Method for manufacturing consumables for use with aerosol delivery devices - Patent Application 20070123633

Abstract

A method of manufacturing an article (1) is disclosed, the article including discrete portions (12) of an aerosol-generating material and a substrate (2). The method includes the steps of providing the substrate (2) and applying an aerosol-generating material slurry to the substrate (2), where the aerosol-generating material slurry is applied to the substrate (2) using silk screen or rotary screen printing techniques.

Description

[Technical field]

[0001] The present disclosure relates to the field of non-combustion aerosol delivery systems, and in particular to methods of manufacturing products including aerosol generating materials for use as consumables for use with aerosol delivery devices, methods for manufacturing consumables for use with aerosol delivery devices, and aerosol delivery systems including consumables and aerosol delivery devices. [Background technology]

[0002] Aerosol-producing articles release inhalable aerosols or vapors by releasing compounds from a substrate material through heating without combustion. These may be referred to as non-combustion articles, aerosol generating assemblies, or aerosol delivery devices.

[0003] One example of such a product is a heating device that releases a compound by heating an aerosolizable material, which may be referred to as a solid aerosol-generating material. The heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as non-combustion heating devices.

[0004] Another example is a hybrid device, which includes a liquid source (which may or may not contain an active substance) that is vaporized by heating to produce an inhalable vapor or aerosol. The device further includes a solid aerosol-generating material (which may or may not include plant material), the components of which are entrained in the inhalable vapor or aerosol to produce the inhalation medium. Summary of the Invention

[0005] According to a first aspect of the present disclosure, there is provided a method of making a product comprising an aerosol-generating material and a substrate, the method comprising: Providing a support; applying the aerosol-generating material slurry to a substrate; Including, The aerosol-forming material slurry is applied to a substrate using silk screen or rotary screen printing techniques.

[0006] According to a second aspect of the present disclosure, there is provided an article of manufacture for use in the manufacture of a consumable for use with a non-combustion aerosol delivery system, the article being a product of a method according to the first aspect of the present disclosure.

[0007] According to a third aspect of the present disclosure, there is provided a consumable for use with a non-combustion aerosol delivery system, the consumable being a part of a product according to the second aspect of the present disclosure, the part of the product being shaped and dimensioned in a desired configuration.

[0008] According to a fourth aspect of the present disclosure, there is provided an aerosol delivery device for use with a consumable according to the third aspect of the present disclosure, the device comprising an aerosol generator configured to heat at least a portion of an aerosol-generating material supported on the consumable.

[0009] According to a fifth aspect of the present disclosure, there is provided an aerosol delivery system comprising an aerosol delivery device according to the fourth aspect of the present disclosure and a consumable according to the third aspect of the present disclosure.

[0010] According to a sixth aspect of the present disclosure, there is provided a method of generating aerosol from a consumable according to the third aspect of the present disclosure using an aerosol generation device having at least one aerosol generator arranged to heat but not burn the consumable during use, wherein the at least one aerosol generator is a resistive heater element, or a magnetic field generator and a susceptor.

[0011] Further features and advantages of the present disclosure will become apparent from the following description of embodiments of the disclosure, given by way of example with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0012] [Figure 1]1 is a schematic diagram of a first embodiment of a product according to the present disclosure. [Diagram 2] FIG. 2 is a schematic diagram of a detail of the product of FIG. 1. [Diagram 3] FIG. 2 is a schematic diagram of an embodiment of a second detail of the product of FIG. 1 . [Figure 4] FIG. 4 is a cross-sectional view of the detail of FIG. 3 along section line AA. [Diagram 5] FIG. 2 is a schematic diagram of a second embodiment of a second detail of the product of FIG. 1; [Figure 6] FIG. 6 is a cross-sectional view of the detail of FIG. 5 along section line BB. [Figure 7] 1 is a schematic diagram of one embodiment of a consumable of the present disclosure. [Figure 8] FIG. 2 is a schematic diagram of one embodiment of a method for manufacturing the product of FIG. 1. [Figure 9] FIG. 2 is a schematic diagram of a second embodiment of a product according to the present disclosure. [Figure 10] 10 is a flow chart of steps of one embodiment of a method for manufacturing the product of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Consumables herein may alternatively be referred to as articles.

[0014] In some embodiments, the consumable includes an aerosol-generating material. The consumable 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 ingredients, one or more flavorings, one or more aerosol former materials, and / or one or more other functional materials.

[0015] The device for heating the aerosol-generating material with which the consumable is used is part of a non-combustion aerosol delivery system that releases compounds from the aerosol-generating material without combusting the aerosol-generating material, such as e-cigarettes, tobacco heating products, and hybrid systems that generate aerosols using a combination of aerosol-generating materials.

[0016] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0017] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0018] In some embodiments, the non-combustion aerosol delivery system is an e-cigarette, also known as a vaporization device or an electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0019] 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.

[0020] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0021] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0022] In some embodiments, the present disclosure relates to consumables that include an aerosol generating material and are configured for use with a non-combustion aerosol delivery device. These consumables may be referred to as articles throughout this disclosure.

[0023] In some embodiments, the non-combustion aerosol delivery system, such as the non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, a power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol generating material or a heat transfer material in proximity to the heat generating power source.

[0024] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0025] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include aerosol generating materials, aerosol generating material storage areas, aerosol generating material transfer components, aerosol generators, aerosol generating areas, housings, packaging materials, filters, mouthpieces, and / or aerosol modifiers.

[0026] According to a first aspect of the present disclosure, there is provided a method of making a product comprising an aerosol-generating material and a substrate, the method comprising: Providing a support; applying the aerosol-generating material slurry to a substrate; and the aerosol-generating material slurry is applied to a substrate using silk screen or rotary screen printing techniques.

[0027] An advantage of the present disclosure is that by using silk screen or rotary screen printing techniques, the layer of the aerosol-generating material slurry is thin enough that the aerosol-generating material slurry at least partially solidifies in a short period of time. The thinness of the aerosol-generating material slurry has the added advantage that the aerosol-generating material slurry is less likely to crack or form splits in the aerosol-generating material while it is solidifying.

[0028] In one embodiment of the above embodiments, the application of the aerosol-forming material slurry is the application of one or more discrete portions of the aerosol-forming material slurry.

[0029] In one embodiment of any of the above embodiments, one or more discrete portions of the aerosol-forming material slurry are applied to predetermined locations on a substrate.

[0030] In one embodiment of any of the above embodiments, there are two or more distinct portions of the aerosol-generating material slurry, and at least two distinct portions of the aerosol-generating material slurry are applied to the substrate at predetermined locations relative to one another, hi some embodiments, the distinct portions are applied to the substrate in a grid pattern or other regular pattern.

[0031] In one embodiment of any of the above embodiments, there are two or more individual portions of the aerosol-generating material slurry, at least one of the individual portions of the aerosol-generating material slurry is formed from an aerosol-generating material slurry of a first composition, and at least one of the individual portions of the aerosol-generating material slurry is formed from an aerosol-generating material slurry of a second composition, and the first and second compositions are different. This has the effect that the different individual portions may generate different sensory experiences for a user of the consumable. For example, but not limited to, the different individual portions may have different flavors.

[0032] In one embodiment of any of the above embodiments, there are two or more distinct portions of the aerosol-generating material slurry, at least one of the distinct portions of the aerosol-generating material slurry is a first size and at least one of the distinct portions of the aerosol-generating material slurry is a second size, and the first and second sizes are different.

[0033] In one embodiment of any of the above embodiments, there are two or more distinct portions of the aerosol-generating material slurry, at least one of the distinct portions of the aerosol-generating material slurry is a first shape and at least one of the distinct portions of the aerosol-generating material slurry is a second shape, and the first and second shapes are different.

[0034] In one embodiment of any of the above embodiments, there are two or more distinct portions of the aerosol-generating material slurry, at least one of the distinct portions of the aerosol-generating material slurry includes a first mass of aerosol-generating material and at least one of the distinct portions of the aerosol-generating material slurry includes a second mass of aerosol-generating material, and the first and second masses are different.

[0035] In one embodiment of any of the above embodiments, a stencil is used in a silk screen or rotary screen printing technique, the stencil being configured to determine the location and size of one or more discrete portions of the aerosol-generating material slurry as application of the aerosol-generating material occurs.

[0036] In one embodiment of any of the above embodiments, the silk screen or rotary screen printing technique involves the use of a screen or mesh through which the aerosol-generating material slurry is forced by a squeegee or equivalent. In some embodiments, the mesh count (the number of cross threads per inch or centimeter) of the screen may be selected so as not to impede the components of the aerosol-generating material slurry from passing through the screen. In alternative embodiments, the mesh size may be selected based on the desired shape and size of the aerosol-generating material slurry to be applied to the substrate.

