Aerosol-generating components and methods for preparing same - Patents.com

Abstract

An integrated aerosol-generating component is provided that includes at least two parts that include different aerosol-generating materials. Also provided is a method for preparing an integrated aerosol-generating component that includes at least two parts that include different aerosol-generating materials, wherein the parts are formed using an additive manufacturing process. Also provided is a delivery system that includes an integrated aerosol-generating component as described herein.

Description

[Technical field]

[0001] The present invention relates to an aerosol-generating component included in an aerosol delivery system, e.g., an apparatus for heating an aerosol-generating material to volatilize at least one component of the material. The present invention also relates to a method for preparing such a component.

[0002] The aerosol-generating materials can include a wide variety of actives and / or flavorings, allowing the user to select the aerosol-generating material to achieve the desired user experience.

[0003] According to a first aspect described herein, there is provided an integrated aerosol generating component comprising at least two parts comprising different aerosol generating materials.

[0004] In some embodiments, the first portion includes a first fragrance and the second portion includes a second fragrance that is different from the first fragrance.

[0005] In some embodiments, the first portion includes a first active and the second portion includes a second active that is different from the first active.

[0006] In some embodiments, the first portion and the second portion have different pH.

[0007] In some embodiments, the first portion and the second portion deliver different aerosols in use.

[0008] In some embodiments, the first portion and the second portion have different aerosol release profiles.

[0009] In some embodiments, the unitary aerosol generation component comprises two or more portions aligned and attached to one another.

[0010] In some embodiments, the components are formed by an additive manufacturing process.

[0011] In some embodiments, the integrated aerosol generating component is for use in a combustion or non-combustion aerosol delivery system.

[0012] According to a second aspect described herein, there is provided a method for preparing an integrated aerosol-generating component comprising at least two parts comprising different aerosol-generating materials, wherein the parts are formed using an additive manufacturing process.

[0013] In some embodiments, the integral aerosol generation component is a component according to the first aspect.

[0014] In some embodiments, the at least two portions are formed by an additive manufacturing process using different feedstock materials.

[0015] In some embodiments, additive manufacturing processes use computer-aided design (CAD) models to create three-dimensional objects from feedstock materials.

[0016] In some embodiments, the additive manufacturing process is a 3D printing process that deposits layer upon layer of a feedstock.

[0017] According to a third aspect described herein, there is provided a delivery system comprising an integrated aerosol generation component according to the first aspect.

[0018] In some embodiments, two or more portions of the integrated aerosol generating component are heated sequentially to generate an aerosol.

[0019] In some embodiments, the delivery system is a non-combustion aerosol delivery system. In some embodiments, the delivery system comprises heating means for sequentially heating portions of the aerosol generating components.

[0020] According to a fourth aspect described herein, there is provided a consumable product comprising an aerosol generating component according to the first aspect.

[0021] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0022] [Figure 1] 1A-1D are schematic diagrams of aerosol generating components according to various embodiments described herein. [Diagram 2] 1A-1D are schematic diagrams of aerosol generating components according to various embodiments described herein. [Diagram 3] FIG. 1 is a schematic diagram of an aerosol generating component according to various embodiments described herein. Detailed Description

[0023] In some embodiments, the present invention relates to a unitary aerosol generating component that includes at least two portions that include different aerosol generating materials.

[0024] A particularly convenient process for producing such an aerosol-generating component is by additive manufacturing processes: using such processes, different parts can be formed sequentially from different feedstocks, such that the different parts adhere to each other to form a unitary component, by depositing material layer upon layer.

[0025] The aerosol-generating component portion includes different aerosol-generating materials, which are materials capable of generating an aerosol when, for example, heated, irradiated or in any other way energized.

[0026] As used herein, an aerosol generating component is a component that is ready for use in a delivery system, such as a non-combustion type aerosol delivery system. In some embodiments, this means that the aerosol generating component is ready for use in the delivery system without the need for further adaptation or processing.

[0027] Aerosol-Generating Materials The portions of the aerosol-generating component include different aerosol-generating materials, which in some embodiments may include one or more active substances and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0028] As used herein, an active substance may be a bioactive material and / or a functional nutrient, which is a material intended to achieve or enhance or balance a physiological response. In some embodiments, the active substance may achieve or enhance or balance a physiological response (i.e., a sensory effect). The active substance may be selected from, for example, dietary supplements, nootropics, psychotropic drugs, adaptogens, and phytochemicals. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, C, melatonin, cannabinoids, or components, derivatives, or combinations thereof, if permitted by local regulations. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance. In some embodiments, the active substance may be one that is typically supplied with the diet, such as creatine and amino acids, or one that is typically produced by the human body, such as hormones and some amino acids.

