Consumable comprising two different aerosol generating materials for a non-combustion aerosol delivery device

Abstract

A consumable for use with an aerosol provision system is provided that is configured to enable a user to obtain a wide variety of smoking experiences according to preference.SOLUTION: The consumable 101 comprises a first aerosol generating material and a second aerosol generating material, wherein each of the first and second aerosol generating materials comprises an amorphous solid comprising 0. 5-60% by weight of a gelling agent, 0-80% by weight of an aerosol forming material, and 0-60% by weight of at least one of an active, a flavorant, and an acid, wherein the weights are calculated on a dry weight basis, and wherein the amorphous solid of the first aerosol generating material has a composition that is different from the composition of the amorphous solid of the second aerosol generating material.SELECTED DRAWING: Figure 1

Description

Detailed Description of the Invention

[0001] [Technical field] The present invention relates to a consumable for use with a non-combustion aerosol delivery device, the consumable comprising an aerosol-forming material comprising an amorphous solid.

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

[0003] One example of such a product is a heating device that releases compounds by heating, but not burning, a solid aerosol-forming material. The solid aerosol-forming material may, in some instances, comprise tobacco material. The heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products are sometimes referred to as heat not burn devices, tobacco heating devices, or tobacco heating products. A variety of different configurations are known for volatilizing at least one component of the solid aerosol-forming material.

[0004] Another example is a hybrid device, which includes a liquid source (which may or may not contain nicotine) that is vaporized by heating to produce an inhalable vapor or aerosol, and further includes a solid aerosol-forming material (which may or may not contain tobacco material), the components of which are entrained in the inhalable vapor or aerosol to produce the inhalation medium.

[0005] [overview] The present invention provides a consumable for use with a non-combustion type aerosol delivery device, the consumable comprising: a first aerosol-forming material; and a second aerosol-forming material; and wherein each of the first and second aerosol-forming materials comprises an amorphous solid, the amorphous solid comprising: 0.5 to 60 wt. % of a gelling agent; 0 to 80 wt. % of an aerosol former; 0-60% by weight of at least one of an active substance, a flavoring agent, and an acid; wherein the weights are calculated on a dry weight basis, and wherein the amorphous solid of the first aerosol-forming material has a composition that is different from the composition of the amorphous solid of the second aerosol-forming material.

[0006] The present invention also provides a method of making a consumable for use with a non-combustion aerosol delivery device, the method comprising: providing a support; depositing at least two separate portions of a slurry comprising a gelling agent, an aerosol-forming material, and at least one of an active agent, a flavoring agent, and an acid onto a substrate; drying at least two separate portions of the slurry to obtain a first aerosol-forming material and a second aerosol-forming material, the first and second aerosol-forming materials being attached to a support; forming a consumable; wherein each of the first and second aerosol-forming materials comprises an amorphous solid, the amorphous solid comprising: 0.5 to 60 wt. % of a gelling agent; 0 to 80 wt. % of an aerosol-forming material; 0-60% by weight of at least one of an active substance, a flavoring agent, and an acid; wherein the weights are calculated on a dry weight basis, and wherein the amorphous solid of the first aerosol-forming material has a composition that is different from the composition of the amorphous solid of the second aerosol-forming material.

[0007] In a further aspect of the present invention, there is provided a non-combustion aerosol delivery system comprising the consumable of the present invention and a non-combustion aerosol delivery device comprising an aerosol generation device arranged to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

[0008] The present invention also relates to the use of the consumables described herein in a non-combustion aerosol delivery device that is configured to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

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

[0010] [Figure 1] FIG. 2 is a cross-sectional view of an example of a consumable item. [Figure 2] FIG. 2 is a perspective view of the consumable item of FIG. 1. [Figure 3] FIG. 1 is a cross-sectional elevation view of an example consumable item. [Figure 4] FIG. 4 is a perspective view of the consumable item of FIG. 3. [Figure 5] FIG. 1 is a perspective view of an example of a non-combustion aerosol delivery system. [Figure 6] FIG. 1 is a cross-sectional view of an example of a non-combustion aerosol delivery system. [Figure 7] FIG. 1 is a perspective view of an example of a non-combustion aerosol delivery system.

[0011] [Detailed explanation] As discussed above, one aspect of the present invention provides a consumable for use with a non-combustion type aerosol delivery device. The consumable comprises: a first aerosol-forming material; and a second aerosol-forming material; and wherein each of the first and second aerosol-forming materials comprises an amorphous solid, the amorphous solid comprising: 0.5 to 60 wt. % of a gelling agent; 0 to 80 wt. % of an aerosol-forming material; 0-60% by weight of at least one of an active substance, a flavoring agent, and an acid; wherein the weights are calculated on a dry weight basis, and wherein the amorphous solid of the first aerosol-forming material has a composition that is different from the composition of the amorphous solid of the second aerosol-forming material.

[0012] In this aspect of the invention, the weight percentages of the at least one active, flavor, and acid represent the combined total weight of any combination of active, flavor, and acid described herein.

[0013] In one embodiment, the amorphous solid of the first aerosol-generating material comprises an active substance, and the amorphous solid of the second aerosol-generating material comprises a flavorant. In certain such instances, the amorphous solid of the first aerosol-generating material is free of flavorant and acid. In some embodiments, the amorphous solid of the first aerosol-generating material is free of flavor and acid contained in the second aerosol-generating material. In other embodiments, the amorphous solid of the first aerosol-generating material also comprises flavor and / or acid. In some instances, the amorphous solid of the second aerosol-generating material is free of active substance and acid. In some embodiments, the amorphous solid of the second aerosol-generating material is free of active substance and acid contained in the first aerosol-generating material. In alternative embodiments, the amorphous solid of the second aerosol-generating material also comprises an active substance and / or acid.

[0014] In these embodiments, the amorphous solid of the first aerosol-forming material comprising the active agent is 0.5 to 60 wt. % of a gelling agent; 5 to 80 weight percent of an aerosol-forming material; 0.1 to 60% by weight of at least one active substance; where these weights are calculated on a dry weight basis.

[0015] In this embodiment, the amorphous solid of the first aerosol-forming material may have the following composition, expressed as a percentage of the total dry weight, i.e., on a dry weight basis (all calculated on a dry weight basis): gelling agent in an amount of about 5% to about 40% by weight, or about 10% to about 30% by weight, or about 15% to about 25% by weight; aerosol-forming material in an amount of about 10% to about 70% by weight, or about 20% to about 60% by weight, or about 25% to about 40% by weight (all calculated on a dry weight basis); active agent in an amount of about 0.5% to about 50% by weight, or about 1% to about 40% by weight, or about 2% to about 30% by weight, or about 5% to about 20% by weight, or about 2% to about 10% by weight. Preferably, the amorphous solid of the first aerosol-generating material may have the following composition (all calculated on a dry weight basis): about 30% to about 60% by weight of gelling agent, about 20% to about 60% by weight of aerosol-forming material, and about 0.1% to about 10% by weight of active agent. In some of these embodiments, the amorphous solid of the first aerosol-generating material does not include the flavoring and acid contained in the second aerosol-generating material. In alternative embodiments, the amorphous solid of the first aerosol-generating material also includes a flavoring and / or an acid.

[0016] In this embodiment, the amorphous solid of the second aerosol-forming material comprising the flavoring agent is 0.5 to 60 wt. % of a gelling agent; 0 to 80 wt. % of an aerosol-forming material; 5 to 60% by weight of a flavoring; where these weights are calculated on a dry weight basis.

[0017] In this embodiment, the amorphous solid of the second aerosol-forming material may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 5% to about 40% by weight, or about 10% to about 30% by weight, or about 15% to about 25% by weight; aerosol-forming material in an amount of about 10% to about 70% by weight, or about 20% to about 60% by weight, or about 25% to about 40% by weight (all calculated on a dry weight basis); and flavoring in an amount of about 10% to about 50% by weight, or about 20% to about 40% by weight, or about 25% to about 30% by weight. Preferably, the amorphous solid of the second aerosol-generating material may have the following composition (all calculated on a dry weight basis): about 30% to about 60% by weight of gelling agent, about 10% to about 40% by weight of aerosol-forming material, and about 20% to about 50% by weight of flavoring. In some embodiments, the amorphous solid of the second aerosol-generating material does not contain the active substance and acid contained in the amorphous solid of the first aerosol-generating material. In some embodiments, the amorphous solid of the second aerosol-generating material also contains an active substance and / or an acid.

[0018] In further embodiments, the amorphous solid of the first aerosol-generating material comprises an active agent, and the amorphous solid of the second aerosol-generating material comprises an acid. In certain such embodiments, the amorphous solid of the first aerosol-generating material does not comprise a flavorant or an acid. In some embodiments, the amorphous solid of the first aerosol-generating material does not comprise the acid and flavorant contained in the second aerosol-generating material. In other embodiments, the amorphous solid of the first aerosol-generating material also comprises an acid and / or a flavorant. In certain such embodiments, the amorphous solid of the second aerosol-generating material does not comprise the active agent and flavorant contained in the first aerosol-generating material. In some embodiments, the amorphous solid of the second aerosol-generating material does not comprise the active agent and flavorant contained in the first aerosol-generating material. In other embodiments, the amorphous solid of the second aerosol-generating material also comprises an active agent and / or a flavorant.

[0019] In this embodiment, the amorphous solid of the first aerosol-forming material comprising the active agent is 0.5 to 60 wt. % of a gelling agent; 5 to 80 weight percent of an aerosol-forming material; 0.1 to 60% by weight of at least one active substance; where these weights are calculated on a dry weight basis.

[0020] In this embodiment, the amorphous solid of the first aerosol-forming material may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 5% to about 40% by weight, or about 10% to about 30% by weight, or about 15% to about 25% by weight; aerosol-forming material in an amount of about 10% to about 50% by weight, or about 20% to about 40% by weight, or about 25% to about 35% by weight (all calculated on a dry weight basis); active agent in an amount of about 1% to about 50% by weight, or about 2% to about 40% by weight, or about 5% to about 30% by weight. Preferably, the amorphous solid of the first aerosol-generating material may have the following composition (all calculated on a dry weight basis): about 30% to about 60% by weight of gelling agent, about 20% to about 60% by weight of aerosol-forming material, and about 0.1% to about 10% by weight of active agent. In some embodiments, the amorphous solid of the first aerosol-generating material is acid- and flavor-free. In alternative embodiments, the amorphous solid of the first aerosol-generating material also comprises a flavor and / or an acid.

[0021] In this embodiment, the amorphous solid of the second aerosol-forming material comprises an acid. 0.5 to 60 wt. % of a gelling agent; 5 to 80 weight percent of an aerosol-forming material; 0.1 to 10% by weight of an acid; where these weights are calculated on a dry weight basis.

[0022] In this embodiment, the amorphous solid of the second aerosol-forming material may have the following composition (calculated on a dry weight basis): gelling agent in an amount of about 5% to about 40% by weight, or about 10% to about 30% by weight, or about 15% to about 25% by weight; aerosol-forming material in an amount of about 10% to about 50% by weight, or about 20% to about 40% by weight, or about 25% to about 35% by weight (all calculated on a dry weight basis); acid in an amount of about 0.1% to about 8% by weight, or about 0.5% to about 7% by weight, or about 1% to about 5% by weight, or about 1% to about 3% by weight. Preferably, the amorphous solid of the second aerosol-generating material may have the following composition (all calculated on a dry weight basis): about 40% to about 70% by weight of gelling agent, about 20% to about 50% by weight of aerosol-forming material, and about 0.1% to about 5% by weight of acid. In some embodiments, the amorphous solid of the second aerosol-generating material is free of active substances and flavorings. In alternative embodiments, the amorphous solid of the second aerosol-generating material also comprises an active substance and / or flavoring.

