Method for Producing a Product Including an Aerosol-Forming Material

Abstract

An article (2) for use with a non-flammable aerosol delivery device is disclosed. The article (2) comprises an aerosol-generating material and a support (8). The support (8) has first and second opposed surfaces (10, 12), with at least one distinct portion (6) of the aerosol-generating material supported on the first surface (10) and at least one distinct portion (6) of the aerosol-generating material supported on the second surface (12).

Description

[Technical field]

[0001] The present disclosure relates to the field of non-flammable 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 of manufacturing consumables for use with aerosol delivery devices, and aerosol delivery systems including consumables and aerosol delivery devices.

[0002] Aerosol delivery systems generate an inhalable aerosol or vapor during use by releasing a compound from an aerosol-generating material, and may also be referred to as, for example, a non-combustible smoking article, an aerosol generating assembly, or an aerosol delivery device.

[0003] One example of such a product is an aerosol delivery device that releases a compound by heating, without combustion, an aerosol-forming material. The solid aerosol-forming material may optionally include botanical matter. Upon heating, at least one component of the aerosol-forming material is volatilized, typically resulting in an inhalable aerosol. These products may also be referred to as, for example, non-combustion heating devices, tobacco heating devices, or tobacco heating products.

[0004] Another example is a hybrid device. These hybrid devices include a liquid aerosol-generating material that vaporizes upon heating to produce an inhalable vapor or aerosol. They also include a solid aerosol-generating material, the components of which are entrained in the inhalable vapor or aerosol to produce the inhalation medium. Overview

[0005] According to a first aspect of the present disclosure, there is provided an article for use with a non-flammable aerosol delivery device, the article comprising an aerosol-generating material and a support, the support having first and second opposed surfaces, at least one discrete portion of the aerosol-generating material supported on the first surface and at least one discrete portion of the aerosol-generating material supported on the second surface.

[0006] According to a second aspect of the present disclosure, there is provided a consumable for use with a non-flammable aerosol delivery device, the consumable comprising a portion of an article of the first aspect of the present disclosure, the portion of the article configured in a shape and size suitable for use with the device.

[0007] According to a third aspect of the present disclosure, there is provided a method of making an article comprising an aerosol-generating material and a support, the method comprising the steps of: Providing a support; applying an aerosol-generating material to at least one predetermined area on a first surface of a support; applying an aerosol-generating material to at least one predetermined area on a second surface of the support; A method is provided, comprising:

[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 second aspect of the present disclosure, the aerosol delivery device comprising an aerosol generator configured to heat at least a portion of an aerosol-generating material supported by the consumable.

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

[0010] According to a sixth aspect of the present disclosure, there is provided a method for generating an aerosol from a consumable using an aerosol generation device comprising at least one aerosol generator arranged to heat, in use, the consumable according to the second aspect of the present disclosure without combustion, 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 thereof, given by way of example only and with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0012] [Figure 1] 1 is a schematic perspective view of a portion of a first embodiment of an article according to the present disclosure. FIG. [Diagram 2] 2 shows a cross-section of the article of FIG. 1 taken along section line AA'. [Diagram 3] 2 is a perspective view of a first embodiment of a consumable product constructed from the article of FIG. 1. [Figure 4] FIG. 2 is a schematic perspective view of a portion of a second embodiment of an article according to the present disclosure. [Diagram 5] 5 is a second schematic perspective view of the article of FIG. 4. [Figure 6] 5 shows a cross-section of the article of FIG. 4 taken along section line BB'. [Figure 7] 5 is a schematic perspective view of a first embodiment of a consumable item constructed from the article of FIG. 4. [Figure 8] 1A-1C are schematic perspective views of a method of constructing a cured or partially cured film of aerosol-generating material. Detailed Description

[0013] An article herein may be a consumable product, a component of a consumable product, or a product capable of constituting a consumable product.

[0014] In some embodiments, the consumable includes an aerosol-generating material, which may include an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, an aerosol modifier, one or more active constituents, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

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

[0016] According to the present disclosure, a "non-flammable" aerosol delivery system is one in which the aerosol-generating material (or components thereof) that constitute the aerosol delivery system is not combusted to facilitate delivery of at least one substance to a user.

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

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

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

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

[0022] In some embodiments, the present disclosure relates to a consumable product that includes an aerosol generating material and is configured for use with a non-flammable aerosol delivery device.

[0023] In some embodiments, the non-flammable aerosol delivery system (e.g., the non-flammable aerosol delivery device) can include a power source and a controller. The power source can be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that can be energized to provide power in the form of heat to an aerosol-generating material or a heat transfer material in proximity to the heat generating power source.

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

[0025] In some embodiments, a consumable for use with a non-flammable aerosol delivery device may comprise an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0026] According to a first aspect of the present disclosure, there is provided an article for use with a non-flammable aerosol delivery device, the article comprising an aerosol-generating material and a support, the support having first and second opposing surfaces, at least one distinct portion of the aerosol-generating material supported on the first surface and at least one distinct portion of the aerosol-generating material supported on the second surface.

[0027] In one embodiment of the above embodiments, the article is free-standing, and the article is free-standing when the length of the article is gripped at one end of the length in at least one direction across the first surface or the second surface of the support, and the article can extend horizontally without support from the gripper.

[0028] An advantage of the article of the present disclosure is that a support that is not rigid enough to be self-supporting can be used. The combination of at least one separate portion of aerosol-generating material on the first surface, the support, and at least one separate portion of aerosol-generating material on the second surface results in a sufficiently rigid and self-supporting article, as described above. As a result, the support of the article can be thinner than would be possible with known articles, and less material is used than with known articles, which is at least economically advantageous. Also, the thinner material used for the support has the advantage that when a consumable product formed by the article of the present disclosure is heated during use, particularly when the aerosol-generating material supported by the support is heated, less energy is required to heat the support than if the support were thicker. This results in an aerosol delivery device that is more energy efficient, and in the case of a battery or similarly powered device, this increases the battery life or the period before the device's power source needs to be recharged.

[0029] Until now, the thickness of the article (and consumables made therefrom) has been determined, at least in part, by the need for the article / consumable to be sufficiently rigid so that a user can handle it and insert it into a non-flammable aerosol delivery device without damage. This did not allow for the support to be made thinner. The article / consumable of the present disclosure reduces the limitations on the possibility of making the support thinner. It should be noted that once the article / consumable is used, the need for the support to be rigid is reduced or eliminated, i.e., all aerosol-generating material supported by the support is heated and no significant aerosol (or vapor that will later be converted into an aerosol) is further emitted. This is because the article / consumable is then discarded, and any bending or damage to the used article / consumable is not significant.

[0030] In one embodiment of the above embodiments, the article comprises an aerosol-forming material and a support.

[0031] In one embodiment of any of the above embodiments, when the article is dimensioned to be consumable, it is self-supporting if up to 30%, up to 40%, up to 50%, up to 60%, up to 70%, up to 80%, up to 90%, or up to 99% of the dimension of the article in a direction across the first surface or second surface of the support can extend horizontally without support from the gripper that grips the article.

[0032] In one embodiment of any of the above embodiments, the position, shape, and size of each of the at least one separate portion of the aerosol-generating material on the first surface and the position, shape, and size of each of the at least one separate portion of the aerosol-generating material on the second surface are such that the separate portions on the first and second surfaces at least partially correspond to each other. In one such embodiment, the at least partial correspondence between each of the at least one separate portion on the first and second surfaces means that the separate portions at least partially overlap each other when viewed perpendicular to one of the first and second surfaces. In some embodiments, for example, one of the separate portions on one surface may have a larger dimension than the separate portion on the other surface. Thus, when viewed perpendicular to one of the surfaces, the separate portion on one surface may appear to be entirely within the perimeter of the separate portion on the other surface.

[0033] In one embodiment of any of the above embodiments, the position, shape, and size of each of the at least one separate portions of the aerosol-generating material on the first surface and the position, shape, and size of each of the at least one separate portions of the aerosol-generating material on the second surface correspond to one another. In one such embodiment, the correspondence between each of the at least one separate portions on the first and second surfaces means that the separate portions completely overlap each other when viewed perpendicular to one of the first and second surfaces. In such an example, the separate portions on the first and second surfaces have the same size and shape, and the perimeters of the separate portions on each surface overlap each other when viewed perpendicular to one of the surfaces.