[0037] The mesh of the screen can be made from wires or filaments formed from metal, fabric, woven or non-woven materials, or plastics, for example, but not limited to, monofilament polyester or stainless steel.

[0038] In one embodiment of any of the above embodiments, the screen of the screen printing apparatus has a mesh count of 80 threads / inch (about 32 threads / centimeter) to 325 threads / inch (about 128 threads / centimeter).

[0039] In one embodiment of any of the above embodiments, the aerosol-generating material slurry is applied to the support in the form of a plurality of microdots of aerosol-generating material. In some embodiments, applying the aerosol-generating material slurry as microdots includes applying using a screen having a mesh count of at least 200 threads per inch (about 79 threads per centimeter). In some embodiments, the stencil is configured such that only a small number of holes in the mesh are unblocked and the aerosol-generating material slurry can be extruded through those holes. In one embodiment of any of the above embodiments, when the screen has a mesh count of 200 threads per inch (about 79 threads per centimeter), the distance between adjacent wires or filaments (and thus the size of each hole in the screen) is about 0.074 mm.

[0040] In one embodiment of any of the above embodiments, the microdots may be disposed adjacent to one another or may at least partially overlap. Application of the microdots may continue until sufficient aerosol-generating material has been applied to form a discreet portion of the aerosol-generating material, the portion including a predetermined amount of the aerosol-generating material. An advantage of forming a discrete portion of the aerosol-generating material from a plurality of microdots is that there may be gaps between at least some of the microdots that allow gas and / or aerosol to escape the aerosol-generating material portion once the consumable has been used. This helps to minimize delamination of the aerosol-generating material.

[0041] In one embodiment of any of the above embodiments, at least one of the microdots of the aerosol-generating material slurry is formed from an aerosol-generating material slurry of a first composition, and at least one of the microdots of the aerosol-generating material slurry is formed from an aerosol-generating material slurry of a second composition, and the first and second compositions are different.

[0042] In one embodiment of any of the above embodiments, the method further comprises filtering the aerosol-generating material slurry before applying it to the substrate, which is preferred because filtering removes solids in the aerosol-generating material that may block the screens of the silk screen or rotary screen device.

[0043] In one embodiment of any of the above embodiments, when the aerosol-generating material slurry is applied to the substrate, the substrate is oriented at an angle to the horizontal.

[0044] In one embodiment of any of the above embodiments, when the aerosol-generating material slurry is applied to the substrate, the substrate is oriented at an angle of at least 30 degrees, at least 40 degrees, at least 50 degrees, at least 60 degrees, at least 70 degrees, or at least 80 degrees relative to the horizontal.

[0045] In one embodiment of any of the above embodiments, when the aerosol-generating material slurry is applied to the substrate, the substrate is oriented at an angle of 70 to 90 degrees relative to the horizontal.

[0046] It has been found that known methods of applying an aerosol-generating material slurry to a substrate require that the amount of aerosol-generating material slurry applied to the substrate must be significantly thicker than the desired thickness of the aerosol-generating material after it has solidified, since it is known that the thickness of the aerosol-generating material slurry can decrease by up to 90% between the application of the slurry and the time the aerosol-generating material becomes a dimensionally stable material, typically an aerosol-generating material film. As a result of the thickness of the aerosol-generating material slurry that must be initially applied to the substrate, it has been found that the surface of the substrate to which the aerosol-generating material slurry is applied must be horizontal during application and until the aerosol-generating material has solidified sufficiently that it will not flow across the surface of the substrate if the substrate becomes non-horizontal.

[0047] It has been found that when the aerosol-generating material slurry is applied to a substrate by using silk screen printing techniques and / or rotary screen printing techniques, the aerosol-generating material slurry does not flow across the surface of the substrate, regardless of the angle of the substrate's surface relative to the horizontal. This is believed to be because the silk screen and / or rotary screen printing techniques apply the aerosol-generating material slurry at a thickness small enough that the applied aerosol-generating material slurry does not flow. It has also been found that the silk screen and / or rotary screen printing techniques are sufficiently accurate in the placement of the aerosol-generating material slurry on the substrate's surface that, if a greater depth of aerosol-generating material is desired than can be achieved using a single application of aerosol-generating material slurry, one or more regions of the aerosol-generating material can be precisely coated with additional aerosol-generating material slurry in those regions using those techniques.

[0048] It is preferred that the aerosol-generating material slurry can be applied to the support while the support is oriented at an angle to the horizontal, since the support is a longitudinally stretched sheet material and the sheet material travels along a production path that may be configured such that the production path is not a straight, unbent production path. For example, the production path may include one or more bends or curves in a direction perpendicular to the major surface of the sheet, e.g., the production path may be serpentine. This results in the production equipment used to apply the aerosol-generating material slurry to the support having a smaller footprint at the production site than known production equipment, without reducing the length of the production path. Alternatively, the same size equipment currently used may include a longer production path.

[0049] In one embodiment of any of the above embodiments, the method further comprises at least partially solidifying or allowing the aerosol-generating material slurry applied to the substrate to at least partially solidify, the aerosol-generating material slurry at least partially solidifying into an aerosol-generating material film. Solidification of the aerosol-generating material may also be known as curing.

[0050] In one embodiment of any of the above embodiments, the method further comprises: The method further includes measuring the thickness of the aerosol-forming material after the aerosol-forming material slurry has been applied to the substrate.

[0051] In one embodiment of any of the above embodiments, the thickness measurement is performed after the aerosol-generating material slurry has solidified or at least partially solidified.

[0052] In one embodiment of any of the above embodiments, the application of the aerosol-forming material slurry to the substrate is repeated at least one time.

[0053] In the context of the present disclosure, application of an aerosol-forming material slurry to a substrate should be understood to be application of the aerosol-forming material slurry to the surface of the substrate or to the surface of an aerosol-forming material that has already been applied to a substrate.

[0054] The technique of applying layers of aerosol-generating material slurry and measuring the thickness of the aerosol-generating material slurry or aerosol-generating material after each application allows for a precise final thickness of the aerosol-generating material to be achieved, thereby allowing for the formation of a consistent product.

[0055] In one embodiment of any of the above embodiments, each application of the aerosol-forming material slurry to the substrate is an application of the aerosol-forming material slurry to one or more identical locations on the substrate.

[0056] In one embodiment of any of the above embodiments, the at least two applications of the aerosol-forming material slurry to the substrate are applications of the aerosol-forming material slurry to a surface of the substrate.

[0057] In one embodiment of any of the above embodiments, each application of the aerosol-generating material slurry to the substrate is carried out using a different silk screen or rotary screen printing apparatus, which has the advantage that the aerosol-generating material slurry can at least partially solidify while the substrate, or the portion of the substrate to which the aerosol-generating material has been applied, is moved between the different silk screen or rotary screen printing apparatus.

[0058] In one embodiment of any of the above embodiments, the stencils used in association with each of the different silk screen or rotary screen printing apparatus are of the same construction, allowing for precise application of each application of aerosol-generating material slurry to the substrate, with each subsequent application being on top of the previous application of aerosol-generating material.

[0059] In one embodiment of any of the above embodiments, the method further comprises moving the support along a manufacturing path; The manufacturing pathway includes two or more silk screen machines, two or more rotary screen printing machines, or at least one silk screen machine and at least one rotary screen printing machine.

[0060] In one embodiment of any of the above embodiments, the aerosol-generating material slurry applied to the substrate is at least partially solidified or cured or is allowed to at least partially solidify or cure as the substrate moves between each silk screen and / or rotary screen printing apparatus.

[0061] In one embodiment of any of the above embodiments, the thickness measurement is performed while the substrate moves through the silk screen and / or rotary screen printing apparatus.

[0062] In one embodiment of any of the above embodiments, the support is a longitudinally extending material extending in a direction X, At least two portions of the aerosol-generating material slurry are applied to a substrate; each group of aerosol-forming material slurries is comprised of at least one individual portion of aerosol-forming material slurries; and The groups of aerosol-generating material slurry are spaced apart from one another in either or both of a direction X or a direction Y perpendicular to the direction X.

[0063] In one embodiment of any of the above embodiments, the manufacturing path extends in a direction X.

[0064] In one embodiment of any of the above embodiments, at least one of the repeated applications of the aerosol-generating material slurry to the substrate includes an application of an aerosol-generating material slurry of a first composition, and at least one of the repeated applications of the aerosol-generating material slurry to the substrate includes an application of an aerosol-generating material slurry of a second composition.

[0065] In one embodiment of any of the above embodiments, at least one of the discrete portions of the aerosol-generating material slurry comprises an aerosol-generating material slurry of a first composition, and at least one of the discrete portions of the aerosol-generating material slurry comprises an aerosol-generating material slurry of a second composition.