[0023] In still further embodiments, the amorphous solid of the first aerosol-generating material comprises a flavoring agent, and the amorphous solid of the second aerosol-generating material comprises an acid. In certain such embodiments, the amorphous solid of the first aerosol-generating material does not comprise an acid or an active substance. In some embodiments, the amorphous solid of the first aerosol-generating material does not comprise the acid and active substance contained in the second aerosol-generating material. In other embodiments, the amorphous solid of the first aerosol-generating material also comprises an acid and / or an active substance. In certain embodiments, the amorphous solid of the second aerosol-generating material does not comprise the flavoring agent and an active substance. In some embodiments, the amorphous solid of the second aerosol-generating material does not comprise the flavoring agent and active substance contained in the first aerosol-generating material. In other embodiments, the amorphous solid of the second aerosol-generating material also comprises a flavoring agent and / or an active substance.

[0024] In this embodiment, the amorphous solid of the first aerosol-forming material comprising the flavoring agent is 0.5 to 60 wt. % of a gelling agent; 0 to 80 wt. % of an aerosol-forming material; 5 to 60% by weight of a flavoring; where these weights are calculated on a dry weight basis.

[0025] In this embodiment, the amorphous solid of the first aerosol-forming material may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 5% to about 40% by weight, or about 10% to about 30% by weight, or about 15% to about 25% by weight; aerosol-forming material in an amount of about 10% to about 50% by weight, or about 20% to about 40% by weight, or about 25% to about 35% by weight (all calculated on a dry weight basis); and flavoring in an amount of about 30% to about 60% by weight, or about 40% to about 55% by weight, or about 45% to about 50% by weight. Preferably, the amorphous solid of the first aerosol-generating material may have the following composition (all calculated on a dry weight basis): about 30% to about 60% by weight of gelling agent, about 10% to about 40% by weight of aerosol-forming material, and about 10% to about 50% by weight of flavoring. In some embodiments, the amorphous solid of the first aerosol-generating material is acid- and active-free. In alternative embodiments, the amorphous solid of the first aerosol-generating material also comprises an acid and / or an active.

[0026] In this embodiment, the amorphous solid of the second aerosol-forming material comprises an acid. 0.5 to 60 wt. % of a gelling agent; 5 to 80 weight percent of an aerosol-forming material; 0.1 to 10% by weight of an acid; where these weights are calculated on a dry weight basis.

[0027] In this embodiment, the amorphous solid of the second aerosol-forming material may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 5% to about 40% by weight, or about 10% to about 30% by weight, or about 15% to about 25% by weight; aerosol-forming material in an amount of about 10% to about 50% by weight, or about 20% to about 40% by weight, or about 25% to about 35% by weight (all calculated on a dry weight basis); acid in an amount of about 0.1% to about 8% by weight, or about 0.5% to about 7% by weight, or about 1% to about 5% by weight, or about 1% to about 3% by weight. Preferably, the amorphous solid of the second aerosol-generating material may have the following composition (all calculated on a dry weight basis): about 40% to about 70% by weight of gelling agent, about 20% to about 50% by weight of aerosol-forming material, and about 0.1% to about 5% by weight of acid. In some embodiments, the amorphous solid of the second aerosol-generating material does not include an active substance or flavoring. In alternative embodiments, the amorphous solid of the second aerosol-generating material also includes an active substance and / or flavoring.

[0028] In further embodiments, the amorphous solid of one of the first or second aerosol-generating materials is free of active substances, flavorings, and acids. In some embodiments, the amorphous solid of the first aerosol-generating material is free of active substances, flavorings, or acids. In this embodiment, the aerosol-generating material free of active substances, flavorings, and acids is provided for the purpose of providing a source of aerosol-forming material, e.g., a humectant. Thus, in this embodiment, the amorphous solid of the aerosol-generating material free of active substances, flavorings, and acids comprises at least 5% by weight of the aerosol-forming material, e.g., about 10% to about 50% by weight, or about 20% to about 40% by weight, or about 25% to about 35% by weight (all calculated on a dry weight basis). In exemplary embodiments, the first aerosol-generating material is 0.5 to 60 wt. % of a gelling agent; 5 to 80 weight percent of an aerosol-forming material; and is free of active substances, flavorings and acids, the second aerosol-forming material comprises 0.1 to 60% by weight of at least one of an active substance, a flavoring agent, and an acid; Here, these weights are calculated on a dry weight basis.

[0029] In some such embodiments, the consumable product of the invention comprises such a first aerosol-generating material in combination with any other second aerosol-generating material described herein.

[0030] In some embodiments, the amorphous solids of the first and second aerosol-generating materials both comprise an active agent. In some such embodiments, the amorphous solids of the first and second aerosol-generating materials comprise the same active agent. In some such embodiments, the active agents are present in different amounts. As used herein, "amount" can mean that the amorphous solid contains 0% active agent, or in other words, that the amorphous solid of the first or second aerosol-generating material does not contain the active agent present in the amorphous solid of the other aerosol-generating material.

[0031] In some embodiments, the amorphous solids of the first and second aerosol-generating materials both comprise an active agent. In some such embodiments, the amorphous solids of the first and second aerosol-generating materials comprise the same active agent, wherein the amorphous solid of the first aerosol-generating material comprises a greater amount of the active agent than the amorphous solid of the second aerosol-generating material. In some embodiments, the amorphous solids of the first and second aerosol-generating materials comprise the same active agent, wherein the amorphous solid of the first aerosol-generating material comprises a lesser amount of the active agent than the amorphous solid of the second aerosol-generating material.

[0032] In some such embodiments, the amorphous solids of the first and second aerosol-generating materials comprise more than 0.1% active substance (all calculated on a dry weight basis), e.g., the amorphous solids of both the first and second aerosol-generating materials comprise at least 0.2, 0.5, 1.0, 1.5, or 2% active substance. In exemplary embodiments, the amorphous solid of the first aerosol-generating material comprises 0-30% active substance by weight, and the amorphous solid of the second aerosol-generating material comprises 31-60% active substance by weight. Preferably, the amorphous solid of the first aerosol-generating material comprises 0-20% active substance by weight (e.g., 1-15% or 5-10% by weight), and the amorphous solid of the second aerosol-generating material comprises 30-60% active substance by weight (e.g., 30-50% or 40-60% by weight). In some such embodiments, the amorphous solid of the first aerosol-generating material comprises the same active agent as the active agent present in the amorphous solid of the second aerosol-generating material, or in some such embodiments, the amorphous solid of the first aerosol-generating material comprises a different active agent than the active agent present in the amorphous solid of the second aerosol-generating material.

[0033] In such embodiments, the two aerosol-forming materials may comprise substantially the same ingredients, except for the amount of active agent present in each of the two aerosol-forming materials. a first aerosol-forming material; and a second aerosol-forming material; and wherein the first aerosol-generating material comprises an amorphous solid, the amorphous solid comprising: 0.5 to 60 wt. % of a gelling agent; 0 to 80 wt. % of an aerosol-forming material; and 0 to 5 wt. % of the active substance, wherein these weights are calculated on a dry weight basis; and the second aerosol-forming material comprises an amorphous solid, the amorphous solid comprising: 0.5 to 60 wt. % of a gelling agent; 0 to 80 wt. % of an aerosol-forming material; and 5-10% by weight of an active substance, where these weights are calculated on a dry weight basis. Preferably, the amorphous solid of the first aerosol-forming material comprises 0.1-2% by weight of the active substance contained therein, and the amorphous solid of the second aerosol-forming material comprises 2-10% by weight of the active substance contained therein. Preferably, the active substance is nicotine.

[0034] In such embodiments, the first and second aerosol-generating materials may further comprise varying amounts of flavoring and / or acid. In other embodiments, the first and / or second aerosol-generating materials are free of flavoring and / or acid.

[0035] In the above embodiment, preferably the active substance is nicotine, the amorphous solid of the first aerosol-generating material comprises 0.1 to 5 wt.% nicotine, for example 0.5 to 4 wt.%, 1 to 3 wt.%, or 2 to 5 wt.% nicotine, and the amorphous solid of the second aerosol-generating material comprises 5 to 10 wt.% nicotine, for example 6 to 9 wt.%, or 7 to 8 wt.% nicotine, wherein these weights are calculated on a dry weight basis, and the amorphous solid of the first aerosol-generating material comprises a different amount of nicotine than the amount of nicotine contained in the amorphous solid of the second aerosol-generating material.

[0036] In some embodiments, the amorphous solid of the first aerosol-forming material comprises an active agent that is different from the active agent present in the amorphous solid of the second aerosol-forming material.

[0037] In some embodiments, the amorphous solid of the first aerosol-forming material comprises a flavoring that is different from a flavoring present in the amorphous solid of the second aerosol-forming material.

[0038] In some instances, the amorphous solid of at least one of the aerosol-generating materials mentioned above comprises two or more of a flavorant, an active substance, and / or an acid. For example, in some embodiments, the amorphous solid of the first and / or second aerosol-generating material comprises a flavorant and an active substance but does not comprise an acid. In other instances, the amorphous solid of the first and / or second aerosol-generating material comprises an acid and an active substance but does not comprise a flavorant. In other instances, the amorphous solid of the first and / or second aerosol-generating material comprises a flavorant and an acid but does not comprise an active substance.

[0039] Consumable products of the present invention are also contemplated to include aerosol-generating materials, as discussed above, that contain different flavorings. In such embodiments, the amorphous solid of a first aerosol-generating material contains a flavoring that is different from the flavoring contained in the amorphous solid of a second aerosol-generating material. In such embodiments, two aerosol-generating materials (e.g., the first and second aerosol-generating materials) may contain substantially the same ingredients, except that the amorphous solid of the first aerosol-generating material contains a flavoring that is different from the flavoring present in the amorphous solid of the second aerosol-generating material. In a non-limiting example, the amorphous solids of the two aerosol-generating materials contain an active agent, an acid, and a flavoring, where the flavoring in the amorphous solid of the first aerosol-generating material is different from the flavoring in the amorphous solid of the second aerosol-generating material. In some embodiments, the consumable product of the present invention may comprise three or more aerosol-forming materials, wherein the amorphous solid of each aerosol-forming material comprises a flavoring that is different from a flavoring present in at least one other amorphous solid of another aerosol-forming material in the consumable product of the present invention.

[0040] It is also contemplated that the aerosol-generating materials in a consumable product of the present invention differ from one another in the type of active agent. In such embodiments, the amorphous solids of two aerosol-generating materials may have substantially the same components, except for the active agent present in the amorphous solids. In one embodiment, the amorphous solid of a first aerosol-generating material has an active agent that is different from the active agent present in the amorphous solid of a second aerosol-generating material. In some embodiments, a consumable product of the present invention includes three or more aerosol-generating materials, each of which has an active agent that is different from the active agent present in the amorphous solid of at least one other aerosol-generating material in the consumable product.