[0034] In one embodiment of any of the above embodiments, the position, shape, and size of the at least one distinct portion of the aerosol-generating material on the first surface and the position, shape, and size of the at least one distinct portion of the aerosol-generating material on the second surface are different. In such embodiments, the arrangement of the distinct portions on the first surface of the support may differ to a greater or lesser extent from the arrangement of the distinct portions on the second surface of the support. For example, the distinct portions on the first surface of the support may be arranged as at least one set of substantially parallel longitudinally stretched strips. Such strips provide resistance to bending of the support about an axis substantially perpendicular to the longitudinally stretched strips. On the second surface of the support, the aerosol-generating material may be arranged in a rectangular array of substantially circular portions. In some embodiments, the first surface may include a second set of substantially parallel longitudinally stretched strips that intersect with the first set of substantially parallel longitudinally stretched strips at an angle between 0° and 90° (e.g., one of 30, 45, 60, or 90°).

[0035] In one embodiment of any of the above embodiments, the article or consumable that the article comprises is for use in a non-flammable aerosol delivery device configured to heat aerosol-generating material on first and second surfaces of a support, the device configured to allow a user to inhale the vapor and aerosol regardless of the surface of the support that is the source of such vapor / vapor-transformed aerosol.

[0036] In one embodiment of any of the above embodiments, the support includes a plurality of perforations or openings extending between the first and second surfaces of the support and allowing aerosols and vapors to pass from one side of the support to the other.

[0037] In one embodiment of any of the above embodiments, the composition of the aerosol-generating material of the at least one distinct portion of aerosol-generating material on the first surface is different from the composition of the at least one distinct portion of aerosol-generating material on the second surface, which may enhance and / or alter the user experience when using the consumable.

[0038] In one embodiment of any of the above embodiments, a thickness of the at least one distinct portion of aerosol-generating material on the first surface is different from a thickness of the at least one distinct portion of aerosol-generating material on the second surface.

[0039] In one embodiment of any of the above embodiments, the thickness of the at least one distinct portion of aerosol-generating material on the first surface is substantially the same as the thickness of the at least one distinct portion of aerosol-generating material on the second surface.

[0040] In one embodiment of the above embodiment, each of the distinct portions on the surface of the support is of substantially the same thickness.

[0041] In one embodiment of any of the above embodiments, the support has a thickness of 0.025 mm or less, hi some embodiments, the support has a thickness of less than 0.020 mm, less than 0.015 mm, less than 0.010 mm, around 0.020 mm, or around 0.007 mm.

[0042] In one embodiment of any of the above embodiments, the article has a thickness of 0.100 mm to 0.610 mm. In some embodiments, the support may have a thickness in the range of 0.005 mm to 0.020 mm, and the thickness of the aerosol-generating material is 0.040 mm to 0.301 mm on each of the first and second surfaces of the support. In other embodiments, the support may have a thickness in the range of 0.005 mm to 0.020 mm, and the cumulative thickness of the aerosol-generating material on the first and second surfaces of the support is 0.080 mm to 0.602 mm.

[0043] It is to be understood that the thickness of the article is the maximum thickness of the article measured in a direction perpendicular to the first or second surface of the support at the location where the measurement is made.

[0044] According to a second aspect of the present disclosure, there is provided a consumable for use with a non-flammable aerosol delivery device, the consumable comprising a portion of an article of the first aspect of the present disclosure, the portion of the article configured in a shape and size suitable for use with the device.

[0045] According to a third aspect of the present disclosure, there is provided a method of making an article comprising an aerosol-generating material and a support, the method comprising the steps of: Providing a support; applying an aerosol-generating material to at least one predetermined area on a first surface of a support; applying an aerosol-generating material to at least one predetermined area on a second surface of the support; A method is provided, comprising:

[0046] In one embodiment of the above embodiments, the article is free-standing when the length of the article is gripped at one end of the length and the product can extend horizontally unsupported from the gripper in at least one direction across the first or second surface of the support.

[0047] In one embodiment of any of the above embodiments, when the article is dimensioned to be consumable, it is self-supporting if up to 30%, up to 40%, up to 50%, up to 60%, up to 70%, up to 80%, up to 90%, or up to 99% of the dimension of the article in a direction across the first surface or second surface of the support can extend horizontally without support from the gripper that grips the article.

[0048] In one embodiment of any of the above embodiments, the article comprises an aerosol-forming material and a support.

[0049] In one embodiment of any of the above embodiments, the step of applying the aerosol-forming material includes applying a slurry of the aerosol-forming material.

[0050] In one embodiment of any of the above embodiments, the method further includes allowing or effecting hardening of the aerosol-generating material slurry applied to the first surface of the support, where the aerosol-generating material slurry hardens into an aerosol-generating material that, as it hardens, loses a majority of its volume and therefore thickness as a result of evaporation of a solvent used to form the aerosol-generating material slurry.

[0051] In one embodiment of any of the above embodiments, the method further includes allowing or performing hardening or at least partial hardening of the aerosol-generating material slurry applied to the first surface of the support before the aerosol-generating material slurry is applied to the second surface of the support.

[0052] In one embodiment of any of the above embodiments, the step of effecting curing of the aerosol-generating material slurry applied to the first surface of the support includes using ultraviolet radiation, which helps accelerate the curing of the aerosol-generating material slurry, although in other embodiments, alternative or additional known techniques for increasing the rate of curing of the aerosol-generating material slurry may be used.

[0053] In one embodiment of any of the above embodiments, the steps of applying the aerosol-generating material to the first surface of the support and allowing or causing the aerosol-generating material slurry applied to the first surface of the support to cure or at least partially cure are repeated one or more times. In such embodiments, there may be a predetermined desired thickness of the aerosol-generating material. In such embodiments, the aerosol-generating material may be applied in two or more layers, which may provide better control of the final thickness than a single application of the aerosol-generating material. It has also been found that a thinner layer of aerosol-generating material provides more uniform and consistent curing than a thicker layer of aerosol-generating material. It has also been found that such a thinner layer provides a shorter cumulative cure time than a thicker layer of the same final thickness.

[0054] In one embodiment of any of the above embodiments, the method further includes measuring a thickness of the cured or partially cured aerosol-generating material applied to the first surface of the support.

[0055] In one embodiment of any of the above embodiments, the method further includes forming a cured or partially cured film of aerosol-generating material on the film-forming surface and separating the cured or partially cured film of aerosol-generating material from the film-forming surface. The step of applying the aerosol-generating material to the first surface of the support includes applying a cured or partially cured film of aerosol-generating material to the first surface of the support. In such an embodiment, the cured or partially cured film is formed on a separate surface, which has the advantage that film formation can occur separately from the manufacture of the article of the present disclosure. This is advantageous because the use of a cured or partially cured film in the manufacture of the article of the present disclosure is likely to be quicker than producing a cured or partially cured film.

[0056] In one embodiment of any of the above embodiments, the method further includes providing a film of cured or partially cured aerosol-generating material, and the step of applying the aerosol-generating material to the first surface of the support includes applying the film of cured or partially cured aerosol-generating material to the first surface of the support. In such an embodiment, the cured or partially cured film is formed on a separate surface, which has the advantage that film formation occurs separately from the manufacture of the article of the present disclosure. This is advantageous because the use of a cured or partially cured film in the article of the present disclosure is likely to be quicker than producing a cured or partially cured film.

[0057] In one embodiment of any of the above embodiments, the method further includes measuring a thickness of the cured or partially cured aerosol-forming material film.

[0058] In one embodiment of any of the above embodiments, the step of applying the cured or partially cured film of aerosol-generating material is repeated one or more times.

[0059] In one embodiment of any of the above embodiments, the step of applying the aerosol-forming material to the second surface of the support includes applying a slurry of the aerosol-forming material.

[0060] In one embodiment of any of the above embodiments, the method further includes allowing or effecting hardening or at least partial hardening of the aerosol-generating material slurry applied to the second surface of the support, wherein the aerosol-generating material slurry hardens into an aerosol-generating material.

[0061] In one embodiment of any of the above embodiments, the step of curing or at least partially curing the aerosol-generating material slurry applied to the second surface of the support includes using ultraviolet radiation to help accelerate the curing of the aerosol-generating material slurry, while in other embodiments, alternative or additional known techniques for increasing the rate of curing of the aerosol-generating material slurry may be used.

[0062] In one embodiment of any of the above embodiments, the steps of applying the aerosol-generating material to the second surface of the support and allowing or causing the aerosol-generating material slurry applied to the second surface of the support to harden or at least partially harden are repeated one or more times, which has the advantages discussed above.

