[0024] In one embodiment of any of the above embodiments, when a portion of the covering portion of the support surface and a portion of the cover surface touch each other in the contact zone, they are in direct contact with each other.

[0025] In one embodiment of any of the above embodiments, the portion of the covering of the support surface and the portion of the cover surface in the contact zone are in indirect contact with each other if (i) there is an intermediate element or substance between the portion of the covering of the support surface and the portion of the cover surface, and (ii) the portion of the covering of the support surface and the portion of the cover surface are both touching / in direct contact with the intermediate element or substance. For the purposes of determining whether the portion of the covering of the support surface and the portion of the cover surface are in indirect contact, a gaseous substance such as air is not considered as an intermediate element or substance. In one embodiment of the above embodiment, two or more (n) intermediate elements E 1 ~E n exists, Middle element E 1 is in contact with said portion of the covering portion of the support surface, Middle element E n However, the above-mentioned part of the cover surface is touching the n is 3 or more, and the middle element E 1 and E n Each intermediate element E between x But the middle element E (x-1) and E (x+1) or n is 2, and the middle element E 1But the middle element E 2 It touches on.

[0026] Alternatively, if there are one or more intermediate elements between the portion of the covering part of the support surface and the portion of the cover surface in the contact zone, the portions of the support surface and the cover surface are in indirect contact if there is no air / gas filled gap between these surfaces.

[0027] In one embodiment of any of the above embodiments, the at least one intermediate component comprises one of a non-gaseous material, a solid material, a gel, a paste, a shim, a seal, a gasket, an adhesive, a caulking, or a sealing compound.

[0028] The support may be of any material suitable for the construction of the substrate, for example, the support may be or include paper, cardboard, paperboard, cardboard, recycled materials, plastic materials, ceramic materials, composites, glass, metals, or alloys.

[0029] In one embodiment of any of the above embodiments, the support comprises a plastic material capable of withstanding temperatures typically encountered in a non-flammable aerosol delivery device. In some embodiments, the support comprises polyetheretherketone (PEEK). Such an embodiment has the advantage that the support is reusable and the consumable is less susceptible to condensation in a non-flammable aerosol delivery device than consumables with supports that use adsorbent materials for structural purposes.

[0030] The cover may be of a material suitable for the construction of the substrate, for example, the cover may be or include paper, cardboard, paperboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or alloy.

[0031] In one embodiment of any of the above embodiments, the cover comprises a plastic material capable of withstanding temperatures typically encountered in a non-flammable aerosol delivery device. In some embodiments, the cover comprises polyetheretherketone (PEEK). Such an embodiment has the advantage that the cover is reusable and consumables are less susceptible to condensation in a non-flammable aerosol delivery device than covers that use adsorbent materials.

[0032] In one embodiment of any of the above embodiments, the covering portion of the support surface and the cover surface are configured to define at least one passageway, the at least one passageway including at least one portion location.

[0033] This has the advantage that discrete portions of aerosol-generating material located at partial locations within the passageway are protected from contamination due to contact with a user of objects such as consumables that may carry chemical or biological materials that may also contaminate the aerosol-generating material, and also from physical damage or abrasion due to collision with objects such as parts of the aerosol generating device or mishandling of the consumables by a user.

[0034] In one embodiment of any of the above embodiments, each portion location is located in a passageway.

[0035] In one embodiment of any of the above embodiments, the or each passageway is configured to allow fluid (e.g., aerosol) at or near atmospheric pressure to flow along the passageway in a volume sufficient to cause a user of the aerosol delivery device to draw at least a predetermined minimum flow rate of fluid through the or each passageway when the consumable is being used in connection with the aerosol delivery device. In some embodiments, the predetermined minimum flow rate is in the range of 20 ml / s to 100 ml / s, in the range of 20 ml / s to 80 ml / s, in the range of 20 ml / s to 60 ml / s, in the range of 30 ml / s to 60 ml / s, around 30 ml / s, around 40 ml / s, around 50 ml / s, or around 60 ml / s.

[0036] In one embodiment of any of the above embodiments, the cover surface has a perimeter extending around an edge of the cover surface, and a first end of at least one passageway is open and partially defined by a portion of the perimeter of the cover surface, where open, in the context of this disclosure, is understood to mean that fluid can pass through the end to enter or exit the passageway.

[0037] In one embodiment of any of the above embodiments, a second end of the at least one passageway is open and is defined in part by a portion of the periphery of the cover surface.

[0038] In one embodiment of any of the above embodiments, a first end of the at least one passageway is open and defined by an opening extending through one of the covering surface or the covering portion of the support surface.

[0039] In one embodiment of any of the above embodiments, a second end of the at least one passageway is open and defined by an opening extending through one of the covering surface or the covering portion of the support surface.

[0040] In one embodiment of any of the above embodiments, at least one end of at least one passageway is open and opens to another passageway. In such an embodiment, at least one end of the passageway is defined by a wall of the open passageway. In such an embodiment, two or more passageways are connected and fluid may flow through multiple passageways during movement through the consumable product during use of the consumable product of the present disclosure.

[0041] In one embodiment of any of the above embodiments, at least one passage has a non-uniform cross-section along the length of the passage. In some embodiments, the cross-section may be non-uniform for fluid flow control reasons (e.g., to accelerate or decelerate the flow of air, aerosol, or a mixture of air and aerosol along the passage).

[0042] In one embodiment of any of the above embodiments, there are two or more passages, and two of the passages are separated from each other by a contact zone. In some embodiments of this embodiment, the separation of the passages is lateral, i.e., the passages are side-by-side, and the contact zone is at least part of the material that separates the passages.

[0043] In one embodiment of any of the above embodiments, each passageway is separated from the other passageways by one or more contact zones.

[0044] In one embodiment of any of the above embodiments, there are two or more passageways and at least two of the passageways are generally parallel to one another. In some embodiments, at least two of the generally parallel passageways are adjacent to one another.

[0045] In one embodiment of any of the above embodiments, at least one passageway is generally linear between the first and second ends of the passageway. In some embodiments, each of the passageways is generally linear between the first and second ends.

[0046] In one embodiment of any of the above embodiments, the covering portion of the support surface and the cover surface are configured such that, at at least one partial position, the support surface and the cover surface define one or more chambers, at least one of the chambers is configured such that there is no contact between the discrete portions of aerosol-forming material and the cover surface in the one or more chambers, hi some embodiments, the chamber is of a dimension in a particular direction that is greater than an equivalent dimension in that direction of the or each passageway opening into the chamber.

[0047] In one embodiment of any of the above embodiments, at least one of the chambers is in fluid contact with at least one of the passages.

[0048] In one embodiment of any of the above embodiments, at least one end of the at least one passageway opens into one of the chambers.

[0049] In one embodiment of any of the above embodiments, at least one of the contact zones is configured such that the portion of the covering part of the support surface and the portion of the cover surface which are in direct or indirect contact with each other in the one or more contact zones are fixed to each other by a fixing means.

[0050] In one embodiment of any of the above embodiments, the fastening means is an adhesive.

[0051] In one embodiment of any of the above embodiments, the fastening means is a melt-and-solidify portion of one or both of the support surface and the cover surface.

[0052] In one embodiment of any of the above embodiments, the fastening means is a physical connection means mounted to or extending through the contact zone.

[0053] In one embodiment of any of the above embodiments, at least one of the contact zones is configured such that said portion of the covering portion of the support surface and said portion of the cover surface are adjacent to but not fixed to one another.

[0054] In one embodiment of any of the above embodiments, the support and the cover are held in fixed relationship to one another by at least one packaging element extending around at least a portion of the support and the cover.

[0055] In one embodiment of any of the above embodiments, one of the covering portion of the support surface and the cover surface is substantially flat.

[0056] In one embodiment of any of the above embodiments, the three-dimensional configuration of the cover surface and / or the cover surface of the support is the result of molding of the cover and / or the cover of the support. In some embodiments, molding occurs during the formation of the cover and / or the cover of the support. In other embodiments, the cover and / or the cover of the support is molded after formation of the cover and / or the cover of the support, for example by plastic deformation of the cover and / or the cover of the support.