[0041] It is also contemplated that the aerosol-generating materials in the consumable product of the present invention may differ from one another in the amount of flavorant or acid. In some embodiments, the amount of flavorant in the amorphous solid of a first aerosol-generating material is different from the amount of flavorant in the amorphous solid of a second aerosol-generating material. For example, the amount of flavorant present in the amorphous solid of the first aerosol-generating material is greater than the amount of flavorant present in the second aerosol-generating material. In some such embodiments, the amount of acid in the amorphous solid of the first aerosol-generating material is different from the amount of acid in the amorphous solid of the second aerosol-generating material. For example, the amount of acid present in the amorphous solid of the first aerosol-generating material is greater than the amount of acid present in the second aerosol-generating material.

[0042] It will be appreciated that there are numerous combinations of aerosol-forming materials that may be included in the consumables of the present invention. All combinations of actives, flavorings, and acids are included within the scope of the present invention.

[0043] In some embodiments, the consumable product comprises a third aerosol-generating material comprising an amorphous solid, the amorphous solid comprising: 0.5 to 60 wt. % of a gelling agent; 0 to 80 wt. % of an aerosol-forming material; 0-60% by weight of at least one of an active substance, a flavoring agent, and an acid; wherein the weights are calculated on a dry weight basis, and wherein the amorphous solid of the third aerosol-forming material has a composition that is different from the composition of the amorphous solid of the first aerosol-forming material and / or the second aerosol-forming material.

[0044] In some embodiments, the consumable product comprises a fourth aerosol-generating material comprising an amorphous solid, the amorphous solid comprising: 0.5 to 60 wt. % of a gelling agent; 0 to 80 wt. % of an aerosol-forming material; 0-60% by weight of at least one of an active substance, a flavoring agent, and an acid; wherein the weights are calculated on a dry weight basis, and wherein the amorphous solid of the fourth aerosol-forming material has a composition that is different from the composition of the amorphous solid of at least one of the first, second, or third aerosol-forming materials.

[0045] In some embodiments, the consumable product comprises five or more aerosol-generating materials having the above characteristics. Preferably, the amorphous solid of each additional aerosol-generating material has a composition that is different from the composition of the amorphous solid of at least one other aerosol-generating material included in the consumable product. Indeed, in some embodiments, the consumable product comprises five, six, seven, eight, nine, or ten aerosol-generating materials, each of which comprises an amorphous solid having a composition that is different from the composition of the amorphous solid of at least one other aerosol-generating material included in the consumable product. In such embodiments, each of the additional aerosol-generating materials comprises an amorphous solid, the amorphous solid being: 0.5 to 60 wt. % of a gelling agent; 0 to 80 wt. % of an aerosol-forming material; 0-60% by weight of at least one of an active substance, a flavoring agent, and an acid; wherein the weights are calculated on a dry weight basis, and wherein the amorphous solid of the fifth, sixth, seventh, eighth, ninth, or tenth aerosol-forming material has a different composition from the amorphous solid of at least one other aerosol-forming material included in the consumable.

[0046] In some instances, the amorphous solid of each aerosol-forming material comprises one of a flavoring, an acid, and an active substance, or does not contain a flavoring, an acid, or an active substance, and contributes only a humectant when subjected to aerosolization.

[0047] In a non-limiting exemplary embodiment, a consumable product according to the present invention comprises: a first aerosol-forming material; and a second aerosol-forming material; and a third aerosol-generating material; and a fourth aerosol-generating material; and each of the first through fourth aerosol-generating materials comprises an amorphous solid, the amorphous solid comprising: 0.5 to 60 wt. % of a gelling agent; 0 to 80 wt. % of an aerosol former; 0-60% by weight of at least one of an active substance, a flavoring agent, and an acid; wherein these weights are calculated on a dry weight basis, and the amorphous solid of the first aerosol-forming material is exclusive of the active substance, flavoring, and acid; the amorphous solid of the second aerosol-forming material comprises a flavoring agent but is free of an active substance and an acid; the amorphous solid of the third aerosol-forming material comprises an active substance but is free of flavoring and acid; The amorphous solid of the fourth aerosol-forming material comprises an acid but does not contain an active agent or a flavoring agent.

[0048] In this embodiment, the amorphous solid of the first aerosol-forming material, which is free of flavorants, active agents, and acids, is 0.5 to 60 wt. % of a gelling agent; 5 to 80 weight percent of an aerosol-forming material; where these weights are calculated on a dry weight basis.

[0049] In this embodiment, the amorphous solid of the first aerosol-forming material may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 5% to about 40% by weight, or about 10% to about 30% by weight, or about 15% to about 25% by weight; aerosol-forming material in an amount of about 10% to about 50% by weight, or about 20% to about 40% by weight, or about 25% to about 35% by weight (all calculated on a dry weight basis).

[0050] In this embodiment, the amorphous solid of the second aerosol-forming material, which comprises a flavoring agent but is free of an active agent and an acid, is 0.5 to 60 wt. % of a gelling agent; 0 to 80 wt. % of an aerosol-forming material; 5 to 60% by weight of a flavoring; where these weights are calculated on a dry weight basis.

[0051] In this embodiment, the amorphous solid of the second aerosol-forming material may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 5% to about 40% by weight, or about 10% to about 30% by weight, or about 15% to about 25% by weight; aerosol-forming material in an amount of about 10% to about 50% by weight, or about 20% to about 40% by weight, or about 25% to about 35% by weight (all calculated on a dry weight basis); and flavoring in an amount of about 30% to about 60% by weight, or about 40% to about 55% by weight, or about 45% to about 50% by weight. Preferably, the amorphous solid of the second aerosol-forming material may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 30% to about 60% by weight, aerosol-forming material in an amount of about 10% to about 40% by weight, and flavoring agent in an amount of about 10% to about 50% by weight.

[0052] In this embodiment, the amorphous solid of the third aerosol-forming material, which comprises the active substance but does not include flavoring or acid, is 0.5 to 60 wt. % of a gelling agent; 5 to 80 weight percent of an aerosol-forming material; 5 to 60% by weight of at least one active substance; where these weights are calculated on a dry weight basis.

[0053] In this embodiment, the amorphous solid of the third aerosol-forming material may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 5% to about 40% by weight, or about 10% to about 30% by weight, or about 15% to about 25% by weight; aerosol-forming material in an amount of about 10% to about 50% by weight, or about 20% to about 40% by weight, or about 25% to about 35% by weight (all calculated on a dry weight basis); active agent in an amount of about 30% to about 60% by weight, or about 40% to 55% by weight, or about 45% to about 50% by weight. Preferably, the amorphous solid of the first aerosol-forming material may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 30% to about 60% by weight, aerosol-forming material in an amount of about 20% to about 60% by weight, and active agent in an amount of about 0.1% to about 10% by weight.

[0054] In this embodiment, the amorphous solid of the fourth aerosol-forming material, which comprises an acid but is free of an active agent and a flavoring agent, is 0.5 to 60 wt. % of a gelling agent; 5 to 80 weight percent of an aerosol-forming material; 0.1 to 10% by weight of acid where these weights are calculated on a dry weight basis.

[0055] In this embodiment, the amorphous solid of the fourth aerosol-forming material may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 5% to about 40% by weight, or about 10% to about 30% by weight, or about 15% to about 25% by weight; aerosol-forming material in an amount of about 10% to about 50% by weight, or about 20% to about 40% by weight, or about 25% to about 35% by weight (all calculated on a dry weight basis); acid in an amount of about 0.1% to about 8% by weight, or about 0.5% to about 7% by weight, or about 1% to about 5% by weight, or about 1% to about 3% by weight. Preferably, the amorphous solid of the fourth aerosol-forming material may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 40% to about 70% by weight, aerosol-forming material in an amount of about 20% to about 50% by weight, and acid in an amount of about 0.1% to about 5% by weight.

[0056] compound The following formulations represent exemplary component amounts of each excipient in the aerosol-forming materials included in the consumables of the present invention.

[0057] In embodiments in which the amorphous solid of the aerosol-forming material in the consumable product comprises an active agent, in some such embodiments, the amorphous solid comprises: 0.5 to 60 wt. % of a gelling agent; 0 to 80 wt. % of an aerosol-forming material; 0.1 to 60% by weight of at least one active substance; where these weights are calculated on a dry weight basis.

[0058] In these embodiments, the amorphous solid of the aerosol-forming material may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 5% to about 40% by weight, or about 10% to about 30% by weight, or about 15% to about 25% by weight; aerosol-forming material in an amount of about 10% to about 70% by weight, or about 20% to about 60% by weight, or about 25% to about 40% by weight (all calculated on a dry weight basis); active agent in an amount of about 0.5% to about 50% by weight, or about 1% to about 40% by weight, or about 2% to about 30% by weight, or about 5% to about 20% by weight, or about 2% to about 10% by weight. Preferably, the amorphous solid of the aerosol-forming material may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 30% to about 60% by weight, aerosol-forming material in an amount of about 20% to about 60% by weight, and active agent in an amount of about 0.1% to about 10% by weight.

[0059] In embodiments in which the amorphous solid of the aerosol-forming material in the consumable product comprises a flavoring, in some such embodiments, the amorphous solid comprises: 0.5 to 60 wt. % of a gelling agent; 0 to 80 wt. % of an aerosol-forming material; 5 to 60% by weight of a flavoring; where these weights are calculated on a dry weight basis.

[0060] In these embodiments, the amorphous solid of the aerosol-forming material may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 5% to about 40%, or about 10% to about 30%, or about 15% to about 25% by weight; aerosol-forming material in an amount of about 10% to about 70%, or about 20% to about 60%, or about 25% to about 40% by weight (all calculated on a dry weight basis); and flavoring in an amount of about 10% to about 50%, or about 20% to about 40%, or about 25% to about 30% by weight. Preferably, the amorphous solid of the second aerosol-forming material may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 30% to about 60% by weight, aerosol-forming material in an amount of about 10% to about 40% by weight, and flavoring agent in an amount of about 20% to about 50% by weight.

[0061] In embodiments in which the amorphous solid of the aerosol-forming material in the consumable comprises an acid, in some such embodiments, the amorphous solid comprises: 0.5 to 60 wt. % of a gelling agent; 5 to 80 weight percent of an aerosol-forming material; 0.1 to 10% by weight of an acid; where these weights are calculated on a dry weight basis.

[0062] In these embodiments, the amorphous solid may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 5% to about 40% by weight, or about 10% to about 30% by weight, or about 15% to about 25% by weight; aerosol-forming material in an amount of about 10% to about 50% by weight, or about 20% to about 40% by weight, or about 25% to about 35% by weight (all calculated on a dry weight basis); acid in an amount of about 0.1% to about 8% by weight, or about 0.5% to about 7% by weight, or about 1% to about 5% by weight, or about 1% to about 3% by weight. Preferably, the amorphous solid of the second aerosol-forming material may have the following composition (all calculated on a dry weight basis): gelling agent in an amount of about 40% to about 70% by weight, aerosol-forming material in an amount of about 20% to about 50% by weight, and acid in an amount of about 0.1% to about 5% by weight.

[0063] Amorphous Solid Composition The following discussion of amorphous solid compositions applies independently to each amorphous solid of the aerosol-forming material present in the consumables of the present invention.

[0064] In some instances, the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Preferably, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm, 0.3 mm, or 0.2 mm. The inventors have found that an amorphous solid having a thickness of 0.2 mm is particularly suitable. In some embodiments, the amorphous solid may have a thickness of about 0.1 to 0.2 mm. The amorphous solid may comprise two or more layers, and the thicknesses described herein refer to the combined thickness of these layers.