[0063] In one embodiment of any of the above embodiments, the method further includes measuring a thickness of the cured or at least partially cured aerosol-generating material applied to the second surface of the support.

[0064] In one embodiment of any of the above embodiments, the method further comprises forming a film of cured or partially cured aerosol-generating material on the film forming surface and separating the film of cured or partially cured aerosol-generating material from the film forming surface, and the step of applying the aerosol-generating material to the second surface comprises applying the film of cured or partially cured aerosol-generating material to the second surface of the support, the advantages of which are as described above.

[0065] In one embodiment of any of the above embodiments, the method further comprises providing a film of cured or partially cured aerosol-generating material, and the step of applying the aerosol-generating material to the second surface comprises applying the cured or partially cured film of aerosol-generating material to the second surface of the support, the advantages of this approach being as described above.

[0066] In one embodiment of any of the above embodiments, the method further includes measuring a thickness of the cured or partially cured aerosol-forming material film.

[0067] In one embodiment of any of the above embodiments, the step of applying the aerosol-forming material to the second surface of the support is repeated one or more times.

[0068] In one embodiment of any of the above embodiments, the haptic portion is less than 0.025 mm thick. In some embodiments, the haptic portion has a thickness of less than 0.020 mm, less than 0.015 mm, less than 0.010 mm, around 0.020 mm, or around 0.007 mm.

[0069] In one embodiment of any of the above embodiments, the support is a metal foil. In some embodiments, the support is an aluminum foil.

[0070] In one embodiment of any of the above embodiments, the step of applying the aerosol-generating material to one or both of the first and second surfaces of the support comprises applying separate portions of the aerosol-generating material to two or more predetermined areas on one or both surfaces of the support.

[0071] In one embodiment of any of the above embodiments, the position, shape, and dimensions of each of the at least one separate portion of aerosol-generating material on the first surface and the position, shape, and dimensions of each of the at least one separate portion of aerosol-generating material on the second surface are such that the separate portions on the first surface and the second surface at least partially correspond to each other.

[0072] In one embodiment of any of the above embodiments, the position, shape, and size of each of the at least one separate portion of aerosol-generating material on the first surface and the position, shape, and size of each of the at least one separate portion of aerosol-generating material on the second surface correspond to each other.

[0073] In one embodiment of any of the above embodiments, the position, shape, and size of the at least one distinct portion of the aerosol-generating material on the first surface and the position, shape, and size of the at least one distinct portion of the aerosol-generating material on the second surface are different.

[0074] In one embodiment of any of the above embodiments, the composition of the at least one distinct portion of aerosol-generating material on the first surface differs from the composition of the at least one distinct portion of aerosol-generating material on the second surface.

[0075] In one embodiment of any of the above embodiments, a thickness of the at least one distinct portion of aerosol-generating material on the first surface is different from a thickness of the at least one distinct portion of aerosol-generating material on the second surface.

[0076] In one embodiment of any of the above embodiments, the thickness of the at least one distinct portion of aerosol-generating material on the first surface is substantially the same as the thickness of the at least one distinct portion of aerosol-generating material on the second surface.

[0077] In one embodiment of any of the above embodiments, the article has a thickness of 0.085 mm to 0.610 mm.

[0078] In one embodiment of any of the above embodiments, two or more folds are formed in the support.

[0079] In one embodiment of any of the above embodiments, two or more predetermined areas are disposed on one or both of the first and second surfaces of the support such that creases may be formed between the predetermined areas on one or both of the first and second surfaces of the support.

[0080] In one embodiment of any of the above embodiments, the folds may be spaced apart such that the item may be folded in an accordion-like manner, thereby allowing the item to be stored compactly.

[0081] In one embodiment of any of the above embodiments, the article is larger than a size compatible for use with the non-flammable aerosol delivery system, and the method further includes configuring the article for storage.

[0082] In one embodiment of any of the above embodiments, the article is larger than a size compatible for use with the non-flammable aerosol delivery system, and the method further includes separating the article into two or more article portions, each article portion shaped and dimensioned for use as a consumable for use with the non-flammable aerosol delivery system.

[0083] An aerosol-forming material is a material that is capable of generating an aerosol when energized, e.g., by heating, irradiating, or in any other manner. The aerosol-forming material may be, for example, in solid, liquid, or semi-solid (e.g., gel) form, and may or may not contain active substances and / or flavorings.

[0084] The aerosol-generating material may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0085] The aerosol-generating material may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a delivery substance and / or a filler may also be present. Optionally, a solvent, such as water, may also be present, in which one or more other components of the aerosol-generating material may or may not be soluble. In some embodiments, the aerosol-generating material is substantially free of plant matter. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0086] The aerosol-generating material may include or be in the form of an aerosol-generating film. The aerosol-generating film may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a delivery substance and / or a filler may also be present. The aerosol-generating film may be substantially free of plant matter. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0087] The aerosol-generating film may have a thickness of from about 0.015 mm to about 1 mm. For example, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

[0088] The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-forming agent, and one or more other ingredients (e.g., one or more delivery substances) to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent.

[0089] The slurry may be adapted such that at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent is removed by heating.

[0090] The aerosol-generating material may include or be an "amorphous solid." In some embodiments, the aerosol-generating material includes an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid." The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that is capable of retaining some fluid therein, such as a liquid. In some embodiments, the amorphous solid may include, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0091] The amorphous solid may be substantially free of plant matter.The amorphous solid may be substantially free of tobacco.

[0092] A susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that the penetration of a varying magnetic field causes inductive heating of the susceptor by resistive heating as a result of eddy currents. The susceptor may be a magnetic material, such that the penetration of a varying magnetic field causes magnetic hysteresis heating of the susceptor. The susceptor may be bi-directional, such that it can be heated by both conductive and magnetic heating mechanisms. A device configured to generate a varying magnetic field is referred to as a magnetic field generator.

[0093] The susceptor may comprise a ferromagnetic metal (such as iron) or an iron alloy (such as steel) or an iron-nickel alloy. Some exemplary ferromagnetic metals are 400 series stainless steel, such as 410 grade stainless steel, 420 grade stainless steel, 430 grade stainless steel, or similar grade stainless steel. Alternatively, the susceptor may comprise a suitable non-magnetic, particularly paramagnetic, conductive material, such as aluminum. In a paramagnetic conductive material, induction heating occurs solely through resistive heating due to eddy currents. Alternatively, the susceptor may comprise a non-conductive ferrimagnetic material, such as a non-conductive ferrimagnetic ceramic. In this case, heat is generated solely through hysteresis losses. The susceptor may comprise a commercially available alloy, such as Phytherm 230 (composition including 50 wt% Ni, 10 wt% Cr, and the rest Fe (weight % = wt%) or Phytherm 260 (composition including 50 wt% Ni, 9 wt% Cr, and the rest Fe).

[0094] In one embodiment of any of the above embodiments, the aerosol forming material includes an active agent.

[0095] As used herein, an active substance may be a physiologically active material (a material intended to produce or enhance a physiological response). The active substance may be selected from, for example, dietary supplements, psychotropic drugs, psychoactive agents. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, terpenes of non-cannabinoid origin, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may include one or more constituents, derivatives, or extracts of tobacco, cannabis, or another plant.

[0096] The active substance may include one or more constituents, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0097] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0098] The active material may include or be derived from one or more botanical substances or constituents, derivatives or extracts thereof. As used herein, the term "botanical" may include any material derived from a plant, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, pods, etc. Alternatively, the material may include active compounds naturally present in plants or synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, chips, strips, sheets, etc. Exemplary plants include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, Lavender, lemon peel, mint, juniper, elderberry, vanilla, wintergreen, sedge, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiene, marjoram, olive, lemon balm, lemon basil, chives, ribeye, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0099] In some embodiments, the active agent comprises or is derived from one or more botanical substances or constituents, derivatives or extracts thereof, and the plant is tobacco.

[0100] In some embodiments, the active agent comprises or is derived from one or more botanical substances or constituents, derivatives or extracts thereof, the plant being selected from eucalyptus, star anise, cocoa, and hemp.

[0101] In some embodiments, the active agent comprises or is derived from one or more botanical substances or constituents, derivatives or extracts thereof, the plant being selected from rooibos and fennel.

[0102] In some embodiments, the aerosol-forming material comprises a fragrance or flavoring.