[0057] In one embodiment of any of the above embodiments, the three dimensional configuration of one or both of the covering and cover surfaces of the support surface is the result of embossing or debossing of one or both of the covering and cover of the support.

[0058] In one embodiment of any of the above embodiments, the three-dimensional configuration of the support surface and / or cover surface is the result of folding of the covering portion of the support and / or the cover.

[0059] In one embodiment of any of the above embodiments, one or both of the support and the cover are sheet materials.

[0060] In one embodiment of any of the above embodiments, the support surface further comprises a second portion and the cover further comprises a second cover surface, and the support and support surface are configured to fold the support into the folded configuration, and the second portion of the support surface covers the second cover surface when the support is in the folded configuration. In some embodiments, the support and support surface at least partially wrap around the cover when the support is in the folded configuration. In one embodiment of the above embodiment, at least one discrete portion of aerosol-forming material is supported on a second portion of the support surface; each discrete portion of aerosol-forming material supported on the second portion of the support surface is supported at a second portion location; one or both of the second portion of the support surface and the second cover surface are configured three-dimensionally; the second portion of the support surface and the second cover surface are configured such that, at each of the second partial positions, the second cover surface is sufficiently spaced from the second portion of the support surface such that at least a portion of the discrete portions of the aerosol-forming material at the second partial positions does not come into contact with the second cover surface; The second portion of the support surface and the second cover surface are configured to include one or more second contact zones, and a portion of the second portion of the support surface and a portion of the second cover surface are in direct or indirect contact with each other.

[0061] In one embodiment of any of the above embodiments, a plurality of discrete portions of aerosol-forming material are supported on a second portion of the support surface.

[0062] In one embodiment of any of the above embodiments, the second portion of the support surface and the second cover surface are configured to define at least one second passageway, the at least one second passageway including at least one second portion location.

[0063] In one embodiment of any of the above embodiments, each of the second partial locations is disposed in the second passageway.

[0064] In one embodiment of any of the above embodiments, the second cover surface has a perimeter extending around an edge of the second cover surface, and a first end of at least one second passage is open and partially defined by a portion of the perimeter of the second cover surface.

[0065] In one embodiment of any of the above embodiments, a second end of the at least one second passageway is open and is defined in part by a portion of the periphery of the second cover surface.

[0066] In one embodiment of any of the above embodiments, a first end of the at least one second passage is open and defined by an opening extending through one of the second portion of the support surface or the second cover surface.

[0067] In one embodiment of any of the above embodiments, a second end of the at least one second passage is open and defined by an opening extending through one of the covering surface or the cover surface of the support surface.

[0068] In one embodiment of any of the above embodiments, at least one end of at least one second passageway is open and opens to another second passageway, in such an embodiment, at least one end of the second passageway is defined by a wall of the open second passageway.

[0069] In one embodiment of any of the above embodiments, at least one end of the at least one first passageway is open and opens into the second passageway.

[0070] In one embodiment of any of the above embodiments, at least one end of the at least one second passageway is open and opens into the first passageway.

[0071] In one embodiment of any of the above embodiments, at least one second passage has a non-uniform cross-section along the length of the second passage. In some embodiments, the cross-section may be non-uniform for fluid flow control reasons (e.g., to accelerate or decelerate the flow of air, aerosol, or a mixture of air and aerosol along the second passage).

[0072] In one embodiment of any of the above embodiments, there are two or more second passages, two of the second passages being separated from each other by a second contact zone.

[0073] In one embodiment of any of the above embodiments, each of the second passages is separated from the other second passages by one or more second contact zones. In some embodiments of this embodiment, the separation of the second passages is lateral, i.e., the passages are side-by-side and the second contact zone is at least a portion of the material separating the second passages.

[0074] In one embodiment of any of the above embodiments, there are two or more second passages, and at least two of the second passages are generally parallel to one another. In some embodiments, at least two of the generally parallel second passages are adjacent to one another.

[0075] In one embodiment of any of the above embodiments, the at least one second passageway is generally linear between the first and second ends of the second passageway.

[0076] In one embodiment of any of the above embodiments, the second portion of the support surface and the second cover surface are configured such that, at at least one second portion position, the support surface and the second cover surface define one or more chambers, and at least one of the chambers is configured such that there is no contact between the discrete portions of aerosol-generating material and the second cover surface in the one or more chambers.

[0077] In one embodiment of any of the above embodiments, at least one of the chambers is in fluid contact with at least one of the second passages.

[0078] In one embodiment of any of the above embodiments, at least one end of the at least one second passageway opens into one of the chambers.

[0079] In one embodiment of any of the above embodiments, at least one of the second contact zones is configured such that said portion of the second portion of the support surface and said portion of the second cover surface, which are in direct or indirect contact with each other in said one or more contact zones, are fixed to each other by a fixing means.

[0080] In one embodiment of any of the above embodiments, the fastening means is an adhesive.

[0081] In one embodiment of any of the above embodiments, the fastening means is a melt-and-solidify portion of one or both of the support surface and the second cover surface.

[0082] In one embodiment of any of the above embodiments, the fastening means is a physical connection means mounted to or extending through the second contact zone.

[0083] In one embodiment of any of the above embodiments, at least one of the second contact zones is configured such that the support surface and the second cover surface are adjacent but not fixed to one another.

[0084] In one embodiment of any of the above embodiments, one of the second portion of the support surface and the second cover surface is substantially flat.

[0085] In one embodiment of any of the above embodiments, the covering portion and the second portion of the support surface are both substantially flat, and the cover is a sheet material of substantially uniform thickness and three-dimensionally configured such that the cover surface and the second cover surface are generally parallel to one another.

[0086] In one embodiment of any of the above embodiments, the three-dimensional configuration of the second portion of the support surface and / or the second cover surface is a result of molding of the second portion of the support and / or the cover. In some embodiments, molding occurs during formation of the second portion of the support and / or the cover. In other embodiments, the second portion of the support and / or the cover are molded after formation of the second portion of the support and / or the cover, for example by plastic deformation of the second portion of the support and / or the cover.

[0087] In one embodiment of any of the above embodiments, the three-dimensional configuration of one or both of the second portion of the support surface and the second cover surface is the result of embossing or debossing of one or both of the support and the cover.

[0088] In one embodiment of any of the above embodiments, the three-dimensional configuration of one or both of the second portion of the support surface and the second cover surface is the result of folding one or both of the support and the cover.

[0089] In one embodiment of any of the above embodiments, the support comprises latch means for holding the support in the folded configuration.

[0090] In one embodiment of any of the above embodiments, the support comprises at least one susceptor.

[0091] In one embodiment of any of the above embodiments, the cover comprises at least one susceptor.

[0092] In one embodiment of any of the above embodiments, the susceptor is a metal or alloy.

[0093] In one embodiment of any of the above embodiments, the susceptor is a metal foil or film, hi some embodiments, the susceptor is an aluminum foil.

[0094] In one embodiment of any of the above embodiments, one or both of the covering portion of the support surface and the second portion of the support surface comprise a susceptor.

[0095] In one embodiment of any of the above embodiments, the aerosol-forming material is an aerosolizable gel.

[0096] In one embodiment of any of the above embodiments, there are at least two discrete portions of aerosol-generating material, and the at least two discrete portions of aerosol-generating material have different compositions from one another. This has the advantage that a user of a consumable manufactured in accordance with the present disclosure may have a different experience when different discrete portions of aerosol-generating material on the consumable are aerosolized. This may make use of the consumable more enjoyable and / or more interesting than use of a consumable having an aerosol-generating material of only one composition.

[0097] A susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that the penetration of a varying magnetic field causes inductive heating of the susceptor by resistive heating as a result of eddy currents. The susceptor may be a magnetic material, such that the penetration of a varying magnetic field causes magnetic hysteresis heating of the susceptor. The susceptor may be bi-directional, such that it can be heated by both conductive and magnetic heating mechanisms. A device configured to generate a varying magnetic field is referred to as a magnetic field generator.