[0065] The inventors have found that if the amorphous solid is too thick, heating efficiency is compromised, which negatively impacts power consumption during use. Conversely, if the amorphous solid is too thin, it is difficult to manufacture and handle. That is, very thin materials are more difficult to cast and are prone to breakage, which can impair aerosol formation during use.

[0066] The inventors have found that the thickness of the amorphous solid defined herein optimizes material properties taking into account these competing considerations.

[0067] The thicknesses specified herein are the average thickness of the material. In some instances, the thickness of the amorphous solid may vary by 25%, 20%, 15%, 10%, 5%, or 1% or less.

[0068] In some instances, the amorphous solid may be heated once to generate the aerosol. In some instances, the amorphous solid may be heated more than once, for example, two or three times, to generate the aerosol.

[0069] If the amorphous solid is heated more than once, a thicker amorphous solid may be used, for example, in some embodiments, the thickness may be 0.2 to 0.5 mm.

[0070] In some instances, the amorphous solid may comprise 1 to 60% by weight of gelling agent, where these weights are calculated on a dry weight basis.

[0071] In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginate, pectin, starch (and derivatives), cellulose (and derivatives, e.g., methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginate, pectin, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some examples, the gelling agent comprises alginate and / or pectin, which may be combined with a setting agent (such as a calcium source) during the formation of the amorphous solid. In some examples, the amorphous solid may comprise calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0072] In some instances, the gelling agent may be combined with a hardening agent (such as a calcium source) during the formation of the amorphous solid.

[0073] In examples, the hardening agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the hardening agent comprises or consists of calcium formate and / or calcium lactate. In particular examples, the hardening agent comprises or consists of calcium formate. The inventors have determined that the use of calcium formate as a hardening agent typically results in an amorphous solid having higher tensile strength and higher elongation resistance.

[0074] The total amount of hardening agent, e.g., calcium source, may be 0.5 to 5 wt. % (calculated on a dry weight basis). Preferably, 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 adding too little hardening agent may result in an amorphous solid that does not stabilize the amorphous solid components, causing these components to fall off the amorphous solid. The inventors have found that adding too much hardening agent results in an amorphous solid that is very sticky and therefore difficult to handle.

[0075] When the amorphous solid does not contain tobacco, a larger amount of hardener may need to be applied. In some instances, therefore, the total amount of hardener may be 0.5 to 12% by weight, e.g., 5 to 10% by weight, calculated on a dry weight basis. Preferably, the total amount may be about 5%, 6%, or 7% by weight to about 12% by weight or 10% by weight. In this instance, the amorphous solid generally does not contain tobacco.

[0076] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of 10-30% by weight (calculated on a dry weight basis) of the amorphous solid. In some embodiments, the alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one additional gelling agent, such as pectin.

[0077] In some embodiments, the gelling agent comprises a mixture of alginate and carboxymethylcellulose (CMC). Preferably, the gelling agent comprises a greater amount of CMC than alginate. For example, in some instances, the ratio of CMC to alginate is about 5:1, about 3:1, about 2:1, or about 1.5:1, e.g., within the range of 5:1 to 1.5:1.

[0078] In some embodiments, the amorphous solid may include a gelling agent comprising carrageenan.

[0079] In some embodiments, the gelling agent may comprise one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum, and combinations thereof.

[0080] In some embodiments, the cellulosic gelling agent is selected from the group consisting of hydroxypropyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0081] 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.

[0082] 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.

[0083] Preferably, the amorphous solid may comprise from about 5%, 10%, 15%, or 20% to about 80%, 70%, 60%, 55%, 50%, 45%, 40%, or 35% by weight of the aerosol-forming material (all calculated on a dry weight basis). The aerosol-forming material may act as a plasticizer. For example, the amorphous solid may comprise 10-60%, 15-50%, or 20-40% by weight of the aerosol-forming material. In some examples, the aerosol-forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some examples, the aerosol-forming material comprises, consists essentially of, or consists of glycerol. The inventors have found that if the content of aerosol-forming material is too high, the amorphous solid may absorb water, resulting in a material that does not produce a satisfactory consumption experience upon use. The inventors have found that if the content of aerosol-forming material is too low, the amorphous solid may become brittle and break easily.

[0084] In some embodiments, the aerosol forming agent comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols, such as glycerol mono-, di-, or triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0085] In embodiments in which the amorphous solid comprises a flavorant, the amorphous solid preferably comprises up to about 60%, 50%, 40%, 30%, 20%, 10%, or 5% by weight of flavorant. In some examples, the amorphous solid may comprise at least about 0.5%, 1%, 2%, 5%, 10%, 20%, or 30% by weight of flavorant (all calculated on a dry weight basis). For example, the amorphous solid may comprise 0.1-60%, 1-60%, 5-60%, 10-60%, 20-50%, or 30-40% by weight of flavorant. In some examples, the flavorant (if present) comprises, consists essentially of, or consists of menthol. In some examples, the amorphous solid does not comprise a flavorant.

[0086] In embodiments of the aerosol-forming material of the present invention comprising an active substance, in some instances, the amorphous solid comprises tobacco material and / or nicotine. For example, the amorphous solid may comprise powdered tobacco and / or nicotine and / or tobacco extract. In some instances, the amorphous solid may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 70%, 50%, 45%, or 40% by weight (calculated on a dry weight basis) of the active substance. In some instances, the amorphous solid may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 70%, 60%, 50%, 45%, or 40% by weight (calculated on a dry weight basis) of tobacco material and / or nicotine.

[0087] In embodiments in which the aerosol-forming material comprises an active substance such as tobacco extract, in some instances, the amorphous solid may comprise 5-60% by weight (calculated on a dry weight basis) of tobacco extract. In some instances, the amorphous solid may comprise about 5%, 10%, 15%, 20%, or 25% by weight to about 55%, 50%, 45%, or 40% by weight (calculated on a dry weight basis) of tobacco extract. For example, the amorphous solid may comprise 5-60%, 10-55%, or 25-55% by weight of tobacco extract. The tobacco extract may comprise nicotine at a concentration such that the amorphous solid comprises 1%, 1.5%, 2%, or 2.5% by weight to about 6%, 5%, 4.5%, or 4% by weight of nicotine (calculated on a dry weight basis). In some instances, no nicotine other than that originating from the tobacco extract may be present in the amorphous solid.

[0088] In some embodiments, the amorphous solid does not comprise tobacco material but does comprise nicotine. In some such examples, the amorphous solid may comprise from about 1%, 2%, 3%, or 4% to about 20%, 15%, 10%, or 5% by weight of nicotine (calculated on a dry weight basis). For example, the amorphous solid may comprise from 1 to 20% or from 2 to 5% by weight of nicotine.

[0089] In embodiments in which the amorphous solid comprises an acid, the amorphous solid may comprise 1 to 20%, 5 to 15%, or 8 to 12% by weight of acid (calculated on a dry weight basis), for example, 1%, 2%, 3%, or 4% to about 20%, 15%, 10%, or 5% by weight of acid (calculated on a dry weight basis).

[0090] Without wishing to be bound by theory, it is believed that the inclusion of an acid in the amorphous solid protonates the nicotine, resulting in an aerosol that some users of smoking devices find more satisfactory.

[0091] The aerosol-forming material or amorphous solid may comprise an acid.

[0092] The inclusion of an acid is particularly preferred in embodiments in which the aerosol-forming material or amorphous solid comprises nicotine. In such embodiments, the presence of an acid can stabilize dissolved species in the slurry from which the aerosol-forming material or amorphous solid is formed. The presence of an acid can reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing nicotine loss during manufacturing.

[0093] In some such embodiments, the acid may comprise an acidic functional group, which has a pK in the range of 2 to 6, e.g., in the range of 3 to 6, or in the range of 4 to 5, when measured at 25°C. a It has a value.

[0094] In some such embodiments, the acid may have a boiling point in the range of 70°C to 450°C, for example, in the range of 100°C to 320°C.

[0095] In some such embodiments, the amorphous solid may comprise 1 to 20 wt. % of an acid, the acid having a pK in the range of 2 to 6 when measured at 25°C. a The acid has a functional group having a value of 0.05, and the acid has a boiling point in the range of 70°C to 350°C.

[0096] In some such embodiments, the acid may be an organic acid.

[0097] In some of these embodiments, the acid may be at least one of a monobasic acid, a dibasic acid, and a tribasic acid.

[0098] In some such embodiments, the acid may include at least one carboxyl functional group.

[0099] In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid.

[0100] In some such embodiments, the acid may be an alpha-keto acid.

[0101] In some such embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic acid, and pyruvic acid.

[0102] Preferably, the acid is lactic acid. In another embodiment, the acid is benzoic acid.

[0103] In other embodiments, the acid may be an inorganic acid. In some of these embodiments, the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulfuric acid, hydrochloric acid, boric acid, and phosphoric acid.

[0104] In some embodiments, the acid is levulinic acid.

[0105] In embodiments in which the amorphous solid comprises an acid, the amorphous solid may comprise from 1%, 2%, 3%, or 4% to about 20%, 15%, 10%, or 5% by weight (calculated on a dry weight basis) of an organic acid.

[0106] In embodiments in which the amorphous solid comprises an acid, the amorphous solid may comprise from 1%, 2%, 3%, or 4% to about 20%, 15%, 10%, or 5% by weight (calculated on a dry weight basis) of an acid with carboxyl functionality.

[0107] In embodiments in which the amorphous solid comprises an acid, the amorphous solid may comprise from 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 15 wt%, 10 wt%, or 5 wt% (calculated on a dry weight basis) of an acid containing an acidic functional group, which has a pK of 2 to 6 when measured at 25°C. a It has a value.

[0108] In certain embodiments, the aerosol-forming material or amorphous solid comprises a gelling agent, including a cellulosic gelling agent and / or a non-cellulosic gelling agent, an active agent, and an acid.

[0109] The amorphous solid may, in some instances, be a hydrogel and comprise less than about 20%, 15%, 12%, or 10% water by weight, calculated on a wet weight basis (WWB). In some instances, the amorphous solid may comprise at least about 1%, 2%, or 5% water by weight (WWB). The amorphous solid may comprise from about 1% to about 15%, or from about 5% to about 15% water by weight, calculated on a wet weight basis. Preferably, the water content of the amorphous solid may be from about 5%, 7%, or 9% to about 15%, 13%, or 11% by weight (WWB), most preferably about 10% by weight.

[0110] The amorphous solid may be made from a gel, which may further comprise a solvent present at 0.1 to 50% by weight. However, the present inventors have found that the inclusion of a solvent in which the flavoring agent can dissolve reduces gel stability and may cause the flavoring agent to leave the gel and crystallize. Therefore, in some examples, the gel does not include a solvent in which the flavoring agent can dissolve.

[0111] In some instances, the amorphous solid comprises 1-60 wt% filler, e.g., 5-50 wt%, 10-40 wt%, or 15-30 wt% filler, hi some such instances, the amorphous solid 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.

[0112] In some embodiments, the amorphous solid comprises less than 60% by weight of filler, for example, between 1% and 60% by weight, or between 5% and 50% by weight, or between 5% and 30% by weight, or between 10% and 20% by weight of filler.

[0113] In other embodiments, the amorphous solid comprises less than 20% by weight of filler, preferably less than 10% by weight or less than 5% by weight, hi some instances, the amorphous solid comprises less than 1% by weight of filler, and in some instances, no filler.

[0114] When a filler is present, the filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents (such as molecular sieves). The filler may comprise one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives (such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). In some instances, the amorphous solid comprises less than 1% by weight of a filler, and in some instances, no filler. In particular, in some instances, the amorphous solid does not comprise calcium carbonate, such as chalk.