[0103] As used herein, the terms "flavour" and "flavourant" refer to materials that can be used to produce a desired flavour, aroma, or other sensory experience in products intended for adult consumers, where local regulations permit.These include naturally occurring flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, heat, spices, flavors, aromas, flavor ... Belly fruit, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberries, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pineapple, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, i Lang ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil of any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, yerba mate, orange skin, rose, tea such as green or black tea, thyme, juniper, elderberry, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiogamag ... damiene, marjoram, olive, lemon balm, lemon basil, chives, ribes, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulators, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be imitation, synthetic or natural ingredients, or mixtures 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.

[0104] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavor components extracted from tobacco. In some embodiments, the flavoring comprises flavor components extracted from cannabis.

[0105] In some embodiments, the fragrance may include sensates intended to achieve the sensations usually chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves, and these may include agents that produce a heating, cooling, tingling, or numbing effect.Suitable heating agents may be, but are not limited to, vanillyl ethyl ether.Suitable cooling agents may be, but are not limited to, eucalyptol, WS-3.

[0106] The aerosol generating material includes an aerosol generating agent. In some embodiments, the aerosol generating agent may include one or more constituents capable of forming an aerosol. In some embodiments, the aerosol generating agent may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl sulfate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In certain examples, the aerosol generating agent includes glycerol.

[0107] In some embodiments, the aerosol generating agent comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols, such as glycerol monoacetate, diacetate, or triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0108] In some embodiments, the aerosol-generating material may comprise from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10 wt% to about 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of the aerosol-generating agent (all calculated on a dry weight basis). The aerosol-generating agent may act as a plasticizer. For example, the aerosol-generating material may comprise from 0.5 to 40 wt%, from 3 to 35 wt%, or from 10 to 25 wt% of the aerosol-generating agent.

[0109] 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.

[0110] In some embodiments, the aerosol-forming material may include up to about 80 wt% aerosol-generating agent (DWB), such as about 40-80 wt%, 40-75 wt%, 50-70 wt%, or 55-65 wt%.

[0111] The aerosol-generating material may also include a gelling agent. In some embodiments, the gelling agent includes a hydrocolloid. In some embodiments, the gelling agent includes one or more compounds selected from the group including alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohols, and combinations thereof. For example, in some embodiments, the gelling agent includes one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the gelling agent includes alginates and / or pectins, which are combined with a hardening agent (such as a calcium source) during formation of the aerosol-generating material. In some embodiments, the aerosol-generating material may include calcium cross-linked alginates and / or calcium cross-linked pectins.

[0112] 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.

[0113] In some embodiments, the cellulose gelling agent is selected from the group consisting of hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0114] 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.

[0115] 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.

[0116] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the aerosol-forming material in an amount of 10-30 wt % (calculated on a dry weight basis) of the aerosol-forming material. In some embodiments, the only gelling agent present in the aerosol-forming material is alginate. In other embodiments, the gelling agent comprises alginate and at least one other gelling agent, such as pectin.

[0117] In some embodiments, the aerosol-forming material comprises from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of a gelling agent (all calculated on a dry weight basis). For example, the aerosol-forming material may comprise from 1 to 50 wt%, 5 to 45 wt%, 10 to 40 wt%, or 20 to 35 wt% of a gelling agent.

[0118] In some embodiments, the aerosol-forming material comprises from about 20 wt%, 22 wt%, 24 wt%, or 25 wt% to about 30 wt%, 32 wt%, or 35 wt% of the gelling agent (all calculated on a dry weight basis). For example, the aerosol-forming material may comprise from 20 to 35 wt% or from 25 to 30 wt% of the gelling agent.

[0119] In some cases, the aerosol-forming material may include from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, or 20% to about 60 wt%, 50 wt%, 40 wt%, 30 wt%, or 25 wt% of the gelling agent (DWB). For example, the aerosol-forming material may include from 10 to 40 wt%, 15 to 30 wt%, or 20 to 25 wt% of the gelling agent (DWB).

[0120] For example, the aerosol-forming material may comprise, in total, the gelling agent and the bulking agent in an amount of about 10 wt%, 20 wt%, 25 wt%, 30 wt%, or 35% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the aerosol-forming material. For example, the aerosol-forming material may comprise, in total, the gelling agent and the bulking agent in an amount of about 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt% of the aerosol-forming material.

[0121] By way of example, the aerosol-forming material may comprise a gelling agent in an amount of about 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, or 35% to about 60 wt%, 55 wt%, 50 wt%, or 45 wt% of the aerosol-forming material (i.e., not taking into account the amount of filler). By way of example, the aerosol-forming material may comprise a gelling agent in an amount of about 5-60 wt%, 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt% of the aerosol-forming material (i.e., not taking into account the amount of filler).

[0122] In some examples, the alginate is included in the gelling agent in an amount of about 5-40 wt% or 15-40 wt% of the aerosol-forming material, i.e., the aerosol-forming material comprises alginate in an amount of about 5-40 wt% or 15-40 wt% of the aerosol-forming material by dry weight, in some examples, the aerosol-forming material comprises alginate in an amount of about 20-40 wt% or about 15 wt% to 35 wt% of the aerosol-forming material.

[0123] In some examples, the pectin is included in the gelling agent in an amount of about 3-15 wt% of the aerosol-forming material, i.e., the aerosol-forming material comprises pectin in an amount of about 3-15 wt% of the aerosol-forming material by dry weight, hi some examples, the aerosol-forming material comprises pectin in an amount of about 5-10 wt% of the aerosol-forming material.

[0124] In some examples, the guar gum is present in the gelling agent in an amount of about 3-40 wt% of the aerosol-generating material. That is, the aerosol-generating material comprises guar gum in an amount of about 3-40 wt% of the aerosol-generating material by dry weight. In some examples, the aerosol-generating material comprises guar gum in an amount of about 5-10 wt% of the aerosol-generating material. In some examples, the aerosol-generating material comprises guar gum in an amount of about 15-40 wt%, or about 20-40 wt%, or about 15-35 wt% of the aerosol-generating material.

[0125] For example, the alginate is present in an amount of at least about 50 wt% of the gelling agent. For example, the aerosol-forming material includes alginate and pectin, and the ratio of alginate to pectin is 1:1 to 10:1. The ratio of alginate to pectin is usually greater than 1:1. That is, the alginate is present in an amount greater than the amount of pectin. For example, the ratio of alginate to pectin is about 2:1 to 8:1, or about 3:1 to 6:1, or about 4:1.

[0126] The aerosol-generating material may be formed by (a) forming a slurry including components of the aerosol-generating material or a precursor thereof, (b) forming a layer of the slurry, (c) curing the slurry to form a gel, and (d) drying to form the aerosol-generating material.

[0127] (b) Forming the slurry layer typically involves spraying, casting, or extruding the slurry. For example, the slurry layer may be formed by electrospraying the slurry. For example, the slurry layer may be formed by casting the slurry.

[0128] In some instances, (b), and / or (c), and / or (d) occur at least partially simultaneously (e.g., in an electrospray). In some instances, (b), (c), and (d) occur sequentially.

[0129] In some instances, the slurry may be applied to a support such that a layer is formed on the support.

[0130] By way of example, the slurry may include a gelling agent, an aerosol-forming material, and an active agent. The slurry may include these components in any of the proportions described herein for the composition of the aerosol-generating material. For example, the slurry may include (on a dry weight basis): a gelling agent and optionally a filler, the amount of gelling agent and filler together being about 10-60 wt% of the slurry; an aerosol-forming material in an amount of about 40-80 wt % of the slurry; Optionally, an active material in an amount of up to about 20 wt. % of the slurry; and may also include

[0131] Hardening the gel (c) may include providing a hardening agent to the slurry, for example the slurry may include sodium, potassium or ammonium alginate as a gel precursor and the addition of a hardening agent to the slurry including a calcium source (such as calcium chloride) to form a calcium alginate gel.

[0132] By way of example, the sclerosing agent may include or consist of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the sclerosing agent may include or consist of calcium formate and / or calcium lactate. In certain examples, the sclerosing agent may include or consist of calcium formate. The inventors have determined that when calcium formate is employed as a sclerosing agent, the aerosol generating material typically exhibits higher tensile strength and resistance to elongation.

[0133] The total amount of hardening 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 about 1 wt %, 2.5 wt %, or 4 wt % to about 4.8 wt % or 4.5 wt %. The inventors have found that if too little hardening agent is added, the components of the aerosol-generating material may not be stable and may drop out of the aerosol-generating material. Also, if too much hardening agent is added, the aerosol-generating material may become very sticky and therefore difficult to handle.