[0066] In one embodiment of any of the above embodiments, the step of at least partially solidifying the aerosol-forming material slurry applied to the substrate comprises exposing the aerosol-forming material slurry to electromagnetic radiation having wavelengths in the range of 700 nanometers to 1 millimeter, i.e., radiation in the infrared portion of the electromagnetic spectrum.

[0067] In one embodiment of any of the above embodiments, the method further includes the step of forcibly cooling the at least partially solidified aerosol-generating material, the cooling being carried out after the aerosol-generating material slurry applied to the support has at least partially solidified or has been allowed to at least partially solidify.

[0068] In one embodiment of any of the above embodiments, the aerosol-generating material slurry may be exposed to radiation from other portions of the electromagnetic spectrum, at least a partial vacuum, direct heat, an increased rate relative to the rate at which the aerosol-generating material solidifies at ambient conditions, or other conditions that cause the aerosol-generating material slurry to solidify.

[0069] In one embodiment of any of the above embodiments, the support comprises a flexible sheet material.

[0070] In one embodiment of any of the above embodiments, the support comprises one or more of a metal foil, a metal film, or a plastic film.

[0071] In one embodiment of any of the above embodiments, the support comprises aluminum foil.

[0072] In one embodiment of any of the above embodiments, each application of the aerosol-forming material slurry to the substrate is performed using a silk screen printing apparatus.

[0073] In one embodiment of any of the above embodiments, each application of the aerosol-generating material slurry to the substrate is performed using a rotary screen printing apparatus.

[0074] In one embodiment of any of the above embodiments, the product includes at least one additional material, and the method includes applying the aerosol-generating material slurry to a substrate, followed by applying a first additional material to at least a portion of the aerosol-generating material previously applied to the substrate, where the first additional material is applied to the aerosol-generating material using silk screen or rotary screen printing techniques.

[0075] In one embodiment of any of the above embodiments, the additional material is a material having a composition different from the composition of the aerosol-forming material slurry / aerosol-forming material.

[0076] In one embodiment of any of the above embodiments, the additional material is a material that produces a sensory experience in a user of a product made using the methods of the present disclosure that is different from that of the aerosol-forming material slurry / aerosol-forming material.

[0077] In one embodiment of any of the above embodiments, the additional material is a material that has one or more physical properties that differ from the physical properties of the aerosol-forming material slurry / aerosol-forming material.

[0078] The use of silk screen or rotary screen printing techniques to apply the additional material is preferred due to the precision of placement of the additional material that such techniques allow.

[0079] In one embodiment of any of the above embodiments, the second or subsequent additional material is applied to at least a portion of one or more of the aerosol-generating material, the first additional material, and the second and subsequent additional material after application of the first or the second or subsequent additional material.

[0080] In some embodiments, there may be three or more additional materials applied sequentially.

[0081] In one embodiment of any of the above embodiments, the second additional material is a material having a composition that differs from the composition of the aerosol-forming material slurry / aerosol-forming material and the first additional material.

[0082] In one embodiment of any of the above embodiments, the second additional material is a material that produces a sensory experience in a user of a product made using the method of the present disclosure that is different from that of the aerosol-forming material slurry / aerosol-forming material and the first additional material.

[0083] In one embodiment of any of the above embodiments, the second additional material is a material that has one or more physical properties that differ from the physical properties of the aerosol-forming material slurry / aerosol-forming material and the first additional material.

[0084] In one embodiment of any of the above embodiments, one or more of the aerosol-generating material slurries applied to the support and the additional material are at least partially solidified or allowed to at least partially solidify prior to subsequent application of the additional material.

[0085] In one embodiment of any of the above embodiments, at least one of the first, second or subsequent further material entirely overlies the aerosol-generating material or further material to which the first, second or subsequent further material is applied.

[0086] In one embodiment of any of the above embodiments, at least one of the first, second or subsequent further materials entirely overlaps less than all of the aerosol-generating material or further material to which the first, second or subsequent further material is applied.

[0087] In one embodiment of any of the above embodiments, the support comprises a support material and at least one further base material, and the further base material is applied to the support material before the aerosol-generating material is applied to the support, and the further base material is applied to the support material using silk screen or rotary screen printing techniques.

[0088] In one embodiment of any of the above embodiments, the additional base material is a material having a composition that is different from the composition of the aerosol-forming material slurry / aerosol-forming material, the first additional material, and the second subsequent additional material.

[0089] In one embodiment of any of the above embodiments, the additional base material is a material that produces a sensory experience in a user of a product made using the method of the present disclosure that is different from that of the aerosol-forming material slurry / aerosol-forming material, the first additional material, and the second subsequent additional material.

[0090] In one embodiment of any of the above embodiments, the base additional material is a material having one or more physical properties that are different from the physical properties of the aerosol-generating material slurry / aerosol-generating material, the first additional material, and the second subsequent additional material.

[0091] In one embodiment of any of the above embodiments, the product is larger than is compatible for use with a non-combustion aerosol delivery system, and the method further includes configuring the product for storage.

[0092] In one embodiment of any of the above embodiments, configuring the product for storage includes winding the product on a bobbin or folding the product into a bellows shape.

[0093] In one embodiment of any of the above embodiments, the step of configuring the product for storage further comprises slitting the product into two or more longitudinally extending strips.

[0094] In one embodiment of any of the above embodiments, the product is larger than is suitable for use in a non-combustion aerosol delivery system, and the method further comprises separating the product into two or more product portions; Each product portion is shaped and dimensioned for use as a consumable for use with a non-combustion aerosol delivery system.

[0095] In one embodiment of the above embodiments, the consumable is a substantially flat consumable.

[0096] In alternative embodiments of the above embodiments, the product portion is formed into a tube. In some embodiments, the tube is substantially cylindrical. In some embodiments, the tube is not cylindrical, but is, for example, but not limited to, triangular, rectangular, square, or polyhedral in cross section.

[0097] In one embodiment of any of the above embodiments, at least one of the discrete portions of aerosol-forming material faces a cavity defined by the tube, the cavity extending along the length of the tube.

[0098] In one embodiment of any of the above embodiments, the cavity formed by the tube is at least partially filled with a material that enhances the sensory experience of a user of the consumable. For example, the cavity formed by the tube may be at least partially filled with rag tobacco.

[0099] An aerosol-forming material is a material that is capable of generating an aerosol when, for example, heated, irradiated, or energized in any other manner. The aerosol-forming material can be, for example, in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain active substances and / or fragrances.

[0100] The aerosol-generating materials may include one or more active agents and / or flavorants, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0101] The aerosol-generating material may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a substance to be delivered and / or a filler material may also be present. Optionally, a solvent, such as water, is also present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0102] 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 substance to be delivered and / or a filler material may also be present. The aerosol-generating film may be substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0103] In some cases, the layer of aerosol-forming aerosol-generating material 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.

[0104] The aerosol-generating film can be formed by combining a binder, such as a gelling agent, with one or more other ingredients, such as a solvent, such as water, an aerosol-forming agent, and one or more substances to be delivered, to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent to form the aerosol-generating film.

[0105] The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent.

[0106] An 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 may retain some fluid, such as a liquid, within the amorphous solid. In some embodiments, the amorphous solid may include, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0107] The amorphous solid may be substantially free of plant material.The amorphous solid may be substantially free of tobacco.

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

[0109] The susceptor may include a ferromagnetic metal such as iron, or an iron alloy such as steel or an iron-nickel alloy. Some exemplary ferromagnetic metals are 400 series stainless steel, such as grade 410 stainless steel, or grade 420 stainless steel, or grade 430 stainless steel, or similar grade stainless steel. Alternatively, the susceptor may include a suitable non-magnetic, especially paramagnetic, conductive material, such as aluminum. With paramagnetic conductive materials, induction heating occurs only by resistive heating due to eddy currents. Alternatively, the susceptor may include a non-conductive ferrimagnetic material, such as a non-conductive ferrimagnetic ceramic. In that case, heat is generated only by hysteresis losses. The susceptor may include a commercially available alloy, such as Phytherm 230 (having a composition (weight %=wt%) of 50 wt% Ni, 10 wt% Cr, and the remainder Fe) or Phytherm 260 (having a composition of 50 wt% Ni, 9 wt% Cr, and the remainder Fe).

[0110] In one embodiment of any of the above embodiments, the aerosol-forming material includes an active agent.

[0111] As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. An active substance may be selected from, for example, dietary supplements, nootropics, and psychostimulants. An active substance may be naturally derived or synthetically obtained. An active substance may include, for example, nicotine, caffeine, taurine, non-cannabinoid-derived terpenes, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. An active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another plant.