[0115] 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 (such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). Without wishing to be bound by theory, it is believed that including a fibrous filler in an amorphous solid can increase the tensile strength of the material.

[0116] In some embodiments, the amorphous solid does not comprise tobacco fiber. In certain embodiments, the amorphous solid does not comprise fibrous material.

[0117] In some embodiments, the aerosol-forming material does not comprise tobacco fiber. In certain embodiments, the aerosol-forming material does not comprise fibrous material.

[0118] In some embodiments, the aerosol-forming material does not comprise tobacco fiber. In certain embodiments, the aerosol-forming material does not comprise fibrous material.

[0119] In some embodiments, the consumable product does not comprise tobacco fiber. In certain embodiments, the consumable product does not comprise fibrous material.

[0120] The aerosol-forming material comprising an amorphous solid may have any suitable areal density, for example, 30 g / m 2 ~120g / m 2 In some embodiments, the aerosol-forming material may have a density of about 30 to 70 g / m 2 , or about 40 to 60 g / m 2 In some embodiments, the amorphous solid may have an areal density of about 80-120 g / m 2 , or approximately 70 to 110 g / m 2 , or in particular about 90 to 110 g / m 2 The surface density may be

[0121] In some cases, the amorphous solid in sheet form may have a tensile strength of about 200 N / m to about 900 N / m. In some cases, such as when the amorphous solid does not include a filler, the amorphous solid may have a tensile strength of 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or about 250 N / m. In some cases, such as when the amorphous solid includes a filler, the amorphous solid may have a tensile strength of 600 N / m to 900 N / m, or 700 N / m to 900 N / m, or about 800 N / m.

[0122] The amorphous solid may comprise a colorant. The addition of a colorant can change the visual appearance of the amorphous solid. The presence of a colorant in the amorphous solid can enhance the visual appearance of the amorphous solid and the aerosol-forming material. By adding a colorant to the amorphous solid, the amorphous solid can match the color of other components of the aerosol-forming material or other components of an article comprising the amorphous solid.

[0123] Various colorants may be used depending on the desired color of the amorphous solid. The color of the amorphous solid may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food-grade colorants, and pharmaceutical-grade colorants. In certain embodiments, the colorant is caramel, which may impart a brown appearance to the amorphous solid. In such embodiments, the color of the amorphous solid may be similar to the color of other components (e.g., tobacco material) in the aerosol-forming material that comprises the amorphous solid. In some embodiments, the addition of a colorant to the amorphous solid renders the amorphous solid visually indistinguishable from other components in the aerosol-forming material.

[0124] The colorant may be incorporated during the formation of the amorphous solid (e.g., when forming a slurry with the materials that will form the amorphous solid), or the colorant may be applied to the amorphous solid after its formation (e.g., by spraying the colorant onto the amorphous solid).

[0125] How to manufacture consumables The present invention also provides a method of making a consumable for use with a non-combustion aerosol delivery device, the method comprising: providing a support; depositing at least two separate portions of a slurry comprising a gelling agent, an aerosol forming agent, and at least one of an active agent, a flavoring agent, and an acid onto a substrate; drying at least two separate portions of the slurry to obtain a first aerosol-forming material and a second aerosol-forming material, the first and second aerosol-forming materials being attached to a support; forming a consumable; wherein each of the first and second aerosol-forming materials comprises an amorphous solid, the amorphous solid comprising: 0.5 to 60 wt. % of a gelling agent; 0 to 80 wt. % of an aerosol-forming material; 0-60% by weight of at least one of an active substance, a flavoring agent, and an acid; wherein the weights are calculated on a dry weight basis, and wherein the amorphous solid of the first aerosol-forming material has a composition that is different from the composition of the amorphous solid of the second aerosol-forming material.

[0126] The embodiments described throughout this application in connection with the consumables of the present invention also apply mutatis mutandis to the methods of manufacturing the consumables.

[0127] The present invention also includes the use of the consumables described throughout this application in a non-combustion aerosol delivery device that is configured to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

[0128] The embodiments described throughout this application in connection with the consumables of the present invention also apply mutatis mutandis to the use of the consumables.

[0129] consumables In some instances, the aerosol-generating materials (e.g., the first and second aerosol-generating materials) are attached to a support. Advantageously, the support is a flat support. In some instances, the support may be substantially or completely impermeable to gases and / or aerosols. This prevents the aerosol or gas from passing through the support, thereby controlling flow and ensuring good delivery to the user. This can also be used to prevent condensation or other deposition of the gas / aerosol during use, for example, on the surface of a heater provided in a non-combustion aerosol delivery system. In this way, consumption efficiency and hygiene can be improved in some instances. Thus, in certain embodiments, the present invention provides a consumable for use in a non-combustion aerosol delivery system, the consumable comprising: A support; a first aerosol-generating material attached to a support; a second aerosol-generating material attached to a support; and each aerosol-forming material comprises an amorphous solid, the amorphous solid comprising: 0.5 to 60 wt. % of a gelling agent; 0 to 80 wt. % of an aerosol-forming material; 0-60% by weight of at least one of an active substance, a flavoring agent, and an acid; wherein these weights are calculated on a dry weight basis; The amorphous solid of the first aerosol-forming material has a different composition than the amorphous solid of the second aerosol-forming material.

[0130] The support may be at least partially porous in the area of ​​its surface that abuts the amorphous solid. The inventors have found that such supports are particularly suitable for the present invention, with the porous section of the support abutting the amorphous solid and forming a strong bond. The amorphous solid is formed by drying a gel, and, without being limited by theory, it is believed that the slurry that forms the amorphous solid partially impregnates the porous material of the support, such that the support is partially bonded to the amorphous solid as it hardens and forms crosslinks. This results in a strong bond between the amorphous solid and the support.

[0131] Additionally, surface roughness can contribute to the strength of the bond between the amorphous solid and the substrate. The inventors have found that the roughness of the paper (the surface that contacts the aerosol-generating material) can be preferably in the range of 50 to 1000 Bekk seconds, preferably in the range of 50 to 150 Bekk seconds, and preferably 100 Bekk seconds (measured over a pressure range of 50.66 to 48.00 kPa). (The Bekk smoothness tester is an instrument used to measure the smoothness of paper surfaces. In this tester, air at a specified pressure is forced between a smooth glass surface and a paper sample. The time (in seconds) for a fixed volume of air to penetrate between these surfaces is the "Bekk smoothness.")

[0132] Conversely, the surface of the support that does not face the amorphous solid may be placed in contact with the heater, and the smoother surface may provide more efficient heat transfer. Thus, in some instances, the support is positioned to have a rougher side that abuts the amorphous solid and a smoother side that does not face the amorphous solid.

[0133] In one particular example, the support may itself be a laminated structure. For example, the support may comprise a foil backed with cardboard, the cardboard layer abutting the amorphous solid, which abuts to provide the properties discussed in the preceding paragraphs. The foil backing is substantially impermeable and provides aerosol flow path control. The metal foil backing may also act to transfer heat to the amorphous solid.

[0134] In another example, a foil layer of a cardboard backing foil abuts the amorphous solid, the foil being substantially impermeable to prevent moisture provided in the amorphous solid from being absorbed into the paper, which could weaken the structural integrity of the paper.

[0135] In some examples, the support is formed from or comprises a metal foil (e.g., aluminum foil). A metal support may allow for better transfer of thermal energy to the amorphous solid. Additionally, or alternatively, the metal foil may function as a susceptor in an induction heating system. In certain embodiments, the support comprises a metal foil layer and a support layer (e.g., cardboard). In these embodiments, the metal foil layer may have a thickness of less than 20 μm, for example, from about 1 μm to about 10 μm, preferably about 5 μm.

[0136] The consumable may also be referred to herein as a cartridge. The consumable may be adapted for use in a THP, a hybrid device, or another aerosol generating device. In some examples, the consumable may be in the form of a rod. In some examples, the consumable may further comprise a filter and / or a cooling element as previously described. In some examples, the consumable may be surrounded by a packaging material, such as paper.

[0137] The consumable may further include vent holes. These may be located in the sidewalls of the consumable. In some instances, the vent holes may be located in the filter and / or cooling element. These holes allow cool air to be drawn into the consumable during use, where it can mix with the heated volatile components, thereby cooling the aerosol.

[0138] Ventilation promotes the production of visible heated volatiles from the consumable when the consumable is heated during use. The heated volatiles are made visible by cooling the heated volatiles such that supersaturation of the heated volatiles occurs. The heated volatiles then undergo droplet formation (also known as nucleation), and ultimately, the size of the aerosol particles of the heated volatiles increases due to further condensation of the heated volatiles and coalescence of newly formed droplets from the heated volatiles.

[0139] In some instances, the ratio of cool air to the sum of heated volatiles and cool air (known as the ventilation ratio) is at least 15%. A ventilation ratio of 15% allows the heated volatiles to be visualized by the methods described above. The visibility of the heated volatiles allows the user to discern that volatiles are being produced, enhancing the sensory experience of the smoking experience.

[0140] In another example, the ventilation ratio is between 50% and 85% to further cool the heated volatile components. In some examples, the ventilation ratio may be at least 60% or 65%.

[0141] 1 and 2, there are shown a partially cutaway cross-sectional view and a perspective view of an example aerosol-generating consumable 101. The consumable 101 is adapted for use with a device having a power source and a heater. This embodiment of the consumable 101 is particularly suited for use with the device 51 shown in FIGS. 5-7, which are described below. In use, the consumable 101 can be removably inserted into the device 51 at insertion point 20 shown in FIG. 5.

[0142] One example consumable 101 is in the form of a generally cylindrical rod including a body of aerosol-generating material 103 and a filter assembly 105 in the form of a rod. The aerosol-generating material comprises an amorphous solid material as described herein. In some embodiments, it may be included in sheet form. In some embodiments, it may be included in chopped sheet form. In some embodiments, the aerosol-generating material as described herein may be incorporated in both sheet and chopped form.

[0143] The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109, and an oral end segment 111. The consumable 101 has a first end 113, also known as the oral or proximal end, and a second end 115, also known as the distal end. The body of aerosol-generating material 103 is disposed at the distal end 115 of the consumable 101. In one example, the cooling segment 107 is disposed adjacent to the body of aerosol-generating material 103, between the body of aerosol-generating material 103 and the filter segment 109, such that the cooling segment 107 is in abutting relationship with the aerosol-generating material 103 and the filter segment 109. In another example, there may be separations between the body of aerosol-generating material 103 and the cooling segment 107 and between the body of aerosol-generating material 103 and the filter segment 109. The filter segment 109 is disposed between the cooling segment 107 and the oral end segment 111. Oral end segment 111 is disposed at proximal end 113 of consumable 101 and is adjacent to filter segment 109. In one example, filter segment 109 is in an abutting relationship with oral end segment 111. In one embodiment, the overall length of filter assembly 105 is between 37 mm and 45 mm, and more preferably, the overall length of filter assembly 105 is 41 mm.

[0144] In one example, the rod of aerosol-forming material 103 has a length between 34 mm and 50 mm, preferably between 38 mm and 46 mm, and preferably 42 mm.

[0145] In one example, the overall length of the consumable 101 is between 71 mm and 95 mm, preferably between 79 mm and 87 mm, and more preferably 83 mm.