[0134] If the aerosol-forming material does not contain tobacco, it may be necessary to apply more stiffening agent. Thus, in some cases, the total amount of stiffening agent may be 0.5 to 12 wt %, such as 5 to 10 wt %, calculated on a dry weight basis. Suitably, the total amount may be from about 5 wt %, 6 wt %, or 7 wt % to about 12 wt % or 10 wt %. In this case, the aerosol-forming material will generally not contain any tobacco.

[0135] Applying the hardener to the slurry may include spraying the hardener onto the slurry, such as on top of the slurry, or may include combining the hardener with the slurry prior to casting the slurry.

[0136] Alginates are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) linked together by (1,4)-glycosidic bonds to form a polysaccharide. Upon addition of calcium cations, alginates crosslink to form a gel. Alginates with a high G monomer content have been found to gel more readily with the addition of a calcium source. Thus, in some cases, the gel precursor may include an alginate in which at least about 40%, 45%, 50%, 55%, 60%, or 70% of the monomer units in the alginic acid copolymer are α-L-guluronic acid (G) units.

[0137] For example, drying (d) removes from about 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% to about 80 wt%, 90 wt%, or 95 wt% (WWB) of the water in the slurry. For example, drying (d) reduces the thickness of the cast material by at least 80%, preferably 85% or 87%. For example, the slurry is cast to a thickness of 2 mm and the resulting dried aerosol-generating material has a thickness of 0.2 mm.

[0138] 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).

[0139] In instances where the solvent comprises water, the dry weight content of the slurry may correspond to the dry weight content of the aerosol-forming material, such that any discussion herein of solid components is expressly disclosed in conjunction with the slurry aspects of the invention.

[0140] The aerosol-forming material may include a flavoring. Suitably, the aerosol-forming material may include up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% of flavoring. Optionally, the aerosol-forming material may include at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% of flavoring (all calculated on a dry weight basis). For example, the aerosol-forming material may include 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, 30-45 wt%, or 1-30 wt% of flavoring. Optionally, the flavoring includes, consists essentially of, or consists of menthol.

[0141] The aerosol-forming material may include a bulking agent.

[0142] 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%.

[0143] In other embodiments, the aerosol forming material contains less than 20 wt%, preferably less than 10 wt% or less than 5 wt% of a filler. Optionally, the aerosol forming material contains less than 1 wt% of a filler, and optionally no filler.

[0144] In some cases, the aerosol-forming material comprises at least 1 wt% filler (e.g., at least 5 wt%, at least 10 wt%, at least 20 wt%, at least 30 wt%, at least 40 wt%, or at least 50 wt% filler), hi some embodiments, the aerosol-forming material comprises between 5 and 25 wt% filler.

[0145] When present, the filler may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler may also include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives (e.g., methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). In certain cases, the aerosol-generating material does not include calcium carbonate, such as chalk.

[0146] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fiber, cellulose, or a cellulose derivative (e.g., methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)).

[0147] Without being bound by theory, it is believed that including a fibrous filler in the aerosol-generating material may increase the tensile strength of the material, which may be particularly advantageous in instances where the aerosol-generating material is provided as a sheet, such as when the sheet defines a rod of aerosolizable material.

[0148] In some embodiments, the aerosol-forming material does not include tobacco fibers. In some embodiments, the aerosol-forming material does not include fibrous materials.

[0149] The aerosol-generating material may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0150] In some embodiments, the aerosol-forming material further comprises an active agent. For example, the aerosol-forming material optionally further comprises tobacco material and / or Nichicon. In some embodiments, the aerosol-forming material further comprises powdered tobacco, and / or nicotine, and / or tobacco extract.

[0151] In some cases, the aerosol-forming material may comprise between 5 and 60 wt% (calculated on a dry weight basis) of tobacco material and / or nicotine. In some cases, the aerosol-forming material may comprise between about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of an active substance. In some cases, the aerosol-forming material may comprise between about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of tobacco material. For example, the aerosol-forming material may include 10-50 wt%, 15-40 wt%, or 20-35 wt% tobacco material. In some cases, the aerosol-forming material may include about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% nicotine (calculated on a dry weight basis). For example, the aerosol-forming material may include 1-20 wt%, 2-18 wt%, or 3-12 wt% nicotine.

[0152] In some cases, the aerosol-forming material includes an active agent such as a tobacco extract. In some cases, the aerosol-forming material may include 5-60 wt% tobacco extract (calculated on a dry weight basis). In some cases, the aerosol-forming material may include about 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% tobacco extract (calculated on a dry weight basis). For example, the aerosol-forming material may include 10-50 wt%, 15-40 wt%, or 20-35 wt% tobacco extract. The tobacco extract may contain nicotine in a concentration such that the aerosol-forming material contains from 1 wt%, 1.5 wt%, 2 wt%, or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt%, or 4 wt% nicotine (calculated on a dry weight basis). In some cases, no nicotine may be present in the aerosol-forming material other than the nicotine from the tobacco extract.

[0153] In some embodiments, the aerosol-forming material does not include tobacco material and does include nicotine. In some cases, the aerosol-forming material may include from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% nicotine (calculated on a dry weight basis). For example, the aerosol-forming material may include from 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% nicotine.

[0154] In some cases, the total content of actives and / or flavorings may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or flavorings may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis). In some cases, the total content of tobacco material, nicotine, and flavorings may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or fragrances may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0155] The aerosol-generating composition may include one or more active agents. In some examples, the aerosol-generating material includes one or more active agents (e.g., up to about 20 wt% of the aerosol-generating material). For example, the aerosol-generating material includes active agents in an amount of about 1 wt%, 5 wt%, 10 wt%, or 15% to about 20 wt%, 15 wt%, 15 wt%, or 5 wt% of the aerosol-generating material.

[0156] The active substances may include physiologically and / or olfactory active substances that are included in the aerosol forming composition to achieve a physiological and / or olfactory response.

[0157] 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%.

[0158] The tobacco material may be in any form, but is typically shredded (e.g., cut into small pieces). Shredded tobacco material is advantageous because it can be mixed with an aerosol-forming material to provide an aerosol-forming composition having a uniform distribution of tobacco material and aerosol-forming material throughout.

[0159] By way of example, the tobacco material comprises one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extract. Surprisingly, the inventors have determined that relatively large amounts of laminar tobacco can be used in the aerosol-generating composition and still provide an acceptable aerosol when heated by a non-combustible aerosol delivery system. Laminar tobacco typically provides superior sensory properties. By way of example, the tobacco material comprises laminar tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material. In certain examples, the tobacco material comprises cut tobacco in an amount of at least about 50 wt%, 60 wt%, 70 wt%, 80 wt%, 85 wt%, 90 wt%, or 95 wt% of the tobacco material.

[0160] The tobacco used to produce the tobacco material may be any suitable tobacco, such as a single grade or blend, cut rag or whole leaf, including Virginia, and / or Burley, and / or Oriental.

[0161] In some embodiments, the one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0162] Optionally, the aerosol-forming material may additionally include an emulsifier to emulsify the molten flavoring during preparation. For example, the aerosol-forming material may include about 5 wt% to about 15 wt%, preferably about 10 wt% (calculated on a dry weight basis) of an emulsifier. The emulsifier may include gum acacia.

[0163] In some embodiments, the aerosol-forming material is a hydrogel and contains less than about 20 wt% water, calculated on a wet weight basis. Optionally, the hydrogel contains less than about 15 wt%, 12 wt%, or 10 wt% water, calculated on a wet weight basis. Optionally, the hydrogel contains at least about 1 wt%, 2 wt%, or at least about 5 wt% water (WWB).

[0164] The aerosol-forming material may have any suitable water content, such as between 1 wt% and 15 wt%. Preferably, the water content of the aerosol-forming material is between about 5 wt%, 7 wt%, or 9 wt% and about 15 wt%, 13 wt%, or 11 wt% (WWB), most preferably about 10 wt%. The water content of the aerosol-forming material may be determined, for example, by Karl-Fischer titration or Gas Chromatography with Thermal Conductivity Detector (GC-TCD).

[0165] 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.

[0166] In some cases, the aerosol-forming materials may consist essentially of or consist of gelling agent, water, aerosol-forming agent, flavorings, and optionally tobacco materials and / or a nicotine source.