[0098] The susceptor may comprise a metal or may comprise an alloy. The susceptor may comprise a ferromagnetic metal (such as iron) or an iron alloy (such as steel) or an iron-nickel alloy. Some exemplary ferromagnetic metals are 400 series stainless steel, such as 410 grade stainless steel, 420 grade stainless steel, 430 grade stainless steel, or similar grade stainless steel. Alternatively, the susceptor may comprise a suitable non-magnetic, particularly paramagnetic, conductive material, such as aluminum. In a paramagnetic conductive material, induction heating occurs solely through resistive heating due to eddy currents. Alternatively, the susceptor may comprise a non-conductive ferrimagnetic material, such as a non-conductive ferrimagnetic ceramic. In this case, heat is generated solely through hysteresis losses. The susceptor may comprise a commercially available alloy such as Phytherm 230 (composition including 50 wt% Ni, 10 wt% Cr, and the rest of the Fe (weight % = wt %)) or Phytherm 260 (composition including 50 wt% Ni, 9 wt% Cr, and the rest of the Fe).

[0099] In some embodiments of any of the above embodiments, the susceptor may be a metal foil or film, optionally an aluminum foil or film, or an iron foil or film, or any conductive material that can be sprayed or deposited onto the material that makes up the support.

[0100] An aerosol-forming material is a material that is capable of generating an aerosol when energized, e.g., by heating, irradiating, or in any other manner. The aerosol-forming material may be, for example, in solid, liquid, or semi-solid (e.g., gel) form, and may or may not contain active substances and / or flavorings.

[0101] The aerosol-generating material may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0102] The aerosol-generating material may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a delivery substance and / or a filler may also be present. Optionally, a solvent, such as water, may also be present, in which one or more other components of the aerosol-generating material may or may not be soluble. In some embodiments, the aerosol-generating material is substantially free of plant matter. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0103] The aerosol-generating material may include or be in the form of an aerosol-generating film. The aerosol-generating film may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a delivery substance and / or a filler may also be present. The aerosol-generating film may be substantially free of plant matter. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0104] The aerosol-generating film may have a thickness of from about 0.015 mm to about 1 mm. For example, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

[0105] The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-forming agent, and one or more other ingredients (e.g., one or more delivery substances) to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent.

[0106] The slurry may be adapted such that at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent is removed by heating.

[0107] The aerosol-generating material may include or be an "amorphous solid." In some embodiments, the aerosol-generating material includes an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid." The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that is capable of retaining some fluid therein, such as a liquid. In some embodiments, the amorphous solid may include, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0108] The amorphous solid may be substantially free of plant matter.The amorphous solid may be substantially free of tobacco.

[0109] In one embodiment of any of the above embodiments, the aerosol forming material includes an active agent.

[0110] As used herein, an active substance may be a physiologically active material (a material intended to produce or enhance a physiological response). The active substance may be selected from, for example, dietary supplements, psychotropic drugs, psychoactive agents. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, terpenes of non-cannabinoid origin, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may include one or more constituents, derivatives, or extracts of tobacco, cannabis, or another plant.

[0111] The active substance may include one or more constituents, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0112] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0113] The active material may include or be derived from one or more botanical substances or constituents, derivatives or extracts thereof. As used herein, the term "botanical" may include any material derived from a plant, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, pods, etc. Alternatively, the material may include active compounds naturally present in plants or synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, chips, strips, sheets, etc. Exemplary plants include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, Lavender, lemon peel, mint, juniper, elderberry, vanilla, wintergreen, sedge, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiene, marjoram, olive, lemon balm, lemon basil, chives, ribeye, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0114] In some embodiments, the active agent comprises or is derived from one or more botanical substances or constituents, derivatives or extracts thereof, and the plant is tobacco.

[0115] In some embodiments, the active agent comprises or is derived from one or more botanical substances or constituents, derivatives or extracts thereof, the plant being selected from eucalyptus, star anise, cocoa, and hemp.

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

[0117] In some embodiments, the aerosol-forming material comprises a fragrance or flavoring.

[0118] As used herein, the terms "flavour" and "flavourant" refer to materials that can be used to produce a desired flavour, aroma, or other sensory experience in products intended for adult consumers, where local regulations permit.These include naturally occurring flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, heat, spices, flavors, aromas, flavor ... Belly fruit, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberries, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pineapple, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, i Lang ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil of any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, yerba mate, orange skin, rose, tea such as green or black tea, thyme, juniper, elderberry, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiogamag ... damiene, marjoram, olive, lemon balm, lemon basil, chives, ribes, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulators, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.These may be of imitation, synthetic or natural origin, or a mixture thereof. They may be in any suitable form, for example a liquid such as an oil, a solid such as a powder, or a gel.

[0119] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavor components extracted from tobacco. In some embodiments, the flavoring comprises flavor components extracted from cannabis.

[0120] In some embodiments, the fragrance may include sensates intended to achieve the sensations usually chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves, and these may include agents that produce a heating, cooling, tingling, or numbing effect.Suitable heating agents may be, but are not limited to, vanillyl ethyl ether.Suitable cooling agents may be, but are not limited to, eucalyptol, WS-3.

[0121] An aerosol-forming material is a material that is capable of generating an aerosol when energized, for example by heating, irradiating, or in any other manner. The aerosol-forming material may be in the form of, for example, a solid, liquid, or gel, and may or may not contain active substances and / or flavorings.

[0122] The aerosol-generating material includes an aerosol forming agent.

[0123] In some embodiments, the aerosol generating agent may include one or more constituents capable of forming an aerosol. In some embodiments, the aerosol generating agent may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl sulfate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In certain examples, the aerosol generating agent includes glycerol.

[0124] In some embodiments, the aerosol generating agent comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols, such as glycerol monoacetate, diacetate, or triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0125] In some embodiments, the aerosol-generating material may comprise from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10 wt% to about 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of the aerosol-generating agent (all calculated on a dry weight basis). The aerosol-generating agent may act as a plasticizer. For example, the aerosol-generating material may comprise from 0.5 to 40 wt%, from 3 to 35 wt%, or from 10 to 25 wt% of the aerosol-generating agent.

[0126] In some embodiments, the aerosol-generating material may comprise from about 5 wt%, 10 wt%, 20 wt%, 25 wt%, 27 wt%, or 30 wt% to about 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of the aerosol-generating agent (DWB). For example, the aerosol-generating material may comprise from 10 to 60 wt%, 20 to 50 wt%, 25 to 40 wt%, or 30 to 35 wt% of the aerosol-generating agent.

[0127] In some embodiments, the aerosol-forming material may include up to about 80 wt% aerosol-generating agent (DWB), such as about 40-80 wt%, 40-75 wt%, 50-70 wt%, or 55-65 wt%.

[0128] The aerosol-generating material may also include a gelling agent. In some embodiments, the gelling agent includes a hydrocolloid. In some embodiments, the gelling agent includes one or more compounds selected from the group including alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohols, and combinations thereof. For example, in some embodiments, the gelling agent includes one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the gelling agent includes alginates and / or pectins, which are combined with a hardening agent (such as a calcium source) during formation of the aerosol-generating material. In some embodiments, the aerosol-generating material may include calcium cross-linked alginates and / or calcium cross-linked pectins.

[0129] 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.

[0130] In some embodiments, the cellulose gelling agent is selected from the group consisting of hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0131] In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia gum.

[0132] 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.

[0133] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the aerosol-forming material in an amount of 10-30 wt % (calculated on a dry weight basis) of the aerosol-forming material. In some embodiments, the only gelling agent present in the aerosol-forming material is alginate. In other embodiments, the gelling agent comprises alginate and at least one other gelling agent, such as pectin.

[0134] In some embodiments, the aerosol-forming material comprises from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol-forming material may comprise from 1 to 50 wt%, 5 to 45 wt%, 10 to 40 wt%, or 20 to 35 wt% of a gelling agent.