[0146] One axial end of the body 103 of aerosol-generating material is visible at the distal end 115 of the consumable 101. However, in other embodiments, the distal end 115 of the consumable 101 may include an end piece (not shown) that covers one axial end of the body 103 of aerosol-generating material.

[0147] The body of aerosol-generating material 103 is joined to the filter assembly 105 by an annular tipping paper (not shown) that is disposed substantially around the periphery of the filter assembly 105 to surround it and extends partially along the length of the body of aerosol-generating material 103. In one example, the tipping paper is made from 58 GSM standard tipping base paper. In one example, the tipping paper has a length of 42 mm to 50 mm, preferably 46 mm.

[0148] In one example, the cooling segment 107 is an annular tube that surrounds and defines a cavity within the cooling segment. This cavity provides a chamber through which heated volatile components generated from the body of aerosol-generating material 103 flow. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and use of the consumable 101 during insertion into the device 51. In one example, the wall thickness of the cooling segment 107 is approximately 0.29 mm.

[0149] The cooling segment 107 provides a physical displacement between the aerosol-generating material 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 creates a thermal gradient across the length of the cooling segment 107. In one example, the cooling segment 107 is configured to create a temperature difference of at least 40 degrees Celsius between the heated volatile component entering the first end of the cooling segment 107 and the heated volatile component exiting the second end of the cooling segment 107. In one example, the cooling segment 107 is configured to create a temperature difference of at least 60 degrees Celsius between the heated volatile component entering the first end of the cooling segment 107 and the heated volatile component exiting the second end of the cooling segment 107. This temperature difference across the length of the cooling segment 107 protects the temperature-sensitive filter segment 109 from the high temperatures of the aerosol-generating material 103 when the aerosol-generating material 103 is heated by the device 51. If no physical displacement is provided between the filter segment 109 and the aerosol-generating material body 103 and the heating element of the device 51, the temperature-sensitive filter segment 109 may be damaged during use and may no longer be able to effectively perform its required function.

[0150] In one example, the length of the cooling segment 107 is at least 15 mm. In one example, the length of the cooling segment 107 is between 20 mm and 30 mm, more specifically between 23 mm and 27 mm, even more specifically between 25 mm and 27 mm, and preferably 25 mm.

[0151] The cooling segment 107 is made from paper, meaning that the cooling segment 107 is constructed from a material that, in use, does not produce compounds of concern (e.g., toxic compounds) when adjacent to the heater of the device 51. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube that provides a hollow interior chamber but maintains mechanical rigidity. The spirally wound paper tube can meet the stringent dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness, and straightness.

[0152] In another example, cooling segment 107 is a recess made from stiff plug wrap or tipping paper that is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacturing and use of consumable 101 during insertion into device 51.

[0153] The filter segment 109 may be formed from any filter material sufficient to remove one or more volatile compounds from the heated volatile components from the aerosol-generating material. In one example, the filter segment 109 is made from a monoacetate material, such as cellulose acetate. The filter segment 109 provides cooling and reduced irritation of the heated volatile components without depleting the amount of the heated volatile components to an unsatisfactory level for the user.

[0154] In some embodiments, a capsule (not shown) may be provided within filter segment 109. The capsule may be located substantially in the center of filter segment 109, both radially and longitudinally. In other examples, the capsule may be off-center in one or more dimensions. In some examples, if a capsule is present, the capsule may contain a volatile component, such as a flavoring or an aerosol-forming agent.

[0155] The density of the cellulose acetate tow material of the filter segment 109 controls the pressure drop across the filter segment 109, which in turn controls the resistance to draw of the consumable 101. Therefore, the selection of material for the filter segment 109 is important in controlling the resistance to draw of the consumable 101. Additionally, the filter segment performs a filtration function in the consumable 101.

[0156] In one example, filter segment 109 is made from 8Y15 grade filter tow material, which provides filtering for the heated volatilized material while reducing the size of the condensed aerosol droplets resulting from the heated volatilized material.

[0157] The presence of filter segment 109 provides an insulating effect by further cooling the heated volatile components exiting cooling segment 107. This additional cooling effect reduces the contact temperature of the user's lips against the surface of filter segment 109.

[0158] In one example, the filter segment 109 has a length of 6 mm to 10 mm, preferably 8 mm.

[0159] The oral end segment 111 is an annular tube that surrounds and defines a cavity within the oral end segment 111. This cavity provides a chamber for heated volatile components flowing from the filter segment 109. The oral end segment 111 is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during use of the consumable during manufacturing and insertion into the device 51. In one example, the wall thickness of the oral end segment 111 is approximately 0.29 mm. In one example, the length of the oral end segment 111 is between 6 mm and 10 mm, preferably 8 mm.

[0160] The mouth end segment 111 may be manufactured from a spiral wound paper tube that provides a hollow interior chamber but maintains significant mechanical rigidity. A spiral wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes with respect to tube length, outer diameter, roundness, and straightness.

[0161] The mouth end segment 111 serves the function of preventing liquid condensate that accumulates at the outlet of the filter segment 109 from coming into direct contact with the user.

[0162] It should be understood that in one example, the mouth end segment 111 and the cooling segment 107 may be formed from a single tube, with the filter segment 109 positioned within the tube to separate the mouth end segment 111 and the cooling segment 107.

[0163] 3 and 4, there are shown a partial cutaway cross-sectional view and a perspective view of an example consumable 301. The reference numbers shown in Figures 3 and 4 correspond to the reference numbers shown in Figures 1 and 2, but are increased by 200.

[0164] 3 and 4, a ventilation region 317 is provided in the consumable 301 to allow air to flow from the exterior of the consumable 301 to the interior of the consumable 301. In one example, the ventilation region 317 takes the form of one or more ventilation holes 317 formed through an outer layer of the consumable 301. The ventilation holes may be located in the cooling segment 307 to aid in cooling the consumable 301. In one example, the ventilation region 317 comprises one or more rows of holes, preferably each row of holes located along the periphery of the consumable 301 in a cross section substantially perpendicular to the longitudinal axis of the consumable 301.

[0165] In one example, there are 1 to 4 rows of vent holes to provide ventilation to the consumable 301. Each row of vent holes may have 12 to 36 vent holes 317. The diameter of the vent holes 317 may be, for example, 100 to 500 μm. In one example, the axial spacing between rows of vent holes 317 is 0.25 mm to 0.75 mm, preferably 0.5 mm.

[0166] In one example, the vent holes 317 have a uniform size. In another example, the vent holes 317 have a variety of sizes. The vent holes can be created using any suitable technique, such as one or more of laser techniques, mechanical drilling of the cooling segment 307, or pre-drilling of the cooling segment 307 before it is formed in the consumable 301. The vent holes 317 are positioned to effectively cool the consumable 301.

[0167] In one example, the row of vent holes 317 is located at least 11 mm from the proximal end 313 of the consumable, and preferably 17 mm to 20 mm from the proximal end 313 of the consumable 301. The location of the vent holes 317 is determined so that the user will not block the vent holes 317 when the consumable 301 is in use.

[0168] By providing a row of vent holes 17-20 mm from the proximal end 313 of the consumable 301, the vent holes 317 can be positioned on the outside of the device 51 when the consumable 301 is fully inserted into the device 51, as seen in Figures 6 and 7. By positioning the vent holes on the outside of the device, unheated air can enter the consumable 301 from outside the device 51 through the vent holes to help cool the consumable 301.

[0169] The length of the cooling segment 307 is such that when the consumable 301 is fully inserted into the device 51 , the cooling segment 307 is partially inserted into the device 51 . The length of the cooling segment 307 serves two functions: first, to provide a physical gap between the heating device of the device 51 and the heat-sensitive filter device 309; and second, to allow the vent hole 317 to be located within the cooling segment while also being located outside the device 51 when the consumable 301 is fully inserted into the device 51. As can be seen in FIGS. 6 and 7 , the majority of the cooling element 307 is located within the device 51. However, there is a portion of the cooling element 307 that extends outside the device 51. The vent hole 317 is located in this portion of the cooling element 307 that extends outside the device 51.

[0170] 5-7, an example of a device 51 is shown that is configured to heat an aerosol-forming material to volatilize at least one component of the aerosol-forming material, typically to form an inhalable aerosol. Device 51 is a heating device that releases compounds by heating, but not burning, the aerosol-forming material.

[0171] The first end 53 may be referred to herein as the oral or proximal end 53 of the device 51, and the second end 55 may be referred to herein as the distal end 55 of the device 51. The device 51 has an on / off button 57 that allows the entire device 51 to be activated and deactivated as desired by the user.

[0172] The device 51 includes a housing 59 for arranging and protecting the various internal components of the device 51. In the illustrated example, the housing 59 includes a unitary sleeve 11 that surrounds the outer edge of the device 51, the sleeve 11 being capped by a top panel 17 that generally forms the "top" of the device 51 and a bottom panel 19 that generally forms the "bottom" of the device 51. In another example, the housing includes a front panel, a rear panel, and a pair of opposing side panels in addition to the top panel 17 and bottom panel 19.

[0173] Top panel 17 and / or bottom panel 19 may be removably secured to unitary sleeve 11 to allow easy access to the interior of device 51, or may be "permanently" secured to unitary sleeve 11, for example, to prevent a user from accessing the interior of device 51. In one example, panels 17 and 19 are made of a plastic material (including, for example, glass-filled nylon formed by injection molding) and unitary sleeve 11 is made of aluminum, although other materials and manufacturing processes may be used.

[0174] The top panel 17 of the device 51 has an opening 20 at the mouth end 53 of the device 51, through which a user can insert and remove consumables 101, 301 containing aerosol-generating materials into and from the device 51 during use.

[0175] Housing 59 has disposed therein or secured thereto heating device 23, control circuitry 25, and power supply 27. In this example, heating device 23, control circuitry 25, and power supply 27 are laterally adjacent (i.e., adjacent when viewed from one end), with control circuitry 25 generally located between heating device 23 and power supply 27, although other arrangements are possible.

[0176] The control circuitry 25 may include a controller, such as a microprocessor device, constructed and arranged to control the heating of the aerosol-generating material within the consumable 101, 301, as discussed further below.

[0177] Power source 27 may be, for example, a battery, which may be rechargeable or non-rechargeable. Suitable examples of batteries include, for example, lithium-ion batteries, nickel batteries (e.g., nickel-cadmium batteries), alkaline batteries, etc. Battery 27 is electrically coupled to heating device 23 and, under the control of control circuitry 25, provides power when needed to heat the aerosol-forming material within the consumable (to volatilize the aerosol-forming material without burning it, as described above).

[0178] An advantage of locating power supply 27 laterally adjacent to heating apparatus 23 is that a physically larger power supply 25 can be used without excessively lengthening the overall length of device 51. Of course, a physically larger power supply 25 generally has a higher capacity (i.e., the total electrical energy it can deliver, often measured in ampere-hours or the like) and therefore can provide a longer battery life for device 51.

[0179] In one example, the heating device 23 is generally in the form of a hollow cylindrical tube having a hollow internal heating chamber 29 into which the consumable 101, 301 comprising the aerosol-generating material is inserted for heating during use. Various configurations of the heating device 23 are possible. For example, the heating device 23 may comprise a single heating element or may be formed from multiple heating elements aligned along the longitudinal axis of the heating device 23. The or each heating element may be annular or tubular, or may be at least partially annular or at least partially tubular around its circumference. In one example, the or each heating element may be a thin-film heater. In another example, the or each heating element may be made from a ceramic material. Examples of suitable ceramic materials include alumina ceramic and aluminum nitride ceramic, as well as silicon nitride ceramic, which may be layered and sintered. Other heating configurations are also possible, including, for example, induction heating, infrared heating elements (which heat by radiating infrared radiation), and resistive heating elements formed by resistive electrical windings, etc.