[0167] By way of example, the aerosol-forming material may consist essentially of, or consist of, a gelling agent, an aerosol-forming agent, an active substance, and water.By way of example, the aerosol-forming material may consist essentially of, or consist of, a gelling agent, an aerosol-forming agent, and water.

[0168] As an example, the aerosol-forming material does not include flavorants. In certain instances, the aerosol-forming material does not include active agents.

[0169] 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 fragrance, Including, These weights are calculated on a dry weight basis.

[0170] In some embodiments, the aerosol-forming material comprises 1-80 wt % (dry weight basis) of flavoring.

[0171] In some embodiments, the aerosol-forming material comprises: 1 to 50 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol generating agent; 30-60wt% fragrance, Including, These weights are calculated on a dry weight basis.

[0172] 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 to 60 wt % of a gelling agent; Including, These weights are calculated on a dry weight basis.

[0173] 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.

[0174] In some embodiments, the aerosol-generating material comprises 20-35 wt.% gelling agent, 10-25 wt.% aerosol-forming material, 5-25 wt.% fiber-containing filler, and 35-50 wt.% flavoring and / or active agent.

[0175] In some cases, the aerosol-forming materials may consist essentially of or consist of a gelling agent, an aerosol-forming agent, tobacco extract, water, and optional flavorings. In some cases, the aerosol-forming materials may consist essentially of or consist of glycerol, alginate and / or pectin, tobacco extract, and water.

[0176] In some embodiments, the aerosol-generating material may have a composition (DWB) as follows: a gelling agent (preferably including alginate) in an amount of about 5 wt% to about 40 wt%, or about 10 wt% to 30 wt%, or about 15 wt% to about 25 wt%, a tobacco extract in an amount of about 30 wt% to about 60 wt%, or about 40 wt% to 55 wt%, or about 45 wt% to about 50 wt%, and an aerosol-generating agent (preferably including glycerol) in an amount of about 10 wt% to about 50 wt%, or about 20 wt% to about 40 wt%, or about 25 wt% to about 35 wt% (DWB).

[0177] 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).

[0178] The "thickness" of an aerosol-generating material refers to the shortest distance between a first surface and a second surface. In embodiments in which the aerosol-generating material is in the form of a sheet, the thickness of the aerosol-generating material is the shortest distance between a first planar surface of the sheet and a second surface of the sheet opposite the first planar surface of the sheet.

[0179] In some cases, the layer of aerosol-forming material for forming the aerosol has a thickness of about 0.015 mm to about 1.5 mm, preferably about 0.05 mm to about 1.5 mm or 0.05 mm to about 1.0 mm. Preferably, the thickness may be in the range of about 0.1 mm or 0.15 mm to about 1.0 mm, 0.5 mm, or 0.3 mm.

[0180] In some cases, the aerosol-forming material may have a thickness of from about 0.015 mm to about 1.0 mm. Suitably, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

[0181] A material having a thickness of 0.2 mm is particularly suitable. The aerosol-generating material may comprise two or more layers, and the thicknesses given herein refer to the combined thicknesses of these layers.

[0182] It has been found that if the aerosol-generating material is too thick, it will heat less efficiently, which will have a negative impact on power consumption during use. Conversely, if the aerosol-generating material is too thin, it will be difficult to manufacture and handle. If the material is too thin, it will be more difficult to mold and may even be fragile, compromising aerosol formation during use.

[0183] The thicknesses specified herein are the average thickness of the material. In some cases, the thickness of the aerosol-generating material may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1%.

[0184] 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.

[0185] Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is formed into a sheet, which is then chopped and incorporated into an aerosol product. In some instances, such as where the aerosol-generating material includes a filler, the aerosol-generating material may have a tensile strength of around 600N / m to 900N / m, or 700N / m to 900N / m, or 800N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material is included in an aerosol product / assembly as a rolled sheet, preferably in the form of a tube.

[0186] In some examples, the aerosol-generating material in sheet form may have a tensile strength of about 200 N / m to about 2600 N / m. In some examples, the aerosol-generating material may have a tensile strength of about 600 N / m to about 2000 N / m, or 700 N / m to 1500 N / m, or about 1000 N / m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material comprising the aerosol-generating material is formed and incorporated into an aerosol-generating consumable as a sheet.

[0187] The aerosol-forming material, including the aerosol-forming material, has a density of 30 g / m 2 ~350g / m 2 In some cases, the mass per unit area of ​​the sheet may be 50 to 250 g / m 2 , or about 70 to 210 g / m 2 , or about 90 to 190 g / m 2 , or preferably about 100 g / m 2 (which has a density similar to that of cut rag tobacco and mixtures of these materials do not easily separate). Optionally, the mass per unit area of ​​the sheet is about 30 to 70 g / m 2 , 40~60g / m 2 , or 25 to 60 g / m 2 and may be adapted to be used to wrap aerosolizable material such as tobacco.

[0188] All weight percentages (expressed as wt%) referred to herein are calculated on a dry weight basis unless expressly stated otherwise. All weight ratios are also calculated on a dry weight basis. Weights quoted on a dry weight basis represent the totality of the extract, or slurry, or material, excluding water, and may include ingredients that are themselves liquids at room temperature and pressure, such as glycerol. In contrast, weight percentages quoted on a wet weight basis represent all ingredients, including water.

[0189] As used herein, the term "sheet" refers to an element having a width and length substantially greater than its thickness. A major surface of a sheet is the surface along which both the width and length dimensions extend and after which the sheet is flat. A sheet may be, for example, a strip.

[0190] The aerosol-generating material may include a colorant. The addition of a colorant can change the visual appearance of the aerosol-generating material. The presence of a colorant in the aerosol-generating material can improve the aerosol-generating material and the visual appearance of the aerosol-generating material. By adding a colorant to the aerosol-generating material, the aerosol-generating material can be color-matched to other components of the aerosol-generating material or other components of the article that includes the aerosol-generating material.

[0191] A variety of colorants may be used depending on the desired color of the aerosol-generating material. The color of the aerosol-generating material may be, for example, white, green, red, purple, blue, brown, or black. Other colors are contemplated. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food grade colors, and pharmaceutical grade colors. In certain embodiments, the colorant may be caramel, giving the aerosol-generating material a brown appearance. In such embodiments, the color of the aerosol-generating material may be similar to the color of other components, such as the tobacco material. In some embodiments, the colorant is added to the aerosol-generating material such that it is visually indistinguishable from other components in the aerosol-generating material.

[0192] The colorant may be incorporated into the aerosol-forming material during formation (e.g., during formation of a slurry containing the materials that make up the aerosol-forming material) or may be applied after formation of the aerosol-forming material (e.g., by spraying onto the aerosol-forming material).

[0193] In some embodiments of any of the above embodiments, talc powder, calcium carbonate powder, or other powder is applied to an exposed surface of at least one distinct portion of the aerosol-generating material, which may reduce the level of tackiness or adhesiveness of the aerosol-generating material.

[0194] In the following discussion of the accompanying drawings, when an identical element is present in more than one embodiment, the same reference number is used for that element throughout, and when similar elements are present, like reference numbers (the same number plus a multiple of 100) are used.

[0195] 1-3, an article 2 for use in the manufacture of a consumable 4 for use with a non-flammable aerosol delivery device comprises an aerosol-generating material and a support 8. The support 8 has first and second opposed surfaces 10, 12. The support 8 is a sheet of material, and the opposed surfaces 10, 12 are major surfaces of the sheet.

[0196] A discrete portion 6 of aerosol-generating material is supported on a first surface 10 and a plurality of discrete portions 6 of aerosol-generating material are supported on a second surface 12. In Figures 1 and 2, three discrete portions 6 of aerosol-generating material are supported on each of the first and second surfaces 10, 12 of the support 8. The number of discrete portions supported on the support may vary from one to two or more depending on the size of the article 2.

[0197] The positions of the portions 6 on the first surface 10 and the second surface 12 correspond to each other at the points where, when viewed from a position perpendicular to the surfaces 10 or 12, there is complete overlap or overlap of the portions 6 with each other and the perimeters of the portions 6 overlap each other.

[0198] The support 8 is formed of aluminum foil having a thickness of approximately 0.007 mm. Such foil is insufficiently rigid to be self-supporting. However, the combination of the support 8 and the separate portions 6 of aerosol-generating material on the first and second surfaces 10, 12 of the support collectively provide an article 2 that is sufficiently rigid to be self-supporting in at least one direction across the first or second surfaces 10, 12 of the support 8. For purposes of this disclosure, an article 2, when sized to be a consumable 4, is self-supporting when the length of the article 2 can be gripped at one end of its length and extend horizontally unsupported from the gripping portion in at least one direction across the first or second surface of the support.