[0112] The active substance may include one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0113] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0114] The active material may include or be derived from one or more botanical materials or their components, derivatives, or extracts. As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, or shells. Alternatively, the material may include active compounds naturally occurring in plants that are synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, or sheets, etc. Exemplary botanicals include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea, such as green or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chive, caraway, 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: peppermint, mentha, Egyptian mint, peppermint, cologne mint, candy mint, curly mint, Kentucky kernel mint, horse mint, pineapple mint, benny royal mint, green peppermint, and apple mint.

[0115] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substance is tobacco.

[0116] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0117] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0118] In some embodiments, the aerosol-forming material comprises a flavoring or fragrance.

[0119] As used herein, the terms "flavoring agent" and "flavoring agent" refer to materials that may be used, where local regulations permit, to create a desired taste, aroma, or other somatic sensation in products intended for adult consumers.They may be any naturally derived flavoring material, botanical substance, extract of botanical substance, synthetically derived material, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherries, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes, etc.). , tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascara, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine ylang-ylang, sage, fennel, wasabi, pimenta, ginger, coffee, hemp, peppermint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damienne, magic The flavor enhancers may include other additives such as maltitol, stearyl alcohol, stearyl alcohol, olive oil, lemon balm, lemon basil, chives, caraway seeds, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), as well as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be of imitation, synthetic or natural origin, or blends thereof. They may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

[0120] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus, and / or red berry flavoring ingredients. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavoring ingredients extracted from tobacco. In some embodiments, the flavoring comprises flavoring ingredients extracted from cannabis.

[0121] In some embodiments, the flavoring agent may include a sensory elicitor, which is intended to achieve somatic sensations that are usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the aroma or taste nerves, and these may include agents that produce a heating, cooling, tingling, or numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucoliptol, WS-3.

[0122] The aerosol generating material includes an aerosol generating agent. In some embodiments, the aerosol generating agent may include one or more components capable of forming an aerosol. In some embodiments, the aerosol generating agent may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In a particular example, the aerosol generating agent includes glycerol.

[0123] 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 mono-, di-, or triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0124] 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% 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.

[0125] 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.

[0126] In some embodiments, the aerosol-generating 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%.

[0127] 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 cases, the gelling agent includes alginates and / or pectins and may be combined with a solidifying agent (such as a calcium source) during formation of the aerosol-generating material. In some cases, the aerosol-generating material may include calcium cross-linked alginates and / or calcium cross-linked pectins.

[0128] 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.

[0129] In some embodiments, the cellulosic 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.

[0130] 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.

[0131] 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.

[0132] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the aerosol-generating material in an amount of 10-30 wt % of the aerosol-generating material (calculated on a dry weight basis). In some embodiments, the alginate is the only gelling agent present in the aerosol-generating material. In other embodiments, the gelling agent comprises alginate and at least one further gelling agent, such as pectin.

[0133] 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 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 gelling agent.

[0134] In some embodiments, the aerosol-forming material comprises about 20 wt%, 22 wt%, 24 wt%, or 25 wt% to about 30 wt%, 32 wt%, or 35 wt% gelling agent (all calculated on a dry weight basis). For example, the aerosol-forming material may comprise 20-35 wt% or 25-30 wt% gelling agent.

[0135] In some cases, the aerosol-generating material may include from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, or 20 wt% to about 60 wt%, 50 wt%, 40 wt%, 30 wt%, or 25 wt% of the gelling agent (DWB). For example, the aerosol-generating material may include from 10 to 40 wt%, 15 to 30 wt%, or 20 to 25 wt% of the gelling agent (DWB).

[0136] In examples, the aerosol-generating material comprises the gelling agent and the filler together in an amount between about 10 wt%, 20 wt%, 25 wt%, 30 wt%, or 35 wt% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the aerosol-generating material. In examples, the aerosol-generating material comprises the gelling agent and the filler together in an amount between about 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt% of the aerosol-generating material.

[0137] In examples, the aerosol-generating material comprises gelling agent in an amount of about 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, or 35 wt% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the aerosol-generating material (i.e., not considering the amount of filler). In examples, the aerosol-generating material comprises 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-generating material (i.e., not considering the amount of filler).

[0138] 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-generating material. That is, the aerosol-generating material comprises alginate in an amount of about 5-40 wt%, or 15-40 wt%, of the aerosol-generating material by dry weight. In some examples, the aerosol-generating material comprises alginate in an amount of about 20-40 wt%, or about 15 wt% to 35 wt%, of the aerosol-generating material.

[0139] 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, in some examples, the aerosol-forming material comprises pectin in an amount of about 5-10 wt% of the aerosol-forming material.

[0140] In some examples, the guar gum is included in the gelling agent in an amount of about 3-40 wt% of the aerosol-generating material. That is, the aerosol-generating material includes 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 includes guar gum in an amount of about 5-10 wt% of the aerosol-generating material. In some examples, the aerosol-generating material includes 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.

[0141] In examples, the alginate is present in an amount of at least about 50 wt% of the gelling agent. In examples, 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 typically >1:1, i.e., the alginate is present in an amount greater than the amount of pectin. In examples, the ratio of alginate to pectin is about 2:1 to 8:1, or about 3:1 to 6:1, or approximately 4:1.

[0142] The aerosol-generating material may be formed by (a) forming a slurry including components of the aerosol-generating material or its precursors, (b) forming a layer of the slurry, (c) solidifying the slurry to form a gel, and (d) drying to form the aerosol-generating material.

[0143] (b) forming the layer of the slurry typically includes spraying, casting, or extruding the slurry. In an example, the slurry layer is formed by electrospraying the slurry. In an example, the slurry layer is formed by casting the slurry.

[0144] In some examples, (b) and / or (c) and / or (d) are performed at least partially simultaneously (e.g., during electrospraying). In some examples, (b), (c), and (d) are performed sequentially.

[0145] In some examples, the slurry is applied to a substrate and a layer may be formed on the substrate.

[0146] In an example, the slurry includes a gelling agent, an aerosol forming agent, and an active agent. The slurry may include these components in any of the proportions given 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 the gelling agent and the filler together being about 10-60 wt% of the slurry; an aerosol former material in an amount of about 40-80 wt % of the slurry; Optionally, an active material in an amount of up to about 20 wt.% of the slurry; and may include.

[0147] (c) solidifying the gel can include providing a solidifying agent to the slurry. For example, the slurry can include sodium alginate, potassium alginate, or ammonium alginate as a gel precursor, and a solidifying agent including a calcium source (such as calcium chloride) can be added to the slurry to form a calcium alginate gel.

[0148] In examples, the solidifying agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or combinations thereof. In some examples, the solidifying agent comprises or consists of calcium formate and / or calcium lactate. In particular examples, the solidifying agent comprises or consists of calcium formate. The inventors have determined that employing calcium formate as a solidifying agent typically results in aerosol generating materials having greater tensile strength and greater resistance to elongation.

[0149] The total amount of solidifying agent, such as a calcium source, may be 0.5 to 5 wt % (calculated on a dry weight basis). Suitably, the total amount may be from about 1 wt %, 2.5 wt %, or 4 wt % to about 4.8 wt % or 4.5 wt %. The inventors have found that adding too little solidifying agent may result in an aerosol-generating material in which the aerosol-generating material components are not stabilized and these components fall off the aerosol-generating material. The inventors have found that adding too much solidifying agent results in an aerosol-generating material that is very sticky and therefore difficult to handle.

[0150] If the aerosol-forming material does not contain tobacco, it may be necessary to apply a larger amount of solidifying agent. Thus, in some cases, the total amount of solidifying 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 be tobacco-free.

[0151] In an example, adding the solidifying agent to the slurry includes spraying the solidifying agent onto the slurry, such as onto a 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) units and α-L-guluronic acid (G) units (blocks) linked together by (1,4)-glycosidic bonds to form a polysaccharide. Upon addition of calcium cations, alginates crosslink to form gels. Alginates with a high G monomer content have been found to form gels more readily upon addition of a calcium source. Thus, in some cases, the gel precursor may include alginates in which at least about 40%, 45%, 50%, 55%, 60%, or 70% of the monomer units in the alginate copolymer are α-L-guluronic acid (G) units.

[0153] In examples, 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.

[0154] In an example, drying (d) reduces the thickness of the cast material by at least 80%, preferably 85% or 87%. For example, the slurry is cast at a thickness of 2 mm and the resulting dried aerosol-generating material has a thickness of 0.2 mm.

[0155] 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).

[0156] In instances where the solvent comprises water, the dry weight content of the slurry can match the dry weight content of the aerosol-forming material. Thus, discussions herein of solids compositions are expressly disclosed in conjunction with the slurry aspects of the present disclosure.