[0180] In one particular example, the heating device 23 is supported by a stainless steel support tube and includes a polyimide heating element. The heating device 23 is dimensioned such that when the consumable 101, 301 is inserted into the device 51, substantially the entire body of the aerosol-forming material 103, 303 of the consumable 101, 301 is inserted into the heating device 23.

[0181] The or each heating element may be arranged to heat selected zones (areas) of aerosol-forming material independently, for example sequentially (over time as described above) or together (simultaneously), as desired.

[0182] The heating device 23 in this example is surrounded by insulation 31 along at least a portion of its length. The insulation 31 helps reduce heat passing from the heating device 23 to the exterior of the device 51. This generally reduces heat loss, and therefore helps keep the power requirements of the heating device 23 low. The insulation 31 also helps keep the exterior of the device 51 cool during operation of the heating device 23. In one example, the insulation 31 may be a double-walled sleeve that provides a low-pressure region between the two walls of the sleeve. That is, the insulation 31 may be, for example, a "vacuum" tube, i.e., a tube that is at least partially evacuated to minimize heat transfer by conduction and / or convection. Other configurations for the insulation 31 are possible, including the use of insulating materials (e.g., including suitable foam-type materials) in addition to or in place of the double-walled sleeve.

[0183] The housing 59 may further include various internal support structures 37 for supporting all internal components as well as the heating device 23 .

[0184] The device 51 further includes a collar 33 extending around the opening 20 and projecting from the opening 20 into the interior of the housing 59, and a generally tubular chamber 35 disposed between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further includes a cooling structure 35f, which in this example includes a plurality of cooling fins 35f spaced along the exterior surface of the chamber 35, each fin circumferentially disposed about the exterior surface of the chamber 35. When the consumable 101, 301 is inserted into the device 51 over at least a portion of the length of the hollow chamber 35, a gap 36 exists between the hollow chamber 35 and the consumable 101, 301. The gap 36 surrounds the entire periphery of the consumable 101, 301 over at least a portion of the cooling segment 307.

[0185] The collar 33 includes a plurality of ridges 60 arranged around the periphery of the opening 20, which protrude into the opening 20. The ridges 60 occupy space within the opening 20 such that the opening distance of the opening 20 at the location of the ridges 60 is less than the opening distance of the opening 20 without the ridges 60. The ridges 60 are configured to engage with the consumable 101, 301 inserted within the device 51 to help secure it therein. Open spaces (not shown) defined by adjacent pairs of the ridges 60 and the consumable 101, 301 form ventilation paths around the outer surface of the consumable 101, 301. These ventilation paths allow hot steam escaping from the consumable 101, 301 to exit the device 51 and allow cooling air to flow within the gap 36 around the consumable 101, 301 and into the device 51.

[0186] In operation, the consumable 101, 301 is removably inserted into the insertion site 20 of the device 51, as shown in Figures 5-7. Referring particularly to Figure 6, in one example, the body of aerosol-generating material 103, 303 (which is located at the distal end 115, 315 of the consumable 101, 301) is completely contained within the heating assembly 23 of the device 51. The proximal end 113, 313 of the consumable 101, 301 extends from the device 51 and serves as a mouthpiece assembly for the user.

[0187] During operation, the heating device 23 heats the consumable 101, 301 to volatilize at least one component of the aerosol-forming material from the body 103, 303 of aerosol-forming material.

[0188] The primary flow path for heated volatiles from the body of aerosol-generating material 103, 303 is axially through the consumable 101, 301, through the inner chamber of the cooling segment 107, 307, through the filter segment 109, 309, and through the mouth-end segment 111, 313 to the user. In one example, the temperature of heated volatiles generated from the body of aerosol-generating material ranges from 60°C to 250°C, which may exceed acceptable inhalation temperatures for a user. As the heated volatiles travel through the cooling segment 107, 307, they cool, causing some volatiles to condense on the interior surface of the cooling segment 107, 307.

[0189] 3 and 4, cool air can enter the cooling segment 307 through vents 317 formed in the cooling segment 307. This cool air mixes with the heated volatile components to further cool the heated volatile components.

[0190] Advantageously, the consumables of the present invention allow each of the first and second aerosol-generating materials to be aerosolized separately. In other words, the generation of aerosol from each aerosol-generating material may be under separate control, such that the generation of aerosol produced by each aerosol-generating material can be individually varied. In embodiments in which the non-combustion aerosol delivery system uses heat to generate aerosol, each aerosol-generating material in the consumable may be under the control of a separate heat-generating component. In such embodiments, the temperature of each aerosol-generating material may be separately controlled to stimulate the release of a desired amount of aerosol from each aerosol-generating material. In this manner, the non-combustion aerosol delivery system is configured to allow a user to aerosolize the first and / or second aerosol-generating materials according to personal preference. As a non-limiting example provided to illustrate the present invention, the amorphous solid of a first aerosol-generating material may comprise a flavoring and no active substance, while the amorphous solid of a second aerosol-generating material may comprise an active substance and no flavoring. If a user wishes to inhale only the flavoring, the non-combustion aerosol delivery system may enable this; for example, the user may program the non-combustion aerosol delivery device to aerosolize the first aerosol-generating material (which comprises the flavoring) but not the second aerosol-generating material (which comprises the active substance). It will be appreciated that such systems may be further configured to allow users to obtain a wide variety of smoking experiences according to their preferences.

[0191] In some embodiments, the aerosol-generating materials are arranged in a consumable such that, when used in a non-combustion aerosol delivery system, the aerosol-generating materials can be stimulated to generate an aerosol under separate control from one another.

[0192] The advantage of the consumable product of the present invention is that a single type of consumable product can be manufactured on a single manufacturing line or facility, thereby providing a variety of experiences according to user preferences.

[0193] In some examples, the heater (e.g., a heater in a non-combustion aerosol delivery system) may heat the amorphous solid to between 120°C and 350°C in use without burning the amorphous solid. In some examples, the heater may heat the amorphous solid to between 140°C and 250°C in use without burning the amorphous solid.

[0194] The heater may comprise one or more electrical resistance heater(s), including one or more nichrome resistance heaters and / or one or more ceramic heater(s). The one or more heaters may comprise one or more induction heaters, including a structure comprising one or more susceptors, which, in use, may form a chamber into which an article comprising the aerosol-generating material is inserted or otherwise disposed. Alternatively, or in addition, the one or more susceptors may be disposed within the aerosol-generating material. Other heating structures may be used.

[0195] Illustrative Embodiments The following embodiments are provided as examples to better illustrate how the present invention may be implemented.

[0196] In one embodiment, a consumable for use with a non-combustion aerosol delivery device is provided, the consumable comprising: a first aerosol-forming material; and a second aerosol-forming material; and and the first aerosol-generating material comprises an amorphous solid, the amorphous solid comprising: 30 to 60 wt. % of a gelling agent; 15 to 60 weight percent of an aerosol-forming material; 1 to 10% by weight of an active substance; and the second aerosol-forming material comprises an amorphous solid, the amorphous solid comprising: 30 to 60 wt. % of a gelling agent; 10 to 40 weight percent of an aerosol-forming material; 20 to 50% by weight of a flavoring; wherein these weights are calculated on a dry weight basis; The amorphous solid of the first aerosol-forming material has a different composition than the amorphous solid of the second aerosol-forming material.

[0197] In a further embodiment, a consumable for use in a non-combustion aerosol delivery device is provided, the consumable comprising: A support; a first aerosol-generating material attached to a support; a second aerosol-generating material attached to a support; and each of the first and second aerosol-forming materials comprises an amorphous solid, the amorphous solid comprising: 30 to 60 wt. % of a gelling agent; 15 to 60 weight percent of an aerosol-forming material; 0-60% by weight of at least one of nicotine, flavoring, and acid, wherein the acid has a boiling point in the range of 100°C to 350°C and / or a PK in the range of 3 to 7 when measured at 25°C. a having an acidic functional group having a value where these weights are calculated on a dry weight basis, The amorphous solid of the first aerosol-forming material has a different composition than the amorphous solid of the second aerosol-forming material.

[0198] In a further embodiment, there is provided a consumable for use in a non-combustion aerosol delivery device, the consumable comprising: A support; a first aerosol-generating material attached to a support; a second aerosol-generating material attached to a support; and each of the first and second aerosol-forming materials comprises an amorphous solid, the amorphous solid comprising: 30 to 60 wt. % of a gelling agent; 15 to 60 weight percent of an aerosol-forming material; 0 to 60% by weight of nicotine, a flavoring, and at least one of benzoic acid and / or lactic acid; wherein these weights are calculated on a dry weight basis; The amorphous solid of the first aerosol-forming material has a different composition than the amorphous solid of the second aerosol-forming material.

[0199] Exemplary non-limiting formulations of four aerosol-forming materials comprising amorphous solids that may be included in the consumables of the present invention are provided in the table below.

[0200] [Table 1]

[0201] definition Delivery System As used herein, the term "delivery system" is intended to encompass a system that delivers a substance to a user; Combustion-type aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or hand-rolled or handmade cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smoking materials); Non-combustion aerosol delivery systems that release compounds from aerosol-forming materials without burning the aerosol-forming materials, such as hybrid systems that generate aerosols using a combination of electronic cigarettes, tobacco heating products, and aerosol-forming materials; and Aerosol-free delivery systems that deliver at least one substance (which may or may not comprise nicotine) to a user orally, nasally, transdermally, or otherwise without forming an aerosol (including, but not limited to, oral products such as lozenges, gums, patches, articles comprising inhalable powders, and oral tobacco, including snus or moist snuff). Includes:

[0202] Non-combustion aerosol delivery system According to this disclosure, a "non-combustion" aerosol delivery system is one in which the component aerosol-forming materials (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0203] In some embodiments, the delivery system is a non-combustion aerosol delivery system, for example, a powdered non-combustion aerosol delivery system.

[0204] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as an electronic smoking device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0205] 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.

[0206] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may, for example, comprise a tobacco or non-tobacco product.

[0207] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable item for use with the non-combustion aerosol delivery device.

[0208] In some embodiments, the present disclosure relates to consumables that include aerosol-generating materials and are configured for use with non-combustion aerosol delivery devices. These consumables may be referred to as articles throughout this disclosure.

[0209] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, may include a power source and a controller. The power source may 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 or heat conducting material in proximity to the carbon substrate, which may be energized to distribute power in the form of heat to the aerosol-generating material.

[0210] In some embodiments, the non-combustion aerosol delivery system may include a consumable receiving area, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0211] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include an aerosol-forming material, an aerosol-forming material storage area, an aerosol-forming material transfer component, an aerosol generator, an aerosol-generating area, a housing, a paper wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0212] active substance In some embodiments, the substance to be delivered comprises an active agent.

[0213] As used herein, an active substance is a bioactive material, i.e., a material for achieving or enhancing a physiological response. The active substance may be selected from, for example, functional foods, nootropics, and psychoactive substances. The active substance may be naturally occurring or synthetically derived. The active substance may comprise, for example, nicotine, caffeine, taurine, theine, vitamins (such as B6, B12, C), melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may comprise one or more components, derivatives, or extracts of tobacco, cannabis, or other botanical materials.

[0214] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0215] In some embodiments, the active agent comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), and cannabielsoin (CBE), cannabicitran (CBT).