[0199] To construct consumables 4 from article 2, article 2 is cut along cut lines 16.

[0200] 4-7, an article 102 for use in the manufacture of a consumable 104 for use with a non-flammable aerosol delivery device comprises an aerosol-generating material and a support 8. The support 8 has first and second opposed surfaces 10, 12.

[0201] A plurality of separate portions 106A of aerosol-generating material are supported on the first surface 10. A plurality of separate portions 106B of aerosol-generating material are supported on the second surface 12. In FIGS. 4-6, three separate portions 106A of aerosol-generating material are shown supported on the first surface 10 of the support 8, and seven separate portions 106B of aerosol-generating material are shown supported on the second surface 12. The number of separate portions supported on either the first or second surface of the support 8 may vary from one to two or more depending on the size of the article 102.

[0202] The separate portions 106A of aerosol-generating material are longitudinally stretched strips of material having their respective longitudinal axes oriented in a first direction. The separate portions 106B of aerosol-generating material are longitudinally stretched strips of material having their respective longitudinal axes oriented in a second direction. In Figures 4-7, the second direction is generally perpendicular to the first direction. In other embodiments, the separate portions 106A and 106B of aerosol-generating material may be oriented at different angles to one another.

[0203] In the embodiment shown in Figures 4 to 7, the separate portions 106A of aerosol-generating material on the first surface 10 and the separate portions 106B of aerosol-generating material on the second surface 12 partially correspond to one another in that portions of the portions 106A / 106B overlap one another when viewed perpendicular to the surfaces 10 or 12.

[0204] The support 8 includes a number of openings 118 (only shown in FIG. 4 and not all numbered for clarity) that extend between the first and second surfaces 10, 12 of the support 8. The openings 118 allow for the passage of aerosols or vapors from one side of the support 8 to the other.

[0205] The support 8 is formed of aluminum foil having a thickness of approximately 0.020 mm. Such foil is insufficiently rigid to be self-supporting. However, the combination of the support and the separate portions 106A and 106B of aerosol-generating material on the first and second surfaces 10, 12 of the support together provide an article 102 that is sufficiently rigid to be self-supporting in at least one direction across the first or second surface of the support.

[0206] To construct consumables 104 from article 102, article 102 is cut along cut lines 116.

[0207] In one embodiment of article 2 or 102 , the composition of the distinct portion 6 / 106A of aerosol-forming material on first surface 10 differs from the composition of the distinct portion 6 / 106B of aerosol-forming material on second surface 12 .

[0208] In one embodiment of article 2 or 102, the thickness of the distinct portion 6 / 106A of aerosol-generating material on the first surface 10 is different from the thickness of the distinct portion 6 / 106B of aerosol-generating material on the second surface 12.

[0209] In an alternative embodiment of article 2 or 102, the thickness of the separate portion 6 / 106A of the aerosol-generating material on the first surface 10 is substantially the same as the thickness of the separate portion 6 / 106B of the aerosol-generating material on the second surface 12.

[0210] In one embodiment of any of the above embodiments, the support 8 has a thickness of 0.025 mm or less. In some embodiments, the support has a thickness of less than 0.020 mm, less than 0.015 mm, less than 0.010 mm, around 0.020 mm, or around 0.007 mm.

[0211] A method for manufacturing article 2 / 102 includes the steps of providing a support 8, applying a separate portion 6 / 106A of aerosol-generating material to a first surface 10 of the support 8, and applying a separate portion 6 / 106B of aerosol-generating material to a second surface 12 of the support 8.

[0212] In some embodiments, the step of applying the aerosol-generating material portion 6, 106A, 106B includes applying a slurry of the aerosol-generating material to the surface 10 / 12 of the support portion 8.

[0213] In such embodiments, the method further includes allowing or causing hardening or at least partial hardening of the aerosol-generating material slurry applied to the first surface 10 of the support 8. In some embodiments, the aerosol-generating material slurry hardens or partially hardens into an aerosol-generated film.

[0214] The separate portion 6 / 106A of the aerosol-generating material applied to the first surface 10 of the support 8 is allowed to harden or at least partially harden before the separate portion 6 / 106B of the aerosol-generating material slurry is applied to the second surface 12 of the support 8.

[0215] To cure or at least partially cure the separate portions 6 / 106A / 106B of the aerosol-forming material slurry, the portions are exposed to ultraviolet radiation which promotes curing of the aerosol-forming material slurry.

[0216] In some embodiments of any of the above embodiments, the steps of applying the separate portions 6 / 106A / 106B of aerosol-generating material to the first or second surface 10, 12 of the support 8 and allowing or causing the aerosol-generating material slurry to harden or at least partially harden are repeated one or more times. In other words, the separate portions 6 / 106A / 106B of aerosol-generating material are constructed of two or more layers of aerosol-generating material. The thickness of the hardened or at least partially hardened aerosol-generating material may be measured after application of each layer.

[0217] In an alternative embodiment, referring to Figure 8, a film 6 of cured or partially cured aerosol-generating material is formed on a film forming surface 20. The cured or partially cured film 6 is separated from the film forming surface and applied to a surface 10, 12 of a support 8. The thickness of the cured or partially cured film of aerosol-generating material is then measured. The application of the cured or partially cured film of aerosol-generating material may be repeated one or more times.

[0218] In a non-illustrated embodiment of the embodiments of Figures 1-3 and / or 4-7, two or more folds are formed in the support 8. The folds are spaced apart such that the article 2 / 102 is folded in an accordion-like manner, thereby allowing for compact storage of the article 2 / 102.

[0219] If the article 2 / 102 is larger than is compatible with the non-flammable aerosol delivery system, it may be configured for storage. In a preferred configuration, the article 2 / 102 is folded accordion-like to form a roll around a bobbin, or cut into sheets and stored in a stack. The placement of a suitable barrier material between layers of the article may reduce the possibility of those layers adhering to one another.

[0220] If article 2 / 102 is larger than a size compatible with use with the non-flammable aerosol delivery system, it is separated into two or more article portions, which are shaped and dimensioned for use as consumables 4 / 104 for use with the non-flammable aerosol delivery system.

[0221] The above description is by way of example only, and those skilled in the art will recognize that modifications may be made to the described embodiments without departing from the scope of the disclosed invention. Still other modifications, which fall within the scope of the invention, will be apparent to those skilled in the art in light of a review of the present disclosure.

[0222] Various aspects of the methods, articles, and consumables disclosed in the various embodiments may be used alone or in combination, or in various configurations not specifically discussed in the above embodiments. Thus, the present disclosure is not limited in its application to the details and configurations of the components described in the above description or 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 can be made in the broader aspects without departing from the present invention. The following claims are not limited by the embodiments described in the above examples, but are to be accorded the broadest reasonable interpretation consistent throughout this specification.

Claims

1. 1. An article for use with a non-flammable aerosol delivery device, the article comprising an aerosol-generating material and a support, the support having first and second opposing surfaces, at least one separate portion of the aerosol-generating material supported on the first surface, and at least one separate portion of the aerosol-generating material supported on the second surface.

2. 2. The article of claim 1, wherein the article is freestanding when a length of the article is gripped at one end of the length in at least one direction across the first surface or the second surface of the support and the article is allowed to extend horizontally without support from the gripping portion.

3. The article of claim 1 or 2, wherein the article is comprised of the aerosol-forming material and the support.

4. The article of any one of claims 1 to 3, wherein a position, shape, and size of each of the at least one separate portion of the aerosol-generating material on the first surface and a position, shape, and size of each of the at least one separate portion of the aerosol-generating material on the second surface are such that the separate portions on the first surface and the second surface at least partially correspond to one another.

5. The article of any one of claims 1 to 3, wherein a position, shape, and size of each of the at least one separate portion of the aerosol-generating material on the first surface and a position, shape, and size of each of the at least one separate portion of the aerosol-generating material on the second surface correspond to each other.

6. The article of any one of claims 1 to 3, wherein a position, shape, and size of the at least one distinct portion of the aerosol-generating material on the first surface is different from a position, shape, and size of the at least one distinct portion of the aerosol-generating material on the second surface.

7. 7. The article of any one of claims 1 to 6, wherein a composition of the aerosol-generating material of at least one distinct portion of aerosol-generating material on the first surface is different from a composition of at least one distinct portion of aerosol-generating material on the second surface.