[0135] In some embodiments, the aerosol-forming material comprises from about 20 wt%, 22 wt%, 24 wt%, or 25 wt% to about 30 wt%, 32 wt%, or 35 wt% of the gelling agent (all calculated on a dry weight basis). For example, the aerosol-forming material may comprise from 20 to 35 wt% or from 25 to 30 wt% of the gelling agent.

[0136] In some cases, the aerosol-forming material may include from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, or 20% to about 60 wt%, 50 wt%, 40 wt%, 30 wt%, or 25 wt% of the gelling agent (DWB). For example, the aerosol-forming material may include from 10 to 40 wt%, 15 to 30 wt%, or 20 to 25 wt% of the gelling agent (DWB).

[0137] For example, the aerosol-forming material may comprise, in total, the gelling agent and the bulking agent in an amount of about 10 wt%, 20 wt%, 25 wt%, 30 wt%, or 35% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the aerosol-forming material. For example, the aerosol-forming material may comprise, in total, the gelling agent and the bulking agent in an amount of about 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt% of the aerosol-forming material.

[0138] By way of example, the aerosol-forming material may comprise a gelling agent in an amount of about 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, or 35% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the aerosol-forming material (i.e., not taking into account the amount of filler). By way of example, the aerosol-forming material may comprise a gelling agent in an amount of about 5-60 wt%, 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt% of the aerosol-forming material (i.e., not taking into account the amount of filler).

[0139] In some examples, the alginate is included in the gelling agent in an amount of about 5-40 wt% or 15-40 wt% of the aerosol-forming material, i.e., the aerosol-forming material comprises alginate in an amount of about 5-40 wt% or 15-40 wt% of the aerosol-forming material by dry weight, in some examples, the aerosol-forming material comprises alginate in an amount of about 20-40 wt% or about 15 wt% to 35 wt% of the aerosol-forming material.

[0140] In some examples, the pectin is included in the gelling agent in an amount of about 3-15 wt% of the aerosol-forming material, i.e., the aerosol-forming material comprises pectin in an amount of about 3-15 wt% of the aerosol-forming material by dry weight, hi some examples, the aerosol-forming material comprises pectin in an amount of about 5-10 wt% of the aerosol-forming material.

[0141] In some examples, the guar gum is present in the gelling agent in an amount of about 3-40 wt% of the aerosol-generating material. That is, the aerosol-generating material comprises guar gum in an amount of about 3-40 wt% of the aerosol-generating material by dry weight. In some examples, the aerosol-generating material comprises guar gum in an amount of about 5-10 wt% of the aerosol-generating material. In some examples, the aerosol-generating material comprises guar gum in an amount of about 15-40 wt%, or about 20-40 wt%, or about 15-35 wt% of the aerosol-generating material.

[0142] For example, the alginate is present in an amount of at least about 50 wt% of the gelling agent. For example, the aerosol-forming material includes alginate and pectin, and the ratio of alginate to pectin is 1:1 to 10:1. The ratio of alginate to pectin is usually greater than 1:1. That is, the alginate is present in an amount greater than the amount of pectin. For example, the ratio of alginate to pectin is about 2:1 to 8:1, or about 3:1 to 6:1, or about 4:1.

[0143] The aerosol-generating material may be formed by (a) forming a slurry containing components of the aerosol-generating material or a precursor thereof, (b) forming a layer of the slurry, (c) curing the slurry to form a gel, and (d) drying to form the aerosol-generating material.

[0144] (b) Forming the slurry layer typically involves spraying, casting, or extruding the slurry. For example, the slurry layer may be formed by electrospraying the slurry. For example, the slurry layer may be formed by casting the slurry.

[0145] In some instances, (b), and / or (c), and / or (d) occur at least partially simultaneously (e.g., in an electrospray). In some instances, (b), (c), and (d) occur sequentially.

[0146] In some instances, the slurry may be applied to a support such that a layer is formed on the support. By way of example, the slurry may include a gelling agent, an aerosol-forming material, and an active agent. The slurry may include these components in any of the proportions described herein for the composition of the aerosol-generating material. For example, the slurry may include (on a dry weight basis): a gelling agent and optionally a filler, the amount of gelling agent and filler together being about 10-60 wt% of the slurry; an aerosol-forming material in an amount of about 40-80 wt % of the slurry; Optionally, an active material in an amount of up to about 20 wt. % of the slurry; and may also include

[0147] Hardening the gel (c) may include providing a hardening agent to the slurry, for example the slurry may include sodium, potassium or ammonium alginate as a gel precursor and the addition of a hardening agent to the slurry including a calcium source (such as calcium chloride) to form a calcium alginate gel.

[0148] By way of example, the sclerosing agent may include or consist of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the sclerosing agent may include or consist of calcium formate and / or calcium lactate. In certain examples, the sclerosing agent may include or consist of calcium formate. The inventors have determined that when calcium formate is employed as a sclerosing agent, the aerosol generating material typically exhibits higher tensile strength and resistance to elongation.

[0149] The total amount of hardening agent, such as a calcium source, may be 0.5 to 5 wt % (calculated on a dry weight basis). Preferably, the total amount is about 1 wt %, 2.5 wt %, or 4 wt % to about 4.8 wt % or 4.5 wt %. The inventors have found that if too little hardening agent is added, the components of the aerosol-generating material may not be stable and may drop out of the aerosol-generating material. The inventors have also found that if too much hardening agent is added, the aerosol-generating material may become very sticky and difficult to handle.

[0150] If the aerosol-forming material does not contain tobacco, it may be necessary to apply more stiffening agent. Thus, in some cases, the total amount of stiffening agent may be 0.5 to 12 wt %, such as 5 to 10 wt %, calculated on a dry weight basis. Suitably, the total amount may be from about 5 wt %, 6 wt %, or 7 wt % to about 12 wt % or 10 wt %. In this case, the aerosol-forming material will generally not contain any tobacco.

[0151] As an example, applying the hardener to the slurry includes spraying the hardener onto the slurry, such as onto the top surface of the slurry.

[0152] Alginates are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) linked together by (1,4)-glycosidic bonds to form a polysaccharide. Upon addition of calcium cations, alginates crosslink to form a gel. Alginates with a high G monomer content have been found to gel more readily with the addition of a calcium source. Thus, in some cases, the gel precursor may include an alginate in which at least about 40%, 45%, 50%, 55%, 60%, or 70% of the monomer units in the alginic acid copolymer are α-L-glucuronic acid (G) units.

[0153] For example, drying (d) removes from about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% to about 80 wt%, 90 wt%, or 95 wt% (WWB) of the water in the slurry. For example, drying (d) reduces the thickness of the cast material by at least 80%, preferably 85% or 87%. For example, the slurry is cast to a thickness of 2 mm and the resulting dried aerosol-generating material has a thickness of 0.2 mm.

[0154] In some examples, the slurry solvent consists essentially of or consists of water, hi some examples, the slurry comprises about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% solvent (WWB).

[0155] In instances where the solvent comprises water, the dry weight content of the slurry may correspond to the dry weight content of the aerosol-forming material, such that any discussion herein of solid components is expressly disclosed in conjunction with the slurry aspects of the invention.

[0156] The aerosol-forming material may include a flavoring. The aerosol-forming material may include up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% of flavoring. In some cases, the aerosol-forming material may include at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% of flavoring (all calculated on a dry weight basis). For example, the aerosol-forming material may include 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% of flavoring. In some cases, the flavoring includes, consists essentially of, or consists of menthol.

[0157] The aerosol-forming material may include a bulking agent.

[0158] In some embodiments, the aerosol-forming material contains less than 60 wt% filler, such as between 1 wt% and 60 wt%, or between 5 wt% and 50 wt%, or between 5 wt% and 30 wt%, or between 10 wt% and 20 wt%.

[0159] In other embodiments, the aerosol forming material contains less than 20 wt%, preferably less than 10 wt% or less than 5 wt% of a filler. Optionally, the aerosol forming material contains less than 1 wt% of a filler, and optionally no filler.