[0216] The active substance may comprise one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0217] The active substance may comprise cannabidiol (CBD).

[0218] The active substances may comprise nicotine and cannabidiol (CBD).

[0219] The active substances may comprise nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0220] plant matter As described herein, the active agent may comprise or be derived from one or more botanical materials or components, derivatives, or extracts thereof. As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, peels, etc. Alternatively, the material may comprise an active compound naturally occurring in the plant material or synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, shreds, sheets, etc. Examples of botanical ingredients include tobacco, eucalyptus, star anise, hemp, cacao, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba extract, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea (green tea, black tea, etc.), thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, Calvi, 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: common mint (Mentha arvensis), grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), lime mint (Mentha piperita citrata cv), chocolate mint (Mentha piperita cv), curly mint (Mentha spicata crispa), wild mint (Mentha cordifolia), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and apple mint (Mentha suaveolens).

[0221] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substance is tobacco.

[0222] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0223] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0224] fragrance In some embodiments, the substance delivered comprises a fragrance.

[0225] As used herein, the terms "flavoring" and "flavoring agent" refer to materials that can be used to create a desired taste, aroma, or other somatic sensation in products for adult consumers, where local regulations permit. They include naturally occurring flavoring materials, botanical materials, extracts of botanical materials, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (aniseed), cinnamon, turmeric, Indian spice, Asian spice, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, etc.). , clementine, lemon, lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, sheesh Shisha, pineapple, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of mint, eucalyptus, star anise, cacao, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea (green tea, black tea, etc.), Thai citric acid, citric acid, citric acid, citric acid salts ...They may contain sugars, maltodextrins, cellulose, cellulose gums, cellulose acetates, cellulose syrups, cellulose gum ...

[0226] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus fruit, and / or red berry flavoring components. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavoring components extracted from tobacco. In some embodiments, the flavoring comprises flavoring components extracted from cannabis.

[0227] In some embodiments, the flavoring agent may comprise a sensory agent intended to achieve somatic sensations typically 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 provide a heating, cooling, tingling, or numbing effect. Suitable heating agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucalyptol or WS-3.

[0228] Aerosol-Generating Materials An aerosol-generating material is a material capable of generating an aerosol when energized, for example, by heating, irradiation, or any other method. The aerosol-generating material may be, for example, in the form of a solid, liquid, or gel, and may or may not contain active substances and / or flavorings. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain some fluid, e.g., a liquid, within it. In some embodiments, the aerosol-generating material may comprise, for example, about 50%, 60%, or 70% amorphous solid by weight to about 90%, 95%, or 100% amorphous solid by weight.

[0229] The aerosol-generating material may comprise one or more active agents and / or flavoring agents, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0230] Aerosol-forming materials The aerosol-forming material may comprise one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material may comprise one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0231] In some embodiments, the aerosol forming agent comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols, such as glycerol mono-, di-, or triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0232] functional materials The one or more other functional materials may comprise one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0233] base body The material may be on or in a support to form a substrate. The support may be or comprise, for example, paper, card, paperboard, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is incorporated within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0234] consumables A consumable is an article comprising or consisting of an aerosol-generating material intended to be consumed, in part or in whole, during use by a user. A consumable may also comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also comprise an aerosol generator, such as a heater that generates heat upon use to cause the generation of an aerosol from the aerosol-generating material. The heater may comprise, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0235] Susceptor A susceptor is a material that can be heated by the penetration of a varying magnetic field, for example, an alternating magnetic field. The susceptor may be an electrically conductive material, in which case penetration with a varying magnetic field causes induction heating of the heating material. The heating material may be a magnetic material, in which case penetration with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically conductive and magnetic, in which case the susceptor is heatable by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0236] Aerosol Modifiers Aerosol modifiers are substances, typically located downstream of the aerosol-generation region, configured to modify the aerosol generated, for example, by altering the taste, aroma, acidity, or another property of the aerosol. The aerosol modifier may be provided in an aerosol modifier-releasing component operable to selectively release the aerosol modifier.

[0237] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may comprise, for example, one or more of a flavoring, a coloring, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in powder, thread, or granular form. The aerosol modifier may not include a filtration material.

[0238] Aerosol Generator An aerosol generator is a device configured to cause the generation of an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy to release one or more volatile substances from the aerosol-generating material and form an aerosol. In some embodiments, the aerosol generator is configured to cause the generation of an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibrational, high pressure, or electrostatic energy.

Claims

1. 1. A consumable for use with a non-combustion aerosol delivery device, the consumable comprising: a first aerosol-forming material; and a second aerosol-forming material; and wherein each of the first and second aerosol-forming materials comprises an amorphous solid, the amorphous solid comprising: 0.5 to 60 wt. % of a gelling agent; 0 to 80% by weight of an aerosol-forming material; 0-60% by weight of at least one of an active substance, a flavoring agent, and an acid; wherein the weights are calculated on a dry weight basis, and wherein the amorphous solid of the first aerosol-forming material has a composition that is different from the composition of the amorphous solid of the second aerosol-forming material.

2. The consumable product of claim 1 , wherein the amorphous solid of the first aerosol-forming material comprises the active substance and the amorphous solid of the second aerosol-forming material comprises the flavoring agent.

3. The consumable product of claim 1 or claim 2, wherein the amorphous solid of the first aerosol-forming material is free of the flavoring agent and the acid.

4. The consumable product of any one of claims 1 to 3, wherein the amorphous solid of the second aerosol-forming material is free of the active substance and the acid.

5. 4. The consumable product of claim 1, wherein the amorphous solid of the first aerosol-generating material comprises the active substance and the amorphous solid of the second aerosol-generating material comprises the acid.

6. The consumable product of claim 5 , wherein the amorphous solid of the first aerosol-forming material is free of the acid and the flavoring agent.

7. 7. The consumable product of claim 5 or claim 6, wherein the amorphous solid of the second aerosol-forming material is free of the flavoring agent and the active agent.

8. The consumable product of claim 1 , wherein the amorphous solid of the first aerosol-forming material comprises the flavoring agent and the amorphous solid of the second aerosol-forming material comprises the acid.

9. 9. The consumable product of claim 8, wherein the amorphous solid of the first aerosol-forming material is free of the active substance and the acid.

10. 10. The consumable product of claim 8 or claim 9, wherein the amorphous solid of the second aerosol-forming material is free of the flavoring agent and the active agent.

11. the first aerosol-forming material comprising: 0.5 to 60 wt. % of a gelling agent; 5 to 80% by weight of an aerosol-forming material; and is free of active substances, flavorings and acids, the second aerosol-forming material comprising 0.1 to 60% by weight of at least one of an active agent, a flavoring agent, and an acid; 10. The consumable of claim 1, wherein these weights are calculated on a dry weight basis.

12. 12. The consumable product of claim 1, wherein the active agent in the amorphous solid of the first aerosol-generating material is present in an amount that is different from the amount of the active agent in the amorphous solid of the second aerosol-generating material.

13. 13. The consumable product of claim 12, wherein the active agent in the amorphous solid of the first aerosol-forming material is present in an amount that is less than the amount of the active agent in the amorphous solid of the second aerosol-forming material.

14. 14. The consumable product of claim 13, wherein the amorphous solid of the first aerosol-generating material comprises 0 to 10% by weight of the active agent present therein, and the amorphous solid of the second aerosol-generating material comprises 10 to 60% by weight of the active agent present therein.

15. 15. The consumable product of claim 1, wherein the amorphous solid of the first aerosol-forming material comprises a flavoring that is different from the flavoring of the amorphous solid of the second aerosol-forming material.

16. 15. The consumable product of claim 1, wherein the amorphous solid of the first aerosol-generating material comprises an active substance that is different from the active substance of the amorphous solid of the second aerosol-generating material.

17. The consumable product of any preceding claim, wherein the consumable product comprises a support, and the first and second aerosol-forming materials are attached to the support.

18. 18. The consumable of claim 17, wherein the support is a flat support.

19. a third aerosol-forming material comprising an amorphous solid, the amorphous solid comprising: 0.5 to 60 wt. % of a gelling agent; 0 to 80% by weight of an aerosol-forming material; 0-60% by weight of at least one of an active substance, a flavoring agent, and an acid; 19. The consumable product of claim 1, wherein the weights are calculated on a dry weight basis, and wherein the amorphous solid of the third aerosol-generating material has a composition that is different from the composition of the amorphous solid of the first aerosol-generating material and / or the second aerosol-generating material.

20. a fourth aerosol-forming material comprising an amorphous solid, the amorphous solid comprising: 0.5 to 60 wt. % of a gelling agent; 0 to 80% by weight of an aerosol-forming material; 0-60% by weight of at least one of an active substance, a flavoring agent, and an acid; 20. The consumable of claim 19, wherein the weights are calculated on a dry weight basis, and wherein the amorphous solid of the fourth aerosol-forming material has a composition that is different from the composition of the amorphous solid of at least one of the first, second, or third aerosol-forming materials.

21. the amorphous solid of the first aerosol-forming material comprises the active substance and is free of the flavoring agent and the acid; the amorphous solid of the second aerosol-forming material comprises the flavoring agent and is free of the active substance and the acid; the amorphous solid of the third aerosol-forming material comprises the acid and is free of the flavoring agent and the active agent; 21. The consumable product of claim 20, wherein the amorphous solid of the fourth aerosol-forming material is free of the active agent, the flavoring agent, and the acid.

22. When the amorphous solid comprises an acid, the acid has a boiling point in the range of 100°C to 350°C, and / or The acid has a PK in the range of 3 to 7 when measured at 25°C. ａ 22. The consumable product of claim 1, having an acidic functional group having a value of 0.

05.

23. 23. The consumable product of any one of claims 1 to 22, wherein when the amorphous solid comprises an acid, the acid is an organic acid.

24. 24. The consumable product of any one of claims 1 to 23, wherein when the amorphous solid comprises an acid, the acid is lactic acid and / or benzoic acid.

25. 25. The consumable product of claim 24, wherein the acid is lactic acid.

26. 26. A non-combustion aerosol delivery system comprising the consumable product of any one of claims 1 to 25 and a non-combustion aerosol delivery device, the non-combustion aerosol delivery device comprising an aerosol generating device arranged to generate an aerosol from the consumable product when the consumable product is used with the non-combustion aerosol delivery device.

27. 1. A method of manufacturing a consumable for use with a non-combustion aerosol delivery device, comprising: providing a support; depositing at least two separate portions of a slurry comprising a gelling agent, an aerosol-forming material, and at least one of an active agent, a flavoring agent, and an acid onto the substrate; drying the at least two separate portions of the slurry to obtain a first aerosol-forming material and a second aerosol-forming material, the first and second aerosol-forming materials being attached to the support; wherein each of the first and second aerosol-forming materials comprises an amorphous solid, the amorphous solid comprising: 0.5 to 60 wt. % of a gelling agent; 0 to 80% by weight of an aerosol-forming material; 0-60% by weight of at least one of an active substance, a flavoring, and an acid, wherein these weights are calculated on a dry weight basis, and wherein the amorphous solid of the first aerosol-forming material has a composition that is different from the composition of the amorphous solid of the second aerosol-forming material; forming the consumable; A method for providing

28. The method of claim 27, wherein the consumable product is one of claims 1 to 25.

29. 26. Use of a consumable according to any one of claims 1 to 25 in a non-combustion aerosol delivery device, the device being arranged to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

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