[0029] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0030] In some embodiments, the active agent may include or be derived from one or more botanical substances or components, derivatives, or extracts thereof. As used herein, the term "botanical substances" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, shells, skins, and the like. Alternatively, the material may include active compounds that are naturally present in the botanical substances and are obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, shreds, strips, sheets, and the like. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cacao, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, Ginkgo biloba, and the like. biloba), hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, chili pepper, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, chili pepper, thyme, cloves, cinnamon, ginger ... The preferred active ingredients include oleander, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiane, 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.Mint includes the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens. suaveolens).

[0031] 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.

[0032] 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.

[0033] 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.

[0034] In some embodiments, the active substance is nicotine, which may be provided in the form of particulate supplies of tobacco material and aerosol-forming materials, tobacco extracts, and / or purified or synthetic forms of nicotine. In some embodiments, the active substance is an active nicotine metabolite or derivative, such as cotinine.

[0035] In some embodiments, the aerosol-forming material comprises one or more actives selected from the group consisting of the actives listed in Table 1 below.

[0036] [Table 1] JPEG0007607668000002.jpg70148

[0037] In some embodiments, the aerosol-forming material includes one or more actives that are associated with a particular physiological and / or psychological effect, for example, an active may be associated with improved attention, improved focus, increased energy, increased stamina, increased calm, or improved sleep.

[0038] A number of actives have been demonstrated to have such effects. For example, taurine has been associated with improved performance in strength and endurance, endurance exercise tests, jumping, and sport-specific movements (see Souza, DB, et al., Acute effects of caffeine-containing energy drinks on physical performance: a systematic review and meta-analysis. Eur J Nutr 56, 13-27 (2017)). L-theanine has been shown to have some relaxing effects in the resting state and may be a more effective relaxant in such situations than the standard benzodiazepine anxiolytic alprazolam (see Kristy Lu et al., The acute effects of L-theanine in comparison with alprazolam on anticipatory anxiety in humans. Human Psychopharmacol Clin Exp 2004;19;457-465). Caffeine and L-theanine have been shown to improve performance on cognitively demanding tasks, demonstrating improvements in attention, speed and accuracy (see Gail N. Owen et al., The combined effects of L-theanine and caffeine on cognitive performance and mood, Nutritional Neuroscience, 11:4, 193-198 (2008); and T. Giesbrecht et al., (2010) The combination of L-theanine and caffeine improves cognitive performance and increases subjective alertness, Nutritional Neuroscience, 13:6, 283-290).GABA (gamma-aminobutyric acid) and L-theanine have also been shown to effectively improve sleep quality (see Suhyeon Kim et al. (2019) GABA and L-theanine mixture decreases sleep latency and improves NREM sleep, Pharmaceutical Biology, 57:1, 64-72).

[0039] In some embodiments, the supply and the aerosol-forming material include a fragrance.

[0040] As used herein, the terms "flavor" and "flavoring agent" refer to materials that can be used, where local regulations permit, to create a desired taste, odor, or other somatic sensation in products intended for adult consumers.They may be any naturally occurring flavoring material, botanical substance, extract of botanical substance, synthetically derived material, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed (aniseed), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, citrus ... rufruit, 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 quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine Sumin, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay leaf, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, melon, The flavor enhancers may include, for example, sucralose, damiane, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be of imitation, synthetic or natural ingredients, or blends thereof. They may be in any suitable form, for example a liquid such as an oil, a solid such as a powder, or a gas.

[0041] 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 flavor components. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavor components extracted from tobacco. In some embodiments, the flavoring comprises flavor components extracted from cannabis.

[0042] In some embodiments, the flavoring may include sensory agents aimed at achieving somatic sensations that are usually chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves, and these may include agents that produce a heating, cooling, tingling, or numbing effect. A suitable heating effect agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucolyptol, WS-3.

[0043] In some embodiments, the supply and the aerosol generating material include an aerosol forming material. The aerosol forming material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol forming material may include 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 mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0044] In some embodiments, the feed and the aerosol-forming materials include one or more functional materials. The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0045] Suitable binders include, for example, pectin, guar gum, fruit pectin, citrus pectin, tobacco pectin, hydroxyl ethyl guar gum, hydroxyl propyl guar gum, hydroxyl ethyl locust bean gum, hydroxyl propyl locust bean gum, alginates, starch, modified starch, derivatized starch, methyl cellulose, ethyl cellulose, ethyl hydroxymethyl cellulose, carboxymethyl cellulose, tamarind gum, dextran, pullalon, konjac flour or xanthan gum.