[0160] In some cases, the aerosol-forming material comprises at least 1 wt% filler (e.g., at least 5 wt%, at least 10 wt%, at least 20 wt%, at least 30 wt%, at least 40 wt%, or at least 50 wt% filler), hi some embodiments, the aerosol-forming material comprises between 5 and 25 wt% filler.

[0161] When present, the filler may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler may also include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives (e.g., methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). In certain cases, the aerosol-generating material does not include calcium carbonate, such as chalk.

[0162] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fiber, cellulose, or a cellulose derivative (e.g., methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)).

[0163] Without being bound by theory, it is believed that including a fibrous filler in the aerosol-generating material may increase the tensile strength of the material, which may be particularly advantageous in instances where the aerosol-generating material is provided as a sheet, such as when the sheet defines a rod of aerosolizable material.

[0164] In some embodiments, the aerosol-forming material does not include tobacco fibers, hi certain embodiments, the aerosol-forming material does not include fibrous materials.

[0165] The aerosol-generating material may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0166] In some embodiments, the aerosol-forming material further comprises an active agent. For example, the aerosol-forming material optionally further comprises tobacco material and / or Nichicon. In some embodiments, the aerosol-forming material further comprises powdered tobacco, and / or nicotine, and / or tobacco extract.

[0167] In some cases, the aerosol-forming material may comprise between 5 and 60 wt% (calculated on a dry weight basis) of tobacco material and / or nicotine. In some cases, the aerosol-forming material may comprise between about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of an active substance. In some cases, the aerosol-forming material may comprise between about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of tobacco material. For example, the aerosol-forming material may include 10-50 wt%, 15-40 wt%, or 20-35 wt% tobacco material. In some cases, the aerosol-forming material may include about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% nicotine (calculated on a dry weight basis). For example, the aerosol-forming material may include 1-20 wt%, 2-18 wt%, or 3-12 wt% nicotine.

[0168] In some cases, the aerosol-forming material includes an active agent such as a tobacco extract. In some cases, the aerosol-forming material may include 5-60 wt% tobacco extract (calculated on a dry weight basis). In some cases, the aerosol-forming material may include about 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% tobacco extract (calculated on a dry weight basis). For example, the aerosol-forming material may include 10-50 wt%, 15-40 wt%, or 20-35 wt% tobacco extract. The tobacco extract may contain nicotine in a concentration such that the aerosol-forming material contains from 1 wt%, 1.5 wt%, 2 wt%, or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt%, or 4 wt% nicotine (calculated on a dry weight basis). In some cases, no nicotine may be present in the aerosol-forming material other than the nicotine from the tobacco extract.

[0169] In some embodiments, the aerosol-forming material does not include tobacco material and does include nicotine. In some cases, the aerosol-forming material may include from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% nicotine (calculated on a dry weight basis). For example, the aerosol-forming material may include from 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% nicotine.

[0170] In some cases, the total content of actives and / or flavorings may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or flavorings may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis). In some cases, the total content of tobacco material, nicotine, and flavorings may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or fragrances may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0171] The aerosol-generating composition may include one or more active agents. In some examples, the aerosol-generating material includes one or more active agents (e.g., up to about 20 wt% of the aerosol-generating material). For example, the aerosol-generating material includes active agents in an amount of about 1 wt%, 5 wt%, 10 wt%, or 15% to about 20 wt%, 15 wt%, 15 wt%, or 5 wt% of the aerosol-generating material.

[0172] The active substances may include physiologically and / or olfactory active substances that are included in the aerosol forming composition to achieve a physiological and / or olfactory response.

[0173] 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%.

[0174] The tobacco material may be in any form, but is typically shredded (e.g., cut into small pieces). Shredded tobacco material is advantageous because it can be mixed with an aerosol-forming material to provide an aerosol-forming composition having a uniform distribution of tobacco material and aerosol-forming material throughout.

[0175] By way of example, the tobacco material comprises one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extract. Surprisingly, the inventors have determined that relatively large amounts of laminar tobacco can be used in the aerosol-generating composition and still provide an acceptable aerosol when heated by a non-combustible aerosol delivery system. Laminar tobacco typically provides superior sensory properties. By way of example, the tobacco material comprises laminar tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material. In certain examples, the tobacco material comprises cut tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material.

[0176] The tobacco used to produce the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia, and / or Burley, and / or Oriental.

[0177] 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.

[0178] Optionally, the aerosol-forming material may additionally include an emulsifier to emulsify the molten flavoring during preparation. For example, the aerosol-forming material may include about 5 wt% to about 15 wt%, preferably about 10 wt% (calculated on a dry weight basis) of an emulsifier. The emulsifier may include gum acacia.

[0179] In some embodiments, the aerosol-forming material is a hydrogel and contains less than about 20 wt% water, calculated on a wet weight basis. Optionally, the hydrogel contains less than about 15 wt%, 12 wt%, or 10 wt% water, calculated on a wet weight basis. Optionally, the hydrogel contains at least about 1 wt%, 2 wt%, or at least about 5 wt% water (WWB).

[0180] The aerosol-forming material may have any suitable water content, such as between 1 wt% and 15 wt%. Preferably, the water content of the aerosol-forming material is between about 5 wt%, 7 wt%, or 9 wt% and about 15 wt%, 13 wt%, or 11 wt% (WWB), most preferably about 10 wt%. The water content of the aerosol-forming material may be determined, for example, by Karl-Fischer titration or Gas Chromatography with Thermal Conductivity Detector (GC-TCD).

[0181] In some cases, the aerosol-forming material may consist essentially of or consist of a gelling agent, water, an aerosol-forming agent, a flavoring agent, and optionally an active agent.

[0182] In some cases, the aerosol-forming materials may consist essentially of or consist of gelling agent, water, aerosol-forming agent, flavorings, and optionally tobacco materials and / or a nicotine source.

[0183] By way of example, the aerosol-forming material may consist essentially of, or consist of, a gelling agent, an aerosol-forming agent, an active substance, and water.By way of example, the aerosol-forming material may consist essentially of, or consist of, a gelling agent, an aerosol-forming agent, and water.

[0184] As an example, the aerosol-forming material does not include flavorants. In certain instances, the aerosol-forming material does not include active agents. In some embodiments, the aerosol-forming material comprises: 1 to 60 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol generating agent; 0.1 to 80 wt% of fragrance, Including, These weights are calculated on a dry weight basis.

[0185] In some embodiments, the aerosol-forming material comprises 1-80 wt % (dry weight basis) of flavoring. In some embodiments, the aerosol-forming material comprises: 1 to 50 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol generating agent; 30-60wt% fragrance, Including, These weights are calculated on a dry weight basis. In an alternative embodiment, the aerosol-forming material is: 1 to 60 wt % of a gelling agent; 5 to 60 wt % of an aerosol generating agent; 10 to 60 wt % of a gelling agent; Including, These weights are calculated on a dry weight basis. In some embodiments, the aerosol-forming material comprises: 1 to 60 wt % of a gelling agent; 20 to 60 wt % of an aerosol generating agent; 10-60 wt% tobacco extract; Including, These weights are calculated on a dry weight basis.

[0186] In some embodiments, the aerosol-generating material comprises 20-35 wt.% gelling agent, 10-25 wt.% aerosol-forming material, 5-25 wt.% fiber-containing filler, and 35-50 wt.% flavoring and / or active agent.

[0187] In some cases, the aerosol-forming materials may consist essentially of or consist of a gelling agent, an aerosol-forming agent, tobacco extract, water, and optional flavorings. In some cases, the aerosol-forming materials may consist essentially of or consist of glycerol, alginate and / or pectin, tobacco extract, and water.

[0188] In some embodiments, the aerosol-generating material may have a composition (DWB) as follows: a gelling agent (preferably including alginate) in an amount of about 5 wt% to about 40 wt%, or about 10 wt% to 30 wt%, or about 15 wt% to about 25 wt%, a tobacco extract in an amount of about 30 wt% to about 60 wt%, or about 40 wt% to 55 wt%, or about 45 wt% to about 50 wt%, and an aerosol-generating agent (preferably including glycerol) in an amount of about 10 wt% to about 50 wt%, or about 20 wt% to about 40 wt%, or about 25 wt% to about 35 wt% (DWB).