[0157] The aerosol-generating material may include a flavoring. Suitably, the aerosol-generating material may include up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the flavoring. In some cases, the aerosol-generating material may include at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% of the flavoring (all calculated on a dry weight basis). For example, the aerosol-generating material may include 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% of the flavoring. In some cases, the flavoring includes, consists essentially of, or consists of menthol.

[0158] The aerosol-forming material may include a bulking agent.

[0159] 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%.

[0160] In other embodiments, the aerosol forming material contains less than 20 wt%, preferably less than 10 wt%, or less than 5 wt% filler. In some cases, the aerosol forming material contains less than 1 wt% filler, and in some cases, no filler.

[0161] In some such 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.

[0162] The filler, when present, 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 include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives, such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC). In certain cases, the aerosol-generating material does not include calcium carbonate, such as chalk.

[0163] 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 (methylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), etc.).

[0164] Without wishing to be bound by theory, it is believed that the inclusion of fibrous fillers 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 circumscribes a rod of aerosolizable material.

[0165] In some embodiments, the aerosol-forming material does not include tobacco fibers, hi certain embodiments, the aerosol-forming material does not include fibrous materials.

[0166] The aerosol-generating materials may include one or more active agents and / or flavorants, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0167] In some embodiments, the aerosol-generating material further comprises an active agent. For example, in some cases, the aerosol-generating material further comprises tobacco material and / or nicotine. In some embodiments, the aerosol-generating material comprises powdered tobacco and / or nicotine and / or a tobacco extract.

[0168] In some cases, the aerosol-forming material may comprise between 5 and 60 wt% tobacco material and / or nicotine (calculated on a dry weight basis). 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% active agent (calculated on a dry weight basis). 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% tobacco material (calculated on a dry weight basis). For example, the aerosol-generating material may include 10-50 wt%, 15-40 wt%, or 20-35 wt% tobacco material. In some cases, the aerosol-generating 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-generating material may include 1-20 wt%, 2-18 wt%, or 3-12 wt% nicotine.

[0169] In some cases, the aerosol-generating material includes an active agent such as tobacco extract. In some cases, the aerosol-generating material may include 5-60 wt% tobacco extract (calculated on a dry weight basis). In some cases, the aerosol-generating 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-generating 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, there may be no nicotine present in the aerosol-forming material other than the nicotine originating from the tobacco extract.

[0170] In some embodiments, the aerosol-generating material does not include tobacco material, but does include nicotine. In some such cases, the aerosol-generating 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-generating material may include from 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% nicotine.

[0171] 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).

[0172] In some cases, the total content of tobacco material, nicotine, and flavorings may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or flavorings may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0173] The aerosol-generating composition may include one or more active agents. In examples, the aerosol-generating material includes one or more active agents, for example, up to about 20 wt% of the aerosol-generating material. In examples, the aerosol-generating material includes the active agents in an amount of about 1 wt%, 5 wt%, 10 wt%, or 15 wt% to about 20 wt%, 15 wt%, 15 wt%, or 5 wt% of the aerosol-generating material.

[0174] Active substances may include physiologically and / or olfactory active substances that are included in the aerosol generating composition to achieve a physiological and / or olfactory response.

[0175] 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%.

[0176] The tobacco material may be present in any form, but is typically shredded (e.g., cut into narrow strips). The shredded tobacco material may be suitably blended with the aerosol-forming material to provide an aerosol-forming composition having a uniform distribution of the tobacco material and the aerosol-forming material throughout the aerosol-forming composition.

[0177] In examples, the tobacco material comprises one or more of ground tobacco, tobacco fiber, shredded tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extract. Surprisingly, the inventors have determined that it is possible to use relatively large amounts of flake tobacco in the aerosol-generating composition and still provide an acceptable aerosol when heated by a non-combustion aerosol delivery system. The flake tobacco typically provides superior sensory properties. In examples, the tobacco material comprises flake 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 shredded 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.

[0178] The tobacco used to make 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.

[0179] In some embodiments, the one or more other functional ingredients may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0180] In some cases, the aerosol-forming material may further include an emulsifier that emulsifies the molten flavoring during manufacture. For example, the aerosol-forming material may include about 5 wt% to about 15 wt% (calculated on a dry weight basis), preferably about 10 wt%, of an emulsifier. The emulsifier may include gum acacia.

[0181] In some embodiments, the aerosol-generating material is a hydrogel and contains less than about 20 wt% water, calculated on a wet weight basis. In some cases, the hydrogel may contain less than about 15 wt%, 12 wt%, or 10 wt% water, calculated on a wet weight basis. In some cases, the hydrogel may contain at least about 1 wt%, 2 wt%, or at least about 5 wt% water (WWB).

[0182] The aerosol-forming material may have any suitable water content, such as from 1 wt% to 15 wt%. Preferably, the water content of the aerosol-forming material is from about 5 wt%, 7 wt%, or 9 wt% to about 15 wt%, 13 wt%, or 11 wt% (WWB), and 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 detection (GC-TCD).

[0183] 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.

[0184] In some cases, the aerosol-forming materials may consist essentially of or consist of a gelling agent, water, an aerosol-forming agent, flavorants, and optionally tobacco materials and / or a nicotine source.

[0185] In examples, the aerosol-generating material consists essentially of or consists of a gelling agent, an aerosol-generating agent, an active agent, and water.In examples, the aerosol-generating material consists essentially of or consists of a gelling agent, an aerosol-generating agent, and water.

[0186] In examples, the aerosol-forming material does not include a fragrance, and in certain examples, the aerosol-forming material does not include an active agent.

[0187] In some embodiments, the aerosol forming material comprises an aerosol forming material, the aerosol forming material comprising: 1 to 60 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol generating agent; 0.1 to 80 wt% of flavoring; Including, These weights are calculated on a dry weight basis. In some embodiments, the aerosol-forming material comprises 1-80 wt% flavoring (on a dry weight basis).

[0188] In some embodiments, 1 to 50 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol generating agent; 30-60wt% flavoring, Including, These weights are calculated on a dry weight basis of the aerosol-forming material.

[0189] In an alternative embodiment of the aerosol-forming material, the aerosol-forming material comprises an aerosol-forming material, the aerosol-forming material comprising: 1 to 60 wt % of a gelling agent; 5 to 60 wt % of an aerosol generating agent; 10-60 wt% tobacco extract; Including, These weights are calculated on a dry weight basis.

[0190] 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.

[0191] In some embodiments, the aerosol-generating material comprises 20-35 wt% gelling agent, 10-25 wt% aerosol former material, 5-25 wt% fiber-containing filler, and 35-50 wt% flavoring and / or active.

[0192] In some cases, the aerosol-forming materials may consist essentially of or consist of a gelling agent, an aerosol-forming agent, a tobacco extract, water, and optionally a flavoring. In some cases, the aerosol-forming materials may consist essentially of or consist of glycerol, alginate and / or pectin, a tobacco extract, and water.

[0193] In some embodiments, the aerosol generating material may comprise 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), having the following composition (DWB).

[0194] 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).

[0195] 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 planar surface of the sheet opposite the first planar surface of the sheet.

[0196] In some cases, the layer of aerosol-forming aerosol-generating material 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.

[0197] In some cases, the aerosol-generating material may have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

[0198] Materials having a thickness of 0.2 mm are particularly suitable. The aerosol-generating material may comprise two or more layers, and the thicknesses mentioned herein refer to the combined thicknesses of the layers.

[0199] It has been found that if the aerosol-generating material is too thick, the heating efficiency is reduced, which has a negative impact on power consumption during use. Conversely, if the aerosol-generating material is too thin, it is difficult to manufacture and handle, and very thin materials are difficult to cast and are brittle, which can impair aerosol formation during use.

[0200] The thicknesses specified herein are the average thickness of the material. In some cases, the thickness of the aerosol-generating material may vary by 25%, 20%, 15%, 10%, 5%, or 1% or less.

[0201] 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.

[0202] Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is formed as a sheet and then chopped into an aerosol product. In some examples, such as when the aerosol-generating material includes a filler, the aerosol-generating material may have a tensile strength of 600 N / m to 900 N / m, or 700 N / m to 900 N / m, or about 800 N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is included in an aerosol product / assembly as a rolled sheet, preferably in the form of a tube.

[0203] In some examples, the aerosol generating material in sheet form may have a tensile strength of about 200 N / m to about 2600 N / m. In some examples, the aerosol generating material may have a tensile strength of 600 N / m to 2000 N / m, or 700 N / m to 1500 N / m, or about 1000 N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol generating material constituting the aerosol generating material is formed and incorporated into an aerosol generating consumable as a sheet.