8. 8. The article of any one of claims 1 to 7, wherein a thickness of the aerosol-generating material of at least one distinct portion of aerosol-generating material on the first surface is different from a thickness of the at least one distinct portion of aerosol-generating material on the second surface.

9. 9. The article of any one of claims 1 to 8, wherein a thickness of the aerosol-generating material of at least one distinct portion of aerosol-generating material on the first surface is substantially the same as a thickness of the at least one distinct portion of aerosol-generating material on the second surface.

10. The article of any one of claims 1 to 9, wherein the support portion has a thickness of 0.025 mm or less.

11. The article of any one of claims 1 to 10, wherein the thickness of the article is from 0.085 mm to 0.610 mm.

12. 12. A consumable for use with a non-flammable aerosol delivery device, the consumable comprising a portion of an article according to any one of claims 1 to 11, the portion of the article being configured in a shape and size suitable for use with the non-flammable aerosol delivery device.

13. 1. A method of making an article comprising an aerosol-generating material and a support, comprising: Providing a support; applying an aerosol-generating material to at least one predetermined area on a first surface of the support; applying an aerosol-generating material to at least one predetermined area on a second surface of the support; A method comprising:

14. 14. The method of claim 13, wherein the article is freestanding when a length of the article is gripped at one end of the length in at least one direction across the first surface or the second surface of the support and the article is allowed to extend horizontally without support from the gripper.

15. The method of claim 13 or 14, wherein the article is comprised of the aerosol-generating material and the support.

16. The method of any one of claims 13 to 15, wherein the step of applying an aerosol-forming material comprises applying a slurry of aerosol-forming material.

17. 17. The method of claim 16, further comprising allowing or causing the aerosol-generating material slurry applied to the first surface of the support to harden, the aerosol-generating material slurry hardening as an aerosol-generating material.

18. 18. The method of claim 16 or 17, further comprising the step of allowing or carrying out hardening or at least partial hardening of the aerosol-generating material slurry applied to the first surface of the support before the aerosol-generating material slurry is applied to the second surface of the support.

19. 19. The method of claim 17 or 18, wherein the step of effecting curing of the aerosol-generating material slurry applied to the first surface of the support comprises using ultraviolet radiation.

20. 20. The method of any one of claims 17 to 19, wherein the steps of applying an aerosol-generating material to the first surface of the support and allowing or causing hardening or at least partial hardening of the aerosol-generating material slurry applied to the first surface of the support are repeated one or more times.

21. 21. The method of any one of claims 17 to 20, further comprising measuring a thickness of the cured or at least partially cured aerosol-generating material applied to the first surface of the support.

22. The method further comprising: forming a film of cured or partially cured aerosol-forming material on a film forming surface; Separating the film of cured or partially cured aerosol-forming material from the film-forming surface; and Further comprising:

16. The method of claim 13, wherein the step of applying an aerosol-generating material to the first surface of the support comprises applying a film of the cured or partially cured aerosol-generating material to the first surface of the support.

23. The method further comprising: Providing a film of cured or partially cured aerosol-generating material. Further comprising:

16. The method of claim 13, wherein the step of applying an aerosol-generating material to the first surface of the support comprises applying a film of the cured or partially cured aerosol-generating material to the first surface of the support.

24. 24. The method of claim 22 or 23, further comprising measuring a thickness of the film of cured or partially cured aerosol-forming material.

25. 25. The method of any one of claims 22 to 24, wherein the step of applying a film of the cured or partially cured aerosol-forming material is repeated one or more times.

26. The method of any one of claims 13 to 25, wherein the step of applying an aerosol-generating material to the second surface of the support comprises applying a slurry of aerosol-generating material.

27. 27. The method of claim 26, further comprising allowing or causing hardening or at least partial hardening of the aerosol-generating material slurry applied to the second surface of the support, the aerosol-generating material slurry hardening as an aerosol-generating material.

28. 28. The method of claim 26 or 27, wherein the step of effecting a curing or at least partial curing of the aerosol-generating material slurry applied to the second surface of the support comprises using ultraviolet radiation.

29. 29. The method of claim 27 or 28, wherein the steps of applying an aerosol-generating material to the second surface of the support and allowing or causing hardening or at least partial hardening of the aerosol-generating material slurry applied to the second surface of the support are repeated one or more times.

30. 30. The method of any one of claims 27 to 29, further comprising measuring a thickness of the cured or at least partially cured aerosol-generating material applied to the second surface of the support.

31. The method further comprising: forming a film of cured or partially cured aerosol-forming material on a film forming surface; Separating the film of cured or partially cured aerosol-forming material from the film-forming surface; and Further comprising:

26. The method of any one of claims 13 to 25, wherein the step of applying an aerosol-generating material to the second surface comprises applying a film of the cured or partially cured aerosol-generating material to the second surface of the support.

32. The method further comprising: Providing a cured or partially cured film of aerosol-generating material. Further comprising:

26. The method of any one of claims 13 to 25, wherein the step of applying an aerosol-generating material to the second surface comprises applying a film of the cured or partially cured aerosol-generating material to the second surface of the support.

33. 33. The method of claim 31 or 32, further comprising measuring a thickness of a film of the cured or semi-cured aerosol-forming material.

34. 34. The method of any one of claims 31 to 33, wherein the step of applying an aerosol-forming material to the second surface of the support is repeated one or more times.

35. A method according to any one of claims 13 to 34, wherein the support has a thickness of less than 0.025mm.

36. The method of any one of claims 13 to 35, wherein the support is a metal foil.

37. 37. The method of any one of claims 13 to 36, wherein the step of applying an aerosol-generating material to one or both of the first and second surfaces of the support comprises applying separate portions of an aerosol-generating material to two or more predetermined areas on one or both surfaces of the support.

38. 38. The method of any one of claims 13 to 37, wherein a position, shape, and size of each of the at least one separate portion of the aerosol-generating material on the first surface and a position, shape, and size of each of the at least one separate portion of the aerosol-generating material on the second surface are such that the separate portions on the first surface and the second surface at least partially correspond to each other.

39. 38. The method of any one of claims 13 to 37, wherein the position, shape, and size of each of the at least one separate portion of the aerosol-generating material on the first surface and the position, shape, and size of each of the at least one separate portion of the aerosol-generating material on the second surface correspond to each other.

40. 38. The method of any one of claims 13 to 37, wherein a position, shape, and size of at least one distinct portion of the aerosol-generating material on the first surface and a position, shape, and size of at least one distinct portion of the aerosol-generating material on the second surface are different.

41. 42. The method of any one of claims 13 to 41, wherein the composition of at least one distinct portion of aerosol-generating material on the first surface is different from the composition of at least one distinct portion of aerosol-generating material on the second surface.

42. 42. The method of any one of claims 13 to 41, wherein a thickness of the at least one distinct portion of aerosol-generating material on the first surface is different from a thickness of the at least one distinct portion of aerosol-generating material on the second surface.

43. 43. The method of any one of claims 13 to 42, wherein a thickness of the at least one distinct portion of aerosol-generating material on the first surface is substantially the same as a thickness of the at least one distinct portion of aerosol-generating material on the second surface.

44. A method according to any one of claims 13 to 43, wherein the article has a thickness of between 0.085 mm and 0.610 mm.

45. A method according to any one of claims 13 to 44, wherein two or more folds are formed in the support.

46. 46. ​​The method of claim 45, wherein the folds may be spaced apart such that the article may be folded in an accordion fashion.

47. 47. The method of any one of claims 13 to 46, wherein the article is larger than a size compatible for use with a non-flammable aerosol delivery system, the method further comprising configuring the article for storage.

48. the article is larger than a size compatible with use with a non-flammable aerosol delivery system, the method further comprising separating the article into two or more article portions; The method of any one of claims 13 to 47, wherein each article portion is shaped and dimensioned for use as a consumable for use with a non-flammable aerosol delivery system.

49. 13. An aerosol delivery device for use with the consumable of claim 12, comprising an aerosol generator configured to heat at least a portion of the aerosol-generating material supported by the consumable.

50. 50. An aerosol delivery system comprising: the aerosol delivery device of claim 49; and the consumable of claim 12.

51. 13. A method of generating an aerosol from the consumable of claim 12 using an aerosol generating device comprising at least one aerosol generator, wherein the at least one aerosol generator is a resistive heater element or a magnetic field generator and a susceptor.

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