[0189] In one embodiment, the aerosol forming material comprises about 20 wt% alginate gelling agent, about 48 wt% Virginia tobacco extract, and about 32 wt% glycerol (DWB).

[0190] The "thickness" of an aerosol-generating material refers to the shortest distance between a first surface and a second surface. In embodiments in which the aerosol-generating material is in the form of a sheet, the thickness of the aerosol-generating material is the shortest distance between a first planar surface of the sheet and a second surface of the sheet opposite the first planar surface of the sheet.

[0191] In some cases, the layer of aerosol-forming material for forming the aerosol has a thickness of about 0.015 mm to about 1.5 mm, preferably about 0.05 mm to about 1.5 mm or 0.05 mm to about 1.0 mm. Preferably, the thickness may be in the range of about 0.1 mm or 0.15 mm to about 1.0 mm, 0.5 mm, or 0.3 mm.

[0192] In some cases, the aerosol-forming material may have a thickness of from about 0.015 mm to about 1.0 mm. Suitably, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

[0193] A material having a thickness of 0.2 mm is particularly suitable. The aerosol-generating material may comprise two or more layers, and the thicknesses given herein refer to the combined thicknesses of these layers.

[0194] It has been found that if the aerosol-generating material is too thick, it will heat less efficiently, which will have a negative impact on power consumption during use. Conversely, if the aerosol-generating material is too thin, it will be difficult to manufacture and handle. If the material is too thin, it will be more difficult to mold and may even be fragile, compromising aerosol formation during use.

[0195] The thicknesses specified herein are the average thickness of the material. In some cases, the thickness of the aerosol-generating material may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1%.

[0196] In some examples, the aerosol-generating material in sheet form may have a tensile strength of about 200 N / m to about 900 N / m. In some examples, such as when the aerosol-generating material does not include a filler, the aerosol-generating material may have a tensile strength of 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or about 250 N / m.

[0197] Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is formed into a sheet, which is then chopped and incorporated into an aerosol product. In some instances, such as where the aerosol-generating material includes a filler, the aerosol-generating material may have a tensile strength of around 600N / m to 900N / m, or 700N / m to 900N / m, or 800N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is included in an aerosol product / assembly as a rolled sheet, preferably in the form of a tube.

[0198] In some examples, the aerosol-generating material in sheet form may have a tensile strength of around 200 N / m to around 2600 N / m. In some examples, the aerosol-generating material may have a tensile strength of around 600 N / m to around 2000 N / m, or 700 N / m to 1500 N / m, or around 1000 N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is formed and incorporated into an aerosol-generating consumable as a sheet.

[0199] The aerosol-generating material is 30 g / m 2 ~120g / m 2 In some cases, the mass per unit area of ​​the sheet may be 80 to 120 g / m 2 , or about 70 to 110 g / m 2 , or, in particular, about 90 to 110 g / m 2 , or preferably about 100 g / m 2 (which has a density similar to that of cut rag tobacco so that mixtures of these materials do not easily separate). Optionally, the mass per unit area of ​​the sheet is about 30 to 70 g / m 2 , 40~60g / m 2 , or 25 to 60 g / m 2 and may be adapted to be used to wrap an aerosolizable material such as tobacco.

[0200] All weight percentages (expressed as wt%) referred to herein are calculated on a dry weight basis unless expressly stated otherwise. All weight ratios are also calculated on a dry weight basis. Weights quoted on a dry weight basis represent the totality of the extract, or slurry, or material, excluding water, and may include ingredients that are themselves liquids at room temperature and pressure, such as glycerol. In contrast, weight percentages quoted on a wet weight basis represent all ingredients, including water.

[0201] The aerosol-generating material may include a colorant. The addition of a colorant can change the visual appearance of the aerosol-generating material. The presence of a colorant in the aerosol-generating material can enhance the visual appearance of the aerosol-generating material. By adding a colorant to the aerosol-generating material, the aerosol-generating material can be color-matched to other components of the article that contains the aerosol-generating material.

[0202] A variety of colorants may be used depending on the desired color of the aerosol-generating material. The color of the aerosol-generating material may be, for example, white, green, red, purple, blue, brown, or black. Other colors are contemplated. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food grade colors, and pharmaceutical grade colors. In a particular embodiment, the colorant is caramel, which may give the aerosol-generating material a brown appearance. In such an embodiment, the color of the aerosol-generating material may be similar to the color of other components of the aerosol-generating material, such as the tobacco material.

[0203] The colorant may be incorporated into the aerosol-forming material during formation (e.g., during formation of a slurry containing the materials that make up the aerosol-forming material) or may be applied after formation of the aerosol-forming material (e.g., by spraying onto the aerosol-forming material).

[0204] In some embodiments of any of the above embodiments, talc powder, calcium carbonate powder, or other powder is applied to an exposed surface of at least one discrete portion of the aerosol-generating material, which may reduce the level of tackiness or adhesiveness of the aerosol-generating material.

[0205] In the following discussion of the accompanying drawings, when an identical element is present in more than one embodiment, the same reference number is used for that element throughout, and when similar elements are present, like reference numbers (the same number plus a multiple of 100) are used.

[0206] 1, the aerosol delivery device 2 comprises a casing 4 within which is disposed a heating assembly 6. The heating assembly 6 is comprised of a heating chamber 8 and an aerosol generator 10. The aerosol generator 10 may be an electrical resistance heater or a magnetic field generator for use with a susceptor.

[0207] The heating chamber 8 defines an opening or mouth 12 at a first end of the heating chamber 8. At an opposite end of the heating chamber 8 is an opening 14. The opening 14 is in fluid communication with a mouthpiece 16 via a conduit 18.

[0208] Also disposed within the casing 4 is a controller 20 in electronic communication with the aerosol generator 10 to control its function. The controller 20 may include a memory (not shown) in which one or more tables relating to the operation of the heater 10 may be stored. The aerosol generator 10 and the controller 20 are powered by a power source 22. The power source 22 is a rechargeable battery. In other embodiments, the power source may be another suitable power source.

[0209] The aerosol generating device 2 is suitable for use with a consumable 24. The consumable 24 and the heating chamber 8 are sized and configured such that at least a portion of the consumable 24 can be reversibly inserted into the heating chamber 8. The consumable 24 comprises one or more discrete portions of aerosol-generating material. When the consumable 24 is inserted into the heating chamber 8 to the extent required by the design of the heating device 2 and the consumable 24, one or more of the discrete portions of aerosol-generating material can be heated by the aerosol generator 10. Although the consumable 24 and the heating chamber 8 are shown as rectangular in FIG. 1, they may be other shapes and configurations.

[0210] 2 and 3, the consumable 24 comprises a support 26, a cover 28, and a plurality of discrete portions of aerosol-generating material in the form of an aerosol-generating film 30. As shown in FIG.

[0211] The support 26 is a laminate and includes a first layer 32 and a second layer 36. The first layer 32 is constructed of aluminum foil, and all or a portion of the first layer may act as a susceptor when exposed to an alternating magnetic field. The second layer 36 of the support 26 is constructed of cardboard.

[0212] The first layer 32 is substantially flat or planar and has first and second major surfaces that define the two largest surfaces of the layer 32. The first major surface does not face the second layer 36 of the support 26 and serves as the support surface 34. The second layer 36 is secured to the second major surface of the first layer 32 using an adhesive (not shown).

[0213] 2 and 3, the support surface 34 is configured to be entirely covered by the cover 28, and therefore the covered portion of the support surface 34 is the entire support surface 34. In other examples not shown, a portion of the support surface that is less than the entire support surface constitutes the covered portion of the support surface.

[0214] The cover 28 covers the support surface 34 and has a cover surface 38 facing the support surface 34. The cover 28 is a sheet material and has a three-dimensional structure due to embossing. The embossing introduces two parallel linear ridges 28A, one groove 28B, and two parallel grooves 28C into the cover 28. The shape of the ridges and grooves 28A, 28B is trapezoidal. In other examples not shown, the cover may be configured with more ridges and grooves 28A, 28B, and the shape of the ridges and grooves may be different shapes, such as, but not limited to, sinusoidal, rectangular, or triangular.