[0204] The aerosol-forming material, including the aerosol-forming material, has a density of 30 g / m 2 ~350g / m 2 In some cases, the sheet may have a density of 50 to 250 g / m 2 , or about 70-210g / m 2 , or about 90-190g / m 2 or preferably about 100 g / m 2 (so that it has a density similar to cut rag tobacco and mixtures of these materials do not easily separate). In some cases, the sheet may have a mass per unit area of ​​about 30-70 g / m 2 , 40~60g / m 2 , or 25-60g / m 2 and may be used to encase aerosolizable material such as tobacco.

[0205] All weight percentages (expressed as wt%) described 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 refer to the totality of the extract, slurry or material other than 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 refer to all ingredients, including water.

[0206] As used herein, the term "sheet" refers to an element having a width and length that are substantially greater than its thickness. A major surface of a sheet is the surface that extends in both the width and length dimensions when the sheet is flat. A sheet may be, for example, a strip.

[0207] The aerosol-generating material may include a colorant. The addition of a colorant may change the visual appearance of the aerosol-generating material. The presence of a colorant in the aerosol-generating material may enhance the visual appearance of the aerosol-generating material and the aerosol-generating material. By adding a colorant to the aerosol-generating material, the aerosol-generating material may be color-matched with other components of the aerosol-generating material or other components of an article that includes the aerosol-generating material.

[0208] Depending on the desired color of the aerosol-generating material, various colorants may be used. The color of the aerosol-generating material may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also envisioned. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food-grade colorants, and pharmaceutical-grade colorants. In certain embodiments, the colorant is caramel, which may impart a brown appearance to the aerosol-generating material. In such embodiments, the color of the aerosol-generating material may be similar to the color of other components (such as tobacco materials). In some embodiments, the addition of the colorant to the aerosol-generating material makes it visually indistinguishable from other components in the aerosol-generating material.

[0209] The colorant may be incorporated during the formation of the aerosol-generating material (e.g., when forming a slurry with the materials that form the aerosol-generating material), or the colorant may be applied to the aerosol-generating material after its formation (e.g., by spraying the colorant onto the aerosol-generating material).

[0210] In some embodiments of any of the above embodiments, talcum powder, calcium carbonate powder, or other powder is applied to an exposed surface of at least one discrete portion of the aerosol-generating material, which may reduce the level of tackiness or adhesiveness of the aerosol-generating material.

[0211] In the following description 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, similar reference numbers (the same numbers plus a multiple of 100) are used.

[0212] 1 and 2, product 1 includes a substrate 2. Substrate 2 is a longitudinally stretched sheet of laminated material having a first layer 4 of aluminum foil and a second layer 6 of paper. First layer 4 has a major surface 8 facing opposite second layer 6. On surface 8 of substrate 2 are a plurality of groups 10 of individual portions 12 of aerosol-generating material (for clarity, not all groups 10 are labeled). Each group 10 is comprised of thirteen individual portions 12 of aerosol-generating material, as shown in FIG. 2 (for clarity, not all portions 12 are labeled). All portions 12 of aerosol-generating material are of the same shape and size, and portions 12 are disposed in a predetermined relationship to one another. Similarly, all groups 10 are identical to one another and disposed in a predetermined relationship to one another.

[0213] 1 and 2, there are four groups 10 spaced apart in a direction perpendicular to the longitudinal extent of the support 2, with each group 10 having thirteen discreet portions 12 of aerosol-generating material. The number of groups and discreet portions, as well as the dimensional proportions of the support 2, are for illustration purposes only. Within the scope of this disclosure, there may be one or more groups 10 and one or more individual portions 12 within each group 10. Similarly, different dimensional proportions of the support 2 are within the scope of this disclosure.

[0214] 3 and 4, these figures show a first embodiment of a discrete portion 212 of aerosol-generating material and a cross section through that discrete portion 212 of aerosol-generating material, respectively. The discrete portions 212 are applied to the surface 8 of the support 2 by two prints of the aerosol-generating material, each using silk screen or rotary screen printing techniques. The first and second prints use first and second stencils, respectively. Each stencil is configured to allow printing of one or more circular discrete portions of the aerosol-generating material. The two stencils have the same configuration and are configured such that the second print is on top of the first print.

[0215] The method of manufacturing the individual portions 212 is generally as follows.

[0216] A support 2 is placed in a predetermined position relative to a first silk screen or rotary screen printer.

[0217] A first silk screen or rotary screen printer is activated and a layer 236 of aerosol-generating material is deposited on surface 8 .

[0218] The layer 236 of aerosol-generating material is at least partially solidified or allowed to at least partially solidify.

[0219] The support 2 is placed in a predetermined position relative to a second silk screen or rotary screen printer.

[0220] A second silk screen or rotary screen printer is activated and a layer of aerosol-generating material 238 is deposited onto layer of aerosol-generating material 236 .

[0221] 5 and 6, which respectively show a second embodiment of a discrete portion 312 of aerosol-generating material and a cross section through that discrete portion 312 of aerosol-generating material. The discrete portions 312 are applied to the surface 8 of the support 2 by three prints of the aerosol-generating material, each using silk screen or rotary screen printing techniques. The first, second and third prints use first, second and third stencils, respectively. Each stencil is configured to allow printing of one or more circular discrete portions of the aerosol-generating material. The three stencils have a similar configuration, configured such that the second print is on top of the first print but smaller than the first print, and the third print is on top of the first and second prints but larger than (overlapping) the first and second prints.

[0222] The method of manufacturing the individual portions 312 is generally as follows.

[0223] A support 2 is placed in a predetermined position relative to a first silk screen or rotary screen printer.

[0224] A first silk screen or rotary screen printer is activated and a layer 336 of aerosol-generating material is deposited on surface 8 .

[0225] The layer 336 of aerosol-generating material is at least partially solidified or allowed to at least partially solidify.

[0226] The support 2 is placed in a predetermined position relative to a second silk screen or rotary screen printer.

[0227] A second silk screen or rotary screen printer is activated and a layer 338 of aerosol-generating material is deposited over a portion of the layer 336 of aerosol-generating material. In the illustrated example, layer 338 is circular and centered at the center of layer 336. In other non-illustrated embodiments, layer 338 may have a different shape, or layer 336 may not have a center.

[0228] The layer 338 of aerosol-generating material is at least partially solidified or allowed to at least partially solidify.

[0229] The support 2 is placed in a predetermined position relative to a third silk screen or rotary screen printer.

[0230] A second silk screen or rotary screen printer is activated and a layer 340 of aerosol-generating material is deposited over layers 336 and 338 and a portion of surface 8. In the illustrated example, layer 340 is circular and centered at the center of layers 336 and 338. In other non-illustrated embodiments, layer 340 may have a different shape and layers 336 and / or 338 may not have a center.

[0231] Once the product 1 is formed, the product may be configured for storage. One example of a storage configuration of the product 1 is accomplished by winding the support 2 on a bobbin into a roll, with sheets of protective material disposed between layers of the support 2 within the roll. The product 1 may then be stored until it is needed to be used to manufacture several consumables 14 for use with an aerosol delivery device. The consumables 14 are formed by cutting the support 2 into portions such that each consumable 14 includes a portion of the support 2 and a group 10, as shown in FIG. 7.

[0232] An alternative storage configuration for the product 1 is to form the support 2 into an accordion shape about a fold line that runs perpendicular to the longitudinal extent of the support 2. Again, a sheet of protective material may be placed on the surface 8 of the support 2 before forming the support 2 into an accordion shape.

[0233] With reference to Figure 8, to form product 1, the support 2 is fed from a feeder roll 16. The support 2 then follows a winding or serpentine production path in the direction indicated by arrow D around a number of rollers R until it is taken up on a storage roll 18. In Figure 8, a vertically upward direction is indicated by arrow V, and as can be seen, for most of the production path the support is at an angle to the horizontal. For most of the production path the support is in the direction of the production path or the longitudinal extent of the support is at an angle of more than 60 degrees to the horizontal.

[0234] As the substrate passes along the manufacturing path, it first passes through a first rotary printing apparatus 20A. The rotary printing apparatus 20A includes a mesh screen formed into a tube. The mesh is first prepared for use, and the pre-press process includes the use of a stencil to make the mesh such that the aerosol-generating material slurry can pass through the mesh only at the desired locations of the portion 12 of the aerosol-generating material. Once the mesh is prepared for use, the aerosol-generating material slurry is introduced inside the tube of the mesh. The tube is rotated outside the mesh tube, which rotates at the same speed as the substrate 2 progresses along the manufacturing path, and a squeegee within the tube squeezes the aerosol-generating material slurry out of the tube through the mesh at the locations on the mesh where the aerosol-generating material can pass through. The aerosol-generating material that passes through the mesh is applied to the surface 8 of the substrate 2.