[0046] Two or more different portions of an aerosol-generating component as described herein may comprise different aerosol-generating materials, which in some embodiments means that the portions generate different aerosols.

[0047] In some embodiments, a user inhaling an aerosol generated by a portion of the aerosol generating component may not perceive a difference between the aerosol generated by the different portions. For example, the differences in the aerosol generating materials may be designed to provide a consistent sensory experience to the user. In other embodiments, different portions of the aerosol generating component generate different aerosols that the user can distinguish. In such embodiments, the components provide a user with a changing experience as the different portions generate aerosol.

[0048] In some embodiments, two or more of the portions of the aerosol generating component comprise different flavors.

[0049] In other embodiments, two or more of the portions of the aerosol generating component contain the same flavoring but in different amounts or intensity.

[0050] In some embodiments, two or more of the portions of the aerosol generating component contain different actives.

[0051] In other embodiments, two or more of the portions of the aerosol generating component contain the same active but in different amounts or strengths.

[0052] In some embodiments, two or more of the portions of the aerosol generating component have different pH.

[0053] In some embodiments, the aerosol generating component comprises an aerosol generating material having a basic pH. For example, the pH may be at least about 7.5. In some embodiments, the aerosol generating material having a basic pH comprises one or more bases or a basic buffer system.

[0054] The purpose of adjusting the pH of an aerosol-generating material is to provide the components in a chemical form that means they are easily released from the aerosol-generating component and / or that they are easily transferred from the aerosol-generating component to the aerosol generated by the delivery system used to generate the aerosol.

[0055] For example, adjusting the pH of tobacco alters the natural balance of acid-base reactions that bind certain classes of chemicals within the tobacco. For example, in natural tobacco leaves, nicotine tends to bind with organic acids present in the leaf, and is therefore more stable and less likely to volatilize when exposed to mild heating. When the pH of the leaf is increased, this reduces nicotine's natural binding with the acids. Such unbound "free" nicotine is more likely to volatilize. The same principle applies to other chemical equilibria within tobacco.

[0056] In some embodiments, the pH of the aerosol-forming material is adjusted to at least about 7.5, at least about 8, at least about 8.5, at least about 9, at least about 9.5, or at least about 10. In some embodiments, the pH is adjusted to about 14 or less, about 13.5 or less, about 13 or less, about 12.5 or less, about 12 or less, about 11.5 or less, about 11 or less, about 10.5 or less, or about 10 or less. In some embodiments, the pH of the aerosol-forming material is adjusted to between about 8 and about 10, or between about 8.5 and about 9.5.

[0057] In some embodiments, the pH is adjusted to about 7.5 to about 10, or about 8 to about 9, or about 8.5, about 9, about 9.5, or about 10.

[0058] In some embodiments, the base used to adjust the pH is a hydroxide or carbonate. The hydroxide used may be a mono-, di- or tri-acid base. Suitable bases include, for example, potassium hydroxide, calcium hydroxide, silver hydroxide, ammonium hydroxide, magnesium hydroxide, sodium carbonate, sodium bicarbonate (also known as sodium hydrogen carbonate), and potassium carbonate.

[0059] The base may be added to the feedstock from which the aerosol-generating component is formed when the portion is in liquid form, for example in the form of an aqueous or non-aqueous solution or suspension, or in solid form, for example a powder.

[0060] In some embodiments, the buffer system used to adjust the pH is a mixture of a weak base and its conjugate acid. Suitable buffer systems include, for example, those having a pH of at least about 7.5, at least about 8, at least about 8.5, or at least about 9. In some embodiments, the pH of the buffer system is about 8 to about 10, or about 8.5 to about 9.5. Suitable buffer systems include, for example, those based on ammonia, carbonate, or hydroxide, with suitable counterions. An example of a particular buffer system is a mixture of ammonia and ammonium chloride.

[0061] In some embodiments, two or more of the portions of the aerosol generating component have different aerosol release profiles, meaning that when the aerosol generating components are heated, irradiated, or in any other way energized, aerosols are generated with different release profiles, meaning that the release rate and / or duration of the aerosol and / or one or more components of the aerosol are different.

[0062] While in some embodiments it may be desirable for a portion of the aerosol-generating component to contain a base or acid to achieve an adjusted pH, some components of the aerosol-generating material may not be compatible with the adjusted pH. For example, some actives and fragrances are pH sensitive. The separate portions of the aerosol-generating component described herein allow such pH sensitive components to be separated from the pH adjusted aerosol-generating material. Other incompatible components of the aerosol-generating material may also be accommodated in such separate portions of the aerosol-generating component.