[0215] When cover 28 covers support surface 34, at least a portion of cover surface 38 of each valley 28B or partial valley 28C is in contact with (i.e., touching or adjacent to) support surface 34. The zone where cover surface 38 and support surface 34 are in contact is a contact zone 40. In each contact zone 40, cover surface 38 is secured to support surface 34 by adhesive 42.

[0216] When the cover 28 covers the support surface 34, the cover surface 38 at the peaks 28A, the portions of the cover surface 38 at the valleys 28B that are not in contact with the support surface 34, and the portions of the support surface 34 that are not in contact with the cover 28 collectively define a pair of passages 44. The passages 44 are separated from one another by the contact zones 40, and because the peaks 28A are parallel and linear, the passages 44 are also parallel and linear. Each passage 44 has a first end 44A and a second end 44B. The first and second ends 44A, 44B of the passages 44 are defined by the edges or perimeters of the cover 28 and the support 26, respectively.

[0217] Spaced along each of the passages 44 are a plurality of discrete portions of the aerosol-generating film 30. The portions of the aerosol-generating film 30 are disposed at portion locations 46 on the support surface 34. The configuration of the valleys and peaks 28B, 28A of the cover 28 is such that the discrete portions of the aerosol-generating film 30 do not contact the cover surface 38.

[0218] When the consumable 24 is used in the aerosol generation device 2 with the aerosol generator 10 in the form of a magnetic field generator, the aerosol generator 10 heats the foil of the first layer 32 at one or more partial positions 46. This heats the aerosol-generating membrane 30 at the heated partial positions 46 and generates an aerosol. When a user of the device 2 utilizes the mouthpiece 16, air is drawn along at least one of the passages 44 from one end 44A or 44B to the other end 44B or 44A, drawing the aerosol from the heated aerosol-generating membrane 30 into the mouthpiece 16.

[0219] 4, this shows a consumable 124. The consumable 124 has a support 26 of the same configuration and layout as the support 26 of the consumable 24 of FIGS.

[0220] The cover 128 covers a support surface (not shown in FIG. 4) and has a cover surface (not shown in FIG. 4) facing the support surface side. The cover 128 is a sheet material and has a three-dimensional configuration due to folding. The folding of the cover 128 forms two parallel linear ridges 128A, one groove 128B, and two parallel grooves 128C. The shapes of the ridges and grooves 128A, 128B are trapezoidal.

[0221] When the cover 128 covers the support surface, at least a portion of the cover surface of each valley 128B or partial valley 128C contacts (i.e., touches or is adjacent to) the support surface. The zone where the cover surface and the support surface are in contact is a contact zone (not shown in FIG. 4). At each contact zone, the cover surface is secured to the support surface by melting at least a portion of the cover 128 and fusing the melted portion of the cover 128 with the cover surface before solidifying. In other examples of consumables of the present disclosure not shown, the support and the cover are joined at the contact zone by one or more mechanical fastening means, such as staples (staples are short, thin wires that are pushed through the cover 128 and support 26 and then bent flat).

[0222] When the cover 128 covers the support surface, the cover surface of the peaks 128A, the parts of the cover surface of the valleys 128B that are not in contact with the support surface, and the parts of the support surface that are not in contact with the cover 128 together define a pair of passages (not shown in FIG. 4). The passages are separated from each other by contact zones, and because the peaks 128A are parallel and linear, the passages are also parallel and linear. The ends of the peaks 128A are closed by end plates 148A, 148B, and the passage ends 144A, 144B are formed by openings through the cover 128 adjacent the end plates 148A, 148B. Such an arrangement allows for different management of the airflow through the consumable 124 and / or the aerosol generation device 2.

[0223] Spaced along each of the passages are a plurality of discrete portions of the aerosol-generating film 30. Portions of these aerosol-generating film 30 are disposed at partial locations (not shown in FIG. 4) on the support surface. The configuration of the valleys and peaks 128B, 128A of the cover 128 is such that the discrete portions of the aerosol-generating film 30 do not contact the cover surface.

[0224] 5, 6 and 7, FIG. 5 shows a partially formed consumable 224 including a support 226, a cover 228, and a plurality of aerosol-generating membrane discrete portions 230, 252. As shown in FIG.

[0225] The support 226 is a laminate and includes a first layer 232 and a second layer 236. The first layer 232 is constructed of aluminum foil, and all or a portion of the first layer may act as a susceptor when exposed to an alternating magnetic field. The second layer 236 of the support 226 is constructed of cardboard.

[0226] The first layer 232 is substantially flat or planar and has first and second major surfaces that define the two largest surfaces of the layer 232. The first major surface does not face the second layer 236 of the support 226 and serves as a support surface 234. The second layer 236 is secured to the second major surface of the first layer 232 using an adhesive (not shown).

[0227] The support surface 234 comprises a covering portion 234A, a second portion 234B, and a hinge portion 234C present between the covering portion and the second portion 234A, 234B. The covering portion and the second portion 234A, 234B are joined to the hinge portion 234C by first and second fold lines 250A, 250B.

[0228] The covering portion 234 A of the support surface 234 is configured to be entirely covered by the cover 228 .

[0229] The cover 228 covers the covering portion 234A of the support surface 234 and has a first cover surface 238 facing the covering portion 234A side of the support surface 234. The cover 228 also has a second cover surface 254 facing in the opposite direction to the first cover surface 238. The cover 228 is a sheet material and has a three-dimensional configuration formed by molding. Two parallel linear ridges 228A, one groove 228B, and two partial grooves 228C are formed by molding. The shapes of the ridges and grooves 228A, 228B are trapezoidal.

[0230] When the cover 228 covers the covering portion 234A of the support surface, at least a portion of the covering surface 238 of each valley 228B or partial valley 228C is in contact with (i.e., touching or adjacent to) the covering portion 234A of the support surface. The zone of contact between the first covering surface 238 and the covering portion 234A of the support surface is a contact zone 240. In each contact zone 240, the first covering surface 238 is fixed to the covering portion 234A of the support surface by the adhesive 42.

[0231] When the cover 228 covers the covering portion 234A of the support surface, the first covering surface 238 of the peaks 228A, the portions of the first covering surface 238 of the valleys 228B that are not in contact with the first portion 234A of the support surface, and the portions of the covering portion 234A of the support surface that are not in contact with the cover 228 together define a pair of passages 244. The passages 244 are separated from each other by the contact zones 240, and because the peaks 228A are parallel and linear, the passages 244 are also parallel and linear. Each passage 244 has a first end 244A and a second end 244B. The first and second ends 244A, 244B of the passages 244 are defined by the edges or perimeters of the cover 228 and the support portion 226, respectively.

[0232] Spaced along each of the passages 244 are a plurality of discrete aerosol-generating film portions 230. The portions of the aerosol-generating film 230 are disposed at portion locations 246 on the first portion 234A of the support surface. The configuration of the valleys and peaks 228B, 228A of the cover 228 is such that the discrete aerosol-generating film portions 230 do not contact the first cover surface 238.

[0233] The second portion 234B of the support surface 234 is substantially flat and supports a plurality of aerosol-generating film segments 252 disposed in a second position 260. A barb 256 extends from an edge 258 of the support portion 236.

[0234] The support portion 226 is folded approximately 90° about each of the folds 250A, 250B to provide the necessary configuration for use of the consumable 224 (as shown in FIGS. 6 and 7), such that the second portion 234B of the support surface 234 covers the cover 228 and contacts or rests adjacent to a portion of the second cover surface 254 that forms part of the peak 228A of the cover 228.

[0235] The second cover surface 254 of the valley portion 228B, the portion of the second cover surface 228 of the peak portion 228A that is not in contact with or adjacent to the second portion 234B of the support surface 234, and a portion of the second portion 234B of the support surface 234 together define a passageway 245. The passageway 245 is linear and parallel to the passageway 244 and has first and second ends 245A, 245B.