[0235] After the substrate passes through the first rotary printing apparatus 20A, it passes through a first infrared radiation source 22A which directs infrared radiation onto the surface 8 of the substrate 2 and onto the discrete portions 12 of aerosol-generating material on the surface 8. The infrared radiation increases the solidification rate of the aerosol-generating material slurry.

[0236] The aerosol-forming material slurry portion 12 also at least partially solidifies as the portion 12 travels from the first rotary printing device 20A to the first infrared radiation source 22A and from there to the first measurement means 24A.

[0237] A first measuring means 24A measures the thicknesses of the portions 12 of aerosol-forming material to ensure that they are as expected.

[0238] The substrate 2 then passes to a second rotary printing apparatus 20B, which applies a second layer of aerosol-generating material slurry onto the portion 12 of aerosol-generating material applied to the substrate surface 8 by the first rotary printing apparatus 20A. The substrate then passes to a second infrared radiation source 22B, followed by a second measuring means 24B. Both the second infrared radiation source 22B and the second measuring means 24B function like the first infrared radiation source 22A and the first measuring means 24A.

[0239] The support 2 then passes through third, fourth, fifth and sixth rotary printing devices 20C, 20D, 20E, 20F, infrared radiation sources 22C, 22D, 22E, 22F and measurement means 24C, 24D, 24E, 24F.

[0240] If any of the measuring means 24A-F finds that the portion 12 of aerosol-generating material is thicker than a predetermined thickness, the controller of one of the rotary printing devices 20 further along the production path can prevent that rotary printing device 20 from applying a layer of aerosol-generating material slurry to the excessively thick portion 12 of aerosol-generating material.

[0241] In a non-illustrated embodiment of the method of the present disclosure, there is a seventh rotary printing device 20G, a seventh infrared radiation source 22G, and a seventh measurement means 24G that applies aerosol-generating material slurry to the portion 12 of aerosol-generating material only if the sixth measurement means 24F measures that the portion 12 of aerosol-generating material is less than a predetermined thickness.

[0242] After the final measurement means 24F (or 24G in an embodiment not shown), the support passes through a forced cooling device 26 which reduces the temperature of the support and aerosol-forming material, thereby stabilizing the aerosol-forming material and reducing evaporation from the aerosol-forming material.

[0243] A protective sheet material 30 is then placed on surface 8 of substrate 2, which is then wound onto storage roll 18. Protective sheet material 30 is fed from protective sheet material feed roll 28. Protective sheet 28 stops portions 12 of aerosol-forming material from adhering to second layer 6 of substrate 2 while substrate 2 is on storage roll 18.

[0244] In some embodiments, once the substrate 2 is wound onto a storage roll 18 , the substrate 2 is slit along its length between each longitudinally extending row of groups 10 .

[0245] The number of rotary printing devices 20, infrared radiation sources 22 and measuring means 24 is given by way of example only. Within the scope of the present disclosure, there may be one or more rotary printing devices 20, infrared radiation sources 22 and measuring means 24.

[0246] In other, not shown, embodiments, each rotary printing device 20A-F or G may be replaced by a screen printing device, and the movement of the support 2 along the production path is paused while screen printing is performed.

[0247] 9, product 101 is comprised of a sheet 102 of support material as a first surface 108. Support material 102 is a laminate having the same structure as substrate 2 described in connection with FIGS. 1 and 2 above. On first surface 108 of support material 102 are several groups 10 (for clarity, not all of groups 10 are labeled) of individual portions 12 of aerosol-generating material. Groups 10 are also as described above and shown in FIG. 2.

[0248] In Figure 9, there are 24 groups 10 disposed on the surface 108 of the support 102, with 13 discreet portions 12 of aerosol-generating material in each group 10. These numbers of groups and discreet portions, as well as the dimensional proportions of the sheet of support material 102, are for illustration purposes only. Within the scope of this disclosure, there may be one or more groups 10 and one or more individual portions 12 in each group 10. Similarly, different dimensional proportions of the sheet of support material 102 are within the scope of this disclosure.

[0249] Referring to FIG. 10, this figure shows a flow diagram for the manufacture of product 101. A sheet of support material 102 is first placed in a first screen printing apparatus 120A. The screen printing apparatus 120A includes a mesh screen. The mesh is first prepared for use, and the pre-use preparation of the mesh (pre-press process) includes the use of a stencil to make a mesh on the sheet of support material 102 such that the aerosol-generating material slurry can pass through the mesh only at the desired locations of the portions 12 of the aerosol-generating material. Once the mesh is ready for use, a squeegee pushes the aerosol-generating material slurry through the mesh at the locations on the mesh where the aerosol-generating material can pass through. The aerosol-generating material that passes through the mesh is applied to the surface 108 of the support 102.

[0250] After the sheet of support material 102 has been printed by the first silk screen printing apparatus 120A, the sheet of support material 102 is moved into position adjacent a first infrared radiation source 122A, which directs infrared radiation at the surface 108 of the sheet of support material 102 and the discrete portions 12 of aerosol-generating material on the surface 108. The infrared radiation increases the solidification rate of the aerosol-generating material slurry.

[0251] A portion 12 of the aerosol-forming material slurry, at least partially solidified as a sheet of support material 102, is also moved from the first silkscreen printing device 120A to a first infrared radiation source 122A and from there to a first measurement means 124A.

[0252] A first measuring means 124A measures the thicknesses of the portions 12 of aerosol-forming material to ensure that they are as expected.

[0253] The sheet of support material 102 is then moved to a second silkscreen printing apparatus 120B which applies a second layer of aerosol-forming material slurry onto the portions 12 of aerosol-forming material applied to the surface 108 of the sheet of support material 102 by the first silkscreen printing apparatus 120A. The sheet of support material 102 is then moved to a second infrared radiation source 122B and then to a second measuring means 124B. Both the second infrared radiation source 122B and the second measuring means 124B function like the first infrared radiation source 122A and the first measuring means 124A.

[0254] The controller 132 determines whether the thickness of the portion 12 of aerosol-generating material exceeds a predetermined minimum thickness. If the answer to that determination is yes, the sheet of support material 102 is moved to a storage location 134. If the answer to that determination is no, the sheet of support material 102 is placed in a second silkscreen printing apparatus 120B for more aerosol-generating material slurry to be applied to the portion 12 of aerosol-generating material, dried, and remeasured. The thickness determination is then made again.

[0255] The above description is intended to be illustrative only, and those skilled in the art will recognize that changes can be made to the described embodiments without departing from the scope of the disclosure disclosed. Still other modifications that fall within the scope of the present disclosure will be apparent to those skilled in the art in light of a consideration of the present disclosure.

[0256] Various aspects of the methods, products, and consumables disclosed in the various embodiments may be used alone, in combination, or in various configurations not specifically described in the above embodiments. Thus, the disclosure is not limited in its application to the details and arrangements of components set forth in the foregoing description or illustrated in the drawings. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments. Although specific embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the disclosure in its broader aspects. The scope of the following claims should not be limited by the embodiments described in the examples, but should be accorded the broadest reasonable interpretation consistent with the description as a whole.

Claims

1. 1. A method of making an article comprising an aerosol-forming material and a substrate, comprising: Providing a support; applying an aerosol-forming material slurry to the substrate; Including, The method wherein the aerosol-forming material slurry is applied to the substrate using silk screen or rotary screen printing techniques.

2. The method of claim 1 , wherein the application of the aerosol-forming material slurry is the application of one or more discrete portions of the aerosol-forming material slurry.

3. The method of claim 2 , wherein one or more discrete portions of the aerosol-forming material slurry are applied to predetermined locations on the substrate.

4. 4. The method of claim 2 or 3, wherein there are two or more distinct portions of aerosol-forming material slurry, and at least two distinct portions of aerosol-forming material slurry are applied to the substrate at predetermined locations relative to each other.

5. 5. The method of claim 1, wherein there are two or more distinct portions of aerosol-forming material slurry, at least one of the distinct portions of aerosol-forming material slurry is formed from an aerosol-forming material slurry of a first composition and at least one of the distinct portions of aerosol-forming material slurry is formed from an aerosol-forming material slurry of a second composition, and the first and second compositions are different.

6. 6. The method of claim 1, wherein there are two or more discrete portions of the aerosol-forming material slurry, at least one of the discrete portions of the aerosol-forming material slurry is a first size and at least one of the discrete portions of the aerosol-forming material slurry is a second size, and the first and second sizes are different.