[0063] Additive Manufacturing Process Additive manufacturing builds three-dimensional objects, usually by successively adding material layer by layer, from a computer-aided design (CAD) model. A variety of processes may be used to bond or solidify the material under computer control to create the three-dimensional object.

[0064] The term "additive manufacturing" is used herein to refer to various methods including, for example, printing processes that deposit material layer by layer via a dispensing head ("3D printing").

[0065] In some embodiments, the additive manufacturing process uses two or more different feedstocks to produce the aerosol-generating component. A first feedstock is used to form a first portion of the component, and a second feedstock is used to form a second portion of the component. The additive manufacturing process involves layering feedstock layer upon layer, and in some embodiments, a first layer of a second portion is layered on top of the first portion to produce a monolithic component comprising multiple portions. These portions are attached to each other and cannot be easily separated from each other. This is in contrast to a component made of separate portions that are subsequently attached to each other, for example, by a bonding or fusing step.

[0066] In some embodiments, the apparatus for carrying out additive manufacturing processes is an apparatus that can be used to sequentially deposit feedstock layer on top of layer under the control of a computer program to form a three-dimensional article. In certain embodiments, the additive manufacturing process is 3D printing, and suitable apparatus for carrying out this include 3D printers with print heads that deposit multiple layers of feedstock to form a three-dimensional object. In general, the print head contains a chamber that supplies the feedstock to be deposited, and a nozzle that sprays the feedstock in a highly controlled manner.

[0067] In some embodiments, the feedstock used to prepare the aerosol-generating component is a paste or a slurry, in such embodiments, the additive manufacturing process is a paste or slurry extrusion 3D printing process.

[0068] In some embodiments, a layer of a first feedstock is deposited in a controlled manner to provide a first portion of an aerosol generating component comprising a first aerosol generating material, followed by a layer of a second feedstock deposited in a controlled manner to provide a second portion of an aerosol generating component comprising a different aerosol generating material. This process may optionally be continued with further feedstock to produce an aerosol generating component comprising multiple portions of aerosol generating material in a desired shape and size.

[0069] The viscosity of the feed and the properties of the additive manufacturing device, such as the size of the nozzle orifice and / or the rate at which the feed is delivered, can be optimized to allow the characteristics of the aerosol generating component to be tailored to its intended use.

[0070] In an optional further step, the aerosol-generating component is treated following the additive manufacturing process. For example, the component prepared by the additive manufacturing process may then be cured. Curing may in some embodiments include exposure to a suitable heat source, for example hot air, infrared radiation, a laser or a plasma jet.

[0071] Additive manufacturing processes offer significant flexibility with respect to the three-dimensional shape of the aerosol-generating components disclosed herein. For example, in some embodiments, it is desirable to impart a large surface area to the components, and additive manufacturing processes can be used to fabricate components with channels and / or complex cross-sectional shapes (e.g., Y, X, or star shapes) to maximize surface area while still maintaining the required strength and stability of the component.

[0072] Delivery System As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user, including: Combustion-type aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or hand-rolled or hand-made cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials); and Non-combustion aerosol delivery systems, such as tobacco heating products, that release compounds from an aerosol-forming material without combusting the aerosol-forming material, and hybrid systems that generate aerosols using a combination of aerosol-forming materials. Includes:

[0073] According to this disclosure, a "non-combustion" aerosol delivery system is one in which the component aerosol-generating materials (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0074] In some embodiments, the delivery system is a non-combustion aerosol delivery system, for example a powdered non-combustion aerosol delivery system.

[0075] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

[0076] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may, for example, include tobacco or non-tobacco products.

[0077] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable product for use with the non-combustion aerosol delivery device.

[0078] In some embodiments, the present disclosure relates to a consumable comprising an aerosol generating component as disclosed herein and configured for use with a non-combustion aerosol delivery device.

[0079] 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 that can be energized to distribute electrical power in the form of heat to the aerosol generating material, or a heat conducting material in proximity to the heat generating power source.

[0080] 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.

[0081] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include aerosol generating materials, aerosol generating material storage areas, aerosol generating material transfer components, aerosol generators, aerosol generating areas, housings, wrapping papers, filters, mouthpieces, and / or aerosol modifiers.

[0082] A consumable is an article that comprises or consists of an aerosol-generating material, some or all of which is intended to be consumed during use by a user. A consumable may 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 to generate an aerosol from the aerosol-generating material during use.