[0236] To hold the support portion 226 in the folded configuration, the barb members 256 are secured to the second cover surface 254 using adhesive 242 .

[0237] The positioning locations 260 and the aerosol-generating film discrete portions 252 are disposed on the second portion 234 B of the support surface 234 so as not to contact the second cover surface 254 within the passageway 245 .

[0238] When the consumable 224 is used in the aerosol generating device 2 with the aerosol generator 10 in the form of a magnetic field generator, the aerosol generator 10 heats the foil of the first layer 232 at one or more of the part positions 246, 260. This heats the aerosol-generating membrane 230, 252 at the heated part positions 246, 260 and generates an aerosol. When a user of the device 2 utilizes the mouthpiece 16, air is drawn along at least one of the passages 44, 45 from one end 44A, 45A or 44B, 45B to the other end 44B, 44B or 44A, 45A, drawing the aerosol from the heated aerosol-generating material 230, 252 into the mouthpiece 16.

[0239] In an alternative embodiment of the consumable 224, as shown in FIG. 8, the wrap 262 extends around the longitudinal extent of the support 226 in the consumable 324 to hold the support and cover 228 in the configuration shown in FIG. 8. In this embodiment, the hooks 256 and adhesive 242 of the support 226 used in the embodiment shown in FIGS. 5-7 may all be omitted. As an advantage of this embodiment, the wrap 262 may be a suitable heat resistant film, which can protect the support 226, cover 228, and aerosol-generating films 230, 252 from physical damage and moisture. In some examples, the wrap 262 closes the ends 244A, 244B, 245A, 245B of the passages 244, 245 when it is initially wrapped around the folded support 226 and cover 228. To use consumable 324, it is prepared for use by opening ends 244A, 244B, 245A, 245B of passages 244, 245 by piercing or removing a portion of wrap 262. Consumable 324 is then used in the same manner as described in connection with consumable 224 above.

[0240] 9, this shows an alternative support 426 and cover 428 during manufacture of the consumable 424. The support 426 is the same as that used for the consumable 224 described above, except that the aerosol-generating film discretizations 252 are arranged in a grid pattern on the second portion 234B of the support surface 234.

[0241] The cover 428 is formed from a blow-molded plastic sheet and in combination with the first portion 234A of the support surface defines three passages 444. Each passage 444 includes three chambers 464 (not all of the chambers 464 are numbered for clarity). The centerlines of each passage 444 are linear and parallel to one another. In each passage 444, the chambers 446 are joined in series by two conduits 466 (not all of the chambers 464 are numbered for clarity). The chambers 464 are larger than the conduits 466 in at least one direction perpendicular to the centerline of the passages 444. The discrete aerosol-generating membrane portions 230 (again, not all of the portions 230 are numbered for clarity) are disposed on the first portion 234A of the support surface such that each is approximately in the center of a chamber 464. As described above, the passages 444 extend between the passage ends 444A and 444B.

[0242] The aerosol-generating film discrete portion 252 is positioned on the second portion 234B of the support surface 234 so as to be approximately in the center of the chamber 470 formed between the cover 428 and the second portion 234B of the support surface when the second portion 234B of the support surface 234 covers the cover 428.

[0243] The various embodiments described herein are presented only as aids in understanding and teaching the features of the claims. These embodiments are provided as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, features, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it is understood that other embodiments can be utilized and improved without departing from the scope of the claimed invention. The various embodiments of the present invention may suitably include, consist of, or essentially consist of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein. The present disclosure may also include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. 1. A consumable suitable for use with a non-flammable aerosol delivery system, the consumable comprising: a support; an aerosol-generating material; and a cover; the support portion comprises a support surface having a covering portion; the cover comprises a cover surface; the cover is configured to cover the covering portion of the support surface; at least one discrete portion of aerosol-forming material is supported on the covering portion of the support surface; each discrete portion of aerosol-forming material supported on the covering portion of the support surface is supported at a partial position; One or both of the covering portion and the cover surface of the support surface are configured three-dimensionally, the covering portion of the support surface and the cover surface are configured such that, at each partial position, the cover surface is sufficiently spaced from the covering portion of the support surface so that at least some of the dispersed portions of the aerosol-forming material at that partial position do not come into contact with the cover surface; the covering portion of the support surface and the cover surface are configured to include one or more contact zones; A consumable article, wherein at each contact zone, a portion of the covering portion of the support surface and a portion of the cover surface are in direct or indirect contact with each other.

2. the covering portion of the support surface and the cover surface are configured to define at least one passageway; The consumable of claim 1 , wherein at least one passageway includes at least one partial position.

3. The consumable of claim 2 , wherein each portion location is disposed in an aisle.

4. 4. The consumable product of claim 2 or 3, wherein the cover surface has a perimeter extending around an edge of the cover surface, and wherein a first end of at least one passageway is open and is partially defined by a portion of the perimeter of the cover surface.

5. The consumable product of claim 4 , wherein a second end of at least one passageway is open and is defined in part by a portion of the perimeter of the cover surface.

6. The consumable of claim 2 , wherein a first end of at least one passageway is open and defined by an opening extending through one of the covering portion or the cover surface of the support surface.

7. The consumable of claim 2 , wherein the second end of at least one passageway is open and defined by an opening extending through one of the covering portion or the cover surface of the support surface.

8. The consumable of claim 2 , wherein at least one end of at least one passageway is open and opens into another passageway.

9. 3. The consumable of claim 2, wherein there are two or more passageways, two of the passageways being separated from each other by a contact zone.

10. 2. The consumable product of claim 1, wherein the covering portion and the cover surface of the support surface are configured such that, in at least one partial position, the support surface and the cover surface define one or more chambers, and at least one of the chambers is configured such that the aerosol-forming material dispersion portion does not come into contact with the cover surface in the one or more chambers.

11. The consumable of claim 10 , wherein at least one of the chambers is in fluid contact with at least one of the passages.

12. 2. The consumable of claim 1, wherein at least one of the contact zones is configured such that the portion of the covering portion of the support surface and the portion of the cover surface that are in direct or indirect contact with each other in the one or more contact zones are fixed to each other by a fixing means.

13. The consumable product of claim 1 , wherein the support and the cover are held in fixed relationship to one another by at least one packaging element wrapped around the support and the cover.

14. The consumable of claim 1 , wherein one of the covering portion and the cover surface of the support surface is substantially flat.

15. The consumable of claim 1 , wherein the three-dimensional configuration of one or both of the covering portion and the cover surface of the support surface is the result of molding of one or both of the covering portion and the cover of the support surface.

16. The consumable product of claim 1 , wherein the three-dimensional configuration of one or both of the covering portion and the cover surface of the support surface is the result of embossing or debossing of one or both of the covering portion and the cover of the support portion.

17. The consumable product of claim 1 , wherein the three-dimensional configuration of one or both of the support surface and the cover surface is the result of folding one or both of the covering portion and the cover of the support portion.

18. The consumable of claim 1 , wherein one or both of the support and the cover are sheet materials.

19. 2. The consumable of claim 1, wherein the support surface further comprises a second portion, the cover further comprises a second cover surface, the support portion and the support surface are configured such that the support portion can be folded into a folded configuration, and the second portion of the support surface covers the second cover surface when the support portion is in the folded configuration.

20. at least one discrete portion of aerosol-forming material is supported on the second portion of the support surface; each discrete portion of aerosol-forming material supported on the second portion of the support surface is supported at a second portion position; one or both of the second portion of the support surface and the second cover surface are configured three-dimensionally; the second portion of the support surface and the second cover surface are configured such that, at each second partial position, the second cover surface is sufficiently spaced from the second portion of the support surface so that at least some of the discrete portions of the aerosol-forming material at the second partial position do not come into contact with the second cover surface; 20. The consumable of claim 19, wherein the second portion of the support surface and the second cover surface are configured to include one or more second contact zones in which a portion of the second portion of the support surface and a portion of the second cover surface directly or indirectly contact each other.

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