7. 7. The method of any one of claims 1 to 6, wherein there are two or more distinct portions of the aerosol-forming material slurry, at least one of the distinct portions of the aerosol-forming material slurry has a first shape and at least one of the distinct portions of the aerosol-forming material slurry has a second shape, and the first and second shapes are different.

8. 8. The method of claim 1, wherein there are two or more distinct portions of aerosol-forming material slurry, at least one of the distinct portions of aerosol-forming material slurry comprising a first mass of aerosol-forming material and at least one of the distinct portions of aerosol-forming material slurry comprising a second mass of aerosol-forming material, and the first and second masses are different.

9. The method of any one of claims 1 to 8, wherein the aerosol-forming material slurry is applied to the substrate in the form of a plurality of microdots of aerosol-forming material slurry.

10. 10. The method of claim 9, wherein at least one of the microdots of the aerosol-forming material slurry is formed from an aerosol-forming material slurry of a first composition and at least one of the microdots of the aerosol-forming material slurry is formed from an aerosol-forming material slurry of a second composition, and wherein the first and second compositions are different.

11. The method of any one of claims 1 to 10, further comprising filtering the aerosol-forming material slurry before applying the aerosol-forming material slurry to the substrate.

12. The method of any one of claims 1 to 11, wherein the substrate is oriented at an angle to the horizontal when the aerosol-forming material slurry is applied to the substrate.

13. 13. The method of claim 12, wherein when the aerosol-forming material slurry is applied to the substrate, the substrate is oriented at an angle of at least 30 degrees, at least 40 degrees, at least 50 degrees, at least 60 degrees, at least 70 degrees, or at least 80 degrees relative to the horizontal.

14. 14. The method of claim 13, wherein the substrate is oriented at an angle of between 70 degrees and 90 degrees to the horizontal when the aerosol-forming material slurry is applied to the substrate.

15. the aerosol-forming material slurry applied to the substrate is at least partially solidified or allowed to at least partially solidify; The method of any one of claims 1 to 14, wherein the aerosol-forming material slurry at least partially solidifies as an aerosol-forming material film.

16. Measuring the thickness of the aerosol-forming material slurry after the aerosol-forming material slurry has been applied to the substrate. The method of any one of claims 1 to 15, further comprising:

17. 17. The method of claim 16 when dependent on claim 15, wherein the thickness measurement is performed after the aerosol-generating material slurry has at least partially solidified.

18. The method of any one of claims 1 to 17, wherein the application of the aerosol-forming material slurry to the substrate is repeated at least once.

19. 20. The method of claim 18, wherein each application of the aerosol-forming material slurry to the substrate is an application of the aerosol-forming material slurry to one or more identical locations on the substrate.

20. 20. The method of claim 18, wherein the at least two applications of the aerosol-forming material slurry to the substrate are applications of the aerosol-forming material slurry to a surface of the substrate.

21. The method of any one of claims 18 to 20, wherein each application of the aerosol-forming material slurry to the substrate is performed using a different silk screen or rotary screen printing apparatus.

22. Moving the support along a manufacturing path. Further comprising: The method of any one of claims 1 to 21, wherein the production path comprises two or more silk screen machines, two or more rotary screen printing machines, or at least one silk screen machine and at least one rotary screen printing machine.

23. 23. The method of claim 15, or any one or more of claims 16 to 22 when dependent on claim 15, wherein the aerosol-generating material slurry applied to the substrate is at least partially solidified, or allowed to at least partially solidify, as the substrate moves between each silk screen or rotary screen printing apparatus.

24. A method according to claim 16 or any one or more of claims 17 to 23 when dependent on claim 16, wherein the thickness measurements are performed whilst the support moves between each silk screen or rotary screen printing apparatus.

25. the support is a longitudinally extending material extending in a direction X, At least two portions of an aerosol-forming material slurry are applied to the substrate; each group of aerosol-forming material slurries is comprised of at least one individual portion of aerosol-forming material slurries; and The method of any preceding claim, wherein the groups of aerosol-forming material slurry are spaced apart from one another in one or both of direction X or direction Y perpendicular to direction X.

26. The method according to claim 25 when dependent on any one of claims 22 to 24, wherein the production path extends in the direction X.

27. 27. The method of claim 18, or any one or more of claims 19 to 26 when dependent on claim 18, wherein at least one of the repetitions of applying the aerosol-generating material slurry to the substrate comprises applying an aerosol-generating material slurry of a first composition, and at least one of the repetitions of applying the aerosol-generating material slurry to the substrate comprises applying an aerosol-generating material slurry of a second composition.

28. 28. A method according to claim 15, or any one or more of claims 16 to 27 when dependent on claim 15, wherein the step of at least partially solidifying the aerosol-generating material slurry applied to the support comprises exposing the aerosol-generating material slurry to electromagnetic radiation having a wavelength in the range of 700 nanometers to 1 millimeter.

29. 28. The method of claim 15, or any one or more of claims 16 to 27 when dependent on claim 15, further comprising the step of forcibly cooling the aerosol-generating material slurry, the cooling being carried out after at least partially solidifying or after the aerosol-generating material slurry applied to the support has been at least partially solidified.

30. A method according to any preceding claim, wherein the support comprises a flexible sheet material.

31. The method of claim 30, wherein the support comprises one or more of a metal foil, a metal film, and a plastic film.

32. The method of claim 31 , wherein the support comprises aluminum foil.

33. The product includes at least one additional ingredient, and the method further comprises: applying the aerosol-forming material slurry to the substrate, followed by applying a first additional material to at least a portion of the aerosol-forming material previously applied to the substrate. Including, A method according to any preceding claim, wherein the first further material is applied to the aerosol-generating material using silk screen or rotary screen printing techniques.

34. 34. The method of claim 33, wherein a second or subsequent additional material is applied to at least a portion of one or more of the aerosol-generating material, the first additional material, and the second and subsequent additional materials after the application of the first or second or subsequent additional material.

35. 35. The method of claim 33 or 34, wherein one or more of the aerosol-generating material slurries applied to the support and further material are at least partially solidified or allowed to at least partially solidify prior to the subsequent application of further material.

36. 36. The method of any one of claims 33 to 35, wherein at least one of the first, second or subsequent further materials entirely overlies the aerosol-generating material or further material to which the first, second or subsequent further material is applied.

37. 37. The method of any one of claims 33 to 36, wherein at least one of the first, second or subsequent further material overlies less than all of the aerosol-generating material or further material to which it is applied.

38. 38. The method of any one of claims 1 to 37, wherein the product is larger than is compatible for use with a non-combustion aerosol delivery system, the method further comprising the step of configuring the product for storage.

39. 40. The method of claim 38, wherein the step of configuring the product for storage comprises winding the product on a bobbin or folding the product into an accordion shape.

40. 40. The method of claim 38 or 39, wherein the step of configuring the product for storage further comprises slitting the product into two or more longitudinally stretched strips.

41. the product is larger than is compatible for use with a non-combustion aerosol delivery system, the method further comprising separating the product into two or more product portions; The method of any one of claims 1 to 40, wherein each product portion is shaped and dimensioned for use as a consumable for use with a non-combustion aerosol delivery system.

42. 42. An article of manufacture for use in the manufacture of a consumable for use with a non-combustion aerosol delivery system, the article of manufacture being manufactured using the method of any one of claims 1 to 41.

43. 43. A consumable for use with a non-combustion aerosol delivery system, the consumable being a portion of the product of claim 42, said product portion being shaped and dimensioned in a desired configuration.

44. 44. The consumable product of claim 43, wherein the product portion is formed into a tube.

45. 45. The consumable of claim 44, wherein the tube has a cross-section that is substantially cylindrical or that is triangular, rectangular, square, polyhedral, approximately triangular, approximately rectangular, approximately square, or approximately polyhedral.

46. 46. ​​A consumable product according to claim 44 or 45, wherein at least one of the discrete portions of aerosol-forming material faces a hollow portion defined by the tube.

47. A consumable product according to any one of claims 44 to 46, wherein the hollow space defined by the tube is at least partially filled with a material that enhances the sensory experience of a user of the consumable product.

48. 48. An aerosol delivery device for use with a consumable according to any one of claims 43 to 47, comprising an aerosol generator configured to heat at least a portion of the aerosol generating material supported on the consumable.

49. An aerosol delivery system comprising the aerosol delivery device of claim 48 and the consumable product of any one of claims 43 to 47.

50. A method of generating an aerosol from a consumable according to any one of claims 43 to 47, using an aerosol generation device having at least one aerosol generator arranged to heat but not burn the consumable during use, the at least one aerosol generator being a resistive heater element, or a magnetic field generator and a susceptor.

51. A method of manufacturing a consumable according to any one of claims 43 to 47, comprising the use of silk screen or rotary printing techniques.

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