[0083] The 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 to 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 vibration, high pressure, or electrostatic energy.

[0084] In some embodiments, the aerosol generator is configured to act on the aerosol generating component to generate aerosol from multiple portions of the aerosol generating component simultaneously. In some embodiments, the aerosol generator acts on all portions of the aerosol generating component simultaneously. In other embodiments, the aerosol generator is configured to act on different portions of the aerosol generating component sequentially. In such embodiments, the generated aerosol changes during use of the delivery system.

[0085] Figure 1 is a schematic diagram of an aerosol-generating component according to an embodiment described herein. The aerosol-generating component 1 comprises a series of arranged portions 2a, 2b, 2c, 2d, each containing a different aerosol-generating material.

[0086] 2 is a schematic diagram of another aerosol-generating component according to embodiments described herein. The aerosol-generating component 1 comprises a series of arranged portions. A first portion 2a comprises a first aerosol-generating material and a central second portion 2b comprises a second, different aerosol-generating material.

[0087] 3 is a schematic diagram of yet a further aerosol-generating component according to embodiments described herein. The aerosol-generating component 1 includes a disk-shaped first portion 2a containing a first aerosol-generating material surrounded by a second portion 2b containing a second, different aerosol-generating material.

[0088] Other shapes and configurations of the two or more portions of the aerosol generating component are contemplated. The size and shape of the aerosol generating component is, in some embodiments, dictated by the delivery system used to generate the aerosol.

[0089] The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. It is understood that the advantages, embodiments, examples, functions, features, structures and / or other aspects described herein are not to be considered as limitations to the scope of the invention as defined by the claims or to the equivalents of the claims, and that other embodiments may be utilized and changes may be made without departing from the scope of the invention as claimed. Various embodiments of the present invention may suitably include, consist of, or consist essentially of any suitable combination of elements, components, features, parts, steps, means, etc. of the present disclosure other than those specifically described herein. Furthermore, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. 1. A monolithic aerosol generating component comprising at least two separate portions, a first portion and a second portion comprising different aerosol generating materials, the first portion and the second portion being formed by an additive manufacturing process of layering feed layer on top of layer, using a first feedstock to form the first portion and a second feedstock to form the second portion, such that the first portion and the second portion are attached to one another to form a monolithic component and cannot be readily separated.

2. 2. The unitary aerosol generating component of claim 1, wherein the first portion includes a first fragrance and the second portion includes a second fragrance different from the first fragrance.

3. 3. The integrated aerosol generating component of claim 1 or 2, wherein the first portion includes a first active and the second portion includes a second active that is different from the first active.

4. The integrated aerosol generating component of any one of claims 1 to 3, wherein the first part and the second part have different pH.

5. An integrated aerosol generating component according to any one of claims 1 to 4, wherein the first and second parts deliver different aerosols in use.

6. 6. An integrated aerosol generating component according to claim 1, wherein the first and second parts have different aerosol release profiles.

7. An integrated aerosol generating component according to any one of claims 1 to 6, wherein the first and second parts are aligned in series.

8. An integrated aerosol generating component according to any one of claims 1 to 7 for use in a combustion or non-combustion aerosol delivery system.

9. 1. A method for preparing an integral aerosol-generating component comprising at least two separate parts, a first part and a second part comprising different aerosol-generating materials and attached to one another to form the integral component and cannot be readily separated, comprising forming the at least two separate parts using an additive manufacturing process by using a first feedstock to form the first part and a second feedstock to form the second part, and attaching the separate parts by stacking feed layer on top of layer.

10. The method according to claim 9, wherein the integrated aerosol generating component is as claimed in any one of claims 1 to 8.

11. 11. The method of claim 9 or 10, wherein the first and second portions are formed by the additive manufacturing process using different feedstocks.

12. 12. The method of claim 11, wherein the additive manufacturing process forms a three-dimensional object from the feedstock using a computer-aided design (CAD) model.

13. 13. The method of claim 11 or 12, wherein the additive manufacturing process is a 3D printing process that deposits layer upon layer of a feedstock.

14. A delivery system comprising an integrated aerosol generating component according to any one of claims 1 to 8.

15. 15. The delivery system of claim 14, wherein the at least two separate portions of the integrated aerosol generating component are heated sequentially to generate an aerosol.

16. 16. The delivery system of claim 14 or 15, which is a non-combustion aerosol delivery system.

17. 17. A delivery system according to claim 16, comprising heating means for sequentially heating the at least two separate portions of the aerosol generating component.

18. A consumable product comprising an aerosol generating component according to any one of claims 1 to 8.

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